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PETRONAS TECHNICAL STANDARDS

Preservation of Upstream Production and Process


Facilities

PTS 15.20.16
January 2016

© 2016 PETROLIAM NASIONAL BERHAD (PETRONAS)


All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form
or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright
owner. PETRONAS Technical Standards are Company’s internal standards and meant for authorized users only.
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FOREWORD

PETRONAS Technical Standards (PTS) has been developed based on the accumulated knowledge,
experience and best practices of the PETRONAS group supplementing National and International
standards where appropriate. The key objective of PTS is to ensure standard technical practice across
the PETRONAS group.

Compliance to PTS is compulsory for PETRONAS-operated facilities and Joint Ventures (JVs) where
PETRONAS has more than fifty percent (50%) shareholding and/or operational control, and includes
all phases of work activities.

Contractors/manufacturers/suppliers who use PTS are solely responsible in ensuring the quality of
work, goods and services meet the required design and engineering standards. In the case where
specific requirements are not covered in the PTS, it is the responsibility of the
Contractors/manufacturers/suppliers to propose other proven or internationally established
standards or practices of the same level of quality and integrity as reflected in the PTS.

In issuing and making the PTS available, PETRONAS is not making any warranty on the accuracy or
completeness of the information contained in PTS. The Contractors/manufacturers/suppliers shall
ensure accuracy and completeness of the PTS used for the intended design and engineering
requirement and shall inform the Owner for any conflicting requirement with other international
codes and technical standards before start of any work.

PETRONAS is the sole copyright holder of PTS. No part of this document may be reproduced, stored
in a retrieval system or transmitted in any form or by any means (electronic, mechanical, recording or
otherwise) or be disclosed by users to any company or person whomsoever, without the prior written
consent of PETRONAS.

The PTS shall be used exclusively for the authorised purpose. The users shall arrange for PTS to be
kept in safe custody and shall ensure its secrecy is maintained and provide satisfactory information to
PETRONAS that this requirement is met.
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ANNOUNCEMENT

Please be informed that the entire PTS inventory is currently undergoing transformation exercise from
2013 - 2015 which includes revision to numbering system, format and content. As part of this change,
the PTS numbering system has been revised to 6-digit numbers and drawings, forms and requisition
to 7-digit numbers. All newly revised PTS will adopt this new numbering system, and where required
make reference to other PTS in its revised numbering to ensure consistency. Users are requested to
refer to PTS 00.01.01 (Index to PTS) for mapping between old and revised PTS numbers for clarity. For
further inquiries, contact PTS administrator at ptshelpdesk@petronas.com.my
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Table of Contents
1.0 INTRODUCTION ..................................................................................................... 6
1.1 SCOPE ............................................................................................................................ 6
1.2 GLOSSARY OF TERMS..................................................................................................... 6
1.3 SUMMARY OF CHANGES ............................................................................................... 8
2.0 GENERAL ............................................................................................................... 9
2.1 MODES OF PRESERVATION ............................................................................................ 9
2.2 PRESERVATION REQUIREMENT PROCESS FLOW CHART ............................................... 9
3.0 PRESERVATION MATERIALS AND PRESERVATION METHODS ................................ 11
3.1 INERT MEDIA ............................................................................................................... 11
3.2 RUST PREVENTATIVES AND VAPOUR CORROSION INHIBITORS (VCI) ......................... 11
3.3 PRESERVATION METHODS........................................................................................... 12
4.0 PREPARATORY PHASE .......................................................................................... 13
4.1 PREPARATION FOR PRESERVATION............................................................................. 13
4.2 INSPECTION AND TECHNICAL AUDIT ........................................................................... 13
4.3 EXTENT OF PRESERVATION.......................................................................................... 14
5.0 ACTIONS RELATIVE TO PROCESS UNITS AND NEW PLANTS ................................... 15
5.1 EXISTING (OPERATING) UNITS ..................................................................................... 15
5.2 NEW FACILITIES ........................................................................................................... 15
6.0 PRESERVATION PROCEDURES FOR SPECIAL MATERIALS ....................................... 16
6.1 STAINLESS STEELS ........................................................................................................ 16
6.2 COPPER AND COPPER ALLOYS ..................................................................................... 16
6.3 ALUMINIUM................................................................................................................. 16
6.4 NICKEL, NICKEL ALLOY AND NICKEL STEEL................................................................... 17
6.5 TITANIUM, ZIRCONIUM AND TANTALUM ................................................................... 17
6.6 PLASTIC AND RUBBER .................................................................................................. 17
7.0 PRESERVATION PROCEDURES FOR SPECIFIC EQUIPMENT AND FACILITIES............. 18
7.1 GENERAL ...................................................................................................................... 18
7.2 STATIC EQUIPMENT AND PIPING................................................................................. 18
7.3 ROTATING EQUIPMENT ............................................................................................... 19
7.4 MIXING......................................................................................................................... 19
7.5 STORAGE TANKS AND CIVIL ENGINEERING ITEMS ...................................................... 19
7.6 INSTRUMENTATION AND ASSOCIATED EQUIPMENT .................................................. 19
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7.7 ELECTRICAL EQUIPMENT ............................................................................................. 20


8.0 MONITORING OF PLANT STANDING IDLE ............................................................. 21
9.0 PREPARATION FOR SERVICE ................................................................................. 22
10.0 BIBLIOGRAPHY .................................................................................................... 23
APPENDIX 1: PRESERVATIVE FLUIDS * ............................................................................. 24
APPENDIX 2: TABULATION FOR PRESERVATION PROCEDURES......................................... 25
APPENDIX 3: INSPECTION AND MONITORING OF PRESERVED EQUIPMENT TABLE ........... 26
APPENDIX 4: PRESERVATION PROCEDURE FOR EQUIPMENT AND FACILITIES ................... 27
APPENDIX 4A: STATIC EQUIPMENT AND PIPING .................................................................... 27
APPENDIX 4B: ROTATING EQUIPMENT ................................................................................... 31
APPENDIX 4C: MIXING............................................................................................................ 37
APPENDIX 4D: STORAGE TANKS AND CIVIL ENGINEERING ITEMS ......................................... 38
APPENDIX 4E: INSTRUMENTATION AND ASSOCIATED EQUIPMENT ..................................... 39
APPENDIX 4F: ELECTRICAL EQUIPMENT ................................................................................ 40
APPENDIX 5: MONITORING PLANT STANDING IDLE ......................................................... 42
APPENDIX 6: PREPARATION FOR SERVICE ....................................................................... 43
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1.0 INTRODUCTION

This PTS provides minimum technical requirements for temporary, short term and long term
preservation of equipment and systems.

This PTS was developed to ensure equipment, materials and spare parts in PETRONAS
upstream production and processing facilities are preserved in the correct manner, lowest
asset depreciation with minimum cost and delay for re-commissioning.

1.1 SCOPE

1.1.1 This PTS is applicable for upstream equipment in the following categories:
i. Preservation of new equipment as specified in Section 6 and 7 during storage in
the manufacturer’s plant, transportation from the manufacturer’s plant to the
port, during shipping, storage at the construction site, construction and after
construction prior to commissioning;
ii. Mothballing of equipment during extended shutdown and storage periods.
iii. For onshore equipment, terminal facilities and bulk purchased materials (e.g.
linepipes, pipe stands, cable trays, racks, etc.)

1.1.2 This PTS is not applicable when:


i. The cost of mothballing, re-commissioning and maintaining the equipment in a
mothballing state is nearly equal to the cost of replacement.
ii. The item has deteriorated beyond economic repair
iii. The equipment is obsolete due to unavailability of spare parts or servicing is
excessively expensive.

1.1.3 This PTS is not applicable to:


i. Downhole equipment, operating intra-field / inter-field pipelines, trunk lines and
transmission pipelines.
ii. Subsea production system (SPS) which is from Topside Umbilical Termination
Assembly (TUTA) installed at host facility/topside to subsea equipment which
installed at seabed
iii. Floating LNG facilities

1.2 GLOSSARY OF TERMS

1.2.1 General Definition of Terms & Abbreviations

Refer to PTS Requirements, General Definition of Terms, Abbreviations & Reading Guide PTS
00.01.03 for General Definition of Terms & Abbreviations.
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1.2.2 Specific Definition of Terms

No Term Definition

1 Inert Media A media which is non-corrosive and non-flammable for oil


field applications

2 Mothballing Methodology for safe keeping of in-service equipment to


sustain its integrity and condition for a defined non-
operational period of time prior to re-entry into service
(re-commissioning).

3 Preservation Methodology for safe keeping of new equipment to


sustain its integrity and condition prior to commissioning.
The term Preservation is used in this document to serve
both Mothballing and Preservation terms

4 Vapour Phase Crystalline powders that slowly vaporize into enclosed


Corrosion Inhibitor space inside a package

5 Vapour Space Oily concentrate that can be added to lubricating/seal oil


Inhibitor systems when equipment is not going to be completely
filled.
Table 1: Specific Definition of Terms

1.2.3 Specific Abbreviations

No Abbreviation Description

1 CP Cathodic Protection

2 ESDV Emergency Shut Down Valve

3 HV High Voltage

4 LV Low Voltage

5 MIC Microbiological Induced Corrosion

6 NaHCO3 Sodium Bicarbonate

7 ppm Parts Per Million

8 V Volt

9 VCI Vapour Corrosion Inhibitor


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No Abbreviation Description

10 VpCI Vapour Phase Corrosion Inhibitor

11 VPI Vapour Phase Inhibitor

12 VSI Vapour Space Inhibitor


Table 2: Specific Abbreviations

1.3 SUMMARY OF CHANGES


This is a new PTS.
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2.0 GENERAL

The content of this document does not release the user from undertaking a thorough and
complete review of all HSE requirements.

2.1 MODES OF PRESERVATION

2.1.1 Preservation procedures recommended in this PTS have been developed for three principle
modes of preservations, which are defined as follows:

Temporary Period of idleness between operating periods which may be up to


preservation 2 months.

Short-term Period of idleness up to 1 year


preservation

Long-term Period of idleness more than 1 year.


preservation

2.2 PRESERVATION REQUIREMENT PROCESS FLOW CHART

2.2.1 Figure 1 outlines the process flow chart for the preservation of upstream production and
process facilities.
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Obsolete/not Unsafe in local Safe in local


cost effective environment environment

Up to 2 months < 1 year > 1 year

Extend
preservation Results are not
period satisfactory

Results are
satisfactory

Figure 1: Process Flow Chart for Preservation


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3.0 PRESERVATION MATERIALS AND PRESERVATION METHODS

This section specifies requirement on preservation materials and preservation methods which
are used in this PTS.

3.1 INERT MEDIA

Inert Media Requirement


Nitrogen Nitrogen (99.99% pure) pressure shall be maintained and must be
checked regularly with leak detector or soap solution or pressure
monitoring. When leaks are detected, valves shall have packing
tightened or replaced and flanges and/or threaded connections shall be
sealed. Liquid nitrogen source is recommended.
Dry Air The system shall be maintained at a relative humidity controlled to 40%
or less or the dew point shall be less than +30 °F/ -1 °C.
Water Water with chemical treatment shall be used.
For environmental considerations regarding the use and disposal of
biocided water, refer to PTS 11.12.03.
Table 3: Inert Media

3.2 RUST PREVENTATIVES AND VAPOUR CORROSION INHIBITORS (VCI)


Rust
Preventative Requirement
and VCI
Rust These products are certain grades of oil and grease which are applied as
preventative coating on the surface to be preserved that can provide protection for 6-18
months.
VCI VCI is effective in small enclosures and vessels. Two types of VCI are
considered in this PTS:
a. VpCI:
It can provide up to five (5) years of continuous protection. The
application shall involve three (3) processes:
i. Preparation of the surface by fogging of vapour phase scale
remover to clean and condition the metal surface.
ii. Deposition of the VpCI by fogging or spraying VpCI on the cleaned
surface to develop protective layer.
iii. Maintenance of the protective layer by placing small breathing
powder pouches inside the enclosed space.
b. VSI:
Protection should be effective over an oil temperature range of 15 to
70°C for up to 12 months. For maximum efficiency, given a temperature
of 30°C, oil to surface distances should not exceed 2m. The distances
should be less for lower temperatures and may be increased for
temperatures higher than 30°C.
Table 4: Rust Preventatives and Vapour Corrosion Inhibitors (VCI)
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3.3 PRESERVATION METHODS


Protection
Description
Methods
Cocooning Storage of equipment in a plastic covered and, if required, air conditioned
enclosures or a cover can be installed over the equipment in place.
Air circulated between the Cocoon and the surface of the protected
equipment shall be controlled to relative humidity of 40%
Protective Coating can be permanent industrial maintenance type paint or a rust
Coatings preventative grease or oil. Routine maintenance painting programs for
external protection should be continued. Before application, surfaces shall
be thoroughly cleaned and dried.
Wrapping Equipment wraps with waterproof paper or VPI paper should be stored
under cover.
Protective Plywood boxes constructed over rotating equipment, tape coverings over
housings and exposed motor/pump shafts, or polyethylene bags over instruments
coverings (inside).
Covering of motor, turbine and compressor air inlets and taping over
applied protective greases is recommended. Polyethylene film should not
be used outdoors. If the equipment is designed for outdoor exposure,
constructed box enclosures and/or using plastic bags is generally not
encouraged.
Oil coating Internal oil coating of stationary equipment may be carried out by spraying
or, if the foundation is strong enough, by filling and subsequent draining.
Filling Measures shall be taken to allow for expansion of the filling fluid, which can
be dry sweet fuel gas, dry crude oil, deoxygenated fresh water.
VpCI VpCI can be used advantageously for the internal protection of dry
equipment and closed off from the atmosphere.
Dry inert gas All hermetically closed equipment should be protected by drying the air or
filling displacing it by an inert gas, e.g. nitrogen (99.99% purity), and maintaining
a slight positive internal pressure (10 psig).
Desiccants Drying agents, such as silica gel, can be used inside closed equipment.
Electric The following methods of electric heating should be considered:
heating i. Fan heaters; for space heating, e.g. sub-stations, control rooms,
basements.
ii. Warm air (strip heating, electric trace heating or lamp bulbs); for
equipment which is cocooned or otherwise enclosed.
iii. Anti-condensation heaters for electrical equipment.
Table 5: Methods of Preservation
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4.0 PREPARATORY PHASE

4.1 PREPARATION FOR PRESERVATION

4.1.1 Inspection shall be conducted to ensure all preparatory work has been made on the process
facilities or equipment. This shall include:
i. Draining of all contents;
ii. Removal of all catalysts or containment in such a manner as to minimize the
effects of weathering, ageing or mechanical abuse;
iii. Isolation at battery limits (beware of electrical cross-connections);
iv. Hydrocarbon gas free and avoid entrance of humid air;
v. Draining of plate interceptors;
vi. Draining of cooling water from equipment and piping which are to be preserved.

4.2 INSPECTION AND TECHNICAL AUDIT

4.2.1 Inspection

An external visual inspection shall be carried out and shall include the following as a minimum.
A format is given in Appendix 3 to register the inspection findings.
i. Inspection of "hot" insulation, checking for areas where moisture could penetrate
through the insulation and lead to corrosion under insulation. The condition of
the external coating shall be assessed to determine its effectiveness against
protecting the equipment for the intended duration.
ii. Inspection of "cold" insulation, checking similarly for flaws in the weather
protection/ vapour barrier.
iii. Inspection of the fireproofing applied to steel support structures, checking for
areas, particularly at joints, where moisture could penetrate and corrode the
steelwork.
iv. General inspection of painted steelwork in order to establish the scope of the
painting programme during the period of idleness.
v. Examination of all wire ropes, slings and chains used on the plant in order to select
the items worth preserving and to scrap the remainder.

4.2.2 Technical Audit

A technical audit shall be undertaken jointly by engineering, inspection and operations


personnel supported, where necessary, by specialists and representatives of the
Manufacturers of critical items of equipment. This audit shall extend to the following as a
minimum:
i. All major items of static and rotating equipment.
ii. 20% of major electrical equipment.
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iii. 20% of minor equipment (i.e. indoor instrumentation, electrical equipment such
as batteries, transformers, pressure switches, relays).
iv. Selected piping systems, particularly where there is a history of corrosion;
v. The safety/relief valve interlock system.
vi. Listing the instruments and small items which should be removed to the
warehouse.
vii. Determining any changes which may be required to impressed current CP
systems and insulated flange connections at battery limits. CP systems shall
remain active for preserved equipment to retain its expected life.
viii. Assessing the condition of platforms, stairways and hand rails, chemical and
refractory linings, insulation, fireproofing, coating, etc.

4.3 EXTENT OF PRESERVATION

4.3.1 The following factors shall be considered when deciding on the extent of preservation.
i. Preservation shall be justified economically (refer to 1.1.3)
ii. Many preservation procedures require some services (maintenance, inspection,
power requirements, instrument air and some utilities) during the period of
idleness, and provision needs shall be made for these requirements.
iii. A preservation procedure shall be drawn up for each individual item of
equipment, or group of similar items, which shall be based on the recommended
preservation procedures for special materials in Section 6.0, and on the
preservation procedures recommended for specific items in Section 7.0. A format
is given in Appendix 2 for listing each individual item, its duty, the identity of the
preservation procedure and any on-going requirements linked to it.
iv. The preservation required for the exterior of equipment shall be determined
largely by the information recorded in the post shutdown inspection report, and
by the corrosivity of the local environment. Recommendations for external
insulation are given in Section 7.0. Exterior protection over and above that which
already exists, can be expensive and some calculated risks may be justified. On-
going inspection and maintenance, where this is feasible, should always be an
option.
v. Equipment that has undergone preservation shall be tagged at prominent
locations with the sign “CAUTION: EQUIPMENT / SYSTEM CONTAINS
PRESERVATION MATERIALS”
NOTE:
Always ensure precautions are taken when entering confined spaces and refer to relevant safety guidelines. A
schedule shall be prepared by the Owner, listing the safety and security checks which shall be carried out
at intervals throughout the period the plant is standing idle.
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5.0 ACTIONS RELATIVE TO PROCESS UNITS AND NEW PLANTS

5.1 EXISTING (OPERATING) UNITS

The procedures for preserving existing (operating) equipment are identified in the following
Sections 6.0 and 7.0.
Utilities shall be preserved with clean water treated in accordance with Appendix 4A (i). For
preservation of special materials refer to section 6.0.

Equipment in cryogenic plants where the operating temperature is 0°C or lower, needs only
to be warmed up and thoroughly dried out before purging and filling with inert media at a
positive pressure.

5.2 NEW FACILITIES

5.2.1 New Facilities (Completed)

New completed facilities which have not been exposed to operations shall be preserved with
nitrogen after ensuring all equipment and piping is thoroughly dry.

5.2.2 New Facilities Under Construction (Partially Completed)

All phases from initial purchase to ultimate part erection and storage of equipment on site,
include spares shall be preserved. The responsibilities shall be well defined and agreed to by
Manufacturers, Contractors, Owner and any other personnel involved.

Equipment shall be prepared and shipped in such a manner that corrosion protection of all
functional surfaces, both internal and external are provided for up to five years unsheltered
outdoor storage. If not already painted, non-functional surfaces may be treated by painting
or otherwise as specified by the Owner.

If the Manufacturers have adopted their own procedures for accomplishing the above, it shall
be reviewed and approved by the Owner. On delivery to site, all items shall be checked. If
breakdown of preservation is observed, deteriorated coatings shall be removed and surfaces
shall be re-preserved.

For storage at site, the preservation procedures recommended in Section 6.0 shall be used as
general guidance for preserving new plant. Small items, sub-assemblies, instruments and high-
value equipment shall be stored in an onshore air conditioned warehouse.

If not installed, large items such as ducting may be stored in the open, on wooden sleepers,
provided there is good drainage and the protection will withstand mechanical damage.

Particular attention shall be paid to identification of equipment that has undergone


preservation. Every item shall be prominently and effectively tagged, and each tag shall show
the order number and cross reference to the Supplier’s drawings approved for construction.
Alternatively, items may be identified by marking with paint.
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6.0 PRESERVATION PROCEDURES FOR SPECIAL MATERIALS

6.1 STAINLESS STEELS

6.1.1 Stainless steels equipment shall be thoroughly cleaned and dried internally.

6.1.2 Equipment normally exposed to aqueous solutions containing chlorides shall be thoroughly
rinsed with demineralized water, boiler feed water or condensate (note 1) and dried (note 2)
immediately after shutdown. Filling with a dry inert gas, e.g. nitrogen, after drying to prevent
the introduction of oxygen and maintain a slight positive internal pressure.

NOTES:
i) Demineralized water shall have a maximum chloride content of 2 mg/kg (2 ppm).
ii) Drying with hot air or an inert gas to a dewpoint of +30 °F / -1 °C or lower.
iii) Equipment such as shell-and-tube heat exchangers may have crevices which prevent rapid draining and mechanical
drying. Extended drying may be required.
iv) When flushing with condensate, boiler feed water or demineralized water it is essential that all surfaces are flushed.
The quantity and velocity of the flushing liquid depends on the equipment volume.
v) Removing water or drying by blowing with hot air or gas shall not be performed unless the flushing has been done
with condensate or demineralized water.
vi) When appropriate, consider the use of a biocide to minimize the risk of MIC.

6.1.3 Any deposits on non-insulated surfaces shall be removed. Further measures are not required
on non-insulated surfaces. Insulated stainless steel equipment provided with a correct
paint system under the insulation needs no further treatment. Non-painted, insulated
stainless steel equipment shall (regardless of the temperature of previous operation) be
treated as follows:
i. Wet insulation or insulation in bad condition shall be removed.
ii. Dry insulation in good condition provided with zinc-free metal cladding shall have
the seams in the sheeting, including rivets and fixing screws, sealed to obtain a
moisture-tight and vapour-tight covering. Where galvanized sheet metal has been
used for cladding, it shall be removed and replaced by either metallic jacketing
(i.e. aluminium or austenitic stainless steel) or by non-metallic jacketing (i.e.
wrapped weather-protective covering).
iii. Dry insulation in good condition, covered with a bituminous or similar type
weather protection or with a hard-setting composition shall be inspected for the
presence of cracks and voids which shall be repaired with metallic jacketing
materials according to PTS 15.13.01.

6.2 COPPER AND COPPER ALLOYS

Equipment of copper and copper alloy shall be thoroughly cleaned and dried, and closed for
preservation. Particular attention shall be given to remnants of deposits (e.g. organic debris)
which could possibly generate ammonia, resulting in stress corrosion cracking.

6.3 ALUMINIUM

Aluminium equipment shall be kept clean and dry.


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6.4 NICKEL, NICKEL ALLOY AND NICKEL STEEL

Nickel, nickel alloy and nickel steel equipment shall be cleaned and kept dry. Nickel alloys are
susceptible to pitting corrosion and the precautions given in Section 6.1 shall also apply to
nickel, nickel alloy and nickel steels.

6.5 TITANIUM, ZIRCONIUM AND TANTALUM

Titanium, zirconium and tantalum parts/equipment shall be cleaned and protected against
mechanical damage.

6.6 PLASTIC AND RUBBER

6.6.1 Weather shielding shall be required for all plastic and rubber- based materials.

6.6.2 Rubber-lined equipment shall be protected against exposure to direct heat or radiation by the
sun, either by shielding or covering (allowing free circulation of air around the equipment) or
by keeping it filled with fresh clean water.

6.6.3 Freezing of the water shall be prevented either by complete drainage of the water or by
provision of sufficient heat to prevent freezing.

6.6.4 Protection against mechanical damage shall be required.


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7.0 PRESERVATION PROCEDURES FOR SPECIFIC EQUIPMENT AND FACILITIES

7.1 GENERAL

7.1.1 In preparing a preservation procedure, consider internally protecting associated equipment


collectively as a module, rather than individual. Specialist advice shall be sought from the
Owner on the preservation of items not specifically covered in this section.

7.1.2 For static equipment, piping and civil items, it is recognized that the requirements for short-
term preservation can be, in many cases, the same as would be needed for long-term
preservation. Therefore the requirements for short-term and long term are combined under
the single heading of short/long-term preservation.

7.1.3 Utilities and service items may be preserved with de-aerated clean water treated to the extent
required by the type of unit concerned in accordance with the procedures recommended in
Appendix 4. For preservation of specific materials can be referred to Section 6.

7.1.4 For rotating equipment, plant-mounted instruments and electrical equipment,


recommendations are given for temporary, short-term and long-term preservation.

7.1.5 Winterization shall be considered whenever equipment and/or piping is preserved by filling
with water. For some applications, electrical trace heating may be considered as an
alternative.

7.1.6 Details for methods of protection described in the preservation procedures can be referred to
Appendix 4.

7.2 STATIC EQUIPMENT AND PIPING

7.2.1 Preservation procedure for the following static equipment and piping shall be in accordance
with Appendix 4A:

i. Shell-and-tube heat exchangers coolers, condensers


ii. Air-cooled heat exchangers
iii. Vessels and columns
iv. Boilers
v. Piping and fittings
vi. Valves and attachments
vii. Stuffing box packing
viii. Gaskets
ix. Flanges
x. Relief valves
xi. Cooling water systems
xii. Fire-fighting systems
xiii. Flares and flare lines
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7.3 ROTATING EQUIPMENT

7.3.1 There are different preservation options shall be considered for rotating equipment:
i. Preservation of complete rotating equipment in-situ (offshore/plant)
ii. Preservation of rotating equipment in-situ, but some subassembly (e.g. rotor)
removal and storage in controlled environment
iii. Preservation of complete rotating equipment by removal and storage in
controlled environment

7.3.2 Preservation procedure for the following rotating equipment shall be in accordance with
Appendix 4B:
i. Centrifugal pump
ii. Reciprocating pump
iii. Compressors and blowers
iv. Gas turbines
v. Internal combustion (Gas and diesel) engines
vi. Bearings/Gears/Couplings
vii. Anti-friction bearings

7.4 MIXING

7.4.1 Preservation procedure for the following mixing equipment shall be in accordance with
Appendix 4C:
i. Mixers
ii. Rotating disc contactors
iii. Side entry mixers

7.5 STORAGE TANKS AND CIVIL ENGINEERING ITEMS

7.5.1 It is impractical to control the internal environment in storage tanks. The usual preservation
procedure is to drain, clean, and dry. Good ventilation reduces corrosion by keeping the
interior dry and preventing the accumulation of corrosive fumes.

7.5.2 Preservation procedure for storage tanks and civil engineering items shall be in accordance
with Appendix 4D.

7.6 INSTRUMENTATION AND ASSOCIATED EQUIPMENT

7.6.1 A differentiation is made between instrumentation locally installed in the plant (including local
cabinets), further referred to as 'plant instrumentation', and instrumentation installed in
control rooms, basements, auxiliary rooms and analyser houses, further referred to as 'indoor
instrumentation'.

7.6.2 Preservation procedure for the following instrumentation and its associated equipment shall
be in accordance with Appendix 4E:
i. Plant instrumentation
ii. Indoor instrumentation
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Page 20 of 43

7.7 ELECTRICAL EQUIPMENT

7.7.1 No special action is required for temporary preservation of electrical equipment unless
otherwise required by the equipment Manufacturer. Normal maintenance and checking shall
be applied.

7.7.2 Preservation procedure for the following electrical equipment shall be in accordance with
Appendix 4F:
i. Electric motors
ii. Generators
iii. Transformers
iv. HV and LV switchgears
v. Rectifiers and inverters
vi. Batteries
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Page 21 of 43

8.0 MONITORING OF PLANT STANDING IDLE

8.1.1 Throughout the period in which plant or equipment is standing idle, regular visual inspection
and some operational activity shall be conducted at regular intervals.

8.1.2 Monitoring activities of the following items shall be in accordance with Appendix 5 and
register as per Appendix 3:
i. Safety and security
ii. Stationary equipment and piping
iii. Rotating equipment
iv. Storage tanks and civil engineering items
v. Instrument equipment
vi. Electrical equipment
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9.0 PREPARATION FOR SERVICE

9.1.1 Preparation for service of plant which has been standing idle shall be undertaken safely and
in accordance with good engineering practice. Before start-up, the line-up of the unit has to
be in accordance with the latest revision of the Process Flow Schemes (PFSs) and Process
Engineering Flow Schemes (PEFSs).
The preservation procedures used for the equipment and piping should be reviewed to ensure
proper cleaning and preparation for start-up.
The removal of petroleum-based protective (degreasing) can be achieved by using either low
flash point hydrocarbon solvents or water based chemicals comprising of caustic, phosphates,
carbonates, and water soluble surfactants to ensure no fire and explosion risk.
VPI powders are flammable and careful and thorough removal, either by air blasting or water
washing, is necessary as a safety precaution before starting up fired equipment. This applies
equally where welding on plant may be required before recommissioning.

9.1.2 Preparation for service procedures of the following items shall be in accordance with
Appendix 6:
i. Static equipment
ii. Rotating equipment
iii. Storage tanks and civil engineering items
iv. Instrumentation equipment
v. Electrical equipment
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10.0 BIBLIOGRAPHY

In this PTS, reference is made to the following Standards/Publications. Unless specifically


designated by date, the latest edition of each publication shall be used, together with any
supplements/revisions thereto:

PETRONAS TECHNICAL STANDARDS


Index to PTS PTS 00.01.01
Requirements, General Definition of Terms, Abbreviations & PTS 00.01.03
Reading Guide
Drainage and Sewer Systems for Onshore Facilities PTS 11.12.03
Field Inspection Prior to Commissioning of Mechanical PTS 12.02.01
Equipment
Side-Entry Mixers for Storage Tanks PTS 12.22.05
Hot-Tapping on Pipelines, Piping and Equipment PTS 12.30.07
Field Commissioning and Maintenance of Electrical PTS 13.02.01
Installations and Equipment
Protective Coatings and Linings PTS 15.20.03
Thermal Insulation (Amendments/Supplements to the CINI PTS 15.13.01
Handbook)

INTERNATIONAL STANDARDS
Steel and Steel Products – Inspection Documents ISO 10474
Quality Management Systems - Requirements ISO 9001
Guidelines for the Mothballing of Process Plants NACE MTI 34
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APPENDIX 1: PRESERVATIVE FLUIDS *

Preservative Fluids Properties


PETRONAS MOTOLUB CS3 Available in four viscosity grades (10W, 20, 30 and 40)
Oils** and can be used to protect non-turbocharged
internal combustion engines during storage by
replacing the normal service lubricant for a short
period before shutdown.
PETRONAS Jenteram HC Available in five viscosity grades (32, 46, 68, 78 and
Oils** 100) and are used for the long-term preservation of
steam turbines.

NOTES:
* Reference is made for purpose of example.
** PETRONAS MOTOLUB CS3 Oils and PETRONAS Jenteram HC Oils are PETRONAS lubricant product marketed by
Petronas Lubricant International Sdn. Bhd.
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APPENDIX 2: TABULATION FOR PRESERVATION PROCEDURES


PRESERVATION ROUTINE
FREQUENCY
EQUIPMENT FLUID PROCEDURE ESTIMATED PREPARATION ESTIMATED MAINTENANCE AND
SERVICE AND
NO. HANDLED COST FOR SERVICE COST INSPECTION DURING
Internal External DONE BY
PERIOD OF IDLENESS
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APPENDIX 3: INSPECTION AND MONITORING OF PRESERVED EQUIPMENT TABLE


Pre- Preservation Details Condition Monitoring
Preservation
Equipment
Preliminary Date of Preservation Application Duration of Date of Test/Inspection Acceptance Post-preservation
Tag
Inspection preservation material methods Preservation monitoring conducted criteria inspection findings
Findings
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APPENDIX 4: PRESERVATION PROCEDURE FOR EQUIPMENT AND FACILITIES

APPENDIX 4A: STATIC EQUIPMENT AND PIPING

No Equipment Temporary Preservation Short/Long-Term Preservation


i Shell and Drain inventory, then purge both shell side and 1. Clean all heat exchangers thoroughly and then dry.
Tube Heat tubes with nitrogen and maintain under nitrogen 2. Preserved by applying appropriate oil coating product, dry gas oil, inhibited water or VCI powder (blown into the tubes
Exchangers pressure. Special attention is needed to remove or hang small bags of VCI);
Coolers, liquids trapped at the bottom of vertically hanging 3. Preserve heat exchangers made of copper alloy or stainless steel by cleaning, drying thoroughly using potable water
Condensers hairpin bundles. with chloride ions < 2 ppm and then sealing up;
4. With copper alloys, particular attention should be given to remnants of organic debris that may degrade to produce
For heat exchangers in water services, preservation ammonium compounds;
can be achieved by filling the exchanger with water 5. With stainless steel, particular attention should be given to remnants of water or deposits, the effect of which can be
treated by corrosion inhibitors, pH booster and very detrimental (see Section 6.0);
suitable biocide. 6. During periods of severe freezing, nitrogen may be used to maintain the required pressure.
7. External protection procedure should followed Section 6.0.

ii Air Cooled Drain the fluids, then purge with nitrogen and 1. Clean and flush the tubes and headers. Hang small bags of VPI powder in the headers and then close up;
Heat maintain under nitrogen pressure. Check lubrication 2. If oil cannot be tolerated for process reasons, the equipment shall be dried and preserved with inert gas or dry air at
Exchangers of transmission and run the fans for about one hour slight overpressure;
every week 3. Fan bearing should be greased, and fan blades should be blocked to prevent rotation. Clean fan blades and preserve
metal blades with rust preventive, or remove to store and preserve with rust preventative. Preserve transmission
actuator and drive as recommended in Section 7.3;
4. Cover the bundle completely.
iii Vessels and 1. Drain the inventory 1. Vessels and columns shall be drained out. They shall then be cleaned, dried and purged;
Columns 2. Purge with nitrogen and maintain positive 2. They may be preserved with dry inert gas, desiccants, VPI powder or oil preservant.
nitrogen pressurized (~10 psia) 3. The vessel or column shall then be properly closed up;
3. Associated relief valves can be left in place and 4. All inlet, outlet, vent, relief, etc. nozzles of the vessel can be plugged/blanked or covered over with heavy polyethylene
serviced according to the schedule for normal sheet;
operations. 5. Associated relief valves can be left in place or removed. If left in place, the relief valves shall be spaded off. If removed,
the nozzles shall be blanked off (refer to relevant Appendix 4A (vi))
6. Threaded openings shall have metal plugs of metallurgy equal to the component being capped or plugged;
7. Lubricate door hinges, grease nipples, davits and fastener;
8. Vessel insulation and sealing shall be checked and all defects rectified to ensure no corrosion under insulation (CUI)
9. All ball valves shall be locked in open position.
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No Equipment Temporary Preservation Short/Long-Term Preservation


10. Externally insulated vessels and columns require to remove the insulation when serious corrosion on the steel surface
is revealed during inspection. The external steel surface shall be coated with a suitable paint after removal of
insulation.
iv Boilers Keep in operation on warm stand-by. Condensate 1. Flue gas side cleaning: If sulphur containing fuels have been burned, carry out a thorough neutralization (NH 3OHand
systems should be kept in operation. Due attention NaHCO3) cleaning and dry procedure;
should be given to winterizing in view of the 2. Flue gas side preservation: The flue gas side should be ventilated by leaving open access doors and dampers; the stack
potentially lower system heat loads. draught should also be utilized if possible;
3. Steam/water side: For indefinite long term storage, dry storage is recommended. For periods up to about one year
NOTE: Whilst this could be acceptable for short shutdowns, either dry or wet storage may be applied. Wet storage is easier to implement but routine water testing is necessary.
the costs may be high. Cleaning and neutralizing the acidic Heating will also be necessary if freezing conditions are expected;
constituents on the flue gas side with ammonia, and laying 4. Wet storage of the steam/water side: Fill the boiler and superheater completely (until vent overflow) with water
up the water side under specially prepared wet or dry
containing an approved oxygen scavenger, maintaining a pH above 10. Boiler feed water shall be de-aerated and
conditions are the alternatives.
dosed prior to filling; it should be sampled once each week for 4 weeks then once in 2 weeks, or as considered
necessary. Over dose if necessary to maintain minimum conditions throughout. Connect a nitrogen supply to the
highest vents and maintain overpressure of 10-50 mbarg;
5. Dry storage of the steam/water side: After the flue gas side cleaning operation, the boiler shall be drained. If clean
sulphur-free fuels, have been fired, blow the boiler empty from a pressure of 3-5 barg. Ensure that no carry-over to
the superheater occurs. Dry non drainable pendant superheaters by using steam or electric heaters or by vacuum
drying. Thoroughly dry the boiler and superheater by blowing with dry air or nitrogen, or use a de-humidifier until
existing air humidity is consistently less than 35%. Flush the air out with nitrogen until the oxygen level is less than 1%
by volume. Maintain a nitrogen overpressure of 100-500 mm water gauge. Alternatively, suitable VCI can be used.
6. For period up to 5 years, insulation should be left in place. Inspection and repair the insulation where necessary to
prevent the ingress of water. Where the lay-up period is for 5 years or more, insulation should be removed from
piping and a complete paint system applied.
v Piping and For normal shutdown procedure inspect at regular 1. All piping internals shall be flushed and properly drained. Carbon steel lines should be filled with dry air, then sealed
Fittings intervals and apply any particular safety measures up. For oxygen and chlorine lines, filling with dry inert gas is recommended. Ensure no solid particles or traces of oil
considered necessary. It is good practice to ensure can get into the air or inert gas;
that all liquid piping receives an adequate dosage of 2. Piping in water service can be flushed, drained, and dried, then left as-is, or it may be blown with nitrogen and sealed
corrosion inhibitor before the shutdown. up, continuously purged with dry air, or nitrogen blanketed. The system can also be left full of deaerated or inhibited
water. Piping in hydrogen service can be oil flushed and drained, left full of oil, nitrogen blown and isolated, or
nitrogen blanketed;
3. Steam lines should be drained, then preserved with dry air. If left filled with water, ensure that water is chemically
treated and adequate winterization and thermal relief provisions;
4. Piping constructed of material other than carbon steel shall be cleaned, dried and sealed; see procedures for special
materials in Section 6.0;
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No Equipment Temporary Preservation Short/Long-Term Preservation


5. For process piping where the supporting structure is not designed to carry a full liquid load, dry out thoroughly. For
long lines, it may be necessary to install additional drains at strategic points by "hot-tapping". Hot tapping shall comply
with PTS 12.30.07);
6. For equipment or piping systems where water is used for cleaning or pressure testing, the water should have
antifreeze medium added unless the water is completely drained off;
7. The integrity of pipe supports in the piping system shall be checked to ensure no undue stress/strain on piping system
and possibility of damage to the connected equipment.
8. Pig launchers and receivers shall be treated as the piping / pipeline system in which they are installed.
vi Valves and Valve spindles, gear box manual valve, bolts and nuts 1. Valves and attachments are preserved together with and in the same manner as the system in which they are
Attachments should be protected with appropriate rust incorporated, or by the same procedure applying to the process equipment with which they are associated. Valves
preventative. All valves actuators should be covered should be left slightly open to avoid metal to metal contact, wherever possible; diaphragm valves shall be left in the
during the period of preservation. fully open position;
2. Valve packing is left in place without further attention during the period of idleness;
3. Relief valves that discharge to the atmosphere should be sprayed with rust preventative, and the discharge side should
be sealed with a plastic cover. For indoor storage; spade off the flanged connections and remove the relief valves for
cleaning, servicing and indoor storage;
4. Be sure that steam and water connections to equipment are blinded;
5. All ball valves shall be locked in open position. Hanger support / spring hangers shall be kept in locked position.
6. All valves shall be preserved in both open and closed position, valves supplied for stock to be preserved for long term
storage, all exposed valves spindles shall be covered with grease tape, Teflon-based lubricant and vulcanizing tape or
equal;
7. Gate valves shall be stored and installed in closed position, globe valves shall be locked in open position.
vii Stuffing Box Leave all packings intact. Remove all metal-braided and graphite-fibre packings and replace with non-metallic packings. Otherwise, leave intact.
Packings Attach a metal tag to the stuffing box to indicate that the packing needs renewal at the time of recommissioning.
viii Gaskets Leave all gaskets intact. Leave all gaskets intact. Gasket/O-rings on instrument equipment shall be greased with acid free Vaseline and equal.

ix Flanges No action required. Clean thoroughly, then wrap moisture-proof tape round the aperture between adjacent faces of the flange joint. Apply
appropriate rust preventative type to nuts and exposed threads of studs. All broken flanges shall be fitted with metal
covers and preserved with appropriate rust preventative type.
x Relief Valves Normal shutdown procedure Leave them in place or spade off the flanged connections and remove the relief valves for cleaning, servicing and indoor
storage.
xi Cooling Water Keep in operation. If this is not possible, drain the 1. In many cases it may be preferable to keep cooling water systems operational.
Systems system and refill with inhibited low chloride content
water.
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No Equipment Temporary Preservation Short/Long-Term Preservation


2. When shutting down a closed-loop cooling water system, adequate measures shall be taken to maintain the required
inhibitor levels. The system shall be winterized and regularly inspected. It may be advisable first to drain and clean the
cooling tower basin, and then refill with inhibited make-up.
3. Where fin-fan systems are used the fan drive motor should be removed, cleaned, then preserved in accordance with
the requirements for rotating equipment, see Section 7.3. All unpainted external metal parts should be painted or
preserved.
4. Open cooling water systems using sea or river water may be stopped only when all vital equipment items, such as heat
exchangers, have been isolated. These should be cleaned and preserved by dosing the system with an inhibitor. The
seawater side of the heat exchangers should be drained and this side filled with deaerated fresh water.
xii Fire Fighting Keep all systems functional. 1. Automatic systems should be kept on 'manual' or 'de-energized'/'blocked-in'. Fixed fire-fighting systems should be
Systems kept functional and energized for about 15 minutes every two weeks;
2. Adequate measures shall be taken to winterize where necessary.
xiii Flares and 1. Where all necessary provisions have been made, lower the flare, clean and inspect for iron sulphide corrosion. Should this be detected, hydrojet the flare and dry out.
Flare Lines 2. Spade off the flare and flare gas system and purge with nitrogen. Check earthing and lightning protection.
3. Flare tips provided with a refractory should be removed to the warehouse for storage; alternatively, the refractory shall be protected against water ingress.
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APPENDIX 4B: ROTATING EQUIPMENT

No Equipment Temporary Preservation Short -Term Preservation Long-Term Preservation


i Centrifugal Fill the bearing housings with service oil/grease as 1. Clean and dry the pump internally; 1. Flush pump with appropriate rust preventative type;
Pump appropriate and rotate shafts weekly. 2. Flush the pump and drain the pump and seal system 2. Clean and dry the casing inside and pump internals
with appropriate rust preventative type; thoroughly, then preserve with appropriate rust
3. Seal the suction and discharge connections carefully preventative type. Drain oil-lubricated bearings and
and mark the covers/blinds; refill with appropriate rust preventative type, then plug
4. Fill the bearing housings with appropriate rust the vents on the bearing housing;
preventative type 3. Clean out grease-lubricated bearings and repack with
new grease;
The shaft should be rotated during filling to ensure 4. Where a stuffing box is fitted, remove the old packing,
complete coating of the surfaces in contact. lightly grease the stuffing box then insert two new non-
1. Where a stuffing box is fitted, replace the packing with metallic packing rings and the gland, and tighten
non-metallic packing; slightly;
2. Fill the pump to 10 - 50% of internal volume with 5. Where possible mechanical seals should be removed;
appropriate rust preventative type; 6. Plug all open ports in the gland plate;
3. Plug vents on the bearing housing; 7. Mask the gap between the gland plate and shaft, or
4. Rotate the shaft regularly (at least every two weeks). shaft sleeve;
8. Open gear couplings, clean out and refill with new
grease; clean outside of couplings and preserve with
appropriate rust preventative type;
9. Spade off all pumps in/outlets;
10. Rotate shaft regularly (at least monthly) and offset by
90°;
11. Inspect after 12 months and then at yearly intervals.

In cases of long term preservation of large multistage


pumps, the rotor, cartridge assembly may be removed and
stored in controlled environments.
1. If stored indoors, such rotors should be coated with
coating of rust preventative and stored vertically
2. If stored outdoors (possibly adjacent to the machine),
the rotor can be immersed in a vertical position within
a container filled with rust preventative oil.
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ii Reciprocating Treat as for centrifugal pumps. 1. Drain pump,
Pump 2. Flush pump with appropriate rust preventative type;
3. Remove the cylinder and valve covers;
4. Treat the internal surfaces with appropriate rust preventative type if no moisture is present;
5. Replace the covers and rotate the crankshaft through several revolutions by hand and leave offset by 90°;
6. Remove stuffing box packing, then treat shaft with appropriate rust preventative type & mask the opening between
shaft and gland plate;
7. Fill all lubricators with appropriate rust preventative type and pump through,
8. If gearbox is fitted, refer to Appendix 4B (v)/Appendix 4B (vii) for preservation of enclosed gears,
9. Do not rotate crankshaft during storage,
10. Fill the crankcase with appropriate rust preventative type,
11. Run the oil pump every month.
iii Compressors Compressors Rotary (Centrifugal) Compressors/Blowers General
and Blowers 1. Isolate compressor from the process 1. Purge the gas side with nitrogen and maintain a 1. If rotors cannot be turned periodically, the
connections; nitrogen blanket; rotor/cartridge assembly is removed and stored in
2. Purge the gas side with nitrogen and maintain 2. Add VSI concentrate to lubricating/seal oil and operate controlled environment
a nitrogen blanket; the system weekly for about 30 minutes; 2. The rotors shall be stored in canister preferably in
3. Operate the lubricating oil system once a week 3. Drain the cooling system and refill with inhibited water vertical position with rust preventative coating applied
for about 30 minutes; or, if freezing is possible, drain system, dry it and then to all exposed area and polished surfaces
4. Rotate the shaft once a week simultaneously close it up; 3. The auxiliary system including gas seal skid shall be
with the operation of the lubricating/seal oil 4. Rotate the shaft weekly simultaneously with the positively isolated, drained, purged and maintained
system; operation of the lubricating/seal oil system; with nitrogen pressure.
5. Maintain a nitrogen purge on lubricating/seal 5. Maintain a nitrogen purge on lubricating/seal oil tanks.
oil tanks. Rotary (Centrifugal) Compressors/Blowers
1. Inject condensers/coolers with appropriate rust
NOTE: preventative type and then close up;
Gas turbines with standby duty requirements and operating in 2. Drain cooling system and flush until clean, then dry
corrosive or humid environments should have the compressor
thoroughly with forced hot dry air and close up;
section coated as recommended by the gas turbine Manufacturer.
3. Add VSI concentrate to oil systems;
4. Remove rotors, clean thoroughly. Apply appropriate
Reciprocating Compressors rust preventative type and either store on blocks in a
1. Add VSI concentrate to the lubricating oil and operate warehouse or store on blocks in a container under
the lubricating oil system for about 30 minutes, nitrogen pressure;
simultaneously running the compressor unloaded for 5. Clean and dry the compressor/blower internals and
the same period; bearings then spray or brush on appropriate rust
2. Purge the unit with nitrogen and maintain under a preventative type;
nitrogen pressure;
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3. Close suction and discharge lines; 6. Replace the top casing and seal both ends. Hang small
4. Maintain a nitrogen purge on distance pieces, or hang bags of VPI powder inside the casing, blank off process
small bags of VPI powder inside the distance pieces; piping, seal all vents and ensure all is air-tight;
5. Operate the lubricating oil system weekly for about 30 7. Purge the casing with nitrogen;
minutes, at the same time turning the unit over. 8. Open the gear couplings. Either clean out and refill with
new service grease, or preserve with appropriate rust
preventative type.
9. Clean the external surfaces of couplings and preserve
with appropriate rust preventative type.
10. Depending on the anticipated period of idleness and the
local environment, cocooning the compressor casing and,
separately, its rotor may be considered worthwhile as an
additional measure.
Reciprocating Compressors
1. Drain the cooling system and flush until clean, then dry
thoroughly with forced hot dry air and close up. For a
glycol system, maintain the system;
2. Drain lubricating oil systems and flush until clean, then
refill with appropriate rust preventative type of the
appropriate viscosity and operate systems for about 30
minutes, simultaneously running compressor unloaded
for the same period;
3. Remove valves and store in gas oil;
4. Where applicable, remove V-belts and preserve pulleys;
5. Blank off process piping and ensure all is air-tight;
6. Purge with nitrogen and maintain under nitrogen
pressure. If it is not possible to maintain nitrogen
pressure, then;
7. Remove pistons and rods and preserve with appropriate
rust preventative type;
8. Hang small bags of VPI powder inside the valve ports
and seal up the ports;
9. Clean and dry all internal surfaces in contact with the
gas, including the cylinder walls, then spray or brush on
appropriate rust preventative type;
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No Equipment Temporary Preservation Short -Term Preservation Long-Term Preservation


10. Hang small bags of VPI powder inside crankcase above
the oil level, then seal off the vents and ensure all is air-
tight;
3. Clean and dry the connecting rods, then spray or brush
on appropriate rust preventative type, hang small bags
of VPI powder on the connecting rods.
iv Gas Turbines Follow normal shutdown procedure in line with Areo Derivatives and Industrial Gas Turbines Areo Derivatives
Manufacturer's recommendations and as 1. Wash out internal spaces by hosing with a 1. Thoroughly wash out and dry. Remove the turbine and
recommended for short-term preservation. water/detergent mixture, cranking the rotor at the same store in a warehouse in an air-tight box under nitrogen
time. Ensure the combustion chambers, transition pressure, or return to the Manufacturer for
sections and turbine blading are also thoroughly washed; preservation at their works.
2. Start the turbine and run normally for about 15 minutes 2. Remove power wheel, clean thoroughly and block for
to dry out the unit, then allow to cool down; storage. Flush with appropriate rust preventative type
3. Hang small bags of VPI powder in inlet plenum and close for warehouse storage, or store in an air-tight box
up turbine inlet; under nitrogen pressure;
4. Add VSI concentrate to the lubricating oil and run the 3. For normal oil systems: drain and flush until clean, then
system for about 1 hour; this applies where a normal oil fill with new oil plus VSI concentrate; for synthetic oil
is being used. Seek specialist advice for synthetic oil systems: seek specialist advice;
systems; 4. Clean and dry internals and bearings, and all internal
5. Fill all oil systems to maximum levels with rust surfaces, then spray or brush on appropriate rust
preventative oil. preventative type;
6. Circulate all oil systems in order to wet all system 5. Replace the casing, then seal up and preserve as for
surfaces. other turbines.
7. Seal breathers and other openings to the oil systems. 6. Ensure acoustic hood is clean and dry, then hang small
8. Over grease anti-friction bearings and linkages till fresh bags of VPI powder inside and close up air-tight. Treat
grease appears externally. the exhaust arrangement in a similar manner.
9. Install electric heaters in exhaust plenum and hang small
bags of VPI powder inside. VPI shall not come in contact Industrial Gas Turbines
with or be too close to heaters to avoid decomposition;
Treat as for areo derivatives, or
10. Install electric heaters within the acoustic hood
1. Thoroughly wash out and dry as for short-term
enclosure;
preservation;
11. Close up the unit and ensure that the electric supply to
2. Hang small bags of VPI powder inside the inlet and
heaters is maintained;
exhaust plenums and close up air-tight;
12. Rotating the rotor at weekly or other regular intervals of
3. Clean and dry all levers, valve stems and other exposed
time is optional; refer to Manufacturer's
metal parts around the casing, then apply grease;
recommendations.
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No Equipment Temporary Preservation Short -Term Preservation Long-Term Preservation


13. Protect machine externally for: 4. For the acoustic hood and exhaust arrangements treat
- Water stagnation on enclosure roof as for areo derivatives. Removing the rotor for
- Built up of insect, bird nest through air filter and preservation separately may also be considered.
enclosure filter opening
v Internal Run the engine weekly at normal operating 1. When the engine is warm, drain the lubricating oil 1. When the engine is warm, drain the lubricating oil
Combustion temperature for 30 minutes. system and fill with appropriate rust preventative type system and fill with appropriate rust preventative type
(Gas and of the appropriate viscosity, then run engine for about of the appropriate viscosity;
Diesel) Engines 30 minutes; 2. Drain the cooling water system, flush out, and then fill
2. Hang small bags of VPI powder in the inlet and exhaust with water to which appropriate rust preventative has
manifolds, and then close up; been added;
3. Drain the cooling water system, flush out, then fill with 3. Run the engine for about 30 minutes at normal speed,
inhibited water depending on the anticipated storage taking it up to top speed a few times before stopping;
temperature, or drain system, dry it and close up; then drain the water and blow dry the cooling-water
4. Disconnect the battery; jacket with air;
5. Do not rotate crankshaft during storage. 4. Drain the fuel tanks and fuel filter housings. Fill the diesel
engine tanks with gas oil. Fill petrol engine tanks with
lead-free petrol. Prime the fuel systems;
5. Hang small bags of VPI powder in the inlet and exhaust
manifolds, then close up;
6. Seal all vents, generators, starter motors, air filters,
dipsticks,
7. Disconnect and remove the battery
8. Do not rotate crankshaft during storage.
vi Bearings/ Normal shutdown procedure or alternatively: Bearings: As for short term:
Gears/  Bearings: Fill bearing housing with service 1. Oil-lubricated bearings shall be drained and filled with Warehouse storage is preferred wherever possible and a
Couplings oil/grease as appropriate. appropriate rust preventative type and run for a short thorough inspection every 12 months.
 Enclosed gears: Add VSI concentrate to the while to ensure complete coverage, then closed up;
lubricating oil. 2. Grease-lubricated bearings should be cleaned and re-
 Open gears: Clean, dry, then spray or brush greased with the appropriate grease, turned, then closed
on an appropriate rust preventative type. up thoroughly.

Enclosed gears:
1. Drain the oil from gearbox at operating temperature,
then refill with appropriate rust preventative type;
2. Operate the gear train for about 15 minutes;
3. Where the above procedure is not possible:
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No Equipment Temporary Preservation Short -Term Preservation Long-Term Preservation


 Hang small bags of VPI powder inside the gearbox
and blank off all the openings and ensure that the
gearbox is sealed air-tight;
 Treat the outside of the gearbox, including all sealing
materials, with appropriate rust preventative type.

Open gears/Flexible couplings: Clean, dry, then protect by
applying two coats of appropriate rust preventative type,
allowing an interval of at least six hours, preferably longer,
between applications for solvent evaporation.
vii Anti-Friction To avoid staining of very large bearings use appropriate rust preventative type as follows immerse the bearing in the compound at a temperature of 100 - 120 °C for a sufficiently long
Bearings period to allow the bearing to attain bath temperature. Remove and allow to cool; then package and store.
PTS 15.20.16
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Page 37 of 43

APPENDIX 4C: MIXING

No Equipment Temporary Preservation Short -Term Preservation Long-Term Preservation


i Mixers 1. For vessels and stirrers, apply normal shutdown 1. Drain contents of vessel, clean, and then purge with dry As for short term with the addition of a thorough inspection
procedure; air; of the internals and protective every 12 months; or,
2. Check lubrication of thrust and footstep 2. Disconnect drive to stirrer shaft, then raise and chock preferably, remove stirrer shaft, transmission and motor for
bearings; stirrer shaft just sufficiently to free the load from the separate preservation and warehouse storage.
3. Run motor and stirrer slowly for a minimum of thrust and footstep bearings. Wrap annular gap with
one hour weekly. stout plastic film and tape;
3. Fill vessel with nitrogen under slight positive pressure;
NOTE: or, seal up and hang small bags of VPI powder inside.
Although the stirrer needs to run for 5 minutes only, the
requirements of the motor determine the running time
of the complete unit.
ii Rotating Disc 1. For vessel and stirrer, apply normal shutdown As for mixers, see Clause 7.4.1 As short term with the addition of a thorough inspection of
Contactors procedure; the internals and protective every 12 months. Leave shaft
2. Check lubrication of thrust and footstep in position. It may be necessary to provide some additional
bearing. exterior protection against mechanical damage.
iii Side-Entry 1. Normal shutdown procedure for stirrer relative Remove motor/stirrer assembly for separate preservation and warehouse storage.
Mixers to tank contents;
2. Check lubrication for stirrer shaft bearings and
pivots. If the tank contents are sufficient, run
motor and stirrer weekly for a minimum of one
hour for limiting swept arc clearances.
PTS 15.20.16
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APPENDIX 4D: STORAGE TANKS AND CIVIL ENGINEERING ITEMS

No Equipment Temporary Preservation Short/Long-Term Preservation


i Storage Tanks Keep all tanks and spheres operational. Should this 1. All products shall be removed from cryogenic storage tanks before preservation and this shall also be done for other
and Civil be impractical, short/long term preservation shall be tanks;
Engineering adopted. 2. Remove all sludge from bottom of oil storage tanks, then flush and clean. Other product storage tanks shall be
cleaned, and then dried out thoroughly;
3. Ensure tank or sphere is gas free, and then disconnect all line work to prevent electric current flow to other
equipment. Blank off all open connections. Check lightning protection;
4. Prevent rain water ingress under tank bottom by ensuring that sealing between foundation and tank bottom is in good
condition;
5. Floating roofs shall be supported on the high position supporting legs. Ensure that rainwater drainage is fully effective
by opening the drains and the emergency drain in the roof. Any rainwater that may be collected on the tank bottom
via the emergency opening in the roof shall be removed periodically; the roof shall be brought to the lowest level to
rest on legs, and the drain cleaned out;
6. Leave a number of manholes or other suitable openings near the bottom party open (25mm), and provide some
protection from rain and flying debris without obstructing air flow through the opening. All pressure/vacuum valves
shall be serviced;
7. Check emergency drain systems and plan to inspect at three monthly intervals;
8. Spheres shall be purged with nitrogen, and then maintained under nitrogen pressure;
9. Check external CP system and keep in operation;
10. If products cannot be removed from tanks or spheres, adequate measures shall be taken to ensure the safety of the
installation, particularly where the formation of explosive mixtures may occur during the period of idleness;
11. Proper measures shall be taken to prevent corrosion due to condensation and arising from contact of the product with
the surrounding atmosphere.
PTS 15.20.16
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APPENDIX 4E: INSTRUMENTATION AND ASSOCIATED EQUIPMENT

No Equipment Temporary Preservation Short -Term Preservation Long-Term Preservation


i Plant 1. The instrument power supply (air or 1. The instrument power supply shall stay on. 1. The instrument air supply shall stay on;
Instrumentation electric) shall stay on; 2. The block valves to the impulse lines shall be closed and 2. The block valves to the impulse lines shall be closed and
2. Continue with routine maintenance and the impulse lines shall be drained, including the pressure the impulse lines shall be drained, including the pressure
checking. chamber of the instruments, and the drain plugs shall be chamber of the instruments, and the drain plug shall be
left out. left out;
3. If the instrument power supply is switched off, the flow 3. Pneumatic instruments which are self-purging can
transmitters shall be removed and safely stored in an air- remain untouched;
conditioned and locked room. 4. If applicable, small bags of VPI powder shall be hung in
4. The body and plug of each control valve shall be treated the enclosures of the electronic instruments. The
in accordance with Appendix 4A (vi). The valve stem shall enclosures shall be sealed with good quality self-
be cleaned and protected with suitable grease. adhesive tape;
5. The body and plug of each control valve shall be treated
in accordance with Appendix 4A (vi) of this document;
6. The valve positioner shall be treated as an instrument.
The valve stem shall be cleaned and protected with
suitable rust preventative compound.
ii Indoor As for plant instrumentation, Appendix 4E (i), 1. As for the plant instrumentation, Appendix 4E (i), the 1. The electric instrument power supply shall be switched
Instrumentation and, if applicable, the air conditioning/ instrument power supply should stay on; off and the batteries shall be removed from the system;
purification system shall stay on. 2. Computer equipment and peripherals, however, should 2. The air-conditioning/purification system shall stay on but
be switched off. The batteries of the switched off the capacity can be trimmed to suit the loading after
supplies should be removed from the system. other equipment is removed/preserved.
PTS 15.20.16
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APPENDIX 4F: ELECTRICAL EQUIPMENT

No Equipment Temporary Preservation Short -Term Preservation Long-Term Preservation


i Electric Motors When anti-condensation heaters are fitted, they 1. When anti-condensation heaters are fitted, they shall be 1. Where electric motors are not installed inside a building,
should be switched on. switched on; they shall be protected against the weather. Where this
2. When sleeve-type bearings are fitted, the rotors shall be is not possible, they shall be removed to warehouse
jacked up with wooden blocks, and VSI concentrate storage;
added to the lubrication system; 2. Where anti-condensation heaters are fitted, they shall
3. When anti-friction bearings are fitted, they shall be re- be switched on;
greased in order to prevent moisture accumulation; 3. Where sleeve-type bearings are fitted, the lubrication
4. Brushes, if installed, shall be lifted off the slip rings and system shall be drained, flushed and filled with service
commutators. oil plus VSI concentrate;
4. Anti-friction bearings shall be re-greased in order to
prevent moisture accumulation. Brushes, if installed,
shall be lifted off the slip rings and commutators
5. Where a motor is required to be run periodically for
the preservation of the driven equipment, this shall be
done for a minimum of one hour.
ii Generators Where anti-condensation heaters are fitted, they 1. Where anti-condensation heaters are fitted, they shall 1. Generators installed outdoors shall be protected
should be switched on. be switched on. All other auxiliary supplies shall be against the weather or removed to warehouse
switched off; storage;
2. Where sleeve-type bearings are fitted, VSI concentrate 2. Where anti-condensation heaters are fitted, they shall
shall be added to the lubrication system. When anti- be switched on. All other auxiliary supplies shall be
friction bearings are fitted, they shall be re-greased; switched off;
3. Brushes, if installed, shall be lifted off the slip rings and 3. Slip rings shall be protected against the weather by
commutators. covering them with a suitable waterproofing material
such as 'cling-film' plastic wrapping;
4. For sleeve-type bearings the rotor shall be jacked up and
supported with wooden blocks;
5. The lubrication system shall be drained, flushed and
filled with suitable rust preventative type or with service
oil plus VSI concentrate;
6. Anti-friction bearings shall be re-greased;
7. Brushes, if installed, shall be lifted off the slip rings and
commutators.
PTS 15.20.16
PRESERVATION OF UPSTREAM PRODUCTION AND PROCESS FACILITIES January 2016
Page 41 of 43

No Equipment Temporary Preservation Short -Term Preservation Long-Term Preservation

NOTE:
Where it is required that a generator is run for the preservation of the
driver, this shall be done for one hour minimum. The unit should be
loaded as close as possible to full current.
iii Rectifiers and The equipment is to be considered as in normal 1. Inverters in general and chargers for nickel-cadmium 1. The equipment shall be de-energized where possible;
Inverters use and shall remain energized. batteries shall be de-energized where possible; 2. Chargers for lead-acid batteries may have to remain in
2. Chargers for lead-acid batteries shall remain energized service to float charge the batteries;
for 'float charging' the associated batteries; 3. Anti-condensation heaters, if fitted, shall be switched on.
3. When anti-condensation heaters are fitted, they should
be switched on.
iv Batteries Batteries are to be considered as if in normal use Whenever possible nickel-cadmium batteries shall be fully 1. Nickel-cadmium type batteries shall be disconnected and
and should be kept on float charge charged and then be disconnected. Lead-acid batteries shall taken out of service. They shall be discharged to a cell
remain on float charge. voltage of 0.6-0.8 V and then drained;
2. Lead-acid batteries of the vented and valve-regulated
types should remain on float charge. Alternatively
vented-type lead-acid batteries should first be fully
charged, then drained and flushed with distilled water;
3. Vent holes shall be sealed and the electrolyte stored for
future use in suitable containers. Reference should also
be made to Manufacturer's instructions.
v Transformers Transformers to be considered as in normal Transformers to be de-energized and isolated;
service and shall remain energized.
Dry-type transformers require heating when switched off. Deterioration of the core and insulation may otherwise occur due
to humidity;
1. The supply to tap changer control panels shall be switched off;
2. For protection of panels, a dry agent such as silica gel can be used.
vi HV and LV Switchgear is to be considered as in normal use Where possible, panel heaters shall be switched on. Switchgear shall be de-energized when a supply is not required;
Switchgear and shall remain energized.
Supplies to equipment that is not in use during the idle period shall be isolated and/or padlocked in the 'off' position;
For safety reasons live switchgear shall not be covered with plastic sheets;
PTS 15.20.16
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APPENDIX 5: MONITORING PLANT STANDING IDLE


Items Monitoring Activities
Safety and 1. Safety checks shall be carried out at specified intervals. Occasional spot checks should also be
Security considered;
2. Control rooms, switch houses, analyzer houses and other buildings which have been locked up
shall be checked and any signs of unauthorized use shall be investigated and corrective action
taken;
3. It shall be ensured that the electrical supply for lighting and minor power requirements continues
to function satisfactorily;
4. Evaporation of water from idle drainage systems can result in the fire seals being broken, with
consequent hazards.
Stationary 1. Desiccants, and the continued effectiveness of air/gas tightness, shall be checked;
Equipment and 2. Dissolved oxygen, pH, bacteria and residual concentration of treating chemicals (oxygen
Piping scavenger, biocide, anti-freeze, etc.) shall be checked;
3. It shall be ensured that furnace refractories and stack linings are dry and not freezing;
4. Preservation of all exposed metal surfaces shall be checked by visual inspection;
5. All items removed to warehouse storage shall be accounted for and their preservation should be
checked.
Rotating 1. It shall be checked that shafts are rotated at specified intervals;
Equipment 2. Lubrication and, where specified, oil circulation through the lubrication systems should be
checked at regular intervals;
3. Dissolved oxygen, pH, bacteria and residual concentration of treating chemicals (oxygen
scavenger, biocide, anti-freeze, etc.) shall be checked;
4. Desiccants, and continued effectiveness of air/gas tightness, should be checked, as should the
preservation of all exposed metal surfaces. It shall be verified that electric heaters and trace
heating continue to function satisfactorily;
5. Acoustic and thermal insulation shall be visually inspected;
6. All items removed to warehouse storage should be accounted for and their preservation checked.
Storage Tanks 1. Bottom drainage of storage tanks, floating roof drains and seal gaps shall be checked;
and Civil 2. The preservation of all wire ropes and slings taken into store shall be verified. External insulation
Engineering and fireproofing of steel support structures shall be inspected;
3. The painting and preservation of all exposed steelwork and metal surfaces shall be checked.
Instrument Plant Instrumentation
Equipment 1. Desiccants shall be checked regularly and be replaced as required;
2. The wrapping and sealing of instruments shall be checked regularly and be
repaired/replaced as required;
3. Stored instruments shall be checked to ensure that they are being kept in good order and are not
being misused for alternative applications (cannibalization).
Indoor Instrumentation
The air humidity and temperature shall be checked to ensure that it is being kept at the required
level and that the environment is being kept clean and dust-free. Batteries shall be maintained as
required.
Electrical 1. When motors are running periodically, the normal maintenance procedures shall be applied to
Equipment re-greasing anti-friction bearings;
2. Oil levels in sumps of sleeve bearings shall be checked and topped up when required. Anti-
condensation heaters shall be checked for proper functioning;
3. Desiccants, including those of transformer breathers, shall be checked every two months and
replaced when required;
4. Weather protection shall be checked for integrity, and repaired when required;
5. For non-hermetically sealed transformers, oil samples shall be taken once every 4 years. The oil
shall be filtered prior to re-energising a transformer;
6. The preservation of exposed metal surfaces shall be checked, and improved where
necessary;
7. The electrolyte level of batteries which are under charge shall be checked once every six months;
8. Impressed current CP systems shall be checked monthly.
PTS 15.20.16
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Page 43 of 43

APPENDIX 6: PREPARATION FOR SERVICE


Items Recommissioning Procedures
Stationary 1. All equipment shall be opened up for internal inspection. Areas of earlier corrosion attack shall be
Equipment logged and the wall thicknesses measured;
and Piping 2. For insulated equipment or systems, random inspections shall be conducted for corrosion under
insulation
3. Valve packings shall not need repacking but there may be certain exceptions, for example where
repacking after start-up would be inconvenient. In such cases the repacking of these shall be listed
as a priority;
4. Stuffing box packings will need replacing only where metal-braided packing is specified in Appendix
4A (vii);
5. Gaskets should not be replaced except if they have failed on pressure test;
6. All piping and equipment shall be system pressure-tested to the maximum operating pressure;
7. Under very special circumstances, pneumatic testing may be required. When this is the only
possible method, full safety precautions shall be taken. Refer to PTS 12.02.01 for details;
8. All relief valves shall be stripped, cleaned and shop-tested, and care taken to ensure each relief
valve is correctly located on plant before start-up;
9. All pre-recommissioning modifications to piping and equipment shall be pressure-tested to code
requirements before start-up.
Rotating 1. Rust preventative oil should be replaced by the service oil before equipment goes into service.
Equipment However, where lubricating/seal oil systems have been filled with clean service oil plus an inhibitor,
or appropriate rust preventative type, there should be no need to change the oil before start up.
2. Before test running turbines, precautions shall be taken to ensure the feed supply is clean and free
of trace particles that could damage the turbine blades.
Storage 1. Storage tanks shall be opened up for internal inspection, including a thorough examination of tank
Tanks and bottoms and pads. When considered necessary, tank pads shall be re-dressed to ensure that water
Civil does not accumulate near the tank shell.
Engineering 2. Insulated tanks shall be checked at random points for corrosion under insulation.
3. The Owner's specialists shall be consulted in regard to requirements prior to the recommissioning
of low-temperature storage tanks and piping.
4. Spheres should not need an internal inspection if the preservation procedures have been followed.
5. All wire ropes, slings and shackles shall be examined and proof-load tested after preservation, and
before being taken on plant for general or specific usage. Rust preventatives need not be removed
before installation, and once operational, the normal greases may be applied to the wire ropes
without danger of contamination.
Instrument 1. After a period during which temporary preservation was applied, no specific actions are required.
Equipment 2. After short-term preservation, complete loop testing shall be carried out, including the functional
testing of alarm, binary logic, safe guarding and control systems. Control valves shall be cleaned and
stroked.
3. After long-term preservation, computer equipment and telecommunication equipment shall be
fully tested. All flow transmitters shall be recalibrated. The plant `in-line' instruments shall be
removed, checked and cleaned as required.
4. Depending on the cleaning method for the piping, the 'in-line' equipment shall be temporarily
replaced by spool pieces.
5. After long-term preservation all plant instrumentation, including the instruments from store, shall
be removed, cleaned, checked and recalibrated as required.
Electrical For re-commissioning of electrical equipment after short, medium and long-term preservation periods,
Equipment the `Maintenance Inspection' requirements of PTS 13.02.01 shall apply. The relevant inspection and
test forms shall be filled out.