What is Pre-Commissioning Chemical Cleaning?

Chemical Cleaning Pre-Commissioning Services 

During the construction stage, new pipeline systems & process equipment can suffer from internal corrosion, the internal accumulation of construction debris, build-up of microbial slimes, and other unwanted fouling. It is therefore essential that all pipelines & equipment undergo thorough pre-commissioning clean in accordance with Industrial Standard. If such pre-commissioning cleaning of the pipelines and process equipment is not completed successfully then the reliability, efficiency, and life expectancy of systems can be seriously compromised.

  • Pre-commissioning Chemical cleaning services including Oxygen Line services.
  • Steam Blowing
  • Pipeline Pigging/ Scraping
  • High-Velocity Hot Water Flushing
  • Lube Oil System Cleaning & Oil Flushing
  • Air Blowing
  • Leak testing & Hydro test
  • Nitrogen Services
  • Cooling Water Passivation
  • Disinfection
  • Dry Ice Blasting

 

Pipeline Pigging / Scrapping:

To remove any debris left in the line from new construction, to fill lines for hydrostatic testing, dewatering following hydrostatic testing, drying and purging operations With a dedicated team of well trained and experienced Scrapping professionals contractors provides the complete suite of Pipeline cleaning.

Chemical Cleaning:

Installations (boilers, heat exchangers, cooling water systems etc.) are often cleaned prior to being put into use. This procedure is called pre-commission cleaning. Various procedures carried out on the installation will have resulted in it being contaminated with grease/oil, welding scale etc. The temporary protective layer of the steel will moreover have been corroded resulting in (fly) rust. There are various methods for removing these types of contamination chemically. The method chosen will depend on, in addition to the technical aspects (from which materials has the system been constructed and the extent to which the system is contaminated), the requirements of the customer. The proper assessment of which cleaning method to apply and the subsequent implementation of it requires expertise.

Chemical Treatments: 

Degreasing treatment for removing hydrocarbon sludge, or oily residues.

Acid treatment for removing mill scale build-up.

Passivation to protect surface layer from oxidation.

Pickling/passivation surface treatment for stainless steel.

Depending On The Application Various Cleaning Methods Can Be Used:

Circulation – pumping a cleaning solution around a process system

Soaking – used when circulation is not feasible

Cascading – to clean columns and towers

Foam – concentrated chemicals mixed with gas

Slug pigging – to clean long run pipelines using chemicals

Two-Phase Flow Cleaning (YO YO) – to clean long run non-uniform diameter pipelines

 

Chemical Cleaning Using Slug / Chemical Batching: 

Both chemical treating and mechanical pigging offer solutions to various pipeline operating problems. However, neither method alone is likely to provide the benefits of a combination program. Chemicals are most effective and efficient when used primarily to treat problems on the pipe surface, such as the formation of wax deposits, bacteria colonies, and corrosion. Pigs are best used to prepare the pipe surface for the application of chemicals, to help distribute the chemicals evenly throughout the pipeline, and to minimize the volume of chemicals needed by removing bulk deposits and entrapped fluids.

Air Blowing: 

The main purpose of Air blowing is to remove the contaminants such as debris, dust and other constituents arising out of construction activities. Chemical Cleaning Contractors can offer a full line of specialized equipment, engineering and field services required to perform both low pressure and high-pressure air blowing service Chemical Cleaning Contractors provides the engineered air blowing inefficient way to remove construction debris, loose rust, liquids, and other contaminants from process piping. Every air blow procedure is specifically engineered for the individual system being cleaned. This approach provides numerous benefits for our clients, including time effective execution by efficiently sequencing the blows, thorough cleaning guaranteed by achieving an optimal cleaning force and safe field execution through following the best industry practices.

Aqua Milling: 

Aqua Milling is a specialized system of high-pressure water blasting for cleaning internal pipe surfaces. The system employs a high-pressure pump and a rotating hose. A cutting nozzle is attached to the end of the rotating hose. Various size nozzles are employed depending upon the application. Using a side force jet, the nozzle travels the circumference of the pipe while rotating across the surface of the pipe, which is being cleaned by the cutting jets. The hose is rotated by utilizing an air-driven motor that is manually controlled for speed adjustment.

Lube Oil Flushing: 

Chemical Cleaning Contractors specialized in removal of harmful contaminants and keep your new rotating and hydraulic equipment operating at peak performance, significantly reducing the potential for premature failure.

During the high-velocity flushing process, particles and debris are filtered out of the system by means of fine mesh filtration units. The flushing oil is sampled and analyzed throughout the flushing process by means of an external calibrated laser particle counter. The particle counter is designed to meet the new ISO 4406 cleanliness classification code, as well as the NAS 1638 code.

 Advance method of particle counter

 Flow rate 200 Gpm, 700 Gpm, and 2650 Gpm

 Filtration unit

 Heat Exchangers

Cooling Water Passivation: 

Newly installed piping and heat exchangers should be pre-cleaned to remove surface rust and passivated to protect against initial corrosion prior to entering service.

High-Velocity Hot Water Flushing: 

The purpose of this service is to clean the newly erected pipeline, before putting into for service, in order to prevent process-related failures. Cleaning will be achieved using Hot water circulation in a closed circuit through a 50-micron filter using Chemical Cleaning Contractors’ High-velocity Centrifugal pumps. We have pumps ranging from 25 cu.m/hr to 1200 cu.m/hr Inspection is done with a sample of the flush fluid taken in a clear jar sample bottle.

Steam Blowing:

Blowing of steam through piping to remove debris from the pipe, cleaning steam lines to a steam turbine, cleaning plant expansion lines, or new installs. Using plant steam to perform targeted and non-targeted steam blows on pipelines.

Nitrogen Services:

We offer a number of reliable, flexible and cost-effective nitrogen solutions such as Nitrogen purging of pipework to remove Oxygen in order to create an inert atmosphere, Drying of pipework systems to client specified dew point, product displacement & Leak testing that will ensure safety and success for any Pre-commissioning project.

Leak Testing (Pneumatic & Hydro test):

The purpose of this task is to prove the integrity of Process Equipment & Pipelines.

Disinfection:

Disinfection is the process by which a disinfectant, (chlorine usually, from sodium hypochlorite/calcium hypochlorite/bleaching powder ) is added to a water system in large amounts to kill bacteria and to burn up organic materials which serve as food for bacteria.

Advanced Cleaning Methods:

Dry Ice Blasting:

Dry ice blasting is a form of carbon dioxide cleaning, where dry ice, the solid form of carbon dioxide, is accelerated in a pressurized air stream and directed at a surface in order to clean it. An alternative media for non-abrasive blasting is water-ice, known as ice blasting. CO2 pellets have a temperature of minus 80°C and every material has a different shrinking factor, a thermo shock will decrease the adhesion of the contamination to the treated surface. The pallets penetrate through the substance and when it hits the surface it sublimes from solid into the gaseous state. Due to this increase in volume (400-800 times) the kinetic energy creates a lifting force which removes the contaminant.

Soda Blasting:

Soda blasting is a mild form of abrasive blasting in which sodium bicarbonate particles are blasted against a surface using compressed air. It has a much milder abrasive effect than sandblasting. Soda blasting is a non-destructive method for many applications in cleaning, industrial equipment maintenance, rust removal, graffiti removal, molecular steel passivation against rust, oil removal by saponification and soot remediation.