International Journal of Science and Research (IJSR)

ISSN: 2319-7064
Index Copernicus Value (2016): 79.57 | Impact Factor (2018): 7.426

Ensuring LNG Liquefaction Facility‟s „System

Cleanliness‟: Pipe Air Blowing as a “Build It Clean”
Attribute
Nirmal Surendran Menon
Associate Member, Institution of Mechanical Engineers (IMechE), Graduate Member, Engineering New Zealand
Email: nirmalsurendranmenon[at]gmail.com
Cell: +1(337)-965-4978

Abstract: Air Blowing is one of the most efficient methods of cleaning piping systems. In this technique a large-volume, clean system is
selected as an air reservoir (a vessel or large-bore piping such as a reservoir header) and used to store dry air, which is then released into
smaller open-ended piping systems where the velocity will significantly exceed the normal operational velocity, thus resulting in debris
removal. This system of cleaning is used on sections of the LNG facility where it is necessary to keep the pipe-work dry, such as Propane,
Mixed Refrigerant (MR), Natural Gas (NG) circuits and Instrument Air (IA) lines. It is also used on large bore systems where a
sufficient flow of water is not possible. Air blowing in a LNG facility also serves the purpose of removing free water from the piping in
order to prevent excessive use of gas for defrosting. In air blowing pipe-work, the objective is to maintain a high air velocity through the
line for an extended period. To achieve this it is normal to include some large volume vessel (reactor, column, etc.) in the circuit to be
blown. The circuit is then pressured up with air, and then rapidly vented out at an open end with the vessel in the circuit acting as an air
reservoir to sustain the blow over a longer period. The velocity achieved during air blowing shall have the required drag force (preferably
1.1 to 1.5 times) higher than drag force during operation.

Keywords: Air Blowing, System Cleanliness, Build-It-Clean (BIC), Pre-Commissioning, LNG facility, Propane Refrigerant, Mixed
Refrigerant, Natural Gas, Instrument Air, PFD (Process Flow Diagram)

1. Introduction lodged within the pipe work being cleaned. This method is
typically applied to small bore piping. A suitable supply
This article focuses on the application of air blowing to a source is selected, either from the utility air supply network or
LNG facility piping system that is best suited for pipe work from a temporary compressor to a temporary storage vessel.
that falls into the categories, that is required to be kept dry A temporary hose from the supply source is connected
(i.e. Propane Refrigerant, Mixed Refrigerant, Instrument Air, directly to the piping to be blown and blown to atmosphere.
Nitrogen, Lubricating Oil, Hot Oil, etc piping systems), The success of continuous air blowing is dependent upon
whose system cannot be associated with being filled with ensuring the air generation system has sufficient capacity to
water, that is fabricated from Stainless Steel and when develop the necessary cleaning air velocity.
insufficient low chloride water is available to support water
flushing large diameter when the supply and B. Rapid Decompression
containment/disposal of the volume of water required for
flushing becomes impractical. Air Blowing shall be In this method the volume tank and piping network being
considered for all piping of 24 inches or less that requires cleaned is pressurized with dry compressed air from a source.
cleaning in order to remove dirt & debris as well as free At a selected pressure the air is released by either opening of
water. Care must be taken not to subject the piping to a quick action blowing valve or rupture of rupture disc. The
extremely high velocities and choked flow as this has the resultant rapid decompression results in a high velocity air
potential to cause catastrophic failure of the piping due to stream which dislodges and removes any rust, scale, dirt,
flow induced vibrations. Typically this will occur at velocities foreign objects, etc that may be lodged within the pipe work
greater than 0.84 Mach so it is recommended that 0.7 Mach is being cleaned. The valve or disc shall be located as close to
never exceeded. This can only be reliably controlled by the reservoir as possible to produce the maximum velocity
restricting the upstream air pressure. Refer to Reservoir within the pipe. The success of rapid decompression blowing
Pressure Limitations in Table A – 1 below for more details. is dependent upon locating a volume tank of adequate
Direct Blowing of small bore piping is not affected by this capacity at the start of the cleaning path. The volume tank is
provided the air supply is restricted to 58 psig. either a process vessel such as a reactor, column, knock out
drum, etc or a special purpose rented volume tank. Volume
2. Air blowing techniques tank capacity is the most significant factor affecting the
length of time the pipe being cleaned is subjected to the target
Two main techniques utilized when cleaning pipe work with cleaning air velocity. For a given cleaning path the greater the
air are Continuous Blowing and Rapid Decompression. capacity of the volume tank the less the number of blows
required to achieve the target cleanliness criteria. Rate of
A. Continuous Blowing decompression is another key factor affecting cleaning air
velocity. Two main means of achieving a rapid
In this method, dry compressed air is blown continuously decompression are typically utilized: (a) Where practical, a
from a source through the piping network being cleaned to quick opening blowing valve arrangement shall be used, (b)
atmosphere. This high velocity air stream dislodges and Where a quick opening valve arrangement is not practical,
removes any rust, scale, dirt, foreign objects, etc that may be rupture discs shall be used. If it is not feasible to place a valve
upstream of the line being cleaned when performing the Air
Volume 8 Issue 1, January 2019
www.ijsr.net
Licensed Under Creative Commons Attribution CC BY
Paper ID: ART20194548 10.21275/ART20194548 1258
 International Journal of Science and Research (IJSR)
ISSN: 2319-7064
Index Copernicus Value (2016): 79.57 | Impact Factor (2018): 7.426
Accumulation Method then as a last resort, a knife valve or cleaned. For pipe work normally in gas service the cleaning
Rupture Disk may be installed on the discharge of the piping. air velocity shall be the greater of 1.3 x normal flow rate or
The effectiveness of this blow set-up is poor and it is likely 132 ft/s (for pipe work normally in liquid service the cleaning
that this blow would have to be repeated multiple times air velocity shall be in the range 66 to 132 ft/s). The capacity
before sufficient cleanliness is achieved. of commercially available portable air compression/drier
systems is normally adequate to support the cleaning of pipe
C. Initial Scavenging Run of Process Compressors work up to 4 inch diameter using the continuous blowing
technique. Pipe work greater than 6” diameter shall be subject
For the pipe connected to the process compressors, air to cleaning with air utilizing rapid decompression.
blowing is conducted with the process compressor operated
with air or nitrogen (It is essential of course to investigate in 4. Tools and equipment required for carrying
advance whether or not the process compressors can be out air-blowing
operated with air).
A. Fast Acting Knife Valves
D. Target Air Blowing
The air blowing shall commence when the valve directly
Target Air Blowing will only apply to the small bore upstream of the line being cleaned (known as the air blow
Compressor suction lines as well as gas turbine fuel gas lines valve) is fully opened. The maximum blow flow rate possible
of Carbon Steel Piping downstream of the inlet filter. occurs when the air blow valve is 100% open and the
Velocity calculations shall be applied in order to estimate the upstream reservoir pressure is at its maximum. During the
required upstream reservoir pressure required to produce a period of time it takes to open the air blow valve fully, the
disturbance factor between 1.2 and 1.5. The target shall reservoir starts depressurizing and loses an initial mass of air
consist of white material, preferably paper mounted on a hard which affects the initial air blow flow rate. It is therefore
board, placed directly in the exhaust path of the line being imperative that the air blow valve is opened in the shortest
blown. A gap of at least 1.5 pipe diameters is required time possible and it is recommended that this time period is
between the exit point and the target so that it does not act as less than 0.5 seconds. For some air blows it may be more
a restriction to the air flow. Blowing Density shall be practical to utilize permanent in-line valves. However, if a
calculated based on the upstream reservoir pressure using the permanent valve is to be used as the air blow valve it must be
following ideal gas equation: confirmed that it can be opened quickly (less than 0.5
seconds) and that the line upstream of the valve has been
Density (kg/m3) = Pressure (Pa) / [287.05*Temperature (°K)] confirmed as clean so that it is not damaged during the blow.
–A When procuring Knife Valves for air blowing, it is
recommended that a minimum of 1 per line size in the range
Density (lb/ft3) = 0.0624 x A of 3 inches up to 24 inches rated for 150# are purchased. For
the larger valves, actuators should also be purchased that
The temperature shall be assumed to be 104°F allow the valves to be opened in less than 0.5 seconds.
Calculating the Reservoir Pressure shall be an iterative B. Adequately Sized Reservoir
process by the following steps: (a)Calculate point to point
line length of piping using isometric drawings or 3-D model, As the reservoir pressure must be limited to protect the
(b)Multiply by a factor of 1.3 to account for equivalent length downstream piping, and the opening of the air-blow valve is
of pipe fittings, (c)Carry out Isothermal Pressure Drop not considered to be instantaneous, the size of the reservoir
Calculation solving for Fluid Flow rate assuming an initial being utilized becomes critical. For example, if a 24 inches
Inlet (Reservoir) Pressure of 2psia and setting the Outlet (600mm) line is being blown using a very small reservoir at
Pressure as 14.5 psia, (d)From the calculation in (c), use the 20.3053 psia (1.4 bara) then there is the possibility that the
Mass Flow rate figure in the Disturbance Factor equation reservoir will have discharged completely by the time the
along with the calculated density, (e)Confirm DF is between valve has been opened fully. A suitable reservoir size can be
1.2 and 1.5, (f)If it is then a reservoir pressure of 29 psia is calculated based on an allowable change in air density in the
acceptable, (g)If it is below 1.2 then repeat steps (c), (d) and reservoir during the time it takes to fully open the air blow
(e) using a higher reservoir pressure, if it is above 1.5 then valve. The following assumptions have been made:
repeat steps (c), (d) and (e) using a lower reservoir pressure.
Operating data shall be taken from PFDs if possible but Air Blow Temperature = 104°F (40°C), Knife Valve opens in
supplementary information from a datasheet for a control <5s, Allowable ΔP in Reservoir while valve opens fully =
valve in the line may prove a more likely source of accurate 5%. Worst case scenario is the Maximum Mach case for each
information. If no information is available then compressor of the scenarios shown in the max allowable reservoir
vendor shall specify the operating flow rate and density. pressure in Table A – 1.
3. Air requirements Density Calculation:

Air supplied for cleaning of pipe work shall be oil free and ΔDensity (kg/m3) = ΔPressure (Pa) / [287.05*Temperature
dried to a dew point < 14oF. Typically a portable oil free air (°K)] – Eq. 1
compressor and heater less drier skid are utilized to generate ΔDensity (lb/ft3) = 0.0624 x Eq. 1
the dry air for pipe work cleaning. The effectiveness of using Volume Calculation:
air to clean pipe work is dependent upon generating sufficient Volume (m3) = Flowrate (kg/s) x Valve opening time (s) /
cleaning forces (air velocities) at the wall of the pipe being ΔDensity (kg/m3) –Eq. 2

Volume 8 Issue 1, January 2019

www.ijsr.net
Licensed Under Creative Commons Attribution CC BY
Paper ID: ART20194548 10.21275/ART20194548 1259
 International Journal of Science and Research (IJSR)
ISSN: 2319-7064
Index Copernicus Value (2016): 79.57 | Impact Factor (2018): 7.426
Volume (ft3) = 35.31 x Eq. 2 maximum operating conditions. That value is the
denominator in the momentum ratio fraction. The numerator
A summary of the results are given in the Table A – 2 is the product of mass flow and specific volume of the
cleaning medium during blow conditions. The target or ideal
For the 16 inches (400mm) to 24 inches (600mm) piping the CFR has been identified as having a value of between 1.2 and
recommended reservoir volumes are considered large and 2.0.
finding a suitable vessel may be difficult. As a minimum the
reservoir shall be rated for 145.038 psia (10bara) and shall be The following formula represents the calculation described
equipped with adequately sized relief valves. It may be above:
possible to use a vessel within a module as the reservoir
before the vessel internals are installed provided that it is CFR = [M (blow) 2 x V (Blow)]/ [M (ref) 2 x V (ref)]
adequately rated, has relief valves protecting it and has been
tightness tested prior to use. M(blow) = Mass flow of medium used for blowing (Air),
lbm/sec (kg/s) V(blow) = Specific volume of blow medium
C. Air Compressor (Air) during the blow, ft3/lbm (m3/kg) M(ref) = Mass flow of
Natural gas under maximum load conditions lbm/sec (kg/s)
Low Pressure 145.038 psig (10barg) oil-free air compressor V(ref) = Specific volume of Natural gas under lowest
(1500scfm) with heatless dryer package & dust filers possible pressure to achieve the maximum flow conditions,
(supplying air with a dew point of -40°F). Provision of a ft3/lbm (m3/kg)
standby compressor shall be considered. To connect the
compressor to the reservoir various rubber flexi hoses fitted 6. Items to be spooled out prior to air blowing
with 150# CS end flanges shall be used.
Prior to air blowing, as a minimum, safety valves as required
D. Pressure Gauge (usually not required), Check valves (as required), Rupture
disks, Orifice plates or flow meter elements, In line
A Pressure Gauge shall be connected to the reservoir prior to mixers/In-line strainers Inline Butterfly Valves, Spray
the introduction of air from the compressor. The pressure nozzles, Analyser probe, Control valves, Self-actuated control
gauge shall be fit for purpose, i.e. for air blows with a low valves, Tight shut off (TSO) valve, Chemical injection probes
max allowable reservoir pressure a gauge with a low shall be removed and spooled out. Where an in-line
maximum shall be used. It is recommended that, as a instrument is to be spooled out, a spool piece designed to the
minimum, pressure gauges are provided with the following specification of the line it is to be installed in shall be used. If
ranges: the exit point of the air blow is considered a dangerous
location to personnel and / or permanent plant equipment,
0 – 23 psig temporary spool pieces shall be used to or an engineered
0 – 36 psig deflector pipe shall be installed to route the air exit point to a
0 – 145 psig safe location (Figure B – 1). Any spool pieces required shall
be identified and specified in the Method statement. A full set
5. Pneumatic blow calculations of spare gaskets for all piping sizes shall be made available. A
set of spades, rated for the system being blown, shall be made
The concept of cleaning force ratio (CFR) momentum available for isolating connecting systems that must not be
calculation provide a method for understanding when velocity pressurized.
and flow conditions have the most chance for dislodging
contaminates and moving them through the piping system. 7. Define blow paths
A. Cleaning Force Ratio (CFR) or Momentum Ratio A set of blow packs shall be created for each system where a
Calculations particular line has been identified as requiring cleaning by Air
Blowing Method. The latest “Master” P&IDs shall be used to
Line blowing effectiveness has been identified to be a mark-up each blow path. Multiple blows can be shown on
function of the cleaning force ratio (CFR) momentum that is each P&ID and the lines being cleaned shall be clearly
achieved. Cleaning force momentum is the product of mass identified. Where possible, blow path shall be ensured as per
flow and velocity that interacts aerodynamically with normal operational direction. Main Header(s) shall be cleaned
particulates extending beyond the pipe wall into the moving first prior to blowing subsequent branch lines. Instruments
fluid at the fluid boundary. It is the goal of the cleaning and in-line fittings to be removed, flanges to be spaded off,
process to pass a fluid (gaseous air or nitrogen) through the spool pieces to be fabricated, blow discharge point(s) and the
piping system with higher cleaning forces than would ever be location of the air blow shall be highlighted. State whether or
achieved from the flow of fuel gas through the pipe during not the air-blow valve will be a temporary installed knife /fast
peak plant operations. A CFR of greater than one ensures that acting valve or if a permanent valve is to be used. If it is the
the momentum achieved during cleaning will exceed the latter then assurances must be made to confirm that the valve
momentum that can be expected during operations. Some can open immediately (100% open in <0.5s) i.e. is not geared,
turbine manufacturers have provided recommended CFRs of or will not be damaged during the air blowing activity. Air
as much as 2. The presumption is that all or nearly all blow reservoir shall be protected by a suitably rated Pressure
particles remaining attached to the pipe walls after pneumatic Relief Valve when connected to an operational compressor.
blows are unlikely to be dislodged during operations. The The maximum Reservoir Pressure that shall be used for the
cleaning force momentum ratio calculation is shown below in blow using shall be as per Table A – 1 for standard air blows
equation. It is calculated by taking the mass flow squared or as calculated for Target Air Blows. Reservoir volume shall
times the specific volume of the fuel gas as it will flow during be confirmed as adequate using Table A – 2 as a guide.

Paper ID: ART20194548 10.21275/ART20194548 1260

 International Journal of Science and Research (IJSR)
ISSN: 2319-7064
Index Copernicus Value (2016): 79.57 | Impact Factor (2018): 7.426

8. Blowing commissioned plays an important factor during

commissioning and subsequent start up of the system.
Reservoir pressure shall be increased to 25% of max
allowable reservoir pressure, then air supply shall be cut off Reference to this paper should be made as follows:
and compressor isolated. Quick acting air blow valve shall be Surendran Menon, N., (2019) „Ensuring LNG liquefaction
opened as quickly as possible and reservoir shall be allowed facility‟s „system cleanliness‟: „Pipe Air Blowing as a
to discharge completely. Discharge piping shall be monitored “BUILD IT CLEAN” attribute‟.
for signs of flow induced vibrations and discharged effluent
shall be monitored at exit point. Reservoir pressure shall be References
confirmed to be 0 psig and that there is no audible sign of air
exiting the piping. Repeat steps above at 50%, 75% and 100% [1] T.K. Jack, A Simplified Pipeline Calculations Program:
of max allowable reservoir pressure. NOTE: NEVER TAKE Liquid Flow (1) ‖, International Journal of Scientific &
THE RESERVOIR PRESSURE ABOVE THE MAXIMUM Engineering Research
ALLOWABLE. If exit point shows signs of excessive [2] C.L. Yaws, Physical Properties, McGraw Hill, 1977
vibration, reduce pressure by 3 psi for the next blow and [3] Aligna Graphics Co., Pipeline Sizing Program, Pipedi
maintain all subsequent blows at that pressure. Continue User Manual, 1998
blowing at the maximum pressure until there are no signs of [4] J.B. Evett, 2500 Solved Problems in Fluid Mechanics
debris or water being discharged at the exit point. For Target and Hydraulics, McGraw-Hill, 1989
Blowing, perform one final blow at maximum reservoir [5] Esposito, Fluid Power with Applications, Prentice Hall,
pressure with white paper mounted on a hard backing 1980
positioned in the air exhaust path at a minimum distance of [6] R.N. Fox, Introduction to Fluid Mechanics, Wiley, 1992.
1.5 pipe diameters. A typical air blowing setup line diagram [7] R.W. Miller, Flow Measurement Engineering Handbook,
is shown in Figure B – 1. McGraw-Hill, 1985
[8] R.H. Perry, and D.W. Green, (eds), Perry‟s Chemical
9. Acceptance criteria Engineers‟ Handbook, 6th edn., McGraw-Hill, 1984
[9] V.L. Streeter, Fluid Mechanics, McGraw-Hill, 1983
The Acceptance Criteria for standard Air Blowing is No
visible signs of free water debris or rust at the blow point at Author Profile
the maximum allowable reservoir pressure and for target air
blowing is “White Paper Test”. No discoloration or particles Nirmal Surendran Menon received his Bachelor of
visible on a sheet of white paper, mounted on a hard backing, Engineering in Mechanical from Anna University, Tamil
positioned in the air exhaust path at a minimum distance of Nadu, India in 2005 and Master of Science in Project
1.5 pipe diameters. Also a post air blow boroscoping shall Management from National University of Singapore in 2010.
also determine the acceptability criteria of the Air Blow. He has more than 12 years of experience in EPC projects in
the Oil/Gas/Petrochemical sector. He is currently working as
10. Conclusion Field Engineer in an LNG Liquefaction Project in South West
Louisiana, US. His interests include pipeline system integrity,
Air blowing of pipelines is extremely important for critical pipeline system cleanliness, Loss Prevention in LNG
service lines such as compressor suction lines and achieving liquefaction facilities as part of project execution.
cleanliness of these critical pipelines for the system to be

Table A – 1:

Volume 8 Issue 1, January 2019

www.ijsr.net
Licensed Under Creative Commons Attribution CC BY
Paper ID: ART20194548 10.21275/ART20194548 1261
 International Journal of Science and Research (IJSR)
ISSN: 2319-7064
Index Copernicus Value (2016): 79.57 | Impact Factor (2018): 7.426
Table A - 2

Figure B – 1

Paper ID: ART20194548 10.21275/ART20194548 1262