bp for preservation of idle eqpts

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Reliance Industries Limited

Copyright: Reliance Industries

Limited, India

Prepared by : K Gopalakrishnan Page: 1 of 29 Checked by : A Venkatraman

Group Manufacturing Services Engineering Services Dept Date: 3-Apr-07

Approved by : V V SuryaRau DOC. No: GMS/RP/32 Revision no.: 0.0

Best Practices

For Preservation

Of Idle Mechanical Equipments

Please send your comments and suggestions to the author.

This document is intended for guidance purpose and may be adopted with minor modifications by any functional department within RIL group of companies.

Reproduction of this document or parts thereof in not allowed unless written permission is

obtained from the Approving authority.

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INDEX Sr. No Title Page No 1. Introduction 03 2. Scope 03 3. Objective 03 4. Selection criteria for equipment selection 03 5. SECTION –A: PRESERVATION OF ROTATING EQUIPMENTS 6. Scope 04 7. Procedure for turbine/Compressor rotors 04 8. Rotor storage 05 9. Preservative coating/covering 05 10. Responsibility matrix 06 11. Rotor condition verification checklist 08 12. Procedure for spare equipments like Pumps/Blower/Fan/Gear Box 09 13. Pumps/Blower and fan 09 14. Gear Box 09 15. Responsibility matrix 11 16. Equipment condition verification check list 12 17. Preservation of Spare components 13 18. Preservation Bare shaft/Gear shaft/Impeller/Coupling 13 19. Preservation of bearing 13 20. Responsibility matrix 15 21. Component condition verification checklist 16 22. Idle rotary components 17 23. Centrifugal/rotary/reciprocating pumps 17 24. Large fans 17 25. Gear box 17 26. Reciprocating compressors 18 27. Centrifugal process compressors 18 28. SECTION –B: PRESERVATION OF STATIC EQUIPMENTS 29. Preservation of Vessel and columns 19 30. Preservation of Shell and tube heat exchangers 20 31. Preservation of Air fin coolers 21 32. Preservation of Reactor without catalyst and with catalyst 22 33. Preservation of Fired heaters along with ducts and stacks 23 34. Preservation of boilers 24 35. Preservation of cooling towers 25 36. Preservation of atmospheric storage tank 26 37. Preservation of Process piping 26 38. Preservation of Safety valves 27 39. Preservation of Heat exchangers 28 40. Preservation of Structurals and tracing 28

41. Reference 29

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1.0 INTRODUCTION Preservation of idle equipments is called “Mothballing”. Mothballing in a process plant involves safeguarding of unattended and non-operational equipments from deterioration during downtime period, generally above one month. Such situation may arise due to reasons like feed problems, haulage problems, major repairs, revamps, modifications, retrofitting, etc. Deterioration of equipments during idle time is caused by conditions entirely different from those that exist during operation. During downtime, moisture or oxygen or both are responsible for idle time corrosion of equipments. Deposits in equipment during operati on become corrosive during downtime due to reason mentioned above. Hence, prevention of idle time corrosion is achieved by adopting any of the following techniques. a) Expelling oxygen b) Using moisture absorbing chemicals called desiccants c) Creating physical barrier between metal & environment by applying paints or grease. 2.0 SCOPE This document deals with most practical and reliable techniques of corrosion pr evention in case of mechanical equipments during idle time. This document is prepared in such a man ner that it is covering both static and rotary equipments preservations separately in two sections. 3.0 OBJECTIVE The objective of these documents is to details best practices guidelines for the preservation of static and rotating equipments during their idle time. 4.0 Selection criteria for equipment preservation Before going for measures for mothballing of equipment, following should be considered. § Period of shutdown § Allowable deterioration & rate of deterioration § Probability of re-use § Expenditure for repair/replacement § Time required for repair/replacement after shutdown § Type of protective system applicable against idle time corrosion § Condition of the equipment § Criticality of service § Type of environment in which equipment need to be preserved Equipments do not need any idle time preservation if § It has become obsolete and will not be put back in service again § It has deteriorated beyond economic repair § It is not in critical service & the estimated value of the equipment § Is not worth the expenditure to be made for preservation.

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SECTION: A

PRESERVATION OF ROTATING EQUIPMENTS

High value rotary components / subassemblies have been procured as Insurance spares to cover

unforeseen failures resulting in huge production loss. It is vital that these components / equipments

are in good usable condition at all times. This necessitates preservation during storage/transportation

to avoid damages like rusting/sagging/physical damages in due course of time. The procedure defines

the methodology to be followed for pr eservation during storage/transportation. The procedure also

covers periodic checks required to certify the condition of spare rotor.

1.0 SCOP E

This procedure is used for preservation of following components / equipments during storage in

warehouse or i ts transportation from one location to another.

§ Turbine / Compressor rotors

§ Spare equipments like Pumps, Gearboxes, and Blowers etc.

§ Spare components like Shafts, Impellers, Couplings, and Bearings etc.

§ Idle rotary equipments (installed at site but not in operation)

2.0 PROCEDURE FOR TURBINE / COMPRESSOR ROTORS

The procedure comprises of three main sections. § STORAGE

The storage procedure takes care of rotor protection against

a. Shaft bends due to sagging

b. Physical damages

c. Rusting

§ PRESERVATIVE COATING & COVERINGS:

The procedure for coating is to ensure protection against corrosion

§ ROTOR TRANSPORTATION:

The procedure outlines the precautions to be taken during transportation to avoid any damage.

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2.1 ROTOR STORAGE:

Proper storage of critical rotors is of high importance to guard against the setting of bend in rotor due

to sagging effect and against physical damages / rusting. The rotors shall be stored in suitably

designed metal containers. Small rotors may be stored in wooden boxes. All the containers are

designed for preservation as well as transportation.

2.1.1 STORAGE IN METAL CONTAINERS

For the rotors stored in metal containers, the following shall be ensured:

§ The rotors are stored in vertical condition.

§ The containers shall be purged with Nitrogen with pressure of 0.3 – 0.5 bar.

§ Wherever the container design envisages use of relief valve, the relief valve shall be calibrated at

the time of periodic inspection.

§ The Nitrogen purge pressure shall be checked every six (06) months. In case it is low, it should be

made up with the assistance of Plant Maintenance.

§ The rotor containers shall be preferably stored on concreted or leveled floor / Ground. The

container shall be made horizontal when cyclonic winds are forecast.

2.1.2 STORAGE IN WOODEN BOXES

For rotors stored in wooden boxes the following shall be ensured:

§ Wooden boxes for storing small rotors are made from wooden panels/plywood boards and

adequately provided on the outside with wooden ribs for strengthening against collapse/breakage

during storage, lifting & shifting and transportation.

§ Wooden boxes are provided with sufficiently rigid wooden blocks on the inside to support the rotor

under its journals and in the mid-section. The block in contact shall be contoured to match the

curvature of the rotor section in contact. Each support shall be closed from top with sufficiently

rigid wooden blocks to clamp the rotor rigidly.

§ Sufficient quantity of DESICCANT bags shall be kept in the box to keep the atmosphere moisture

free.

§ All rotors packed in wooden boxes shall be stored indoors in horizontal condition.

2.2 PRESERVATIVE COATING, COVERINGS 2.2.1 Preservative coating

The recommended preservative coatings are:

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1. Tectyl 846 2. Molykote 3402 3. Molykote metal protector plus

6013 formulae 101 corrosion suppressant (spray form) Stripper compound Z 9313 (brushable). Or

other equivalent approved by Head Rotary (Engineering)

Surface to be coated must be thoroughly cleaned and dried. Suitable cleaning agents such as “8060

safety solvent” or another equivalent approved by Head Rotary may be used. Application of the

coating may be either by brush painting or by spraying on the surface. Allow applied coating to dry for

1 – 1½ hour or as per procedure of coating supplier. Ins pect coating for coverage of entire surface and

no pin holes/voids are left. In case of any defect, removal must be done using the suitable

solvent followed by cleaning the surface with clean, lint-free cloth/tissue paper. Apply coating

again.

2.2.2 Coverings: Critical surface like the journals and probe areas require special attention. The purpose of coverings is

to provide an effective isolation between the surface being preserved and the surroundings. Generally

wax coated lint-free jute cloth or paper or soft rubber/PVC tape with adhesive on one side are used for

covering the more critical and sensitive surface like journals, vibration probe sensing strips etc. For

heavy rotors supported on their journals, soft sheet metal (Aluminium/Brass/Lead) covering shall used

over the rubber/PVC layer on the journals.

Responsibilities:

The responsibility of ensuring proper storage and rotor condition shall be as defined below:

§ RESPONSIBILITY MATRIX

S/N Activities

Ro

tary

Pla

nt

E &

M

Wo

rksh

op

MA

TE

RIA

LS

/ S

TO

RE

S

1.0 Periodic inspection of rotor (once in 02 years for metallic containers and once in 12 months for wooden containers or rotors stored horizontally supported in bearings)

√ √ √

2.0 Lifting shifting and transportation of container with rotor to and from Storage Yard/Plant/E & M (Workshop) √

3.0 Lifting/shifting and transportation of container with rotor within √

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S/N Activities

Ro

tary

Pla

nt

E &

M

Wo

rksh

op

MA

TE

RIA

LS

/ S

TO

RE

S

E & M (Workshop)

4.0 Arrangement for rotor checks like Dimensional checks, Preservative cleaning √ √ √

5.0 Witnessing as per the verification check -list: 5.1 Preservation condition √ √

5.2 Visual inspection of journals, thrust collar & locknut, balancing weights, grub screws, coupling hub etc. after cleaning the preservative.

√ √

5.3 Run-out (radial / axial) checks at both journals, thrust collar, rotor mid-section, labyrinth/seal areas etc. √ √

5.4 NDT (DPT) of impeller / blades, shaft ends etc. first time before applying preservative & every time the rotor is taken out of service.

√ with C&I

√

5.5 Container condition √ √ 5.6 Preservative application √

5.7 Rotor placement and clamping in container and final box-up √ √ √

5.8 Box-up and sealing of container √ √ √

5.9 Nitrogen charging and final pressure at E&M (Workshop) √ √

6.0 Periodic inspection of container for Nitrogen pressure. Inspection of container sealing for Nitrogen leaks. √

7.0 Technical assistance for attending any leak of Nitrogen from container and make-up of Nitrogen √

8.0 Make-up of Nitrogen pressure as required. √

9.0 Nitrogen arrangement √ 10.0 Proper storage √ 11.0 Painting of container if required √ Responsibility as per above matrix is as follows. E & M-Rotary:

1. Rotor checking – Concerned Rotary Engineer -in-Charge 2. Approving any deviations – Head Rotary (Engineering)

E&M-Workshop: Workshop Engineer.

Plant: Plant Maintenance Engineer.

§ RECORDS Rotor condition verification checklist completely filled & duly signed by plant maintenance engineer & Rotary engineer shall be kept with Rotary group with a copy to r espective plant maintenance.

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ROTOR CONDITION VERIFICATION CHECK LIST

Tag No.: Tag Description: Inspected on: Unit: Spares Code Number: Due inspection: Location:

S/N ACTIVITIES OBSERVATIONS RECOMMENDATIONS/ REMARKS

1.0 Nitrogen Pressure Before dismantling the container (bars)

2.0 Physical Check after container opening: 2.1 Preservation Condition

2.2 Shaft Journal condition: 2.2.1 Drive end 2.2.2 Non drive end

2.3 Thrust Collar condition & Lock nut (where provided) tightness (hand movement check)

2.4 Condition of balancing weights (if applicable)

2.5 Condition of Grub Screws (Tightness check) 2.6 Coupling Hub condition 3.0 Run-out checking at E & M WORKSHOP: 3.1 DE Journal

3.2 On mechanical/dry gas seal area (DE)

3.3 Gland labyrinth area (DE) 3.4 Impulse wheel 3.5 Rotor mid-span 3.6 On mechanical/dry gas seal area (NDE)

3.7 Gland labyrinth area (NDE)

3.8 NDE Journal 3.9 On Thrust Collar (axial)

3.10 On Thrust Collar (radial)

4.0 Nitrogen Pressure maintained after container boxed-up (Bar)

5.0 Relief valve set-pressure (calibrated) (Bar) 6.0 Container Type:

6.1 Horizontal Storage 6.2 Vertical Storage

7.0 Future Recommendation for better storage

8.0 Transportation precaution PLANT MAINTENANCE E&M (ROTARY)

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3.0 PROCEDURE FOR SPARE EQUIPMENTS LIKE PUMPS, BLOWERS, FANS, GEARBOXES, ETC 3.1 PUMPS, BLOWERS & FANS

1. Approved antirust spray should be applied inside casing or pump casing should be filled with

mineral oil (containing 5% rust preventive concentrate).

2. Suction & Discharge ends of pumps should be blinded / covered to avoid entry of any foreign

material.

3. Bearing housings should be filled with lubrication oil.

4. Preservative coating should be applied on parts protruded from main body like shaft end including

coupling hub.

5. Equipment body (out side) should be painted.

6. The equipment should be rotated by 10 ~ 20 revolutions by hand at an interval of 6 months.

7. The equipment should be inspected every 6 m onths from available opening for physical

observation of rust etc. If rusting is observed, approved preservative after cleaning should be

applied.

8. Bearing housing oil should be changed at an interval of Two year.

9. Equipment should be stored in house (not in open area) in a leveled condition on concrete /

wooden block minimum 6 inches above the ground.

10. Antirust spray / coating should be properly cleaned by approved solvent, before installation of

such equipment in service.

3.2 GEAR BOXES

1. Complete gear box including lube piping should be filled with lubrication oil.

2. All vents ports should be plugged.

3. Equipment body (out side) should be painted.

4. Preservative coating should be applied on parts protruded from main body like shaft end

including coupling hub.

5. The equipment should be rotated by 10 ~ 20 revolutions by hand at an interval of 6 months.

6. The equipment should be inspected every 6 months by opening the inspection window for

physical observation of rust etc. If rusting is observed, approved preservative after cleaning

should be applied.

7. Gear box oil should be changed at an interval of two years.

8. Antirust spray / coating should be properly cleaned by approved solvent, before installation of

such equipment for service.

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§ RESPOSIBILITY

§ The responsibility of ensuring proper storage and equipment condition shall be as defined

below in page-11

§ The equipment should be inspected once a year as per the checklist defined in page 12.

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RESPONSIBILITY MATRIX

S/N Activities

Ro

tary

Pla

nt

Mat

eria

ls

/ Sto

res

1.0 Initial inspection of equipment √ √

2.0 Preservative application (internal / external) √ √ √

3.0 Blinding of ends (openings) √ 4.0 Lube oil filling / grease application in bearing housing √ √ 5.0 Body painting (if required) √ 6.0 Inspection, rotation of shaft at an interval of 6 months √ √ √ 7.0 Bearing housing oil / grease change √ √

8.0 Proper storage as per procedure √

Responsibility as per above matrix is as follows. § E & M -Rotary: 1. Equipment checking - Concerned Rotary Engineer-in-Charge 2. Approving any deviations - Head Rotary (Engineering)

§ Plant: Plant Maintenance Engineer.

§ Materials/Stores: Material officer / Stores in charge § RECORDS: Equipment condition verification checklist completely filled & duly signed by Materials officer & Plant Maint. Engineer shall be kept with Materials / Stores dept. with a copy to respective plant maintenance.

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EQUIPMENT CONDITION VERIFICATION CHECK LIST

Tag No.: Tag Description: Inspected on: Unit Spares Code Number: Due inspection: Location:


1.0 External physical condition

2.0 Preservative Condition 3.0 Internal physical condition (in openings) 4.0 Rotor freeness checking

5.0 Oil change 6.0 Preservative application

7.0 Storage at proper place 8.0 Future recommendations for better storage

PLANT MAINTENANCE MATERIALS/ STORES

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4.0 SPARE COMPONENTS LIKE SHAFTS, IMPELLERS, COUPLINGS, AND BEARINGS: 4.1 BARE SHAFTS / GEAR SHAFTS / SCREWS/ IMPELLERS / COUPLINGS ETC.

1. Correct identification tag / part no. should be ensured.

2. If the parts are new and in OEM packing, only its physical condition should be inspected

externally. Total packing need not be disturbed for a period of two years.

3. If the parts are used/ old or in storage for more than 1 year, approved preservative coating

(brushable /thick coating in straight portions and Spray / thin coating in parts having close

clearances) should be applied after cleaning b y suitable cleaning agent.

4. After coating drying, the parts should be packed in air tight polyethylene sheet.

5. Few bags of Indicator type Desiccants should be kept in the main packing for moisture

absorption. These bags should be inspected & replaced if moisture is indicated.

6. These parts condition & desiccant bags should be inspected at an interval of one year.

7. The parts should be horizontally supported at marked locations (for support) on a wooden

support frame, in leveled condition.

8. For castings, only the m achined surfaces need to be protected against rusting by preservative

coating.

4.2 BEARINGS (ANTIFRICTION & JOURNAL /TILTING PAD)

1. New bearings supplied with OEM packing should not be broken and should be stored in same

packing.

2. If at all the original seal of bearing is broken, the same should be repacked after thoroughly

applying approved Rust preventive coating (for antifriction bearings only) and applying Rust

preventive coating on Shell of the bearings (for Journal bearings only). Such bearings should

be preserved in polyethylene sheets and joints should be heat sealed or by self adhesive

tape.

3. Bearings should be stored in Horizontal position and piling up should be avoided (for

Antifriction b earings).

4. Bearings should be preferably stored in moisture free and dust free atmosphere.

5. Shifting of bearings from one location to another location during storage should be avoided as

it may damage the bearings.

6. Freeness checking of bearings by hand should be avoided during storage (for Antifriction

bearings).

7. All bearings should be checked / inspected externally once in two years.

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8. In case of small size sealed bearings (Antifriction type), the bearings should not be used after

shelf life of its grease is generally 3 to 4 years.

§ RESPONSIBILITY:

§ The responsibility of ensuring proper storage and components condition shall be defined in

page-15.

§ The components should be inspected once a year as per the checklist in page-16.

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RESPONSIBILITY MATRIX

S/N

Activities R

ota

ry

Pla

nt

MA

TER

IA

-LS

/ S

TO

RE

S

See

No

te 1

.

1.0 Identification tagging √

2.0 External inspection of parts in OEM packing √

3.0 Preservative coating application (if required, after two years of procurement) √

4.0 Packing of parts with desiccant bags (wherever applicable) √ 5.0 Overall proper storage at proper place √

Note 1: In case of any doubts / clarification, Plant / CES to be contacted. Responsibility as per above matrix is as follows. § Plant: Plant Maintenance Engineer.

§ Materials/Stores: Material officer / Stores in charge § RECORDS: Component condition verification checklist completely filled & duly signed by Materials officer & Plant Maint Engineer shall be kept with Materials / Stores dept. with a copy to respective plant maintenance.

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COMPONENT CONDITION VERIFICATION CHECK LIST

Tag No.: Tag Description: Inspected on: Unit: Spares Code Number: Due inspection: Location:


1.0 Packing condition 2.0 Preservative condition

3.0 Physical Condition of parts 4.0 Condition of desiccant bags 5.0 Replacement of desiccant bags

6.0 Overall storage condition and place

MATERIALS/STORES

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5.0 IDLE ROTARY EQUIPMENTS (INSTALLED AT SITE, BUT NOT IN OPERATION)

Requirement of such preservation is very rare & remote. General & broad procedure is given below.

However as & when needed, specific and detailed procedure should be evolved by CES (Rotary) &

Plant Maint Jointly. This is applicable for all equipments in this category.

5.1 CENTRIFUGA L, ROTARY & RECIPROCATING PUMPS

1. Pump casing should be flushed & drained.

2. If service is acidic or alkali, the same should be neutralized.

3. All cooling jackets should be flushed by fresh water followed by air drying.

4. Pump casing should be filled with mineral oil containing 5 percent rust preventive concentrate.

5. Cooling water jackets, bearing housing and stuffing box should be plugged; low point drain

valve should be cracked open slightly.

6. Approved preservative coating should be applied on parts which protrude through bearing or

stuffing box housings like shaft end and cover with tape.

7. All exposed machined surfaces and coupling parts except elastomers should be coated with

preservative.

8. Bearing housing should be completely filled with mineral oil containing 5 percent rust

preventive concentrate.

9. Pump suction and discharge valves closed.

10. The equipment should be given few hand rotations (3 to 4) once in 6 months (or during P.M).

5.2 LARGE FANS

1. Approved preservative coating should be applied on coupling and all external machined

surfaces.

2. Rust preventive spray should be applied on fan wheel.

3. Casing low point drain valve should be crack opened. The equipment should be given few

hand rotations once in 6 Months (or during P.M).

5.3 GEARBOXES

1. Gearbox and piping should be completely filled with oil containing 5 percent rust preventive

concentrate. Some space should be left for thermal expansion.

2. All vents should be plugged.

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3. Preferably a valved pipe should be installed on casing which can serve as filler pipe for

adding oil to fill casing.

4. The equipment should be given few hand rotations once in 6 Months (or during P.M).

5.4 RECIPROCATING COMPRESSORS

1. Compressor casing should be made free of hydrocarbons and purged.

2. Compressor suction and discharge should be closed. Crankcase, connecting rod and valves

should be filled with oil containing 5 percent rust preventive concentrate. Some space should

be left for thermal expansion.

3. All exposed machined parts should be coated with approved preservative.

4. After flushing & drying of cooling jacket, oil can be filled.

5. The equipment should be given few hand rotations once in 6 Months (or during P.M).

6. If the equipment is not in operation for more than one year, all soft packings, elastomers

should be inspected & replaced (if required).

5.5 CENTRIFUGAL PROCESS COMPRESSORS

1. Compressor casing should be made free o f hydrocarbons and purged.

2. Machine internals should be flushed with solvent to remove heavy polymers.

3. Casing should be pressurized with nitrogen.

4. After mixing 5 percent rust preventive concentrate to existing lube and seal oil, it should be

circulated through the entire system for one hour.

5. Upon the above exercise, oil return header should be closed. Shaft openings should be

sealed with silicone rubber caulking and tape.

6. Oil console should be filled with mineral oil containing 5 percent rust preventive concentrate.

7. Filling should be done when compressor is at ambient temperature. All heat tracers should

be turned off.

8. All exposed machined parts; including couplings (except elastomer) should be coated with

approved preservative.

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SECTION B

PRESERVATION OF STATIC EQUIPMENTS

The following procedures are for static equipments preservation

1.0 PRESERVATION OF VESSELS AND COLUMNS § Name of chemical Desiccant to be used. For CS/AS metallurgy, silica gel to be used and for SS metallurgy, activated alumina to be used. § Weight Requirement For both silica gel & activated alumina, weight requirement is calculated as 23Kg/28.3 Cubic meter of enclosed space. § Application Method a) The equipment need to be flushed internally. Neutralizing agents may be used during flushing if required b) In case of austenitic stainless steel equipments, passivation to be done by using solution of DM Water containing 1wt% of sodium carbonate and 0.5 wt% sodium nitrite.. c) Drain the solution after passivation. d) Man ways to be opened e) Internal cleaning to be done. f) The desiccant should be spread in a thin layer on a tray and then placed inside the equipment. In case of column, desiccant can be placed at various elevations inside the equipment g) All the nozzles to be blinded/closed (using similar gaskets as original) After that, all nozzles to be sealed by using tapes. h) All removable fittings such as safety valves & instrument connections to be removed and sent to ware house. i) Grease or preservative oil to be applied on bolts/nuts. j) In case of externally insulated equipment, insulation to be inspected. Hot or cold insulations both to be inspected. k) Damaged or deteriorated insulation to be renewed.

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l) Exposed portion to be painted with Zinc rich primer m) In case of small vessels, entire insulation can be removed and entire external surface to be painted with Zinc rich primer. n) In case of uninsulated equipment, the external paint to be inspected. Wherever paint is in damaged condition, Zinc rich primer to be applied. After removing the damaged paint by emery paper. § Nitrogen Purging: Not required § Regular Checking Once in every three months, desiccants to be inspected for de coloration. The discolored chemicals to be replaced with fresh ones 2 PRESERVATION OF SHELL AND TUBE HEAT EXCHANGER § Name of chemical a) Desiccant to be used in channel box. For CS/AS metallurgy silica gel to be used and for SS metallurgy activated alumina to be used. b) Nitrogen Purging in shell side / tube side both. § Weight Requirement For both silica gel & activated alumina, weight requirement is calculated as 23Kg/28.3 Cubic meter of enclosed space. § Application Method a) Flushing to be done in shell side/tube side separately b) De-assemble the heat exchanger , open and remove all removable components. If the exchanger has fixed tube sheets, all components other than tube bundle to be dismantled. c) All components to be cleaned thoroughly, the tube bundles to be cleaned externally & internally both. In case of fixed tube sheets, tube to be cleaned internally. For cleaning, hydro blasting / hydro jetting may be done, No deposit should be left on inside or outside surface of the components d) Grease/preservative oil to be applied on all the bolts/nuts& fl anges(other than gasket seating surfaces) e) Reassemble all components f) Put desiccants in the channel box.

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f) Blank off all nozzles and close all vents& drains g) Maintain positive nitrogen pressure in tube side/shell side both. h) External insulation if existing to be inspected . Damaged insulation to be renewed or removed. All external bare surfaces to be coated with Zinc rich primer in the areas where existing paint has been found deteriorated or insulation was removed. If the external environment is humid, all insulation to be removed & the complete external surface to be painted with Zinc rich primer. i) If a removable tube bundle is to be kept in the store, wooden flanges to be bolted on both the tube sheets and the tube bundle to be covered with waterproof tarpaulin. § Regular Checking The desiccant in the channel box to checked once in three months If discoloration observed the deteriorated desiccant to be replaced with fresh ones. 3 PRESERVATION OF AIR FIN COOLERS § Name Of Chemical a) Desiccant to be used in either of the two channel boxes. For CS/AS metallurgy, silica gel to be used and for SS metallurgy, activated alumina to be used. b) Nitrogen Purging in tube side. § Weight Measurement For both silica gel & activated alumina, weight requirement is calculated as 23Kg/28.3 Cubic meter of enclosed space. § Application Method a) Flushing to be carried out in tube side b) Deassemble the channel boxes. c) Cleaning of internal surfaces of tubes & channel boxes to be carried out thoroughly. Hydro blasting / hydro jetting may be used. d) Reassemble the channel boxes. e) Put desiccant in either of the two channel boxes f) Positive nitrogen pressure to be maintained inside the tubes. g) Grease to be applied on all fasteners

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§ Regular Checking The desiccant in the channel box to checked once in three months If discoloration observed the deteriorated desiccant to be replaced with fresh ones. 4 PRESERVATION OF REACTORS WITHOUT CATALYST

§ Name of chemical Desiccant to be used for CS/AS metallurgy silica gel to be used and for SS metallurgy activated alumina to be used. § Weight Requirement For both silica gel & activated alumina, weight requirement is calculated as 23Kg/28.3 Cubic meter of enclosed space. § Application Method a) The equipment need to be flushed internally. Neutralizing agents may be used during flushing if required b) In case of austenitic stainless steel equipments, passivation to be done by using solution of DM Water containing 1wt% of sodium carbonate and 0.5 wt% sodium n itrite.. c) Drain the solution after passivation. d) Man ways to be opened e) Internal cleaning to be done. f) The desiccant should be spread in a thin layer on a tray and then placed inside the equipment. In case of column, desiccant can be placed at various elevations inside the equipment g) All the nozzles to be blinded/closed (using similar gaskets as original) After that, all nozzles to be sealed by using tapes. h) All removable fittings such as safety valves & instrument connections to be removed and sent to ware house. i) Grease or preservative oil to be applied on bolts/nuts. j) In case of externally insulated equipment, insulation to be inspected. Hot or cold ins ulations both to be inspected. k) Damaged or deteriorated insulation to be renewed.

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l) Exposed portion to be painted with Zinc rich primer m) In case of small vessels, entire insulation can be removed and entire external surface to be painted with Zinc rich primer. n) In case of uninsulated equipment, the external paint to be inspected. Wherever paint is in damaged condition, Zinc rich primer to be applied. After removing the damaged paint by emery paper. § Nitrogen Purging: Not required § Regular Checking Once in every three months, desiccants to be inspected for de coloration. The discolored chemicals to be replaced with fresh ones

5 PRESERVATION OF REACTOR WITH CATALYST § Name of chemical Nitrogen purging § Application Method a) All safety valves & other removable attachments to be removed. b) All nozzles to be blinded/closed c) If CTS permits, positive nitrogen pressure to be maintained inside the reactor. d) Grease to be applied on all fasteners 6 PRESERVATION OF FIRED HEATERS ALONG WITH DUCTS AND STACKS § Name of chemical NIL § Application Method a) Flushing of tubes to be carried out by using neutralizing agents if required b) If tubes have austenitic SS metallurgy, passivation of tubes inner surfaces to be carried out by using solution of DM Water with 1wt% sodium carbonate & 0.5 wt% sodium nitrite . The holding period of this solution inside the tubes should be decided by CTS.

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c) The passivating solution to be drained. d) All the bolted connections in the flanges in tube coils to be opened. e) All the fasteners to be greased. f) All hinges on access doors, peep holes, drains, and dampers to be greased g) External surfaces of tubes to be cleaned by using wire brush. & 5% solution of soda ash in water. In case of SS tubes, soda ash solution should be made in DM Water h) Refractories should be kept dry i) Wherever feasible, air entry locations should be sealed in the shell/fire box. 7 PRESERVATION OF BOILERS There are basically two methods of idle time protection of boilers :- a) Dry method b) Wet method In this document, only dry method is recommended. § Name of chemical Desiccants to be placed inside the steam drum. Silica gel or dehydrated lime (calcium oxide) or activated alumina to be used. § Weight Requirement For each 1000 square feet of heating surface area, 100 lbs of silica gel or 20 lbs of dehydrated lime or 150 lbs of activated alumina to be used. § Application Method a) The boiler to be drained, flushed and chemically cleaned b) Drying of inner surfaces of tubes to be done by using forced hot air if feasible. c) Open the man way of steam drum, and place desiccant inside the drum. And close the man way. d) All removable instrument attachments to be removed including safety valves. e) All flanges in the pressure envelop to be closed and tightened. f) Refractory inside the fire box to be kept dry. Wherever feasible, all air entry locations in the fire box to be closed.

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g) Before taking shutdown of boiler, operate all soot blowers several times to remove as much deposit from tubes as practicable. h) After shutdown, the external surfaces (flue gas side) of tubes and air heaters should be washed down with 5% solution of soda ash in water. i) The burner tips should be thoroughly cleaned and coated with preservative oil § Regular Checking Once in three months, the desiccants to be checked for decoloration. The deteriorated quantity of desiccants to be renewed with fresh ones. 8 PRESERVATION OF COOLING TOWER § Name of chemicals NIL § Application Method a) Drain and flush all the connected piping b) Drain all water from the basin, remove all debris, muck etc and clean the basin thoroughly c) Replace all unsatisfactory/unhealthy structural members d) Replace warped or missing slats e) Carry out repairs to the concrete walls & floors of the basin for cracks, loose concrete, slope of the floor, etc f) Remove fan motor and protect it as recommended by GMS g) Drain the oil from gear box and refill i t with a high grade mineral oil. h) Clean the exterior surfaces of the gear reducing housing and paint them. Store the reducer in a warm & dry area. i) Wrap all exposed shaft with plastic tape. j) Clean the fan with appropriate cleaner and apply suitable paint k) Clean the fan drive gear with a light grease and water proof paper. l) Secure the fan blades to prevent rotation and to provide supports

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m) If it is undesirable or unnecessary to remove the fan drive components, the fan should be operated every 3 to 4 weeks and routine maintenance to be carried out. n) The dry wood in an idle cooling tower is a serious fire hazard. Therefore, for idle period of about two months, a perforated hose should be laid around the tower and spray water periodically to keep wood in wet condition For downtime longer than two months, all the wooden members should be sprayed with a fire retarding chemical and a biocide. 9 PRESERVATION OF ATMOSPHERIC STORAGE TANK § Name of chemicals NIL § Application Method a) Tank shall be made free of gas & any residue Extra precaution shall be taken if pyropheric iron sulphide or residue of leaded gasoline is present. b) All the loose scales on the internal surface of tank to be removed. c) The internal surface should be sprayed with preservative oil. d) All the removable attachments in the shell to be removed. e) All the flanges connected to shell to be blinded or closed. f) In case of uninsulated tanks, the painting on external surface to be inspected. In the areas of deteriorated paints, coating of zinc rich primer to be applied g) In case of insulated tanks, th e insulation to be inspected. In the areas of damaged insulation, the damaged portion to be renewed. h) In case of steam coil inside the tank, the same should be blinded off after draining. i) In case of floating roof tanks, the floating roofs should be kept float with DM Water with hydrazine inside the shell. j) The roof drains to be kept open j) Water accumulated on the roof tops due to rain etc should be cleaned periodically. 10 PRESERVATION OF PROCESS PIPING § Name of chemicals

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VCI Powder(Nitrite or arine carboxylate powder) (VCI stands for Vapor phase Corrosion Inhibitor) § Weight requirement 30 grams of VCI powder per one cubic feet of enclosed space. § Application Methods a) Flush the lines clean b) Open the flange joints & valves at low points to ensure complete draining. c) Circulate preservative oil thru them or alternatively, spray VCI powder in the interior of pipes. Apply powder through a sandblasting gun or suitable device for spraying powder Attention should be given that pipe ends (approx two feet from each end) have visible powders. d) Inspect insulated and wrapped lines Uncover the piping where leaks are suspected. Both hot & cold insulations to be inspected e) Repair all damaged insulation and wrapping. f) Bare pipes should be wire brushed and painted. g) Lubricate all valves h) Spray all external surfaces of valves with oil and cover valve stem with grease. i) All instrument connections including relief valves should be removed. The flanges to be blinded or closed. j) All process and utility lines (except fire water line) should be drained, internal flushed & blinded near the battery limit. Precaution: The VCI powder mentioned above are combustible and sometimes explosive if heated in a confined space. Do not expose to flame or heat up the outside of pipe containing this powder. Before welding or heating the pipe for any reason, thoroughly blow out the powder by using dry air or wash out with water. § Regular Checking If VCI powder is used for internal protection, once in 24 months, these need to be re-injected. 11 PRESERVATION OF SAFETY VALVES

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§ Name of chemicals NIL § Application Method a) Clean the safety valves from inlet end & outlet end through water spray. b) Dry it by using hot air c) Blind both end flanges with wooden plates. Or wrap with water resistant tapes. 12 PRESERVATION OF PLATE HEAT EXCHANGERS § Name Of Chemical Nitrogen purging § Application Method a) Flush clean both sides b) Drain out both sides c) Maintain positive nitrogen pressure in both sides d) Close/blind all the nozzles 13 PRESERVATION OF STRUCTURALS § Name of chemical NIL § Application Method a) Visual inspection of all the Structurals supporting pipe racks & equipments to be carried out. b) In the accessible areas, if external paint found peeled off, the damaged paint to be removed and repainting by using zinc rich primer to be done c) Fireproofing of skirts of vertical vessels & columns to be inspected. Repair the fire proofing wherever necessary. 14 PRESERVATION OF TRACING

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§ Name of chemical VCI Powder(Nitrite or arine carboxylate powder) § Weight Requirement As given in "Application Method" below § Application Method In case of electrical heat tracing, disconnect and leave in place. In case of steam heat tracing, flush it. After flushing, fill with 40% ante-freeze/60% water solution containing 2.5 % VCI powder and 0.25% suitable wetting agent. § Regular Checking Replenish the solution inside steam heat tracing once in 24 months.

Reference

1. OISD Standard – 171

2. Mothballing manual- by M/S Cortec Corporation, USA

3. Protecting out of service steam boilers by H2O Engg Ltd USA

4. Preservation procedure of JG/HZ/PG

5. Preservation procedure of Baroda approved by WTD

6. Major Process equipment maintenance and repair by H . D Bloch .

7. Recommendation of new OEM

bp for preservation of idle eqpts

Documents

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