Pickling and Flushing of both CS and SS PipelinePickling and Flushing of both CS and SS Pipeline

1.0.SCOPE OF WORK:

The scope of work Pickling and Flushing of both CS and SS Pipeline internal surface at KCC Line II Project. The final result of cleaning of CS pipeline shall be internal surface free from weld particles and rust whereas the SS lines will be free from micro metallic particles.

2.0. PROCEDURE:

To performance chemical cleaning job Written approval and permission prior.

This proposed chemical cleaning procedure is for the DE-GREASING, ACID PICKLING, HIGH SPEED OIL FLUSHING is based on system isometrics and estimated average volume of 1,000 US Gallons for all the three CS & SS lines as per the given drawings. ………had appoined 3B to follow the vendor’s spec for the chemical cleaning job. The following procedure is written in accordance to the vendor’s recommended procedure.

2.1: RIG-UP:

2.1.1 Connect 1” or 2” flexible rubber hose to the inlet and out of the KCC plant lines to be cleaned. 2.1.2 Follow the diagram to rig-up including the mixing tank, boiler, centrifugal pump and frac tanks.2.1.3 Make sure to connect a ¾” hose from top vent point to mixing tank. This will ensure the positive flow of liquid in the line and no air patches in the line.2.1.4 Make sure to connect lower drain point.2.1.5 Connect reducer of 1” or 2” at the ends of the return line for circulate.2.1.6 Install strainer inside the mixing tank at suction hole while performing pickling. Install 20 micronfilter and 5 micron filters in the discharge line during the high speed flushing using oil as media offlushing. 2.1.7 Fill the system using fresh cold water in the CS line, circulate and check for the leaks.

2.2: DEGREASING - FOR CS LINE ONLY:

2.2.1 Clean and physically check all the temporary 3B hoses, mixing tank and all other equipment prior to start of job. If required clean it and make it dust and other contamination free. 2.2.2 Fill the system using fresh water or the water supplied by (brackish water should not be used) and maintain 3/4 level in the mixing tank. Circulate the system and check for the leaks. 2.2.3 Fix the leaks if any and no leaks then flush the water and drain the system.2.2.4 Fill the system again with fresh water. 2.2.5 Heat the system to 150 ºF (65°C).2.2.6 Circulate for fifteen minutes.2.2.7 Add Beyond 2001, non corrosive mild degreaser/ 2.2.8 Circulate for four hours. 2.2.9 After four hours, flush with water to get pH 6 to 7. 2.2.10 Degreasing completed, proceed for the Acid Pickling.

(*: By the Weight of System)

2.3: ACID PICKLING- FOR CS : 1. Fill the system using fresh water or water supplied by DESCON, check for leaks.2. Heat to 150ºF to 180 ºF (65°C).

3. Add 0.2% (bvos**) Rodine-50, or Armohib-28 (HCl acid Inhibitor).4. Circulate for 15 minutes. Use anti foam as needed. 5. Add 5% (bwos*) HCl Acid; Check the HCl concentration and adjust it. (Refer Safety Note).6. Add 0.5% Pen-5 (surfactant) and anti foam (as needed)7. Circulate for minimum four hours while hourly return line sample titration formonitoring iron, pH, and percentage of acid. 8. Drain the system.

PASSIVATION

9. Fill the system and heat to 150 ºF (70°C). 10. Add Soda Ash, Liquid Caustic and Sodium Nitrite. (Refer Safety Note) 11. Circulate for three hours. 12. Drain the system. 13. System is neutralized, passivated and coated with protective thin coating of nitrite. 14. CS pipeline Pickling and Chemical cleaning job completed. 15. Purge with Nitrogen or dry air to dry the internal surface of pipeline.

(* By the Weight of System) (** By the Volume of System)

OIL FLUSHING

16. Rig-up the system by connecting CS & SS lines.

17. Install 20 micron filter or SS mesh at the suction of centrifugal pump or inside the mixing tank.

18. Install 5 micron filter at the discharge line

19. Fill the system with Oil provided by Descon / Client

20. Circulate & check for the leaks, fix the leaks, if any

21. Start circulation using Medium speed ( 2 foot/ sec ) & gradually increase to 4 to 6 foot/ sec

22. Continue circulation for 2 hours and dump the oil

23. Fill the system using the oil provided by Descon / Client and circulate for 6 hours

24. During circulation observe & clean the filters ( if required ) at every 2 hours

25. Drain the system

26. Fill the system using the oil provided by Descon / Client and circulate for 6 hours

27. During circulation observe & clean the filters ( if required ) at every 2 hours

28. Check with Client before dumping / draining the system

29. Job completed

2.4.Cleaning Acceptance Criteria and Testing methods:

2.4.1 The end result of chemical cleaning of the internal surface of compressor pipelining will be the silver gray shining colour or black magnetite (either one) coating on the internal surface. This could be observed by visual inspection at the end of pipeline. 2.4.2 Pipeline internal surface should be free from oil or grease. 2.4.3 Iron, HCl Acid and pH testing will be carried out using Iron testing procedure as provided in the attachment.

NOTE:

1. It is important that DESCON shall maintain 0.5 psi positive nitrogen pressure after

completion of 3B’ job till the boxing the lines or immediately continue oil flushing.

2. End result of chemical cleaning will be a silver shiny colored piping surface internal coating or a black colored magnetite coating. Both are acceptable results. If DESCON disagrees with these criteria then it must be notify to 3B prior to the job.

Safety Note:

1) Acid mask, PPE is required. Acid safety training will be given to the 3B operator and site persons. 2) 3B Automatic suction line system will be used to mix HCl.3) Special care should be taken while dealing with HOT solution of the system. Rubber gloves,rain coat, boots and safety face shield must be used. 4) Daily tool box meeting will be conducted prior to the job.5) Change shift note and job brief will be provided by out going crew to the in coming crew.6) Besides installed temperature gauges on the equipment, laser temperature gun will be used tocheck the temperature of the lines. 7)All area of chemical cleaning should be barricaded with sign board “Chemical Cleaning job in Progress”. 8) Make sure the availability of potable eye wash station (DESCON to provide) at the job site.9) Chemical resistance coverall, gas mask, face shield and PPE is required for the persons mixingthe chemicals whereas all other need general PPE.

3.0: Equipment to be used on job:

Waste tank of 5,000 Gal Cap.

2” Diaphragm Pump

1|/2” Chemical Hose

4” Chemical Hose/20 ft.

Centrifugal pump

Mixing Tank

Frac Tank 22,000 gallon

Steam Generator 6’x12’

1 each, Tanker with drain valve and filling top manhole.

1 each, Teflon body pneumatic pump for Ammonia transfer

Lot, Rubber hoses with 300 PSI bust pressure and 90°C temp.

Lot, Rubber hoses with 300 PSI bust pressure and 90°C temp.

1 each, 800 GPM, 100 PSI, 200 feet head.

2 each, 3.5M x 1.75M x 7.65M, with steam coil, 2000 gal Vol

1 or 2 each, waste holding tank with 22,000 Gal Cap., 7’ x 40’

1 each, 700 KG per hour, diesel driven, with TPI Certificate.

3.1: CHEMICALS TO BE USED ON JOB (3B WILL SUPPLY):

MSDS will be submitted for all the material:

a) Beyond 2001 b) HCl c) Rodine-50 d) PEN- 5 e) Antifoam f) Soda Ash g) Liquid Caustic h) Sodium Nitrite i) Nitrogen cylinders -10 numbers.

3.0. EXTEND OF SUPPLY OF 3B:

Manpower per shift (2 shifts, 12 each)

1 Project Manager 1 As and when needed2 Operators 23 Supervisors 14 Chemical Cleaners 25 Drivers 1

NOTE: All the above manpower will be on 24 hours basis, half numbers each shift.

EQUIPMENT Qty

1 Centrifugal Pump 800 GPM -Size 5’x5’ 1 -2 Mixing tank, 2000 Gal - Size 10’ x4’x5’ 1 -3 Fittings Lot4 Pickup 25 Frac tank /Waste holding tank - Size 40’x7’x8’1 17 Trailer 1 - 40 feet8 Steam generator 1 - 6’ x 12’

4.0. EXTENT OF SUPPLY DESCON:

4.1. Isolation of the system and their components, spools, connections or units not included as a part of the cleaning. All instrumentation shall be removed and tapings shall be either plugged or flanged prior to chemical cleaning.4.2. Clean working access to the working site and space for the equipment set up.

4.3. Fast, good pressure, clean fresh water as required by 3B. This includes cleaning and flushing water. 3B estimate minimum 15,000 gallons of fresh water for the job. 4.4. Air line and fuel to the 3B equipment like pumps, boiler other site equipment.

4.5. Three phase electricity to power the boiler water pump or generator 10 KV to hook up the power line for boiler water pump.

4.6. Supply of dry flushing oil as required. 3B estimate about four volume of the system. 4.7. Chemical waste will be collect in waste holding tank (Frac Tank). Waste disposal cost is not considered. Incase if Descon wants 3B to handle, transport and dispose the waste then separate quotes will be provided. See the waste disposal section -5 below for further details. 4.8. Continuity of work for the duration of project. 4.9. Maintenance support around the clock operation as required at 3B’s site. 4.10. Provide forklift/crane to load, unload, spotting the equipment and rig-up/de-rig.

4.11. Lighting at the site around the clock operation. 4.12. Scaffolding if required at the site to access all the tie-in points. 4.13. All security passes and permits as per the requirement for 3B /ISCO equipment and personnel.

4.14. Representative or inspector of DESCON to witness the results. The degree of cleaning could be judged by visual inspection or black light inspection. Presence of gray shining or black magnetite coating should be end result of cleaning and acceptable. 4.15. One technical person and PRO from DESCON to assist 3B around the clock. 4.16. All special or extra (other than regular) safety gears as required by DESCON safety regulations to all working crew of 3B like H2S masks or any other special safety gears as required by DESCON. 4.17. Written notice to proceed the job and approval of the procedure, terms and condition. 4.18. All safety signs (additional to normal) as required by the DESCON around the contractor’s equipment. 4.19. All fabrication work to provide 2” and 4” 150# flanges connecting points for 3B equipment.

4.20. Suitable shaded 8’ x 20’ space to store chemicals at job site. 4.21. Potable eye wash station close to working site.

5.0. WASTE DISPOSAL

Since chemicals will be used for the cleaning of DESCON pipes therefore waste generated will be property of DESCON. The chemical waste will be collected in a holding tank and after that neutralized to pH 6.5 -8.5. 3B will either dispose the waste within 24 hours at the job location at free of cost OR 3B will transport and treat the waste against DESCON manifest to NCC for the final disposal as per the agreed cost. Approximate 6,000 gallons waste will be generated. In case if NCC refuse to provide waste dumping permit then DESCON should find an alternate waste dumping location from KCC.

6.0. HEALTH & SAFETY

As mentioned in this proposal, 3B will comply and observe all the Health and Safety rules of DESCON. The following are the details to satisfy the CLIENT’S OR (DESCON) questions.

6.1.1 CONTRACTOR (3B ) will submit (if required) all the MSDS for the chemicals used for the job provided if the chemical supplied by the 3B.

6.1.2 All personnel of the CONTRACTOR are familiar with the hydro-jet cleaning safety rules.

6.1.3 All employees of the CONTRACTOR will attend a safety course conducted by the CLIENT.

6.1.4 All personnel of the CONTRACTOR will use the personal protective kit and the other required safety equipment as per the policy of DESCON for mixing the chemicals and handling the equipment.

7.0. MOBILISATION

CLIENT (DESCON) Documents Required for CONTRACTOR (3B) Mobilization of Cleaning Equipment Package:

7.1.1 Contract for the Work

7.1.2 Eight days written notification to proceed.

7.1.3 Final Scope Definition

Rev#1 DESCON (KCC, SHUAIBA AREA) PIPELINES CHEMICAL CLEANING & OIL FLUSHING

Comp. Line

KCC lines.

Centrifugal Pump

Frac Tank/ Waste holding Tank

ATTACHEMENTS

IRON TESTING PROCEDURE:

1. Turn on the DR - 700 and set the reading 50.03.1 by using up / down arrows or side arrows. 2. Take 0.1 ml or (100 µ micro liters) sample; add 100 - ml DI water. 3. Take 25 ml from the above dilution and place the sample, press Zero set. 4. Add 1 reagent pillow for 25 ml in the above step 3 sample, wait for 3 minutes. (If 10 ml

reagent pillow, than take 10 ml sample). 5. Place step 4 sample with reagent and press READ.

ppm Iron = The Calorimeter value × 1000

% Iron = The Calorimeter value × 1000 = ppm divided by 10,000

For HCl testing : 1) Take 2 ml sample of the system acid solution. 2) Add few drops of mixed indicator. 3) Titrate 0.5 NaOH solutions from red to green end point. 4) % HCl = ml of Caustic used x 0.89. 5) Record the conclusion and report the result.

pH testing procedure using pH Meter

1. Turn on the pH meter.

2. Start calibrating it by using Buffer Solution pH 4, keep few minutes until it shows pH 4 on

the main Display of pH meter.

3. After this start calibrating it by using Buffer Solution pH 7, keep few minutes until it shows

pH 7 on the main display of pH meter.

4. After calibration, wash the glass electrode with DI water and dry it with tissue paper.

5. Take the sample in a beaker and place the glass electrode in it.

6. Press READ and measure the pH of the sample and record the reading.

7. Wash the glass electrode and always keep it immersed in water so as to maintain its

sensitivity.

MAK/12/805 Rev#1 3B General Trading & Contracting Co. 12 July

2012

DESCON (KCC, SHUAIBA AREA) PIPELINES CHEMICAL CLEANING & OIL FLUSHING

CHEMICAL CLEANING JOB LOG

CUSTOMER:_________________ LOCATION:________________ DATE:__________

JOB #:__________________ 3B OPERATOR:_______________ UNIT #_________

Date Time Activity pH Iron % Temp Acid Type /

°F %