Pearl GTL Project

LINDE ENGINEERING

Contractor Project No: 5887 Shell Project No: HP-3000-QAT

Project Document Number: T- 4.250.930 Project Rev.: O Page 2 of 19

Purchase Order Number: 2MH127

N/A Tag/Item Number(s):

ASU Unit(s):

Z PCWBS:

QATAR SHELL GTL PROJECT (PEARL) C2 AIR SEPARATION UNITS CONSTRUCTION

C O 10.12.2007 Issued for Company comments BR AU/MC ZG ICC

B 22.11.2007 Issued for Review BR AU/MC ZG IFR

A 20.11.2007 Issued for Internal Review BR AU/MC ZG IIR

Approved By

GAMA Project Rev Rev. Date Description

Prepared By

Checked By Status

No. No. ORIGINATOR

Document Title:

LINDE ENGINEERING AG PROCEDURE FOR CLEANLINESS

Document No.

GAM PRO QAC GTL 037 C LOC470

Contractor

Gama Qatar Co. W. L. L. Org.

Code Doc. Type

Disc. Code

Geogr. Area

Seq. No

Rev. No Vendor Code

Project Document Number: T-4.250.930 Rev No: O

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TABLE OF CONTENTS 1. PURPOSE_____________________________________________________________________6 2. SCOPE________________________________________________________________________6 3. HSSE _________________________________________________________________________6 4. REFERENCES _________________________________________________________________6 5. DEFINITIONS __________________________________________________________________6 6. RESPONSIBILITY ______________________________________________________________7

6.1. SITE MANAGER__________________________________________________________________7 6.2. CONSTRUCTION MANAGER ______________________________________________________7 6.3. EQUIPMENT MANAGER __________________________________________________________7 6.4. SITE ENGINEER__________________________________________________________________7 6.5. SITE SUPERVISOR/FOREMAN_____________________________________________________7 6.6. QC ENGINEER ___________________________________________________________________8 6.7. QC INSPECTOR __________________________________________________________________8 6.8. HSSE MANAGER _________________________________________________________________8 6.9. HSSE OFFICER___________________________________________________________________8

7. Cleanliness of Non-Oxygen Service Piping Systems _____________________________8 General _________________________________________________________________________________8 7.1. Steam blowing_____________________________________________________________________8 7.2. Air blowing _______________________________________________________________________9 7.3. Flushing __________________________________________________________________________9 7.4. Medium/Quality __________________________________________________________________10

8. Cleaning of Gaseous Oxygen System __________________________________________10 9. Cleanliness rEQUIREMENTS __________________________________________________11

9.1. Pre-Cleaning _____________________________________________________________________12 9.2. Post Erection (In-Situ) Cleaning _____________________________________________________13

10. Inspection Methods_________________________________________________________13 10.1. Direct inspection________________________________________________________________13 10.2. Indirect inspection (for Cleanliness Class S2) ________________________________________13 10.3. Target blowing _________________________________________________________________14

11. Cleanliness Classes ________________________________________________________14 12. Additional requirements ____________________________________________________17

12.1. General _______________________________________________________________________17 12.2. Preservation of Cleanliness _______________________________________________________17

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12.3. Pressure and Leak Testing _______________________________________________________17 12.4. Marking_______________________________________________________________________17

13. Documentation, Verification _________________________________________________17 14. QUALITY ASSURANCE______________________________________________________18 15. ATTACHMENTS ____________________________________________________________18

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1. PURPOSE The purpose of this Procedure defines internal cleanliness requirements, cleaning

methods, inspection for piping systems at C2 ASU Pearl GTL Project by Gama Qatar located inside the Ras Laffan Industrial City in Qatar.

2. SCOPE This procedure ensured that all cleaning activities on C2 ASU Pearl GTL project

will be carried out with adequate cleaning and testing methods to the degree required in this Procedure

3. HSSE All works shall be in compliance with the State of Qatar laws and regulations, Ras

Laffan Industrial City and International standards, codes, LINDE ENGINEERING AG and QSGTL and/or its PMC requirements and instructions. In addition all employees and GAMA subcontractor employees on site will have through LINDE ENGINEERING AG Site Safety Induction and GAMA Qatar Safety induction for site safety, health, environmental and security prior to work activities. Other training courses will be attended as required by LINDE ENGINEERING AG or QSGTL and/or its PMC as required.

4. REFERENCES T-4.234.542 : Project Quality Plan GAM-PRO-QAC-GTL-012: HSSE Plan T-13.377.360 : Flawless start-up Initiative (FSI) T-4.096.688 : Cleanliness Procedure Piping systems

T-13.371.359 : Specification for Gaseous oxygen service

70.10.80.11 : Cleaning of Equipment

5. DEFINITIONS Company : QSGTL/or its PMC Contractor : LINDE ENGINEERING AG Sub Contractor : GAMA QATAR

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Contract : QSGTL Pearl Plant - C2 ASU Project CS : Construction Supervisor ITP : Inspection and Test Plan QCR : Quality Control Record QCP : Quality Control Procedure QCE : Quality Control Engineer QCI : Quality Control Inspector QA/QC : Quality Assurance / Quality Control TPI : Third Party Inspection

6. RESPONSIBILITY

6.1. SITE MANAGER The site manager will provide inputs to the project execution plan to ensure that lifting strategies & philosophy are addressed.

6.2. CONSTRUCTION MANAGER The construction manager is responsible for the overall management of the project construction team to ensure that safe and effective operations are conducted and properly documented.

6.3. EQUIPMENT MANAGER The equipment manager will be responsible for the transporting equipments availability and good order.

6.4. SITE ENGINEER Shall report to Construction Manager Shall be responsible for planning, execution and implementation of all site activities related to this procedure

6.5. SITE SUPERVISOR/FOREMAN Shall report to Site Engineer

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Shall be responsible for execution of construction activity Shall also prepare daily site construction records

6.6. QC ENGINEER Shall report to Manager (QA/QC) and shall be responsible for overall implementation, monitoring and control of QC activities.

6.7. QC INSPECTOR Shall report to QC Engineer Shall be responsible for attending all Inspection Stages as required by ITP Shall be responsible of performing all checks and shall prepare necessary Inspection Reports

6.8. HSSE MANAGER Shall report to Project Manager and shall be responsible for over all control and Inspection of HSSE issues.

6.9. HSSE OFFICER Shall report to HSSE Manager Shall be responsible for all safety aspects for this procedure

7. CLEANLINESS OF NON-OXYGEN SERVICE PIPING SYSTEMS

GENERAL This Procedure applies to piping systems where the oxygen content of the medium is less than 25% Volume. For cleanliness of oxygen systems (oxygen content larger than 25% Volume) refer section 8.0 as per cleaning procedure T-4.096.688

7.1. STEAM BLOWING The purpose of steam blowing is to remove debris, loose scale and rust from

recently welded steam lines applicable only for steam turbine operation. The effectiveness depends on the steam velocity, the change of temperature in time and the number of blows. Line cleaning should not commence until all related piping and process equipment

are fully installed, the system has been checked for conformance with the piping and instrumentation diagrams, and the piping systems have been hydro tested. Temporary piping and silencers for depressurizing to atmosphere shall be properly

anchored. All restrictions in the piping such as orifice plates, flow measurement tubes and thermo wells shall be removed prior to steam blowing, openings to be blinded. Control valves shall be replaced with spool pieces. Steam should be blown from a

clean system to unclean systems. In order to thermally shock the piping to remove

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mill scale, the steam valve controlling the blow down should be of the quarter turn type (quick opening). The valve should be located well upstream of the piping to be cleaned. At the inlet

flange of the silencer, a target strip of polished copper or aluminum shall be clamped to judge the finished cleanliness. Blows should first be made at low pressures to remove large objects in the piping, gradually raising the pressure during later blows to the maximum operating pressure. Between the blows there should be a cool down period of at least 60 minutes for UN insulated pipes and 240 minutes for insulated pipes. A system is considered to be acceptably clean when the target plate has less than a predetermined number of impact pock marks. The following requirements apply for blowing steam lines: Steam flow during blowing shall be at least three times the maximum flow rate during operation; There shall be not more than one total particle count (pock mark) per square centimeter of target plate surface if not otherwise specified by manufacturer There shall be no evidence of embedded material (e.g. weld splatter, sand, etc.). Target plates shall not show individual rough impressions The blow shall be of not less than 10 minutes duration, At least 15 blows shall be made if the piping is not to be put immediately into service; the system shall be purged with nitrogen to remove any air and should be placed under an inert nitrogen blanket.

7.2. AIR BLOWING The purpose of Air blowing is to remove debris and loose scale. Air is usually supplied from temporary high-pressure large-capacity air compressors or air filled vessels. These rental air compressors have to be supplied with filters to remove oil and moisture from the compressed air system. An air reservoir may be available during the blow down process. The piping is then cleaned by pressurizing the piping system to be agreed with Company and then opening a temporary quick acting valve to allow depressurization to atmosphere.

7.3. FLUSHING The purpose of the activity, flushing, is to remove loose rust, mill scale and construction debris from piping systems before Erection.

Flushing can be defined as the act of running water, in sufficient quantity and velocity, through a given section of pipe or piping, completely filling that section of

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pipe or piping, such that the flow of water through the system will forcibly remove any loose rust, mill scale or construction debris from the system.

There are some basic guidelines which should always be followed when flushing lines with water:

Flushing shall be carried-out under the supervision of the Gama Piping Superintend. Gama/Linde Piping Inspector inspect the cleaned system and sign the Report. Flushing shall be performed through fully open flanges and/or open pipe ends. Flushing through smaller openings, such as drains or vents, is not acceptable Flush from the highest elevation to the lowest, where possible following the Normal flow Direction of the system. When flushing is completed, de-water the system and dry as soon as possible.

7.4. MEDIUM/QUALITY Stainless steel lines: Potable/demineralized water, with chloride content < 20 ppm. Carbon steel and alloy lines: Potable water/plant water or any other prior approved flushing medium.

The flushing duration for an "open ended" system is such that for a period of > 5 minutes "clear water" (no debris or other foreign materials) must be discharged.

Closed circuit loop flushing until the circulating pump strainer is free of foreign materials (debris) and the circulating water is clear. The following systems and/or lines shall not be flushed. Process lines in which the presence of water would cause operational difficulties. Instrument air lines: these lines will be service tested and blown with air. The air used must be free from oil, use existing instrument air supplies where possible or mobile compressors fitted with oil filtering devices. Nitrogen systems: these will be service tested after blowing with instrument air. Steam supply systems: after hydro test the water shall be drained and the system Blown with steam, when available.

8. CLEANING OF GASEOUS OXYGEN SYSTEM Oxygen in the context of this section is a gas mixture with an oxygen content of

more than 25 percent by volume.

The importance of meticulous degreasing and careful cleaning cannot be over-

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emphasized, as remnants of organic matter and minute solid particles in the presence of high pressure and/or high velocity oxygen may ignite, with the possibility of violent reaction.

Careful attention shall, therefore, be paid to the cleanliness of oxygen systems.

Removal of contaminants such as greases, oil, thread lubricants, dirt, water, filings, weld splatter, paints, and other foreign matter is essential. An acceptable level of cleanliness can be accomplished by pre-cleaning all parts and

maintaining this condition during construction; by completely cleaning the system after construction; or, as is normally the case for a large plant facility, by a combination of the two. Any cleaning procedure shall be such that the final surface cleanliness, prior to system commissioning, will meet the inspection criteria given in section 9 of this procedure

9. CLEANLINESS REQUIREMENTS This section defines methods which are suited to obtain the cleanliness condition

prescribed for the single pipes or assembled piping system. Usually cleaning methods are mechanical processes and chemical processes. it is a condition that the items to be cleaned are either already machined or have, in the state as delivered, a smooth, non-corroded and un scaled surface without painting. Corroded or scaled surfaces shall be prepared by pickling or grit blasting. This section defines methods which are suited to obtain the cleanliness condition prescribed for the single pipes or assembled piping system.

Table 1 Mechanical cleaning

Identification Code

Method

M1 Sweeping or wiping with lint free cloth

M2 Air Blowing or flushing

M3 Vacuum cleaning

M4 Air burst cleaning

M5 Grit Blasting

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Table 2 chemical cleaning

Identification Code

Method

C1 Submerging and moving of the component in a vessel with cleaning agent

C2 Spraying of the component with cleaning agent and running off of the agent

C3 Filling of the component with cleaning agent, moving of component or liquid

C4 Flushing of the component under permanent circulation of the cleaning agent

C5 Degreasing with condensing cleaning agent (in a degreasing facility)

C6 High pressure steam degreasing (steam-cleaning with addition of a cleaning agent)

9.1. PRE-CLEANING All piping materials including, fittings, strainers etc, shall be pre-cleaned prior to final assembly/site erection. In the majority of cases, this cleaning requirement is part of a purchase order or shop fabrication. For Vendor package systems the internal cleanliness of the system components shall be preserved at least until they are installed in the plant on-site, by means of: 1) Hermetically sealed wrapping, containing desiccant bag, for small items 2) Firmly secured end-caps, plugs or gasketed blind flanges, as appropriate, to seal all openings on non-hermetically packaged items 3) Desiccant (bags), but not vapor phase inhibitors, attached to the inside of (temporary) end-caps and blank flanges All pre-cleaned parts or final assemblies shall be lapelled / marked

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9.2. POST ERECTION (IN-SITU) CLEANING If the pre-cleaned condition has been maintained during construction and erection, and there has been minimal site welding, in-situ cleaning can be limited to blowing the pipe work out with high (near sonic) velocity, oil-free air, supplemented where applicable with brush pigs. If the pre-cleaned condition has not been maintained during construction and erection, pipe work shall be cleaned as specified in the relevant cleanliness class s, see par.8.3. Any in-situ cleaning required shall be carried out after any hydrostatic testing and by specialist contractors. A system that is complete and has received final cleaning, but is not to be put into immediate service, shall be preserved by pressurizing with clean, dry, oil-free nitrogen.

10. INSPECTION METHODS

10.1. DIRECT INSPECTION

All surfaces shall be subjected to direct visual inspection where possible, by both bright white light and ultra-violet light methods. The inspected surface shall be dry and free from cleaning agents Adhered scale, weld spatter, loose particles or fibers organic substances such as grease, oil, paint, sealants If direct inspection by ultra-violet light is not possible, surfaces shall be wiped with a clean, white, lint-free cloth that may be dipped in solvent. The cloth shall then be inspected to ensure the absence of any oil, residue, discoloration, fibers, etc.

10.2. INDIRECT INSPECTION (FOR CLEANLINESS CLASS S2) Parts which are inaccessible to visual examination, either directly or with a boroscope or similar instrument, shall be inspected as per table 3- P3. Alternatively the system may be inspected by having a solvent circulated through them. A representative sample of the effluent solvent shall be taken and inspected as follows The sample shall be inspected under bright white light and compared with a sample of new, unused solvent. No difference shall be detectable and there shall be no residue The sample shall also be inspected under ultra-violet light (wavelength between 0.32 m and 0.38 m) and again compared with unused solvent. Contamination of 0.1 g oil/litre or more will cause fluorescence of the solvent In doubtful cases, an analysis of the solvent used may be required. After evaporation at 100 C, the sample shall not contain more than 20 mg/kg solvent residue.

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10.3. TARGET BLOWING

Position a white sheet covered with petroleum jelly, e.g., Vaseline, at the end of the line, and blow line with oil-free nitrogen. Dirt picked up by the nitrogen stream will be visible on the sheet.

Table 3 Inspection Methods

Identification code

Method

P1

Visual examination at clear daylight, or under bright white light.

P2

Visual examination under ultraviolet light

P3

Wiping test by using a white, lint-free cloth or filter paper, aided by ultraviolet light

P4

Solvent flushing test / weight determination of residue after evaporation

P5 Particle measurement / volume determination after vacuum cleaning P6 Particle measurement / visual inspection of an adhesive tape test of

the surface compared with an adhesive tape test of a reference specimen

11. CLEANLINESS CLASSES The cleanliness classes define the requirements for the surfaces of piping being in contact with fluids. The cleanliness class shall be correlated to plant sections or to plant equipment according to oxygen content and allowable working pressure and function. The Cleanliness Classes are selected acc. Linde internal procedure and are shown in the PEFS's-(Piping Engineering Flow Diagrams). The cleanliness requirements are covered by four cleanliness classes S4 to S1 as defined hereafter: S4, being the class with the lowest requirements and S1 the class with the highest requirements. However, cleanliness class S1 is only applicable to equipment such as columns, plate fin heat exchangers in services with oxygen content above 98%. Each cleanliness class is correlated to its own requirements.

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Cleanliness class S2

Cleaning

Inspection

Fabrication Sequence

DN Limits

Ferritic

Steels

Austenitic Steels,

Aluminium

Ferritic Steels

Austenitic Steels, Aluminium

Acceptance Criteria

>50 M5 C6 8) P2 P2 and P3

Piping parts (pipes, fittings, flanges etc.) Prefabricated piping spools

`>25 and 50

N/A M6 11) N/A P3 4)

oil/ grease 50 M5 or

M2 5) P1 Piping parts (pipes, fittings, flanges etc.) Prefabricated piping spools

` >25 and 50

M2 and

C6 6)

M2 and C6 6)

P1 P1

Piping spools prior to installation

ALL

M1 3)

P1

Piping after installation (pre-commissioning)

ALL

M4 7) or M2 P1 4)

Free of mill scale, paint,

dirt and other debris

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Cleanliness class S4

Cleaning

Inspection

Fabrication Sequence

DN Limits

Ferritic Steels

Austenitic Steels,

Aluminium

Ferritic Steels

Austenitic Steels, Aluminium

Acceptance

Criteria

>50

M1 or M2 5) or M5 1) 2)

P1

Piping parts (pipes, fittings, flanges etc.) Prefabricated piping spools

` >25 and 50

M1 or M2 5)

M2

P1 P1

Piping spools prior to installation

ALL

M1 3)

P1

Piping after installation (pre-commissioning)

ALL M2 P1 4)

Free of mill scale, paint,

dirt and other debris

Remarks to Cleanliness Classes S2 to S4 1) Only if necessary for removal of internal coating. Not applicable to water lines. 2) Steam lines shall be internal grit blasted and cleaned as specified in Para. 7.2 3) Ensure the lines are drained / empty before installation and free of dirt and debris. 4) Determination of cleanliness (acceptance criteria) by visual assessment of the quality of blowing or flushing medium 5) Blowing of pipes with dry air during prefabrication only if applicable, to remove dust or debris. 6) Only if presence of oil or grease is detected, i.e.: receiving inspection or during fabrication 7) Apply only to process piping. Not applicable for water lines and utilities 8) Apply final blowing, preferably with hot nitrogen, to ensure dew point of -20 C. 9) Blowing of pipes with oil and moisture free air. 10) Oil content

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12. ADDITIONAL REQUIREMENTS

12.1. GENERAL Process air piping, from the Mol sieve Absorber vessels to the cold box, shall be inspected by means of UV-light

Valves and other piping components such as strainers, have the same cleanliness class than the connected piping.

Gama/Linde witnessed and recorded cleanliness inspections during the installation of underground cooling water pipe.

12.2. PRESERVATION OF CLEANLINESS The cleanliness of each delivered, mechanically finished and already cleaned item shall be preserved during any storage, intermediate transport, pre-fabrication and final installation until commissioning. New contamination of the inner surfaces shall be avoided by suitable preservation measures, i.e. covering of pipe ends with plastic foil properly fastened or closing the pipe ends with plastic caps.

12.3. PRESSURE AND LEAK TESTING Pneumatic tests and leak tests shall be performed with dry, oil free air or dry, oil free nitrogen. Clear potable uncontaminated water shall be used for hydrostatic tests or at least for flushing after hydrostatic tests. Water residues shall be removed by discharging, blowing out with air and, in case of corrosive metals, by drying.

12.4. MARKING The packing of a cleaned component or plant equipment shall be marked punching or by means of an undetectable, durable and well legible label or tag: Furthermore, a note shall be attached for the receivers informing on vacuum packing or inert gas filling or on susceptive bags to be removed (position and number of bags to be stated!).

13. DOCUMENTATION, VERIFICATION Cleaning and Inspection shall be recorded and signed by LINDE /PMC for all spool, as per respective Isometric drawing. The degrees of cleanness depend on service and piping class. The FSI (Flawless startup initiative) should be followed in all categories.

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14. QUALITY ASSURANCE A Quality Assurance System shall be operated conforming to related standards. Controls and checks shall be established and documented.

15. ATTACHMENTS GAM-QCR-QAC-GTL-070

: C2 ASU PEARL GTL PROJECT RAS LAFFAN INDUSTRIAL CITY CLEANLINESS ACCEPTENCE REPORT

Sub Contract Ref:Item Location

Area: Isometric No: Report No

Item Description: sub system: Form No: Inspection Date

s

h

e

e

t

Cleanliness class Spool

Cleaning Method

Inspection method Inspection Result Pre Fabrication Erection

GAMA QATAR LINDE QSGTL or its PMC

Signature Date Signature Date Signature Date

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GAM-QCR-QAC-GTL-070

CLEANLINESS.pdfCLEANING PROCEDURE.doc070-CLEANLINESS TEST REPORT.xlsBLIND TEST SYSTEM