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Engineering Procedure

SAEP-388 4 November 2013


Cleaning of Pipelines
Document Responsibility: Materials and Corrosion Control Standards Committee

Saudi Aramco DeskTop Standards


Table of Contents

1 Purpose.......................................................... 2
2 Scope... 2
3 References.. 2
4 Responsibilities 3
5 Techniques for Cleaning Pipelines.. 6
6 Surfactant Cleaning Procedure.... 8
7 Sampling and Acceptance Criteria.... 19
8 Evaluating Chemical
Cleaning Performance.... 20
9 Wastewater Disposal... 20

APPENDIX I - Safety Requirements.. 21


APPENDIX II - Preparatory Work... 22
APPENDIX III - Nitrogen Amount Calculation.. 23
APPENDIX IV - Cleaning of Pipelines
Containing Valves....... 24

Previous Issue: New Next Planned Update: 4 November 2018


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Primary contacts: Al-Musalami, Faiz Hijji on +966-13-8809569 and
Al-Abdulmohsin, Nader Mohammed on +966-13-8809551

CopyrightSaudi Aramco 2013. All rights reserved.


Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

1 Purpose

It is necessary to clean pipelines for their efficient operations, corrosion control,


minimizing black powder formation and reaching the desired pipelines cleanliness
levels. This specification does not override the pipeline manufacturer's cleaning
recommendations especially where warranty rights are involved. Differences shall be
questioned and resolved by the proponent. It is necessary to clean pipelines to meet the
minimum acceptance criteria stated in SAES-L-388.

Cleaning contractors are chosen from the CSD-approved list to perform the cleaning
operations. A cleanliness criterion has been established as a minimum standard for
evaluating the performance of a chemical cleaning run. Cleaning is accomplished by
(not necessarily in the sequence listed below):
Mechanical cleaning (scraping)
Chemical cleaning
Combination of listed above methods

2 Scope

This procedure defines the responsibilities of various departments involved in the pre
commission and operational cleaning of pipelines. It outlines methods to determine the
need for cleaning and the criteria for selecting specific cleaning procedure, and steps
involved in various cleaning procedure alternatives. Advice is available from
Consulting Services Department (CSD) and Pipelines Department (PD) to review
contractors detailed procedures for cleaning specific pipelines.

The procedures listed herein are applicable to clean undesirable deposits in pipelines.
For evaluation and recommendation of alternative cleaning procedures not listed herein,
contact CSD.

For cleaning pipelines containing valves, contact CSD, see Appendix IV.

3 References

The requirements contained in the following documents apply to the extent specified in
this procedure.

Saudi Aramco References

Saudi Aramco Engineering Procedures


SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement

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Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

SAEP-327 Disposal of Wastewater from Cleaning, Flushing


and Dewatering Pipelines and Vessels
SAEP-1662 Cleaning of Heat Exchangers and Unfired Plant
Equipment

Saudi Aramco Engineering Standards


SAES-A-007 Hydrostatic Testing Fluids and Lay-Up Procedures
SAES-A-104 Wastewater Treatment, Reuse and Disposal
SAES-B-069 Emergency Eyewashes and Showers
SAES-L-388 Pipelines Cleanliness Requirements for
Hydrocarbon Services

Saudi Aramco Best Practice


SABP-L-012 Guidelines for On-Stream Scraping of Pipelines

Saudi Aramco General Instructions


GI-0002.100 Work Permit System
GI-0006.012 Isolation Lock Out and Use of Hold Tag

Saudi Aramco Construction Safety Manual

Chemical Hazard Bulletin (CHB) # 155

Saudi Aramco Hazardous Waste Code (SAHWC)

4 Responsibilities

4.1 The Project Construction Agency is responsible for the overall cleaning activities
of new pipelines.

4.2 Pipelines Department is responsible for cleaning existing pipelines.


Note: Job Safety Analysis (JSA) shall be performed by the proponent before starting
the cleaning activities of a pipeline.

For existing pipelines,

4.3 Pipelines Department/Maintenance


Prepare the pipeline mechanically
Provide maintenance support during the cleaning operation
Coordinate cleaning and obtains approved contractor services.

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Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

4.4 Pipelines Department/Operations Engineering


Prepare necessary operation procedures, advises the foreman of the facility
during the cleaning of pipelines.
Act as a technical representative during pipelines cleaning.
Ensure adequate safety procedures and precautions are taken. Notifies Loss
Prevention Department to review safety before and during cleaning of
pipelines as needed.
Coordinate and obtain the approval of new cleaning chemicals or techniques
from CSD.
Request the presence of specialist personnel from PD and/or CSD as needed.

4.5 Pipelines/Inspection
Has the responsibility for inspection before and after cleaning.
Is responsible to get and keep the cleaning activities records from the
cleaning contractor
Maintains history of pipelines cleaning and incorporates relevant reports and
data into permanent pipelines records

4.6 Loss Prevention Department


Audit cleaning operations and permits
Advise on field safety precautions on request.

4.7 Research and Development Center (R&DC)


Evaluate new cleaning chemicals
Provide specialist/consultant advice and testing on request

4.8 Regional Laboratories


Perform cleanliness criteria test (solid loading), chemical analysis, and
analyses during actual cleaning operations on request.
Verify chemicals used for chemical cleaning on request.
4.9 Consulting Services Department
Maintain and qualify the cleaning chemicals and contractors.
Review and approve the cleaning procedures and subsequent changes
mandated by the field conditions.
Provide specialist/consultant advice on request.

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Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Witness the cleaning operation on request.

4.10 Cleaning Contractor


The cleaning contractor is selected from the CSD- approved list of pipelines
cleaning.
Contractor has the overall responsibility for the planning and execution of
the chemical cleaning operations.
Contractors responsibilities shall be stated in the contract. Usually, this
include, but not limited to, submittal of procedures and documents, supply of
chemicals, inhibitors, auxiliary pumping, heating equipment, on line
monitoring and control of corrosion rates; disposal of all waste water and
chemical solutions and cleaning pipelines to meet, at least, the acceptance
criteria outlined in SAES-L-388.
Provide the required experienced manpower that includes, but not limited to,
Project Manager
Project Supervisor
QA/QC Inspector
Safety Coordinator
Work Permit Receiver
Certified chemist
Cleaning crew

4.11 Design Review Requirements for Pipelines Projects and Major Pipelines Upgrade

Design Basis Scoping Paper (DBSP) and Project Proposal

The DBSP and Project Proposal packages submitted to CSD for review shall
specifically state the need for mechanical/chemical cleaning.

Detailed Design

The detailed design packages shall provide a cleaning document to be used as a


basis during the construction phase of the project for preparation of detailed
cleaning procedures. The cleaning document submitted to CSD for review shall
include:
Scope of work
Proposed cleaning technique(s)
Cleanliness acceptance criteria
Equipment lay-out diagram of the cleaning circuit for the line segments

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Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Marked-up P&IDs for the line segments


Drying and lay-up requirements

5 Techniques for Cleaning Pipelines

Pipelines are either pre-commission cleaned to remove mill scale, construction debris
and any form of solids, or post-commission cleaned to remove deposits which
accumulate while the line is in service.

Pre-commission cleaning is usually carried out on pipelines. Care during design,


manufacture, fabrication, storage and installation of pipes can minimize these problems.
Good storage facilities with end caps on the constructed pipelines, the internal grinding
of welds where possible and ensuring that weld rods, stones and gloves, etc., are kept
out of the line are practices which should-be implemented.

Newly constructed pipelines are to be turned over to the proponent in a clean condition.
To accomplish this clean condition, these pipelines are typically
chemically/mechanically cleaned to remove construction debris and any form of solids.

Existing pipelines in sales gas service are also chemically/mechanically cleaned to


remove black powder that poses multiple operational problems such as delays in inline
inspection (ILI) runs, erosion corrosion of control valves, plugged filters, and
contamination of customer hydrocarbon supply.

Pipelines are cleaned by scraping and/or chemical cleaning.

5.1 Mechanical Cleaning (Scraping)

Scraping is a mechanical cleaning method for pipelines cleaning. Scrapers are


generally made of polyurethane foam and shaped like oversized bullets.
They are inserted into a pipeline by a specially designed launcher which is
connected to a high pressure medium to propel the scrapers. The polyurethane
material used for the scrapers is sufficiently flexible that it will negotiate bends
in the line. Since scrapers have been known to get stuck in lines the contractor
should be questioned as to how blocked scrapers will be located. At the outlet, a
scraper receiver is employed to recover the emerging scrapers and debris.

Depending on the deposit present, scraper design can be hard rubber, silicon
carbide, hardened steel wire, or gel. Sometimes balls with scraper chains are
used. A series of scrapers, in larger sizes, is run through the line until all the
fouling is removed.

Scraping is manpower intensive and requires much field supervision. In many


cases, lines not originally designed for scraping cannot be cleaned by this
method. Scrapers usually contain spring-loaded metal blades which are centered

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Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

in the pipeline and pulled by cable or propelled by hydraulic pressure.

To clean existing pipelines in service, refer to SABP-L-012 Guidelines for


On-Stream Scraping of Pipelines.

For cleaning newly constructed pipelines and existing off stream pipelines, refer
to SABP-L-012 Guidelines for On-Stream Scraping of Pipelines. The scrapers
will be propelled by Nitrogen, dry gas or dry hydrocarbon medium using the
cleaning contractor equipment.

Note: brushes in all supplied scrapers are recommended to be made of brass


material to eliminate sparks due to friction between the scrapers brushes and the
pipe inner wall.

5.2 Chemical Cleaning

The chemical cleaning operation is typically done while the pipeline is in service
or out of service and will be specified by Pipelines Department. The chemical
cleaning methods typically fall under two methods: 1) use of chemicals with
diesel or 2) use of chemicals with gel. Water is not to be used as a mixing
medium when surfactants are used. The chemical cleaning train that contains
the chemicals compartment is typically propelled with dry air or nitrogen.
If air is used to propel the chemical cleaning train, a nitrogen buffer zone
between the chemical train and air is to be utilized. This nitrogen buffer zone
shall be placed immediately upstream and downstream of the chemical cleaning
train. The nitrogen length on each side shall be no less than 10% of the total
length of the pipeline section being chemically cleaned to ensure that diesel and
air do not mix.

Deposits normally include black powder, rust, scale, grease, weld spatter, stones,
etc. Scales and grease are chemically soluble but beads of weld metal are not,
although it is possible for a chemical cleaning operation to loosen these by
undercutting. In this state, they may become detached while the line is in service.

In practice, chemical cleaning should be used to remove soluble scale and grease
but should be followed by multiple scrapers. The line should also be dried as
specified under SAES-A-007 to prevent subsequent corrosion immediately after
cleaning. In the case of pipelines, these shall be filled with nitrogen, dry gas or
dry crude as soon as possible after cleaning. Due to the network length of
piping involved, communication between members of the cleaning crew can be
difficult, and shall be addressed prior to start of the job. Lines containing iron
sulfide will release H2S gas when contacted with acid and suitable precautions
have to be taken as per Chemical Hazard Bulletin (CHB) # 155.

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Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Cleaning Chemicals
There are mainly two chemical categories used for pipelines cleaning:
1. Acids
For detailed chemical cleaning procedure using acids, refer to
SAEP-1662 Cleaning of Heat Exchangers and Unfired Plant
Equipment.
2. Surfactants
Surfactants chemicals are non-corrosive compounds that lower the
surface tension of a liquid, the interfacial tension between two liquids,
or that between a liquid and a solid. Surfactants may act as detergents,
wetting agents, emulsifiers, foaming agents, and dispersants.
For the approved list of surfactants, or approval of new ones, refer to CSD.

6 Surfactant Cleaning Procedure

For newly constructed pipelines, contractors, Pipelines Department and/or Saudi


Aramco Project Management Team (SAPMT) shall submit their respective procedures
covering their area of responsibilities during the chemical cleaning operations.
The procedure shall include the work activities and responsibilities before, during, and
after the chemical cleaning operations.

The contractor, their submitted procedure shall include the following:


Safety requirements (Appendix I)
Responsibilities
Site Access and work permit
Preparatory work (Appendix II)
Equipment layout
Chemical cleaning schedule
Detailed chemical cleaning procedures

The chemical cleaning procedure shall include the valve arrangements before, during, and
after each chemical cleaning run. It shall also include the detailed chemical train
launching procedure, the monitoring and tracking of the chemical train, and the receiving
procedure. The procedure shall also include the data monitoring such as upstream and
downstream pressure of the chemical train, its velocity, and any other important data.

Page 8 of 24
Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Equipment Layout:

VALVE DESCRIPTION:
VALVE DESCRIPTION
MIV Main Isolation Valve
A Chemical/Diesel Injection Valve
B N2/Air Main Injection Valve
C N2/Air Branch Injection Valve
D N2/Air Branch Injection Valve
V1 Launcher Vent
V2 Launcher Vent

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Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Detailed Surfactant Cleaning Procedure

Before performing surfactant cleaning, rigorous mechanical scarping operation shall be


performed to remove as much solids as possible from the pipeline.

Surfactant cleaning of the pipeline shall be executed to ensure the removal of any sand,
corrosion products such as iron carbonate, iron oxides and iron sulfide, metallic iron, weld
spatter, salt and scale generated during the dewatering and swabbing.

Specific chemical cleaning train should be designed for the entire pipeline in the scope of
the procedure. The segment of pipeline from permanent launcher to permanent receiver
trap is to be chemically cleaned by two (2) cleaning train/runs with additional optional runs
if required. Refer to Figure 1 Chemical Cleaning Train for its configuration.

Pre-requisites:

Prior to start the surfactant cleaning train run, an initial back pressure of minimum 40 psig
shall be ensured in order to perform the run in controlled manner and within the required
velocity.

The medium to build up the back pressure and to propel the chemical cleaning train shall be
with nitrogen and dry air having a minimum dew point -1C. Record log of the dry air dew
point shall be maintained during the back pressure build up and the train run. Dew point
reading shall be taken as the dry air entering into the pipeline every 4 hours.

A slug of nitrogen will be injected upstream and downstream of the cleaning train to create
a buffer zone between the dry air and the cleaning train.
Please refer to Table 1 Chemical Train Composition and Run Duration for its volume.
The specified gallons of nitrogen provided in Table 1 is equivalent to at least 20% of the
pipeline length that will be cleaned (10% before that cleaning train and 10% after the
cleaning train).

Whenever the surfactant cleaning is completed as per the approved chemical cleaning
procedure, then the pipeline as required shall be purged and pressurized to a minimum
pressure of 30 psig (Nitrogen) in preparation to the introduction of the transported media.

The planned cleaning run for the pipeline segment along with the expected amount of
chemicals and diluents are to be shown in Table 1.

Page 10 of 24
Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Table 1 - Cleaning Train Composition and Run Duration

Pipeline
From To
Dry Air
High
First Scraper Density N/A
Foam
st
1 Batch of
N2 Gallons XXX
Nitrogen
High
Second Scraper Density N/A
Foam
st
Detergent Gallons XXX
st
1 and 2
nd 1 Batch
Diesel Gallons XXX
Surfactant
Cleaning Third Scraper Conical Scraper Brush
Runs** nd Detergent Gallons XXX
2 Batch
Diesel Gallons XXX
Fourth Scraper Scraper Brush
nd
2 Batch of
N2 Gallons Chemical
Nitrogen
High
Fifth Scraper Density N/A
Foam
Dry Air
*Estimated run duration Hrs. XXX

* Estimated travel time is based on dry air velocity of 1.0 kilometer per hour. Velocity, volumes of
chemicals and diluents and type of chemicals may be adjusted depending on the gathered
results from the previous runs.
** Optional Run Only When Required.

Vacuum Truck will be used on a regular interval to empty the tanks and dispose
it to an approved waste disposal site/company.
Note: Refer to Appendix III for nitrogen amount calculation.

Page 11 of 24
Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Figure 1 - Surfactant Cleaning Train

Surfactant cleaning will be performed as per the sequence described as follows:

Steps Description
1 Rig up equipment for both Launcher and Receiver
2 Deploy hoses supply line for connection
3 Pressurize hose against closed valve for 5 minutes to confirm connection leak test
Nitrogen purity entering the pipeline should be checked by the contractor using a hand held Nitrogen analyzer and as
4 per approved pureness of 95% minimum.
Volume and sequence will be as per Table 1 Pipeline Chemical Train Composition and Run Duration
Prepared the chemical required quantity base on Contractor concentration of diluents slug. Volume and sequence
5 will be as per Table 1 Pipeline Chemical Train Composition and Run Duration.
Collect one set of sample per batch as per Section 7.
As per pre-requisite, verify and confirm that the line is pack to a minimum 40 psig of nitrogen.
6
Re-packed when necessary.

1st Batch of Nitrogen:

Page 12 of 24
Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Steps Description
VALVE START-UP POSITION:
VALVE STATUS DESCRIPTION
MIV CLOSED Main Isolation Valve
A CLOSED Chemical/Diesel Injection Valve
B CLOSED N2/ Air Main Injection Valve
C CLOSED N2/Air Branch Injection Valve
D CLOSED N2/Air Branch Injection Valve
V1 CLOSED Launcher Vent
V2 CLOSED Launcher Vent

Launch 1st Scraper and Inject Nitrogen


De-pressurize Launcher Trap by opening V1 and V2 vent valve.
Check scraper tracking device prior to insertion.
Open Trap Door and insert Scraper (High Density Foam No Brush) up to launcher reducer.
Close Launcher Trap Door.
Crack Open Valve C to purge upstream of the scraper through V1
Once purged, Closed V1 and inject max 3 psi of nitrogen to have a positive pressure upstream of the
scraper. Closed Valve C.
Crack Open Valve D to purge downstream of the scraper through V2.
Once purged, close Valves V2 and D.
Pressurize trap to equal line pressure by opening Valve C.
Open main isolation valve (MIV) and Launch scraper by nitrogen.
Continue pumping nitrogen till the required amount has been injected.
Close C and MIV valve.

Launch 2nd Scraper:


De-pressurize Launcher Trap by opening V1 and V2 vent valve.
Open Trap Door and insert 2d Scraper (High Density Foam No Brush) up to
launcher reducer. Close Launcher Trap Door.
Crack Open Valve C to purge upstream of the scraper through V1.
Once purged, Closed V1 and inject max 3 psi of nitrogen to have a positive
pressure upstream of the scraper. Closed Valve C.
Crack Open Valve D to purge downstream of the scraper through V2.
Once purged, close Valves V2 and D.
Pressurize trap to equal line pressure by opening Valve C.
Open MIV valve and Launch 2d scraper by nitrogen.
After the scraper passes the MIV valve and injection point (Valve A), immediately close C and MIV valve.

VALVE ENDING POSITION


VALVE STATUS DESCRIPTION
MIV CLOSED Main Isolation Valve
A CLOSED Chemical/Diesel Injection Valve
B OPENED N2/ Air Main Injection Valve
C CLOSED N2/Air Branch Injection Valve
D CLOSED N2/Air Branch Injection Valve
V1 CLOSED Launcher Vent
V2 CLOSED Launcher Vent

Page 13 of 24
Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Steps Description
Cleaning Train
Diesel and Surfactant Injection I Scraper Loading and Launching Sequence.

FIRST BATCH CHEMICAL

8
VALVE START-UP POSITION:
VALVE STATUS DESCRIPTION
MIV CLOSED Main Isolation Valve
A CLOSED Chemical/Diesel Injection Valve
B CLOSED N2/ Air Main Injection Valve
C CLOSED N2/Air Branch Injection Valve
D CLOSED N2/Air Branch Injection Valve
V1 CLOSED Launcher Vent
V2 CLOSED Launcher Vent

Insert 3rd Scraper


De-pressurize Launcher Trap by opening V1 and V2 vent valve.
Open Trap Door and insert 3rd Scraper (Conical with Brush) up to launcher reducer.
Close Launcher Trap Door.
Crack Open Valve C to purge upstream of the scraper through V1.
Once purged, Closed VI and inject max 3 psi of nitrogen to have a positive pressure upstream of the
scraper. Closed Valve C.
Crack Open Valve D to purge downstream of the scraper through V2.
Once purged, close Valves V2 and D.

Inject 1st Batch of Chemical and Diesel


Open Valve A and inject the required amount of surfactant followed by the required amount of diesel.
Refer to Table 1 for the batch volume.
Once fully injected, close Valve A.

Page 14 of 24
Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Steps Description

Launched 3rd Scraper


Pressurize trap to equal line pressure by opening Valve C.
Open MIV valve and Launch 3rd scraper by nitrogen.
After the scraper passes the MIV valve and injection point (Valve A), immediately close C and MIV valve.

VALVE ENDING POSITION


VALVE STATUS DESCRIPTION
MIV CLOSED Main Isolation Valve
A CLOSED Chemical/Diesel Injection Valve
B CLOSED N2/ Air Main Injection Valve
C CLOSED N2/Air Branch Injection Valve
D CLOSED N2/Air Branch Injection Valve
V1 CLOSED Launcher Vent
V2 CLOSED Launcher Vent
SECOND BATCH

VALVE START-UP POSITION:


VALVE STATUS DESCRIPTION
MIV CLOSED Main Isolation Valve
A CLOSED Chemical/Diesel Injection Valve
B CLOSED N2/ Air Main Injection Valve
C CLOSED N2/Air Branch Injection Valve
D CLOSED N2/Air Branch Injection Valve
V1 CLOSED Launcher Vent
V2 CLOSED Launcher Vent

Page 15 of 24
Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Steps Description

Insert 4th Scraper


De-pressurize Launcher Trap by opening V1 and V2 vent valve.
Open Trap Door and insert 4th Scraper (With Brush) up to launcher reducer. Close Launcher Trap Door.
Crack Open Valve C to purge upstream of the scraper through V1.
Once purged, Closed V1 and inject max 3 psi of nitrogen to have a positive pressure upstream of the
scraper. Closed Valve C.
Crack Open Valve D to purge downstream of the scraper through V2.
Once purged, close Valves V2 and D.

Inject 2nd Batch of Chemical and Diesel

Open Valve A and inject the required amount of surfactant followed by the required amount of diesel.
Refer to Table 1 for the batch volume.
Once fully injected, close Valve A.

Launched 4th Scraper and Inject 2nd Batch of Nitrogen


Pressurize trap to equal line pressure by opening Valve C.
Open MIV valve and Launch 4th scraper by nitrogen.
Continue pumping nitrogen required volume has been injected.
Close C and MIV valve.

VALVE ENDING POSITION


VALVE STATUS DESCRIPTION
MIV CLOSED Main Isolation Valve
A CLOSED Chemical/Diesel Injection Valve
B OPENED N2/ Air Main Injection Valve
C CLOSED N2/Air Branch Injection Valve
D CLOSED N2/Air Branch Injection Valve
V1 CLOSED Launcher Vent
V2 CLOSED Launcher Vent

Page 16 of 24
Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Steps Description

5th Scraper

10
VALVE START-UP POSITION
VALVE STATUS DESCRIPTION
MIV CLOSED Main Isolation Valve
A CLOSED Chemical/Diesel Injection Valve
B OPENED N2/ Air Main Injection Valve
C CLOSED N2/Air Branch Injection Valve
D CLOSED N2/Air Branch Injection Valve
V1 CLOSED Launcher Vent
V2 CLOSED Launcher Vent

Insert 5th Scraper


De-pressurize Launcher Trap by opening V1 and V2 vent valve.
Check scraper tracking device prior to insertion.
Open Trap Door and insert Scraper (High Density Foam No Brush) up to launcher reducer.
Close Launcher Trap Door.
Crack Open Valve C to purge upstream of the scraper through V1.
Once purged, Closed V1 and inject max 3 psi of nitrogen to have a positive pressure upstream of the
scraper. Closed Valve C.
Crack Open Valve D to purge downstream of the scraper through V2.
Once purged, close Valves V2 and D.
Pressurize trap to equal line pressure by opening Valve C.
When pressure is equalized, close Valve C.
Close Valve Band disconnect NGU and connect the air dryer's outlet hoses to the manifold.

Page 17 of 24
Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Steps Description

Launch 5th Scraper


Open Valve B, followed by Valve C.
Open the MIV valve and Launched 5th scraper by dry air.

VALVE ENDING POSITION


VALVE STATUS DESCRIPTION
MIV OPENED Main Isolation Valve
A CLOSED Chemical/Diesel Injection Valve
B OPENED N2/ Air Main Injection Valve
C OPENED N2/Air Branch Injection Valve
D CLOSED N2/Air Branch Injection Valve
V1 CLOSED Launcher Vent
V2 CLOSED Launcher Vent
11 Continue pumping dry air to propel the chemical slug train until it reach to receiver trap.
Dew Point and line pressures are to be recorded on an hourly basis at launcher and receiver stations as well as the
12
scraper movements.
With a positive back pressure monitored, station contractor crew leader shall control Valve E and/or Valve F and
13 release pressure in a controlled manner, maintaining a balance between dry air injection and release for
smooth/intact surfactant train movement having an average of 1 to 1.5 km/hr speed.
All liquid/solid slurry shall be received in temporary tanks.
14 Note: Vacuum Truck will be used on a regular interval to empty the tanks and dispose it to an approved waste
disposal site/company.
During the arrival of the Cleaning Train into the receiver, collect liquid samples from the two compartments of the
15
chemical cleaning train.
16 Once all the scrapers are inside the receiver trap, close the 30 main isolation valve.
Ensure that the receiver is free of pressure by venting the Receiver trap from the vent provided that Saudi Aramco
17
representative in on location. The receiver may be opened and scrapers retrieved.
18 Stop air injection
Repeat steps 7 to 18 for the 2nd run.
19
And 3rd run if the result requires additional runs.

After the scrapers have been received from the final cleaning run, the remaining collected sludge or waste
materials from the fractionation tanks will be transferred and disposed via vacuum tanker to an approved waste
disposal site/company.

20 PURGING AND FINAL LAYUP


Nitrogen Generating unit should be prepared and hooked-up prior to starting swabbing.

Scraper Loading and Launching Sequence:

VALVE START-UP POSITION


VALVE STATUS DESCRIPTION
MIV CLOSED Main Isolation Valve
A CLOSED Chemical/Diesel Injection Valve
B OPENED N2/ Air Main Injection Valve
C CLOSED N2/Air Branch Injection Valve
D CLOSED N2/Air Branch Injection Valve
V1 CLOSED Launcher Vent
V2 CLOSED Launcher Vent

Page 18 of 24
Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

Insert Foam Scraper


Perform foam scraping runs, following completion of chemical cleaning operation, to remove residual chemicals left
in the pipeline.
De-pressurize Launcher Trap by opening V1 and V2 vent valve.
Open Trap Door and insert Foam Scraper (with No Brush) up to launcher reducer.
Close Launcher Trap Door.
Crack Open Valve C to purge upstream of the scraper through VI.
Once purged, Closed VI and inject max 3 psi of nitrogen to have a positive pressure upstream of the
scraper. Closed Valve C.
Crack Open Valve D to purge downstream of the scraper through V2.
Once purged, close Valves V2 and D.
Pressurize trap to equal line pressure by opening Valve C.
Open MIV valve and Launch Foam scraper by nitrogen.

VALVE ENDING POSITION


VALVE STATUS DESCRIPTION
MIV OPENED Main Isolation Valve
A CLOSED Chemical/Diesel Injection Valve
B OPENED N2/ Air Main Injection Valve
C OPENED N2/Air Branch Injection Valve
D CLOSED N2/Air Branch Injection Valve
V1 CLOSED Launcher Vent
V2 CLOSED Launcher Vent
21 Continue pumping nitrogen to propel the swabbing train until it reach to receiver trap.
22 Dew Point and line pressures are to be recorded on an hourly basis at both launch and receiving stations.
With positive back pressure monitored, manipulate Valve E and/or Valve F and release pressure in a controlled
23
manner, maintaining a balance between nitrogen injection and dry air release.
24 Once the scraper is inside the receiver trap, close the main isolation valve.
Ensure that the receiver is free of pressure by venting the Receiver trap from the vent, and provided that a company
25
representative is on location. The receiver may be opened and scrapers retrieved.
26 Stop nitrogen injection.
Nitrogen Purging and Final Lay-up (as Per SAES-A-007 Section 5.2.3.6)
27 Continue purging the line with nitrogen, once the required dew point (-1C or lower) and N2 purity are reached at
the discharge vent, the vent will be closed and packing of the pipeline to 30 psig will commence.
When the line is at the required pack pressure, the N2 purity will be confirmed at the discharge valve and at all
28
required valves along the length of the pipeline.
29 Stop nitrogen injection.

7 Sampling and Acceptance Criteria

Sampling of cleaning batch (before injection) will be taken at the launching (from
tanks) and receiving locations (from scraper trap) in order to monitor the surfactant
cleaning run.

7.1 Clean containers will be used to collect the samples and they shall be clearly
identified with the following information:
o Pipeline Name, Date, Location (KM), and Batch Number

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Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

o Samples will be sent to a laboratory for their solid in suspension counting


(% in Volume).
o Pipeline will be considered clean enough if it meets the cleanliness criteria
stated in SAES-L-388.

7.2 Sampling at the Receiver


1. Control the surfactant discharging flow rate by throttling the discharge valve.
2. A clean container should be placed under the sample valve.
3. Open the sampling valve and flush at least 500 ml of fluid through the
valve. Do not close the valve after flushing.
4. Place the sample bottle under the valve and collect fluid. Do not touch the
valve whilst taking the sample as this could cause particles to loosen and be
released from the valve.
5. Withdraw the sample bottle leaving the valve open. Rinse the inner surface
to the bottle with fluid and discard the fluid. Repeat Steps 4 and 5 for all
the bottles to be used.
6. Repeat the above without closing the valve and collect two (2) liquid
samples per chemical compartment.
7. One sample of fluid will be analyzed by the cleaning contractor to obtain
solids contain per volume. Second sample shall be given to Saudi Aramco
Operations Representative for any future required confirmation of results.

8 Evaluating Chemical Cleaning Performance

Refer to SAES-L-388.

9 Wastewater Disposal

Disposal of all wastewater, and spent cleaning chemicals shall be in accordance with
SAEP-327, SAES-A-104 and Saudi Aramco Hazardous Waste Code (SAHWC).
The disposal of effluents outside Saudi Aramco facilities shall be sent to an approved
wastewater disposal facility provided by the Environmental Protection Department,
Dhahran. For the disposal of effluents outside Saudi Aramco facilities, the chemical
cleaning contractor shall submit a waste disposal manifest to Saudi Aramco Project
Construction Agency in case of new pipelines or Pipelines Department for existing
pipelines.

Revision Summary
4 November 2013 New Saudi Aramco Engineering Procedure.

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Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

APPENDIX I - Safety Requirements

All personnel shall be aware of emergency procedures and will attend contractor
safety/site introduction meetings on a daily basis before the start of any work or as
required to ensure that everyone understands his responsibility and what to do in case of
emergency.

First aid and fire protection equipment shall be kept on the site (launcher and receiver)
Minimum of 2 dry powder fire extinguishers (30 lb) shall be available on both sites.

All involved personnel on site shall wear proper protective equipment (PPE).
This includes fire resistance coveralls, Neoprene, PVC or NBR gloves or nitrile rubber,
Safety Glasses and Steel Toed Shoes/chemical resistant boot.

Prior to commencing chemical cleaning operations, warning signs indicating Cleaning


is On-going shall be posted at launcher and receiving ends and along the pipeline
section corridor particularly at road crossings. Barriers shall indicate the limits of a
pipeline leaning area. Warning signs, in English and Arabic, shall be placed in
permanent locations.

Use of mobile phones and smoking within the scraper trap areas are prohibited.

Any leaks and repairs identified shall only be corrected when the system under test has
been depressurized to zero.

Provide an effective eye wash station and emergency shower per SAES-B-069 on both
launching and receiving station.

If chemicals are needed, chemical Material Safety Data Sheets (MSDS) should be
attached with the chemical containers and fully understand by all personnel handling it.

Disposal of cleaning waste shall be as per SAEP-327.

Job Safety Analysis (JSA) shall be performed by the proponent before starting the
cleaning activities of pipelines. For more chemical cleaning safety information, refer to
SAEP-1662.

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Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

APPENDIX II - Preparatory Work

For new pipelines cleaning, SAPMT to identify the overall responsible scraping and
cleaning activity coordinator. This coordinator shall ensure that all steps in this
procedure are followed. He should also ensure all safety measures are implemented.
The implementation of this procedure shall be under the direction and supervision of the
operation site coordinator. During the entire cleaning operations, Project inspection
shall be present at all times on site to ensure the monitoring of the chemical cleaning
operations and that it is going according to plan. Constant communications by
personnel on site on the conditions of the chemical cleaning operations shall be done.

For existing pipelines cleaning, the above mentioned responsibilities will be under
Pipelines Department.

The work shall be carried out in accordance with company Standards and General
Instructions. These will include, but not limited to the following:

GI-0002.100 - Work Permit System

GI-0006.012 - Isolation Lock Out and Use of Hold Tag

Check to ensure that all scraper traps' isolation valves and all pertinent branch valves
are not passing. If valves are passing, perform the necessary maintenance to stop the
passing valves.

Page 22 of 24
Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

APPENDIX III - Nitrogen Amount Calculation

NITROGEN GAS CALCULATIONS

V1 = volume of liquid nitrogen (Gallons)


T2 = Final Nitrogen gas Temperature (Kelvin)
P2= Final Nitrogen gas pressure (atm.)
Vg= final volume of Nitrogen gas (ft3)

Example:
The volume of liquid nitrogen you need to fill 36 pipeline with a length of 1 km at pressure of 60 psi
and temperature of 40C:
r = 18 = 0.4572 meters
l = 1000 meters

Vg = volume of pipe = 3.14 * (0.4572)2 * 1000 = 656.3 m3 = 23,177 ft3

P2 = 60 psi = 4.08 atm

T2 = 40C = 313 K

Then: =

Page 23 of 24
Document Responsibility: Materials and Corrosion Control Standards Committee SAEP-388
Issue Date: 4 November 2013
Next Planned Update: 4 November 2018 Cleaning of Pipelines

APPENDIX IV - Cleaning of Pipelines Containing Valves

For cleaning of pipelines containing valves, contact CSD. In general,

It is always recommended not to operate the valve in a dry condition since it can cause
damage to the seat area. In order to avoid such failure it always recommended to top
up the valve prior to any cycling: This will also help to push away any foreign debris
that may have become stuck in the grease from the seal face. Any abrasive
contaminants will do far less damage if well lubricated.

The compatibility of the used chemical with valve soft insert to be checked and
confirmed.

Avoid stroking the valve during the pipeline cleaning to avoid any exposure to the valve
seating area: In case the valve cavity filling is required, then a Jumper Hose Assembly
Method is recommended where jumpers hose assembly from the pipeline to the valve
body cavity through the body drain/vent valve.

At the end of the cleaning process, selected valves might be removed for visual
inspection and seat testing if required. If this is not practical then an inside-out air seat
test to be performed on line to ensure that there was no damage to the valve due to the
commissioning activities.

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