Employer Doc. No.

Customer: Project name:

Contractor Doc. No.

PK ENGINEERING SUPPORT TO CHEMICAL
SVN-RK-CL-001
CO., LTD ACID CLEANING OF SUS TANK
Rev. 0 Page 1 of 11

Employer Contract No.: Contractor JOB Code: Date: 15 Sep 2018

METHOD STATEMENT
FOR CHEMICAL CLEANING
Issue Purpose For Reference

Rev Date Page Description Prep'd Chk'd App'd

A 15 Sep 2018 All First issue A.S M.T M.T

Operation Centre JOB Code: Operation Centre Doc. No.:

Responsible Company Prepared by Checked by Approved by
LE TAN SANG F. ARINAGA Y. OGAWA
 Employer Doc. No.
PK ENGINEERING CO., LTD Rev. 0

Title: Method Statement for Chemical Cleaning Contractor Doc. No.

Page 2 of 12
SVN-RK-CL-001

Contents
1  INTRODUCTION .........................................................................................................................3 
2  SCOPE OF APPLICATION ..........................................................................................................3 
3  HSE.............................................................................................................................................3 
4  METHOD ....................................................................................................................................3 
4.1  Degreasing ............................................................................................................................3 
4.2  Soda Boil-out .........................................................................................................................4 
4.3  Acid Cleaning .......................................................................................................................4 
5  PRECAUTION.............................................................................................................................4 
6  DETAILS FOR IMPLEMENTATION ...............................................................................................5 
6.1  Planning.................................................................................................................................5 
6.2  Preparation............................................................................................................................7 
6.3  Execution...............................................................................................................................7 
6.3.1  Degreasing ........................................................................................................................8 
6.3.2  Soda Boil-out ......................................................................................................................9 
6.3.3  Acid Cleaning .................................................................................................................. 10 
7  ACCEPTANCE CRITERIA ......................................................................................................... 11 
8  POST WORK.............................................................................................................................11 
 Employer Doc. No.
PK ENGINEERING CO., LTD Rev. 0

Title: Method Statement for Chemical Cleaning Contractor Doc. No.

Page 3 of 11
SVN-RK-CL-001

1 INTRODUCTION
This document describes the general requirements for carrying out chemical cleaning applied to
pipes and equipment of the plant’s SUS Tank.
The purpose of chemical cleaning is to remove contaminants that may impair plant operations
caused by foaming and poor heat exchange and may eventually cause damage and loss of
production.
For a newly constructed pipes and equipment, it is assumed that they contain remaining oils,
preservatives and mill scale left over during manufacturing.

Detailed procedures for implementation of chemical cleaning will be prepared as required on a

system basis, based on the philosophies described in this procedure.

2 SCOPE OF APPLICATION
 All systems will be subjected to chemical cleaning by degreasing with heat-up. For the
purpose of minimizing or eliminating the effect of foaming and loss of heat exchange
during start-up and normal operation.
 All systems will be subjected to chemical cleaning by soda boil-out with heat-up to
remove dirt, grease and mill scales.
 All systems will be subjected to chemical cleaning with acid cleaning to remove internal
mill scales from pipes that may damage reciprocating compressor valve discs and linings
and equipment.

3 HSE
The following HSE risks are inherent in chemical cleaning:
 Material Safety Data Sheet shall be available for chemicals being used. All the
precautions and safety measures mentioned must be respected and implemented as
applicable.
 Disposal of chemicals has to be carried out in an environmental manner.
 Appropriate personal protective equipment (PPE) shall be worn or used. Verify that
adequate PPE is available for chemical handling acid gear such as chemical gloves,
face shield, goggles, respirator, etc.
 The area will be barricaded and unnecessary personnel will be asked to leave the
affected area.
 Safety shower and eye washer shall be provided (Temporary or Permanent)
 Spill containment kit available

4 METHOD

4.1 Degreasing
Degreasing is carried out using cleaning agent such as sodium hydroxide. The chemical will be
prepared in accordance with Vendor/Licensor’s instruction/recommendation, as agreed to by
Employer.
Degreasing of Amine circuit shall be carried out following the steps below:
(1) Manual cleaning
(2) Washing and circulation operation
(3) Preparation and filling of chemicals
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(4) Degreasing
(5) Rinsing and circulation
(6) Inspection
(7) Effluent disposal
(8) Re-assembly
(9) Preservation (if required)

4.2 Soda Boil-out

Soda boil-out shall be carried-out to steam boilers following the steps below:.

(1) Manual cleaning

(2) Preparation and filling of chemicals
(3) Soda boil-out
(4) Acid cleaning/Neutralization/Passivation
(5) Rinsing
(6) Re-assembly
(7) Preservation (if required)

4.3 Acid Cleaning

The systems will be chemically cleaned with acid cleaning and shall be carried-out following the
steps below:
(1) Manual cleaning and air blowing
(2) Establishing of circulation loop
(3) Washing and circulation operation
(4) Preparation of chemical use for cleaning and filling
(5) Degreasing (depend on the conditions of pipes/equipment, if too much oil then it need
this step)
(6) Rinsing and circulation
(7) Acid cleaning/Neutralization/Passivation
(8) Final Rinsing
(9) Air blowing

5 PRECAUTION
The following precautions must be paid when chemical cleaning is conducted.
 Chemical cleaning area must be roped-off and warning signs to be displayed in the
area.
 The internal of vessels, columns and pipes will be flushed, air blown or manually cleaned
as pre-cleaning for degreasing/soda boil-out/acid cleaning prior to chemical cleaning.
 Prior to inject chemicals into the system, entire system shall be temporarily boxed up and
tightness tested with water.
 All level gauges and other instruments that can be damaged by alkaline solutions or
acid solutions must be removed or positively isolated.
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 For removable internals of steam drum depending on Vendor instruction/advice, it

should be dismantled or re-arranged to ensure full chemical contact.
 The interior of the equipment must be manually cleaned as much as possible to remove
any excessive oil film.
 Utility systems (such as Instrument Air, Service Air, Water, Cooling Water, Steam and
Electrical Power) are commissioned and ready for use.

 Required control loops and indicators that will be required for operation during chemical
cleaning will be functionally tested prior to operation.
 The use of hydrofluoric acid is not permitted and austenitic stainless steel items shall not
come in contact with hydrochloric acid, acid solutions containing more than 2ppm
chloride or other liquids containing more than 100ppm chloride.
 Suitable water shall be used for water circulation, chemical cleaning and rinsing to
prevent pipes and equipment from damage.
 Steam generators may be fired when alkaline degreasing but acid solutions must be
heated external to the equipment.

6 DETAILS FOR IMPLEMENTATION

6.1 Planning
1. Detail Procedure
Detail procedure shall be prepared in accordance with Vendor/Licensor or chemical cleaning
specialist. Details described below should be shown in the detailed procedure and marked-up
P&IDs.
 Water and chemicals supply point
 Solution discharge point
 Valve open/close
 Temporary piping, spool piece and blind, if any
 Location of temporary equipment, pressure indicator and flow meter
 Pipe fitting and accessories to be removed
 Instrument to be monitored and their target values, if specified
 Sample points
 System isolation limits and means of isolation (by blind or valves)
 Chemical circulation path

2. Water quality
The type of water service used for chemical cleaning shall be clearly mentioned on detailed
procedure. Suitable water shall be used for water circulation, chemical cleaning and rinsing to
prevent pipes and equipment from damage.

3. Chemicals
The typical chemical components for chemical cleaning are as below. It may be changed as
per Vendor/Licensor or Chemical cleaning specialist recommendation, as agreed to by
Employer.
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 Table-1 Recommended chemicals for Degreasing

Chemical Name Concentration in solution

Sodium hydroxide Sodium 3%
metasilicate 3%
Nonionic detergent 0.01%

 Table-2 Recommended chemicals for Soda boil-out

Chemical Name Concentration in solution

Alkaline wash: Sodium
carbonate Trisodium 0.5%

phosphate 0.5%
Nonionic detergent 0.01%
Acid pickle: Citric acid
Ammonia 3%
Suitable inhibitor To pH 3 to 3.5 To be
advised

Passivation: Citric acid

Ammonia 0.5%
Sodium nitrite To pH 9.5
1%
Preservation:
Sodium nitrite 0.5%

 Table-3 Recommended chemicals for Acid Cleaning

Chemical Name Concentration in solution

Acid Cleaning:
Citric acid 3%
Ammonia to pH 3 to 3.5
Suitable inhibitor to be advised
Passivation:
Citric acid 0.5%
Ammonia to pH 9.5
Sodium nitrite 1%
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4. Waste Water Treatment

A large amount of chemical waste water will be discharged after chemical cleaning. Waste
water treatment must be applied to protect environmental pollution.

5. The timing of chemical cleaning will follow the Mechanical Completion Split of Responsibilities
3550-8710-PR-0001. The timing of soda boil out may be before or during the refractory dry-out,
operational test and/or mechanical run-in test. The planned timing of each item is mentioned
in the item lists (Attachment-1).

6. Circulation cleaning will be applied to all systems in listed in Attachment-1. Heat will be applied
during the circulation.

7. For system where no pumps are available to circulate the system, natural circulation of liquid
due to application of heat will be applied or use of pumping facility by subcontractor. This
method is applicable to Soda boil-out.

6.2 Preparation
1. Availability of necessary utilities must be checked/confirmed
 Electricity
 Instrument Air and Plant Air
 Water (potable and utility)
 Cold condensate water
 Boiler Feed Water
 Fuel Gas
 Nitrogen
2. Remove the following and upon completion, reinstate them.
 Some parts, made of non-ferrous metal, of equipment/piping/valve/instrument, which
may be deteriorated by alkaline or acid solution.
 Permanent instrumentations which could be affected by contact with alkaline or acid
solution.

3. Isolation valves connected to instruments except for pressure measurements should be tight
closed where the instrumentation is not utilized during chemical cleaning.
4. Install strainer elements for line strainer and pump suction strainers as per marked-up P&ID, if
required.
5. Piping including temporary piping and blind should be lined up based on detail procedure.
6. An aqueous solution of chemical should be available.
7. Waste water treatment
During chemical cleaning, disposal of waste water to comply with the Effluent Discharge Norms
as specified in the Environmental Design Basis (S-000-1240-0111V).

6.3 Execution
As mentioned in paragraph 6.1, 6.2 and 6.3 of present procedure, the following proposed work
sequences are described below:
NOTE: This proposed work sequence is the typical sequence for chemical cleaning. It may be
changed as per Vendor/Licensor or Chemical cleaning specialist recommendation, as agreed to
by Employer
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6.3.1 Degreasing
(1) Manual Cleaning
As much as possible, interior of vessel must be checked and wiped cleaned by hand to
remove any excess oil or grease. As for piping, it is understood that piping are water flushed
or air blown earlier before water circulation. The timing of manual cleaning is during vessel
internal inspection before box-up. It should be agreed that the purpose of degreasing is
to dissolve grease and oil inside pipes and vessels, therefore, the re-opening of any vessel
is not required since final box-up and permanent gasket is used. The result of oil residue
analysis should be sufficient to judge the chemical results.

(2) Washing and Circulation operation

Washing and circulation operation to be conducted until debris collected from pump
suction strainer is acceptable. For system where no pumps are available, washing by filling-
up and draining is sufficient. Hot circulation is also applied, where applicable.

(3) Preparation and filling of Chemicals

Safety Note: MSDS of chemicals shall be read and displayed all times at site.
Chemical preparation and mixing will be described in detail during development of detail
procedure for each system or group of systems.
The amount of chemical required for its system will be determine after confirming the
estimated volume of solution to be pour into the system or circuit subjected for chemical
cleaning. The detailed procedure shall mention in detail the list of chemicals and
corresponding requirement/amount to be purchased and deliver to site.
Chemicals can be prepared in batch using temporary container or the permanent
chemical injection tank. Detailed procedure with marked-up P&ID will clearly show the
charging point.

(4) Degreasing
Cold circulation will be established after filling the chemicals to stabilize level and make-
up. Gradual heat-up will be established up to a target temperature between 80 – 90degC.
The circulation shall be kept for approximately 2 hours at 80-90degC. The criteria of
degreasing shall be depending on the advice of Vendor/Licensor. In case they do not
provide, Contractor and Employer has to agree on what criteria should be applied.

(5) Rinsing and Circulation

After completion of Degreasing or Soda Boil-out, the oil-laden solution should be drained.
Rinsing is carried out by filling the system with suitable water and circulation is conducted.
This will be repeated several times until pH of water is less than 8.5. For system where
circulating pump is not available, filling up to full level and draining to be carried out until
pH of water is less than 8.5.

(6) Effluent Disposal

Disposal of waste water to comply with the Effluent Discharge Norms as specified in the
Environmental Design Basis (S-000-1240-0111V).

(7) Re-assembly
All dismantled permanent pipes to be re-assembled as per P&ID.
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(8) Preservation (if required)

The surface of pipes and vessel is bared and free to react with free oxygen, therefore, if
system is to be out of service for longer period, it must be purged to dryness and nitrogen
is introduced to keep the system blanketed. This step to be decided depending on
schedule of start-up and initial filling.

6.3.2 Soda Boil-out

(1) Manual Cleaning
As much as possible, interior of vessel must be checked and wiped clean by hand to
remove any excess oil or grease. As for piping, it is understood that piping are water flushed
or air blown earlier before water circulation. The timing of manual cleaning is during vessel
internal inspection before box-up.
(2) Preparation and filling of Chemicals
Safety Note: MSDS of chemicals shall be read and displayed all times at site.
Chemical preparation and mixing will be described in detail during development of detail
procedure for each system.
The amount of chemical required for its system will be determine after confirming the
estimated volume of solution to be poured into the system or circuit subjected for chemical
cleaning. The detailed procedure shall mention in detail the list of chemicals and
corresponding requirement/amount to be purchased and delivered to site.
Chemicals can be prepared in batch using temporary container or the permanent
chemical injection tank. Detailed procedure with marked-up P&ID will clearly show the
charging point.
Fill to normal operating level with chemical solution.
(3) Soda boil-out
Cold circulation will be established after filling the chemicals to stabilize level and make-
up if pump is equipped.
Fire boiler to 20 bar pressure for 4 hours applying intermittent blow down. Allow boiler to
cool 80degC and drain the system quickly. Fill with fresh water heated to 80degC and
circulate for 30 minutes before draining. Alternatively, circulate the degreasing solution at
95 deg C for 8 hours, using temporary pumps.
(4) Acid cleaning/Neutralization/Passivation
Preheat boiler to 90degC and inject the acid solution at 90degC. Circulate at 0.2 to 0.3
m/sec for minimum 4 hours until acceptance criteria are achieved. During acid cleaning,
samples of solution shall be taken frequently, at agreed intervals, and checked for ferric
iron, total ion and acid strength. If solution strength drops below 1%, add ammoniated
citric acid to raise concentration to at least 2%. If iron content and acid strength stabilized,
acid cleaning is deemed to be complete. Drain and flush system with water until pH of
outlet water is higher than 7 or equal to the pH of the inlet water.
If lower than pH of 7, fill system with potable water, circulate and heat to 60degC. Inject
citric acid solution to give 0.5 % concentration, circulate for 30 minutes and then add
ammonia to give a pH of 9.5. Then, add sodium nitrite to give 1% concentration and
continue circulation for a further 4 hours.
(5) Rinsing
Drain and rinse system with ammoniated water.
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(6) Re-assembly
All dismantled permanent pipes to be re-assembled as per P&ID.
(7) Preservation (if required)
Protect the system until start-up. Fill system with potable water with 0.5 % of sodium nitrite
to expel all air and keep filled. Drain before start-up.

6.3.3 Acid Cleaning

(1) Manual cleaning and air blowing
Same as in paragraph 8.3.1, manual cleaning needs to be carried out to remove rust and
mill scales, that can be removed by hand or by air blowing, as much as possible.
(2) Establishing of circulation loop
After hand cleaning or air blowing completed, the system needs to be set-up for good
circulation loop that will ensure all pipes and vessels are in full contact with the circulated
chemical solutions.
(3) Washing and circulation operation
Washing and circulation operation to be conducted until the amount of debris collected
from pump suction strainer are acceptable.
(4) Preparation of chemical use for cleaning and filling
Safety Note: MSDS of chemicals shall be read and displayed all times at site.

Chemical preparation and mixing will be described in detail during the developing of
detail procedure for each system.
The amount of chemical required for its system will be determined after confirming the
estimated volume of solution to be poured into the system or circuit subjected for chemical
cleaning. The detailed procedure shall mention in detail the list of chemicals and the
corresponding requirement/amount to be purchased and delivered to site.
(5) Degreasing (depend on the conditions of pipes/equipment, if too much oil then it need
this step)
The pipes need to be inspected and the decision to degrease it depends on the amount
of oils inside pipes. It may not necessary if it has negligible oil quantity in the surface.
The circulation shall be kept for approximately 2 hours at 80-90 deg C. The criteria of
degreasing shall be depending on the advice of Vendor/Licensor. In case that they do
not provide it, Contractor and Employer has to agree on what criteria should be applied.
(6) Rinsing and circulation
After completion of Degreasing or the oil-laden solution should be drained.
Rinsing is carried out by filling the system with suitable water and circulation is conducted.
This will be repeated until pH of water is less than 8.5. For system where circulating pump is
not available filling up to full level and draining to be carried out until pH of water is less
than 8.5.
(7) Acid cleaning/Neutralization/Passivation
Filling and circulating at 0.2 to 0.3 m/sec for several hours until acceptance criteria are
achieved but for not less than 4 hours. During acid cleaning, samples of solution shall be
taken frequently, at agreed intervals, and checked for ferric iron, total ion and acid
strength. If solution strength drops below 1%, add ammoniated citric acid to raise
concentration to at least 2%. If iron content and acid strength stabilized, acid cleaning is
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deemed to be complete. Drain and flush system with water until pH of outlet water is higher
than 7 or equal to the pH of the inlet water.
If lower than pH of 7, fill system with potable water, circulate and heat to 60 deg C. Inject
citric acid solution to give 0.5 % concentration, circulate for 30 minutes and then add
ammonia to give a pH of 9.5. Then, add sodium nitrite to give 1% concentration and
continue circulation for a further 4 hours. Drain and rinse system with ammoniated water.
(8) Air blowing
Air blow the system using dry-air to completely remove remaining liquid to keep the system
dry
(9) Effluent Disposal
Disposal of waste water to comply with the Effluent Discharge Norms as specified in the
Environmental Design Basis (S-000-1240-0111V).
(10) Re-assembly
All dismantled permanent pipes to be re-assembled as per P&ID.
(11) Preservation (if required)
The surface of pipes and vessel is bared and free to react with free oxygen, therefore, if
system is to be out of service for longer period, it must be purged to dryness and nitrogen
is introduced to keep the system blanketed as required.

7 ACCEPTANCE CRITERIA
Licensor and Vendor’s criteria shall be followed. In case these criteria are not available, Contractor
and Employer have to agree on acceptance cleanliness.
Judgment for completion shall be done by Contractor and Employer.

8 POST WORK
1. After completion of chemical cleaning, all rotary equipment are switched off, de-energized
(locked-out) and preserved until the succeeding operation.
2. Used filters in washing and circulation operation shall be cleaned after draining and rinsing of
system.
3. Upon completion of chemical cleaning, remove temporary pipes/equipment etc. and resume
the whole system as per P&ID.
4. In case it takes longer time to put online the system nitrogen blanketing or other means of
preservation and preventing corrosion shall be applied. Vendor detailed procedure shall be
applied.