EGYPTIAN POLYETHYLENE PROJECT (ETHYDCO)

CARDBOARD BLASTING PROCEDURE FOR COOLING

WATER UNDERGROUND MAIN HEADER
Rev.: Date:

Project Doc. No.: PE-CD-9999-OPE-PRC-000-0001

1 1-Dec-2014

CARDBOARD BLASTING PROCEDURE FOR COOLING

WATER UNDERGROUND MAIN HEADER

A P P R O V E D (C O D E -1 )
(W O R K C A N P R O C E E D )

A P P R O V E D W IT H C O M M E N T S (C O D E -2 )
(D O C U M E N T T O B E R E V IS E D . A FFE C T E D
W O R K S C A N P R O C E E D , P R O V ID E D T H A T
C O M M E N T S A R E P R O P E R LT Y IM P LE M E N T E D )

A P P R O V E D W IT H C O M M E N T S (C O D E -3 )
(D O C U M E N T T O B E R E V IS E D . A FFE C T E D
W O R K S C A N N O T P R O C E E D , U N T IL T H A T
C O M M E N T S A R E P R O P E R LY IM P LE M E N T E D )

R E V IS E A N D R E S U B M IT (C O D E -4 )
(D O C U M E N T T O B E R E V IS E D . A FFE C T E D
W O R K S C A N N O T P R O C E E D U N T IL A P P R O V A L
IS O B T A IN E D )

APPR O V ED BY

ETH YD CO

1 1-Dec-2014 For Approval J. Richardson Kaneko Hosni Takeuchi

0 05-Nov2014 For Approval J. Richardson Kaneko Hosni Takeuchi

Rev. Date Description Orig Ckd By Approved By Authorized

EGYPTIAN POLYETHYLENE PROJECT (ETHYDCO)

DOCUMENT NUMBER Toyo Job Number ENPPI Job Number Rev. No.
PE-CD-9999-OPE-PRC-000-0001 BA-1077 3549-300 1

Revision History
Revision No. Description
Rev.0 For Approval
Rev.1 Owner Comment Implementation

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 EGYPTIAN POLYETHYLENE PROJECT (ETHYDCO)
CARDBOARD BLASTING PROCEDURE FOR COOLING
WATER UNDERGROUND MAIN HEADER
Rev.: Date:

Project Doc. No.: PE-CD-9999-OPE-PRC-000-0001

1 01-Dec-2014

TABLE OF CONTENTS
1. PURPOSE ...................................................................................................... 3
2. SCOPE ........................................................................................................... 3
3. PRECONDITIONS AND PREPARATION ....................................................... 3
4. STEP BY STEP PROCEDURE....................................................................... 4
ATTACHMENT-1 ..................................................................................................... 7

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 EGYPTIAN POLYETHYLENE PROJECT (ETHYDCO)
CARDBOARD BLASTING PROCEDURE FOR COOLING
WATER UNDERGROUND MAIN HEADER
Rev.: Date:

Project Doc. No.: PE-CD-9999-OPE-PRC-000-0001

1 01-Dec-2014

1. PURPOSE

The purpose of this procedure is to describe the method statement of cardboard blasting
for cooling water supply and return underground main headers. This operation will blow
particles (sand, rust, etc.) out from the piping and greatly help to minimize the time required
to clean the cooling water system by circulating water to the complex using permanent
cooling water pumps in Utility Plant.

2. SCOPE

This document is applied to cooling water supply and return underground main headers in
Polyethylene Plant. The cardboard blasting will be implemented prior to hydro-testing of the
system so that particles could be easily removed from dry surface of the piping. After the
hydro-testing, complex water flushing will be carried out in accordance with the procedure,
CD-9999-CPL-PRC-000-004 Complex Cooling Water Flushing Procedure prepared by
Ethylene Project. in addition to the method statement describe the cooling water flushing
prepared by Polyethylene project. This PROCEDURE shall be read in conjunction with the
Procedures for Complex Cooling Water Flushing (CD-9999-CPL-PRC-000-004).

3. PRECONDITIONS AND PREPARATION

The specific system readiness and preparations required for the cardboard blasting are given
as below.
1) System Readiness
a) Underground piping of cooling water system composed of system number
X-9999-U-012 are in a state of readiness for pressure testing (i.e. all A punches are
cleared) or equivalent in view of their physical completeness. Contractor shall send
notification to the owner confirming physical completeness.
b) The above ground CW distribution headers have not at this time been installed,
therefore there is no isolation from the underground cooling water system. NOTE:
Once the cardboard blasting has been completed, temporary piping jumpers from
the CWS to the CWR at 6 (six) locations will be installed to allow for circulation.
These locations will be noted in the Reinstatement section of the Step by Step
Procedure. All instruments (PI , Flow element Temperature thermowell) should be
removed and SC-9201 valve should be closed.
2) Preparations
a) Insure that the PTW for this activity is in place.
b) Provide barricade, caution tags, warning signs as required at each blow point.
c) Wear proper PPE, especially ear protection and safety glasses.
d) Arrange the following temporary materials and install as per the plan:

i. Oil-free air compressor with proper control regulator to regulate the pressure at
or below 6 kg/cm2g.

ii. (2)Pressure gauges – 0-5 or 0-10 kg/cm2g range

iii. Ring flanges for bursting as below:

A) (2) – 24” 150# - to be utilized in 3 different locations – Utility area, Cycle

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 EGYPTIAN POLYETHYLENE PROJECT (ETHYDCO)
CARDBOARD BLASTING PROCEDURE FOR COOLING
WATER UNDERGROUND MAIN HEADER
Rev.: Date:

Project Doc. No.: PE-CD-9999-OPE-PRC-000-0001

1 01-Dec-2014

Gas Compressor Train I, Cycle Gas Compressor Train II.

B) (2) – 14” 150# (chiller area)
C) (2) – 12” 150# (Extrusion I area and Extrusion II area)

iv. Blinds
A) 2 – 52” 150# slip blinds
B) 6 – 24” 150# blind flanges
C) 2 – 14” 150# blind flanges
D) 4 - 12” 150# blind flanges

v. By-Pass Gate Valves

vi. The manual valve on the piping jumpers are removed and the related flanges
are blinded which means 12 - 4".

vii. Notification will be sent to the owner prior to starting the bursting (one day
before starting ) as the owner shall be witness for all points starting from blow #1
till blow #2.

viii. STEP BY STEP PROCEDURE

Step Description Check
1. Install 52” slip blinds at CSW/CWR battery limits. Install blinds at all blow
points except Blow #1.
2. Confirm as per the marked up P&ID, Attachment 1. Blow point will be located
in the Chiller Area.
2a. Connect a temporary hose to the 4” drain valve upstream of 11 TG-9201-2 on
the CWR line in the valve pit.
2b. Install a temporary gage in the location for 11PG-9201-2
2c. Install blinds on all A/G locations as per the marked up P&ID for Blow #1. The
first Blow will be the 14” in the Chiller area. Install the rupture discs (plastic
sheets) on both CWR & CWS lines at the Chiller area.
2d. Slowly pressurize the CWR system from the temporary air compressor
through the 4” valve in the valve pit until the plastic sheets are ruptured. Do
not exceed 1 kg/cm2g on the system. Adjust the number of plastic sheets
accordingly.
2e. Repeat Steps 4 & 5 until the blow air becomes visually clean and acceptable
to the concerned parties present in presence of owner witness.
2f. Disconnect the temporary air hose from the 4” valve in the CWR line and
connect the hose to the 4” valve upstream of 11 FI-9201-1 in the CWS line
2g. Install a temporary gauge in the location for 11 PG-9201-1 on the CWS line.
2h. Slowly pressurize the system from the temporary air compressor through the
4” valve in the valve pit until the plastic sheets are ruptured. Do not exceed 1
kg/cm2g on the system. Adjust the number of plastic sheets accordingly.
2i. Repeat Step 1h until the blow air becomes visually clean and acceptable to
the concerned parties present.

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 EGYPTIAN POLYETHYLENE PROJECT (ETHYDCO)
CARDBOARD BLASTING PROCEDURE FOR COOLING
WATER UNDERGROUND MAIN HEADER
Rev.: Date:

Project Doc. No.: PE-CD-9999-OPE-PRC-000-0001

1 01-Dec-2014

2j. Install 14” blind flanges after blows are complete.

3 Confirm as per the marked up P&ID, Attachment 2. Train I Extrusion area,
Blow #2.
3a The 2nd blow will be located in the Train 1 Extrusion Area. Repeat the set up
preparation as per Step #1, CWR first then CWS.
3c Blow both lines until clean air is visible and acceptable. Install 12” blind
flanges.
4 Confirm as per the marked up P&ID, Attachment 3. Train II Extrusion area,
Blow #3.
4a Repeat the steps from Train I Extrusion Area for Train 2 Extrusion Area.
Install 12” blind flanges when blows are complete.
5 Confirm as per the marked up P&ID, Attachment 4. Train I Reaction area,
Blow #4.
5a Repeat the set up preparations as per the previous blows, CWR first them
CWS.
5b Install the 24” blinds when the blows are complete.
6 Confirm as per the marked up P&ID, Attachment 5. Train II Reaction area,
Blow #5.
6a Repeat the set up preparations as per the previous blows, CWR first them
CWS
6b Install the 24” blinds when the blows are complete.
7 Confirm as per the marked up P&ID, Attachment 6. AG to UG tie-in point
(near main pipe rack). Blow #6.
7a Repeat the set up preparations as per the previous blows, CWR first them
CWS.
b DO NOT install blinds after completion of blowing.
8 Remove all blinds flanges and install the temporary jumpers between the
CWS & CWR lines (6 in total). OPEN the 4” by-pass valves at each location.
9 Remove the 52” slip blinds at the Battery Limits and re-install the 52” spacer
rings.
10 Disconnect and remove the temporary hose located in the valve pit.
Remove the temporary gauges and install a PLUG in the permanent valve in
lieu of the pressure gauge or flow indicator.
REINSTATEMENT
1 Disconnect and remove the temporary air supply hoses from the 4” valves
in the valve pit. Reinstate the 4” 150# blind flanges for both valves as per
the P&ID. CLOSE the valves and install DO NOT OPERATE tags on each
valve.
2 Remove the 52” slip blinds at the Battery Limits and install the 52” spacer
rings as per the P&ID.

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 EGYPTIAN POLYETHYLENE PROJECT (ETHYDCO)
CARDBOARD BLASTING PROCEDURE FOR COOLING
WATER UNDERGROUND MAIN HEADER
Rev.: Date:

Project Doc. No.: PE-CD-9999-OPE-PRC-000-0001

1 01-Dec-2014

3 Install the CWS to CWR jumpers at each riser location (6).

The system is now ready to receive water for the circulation cleaning.

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 EGYPTIAN POLYETHYLENE PROJECT (ETHYDCO)
CARDBOARD BLASTING PROCEDURE FOR COOLING
WATER UNDERGROUND MAIN HEADER
Rev.: Date:

Project Doc. No.: PE-CD-9999-OPE-PRC-000-0001

1 01-Dec-2014

ATTACHMENT-1

Marked up P&ID

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