Table of Contents
- Introduction
- Scope
- Preservation Methods
- Pressure Vessels
- Storage Tanks
- Heat Exchangers
- Special Equipment
- Rotating Machinery
- Fired Heaters, Steam Generators and Incinerators
- Electrical Equipment and Motors
- Instrumentation
- Piping
- References
1. Introduction
Short term care and preservation of equipment procedures are laid down in Reference 9.13.1, covering the period from its delivery on site through construction to pre-commissioning. However:
- when the period from delivery to erection exceeds 12 months,
- or when the period from delivery to the start of pre-commissioning exceeds 24 months,
a more extensive program of care and preservation becomes necessary.
The purpose of this section is to provide guidelines to the relevant Company construction personnel to define and implement such a program. Responsibilities for this work during all phases on site are defined in Reference 9.13.2.
Attention is drawn to the importance of formalizing procedures by keeping appropriate records.
2. Scope
This procedure outlines the minimum requirements to be followed for protection of equipment and material from arrival at jobsite until:
a. Start of pre-commissioning
b. Acceptance by client
Preservation after pre-commissioning has to be discussed separately with the client and is not considered in this procedure.
2.2 The end of guarantee from vendors is to be considered since the requirements in this procedure relate to prolonged storage of material (expected duration of storage 1 year or more).
Specific preservation requirements of vendors will be followed as far as possible. If there is a conflict between manufacturer's recommendation and the recommendation in this procedure, the vendor's recommendation shall take precedence.
2.3 The extent of preservation will depend on the anticipated period that the equipment is to be preserved. This is to be handled in close conjunction with the client's representative and the vendor.
2.4 Rust preventatives and desiccants are sold under various brand names and have to be field purchased as required. Before purchasing starts, agreement has to be reached between field and client on brands and types of rust preventatives and desiccants.
3. Preservation Methods
If it is expected that site storage will be required for a period longer than the time the packaging will protect the equipment, additional preservation measures will be taken and following techniques followed.
3.1 External Protection
The paint specification will be followed. However, attention shall be paid that intermediate paint coats are applied soonest.
Blank metal parts will be protected by e.g. rustban products of ESSO or SHELL Ensis. See also 9.2.4.
3.2 Internal Protection
- Systems containing hydrocarbon will be sprayed, flushed or filled with a suitable oil.
- Nitrogen blankets will be applied and maintained on stainless equipment.
Apply nitrogen blankets preferably after all internal work is finished in order to avoid extensive purging operations. Nitrogen in a vessel can be dangerous. Apply all necessary warning plates near all vessel entrances.
All construction personnel shall be familiarized with the risks of nitrogen blankets. This instruction is the personal responsibility of the safety engineer.
4. Pressure Vessels
4.1 Storage Area
Storage will be in a clean paved area or alternatively on timber baulks, away from construction working areas.
Equipment will be stored with all nozzles or support steel clear of the ground.
Equipment transportation supports or saddles will be checked for soundness and repaired as necessary.
This equipment is designated "open area storage" category, but must be provided with complete tarpaulin covering with free ventilation.
Ensure all nameplates are intact and secure.
4.2 Protection
Stainless steel (alloys containing more than 10% chromium) equipment, components and materials shall be externally protected as follows:
- Under cover.
- Not in contact with the soil or with porous supports such as raw wood. Sound protective coatings, subject to periodical inspection, are acceptable alternatives to covered storage.
In addition, austenitic stainless steel shall not be exposed to salt water, salt spray or salty atmosphere.
4.2.2 Columns/pressure vessels can be internally preserved either by maintaining them under nitrogen pressure or by making use of vapor phase corrosion inhibitors.
4.2.3 Site personnel shall be familiarized with the risk of nitrogen containing equipment (refer 9.3.2).
4.2.4 Austenitic stainless steel items can be internally protected in accordance with the following preservation method:
- Shop installed gaskets and blind flanges shall remain unremoved until installation of piping.
- Maintenance of a nitrogen blanket on austenitic stainless steel is imperative.
- The nitrogen gas pressure in the equipment shall be checked regularly.
- If the pressure is below 0.5 bar(g), a refill with dry nitrogen is required. The oxygen content shall be less than 2 % by volume measured at the flushing outlet which shall be a maximum distance from the flushing inlet. The refill shall not start before nitrogen pressure is at 0.1 bar(g). When a pressure of less than 0.5 bar(g) is recorded, close monitoring is required (at least one a week).
- When depressurizing is required during erection of equipment, it is imperative that the nitrogen blanket immediately be restored when this action is completed. Equipment shall be absolutely dry before refill can start. Temporary covers to avoid ingress of water are mandatory.
- If the equipment is to reinspected, safety precautions are to be taken. Refer to Site Safety Procedures.
4.2.5 All columns/pressure vessels not referred to in 9.4.2.4 above can be protected in accordance with the following preservation method.
4.2.6 Vapor Phase Corrosion Inhibitors
Shell VPI 280 spray or bags can advantageously be used for the internal protection of engines, bearings, turbines, heat exchangers, pipes, drums, small tanks and identical equipment, preferably in non-hydrocarbon services. Equipment in hydrocarbon service shall be sprayed with Shell Ensis oil 30 with addition of 2% VSI 8235. For both vapor phase inhibitors refer to Shell recommendations. The equipment shall be closed thoroughly to allow vapor accumulation . Inspection at regular intervals is required at least every three months.
4.2.7 For all pressure vessels not protected in accordance with 9.4.2.4, temporary covers of nozzles or openings shall be removed, machined flange faces shall be cleaned and reprotected with suitable rust preventative, covers shall be repaired where necessary, then replaced and secured. Non-suitable covers will be replaced by wooden covers or equal.
4.2.8 All exposed bolts and flanges shall be coated with a heavy grease.
4.2.9 Verify openings for non-installed instruments. These shall be plugged or blanked off.
4.2.10 For equipment installed in elevated positions attention shall be paid to lightning protection: the earthing connection shall be made early.
5. Storage Tanks
Corrosive attack in storage tanks appears in varying degrees throughout all parts. Atmospheric corrosion will occur on external surfaces and is easily detected by visual inspection. For external corrosion, prompt and effective remedial action may be taken. Internal corrosion will require a regular and careful inspection.
The procedure practised in preparing tanks and vessels during idle periods shall be given special consideration.
5.2 Protection
Before entering any tank or equipment, it is necessary to take certain special safety-precautions. Refer to site safety procedures.
Inspect through available openings overhead parts for loose purlins, or any other object which might fall and cause personal injury. If nitrogen blanketing is foreseen on a tank the best internal protection will be obtained by applying the blanket soonest.
The following procedures can be used for protecting almost any type of tank against deterioration:
- If necessary dry the walls (consider use of heat guns);
- Coat unprotected interior surfaces by spraying or brushing structural members with a gas oil with 2% VSI 8235. For floating roof tank all unpainted surfaces exposed to open air shall be protected with Shell Ensis 30 or 158 or Shell Autoseal 1835;
- Avoid damaging floating roof seals by covering with tarpaulins or equal.
- Close all manholes with gasketed covers, but breathing not to be obstructed.
- Leave floating roof drains open. Verify periodically for pluggings and support the roof in high position. Inspect periodically for water ingress.
- Maintain the tank exterior according to the plant maintenance painting program or maintain the weather seals on insulated tanks. Pay special attention to the seal between tank bottom and foundation to avoid water ingress under the tank bottom.
- Check cathodic protection periodically.
6. Heat Exchangers
6.1 Air-Cooled Heat Exchangers
Refer to vendor's recommendations.
The following are recommendations that can be used for protecting finned air coolers:
- Pump light oil through the tubes. Drain and seal or spray internally with Shell Ensis H oil with 2% VSI 8233 and cap.
- Open, drain the tubes, dry and close. Fill with inert gas 0.5 bar(g). Verify pressure periodically.
- Spray the exterior parts with a suitable rust preventive such as Shell Ensis Oil 158.
- Coat bolts with a heavy grease such as Shell Rhodina.
- Damaging of finned tubes has to be prevented. Therefore leave the tube bundles in the storage area for as long as possible, properly protected by means of steel plates covering the protection screen of the bundles. These plates shall be reinstalled when tube bundles are fitted and shall be removed during precommissioning activities.
Motors shall have separate preparation and follow up as described under motors (9.10).
Operating mechanisms on the louvers shall be coated with a heavy grease such as Shell Rhodina, to ensure operability when put to service. Operate louvers periodically and verify functioning. Since airfin coolers are generally installed at elevated positions, attention shall be paid to connect earthing at an early stage for lightning protection.
Since deformation of louvers may result in blocking of louver vanes, care should be taken during bolting up. Protection steel plate shall only be removed prior to final installation.
During installation of fans and prior to operating, grease-lines shall be loosened at the bearing ends and be pumped through until clean grease comes out of the grease line ends.
Fans
The fan blades and blade insert reinforcement shall be protected by Shell Ensis Oil 158 or Autoseal 1894.
If idle time exceeds two years, grease will be changed and ball joints checked/regreased.
Protect the hubs from infiltration of dust, sand and water. Protect the bearing discharge screws by grease and cover these with rubber bands or denso tape.
The fan shall be rotated periodically.
V-Belts shall be stored in a loose condition in a dry stock room away from direct heat and sunlight.
They will be properly tagged for identification and installed only shortly before precommissioning.
Enclosed Gears
Separately lubricated gears shall be filled with Shell Ensis Oil 158 with 2% VSI 8235. The oil shall be applied by circulating, flushing or brushing. All openings shall be closed thoroughly afterwards.
6.2 Shell and Tube Heat Exchangers
Refer to vendor's recommendations.
The exchanger shall be drained and dried. Blank off all nozzles and plug all vents and drains.
Coat all exposed bolts and flanges with heavy grease (such as Shell Rhodina). Determine the exterior protective measures as dictated. Provide when specified nitrogen pressure of 0.5 bar(g). Verify blanket pressure.
If nitrogen supply is impractical, dry air can be used combined with moisture absorbents. The equipment shall be pressurized as for nitrogen. Every month the moisture absorbent shall be checked and replaced if required. Location of moisture absorbent shall be noted so that it can be removed easily and completely when the commissioning is started. Other methods can also be selected in conjunction with client representative.
7. Special Equipment
7.1 General
Where vendors provide recommendations for site storage and protection, these are to be followed and take precedence over the following recommendations.
Where prolonged site storage is involved, which is not under the control of vendors concerned, equipment guarantees are invalidated. However, most vendors offer an on site re-furbishing services after which equipment guarantees are re-instated. Clients are recommended to employ this type of service wherever necessary.
Where special equipment includes rotating machinery, motors, instruments, etc., the relevant sections of this document will apply.
7.2 Storage
A warm, clean, dry and vibration free environment in a secure under cover storage area is required. Recommended environment conditions are temperature range of 15°C to 30°C and a humidity of between 30 to 40%.
Equipment and motors to be stored in a level and upright position.
Equipment transportation supports and temporary stiffening to be checked for soundness and repaired as necessary.
Ensure all nameplates are intact and secure.
7.3 Protection
All damaged mark/tag numbers to be re-instated and maintained.
All 'bright parts' on machinery to be inspected and re-greased/rust protected where necessary and maintained throughout storage period.
All protection blanks on flanged connections to be repaired where necessary and maintained.
All threaded connections inspected and re-greased/rust protected where necessary and re-plugged.
Where special equipment is provided with moisture absorbents these are to be replaced with a fresh charge immediately after receipt at site storage area and the protective seals/membranes re-instated. The moisture absorbents to be recharged at regular intervals thereafter.
Mixing Equipment
Refer to vendor's recommendations.
Shafts, propellers and other blank parts shall be sprayed or brushed with Shell Ensis fluid HB. All threaded connections shall be plugged and threads coated with rust preventatives where necessary.
Oil-lubricated bearings shall be filled with Shell Ensis Oil 158 and rotated to ensure complete coverage, after which all openings are closed. Grease-lubricated bearings shall be cleaned and greased with the appropriate grease, turned and closed.
Separately lubricated gears shall be filled with Shell Ensis Oil 158. The oil shall be applied by circulation, flushing, spraying or brushing. If complete oil coverage cannot be realized, small bags with Shell VPI 280 shall be used.
Whatever the treatment, all openings shall be closed thoroughly afterwards. Some manufacturers recommend the seal to be removed or to ship with no seal installed. Verify this per item.
Loading Arms
Refer to vendor's recommendations. Loading arms can be protected as follows:
- Close all openings tightly with gasketed cover.
- Pressurize with an inert gas.
- Close the inert-gas inlet and leave the equipment blanketed with inert gas at 0.5 bar(g).
- Apply same procedure for jacket.
- All exposed bolts and flanges shall be coated with a heavy grease during preservation.
- Determine the appropriate external protective measures as dictated by local conditions. Verify insulation and painting as per recommendation.
- Cover joints with a heavy grease (such as Shell Rhodina) to avoid water penetration.
Conveyors/Elevators
Refer to vendor's recommendations.
Bearing Brackets
Oil-lubricated bearings shall be drained and filled with Shell Ensis Oil 158. Run for a short while to ensure complete coverage and then cover all openings. Lubricated bearings shall be cleaned, greased with the appropriate grease and dried thoroughly.
Gear Boxes
Gear boxes shall be drained and filled with Shell Ensis Oil 158 by circulation, flushing, spraying or brushing. If complete oil coverage cannot be carried out, then small bags with Shell VPI 280 shall be inserted. All openings shall be closed thoroughly afterwards.
Machined Parts
Couplings, shafts, rollers and all blank machined parts shall be solvent cleaned and coated with Shell Ensis fluid HB. Coating shall be applied in accordance with the supplier's requirements. Exposed chains shall be cleaned, grease coated, wrapped in waxed paper and tagged for identification. V-belt pulleys shall be oiled on the bore to avoid rusting.
Sound Enclosures
Until they can be assembled around the equipment, the sound enclosures shall be stored in the warehouse, or under cover, not in contact with soil. Sound enclosures already installed at the vendor shop shall be preserved.
After assembly inspect periodically for mechanical damage (see Reference 9.13.3).
If a sound enclosure is installed over equipment preserved by a nitrogen blanket, safety precautions are to be taken, (see Reference 9.13.4).
Boiler Feedwater system
Refer to vendor's recommendations.
This covers the following type of equipment.
- Deaerator
- Dosing units
- Demineralizer (BFW Treating unit)
The equipment shall be moved as soon as possible to its foundation. If this is not practical it shall be stored in a suitable area, preferably protected from the elements and in any case on timbers. Resins for ion exchangers shall be stored outside the equipment and protected against humidity and frost (See vendors instructions). Special attention shall be paid to avoid mechanical damage of the linings.
Deaerators
Refer to Pressure Vessels (9.4).
Spray internally with VPI-280 solution, close off carefully.
Dosing Units
The equipment shall be protected from the ingress of water. All tank drains to be kept open. Suction pipes of dosing pumps shall be capped and kept filled with water, with 50-100 ppm hydrazine as oxygen scavenger (do not use sulphite). Alternatively provide nitrogen blanket.
Demineralizers
Refer to Pressure Vessels (9.4).
Rubber lined equipment shall be protected against exposure to direct heat or radiation by the sun, or kept full of water. In this case allow for thermal expansion by opening the vent. Be careful of mechanical damage to the lining. Resins shall be put in the equipment only shortly before precommissioning. Refer to vendors instructions.
Weighing Equipment
Refer to vendor's recommendations.
Check structural members in accordance with the coating specification to ensure adequate protection. Various components shall be checked in accordance with the relevant paragraphs of this procedure.
Internal Combustion Engines
Refer to vendor's recommendations. For the preservation of these engines the cooling water system is drained and dried with dry air or nitrogen. Fuel tanks are drained and blanketed with nitrogen if practical. Care shall be taken regarding nitrogen accumulation under sound enclosures (see Reference 9.13.4). All oil systems shall be drained with Shell Ensis Motor Oil or equivalent of adequate viscosity (SAE 10 - SAE 50).
Spark Plugs/Electrical Accessories
Fuel injection nozzles shall be removed and the openings in the cylinders plugged. A small amount of Shell Ensis shall be sprayed into each cylinder through the spark plug or injection nozzle openings. Additional Shell Ensis shall be sprayed into the cylinders each time the crankshaft is rotated, in accordance with the vendor's recommended schedule. Electrical accessories such as magnets, which can be damaged by moisture, shall be protected from condensation or humidity.
Batteries may be shipped wet or dry and subsequently treated at site as per the manufacturer's instructions. The batteries shall be disconnected if feasible and the battery connections coated with vaseline or the manufacturer's recommendations followed.
8. Rotating Machinery
8.1 General
The contents of this section applies to the main items of rotating machinery, where associated motors, instruments and electrical items are concerned reference should be made to the relative sections.
Where vendors provide recommendations for site storage and protection these are to be followed and take precedence over the recommendations contained in this section.
Where prolonged site storage is involved, which is not under the control of vendors concerned, equipment guarantees are invalidated. However most vendors offer a site re-furbishing service after which equipment guarantees are re-instated. Clients are recommended to employ this type of service wherever necessary.
8.2 Storage
A warm, clean, dry and vibration free environment in a secure under cover storage area is required. Recommended environment conditions are temperature range of 15°C to 30°C and a humidity of between 30 to 40%.
Machinery to be stored in level and up-right position.
Machinery transportation supports and temporary stiffeners to be checked for soundness and repaired where necessary.
Ensure all name plates and Tag labels are intact and secure.
8.3 Protection
Centrifugal Compressors/Blowers
Large centrifugal compressors require extensive and detailed preservation. Machinery of this type is complex and a detailed program of protective measures must be undertaken. The environmental effect on a compressor that is to remain in an operating position must be considered. (Protection by a roof, installed in open air). Refer to vendor's instructions.
Due to the heavy weight of compressors, storage in areas remote from field positions should be avoided. A compressor which is not resting on a foundation must be supported the full length of its frame to prevent any possible sag or distortion. Support can be provided by a frame of welded structural steel members. Units shall be protected with tarpaulin covers.
Generally, vendor's packaging allows for 6 months storage. If prolonged storage is necessary intermediate inspections are to be considered. Every six months, suction and discharge shipping covers and bearing caps are removed and a thorough investigation of the internals is to be made. If any signs of corrosion are found, corrective measures are to be taken and inspections varied accordingly (take care of sealing compressor after inspection).
Half yearly internal inspections are to be performed on all items shipped loose in accordance with above, except for items sealed in plastic bags, if no visual corrosion is apparent.
The level of preservation will be designed for unheated or outdoor storage. It is required to place a waterproof cover over all equipment and crates continuously. The following is required:
The first inspection shall be done immediately after transportation to the storage area. This shall include, but is not limited to, inspection for visible external damage to equipment or crates, indication of moistures and or oxidation and degradation of applied preservative compounds. The presence of any such signs shall require a thorough inspection of all equipment. Each month thereafter, all humidity indicators shall be inspected.
The interval for subsequent inspections shall be every six months.
Compressor (including gearbox)
The compressor shall be disassembled and all internals shall be brushed with Shell Ensis Oil 158 with VSI 8325. Dip all journal and thrust bearing assemblies or parts in Shell Ensis Oil, turn to remove air pockets, drain and reinstall in unit. Use multiple strips of denso tape placed over top of journals to take up all bearing clearance when cover is bolted down. Place a tag on the outside of the unit stating:
"REMOVE PLASTIC SHIMS AT JOURNALS BEFORE OPERATING UNIT"
The coupling end of the shaft shall be treated with Shell Ensis 158 and taped with denso. All bearing vents shall be taped with Denso tape and closed.
Sealing the Casing
The intent is to completely seal the unit and prevent pockets of water such as at bolt holes. All openings shall be covered with plastic caps or metal covers. Use 3 mm thick metal covers for all flanged openings. Use plastic caps on small size pipe, NPT holes, dowel and other holes. Rubber shall be used between metal cover and flanges. The edges of all flange covers shall be taped with denso to the flange. As a minimum, bolts will be used in half the number of holes on all flanges. (Minimum to be four bolts per flange).
Suction and discharge nozzle openings shall be blanked as described above. Attach a dehumidifier and operate until drain stops dripping. Each section shall be dehumidified on re-entry type units. Desiccant bags will be provided on the inside of the covers and shall be immediately placed in the unit and unit sealed. The amount of desiccant required is 1.2 units per cubic foot of internal volume to be protected.
Special duty compressors, e.g. for oxygen or chlorine service, shall be preserved by inert gas filling in combination with desiccants. The application of inert gas blanket can also be considered to other centrifugal machines. Allow for a small flow due to seal leakage.
For air blowers, cap the intake stack to avoid rain and humidity ingress.
The shaft shall be rotated regularly leaving the shaft in another position, (if applicable). Follow vendor's recommendation of available.
Console Oil System and Unit Piping
Shell Ensis Oil H shall be used as lube oil during the testing if the console. Add 2% VSI 8235.
Drain oil from unit after satisfactory completion and approval of all testing requirements.
Inspect and clean suction screens.
Coat all exposed unpainted surfaces and flexible couplings and valve steams, etc. except stainless steel parts with Shell Ensis 158.
Spray carbon steel internals which are parts of the pump driver assembly with Shell Ensis Oil H (with 2% VSI 8235).
Remove and discard filter cartridges and wash inside of filter housing with solvent, then apply Shell Ensis Oil H (with 2% VSI 8235).
Install new filter cartridges in all filter housings.
Paint unit in accordance with applicable specification.
Operate the lube oil system weekly for 30 minutes.
The water cooling system shall be drained. Dry and spray with VPI 280 solution. Close all connections carefully.
For electric motors see 9.10.
Sound enclosure to be inspected periodically or stored in the warehouse.
For other elements refer to relevant paragraphs.
8.3.2 Pumps
The following procedure is intended for safeguarding centrifugal pumps, rotary displacement pumps, reciprocating pumps, rotary vacuum pumps and axial pumps. It shall be checked against vendor's recommendations.
Verify that the bright external parts are all coated with Shell Ensis MD (twice) followed by Shell Ensis HB.
For pumps working in hydrocarbon service internal parts shall be flushed with Shell Ensis Oil H with addition of 2% VSI 8235. Repeat every six months. Rotate shaft during flushing. For vertical pumps spray internals with Shell Ensis Oil H. For pumps in water service spray internals with VPI 280 solution, repeat every six months. Close pump completely to allow vapor accumulation.
Bearing house: Follow vendor's recommendation. Fill as high as possible with Shell Ensis Oil H with addition of 2% VSI 8235. Rotate the shaft periodically. Plug vents.
Separately lubricated gears for high speed vertical pumps shall be drained and filled with Shell Ensis Oil H added with 2% VSI 8235. The oil shall be applied by circulation flushing, spraying or brushing. Whatever the treatment, all openings shall be closed thoroughly afterward.
If the pump is to be stored outdoors or installed at service location, protect with plastic sheets to minimize ingress of dirt, dust, etc.
Break all pipe connections and suction and discharge flanges and close all openings. When the pump is to be maintained in a field position, ensure that the suction and discharge valves are closed and blanked off after protective fluids have been applied.
When single mechanical seals are used, the complete mechanical seal remains within the stuffing box chamber. Pour Shell Ensis Oil H with 2% VSI 8235 through the circulation and quench connections and turn pump shaft manually several times while filling with preservative. Check O-ring compatibility with oil. Verify whether all connections are plugged.
Where double mechanical seals are used, plug the lower stuffing box drain and fill with Shell Ensis Oil H with 2% VSI 8235. Slowly rotate the shaft to ensure complete coverage of internal surfaces. Mask clearance between seal gland and shaft to prevent direct from entering the seal cavity. Verify in the manufacturer's instructions whether the rings of the seals are oil resistant.
If the pump will be shipped with the seal not installed, the seal will be stored in the warehouse and installed shortly before precommissioning. The seal cavity shall be filled with Shell Ensis with 2 % USI 8235).
Where conventional packing is used, loosen the packing gland and remove all packing. Coat the interior of the stuffing box with light grease. Repack the pump with a nonmetallic packing and retighten the packing glands slightly. Tag the pump to indicate that the service packing has been removed. Care shall be taken to repack the pump with the service packing at precommissioning.
Wrap the exposed pump shaft with Denso tape. At the points where the shaft enters the pump casing and the bearing housing, carefully wrap to seal off the openings. Allow for regular shaft rotation by hand, leaving shaft in fresh position on each occasion.
Cover all outer exposed surfaces with either paint or a suitable rust preventative (Shell Ensis MD or Autoseal 1894).
For electric/motor drive refer to 9.10.
The sound enclosure shall be inspected periodically for mechanical damage, or stored in the warehouse.
Coupling: Treat gear ring teeth as described under "bright parts" and wrap in denso tape after treatment. Treat coupling hub and spacer as described under "bright parts" and have them wrapped in plastic sheeting and tagged and stored in warehouse. Verify oil filling of installed coupling every six months and have VSI 8235 added.
Reciprocating Pumps: In addition to the above, the following instructions shall be observed to protect reciprocating pumps:
- Reciprocating injection or metering pumps should preferably be stored in warehouse.
- Remove the valve cover plate from the liquid end of the pump.
- Remove a valve from each end of each cylinder on the liquid end. Fill all cylinders with Shell Ensis Oil.
- Apply Shell Ensis Oil to all valves and valve covers.
- Fill all lubricators with oil.
- Have the crank-case unit filled with Shell Ensis oil H with addition of 2% VSI 8235.
- Rotate the pump for a few minutes every 2 months.
8.3.3 Gear Boxes
Refer to vendor's recommendations.
Bearings
Oil-lubricated bearings shall be drained and filled with Shell Ensis Oil 158 and run for a short while to ensure complete coverage, after which all openings are closed. Grease-lubricated bearings shall be cleaned and re-greased with the appropriate grease, turned and closed thoroughly.
Enclosed Gears
Separately lubricated gears shall be drained while hot and then filled with Shell Ensis Oil 158 which is circulated for a while. Where circulation is impracticable, the oil shall be applied by flushing, spraying or brushing. If complete oil coverage cannot be realized, small bags with Shell VPI 280 shall be used. Whatever the treatment, all openings shall be closed thoroughly afterwards.
8.3.4 Reciprocating Compressors
Refer to vendor's recommendations.
Large reciprocating compressors require extensive and detailed preservation. A thorough inspection and a detailed program of protective measures must be foreseen. A compressor that is to remain in an operating position in open air will require special attention for external corrosion. Before assembly all parts will be thoroughly checked for any sign of corrosion.
Due to the heavy weight, compressors will be installed quickly on their foundations. A compressor which is not resting on a foundation must be supported to prevent any possible sag or distortion. Support can be provided by a frame of welded structural steel members. Generally manufacturers packaging allows for six months storage. If prolonged storage is required intermediate inspections are to be considered.
For the preservation, the following general rules are recommended:
- Fill all lubricators completely full of oil, Shell Ensis Oil H with 2% VSI 8235, to prevent rusting of the pumping parts, rotate lubricators to fullness with oil. Also fill the crank case.
- Remove stuffing box, and wiper rings of the compressor. Clean in a suitable solution. Apply a coating of a satisfactory rust preventive and wrap in a waterproof paper or place in a plastic container. A rust preventive may be grease or oil with a high viscosity. Identify the stuffing box to ensure reassembly in their original position.
- Have the main shaft rotated according to manufacturers recommendations.
- Remove the inlet and discharge valves from the compressor cylinders, clean, and apply a coating of Shell Ensis Oil H with 2% VSI 8235. Completely coat the valve bores and piston rods with a spray or other suitable means while the valves are removed. If piston rods are not stainless steel, consideration shall be given to removing the piston and rod. These shall then be coated, wrapped and boxed. The rod must be properly supported to prevent bowing.
- Replace all valves in their original position and tighten in place.
- Seal muffler vents or cover them with plastic.
- Reciprocating compressors are provided with some Shell Ensis Oil H with 2% VSI 8235 and are run on "no load" or turned by hand until the oil is fully distributed. This is repeated according manufacturers recommendations. Separate lubrication systems should be drained and filled with Shell Ensis Oil H with 2% VSI 8235 prior to the above-mentioned treatment.
In case of doubt as to whether all internal parts are reached by the oil, small bags with Shell VPI 280 should be placed in the vicinity of the parts concerned or 2% VSI 8235 added to the oil and the parts closed. Mark the number of bags on red tags on the outside of the equipment.
Clean and apply protective coating to all small auxiliary equipment, relief valves, piping filters, and the like.
A periodic inspection should be made if compressors remain idle for a considerable time. Small surfaces on cylinder bores, crankshafts, bearing journals, piston rods, crossheads, and the like should be wiped free of protective coatings to determine their condition. When protection appears to be satisfactory, the same care as originally used in the application of the protective coating must be used in covering the exposed surfaces.
If there is any sign of rust or corrosion on any of the aforementioned parts, they should be wiped clean and dry and the protective coating reapplied.
8.3.5 Steam Turbines
Refer to vendor's recommendations.
Large turbines require a detailed program of protective measures. The environmental effect on a turbine that is to remain in an operating position must be considered. (Protection by a roof/open air).
Due to the heavy weight of turbines, storage in areas remote from field positions should be avoided. A turbine which is not resting on a foundation must be supported the full length of its frame to prevent any possible sag or distortion. Support can be provided by a frame of welded structural steel members. Units shall be protected with tarpaulin covers.
Generally manufacturer's packaging allows for six months storage if prolonged storage is required.
Half yearly internal inspections are to be performed of all shipped items.
Protection Level
The level of preservation will be designed for storage unheated or outdoor. It is required to place a waterproof cover over all equipment and crates continuously. The following is required.
The first inspection shall be done immediately after transportation to the storage place. This shall include inspection for visible external damage to equipment or crates, indication of moistures and or oxidation and degradation of applied preservative compounds. The presence of any such signs shall require a thorough inspection of all equipment. Each month thereafter, all humidity indicators shall be inspected.
The interval for subsequent inspections shall be every six months.
All bright surfaces of any component parts of the governing system, such as reset linkages, valve levers, piston rods, etc., shall be preserved with Shell Ensis Oil 158.
Both the rotor and guide-blade carrier shall be internally preserved with nitrogen with the turbine casing and the bearing housings closed. A spray of VPI 280 can be given. Alternatively a nitrogen blanket can be applied if practical.
Oil Piping (Internal Preservation)
Lube and control oil piping, mounted prior to the test stand trial run and used during the latter, shall not be preserved. Oil piping mounted to the unit after the trial run shall be preserved.
Prefabricated oil pipes that are field mounted shall be pickled and preserved and sealed with plastic covers on both sides. Piping shipped to site in the usual way shall not be preserved.
The oil reservoirs and baseplates containing an oil reservoir shall be internally (oil chamber) protected with Shell Ensis 30 (with addition of 2% VSI 8235). The lube oil system shall be operated weekly for 30 minutes.
Outdoor Storage
For outdoor storage of the unit prior to putting into operation, the above preservation procedure remains valid and the unit shall moreover be protected with tarpaulin covers.
Cleaning for Operation
All referred preservation, internal and external must be removed before operating the unit. Follow instructions for products used.
Controls
Separately shipped gauges shall be capped, cleaned and carefully wrapped and packed in cellulose cushioning material (CCM).
Vibration pick-up and other vendor devices shall be cleaned, carefully wrapped and packed in cellulose cushioning material (CCM).
The same recommendation applies for electrical devices.
Labyrinths - coat with Shell Ensis Oil H with 2% VSI 8233.
Tools: Coat unpainted surfaces with Shell Ensis H with 2% VSI 8235.
For all other miscellaneous items, coat unpainted surfaces with Shell Ensis 30.
Couplings
All loose remaining coupling parts to be coated with Shell Ensis Oil followed by Shell Ensis HB wrapped in denso tape and packaged separately.
Coat unprotected interior surfaces by spraying or brushing structural members with a gas oil with 2 % VSI 8235. For floating roof tanks, all unpainted surfaces exposed to open air shall be protected with Shell Ensis 30 or 158 or Shell Autoseal 1835:
- Avoid damaging of floating roof seals by covering with tarpaulins or equal.
- Close all manholes with gasketed covers, but do not obstruct breathing.
- Leave floating roof drains open. Verify periodically for pluggings and support roof in high position. Inspect periodically for water ingress.
- Maintain the tank exterior according to the plant maintenance painting program or maintain the weather seals on insulated tanks. Pay special attention to seal between tank bottom and foundation to avoid water ingress under tank bottom.
Fans
Refer to vendor's recommendations. These shall be handled under the main "SYSTEM" in which they are integrated.
- Dry the equipment and keep it dry.
- Make sure no rain or atmospheric humidity can enter the equipment.
- Ensure that the intake stack is capped and closed.
- V-belts shall be stored in the warehouse and installed at precommissioning in conjunction with the vendor representative.
Bearings
Oil-lubricated bearings shall be drained and filled with Shell Ensis Oil 158 and shall be run for a short while to ensure complete coverage, after which all openings are closed. Grease-lubricated bearings shall be cleaned and re-greased with the appropriate grease, turned and closed thoroughly. The internal parts shall be sprayed with Shell Ensis Oil 158. Sound enclosures shall be inspected for mechanical damage.
Enclosed Gears
Separately lubricated gears shall be drained while hot and then filled with Shell Ensis Oil 158 which is circulated for a while. Where circulation is impracticable, the oil shall be applied by flushing, spraying or brushing. If complete oil coverage cannot be realized, small bags with Shell VPI 280 shall be used. Irrespective of any treatment, all openings shall be closed thoroughly afterwards.
9. Fired Heaters, Steam Generators and Incinerators
9.1 General
The contents of this section applies to the main items of fired heaters, steam generators and incinerators. Where associated motors, instruments and electrical items are concerned, reference should be made to the relevant sections.
For preservation of steam boilers see Reference 9.13.5.
Where vendors provide recommendations for site storage and protection these are to be followed and take precedence over the recommendations contained in the appendix.
Where prolonged site storage is involved, which is not under the control of vendors concerned, equipment guarantees are invalidated. However, most vendors offer an on site re-furbishing services after which equipment guarantees are re-instated. Clients are recommended to employ this type of service wherever necessary.
9.2 A warm, clean, dry and vibration free environment in a secure under cover storage area is required for Panels etc. Recommended environment conditions are temperature range of 15°C to 30°C and a humidity of between 30 to 40%.
Fired heaters and Incinerator parts to be stored in level and up-right position.
Fired heaters and Incinerator parts transportation supports and temporary stiffeners to be checked for soundness and repaired where necessary.
When refractory lined steel sections of heaters, furnaces or boilers are stored outside care must be taken that water can not enter between steel and refractory in order to avoid corrosion that can cause cracking of refractory covers are mandatory.
Ensure all name plates and Tag labels are intact and secure.
9.3 Protection
The cleaned boiler shall be thoroughly drained, dried and can be protected as follows:
- A gasketed cover on all manholes.
- Close all other openings tightly.
- Pressurize with nitrogen.
- Close the inert-gas inlet and leave the vessel blanketed with inert gas at 0.5 bar(g).
- All exposed bolts and flanges shall be coated with a heavy grease.
- Determine the appropriate external protective measures as dictated by local conditions. Ensure that the external surfaces have been painted, coated or insulated as per the specification.
Boiler Feedwater Systems
See 9.7.
Header Boxes and Casing
Hinges on header doors, peepholes and access doors shall be coated thoroughly with a heavy grease. Where seating surfaces of openings could corrode because of leakage of rain or moisture, it is advisable to seal the doors with a readily removable mastic.
Burners
Treatment of this equipment is dependent upon the type of burner used, and some will require more care than others. The movable parts shall be covered with heavy grease to protect threads or adjusting mechanisms. Spray nozzles shall be removed, tagged and stored. Fuel supply openings shall be blanked off and secured.
Combustion
Chamber If the combustion chamber is to be preserved, burner holes shall be closed. Protection recommendations shall be checked with vendor's recommendations. Inert gas bleeding can be carried out or moisture absorbents used. Selection shall be made in conjunction with vendor representative.
Breeching and Ducts
For internal surfaces absorption of moisture during the idle period shall be minimized by closing the ducts. Expansion bellows shall be inspected. Operating mechanisms on the dampers shall be coated with heavy grease such as Shell Rhodina to ensure operability when in service. Operate dampers periodically and verify functioning.
Refractory
Refractories shall be kept dry and free of frost at all times. Atmospheric moisture can be excluded by capping stack and duct openings and by sealing locations where water or moisture can enter. Refer to vendor's recommendations.
Tubes
All tubes shall be dried, the headers shall be closed and nitrogen blanket applied at 0.5 bar(g). Nitrogen pressure shall be checked periodically.
Steel Stacks
The stacks shall be capped. External inspection of paint shall be in conjunction with the specification. Particular attention shall be paid to ladders as these are safety items.
Fans
Refer to 9.8.3.6.
10. Electrical Equipment and Motors
10.1 General
Where vendors provide recommendations for site storage and protection, these are to be followed and take precedence over the following recommendations.
Where prolonged site storage is involved, which is not under the control of vendors, equipment guarantees are invalidated. However most vendors offer a re-furbishing service after which equipment guarantees are re-instated. Such a service is outside normal Company contracts but clients are recommended to take up this option where applicable at their own expense.
10.2 Storage
Electrical equipment must be stored in the warehouse.
220 and 110 volt electrical supply to be available adjacent to stored motors and equipment to enable anti-condensation heaters and equipment to be energized where necessary. Equipment transportation supports and temporary stiffening to be checked for soundness and repaired as necessary.
Ensure all nameplates are intact and secure.
All motors to have shafts manually rotated frequently, at least once per week. This must not be carried out with tools which will damage or mark motor shafts.
10.3 Protection
All damaged painted Mark/Tag Numbers to be reinstated and maintained.
All threaded entries to be plugged and threads recoated with rust preventatives where necessary.
All gland plates to be checked and reinstated where required.
Where moisture absorbents are included to protect equipment it should be replaced with a fresh charge immediately on receipt in the site stores and replaced on a regular basis thereafter.
Motors
Motor bearings to be checked regularly to ensure grease is in good condition, should it harden or be discolored the bearings should be cleaned out and regreased.
Motor condensate drain plugs to be removed periodically to remove any accumulated moisture. Plugs to be replaced to avoid ingress of dust.
All bright metal parts, machined surfaces (i.e. shafts) to be coated with rust preventatives.
All 6000V. motors should have insulation resistance values measured and recorded every 3 months against climatic conditions at time of test. If the reading is not greater than 6 megohm an approved method of drying out is to be undertaken to achieve acceptable resistance readings. Connect anti-condensation heaters.
Transformers and Capacitors
Where units are supplied complete with insulation liquids/gases these should be checked on arrival at Site. If level or pressure is not within vendor's tolerances, possible leaks should be located and rectified. Monthly checks on level/pressure should be made and rectification work carried out as necessary.
Any separately supplied insulation liquids should be stored on an incline, containers should not be left stored in upright position.
Switchgear, Motor Control Centres, Inverters, Battery Charger Units, Etc.
Unless provided with anti-condensation heaters the equipment shall be removed from the packing cases with the plastic coverings left in place and resealed where damage has occurred during shipment.
Where anti-condensation heaters are fitted these shall be connected.
Spot insulation tests shall be carried out every 6 weeks and where readings are low an approved drying out procedure shall be adopted to achieve acceptable resistance readings.
Batteries should be stored in an inactive area to avoid accidental breakage and seals should be regularly checked for damage. Damaged seals shall be renewed in accordance with Vendors instructions.
Nickel-cadmium and lead-acid batteries that have been shipped dry do not require maintenance.
Electrolyte levels in batteries that have been shipped wet should be checked and topped up as required.
These batteries should also be given a re-freshing charge tri-monthly.
Cable
Measure and record gas pressure in low pressure gas filled cable when received and weekly thereafter.
If falling pressure indicates a leak in cable, maintain same with dry nitrogen until leak is sealed.
Rotate reels of paper insulated lead sheathed cable 90° every 2 weeks to prevent migrating oil from collecting at low points.
11. Instrumentation
11.1 General
Where vendors provide recommendations for site storage and protection these are to be followed and take precedence over the following recommendations.
Where prolonged site storage is involved, which is not under the control of vendors, equipment guarantees are invalidated. However most vendors offer a re-furbishing service after which equipment guarantees are re-instated. Such a service is outside normal Company contracts but clients are recommended to take up this option where applicable at their own expense.
11.2 Storage
A warm, clean, dry and vibration free environment in a secure under cover storage area is required. Recommended environment conditions are temperature range of 15°C to 30°C and a humidity of between 30 to 40%.
Instruments can be stored in the above environment for up to 4 months in their shipment cases. However, where cases/packing have been opened the plastic coverings are to be retained and resealed in the manner they were shipped.
Where moisture absorbents are included they are to be replace with the new charge on receipt on site and further replaced at regular intervals thereafter.
Adjacent 220 and 110 volt supply made available for energizing equipment as necessary.
Panels to be stored up-right and level, any temporary transportation/strengthening supports to be reinstated and maintained.
Threaded connections to be re-capped and rust protected, also maintained.
Ensure all Nameplates/Tags/Gland plates are intact and secure, also maintain.
11.3 Protection
Local Instruments
All openings shall be tightly plugged against entry of water.
Panel Instruments
The power pack units of the control panel racks shall be energized at monthly intervals. For storage in original packing refer to recommendation of vendor.
Delicate Instruments as e.g.
- panel instruments
- distribution control components
- racks with power supply and/or cards
- computer racks and components
- programmable controllers
will be stored in air conditioned spaces.
Instruments with Electronic Components as e.g.
- transmitters
- I/P converters, and others
will be stored shielded from direct sun radiation.
Safety Relief Valves and Control Valves
Refer to vendor's recommendations.
Safety valves shall be stored in the warehouse and either dummies installed in the line or the lines blanked off.
The valves shall be stored indoors in a clean, dry environment. Avoid extreme temperatures and humidity conditions.
Threaded connections to the capped and rust protected.
Ensure all Nameplates/Tags/Gland plates are intact and secure, also maintain.
For stainless steel safety valves special instructions should be followed.
Stainless steel (alloys containing more than 10% chromium) equipment, components, and materials shall be protected as follows:
- Indoor storage,
- Not in contact with the soil or with porous supports such as raw wood. Protective coatings are acceptable alternatives to covered storage.
In addition, austenitic stainless steels shall not be exposed to salt water or salt spray.
Internals of carbon steel relief valves are to be treated with Shell Ensis.
12. Piping
12.1 Storage
Particular attention shall be paid to inner cleanliness of piping. Prefabricated piping transported to the construction site shall be laid down on supports. Adequate measures (such as capping) shall be taken to ensure that piping is protected from the ingress of sand and foreign material. Protective coatings shall be inspected periodically. All machined parts to be coated with Shell Ensis fluid.
Stainless Steel
Stainless steel (alloys containing more than 10% chromium) equipment, components and materials shall be protected as follows:
- Under cover.
- Not in contact with the soil or with porous supports such as raw wood. Protective coatings are acceptable alternatives to covered storage.
In addition, austenitic stainless steel shall not be exposed to salt water or salt spray.
Consideration shall be given to pipelines integrated in a "SYSTEM" with a main piece of equipment (exchanger, pump etc.) If this is the case they come under the responsibility of the "SYSTEM" engineer when ready. The "SYSTEM" is drained, dried and a nitrogen blanket of O.5 bar(g) applied. Nitrogen pressure is checked periodically.
12.2 Protection
Inspect painting and insulation periodically and take remedial action where required.
Bolts and Gaskets
Bolts shall be coated with heavy grease, such as Shell Rhodina. When the "SYSTEM" is being prepared for precommissioning, after a prolonged shutdown, selective service testing shall be considered and only those gaskets that fail shall be renewed.
Flanges
Machined parts shall be coated with Shell Ensis fluid during storage. After erection moisture proof tape shall be wrapped around aperture of adjacent faces of flange joints. Shell Ensis fluid SDC shall be applied to nuts and exposed threading of studs.
Valve Packings
Stuffing box packings are left intact during idle periods. If repacking after start-up would be very cumbersome, packings can be replaced before precommissioning.
Pipe and Fittings
All piping shall be properly drained and dried after testing. Open flanges if required. For all lines filling with nitrogen is recommended if prolonged standstill is forecasted, (especially for gas, oxygen and chlorine lines). Alternatively dry air can be considered if nitrogen is impractical.
The dry air or inert gas system shall not contain oily matter or solid particles. After the preservation treatment is finished the system shall be blanked off and the gas pressure of the system checked periodically
Valves and Other Appurtenances
Valves and appendages, except instruments, are treated together with the "SYSTEM" they are incorporated in and inspected valves shall be opened fully. Motor operated valves and hydraulic valves are operated periodically. Exterior parts shall be coated, especially the threaded stem. During idle periods no special care is given to valve packings.
For large piping systems installation of thermal relief valves can be considered when filled with liquid.
Instruments
Special attention shall be paid instrument connections to be capped or plugged and spools to be installed where required.
Lightning Protection
Special attention shall be paid at an early stage to lightning protection of elevated lines. Verify the earthing connection.
13 References
| Document Number | Title | Level | |
| 13.1 | BN-CO-107 | Standard Procedure for Material Control and Warehousing | 3 |
| 13.2 | BN-G-Y008 | Materials Quality Management | 5 |
| 13.3 | API Guide for Inspection of Refinery Equipment, Section 18, point 18.2.2.4 | ||
| 13.4 | API Guide for Inspection of Refinery Equipment, Section 5 | ||
| 13.5 | ASME Boiler and Pressure Vessel Code, Section 7, Subsection C-7 |