What You Should Do Before a Plant

Closure

Bernie Price
Tags: condition monitoring, inventory management, overall equipment effectiveness, workplace safety

Its happened the announcement that a major portion of your facility is being closed
for the foreseeable future. What do you do next?
1. Accept the news that your plant is facing an impending plant shutdown. It is not
necessarily a knockout for the plant or your career. Remember, in the often
uneven battleground called the global marketplace, just about anything can
happen. Be ready to get up and start fighting again.
2. Designate responsibility to an individual for writing a list of possible scenarios.
The individual should have enough clout to implement the chosen strategy, if
necessary.
3. Go to the top of the company and request that sufficient funds be made available
to execute the initial shutdown and preservation strategy.
4. Choose the right type of long-term equipment caretakers. Those selected are
often security or ex-supervisory types rather than experienced
operator/craftsmen with intimate knowledge of the equipment.
5. Dont allow critical components to be pirated (stolen for use elsewhere) if part of
a larger plant.
6. Remove all process materials. Even innocuous materials left in the unit in the
long term will likely cost five times more than at the initial shutdown. The current
operations people are familiar with all the hazards.
7. Seek expert advice on equipment preservation resulting in not getting the best
bang for the buck.
8. Involve the hourly workforce in the shutdown and mothball plan. Almost
unbelievably, our recent experience has been that if the decision to shut down at
some future date has been made, then involving operators and mechanics can
very much improve both the quality of the shutdown plan and its execution.
9. Not only record but clearly and physically mark what has been done to preserve
the item of equipment during deactivation. The reactivating crew (probably a
different group of people) can easily miss that a filter, line blind, internal
component, etc., has been removed or added with serious consequences at a
future start-up.
In our experience, idle plants with small crews operating at a very relaxed tempo can be
dangerous places. Make sure safety programs and routine audits are kept active to avoid
accidents.

Just as with any critical situation, a long-term strategic approach coupled with a series of
medium-term tactics and detailed plans are needed. You should also consider how long
the shutdown is probably going to last (guesstimate) and whether the plant will most
likely be restarted, sold as a complete unit or sold piecemeal.
Examine every item or class of equipment individually and write a specific initial
storage/mothball technique plus a methodology for ongoing maintenance.
For the purposes of this article, lets consider an item of equipment or a whole plant that
might restart as early as six to nine months but could also be several years.
Unused plants and equipment that are properly prepared for shutdown and left in fairly
good condition can retain much of their value. However, if a plant is left as is and
allowed to deteriorate, as is normally the case, much of it can be fit only as scrap in just
a matter of months. Engaging in a well-planned process of deactivation/mothballing can
be worthwhile either way, whether it should ever be reactivated or just sold for its
second-hand value at some future point.

Materials and Equipment You Will Need

Having a clear view of how the constant foes of galvanic/bio corrosion, mold, mildew,
etc., can be mitigated if not defeated is essential. Although much will depend on local
conditions, the wetter and colder situations are much more challenging in terms of
handling humidity, while blowing dust is an issue for those in the high desert regions.
For this article, we will consider a central United States or European location.
A useful analogy in developing a strategy is to compare what it takes to maintain fire. In
the case of fire, there are three essential legs: heat, a fuel source and oxygen. Likewise,
age-related deterioration involves a driving force (such as galvanic action), a conducting
medium (electrolyte) and oxygen. The fundamental approach to stopping or slowing this
age-related deterioration is to remove one or more of the three legs.
In simple terms, we aim to do the following:

Separate dissimilar metals.

Protect surfaces that could be attacked, even with a covering of only a few
molecules thick.
Dry out or remove the conducting medium (electrolyte air or gas). Corrosion
cannot occur when parts are stored in environments where the relative humidity
is held below 40 percent.
Remove any oxygen or sources of chemical or biological attack.

The materials we can use are:

Liquid protective waxes and liquid polyvinyl chloride (PVC) coating

These can be sprayed on any clean, dry surface to protect them. Wherever it is
applied, PVC will form a tough, flexible, waterproof skin that will withstand the

extremes of temperature, thermal shock, differential substrate movement and

impingement even when sprayed on webbing to form a cocoon.
Volatile corrosion inhibitors (VCIs) These generate protective vapors even
at room temperatures. They come in a number of convenient forms, including
time-release vaporizers, sprays, plastic bags and films, powders, oil additives and
coatings. They are adsorbed onto the metallic surfaces of the equipment (just a
few molecules thick), where they can prevent corrosion for up to two years. While
most VCIs are environmentally friendly and create no safety hazards for
employees, there are some that are suspected of being harmful. Most contain no
toxic substances, such as nitrates or chromates. (Note: Volatile organic
compounds should not be used in combination with a desiccant.)
Vapor space inhibitor (VSI) This is an oily concentrate that can be added to
lubricating oil systems (internal combustion engines, etc.) when equipment is not
going to be completely filled.
Heat-shrinkable plastic films These are ideal for enclosing individual
machines that have been cleaned and dried and have internal desiccants added.
VCI-covered polythene films These are used to wrap individual smaller
components.
Chemical oxygen scavengers These are frequently added to fresh water
used to displace more corrosive liquid in systems that cant be effectively cleaned
or dried out.
Chemical inhibitors These are added to liquids and chemicals and are
designed to remove unwanted products while preferentially inhibiting their attack
on the body of the container. (Antifreeze sometimes used in this process contains
them.)
Desiccants These include numerous substances (solids) that absorb water
from gases (air) or liquids.
Biocides These are used to prevent microbial growths in water and fuels such
as gasoline and diesel fuel.
Light waxes These are used as surface protectors for metals.
Sacrificial Anodes These are used in tanks that cannot be drained of their
contents.

The primary pieces of equipment are dehumidifiers. These are available in two forms:
those that work on the refrigeration principle and those that use two-cycle rotary
(wheel) heated desiccant absorption.

Strategies by Equipment Class

Before considering individual techniques, make a best guess of the duration and whether
it is going to be an attended monitored lay-up or a walk-away lay-up. This article is
simply a guide and is not intended to be totally comprehensive and detailed.

Tanks, Pressure Vessels and Pipework

It is essential that tanks, pressure vessels and pipework be left as clean and dry as
possible. Insert line blinds to create manageable zones that can be slightly pressurized

(0.5 psig+) using nitrogen or dry air. Include some small flow and arrange for some
simple telltale mechanism to show pressure flow and the level of humidity (indicator
cards). For large enclosures, use a commercial dehumidifier of an appropriate capacity.
For vessels, tanks and containments that must be kept full of liquid, some form of
oxygen scavenger or anti-biological growth chemical can be used (see boilers). If a
pipework system contains any traps, have its internals removed and clear all strainers.

Boilers
Boilers can be laid up using either the long-term dry method or the hydrazine wet lay-up
method, which involves leaving the wet side (boiler, economizer and super heater) full of
feed-treated water. The feed water is dosed with 15 percent hydrazine and then pHadjusted to raise the alkalinity to a minimum pH of 8.3. The fire side is supplied with
heated air, with desiccant as a backup. Both water-side and fire-side points should have
new gaskets, except for furnace hot-air entry inspection and exit points.

Pumps, Engines, Compressors and

Machinery
To minimize internal corrosion, close off all vents and openings, and completely fill the
casing with the manufacturers recommended lubricant. Alternatively, add a volatile
corrosion inhibitor in the correct proportion to the lubricating oil. For large compressors,
turbines, etc., first centrifuge/circulate the existing oil using a portable filtration cart
through water-absorbing filter elements to remove any free water. For diesel and
gasoline engines, drain the fuel systems and add biocide to the remaining fuel. To
prevent external corrosion, if unpainted, one of the recommended spray-on coatings
should be used (either a light wax or liquid PVC).

Instruments/Controls
Maintaining the driest possible conditions for both electronics and external field devices,
including sensors, transmitters and valves, can be achieved by strategic placement of
desiccant packages and sealing the enclosures. This should be supplemented by placing
small containers of VCI powder wherever possible. These will not adversely affect
electronics. Instruments that normally would be in contact with the process materials
should be removed, cleaned, protected and marked for immediate local storage.

Electrical Enclosures
Seal and insert bags or wraps of desiccants and containers of volatile corrosion
inhibitors. Alternatively, heat using individual strip or built-in heaters.

Motors and Generators

Clean the exterior, grease and apply a protective covering. If completely sealed, add
packets of desiccant. Lift carbon brushes from commutators/slip rings. Where sleevetype bearings are fitted, a VSI concentrate should be added to the lubrication system.

Exercising and Monitoring

Depending on the time involved, it will be necessary to periodically exercise equipment
by rotating it several times and leaving it at a different (90-degree) angle. Where
humidity controls have been set, these need at least weekly monitoring. Where chemical
controls are used, these should be checked every three months. Periodic monitoring of
motor/generator internal resistance, as well as tank oxygen levels and humidity levels, is
necessary for long-term lay-up.

Auxiliaries
In most cases, various fire-protection systems and alarms still need to be maintained
and powered up. Fires are common in dried-out cooling towers. If batteries are normally
used, disconnect them and smear the terminals with petroleum jelly. Vented-type leadacid batteries should first be fully charged, then drained and flushed with distilled water.

A Final Note
A recent discussion with two major plant-dismantling/second-hand equipment vendors
revealed that currently there are very few people looking for used equipment, and many
idle plants are being offered for sale. They reported that when the decision to shut down
comes, most companies remove anything that could present an immediate danger but
essentially close the doors and walk away from millions of dollars worth of equipment.

About the Author

Bernie Price
Bernie Price is CEO of Polaris Veritas Inc. and an active field consultant with the Houston-based consulting
group. He is also an author of numerous articles on reliability and process improvement. ... Read More

Mothballing Requires More Than Idle Thought

Proper steps can protect plant assets and enhance eventual

reactivation or sale.
By Bernie Price, Polaris Veritas Inc.
Aug 19, 2009
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Todays weak global economy is forcing closure and immobilization of plant and equipment
worth billions of dollars. Unfortunately, such actions usually are done hastily and typically
against a background of acrimony. Even worse, they can diminish or even destroy the value
of assets and preclude the possibility of reactivating them once business rebounds.
Two major plant dismantling/second-hand equipment vendors recently told me that when the
decision to shutdown comes most companies remove anything that could present an
immediate danger and essentially close the doors and walk away from millions of dollars
worth of equipment. Leaving assets as is to deteriorate can make them suitable only for
scrap in just a matter of months. Yet, its a fact that an unused plant if properly prepared
for shutdown and left in fairly good condition can retain much of its value. Engaging in a
well-planned process of deactivation/mothballing can pay off whether the intention is
eventual reactivation or sale of assets.
In my experience through three boom/bust phases in the process industries and oil well
drilling, 75% of idled plants or rigs eventually were reactivated in some form. The bottom
line is that while it only should cost 5% or less of Plant Replacement Value (PRV) to
reactivate a well-preserved unit, restarting an inadequately mothballed plant will cost 20+%
of PRV. This often is a deal breaker.
So here, well look at what should be done and describe specific products and techniques.
None of these are new or experimental therere 40+ years of documented experience for
some.
The Approach
Its essential to have a clear view of how to mitigate if not defeat the constant foes of
galvanic/bio corrosion, mold, mildew, etc. While much depends on local conditions, wetter
and colder environments pose greater challenges for handling humidity, while blowing dust is
an issue in high desert regions.
Avoid Common Mistakes
Ten frequent errors can damage or even doom a plants prospects:
1. Not treating news of an impending shutdown as a knock down blow rather than a knock out
one. With adequate preparation, it can be turned into just another blow. In todays global
marketplace just about anything can happen.
2. Not allocating responsibility to an individual beforehand for writing a list of possible scenarios
during tough times. This person should have enough clout to implement the chosen strategy
whether the fatal scene develops suddenly or slowly unfolds.
3. Not making sufficient funds available to execute the initial shutdown and preservation strategy.
4. Not choosing the right type of long-term equipment caretakers. Those selected often are security
or ex-supervisory types rather than experienced operators/craftsmen with intimate knowledge of
the equipment.
5. Not remembering to maintain state and local operating permits grandfathered ones might be
unobtainable in the future if allowed to lapse.
6. Not removing all process materials. Dealing with even innocuous materials left in a unit long-term
likely will cost five times more than at initial shutdown. Plus, the current operations people are
familiar with all the hazards, while those in the future might not be.
7. Not seeking expert advice on equipment preservation, resulting in not getting the best bang for

the buck.
8. Not involving the hourly workforce in the shutdown and mothball plan. Experience actually has
shown that involving operators and mechanics can very much improve both the quality of the
shutdown plan and its execution.
9. Not keeping good records and not clearly marking and keeping track of what has been done to
preserve an item of equipment during deactivation, making it too easy for the reactivating crew (a
different group of people) to miss that a filter, line blind, internal component, etc., has been
removed or added with serious consequences at startup.