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BGS-MX-003 Rev B1

Borouge Project

DOCUMENT No: REV. No: DATE: PAGE OF

BGS-MX-003 B1 15 September 2009 1 10

BOROUGE PROJECT

BOROUGE GENERAL SPECIFICATION

Internal Cleaning of Piping

BGS-MX-003

REV DATE DESCRIPTION BY CHK APPROVED BOROUGE

DISC PROJ

B1 15 Sep 2009 Issued for B3 Project Execution MAE BOV MAB AJ

B 14/12/05 Issued for Project Execution BG BR BR RBT OL

PROPRIETARY INFORMATION

THIS DOCUMENT CONTAINS INFORMATION BELONGING TO BOROUGE. NEITHER THE DOCUMENT,

NOR ANY OF ITS CONSTITUENT PARTS, MAY BE REPRODUCED OR DISCLOSED WITHOUT THE PRIOR

WRITTEN AUTHORISATION OF BOROUGE.

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Borouge ProjectBOROUGE GENERAL SPECIFICATION


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CONTENTS

1.0 PURPOSE .................................................................................................................................. 3 2.0 DEFINITIONS AND ABBREVIATIONS .............................................................................. 3

2.1 DEFINITIONS ............................... ........................................... .................................... .................... 3 2.2 ABBREVIATIONS ......................................... ...................................... ...................................... ...... 4

3.0 CODES AND STANDARDS .................................................................................................... 4 4.0 REFERENCE DOCUMENTS ................................................................................................. 4 5.0 DOCUMENTATION REVIEW .............................................................................................. 5 6.0 SPECIFICATION DEVIATION/CONCESSION CONTROL ............................................ 5 7.0 QUALITY CONTROL ............................................................................................................. 5 8.0 DOCUMENTATION ................................................................................................................ 6 9.0 SERVICE CONDITIONS ........................................................................................................ 6 10.0 PAINTING................................................................................................................................. 6 11.0 PACKING, SHIPPING AND STORAGE .............................................................................. 6 12.0 PIPE FABRICATOR’S RESPONSIBILITIES ..................................................................... 6 13.0 FIELD CLEANING PROCEDURE ....................................................................................... 7

13.1 GENERAL ........................................................................................................................................ 7 13.2 MECHANICAL/PHYSICAL CLEANING .................................. ...................................... ............ 7 13.3 CLEANING AGENTS/MATERIALS .................................. ...................................... .................... 8 13.4 PROCEDURES ........................................ ....................................... ...................................... ............ 8 13.5 CORROSION MONITORING ..................................................... ...................................... ............ 9

14.0 CHEMICAL SOLUTION AND RINSE DISPOSAL ............................................................ 9 15.0 INSPECTION AND PRESERVATION ................................................................................. 9 16.0 SAFETY ................................................................................................................................... 10 17.0 IDENTIFICATION OF CLEANED PIPE ........................................................................... 10

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1.0 PURPOSE

The purpose of this document is to define the technical requirements for cleaning

(chemically or mechanically), pickling, passivating, and protecting the internal surfacesof new carbon steel and stainless steel piping on the Borouge Project. It is provided to theCONTRACTOR for the specification and definition of the COMPANY’S minimum

requirements for the WORKS.

Internal cleaning is applicable when requirements are noted on P&IDs and associated

piping drawings. Internal cleaning and protection shall be done after installation andpressure testing.

Internal cleaning involves removing corrosion products, mill scale, oils, greases, dirt,

organic growth and organic sediments, primarily to avoid damage to or poor performance

of downstream equipment.

Cleaning of equipment, vessels, tanks and transmission pipelines is not covered by thisspecification.

Any references to VENDOR define the requirements to be imposed on the VENDOR by

the CONTRACTOR.

2.0 DEFINITIONS AND ABBREVIATIONS

2.1 DEFINITIONS

For the purposes of this specification, the following definitions shall apply:

COMPANY – means Abu Dhabi Polymers Company Limited (Borouge) and its

successors in interest.

CONCESSION REQUEST – refers to a technical or other deviation requested by theCONTRACTOR or VENDOR to COMPANY. Its submission is often linked to an

authorization to modify the design, to use, repair, recondition, reclaim, or releasematerials, components or equipment already in progress or completely manufactured but

which does not meet or comply with COMPANY requirements. A CONCESSION

REQUEST is subject to COMPANY approval.

CONTRACTOR – means a party contracted to COMPANY to carry out work or servicesto the Project.

PROJECT – means the Borouge Project at Ruwais, Abu Dhabi, UAE.

VENDOR – means any and all persons, firms, partnerships, companies, bodies, entities

or a combination thereof including sub-vendors and suppliers, who are providing

GOODS, and the successors and assigns of such persons, firms, partnerships, companies,bodies, entities or a combination thereof.

GOODS – means any and all things, including but not limited to materials and equipment(including spare parts) required to be incorporated in the WORK.

Shall and Must– indicate a mandatory requirement.

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In addition, supplementary definitions are contained in Article 1 of the AGREEMENT.

2.2 ABBREVIATIONS

ASTM American Society For Testing and Materials

BEDD Basic Engineering Design Data

CR Criticality Rating

ISO International Organization For Standardization

3.0 CODES AND STANDARDS

It shall be the CONTRACTOR’S responsibility to comply with the requirements of allCodes and Standards which are applicable to meet the Specification.

The following Codes and Standards form a part of the Specification:

American Society for Testing and Materials (ASTM)

A380 Cleaning and Descaling Stainless Steel Parts, Equipment, and

Systems

International Organization for Standardization (ISO)

ISO 9001:2000 Quality Management Systems - Requirements

ISO 9004:2000 Quality Management Systems – Guidelines for Performance

Improvements

The edition or revision of the Codes and Standards shall be the edition current at theEFFECTIVE DATE of the AGREEMENT.

CONTRACTOR shall advise COMPANY of any changes to Codes and Standards after

the EFFECTIVE DATE. CONTRACTOR shall comply with COMPANY instruction tocomply with any changed Codes and Standards.

CONTRACTOR shall advise of conflict among any referenced Codes and Standards andany technical specification, and COMPANY will determine which shall govern.

4.0 REFERENCE DOCUMENTS

The following Reference Documents form a part of this Specification:

BGS-MU-002 Preservation and Export Packing Procedure

BGS-MU-013 Criticality Rating System

BGS-MU-014 Minimum Shop Inspection and Certification Requirements

BGS-MW-002 Welding, NDE and Prevention of Brittle Fracture of Piping

BGS-MX-001 Painting

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PPM-GG-B3-001 Document Numbering Procedure

PPM-DU-B3-005 Document and Drawing Format Procedure

PPM-GG-B3-009 Procedure for Concession Requests

PQP-GG-B3-002 Quality Management Requirements for CONTRACTOR

PGS-GG-B3-001 Basic Engineering Design Data

The edition or revision of the Reference Documents shall be the edition current at theEFFECTIVE DATE of the AGREEMENT.

CONTRACTOR shall advise COMPANY of any changes to Reference Documents afterthe EFFECTIVE DATE. CONTRACTOR shall comply with COMPANY instruction to

comply with any changed Referenced Documents.

CONTRACTOR shall advise of conflict among any Reference Documents and anytechnical specification, and COMPANY will determine which shall govern.

5.0 DOCUMENTATION REVIEW

The CONTRACTOR shall notify the COMPANY of any apparent conflict between thisSpecification, Codes and Standards, Referenced Documents and any other applicable

documentation (i.e. Datasheets, AGREEMENT).

The CONTRACTOR shall prepare a tabulated list of discrepancies between any of thesedocuments for review with the COMPANY. Resolution of any conflict shall be obtained

from COMPANY in writing before proceeding.

6.0 SPECIFICATION DEVIATION/CONCESSION CONTROL

Any technical deviations to this Specification shall be sought by the CONTRACTOR

only through the CONCESSION REQUEST procedure. Refer to PPM-GG-B3-009 -Procedure for Concession Requests.

COMPANY will review and consider all proposed CONCESSION REQUESTS.

Approval may be granted at COMPANY’S discretion. No proposed technical deviationshall be implemented prior to approval being granted. Technical deviations implemented

prior to approval shall be subject to rejection.

7.0

QUALITY CONTROL

CONTRACTOR and VENDOR shall comply with the requirements of PQP-GG-B3-002

- Quality Management Requirements for CONTRACTORS.

The Criticality Rating (CR) System outlined in Project Specification BGS-MU-013 shallbe used by CONTRACTOR to develop the design checking levels and minimum

requirements for shop inspection, testing and material certification given in ProjectSpecification BGS-MU-014.

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Regardless of the Criticality Rating CONTRACTOR shall review the VENDOR’S

documentation to ensure compliance with the requirements of the AGREEMENT.CONTRACTOR shall develop a list of Criticality ratings for all equipment items.

8.0 DOCUMENTATION

CONTRACTOR and VENDOR shall comply with the requirements of the PPM-DU-B3-

005 - Procedure for Document and Drawing Format, PPM-GG-B3-001 - DocumentNumbering Procedure.

9.0 SERVICE CONDITIONS

In addition to requirements stated in this specification and related documents, the BasicEngineering Design Data (BEDD) – PGS-GG-B3-001 shall be used in the design and

construction of this Equipment.

10.0 PAINTING

The CONTRACTOR shall ensure surfaces are prepared and painted in accordance with

Specification BGS-MX-001, Painting.

11.0 PACKING, SHIPPING AND STORAGE

As a minimum, the CONTRACTOR shall ensure that items are packed for shipment in

accordance with the requirements of BGS-MU-002 - Preservation and Export Packing

Procedure.

The CONTRACTOR shall ensure that detailed and specific instructions for the

preservation and maintenance of equipment while stored at the construction site, fromreceipt at site to operational start-up, shall be delivered to construction site with theequipment. Such instructions shall include as a minimum the preservation and

maintenance schedule, preservative materials, lubricants to be used etc.

Cleaning solutions shall be prepared, handled and used in accordance with the

VENDOR’S data sheets and recommendations.

Cleaning chemicals shall be stored in containers at a designated area under cover.

All containers shall remain closed until required for use.

A copy of all Material Safety Data Sheets shall be kept at the jobsite and made available

to CONTRACTOR/COMPANY upon request.

12.0 PIPE FABRICATOR’S RESPONSIBILITIES

The pipe fabricator shall be responsible for meeting the added requirements given inBGS-MW-002 for piping designated to be internally cleaned.

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13.0 FIELD CLEANING PROCEDURE

13.1 GENERAL

The internal cleaning contractor shall analyze the surface contaminants and surfacecondition and recommend a cleaning procedure for each piping system to the

CONTRACTOR with the following details:

• Analysis of surface contaminants and surface condition.

• Review of system metallurgy and an evaluation of corrosion risks associated with the

cleaning.

• Options available and recommended for cleaning (see section 13.3).

Recommendations for degreasing, pickling, neutralizing, passivating and drying

should be included.

• Description of recommended cleaning materials (including quantities, quality,

concentration, water quality, etc.) and methods.

• Corrosion rates of the cleaning solutions on the substrate metals.

• Corrosion monitoring method (see section 13.5).

• Logistics of cleaning such as batch immersion or continuous circulation, cleaning

circuits, etc.

• Items to be blocked off, disconnected, or removed prior to cleaning.

• Emissions that may be released during cleaning and methods to protect personnel.

• Proposed method of disposing spent cleaners, equipment to be used and personnel to

be involved.

• Material Safety Data Sheets/Safety Precautions.

The internal cleaning contractor shall use only materials and process(es) approved by the

CONTRACTOR.

The internal cleaning contractor and the CONTRACTOR are solely responsible for all

cleaning operations such as supervision, labor, cleaner storage, pumping equipment,filters, holding tanks, hoses, on-site laboratory, analytical testing, and each and every

item of expense.

No chemical cleaning, degreasing, etc., shall take place until satisfactory completion of

fabrication, heat treatment, examination and hydrotesting (if applicable).

Chemical solutions shall not be introduced into piping systems or equipment unless highpoint vents and low point drains are available to ensure proper filling and complete

removal of solutions.

When circulating fluids through an assembled piping system, vessels, exchangers,compressors, etc. shall be positively isolated by blinds. Extreme care shall be exercised

to prevent the entry of any cleaning chemical or vapors into any part of the machinery.

13.2 MECHANICAL/PHYSICAL CLEANING

Components of piping designated to be chemically cleaned shall be examined beforefabrication, and, where necessary, mechanically and/or physically cleaned (e.g. by

scraping, wire brushing, blasting with abrasive, steam cleaning or shot jet cleaning) to

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remove loose scale, foreign matter and protective coatings, which may otherwise make

satisfactory chemical cleaning impossible, before fabrication commences.

In using mechanical or physical methods, great care shall be taken not to damage the

equipment being cleaned.

Following mechanical and/or physical cleaning, the piping shall be inspected to ensure

that the internal surfaces are free of weld spatter, grinding debris, abrasives, dust, loose

materials, etc. All open ends shall then be temporarily sealed to prevent the ingress offoreign matter pending the chemical cleaning operation.

13.3 CLEANING AGENTS/MATERIALS

Field chemical cleaning materials shall generally be limited to biodegradable detergent

cleaners and/or citric acid based cleaners. Passivation materials will generally be sodiumnitrate or inhibited phosphoric acid. However, other degreasing, pickling, cleaning or

passivation compounds may be submitted for CONTRACTOR/ COMPANY approval.

The cleaners shall not contain chemicals such as chromates and lead compounds whichcould cause soil and ground water contamination.

Chloride content of stainless steel cleaning solutions shall not exceed 2 mg/kg.

All cleaning solutions shall be prepared, handled and used in accordance with the

VENDOR’S data sheets and recommendations.

13.4 PROCEDURES

Cleaning of stainless steel surfaces shall be in accordance with ASTM A380. Piping and

equipment manufactured of austenitic materials shall not be allowed to come in contact

with solutions containing chlorides such as hydrochloric acid and chemicals containingchlorides as impurities.

Aluminum, galvanized carbon steel, magnesium and zinc surfaces shall not be allowed to

come in contact with acid cleaning solutions.

The following items shall be blocked off, disconnected or removed from the piping

system prior to initiation of cleaning:

Bearings Oil Reservoirs and Tanks

Cylinders Orifice Parts

Filters Plug Cocks

Instruments Relief Valves

Equipment Screens

Special valves and miscellaneous items

Items temporarily removed from systems may be replaced by temporary spools whilstthe cleaning is in process.

Care must be taken that “dead” pockets of line do not exist in which fluids and debriscould accumulate.

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13.5 CORROSION MONITORING

A corrosion test shall be carried out in a sample of the inhibited acid to be used for

cleaning. The test duration shall be 24 hour and test coupons shall be the same material

as the equipment or system to be cleaned. From the weight loss of the test coupons thecorrosion rate can be determined, which should not be more than 0.01 mm/24 hours. If

higher corrosion rates are measured or if any pitting is observed, the inhibitor shall bereplaced and the test repeated until acceptable results are obtained.

Corrosion control during chemical cleaning shall be demonstrated by use of suitable

method(s) of corrosion monitoring including the use of corrosion coupons installed forthe total cleaning duration.

14.0 CHEMICAL SOLUTION AND RINSE DISPOSAL

All spent chemical solutions and rinses shall be completely discharged by draining andflowing out with high pressure air jets from lowest points in the system and must be

disposed of in an environmentally acceptable manner approved by the COMPANY.

If detergent, soda ash solution, rinses, and other liquids are discharged to public waters,

these liquid effluents must comply with the applicable state and local dischargeregulations, guidelines, and standards.

If any liquid effluent streams are discharged to a sewer system connected with a sewage

treatment plant, they must comply with the applicable state and local pretreatmentregulations.

15.0 INSPECTION AND PRESERVATION

The piping shall be inspected before and after cleaning to check the effectiveness of thecleaning operations and look for signs of metal attack.

Cleaned surfaces shall be visually examined under a lighting level, including both

general and supplementary lighting, of 2690 lux on the surfaces being examined. Alighting level of 1076 lux may be used upon CONTRACTOR’S approval. Visual

examination shall be supplemented with closed circuit television cameras, bore scopes,mirrors, and other aids, as necessary, to properly examine inaccessible or difficult-to-see

surfaces. Lights shall be positioned to prevent glare on the surfaces being examined.

Where visual examination is not practical, a clean, lint free, white cotton cloth or filterpaper moistened (but not saturated) with high purity isopropyl alcohol (rubbing alcohol)

may be rubbed against the surfaces at all openings. The presence of a smudge on the

cloth or filter paper is evidence of incomplete cleaning and the cleaning shall berepeated.

Cleaning solutions shall be completely removed.

After inspection, cleaned piping shall be filled with nitrogen to 0.35 barg and sealed until

plant start-up.

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16.0 SAFETY

The internal cleaning contractor and the CONTRACTOR are responsible for the health,safety and well being of field cleaning personnel and all other parties in the general

environment where cleaning operations occur.

The internal cleaning contractor and the CONTRACTOR shall employ proper and safe

practices for storage, handling and disposal of chemicals and spent materials.

VENDOR’s and governmental safety guidelines, recommendations, and instructions

shall be complied with for the prevention of harm or injury to any person before, during

or after these cleaning and pickling activities.

The internal cleaning contractor shall enforce the use of protective clothing and safety

accessories such as eye protection, face shields, gloves and breathing apparatus asrequired. Internal cleaning contractor’s safety measures shall be submitted to the

CONTRACTOR for approval.

The cleaning area shall be closed of the unauthorized personnel.

Warning signs shall be posted to forbid smoking, welding, flame cutting and

unauthorized entering of the cleaning area.

During cleaning with acid, adequate venting shall be provided to prevent the

accumulation of an explosive gas mixture; special care shall be taken to vent isolated

pockets in a safe manner.

17.0 IDENTIFICATION OF CLEANED PIPE

Cleaned pipe shall be metal tagged in English and Arabic to avoid subsequent

contamination. The tag shall read “KEEP SEALED UNTIL READY FOR USE.

INTERNALLY CLEANED AND PRESSURIZED WITH NITROGEN ON (Date).”

Pipe shall not be marked with paint or ink, in lieu of metal tagging.