Section 14 — Equipment Protection & Package Units

Preparation for Equipment for Long Term Storage

IPE Engineering Practice IPE-EP-14-1-2

Document number: IPE-EP-14-1-2 · Section: 14 — Equipment Protection & Package Units

SCOPE

• This Practice is intended to be used as a guide for preparing equipment for storage over an extended period of time (i.e. mothballing). Adherence to proper preservation techniques will reduce costs and save time.
• Re-commissioning of equipment is covered in EP 14-1-3.
• Any deviation from this Practice must be approved by the procedure described in EP 1-1-3.

2.0 REFERENCES

The latest edition of the following standards and publications are referred to herein.

STANDARDS AND PUBLICATIONS

DEFINITIONS

• Contractor - Company or business that agrees to furnish materials or perform specified services at a specified price and/or rate to the Owner.
• Inspection - An activity to check that design, materials, fabrication, and testing comply with the requirements of the specification.
• Manufacturer - The recipient of a direct or indirect purchase order for materials and/or equipment. In this context, a direct order is one issued to a Manufacturer by a Contractor or the Owner. An indirect order is one issued to a Manufacturer by a vendor (recipient of a direct order) for materials, fabricated components, or subassemblies.
• Owner - Inflection Point Engineering, LLC.
• Owner's Engineer - A Inflection Point Engineering, LLC appointed engineer.
• Purchaser - The party placing a direct purchase order. The Purchaser is the Owner's designated representative.

GENERAL

• The procedure for protecting idle equipment involves safeguarding unattended and inactive equipment from deterioration during long or short term storage.

• Generally, moisture is the cause of deterioration in idle equipment. When moisture combines with oxygen, serious pitting and rusting can result.
• During the preservative preparations, the most important factor is to establish a barrier between the equipment, moisture, and oxygen.
• The continued effectiveness of even properly applied protection can be ensured only by a program of periodic inspection and planned maintenance.
• In most cases, equipment may be stored in a sealed room or in constructed containers with desiccants. When possible, desiccants should be used in such a manner that there is no need to open the package (barrier) to check the indicator.
• Properly mothballed and stored equipment can remain in its original condition for a long period of time (6-8 years), with a well-planned maintenance program.
• Heavy equipment must be stored on proper dunnage and a suitable foundation to ensure the equipment does not sink over a long period of time.
• Stored mothballed equipment shall be plainly identified on the outside of the package, for easy identification without the need for opening or handling.
• Storage areas shall have proper drainage or run off and enough room between equipment for periodic maintenance.
• All equipment shall be stored free from ground contact.
• Equipment to be stored outside shall be elevated above the normal maximum snow depth (6 inches min).
• Protective coverings shall be constructed to allow free air circulation, and not sealed against the ground.
• Equipment or sections of equipment covered with non-porous film (plastic) shall be covered with at least 2 layers, to set up a moisture barrier.
• New equipment received from vendors which has been packaged for shipping is typically not ready for storage, unless specified by the Purchaser. It is recommended that the received packaged equipment be open and checked for damage and proper storage preparation.
• Proper tools, preservatives and material shall be utilized during storage preparation and maintenance work to assure safe operation and minimum damage.
• When required for warranty purposes, preparation for long term storage should be under the vendors direction, (for example: diesel engines, compressor, turbines, and large motors 4,000 hp class) to assure maximum protection under the warranty.
• The interior surfaces of most vessels, after being cleaned and rendered dry, can be protected with a light coating of oil. In equipment large enough to permit entry, and where all surfaces are accessible, the light oil can be sprayed on. Equipment may also be filled, or 1/3 filled with oil and rolled, then drained, leaving a thin film coating. Equipment should be vented while filling.

SAFETY PRECAUTIONS

• Toxicity is very important in selection of preservation material, and methods of application. Therefore, equipment shall be well vented and normal precautions taken against fires during applications of preservatives.
• Gloves shall always be worn while applying preservatives. Never handle machined surfaces with the bare hands. Long sleeve shirts (sleeves rolled down) and a face mask shall be worn while applying the oil coating.
• All mothballed, sealed vessels shall be vented and drained for a minimum of 24 hours before being moved from their storage location.
• Heating or welding shall not take place on or near any mothballed sealed equipment, unless it has been opened, drained, steamed out and left in a vented condition for a minimum of 24 hours.
• An open flame or other source of ignition shall not be within 100 feet of a sealed, mothballed vessel while opening the vessel. A gas test is required before entering or working on an opened mothballed vessel. An assistant should standby outside a vessel or tank while personnel are inside a vessel. The assistant should have the means to communicate and summon emergency aid, if required.
• Vessels shall not be shipped or erected in a mothballed condition.
• CAUTION: hydrocarbons shall never be used in protective coatings of compressors in oxygen (or almost exclusively oxygen) service. For compressors that merely handle normal amounts of oxygen, thorough removal of hydrocarbons before a return to service is extremely important.
• If any pressure relief valves are removed from equipment (e.g., pipe runs, vessels, tanks, pumps, compressors), the equipment shall be tagged that the pressure relief valve has been removed and stored, and must be reinstalled before equipment is placed into service.

SHUTTING DOWN EQUIPMENT

Temperature and Pressure

• Temperature gradients and depressurizing rates should be considered for each piece of equipment being shut down. Prescribed rates for heavy-walled and multi-layered equipment must be maintained. If these rates are ignored, destructive temperature gradients may occur which will result in stress magnitudes high enough to deform or crack the material of construction. Even if equipment has no prescribed cooling rates, the presence or build-up of catalyst, coke, or other deposits may seriously change thermal patterns. Such equipment warrants special shutdown and startup considerations.
• When hydrogen is present, heavy equipment walls must be cooled and degassed slowly to reduce the possibility of overpressure in laminations and voids within the metal. Similarly, when equipment containing a lining or protective coating is depressurized, a reasonable depressurizing rate reduces the likelihood of bulging and blistering caused by unequalized pressure behind these barriers.

• Some materials become embrittled and are highly susceptible to cracking during exposure to normal ambient temperatures. This susceptibility to brittleness is especially serious in colder climates when temperatures are low. If impact test results are not available, but equipment materials are likely to have high transition (behavior change from ductile to brittle) temperatures in the ambient temperature range, heat must be supplied during periods of special stress, such as maintenance work, hydrostatic testing, and the like. In cold climates additional protective measures, such as draining all low points and cleaning, must be taken to prevent freezing or other damage.

Corrosion Environments

• Shutdown environments, which may also involve deposits accumulated during operation, can be far more hostile to equipment construction materials than the process environment. Some deposits can be removed most effectively during shutdown or before the equipment is opened. Other deposits should be removed as soon as the equipment is opened. Consideration should be given to the immediate removal of all harmful deposits, such as pyrophoric iron sulfide and other corrosive materials, from opened equipment. Equipment in acid services should be washed and completely drained. Such equipment may be further protected by washing with a neutralizing solution.
• Austenitic stainless steels are subject to stress corrosion cracking and pitting when exposed to certain aqueous or ionic solutions. Deposits of chlorides and/or sulfide scales may form during the process operations. If these deposits are not washed away or neutralized before they are exposed to moisture and oxygen, serious cracking or pitting can be caused by the chloride solutions or weak sulfur (polythionic) acids. (See NACE Standard RP-01-70, Protection of Austenitic Stainless Steel in Refineries Against Stress Corrosion Cracking by Use of Neutralizing Solutions During Shut Down, for details of these corrosion mechanisms).
• Austenitic stainless steel equipment that need not be opened or that cannot be easily drained and purged (such as vertical U-bend heater tubes) can be purged most easily with nitrogen, which expels moisture and oxygen. In addition, such equipment should be kept warm, and stored under positive nitrogen pressure for the duration of the shutdown. Before startup, austenitic stainless steel equipment must be tested with a compatible medium such as low chloride water.
• Sulfur deposits, that can occur in heater and boiler convection sections, breechings, and stacks may become actively corrosive during shutdown periods. These areas should be thoroughly cleaned and maintained at temperatures that will exclude moisture precipitation.

7.0 MATERIALS SPECIFICATION

The materials or approved equals in Table 1 shall be used as specified in the actual procedures.

COMPRESSORS (RECIPROCATING)

• All new compressors shall be mothballed and stored under the direction of the supplier, as long as the warranty is valid, which is usually 18 months from delivery time or 12 months from installation.

• All compressors, new or used, shall be stored undercover, and when possible, in a humidity controlled environment.
• Hydrocarbon preservatives in compressors in oxygen service shall not be used.
• Pumping end - drain all water from cylinder jackets and intercoolers and flush with clean potable water.
• Replace the drain plugs and fill to the service level with Axxanol #8110 or its equal and water (1-10 ratio).
• Tag the fill cap, "product used for preservation", and note on tag, "Must be drained and refilled for service."
• For used (previously in-service) reciprocating compressors:
• Drain all lubricators of service oil, and refill with Braycote 154 or equal. Tag the filler cap to indicate that a preservative oil has been installed and must be drained and refilled with the Manufacturer's recommended service oil before start-up.
• If a reciprocating compressor is to be idle for a long period (more than 2 years) it may be necessary to remove piston-rod packing rings and oil wiper rings and clean them, then apply a light coating of oil (Brayco 441) and wrap in a preservative paper, such as Marvelpak-12. Tag each package for identification. Properly identify the rings to assure correct reassembly.
• Remove the valve cover plates, and remove the valves from the cylinders, clean and lightly oil coat with Brayco 441, or its equal. Lightly oil spray coat the cylinder bores and piston rods while the valves are removed.
• Uncouple the driver and manually turn over the crankshaft as required to completely oil coat (thin coating of Brayco 441) all surfaces of the cylinder bores.
• Replace the valves in their original position.
• Completely drain the crankcase of service oil and install a preservative oil (Brayco 441) to the recommended service level. Tag the filler cap or opening to indicate that a preservative oil has been installed and must be replaced with the Manufacturer's recommended service oil before startup. Date the tag.
• Seal muffler vents with Marvelpak-12 preservative paper.
• All exposed machined metal surfaces should be coated with Rust-Oleum (R-9 or R-10 or Braycote #202).
• For new (never in service) reciprocating compressors: Items 8.5.1, 8.5.6, and 8.5.7 will apply, plus the following:
• Remove all desiccant bags enclosed by the supplier.
• Remove valve cover plates and spray coat valves and parts with a very thin coat of (Brayco

441) light preservative oil. Reinstall the cover plates.

• Remove the inspection plate covers on the frame end or chassis. Using a hand oiler or spray gun, spray (Brayco 441) preservative oil, on the bearings, connecting rod bearings, crosshead and crosshead guide.
• Clean all exposed machined metal surfaces. When rendered clean and dry, coat the exposed machined metal surfaces with Rust-Oleum R-10 or R-9 or Braycote #202, or its equal.
• For compressors with a belt drive, remove the tension on the belt and tag the belt to indicate that the tension was removed.
• All exposed openings to inner parts shall be sealed with Marvelpak-12 preservative paper.

• Compressors stored inside other than humidity controlled buildings, shall be covered with Zerust RVC1 7960 plastic sheeting. Compressors stored outside exposed to the elements shall be covered in the same manner as compressors stored inside, and also under a wood frame tarpaulin shelter. The covering shall extend to the base but shall not be sealed to the ground, for circulation.
• Compressors to be stored longer than one year shall be inspected every six months. Any sign of rust or deterioration shall be repaired and the problem resolved.
• Inspect bearing caps and covers every six months. If the preservative is deteriorating, flush the bearing housing and casing, dry thoroughly and apply a new coating of preservative.

COMPRESSORS (CENTRIFUGAL)

• For all centrifugal compressors preservation, first refer to Paragraphs 8.1, 8.2 and 8.3.
• For used (previously in-service) centrifugal compressors:
• Drain and flush the water side of the lube and seal oil coolers, fill the water side with Axxanol #8110 or its equal (1-10 ratio with water).
• Drain the oil reservoir and oil side of lube and seal oil coolers. Replace the drain plugs and fill the lube system with Braycote 154. Note that the system must be vented while draining and filling. The preservative oil (Braycote 154) may be held in place during storage, or drained leaving an oil film. The drain oil may be reused when filtered. Tag the filler cap to indicate that the system is filled or coated with a preservative oil, and must be drained and refilled with the Manufacturer's service oil before start-up.
• Plug and seal all vents, drains and openings.
• Uncouple the driver from the gearbox. Drain the gearbox and refill with Braycote 154 preservative oil. Tag the filler cap to indicate that a preservative oil was installed and must be replaced with service gear oil before start-up.
• Rotate the shaft 2-1/3 turns.
• For long-term storage or thorough short term storage, the following additional steps shall be taken.
• Install blinds on both the suction and discharge flanges. Drain the compressor casing. While running the lube and seal oil system, purge the compressor with nitrogen through the drain opening. Rotate the shaft while purging, at least 2-1/4 turns. Vent the compressor discharge until completely purged. Disconnect the purge line and plug and seal all openings. Shut down the lube and seal oil system and preserve the system per the requirements of (paragraph 9.2.2).
• Remove the cover from the casing, and clean and rotor assembly with a light preservative oil (Braycote 154). Replace the cover and blind suction and discharge and seal all openings.
• Before installing the blinds, grease coat the flange face and use a rubber gasket, grease coated between the flange face and blind. Then blind the suction and discharge. Remove the cover, remove the rotor assembly, bearings, seals, and associated parts, clean and lightly coat with preservative oil before wrapping in preservative paper (Marvelpak-12). Box the wrapped parts, making sure that the shaft is supported to prevent bowing. Add desiccants required per vapor area; (see paragraph 4.7) in the box.
• Block off all inlet and outlet connections. Machined gasket surfaces should be grease coated before being covered with a rubber gasket. The cover and case should be

cleaned and lightly coated with (Braycote 154) preservative oil before resealing. The compressor should be tagged that internals were removed and inside coated with a preservative oil. Properly tag boxed parts.

• See Paragraph 8.13.
• All exposed machined metal surfaces should be coated with Rust-Oleum (R-9 or R-10) or Braycote #202.
• Cover in accordance with paragraph 8.10.
• While in storage the shaft shall be rotated 2-1/4 turns once a month.
• For new (never in-service) centrifugal compressors (only):
• See Paragraphs 8.1, 8.2 and 8.3 of this Practice.
• For new centrifugal compressors out of warranty:
• Most new centrifugal compressors are delivered with oil coated inboard and outboard bearings. It may require removing bearing cover plates and checking. If no oil film is present, apply a light oil film coating to the metal parts, Brayco 441 is recommended, or its equal. Return the cover plates to their original positions.
• Remove temporary shipping covers from both the discharge and suction flanges, install Zerust capsules ,as required per vapor space, inside the pipe or on the back of the cover plate. Reseal openings by grease coating the flange gasket surface, then cover with a rubber gasket and 1/4 inch plywood or composition board, held in place with clips. Cover the entire flange with two layers of Marvelpak -12 preservative paper, with a round or waterproof tape at the paper ends. Tag the flange inlet and outlet that vapor capsules are enclosed and must be removed before start-up.
• Coat the exposed machined metal surface with Rust-Oleum R-9 or R-10 or Braycote

202. The exposed shaft should have a good dry coat before handling.

• All openings should be plugged and/or covered with preservative paper (Marvelpak-12).
• Store the compressor off the ground and on a level base.
• Cover the compressor in accordance with Paragraph 8.10.

TURBINES

The following procedure is recommended for steam-driven turbines of the horizontal type. Note that modification or extension of this procedure can make it suitable for other types of turbines.

• Drain and clean the casing, reinstall the drain plugs. Fill the turbine case with a preservative oil Braycote 154, or its equal. Vent the casing while filling. This may be accomplished by removing the turbine case pressure relief valve. Rotate the shaft slowly and open the governor valve when filling the case to permit flooding. Hold the oil in the turbine for at least 30 minutes, then drain. Reinstall the drain plugs and the pressure relief valve. Tag the filler opening to indicate that a preservative oil coating is in the turbine case area and must be drained and cleaned before start-up.
• Drain the service oil from the inboard and outboard bearing housings. Fill the housings with a preservative oil (Braycote 154) and rotate the turbine shaft slowly. Drain the oil from the bearing housings and reseal. Tag the housings to indicate that a preservative oil was used and must be flushed out before startup.
• Coat the inlet and exhaust flange gasket surface with a heavy grease, cover with a rubber gasket and 1/4 inch plywood or compressed board held in place with clips. Cover the complete flange with 2 layers of Marvelpak -12 and waterproof tape at the paper ends.

• Clean exposed machined metal surfaces (shaft) and coat with Rust-Oleum R-9 or R-10.
• Remove the governor housing. Pack the overspeed trip mechanism with a light grease. Remove the packing from the governor valve and fill the stuffing box with a light grease. Tag the governor valve rod to indicate that the packing was removed and must be repacked before start-up. Replace the governor housing.
• Clean the turbine exposed painted surfaces. Cover the turbine with Zerust RVC1-7900 plastic. Do not seal to the ground. Seal only to the base of turbine to allow circulation.
• The turbine shaft should be rotated 2-1/4 turns each month to prevent the bearing from brinelling.

PUMPS

Centrifugal Pumps

• Disconnect the inlet and outlet flange connections, open all pump case and seal flange drains (if any). Flush and render casing and stuffing box clean and dry. Install the pump case drain plug. Fill the casing with a preservative oil, Braycote 154, or its equal. While filling the casing, rotate the shaft. Let the oil stand for a minimum of 30 minutes, then drain the oil. The oil may be re- used if needed. Reinstall the drain plugs. Seal the inlet and outlet flanges by coating the flange gasket surface with grease, covering with a rubber gasket and 1/4 inch plywood, held in place with clips and completely covered with 2 layers of Marvelpak-12 and waterproof tape. Tag the pump case to indicate that the interior has a coating of preservative oil and should be flushed out before the pump is put back into service.
• For pumps stored for a short period and indoors, the bearing wells and oil reservoirs can remain filled with service lubricant, providing the shaft is rotated 2-1/4 turns each month.
• For pumps stored for an extended period (2 or more years), and/or stored outside, the bearing wells and reservoirs shall be drained and refilled with a light preservative oil, Brayco 441, or its equal. The preservative oil may be held in place or drained and sealed. Tag the fill cap to indicate that a preservative oil was used and must be drained and refilled with the Manufacturer's recommended service oil, before the pump is put back into service. The shaft shall be rotated 2-1/4 turns once a month to prevent brinelling.
• Greased filled ball or roller bearing housing cavities may be filled with service grease providing the shaft is rotated 1-1/4 turns on a regular basis (once a month).
• Stuffing box packing should be renewed before the pump is put into service, if the pump was in storage two (2) or more years.
• Pumps shall be uncoupled from their driver. The exposed shaft shall be clean and dry before coating with Rust-Oleum R-10 clear or Braycote 202, or its equal.
• Rotate the pump shaft 2-1/4 turns each month.

Reciprocating Pumps

• Remove the covers from the inlet and outlet on both the liquid and steam side, render both sections clean and dry. Before reinstalling the cover plates, coat the gasket surface with a heavy grease, and cover with a rubber gasket grease coated on both sides before a 1/4 inch plywood cover plate is installed and held in place with clips and completely covered with 2 layers of Marvelpak-12 and waterproof tape. Fill the liquid and steam sides with a preservative oil, Braycote 154, or its equal, let set for 30 minutes before draining so that a thin coating of oil will remain on the housing walls. Reinstall the filler and drain plugs. Tag both ends to indicate that a preservative oil was used.
• Fill all lubricators with the recommended service oil.
• Remove the packing from the stuffing box and coat the housing with a preservative oil (Tag the stuffing box to indicate that the packing has been removed). Packing may remain in the stuffing box during storage, if storage is less than 2 years. Packing shall be renewed if in place and stored for a longer period of time.
• Render the exposed rods clean and dry, then coat with Rust-Oleum R-10 or R-9, or its equal.
• All grease fittings shall receive an ample supply of grease, and be wiped clean of excess grease.

MOTORS

New Motors (Never Used)

• Large or small new motors shall be stored in a ventilated, dry, temperature and dust controlled shelter (50°F minimum 104°F maximum).
• The new motors shall be stored under the direction of the supplier, in order for the warranty to be valid.
• When the warranty has expired, while the motor is still in storage, preservation preparations shall be followed, with some moderation, as if the motor was used (see paragraph 12.2).

Used Motors

• The exterior shall be cleaned with a suitable solvent, being careful not to wet the windings.
• Terminal leads shall be cleaned before wrapping in a plastic tape.
• If the motor was in a severe environment, this may dictate the need to disassemble the motor and apply solvent cleaning before parts are placed in a drying oven.
• The motor shall be tested by meggering and the reading recorded, then tested on a yearly basis. If the motor is picking up moisture, the method of storage or the environment will need to be altered.
• Windings may require cleaning (air blow dry). Wipe down all surfaces with a lint free cloth, dampened with solvent. Apply a coating of air-drying insulation varnish, over very dry windings.
• Replace and repack bearings with the vendor's recommended grease. If the motor is stored longer than two years, the bearing should be replaced before returning the motor to service.
• For oil lubricated bearings, the oil housing shall be drained and a preservative oil installed, Brayco 441, or its equal. The bearing housing shall be tagged to indicate that a preservative oil was installed and must be replaced with service oil before the motor is put into service.

• The exposed shaft shall be cleaned and then coated with Rust-Oleum R-10 or R-9, or its equal. The shaft shall be rotated several turns each month while in storage.
• The motor shall be stored under cover. If clear plastic is used, a minimum of two (2) layers are required. The cover shall not completely wrap the motor, air must be allowed to circulate from the bottom. Install an externally visible drying desiccant before wrapping the motor in plastic. Inspect the desiccant on a regular basis.
• If the motor has an internal heater, it shall be connected. If no internal heater is provided, the motor windings can be kept warm by heat strips set inside near the windings.

TRANSFORMERS (DISCONNECTED)

• Typical power transformers require only a minimum of preservation during periods of storage.
• Units not designed or intended for outdoor service should be stored in a clean, dry, enclosed environment.
• Bushings in good repair shall have the metal portion cleaned before coating with a heavy preservative grease.
• A tightness test shall be taken; pressurize with nitrogen to 2 psig and repair any leaks until pressure is held for one week. Two psig of nitrogen shall be held during storage.
• If the main tank is filled with oil, less expansion space, the tank shall remain filled to the level mark during storage.
• An insulation test shall be checked as follows:
• Primary to ground
• Secondary to ground
• Primary to secondary
• The external protective coating shall be kept in good repair, to prevent external rust and corrosion.

SWITCHGEAR

• Free-standing metal-enclosed equipment shall be stored upright, under cover in a dry, well ventilated environment.
• Desiccants (Humi-Sorb), or "Zerust" vapor capsules may be installed in the primary enclosure to maintain a dry atmosphere.
• Small equipment such as relays, pushbuttons and circuit breakers, shall be sealed in preservative paper (Marvelpak-12) and boxed.

GENERATORS

• The generator shall be disconnected from its driver in order to rotate the shaft several revolutions each month during periodic maintenance.
• The exterior shall be cleaned with a lint free cloth, lightly moistened with a cleaning solvent, (nonexplosive).

• The insulated windings shall be cleaned by vacuum cleaning then wiped with a slightly moistened, (with solvent) lint free cloth. The winding may require more vacuuming to dry.
• A megger reading shall be taken and recorded. If the insulation resistance is low, it may be necessary to bake the windings (not to exceed 194°F).
• One on-location method of baking the windings is to enclose the generator with canvas, leaving a required hole at the top for moisture to escape, insert heat strips and leave on until insulation resistance becomes constant. Heat strips should be a minimum of 250W.
• If an internal heater is provided it shall be connected. Heaters shall be active during all seasons.
• The bearing reservoir shall be drained and refilled with a preservative oil, Brayco 441, or its equal. Tag the fill cap to indicate that a preservative oil has been installed.
• Because some generators are of the pressure lubricated type and do not have standpipe type oil reservoirs, it will be necessary to provide and attach standpipes to the oil drain flanges at each end, approximately 6 inches above the shaft centerline. Either cap the oil inlet flange at each end, or install standpipes 6 inches above the shaft center line. Fill the drain pipe at each end with preservative oil to 2 inches below the shaft center line. Tag the fill cap to indicate the type of oil used.
• The exposed shaft shall be coated with Rust-Oleum (R-9 or R-10), or its equal.
• If the generator has a water cooler, the cooler shall be drained of all water, then filled with an anti-rust glycol solution.
• Cable connectors and lead ends shall be tape covered.

DIESEL ENGINES

• Run the engine, gradually increase the speed to a fast idle, with no load. When the engine is thoroughly warm, stop the engine and drain all lubricating oil from the sump, lube oil tank, oil- filter housing and fuel-pump housing.
• Fill the engine (sump) and fuel pump housing with Brayco 441 (MlL-L-21260D Type 1 grade 10), or its equal.
• Drain the cooling system and flush thoroughly. Refill with a mixture of water and inhibited glycol soluble oil or cooling system protector.
• Drain the fuel from the tank and fuel filter housing and fill with kerosene. Prime the fuel system.
• Run the engine for 15 minutes at idling speed. Leave all fuel lines filled with kerosene. DO NOT

remove the fuel injectors.

• When the engine has cooled, disconnect the inlet and exhaust manifolds and spray preservative oil, Brayco 441, into the air intakes and exhaust outlets, turning the engine during this operation.
• Where possible, lightly spray oil through other openings, such as indicator holes, starting air valves, etc. with the engine stationary (Do not rotate the crankshaft after completing the above operations).
• Tag the fill openings, intake and exhaust to indicate that a preservative oil was sprayed inside, also tag the sump fill cap with the type of preservative oil used.

• Seal all flange openings. Coat the flange face and gasket area with a heavy grease, cover with a rubberized gasket and 1/4 inch plywood plate, held in place with clips, then completely cover with 2 layers of Marvelpak-12 preservative paper and secure with waterproof tape.
• Coat all exposed machined metal surfaces (shaft's coupling) with Rust-Oleum R-10 or R-9, or its equal.
• Re-install the inlet and exhaust manifolds. Seal all vents (breathers, exhaust and air filters) with preservative paper (Marvelpak-12). Seal dipsticks on engine and fuel tank in place. Seal the oil and fuel tank filler caps with Marvelpak-12.
• Store the engine in a place protected from weather and where the air is dry, and the temperature uniform.

HEAT EXCHANGERS (SHELL AND TUBE)

• The routine shutdown washing, chemical cleaning or mechanical cleaning must still be used before the exchanger is opened.
• Open the exchanger, remove the tube bundle, and disassemble all components.
• Clean all parts thoroughly, including the shell and shell nozzles.
• Any inspection and repair that is recommended shall be done at this time.
• The tube bundle can best be protected during storage in its shell.
• A preservative oil application may be applied while the heat exchanger is disassembled or when it is completely reassembled. A preservative oil, such as Braycote 154 is recommended and shall be applied by spray, dip or brush. Application of this oil must be applied over a clean dry surface.
• The most economical method of oil application to both the shell and tubes is: flood both sides, shell and tube side, with preservative oil when the bundle is installed and sealed. Both sides shall be vented while filling. Hold the oil in the heat exchanger for a minimum of 30 minutes before draining. Drained oil may be reused at a later date or on other pieces of equipment to be stored. A thin coat of preservative oil will remain on all parts and can be removed, if necessary, before service by steam cleaning.
• The following method of sealing an exchanger for storage is recommended:
• Grease coat all gasketed surfaces using a preservative grease, Braycote 610, or its equal. Install service gaskets on the floating head-shell cover, channel and channel cover.
• Nozzle flange bolt surfaces and gasket surfaces should be coated with grease before installing a rubberized full gasket, then covering with a 1/4 inch thick plywood plate, grease coated on both sides. The plywood shall be held in place with clips and the flange completely covered with 2 layers of Marvelpak-12 preservative paper, secured with waterproof tape.
• All threaded openings should be grease coated before installing a steel plug.
• Heat exchangers covered with insulation should be in good condition. If the insulation has been damaged and is not repairable, all the insulation should be removed from the outer metal surface.

• For exchangers stored in the open and not under cover, the exterior should be commercially blasted and coated with a shop primer, 1-1/2 to 3 mils thick.

AIR COOLERS (FINNED)

• Uncouple the drive (fan motor) and store in accordance with the motor preservation requirements in Paragraphs 11.2 and 12.2 of this Practice. Tag the motor to identify which air cooler the motor was removed from.
• Air or steam clean the fins (do not walk on the fins). Blow dry before closing the louver. If no louvers are provided, cover the finned tubes with 2 layers of plastic, (no single layer of plastic) canvas, or tar paper. Louver joints and linkage shall be well greased.
• For short term storage the clean dry finned tube outside diameter can be sprayed with preservative oil (Braycote 154).
• The gear reducer assembly can remain in place. Drain the gear oil, install an oil fill pipe extension to raise the fill line above the gear level. This will eliminate the need for periodic rotation of the gears. Fill the gear box with preservative oil, Braycote 441, and tag the fill pipe to indicate that a preservative oil was used.
• Clean and coat all exposed machined metal parts, such as the coupling, shaft, and hub with Rust-Oleum (R-10 or R-9).
• Remove the tube header plate and clean the tube inside diameter, or chemically clean through the inlet nozzle (same as routine shutdown washing). When tube inside diameter is determined to be clean and dry, oil coat by spray or flooding, with Braycote 154, or equal. If the flooding method is used, hold the oil in the tubes for 30 minutes before draining. Tag the inlet nozzle to indicate that the tubes are oil coated (be sure to vent while filling).
• Blank and seal the inlet and outlet nozzles. Grease coat the gasket and bolt circle before installing a rubberized full gasket covered with 1/4 inch steel or plywood plate, grease coated on both sides, and held in place with clips. Completely cover the flange with two layers of Marvelpak-12 preservative paper and secure with waterproof tape.
• Open threaded fittings shall be grease filled and steel plugged.

POWER BOILERS

• Dry storage is preferred for an extended period of time, as it is also generally preferable for reheaters.
• Since freshly cleaned metal surfaces are more vulnerable to corrosion than surfaces that have operational oxides on them, it is preferred to delay chemical cleaning until the boiler is ready to be returned to service.
• The boiler shall be thoroughly dried. All inlet and outlet connections shall be blanked and sealed.
• Flanged nozzle gasketed surfaces should be protected with a grease (Braycote 202) coating and full gasket. After a blind is installed, the complete nozzle should be covered with 2 layers of Marvelpak-12, and secured with waterproof tape.

• Desiccants (Humi-sorb), at the rate of 5 pounds per 95 ft3 of vapor space shall be hung inside the boiler and drums, before being sealed for storage.
• All access doors and openings shall be closed and sealed, using Marvelpak-12, caulking and/or waterproof tape.
• The effectiveness of the preservative material and need for its renewal may be determined through scheduled inspection.

FURNACES

• No attempt is made to offer a means of protection for masonry, concrete, linings and insulation. It is common practice to inspect these items and make necessary repairs before the furnace is returned to service. Should defects be noted while the equipment is idle which would tend to weaken the structure, repairs shall be made immediately.
• The burner oil guns shall be removed, cleaned, greased, and wrapped in Marvelpak-12, preservative paper. The oil burner guns shall be stored inside the heater on top of their burners. The air registers shall be closed.
• Pipe and hose attachments shall be disconnected, plugged and sealed with preservative paper (Marvelpak-12).
• All burner openings and connections shall be sealed off. he gas burner tips shall be sealed with preservative paper.
• On the inside of the furnace, cap the burner tile using 1/2 inch plywood, cut to fit the round raised opening. Cover the plywood with 2 layers of Visqueen held in place with stainless steel wire.
• All tubes shall be cleaned inside before flushing with a preservative oil, Braycote 154, or equal. A blank shall be installed at the inlet and outlet flange. After the gasket surface is cleaned and greased a rubberized gasket shall be used on both sides of the blank.
• Headers shall be closed and Kaowool shall be stuffed in all openings around the header, tubesheet and tubes.
• The outside surface of tubes and intermediate tubesheets shall be free of loose refractory, sulfur deposits, and dust.
• The furnace deck and walls shall be brushed and free of loose deposits, before re-caulking the openings. Refractories shall be kept dry at all times. Five pound bags of Humi-sorb desiccants shall be hung inside the heater box at the rate of 5 pounds per 95 ft3 of vapor space.
• Motor operated fuel valves shall be serviced and wrapped in 2 layers of Marvelpak-12 preservative paper.
• Instruments shall be clean and housed, boxed or enclosed in preservative paper. Zerust capsules or desiccants shall be used inside the enclosure.
• The breeching and ductwork shall be cleaned and free of loose refractory, and openings caulked with Kaowool.

• The operating parts on the dampers shall be washed and greased. The stack damper shall be closed and the stack opening covered, or capped with 1/2 inch outdoor plywood and sealed with 2 layers of Visqueen held in place with stainless steel wire.
• Hinges on header doors, peepholes and access doors shall be cleaned before being greased. The gasket material shall be in good repair before the doors are sealed by caulking, waterproof tape, or Marvelpak-12.

PIPING AND FITTINGS

• Small pipe and fittings, NPS 2 inch and under, in critical service and in a corrosive environment shall be cleaned and rust freed before receiving a 1.5 to 2.0 mils coat of a preservative paint.
• All pipelines shall be flushed, cleaned and blown dry. All flanges and low point bleed valves shall be opened to permit complete draining. A preservative (Braycote 154 or equal) shall be circulated all through the lines.
• Steam tracers shall be in good repair and drained of all condensate. Inlets and outlets shall be closed after all lines are rendered dry.
• All insulation and pipe wrappings shall be in good condition. Holes in the wrappings, where moisture can get behind the insulation, shall be repaired.
• Valves shall be well lubricated and the valve stem wrapped with 2 layers of Marvelpak-12. The disk shall not be sealed tight but shall be backed off one or two turns. Pressure relief valves shall be removed and sent to the valve bench to be serviced, tagged and stored.
• If blinds are used, the flange gasket surface shall be clean and rust free before being coated with a thin coat of oil or grease. If a rubberized gasket is used in place of the service gasket, it shall be noted along with the recording of the location of blinds and blanks. It shall also be noted that all valves have been "cracked" open.
• Flanges and bolting shall be protected by completely encasing in 2 layers of Marvelpak-12.

PRESSURE VESSELS

• Pressure vessels shall be washed the same as for pre-turnaround preparations, with a solution of soda ash and water, and steamed out.
• The interior shall be vented and blown dry or purged with nitrogen.
• The vessel can then be blanked, or opened, gas tested and the interior sprayed with a thin coating of preservative oil, Braycote 154, or its equal.
• When the vessel is rendered dry or lightly coated with oil, all inlets and outlets shall be closed and sealed. The pressure relief valve shall be tagged, removed, serviced and stored.
• Flanged nozzle gasket surfaces shall be cleaned and be rust free before being coated with oil or grease. A rubberized gasket shall be installed and covered with a 1/4 inch plywood plate held in place with clips. The entire preserved flange and part of the nozzle should be covered with 2 layers of Marvelpak-12 preservative paper, and secured with a waterproof tape.

• If piping is to be left connected to the vessel, the above procedure should be followed except that instead of a blind as the flange, a blank shall be installed between the flanges. Record and tag that a blank has been installed.

• All threaded openings shall be grease coated, plugged and covered with 2 layers of Marvelpak- 12.
• If the vessel is insulated, the insulation shall be in good repair with no cover failures, or the insulation shall be completely removed.

STORAGE TANKS

• The tank interior shall be clean and dry and all loose scale and rust should be removed. This may require a hydro or brush blast.
• With the tank vent and roof hatch open, brush or spray the overhead shell, bottom, and structural members with a preservative oil, Braycote 154, or its equal.
• Close all openings and fill any threaded openings with grease and a plug.
• Flanged inlet and outlet piping shall be sealed off.
• Install a blank after the flange gasket surface is cleaned and greased. A rubberized gasket shall be used in both sides of the blank. The blank shall be recorded for location and date installed.
• Leave all floating roof drains open with the pontoon vent flapper disk free. The cone roof vent should be left open, and screen protection should be clear.
• The tank exterior shall be maintained according to the plant maintenance program.
• If the tank is located in an area subjected to high winds or rising water, consideration should be given to filling the tank with inhibited water with a pH 8 to pH 9, so that it does not float away.
• The tank exterior shall be inspected a minimum of once a year.

FANS AND BLOWERS

• The exterior housing protective coating shall be clean and in good repair.
• Single and double belt drive units shall have the belt tension relieved, or belts removed and pulleys wrapped in 2 layers of Marvelpak-12. Tag the pulley to indicate that the belt tension has been relieved.
• The pillow block bearings shall be grease filled approximately 1/3 full (avoid over-lubrication).
• The exposed shaft should be coated with a preservative (Rust-Oleum R-9 or R-10) or wrapped in Marvelpak-12 (2 layers). The shaft shall be rotated at least 2-1/4 times once a month.
• All openings shall be sealed to keep the interior dust free. Large openings shall be covered with 2 layers of plastic sheeting (Zerust RVCI 7960) or Marvelpak-12.
• Desiccant may be placed inside the housing before the opening is sealed, but must be checked periodically for renewal (every 6 months).
• Place the desiccants in a location that will not restrict the fan rotation.

COOLING TOWERS

The following procedure is suggested for a mechanical-draft cooling tower with a concrete basin and redwood construction.

• Open and drain all exposed (water) piping.
• Drain all water from the basin and flush the basin clean. Repairs to the basin can be completed at this time or before the cooling tower is returned to service.
• Block open the basin drain valves. Lubricate the valve at the grease fittings and leave the valve stem in the open position. Coat the valve stem with grease and wrap in Marvelpak-12 preservative paper.
• Damaged structural members and warped and missing slats shall be repaired at this time, or before the cooling tower is returned to service.
• The dry wood of an idle cooling tower is a potential fire hazard. Therefore, for idle periods of approximately two months duration, a perforated hose shall be laid around for spraying the wood. For extended shutdown periods the plenum and internals shall be sprayed with a fire retardant chemical and biocide to keep all wooden members wet at all times. NOTE: Keeping the tower wet may be a problem in the frost zone; wetting and drying the wood members will accelerate rotting the wood.
• Remove the fan drive motor, tag and protect as described in Sections 11.0 and 12.0 of this Practice.
• Drain the oil from the gear reducer and fill to the operating level with a preservative oil, Brayco 441, or its equal. Tag the fill opening that a preservative oil has been installed. The gear reducer shall be rotated several turns each month, or add an extension pipe at the vent opening or gauge glass and fill to the bottom of the opening. The fill opening must be vented, with a vent cap for oil expansion. Note: If the reducer is oil filled to the bottom of the vent, do not rotate the fans.
• Wrap the exposed opened shaft and coupling in two layers of preservative paper, or coat with Rust-Oleum R-9 or R-10.

CONTROL SYSTEMS

• Flow Meters
• Disconnect the lines linking the orifice to the differential pressure cell.
• Plug the connections in the orifice flanges, and cover the plugged opening with 2 layers of Marvelpak-12 (preservative paper).
• Fill both chambers of the meter body with a light preservative oil (Brayco 441). Tag the chamber inlet to indicate the type of preservative oil used. Plug the chamber inlets and cover with 2 layers of Marvelpak-12 (preservative paper).
• Disconnect the air lines at the pneumatic transmitter housing. Plug the air inlets, vents, and openings, then cover with 2 layers of preservative paper (Marvelpak-12).
• Spray the interior of the pneumatic transmitter housing and all components with a light preservative oil (Brayco 441). Cover the entire cell with 2 layers of preservative paper, (Marvelpak-12).

Receiver-Recorder

• Disconnect all lines entering the receiver-recorder case.
• Plug all vents and openings. Cover all junctures of the metal case with 2 layers of (Marvelpak-12), preservative paper.
• Install the required amount of desiccant needed before the door is closed and sealed with rubber backed sealing tape, or Marvelpak-12.
• Remove all control valves, clean and repair as needed. Wrap in 2 layers of Marvelpak-12, (preservative paper) and store in a sheltered area.
• Control systems components containing batteries, (except standard cells) corrosive solutions, or items with short shelf life that could damage the parent equipment, shall be removed. These items shall be stored in suitable containers to prevent leakage, corrosion or damage to other equipment.

TABLES

TABLE 1 MATERIALS

TABLE 1 MATERIALS (CONTINUED)

NOTES:

• Flush system prior to using.
• Check with supplier about application requirement before ordering protective materials.
• Zerust vapor capsules required per vapor space:

Model No. Area Protection Life Size

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