BN-G-Y009 Care and Preservation of Equipment During

Construction
Table of Contents

1. Introduction
2. Scope
3. Preservation Methods
4. Pressure Vessels
5. Storage Tanks
6. Heat Exchangers
7. Special Equipment
8. Rotating Machinery
9. Fired Heaters, Steam Generators and Incinerators
10. Electrical Equipment and Motors
11. Instrumentation
12. Piping
13. References

1. Introduction
Short term care and preservation of equipment procedures are laid down in Reference 9.13.1,
covering the period from its delivery on site through construction to pre-commissioning.
However:

when the period from delivery to erection exceeds 12 months,

or when the period from delivery to the start of pre-commissioning exceeds 24 months,

a more extensive program of care and preservation becomes necessary.

The purpose of this section is to provide guidelines to the relevant Company construction
personnel to define and implement such a program. Responsibilities for this work during all
phases on site are defined in Reference 9.13.2.
Attention is drawn to the importance of formalizing procedures by keeping appropriate records.
2. Scope
This procedure outlines the minimum requirements to be followed for protection of equipment and material from
arrival at jobsite until:

a. Start of pre-commissioning
b. Acceptance by client
Preservation after pre-commissioning has to be discussed separately with the client and is not
considered in this procedure.
2.2 The end of guarantee from vendors is to be considered since the requirements in this
procedure relate to prolonged storage of material (expected duration of storage 1 year or more).
Specific preservation requirements of vendors will be followed as far as possible. If there is a
conflict between manufacturer's recommendation and the recommendation in this procedure, the
vendor's recommendation shall take precedence.
2.3 The extent of preservation will depend on the anticipated period that the equipment is to be
preserved. This is to be handled in close conjunction with the client's representative and the
vendor.
2.4 Rust preventatives and desiccants are sold under various brand names and have to be field
purchased as required. Before purchasing starts, agreement has to be reached between field and
client on brands and types of rust preventatives and desiccants.
3. Preservation Methods
If it is expected that site storage will be required for a period longer than the time the packaging
will protect the equipment, additional preservation measures will be taken and following
techniques followed.
3.1 External Protection
The paint specification will be followed. However, attention shall be paid that intermediate paint
coats are applied soonest.
Blank metal parts will be protected by e.g. rustban products of ESSO or SHELL Ensis. See also
9.2.4.
3.2 Internal Protection

Systems containing hydrocarbon will be sprayed, flushed or filled with a suitable oil.
Nitrogen blankets will be applied and maintained on stainless equipment.

Apply nitrogen blankets preferably after all internal work is finished in order to avoid extensive
purging operations. Nitrogen in a vessel can be dangerous. Apply all necessary warning plates
near all vessel entrances.
All construction personnel shall be familiarized with the risks of nitrogen blankets. This
instruction is the personal responsibility of the safety engineer.
4. Pressure Vessels
4.1 Storage Area
Storage will be in a clean paved area or alternatively on timber baulks, away from construction
working areas.
Equipment will be stored with all nozzles or support steel clear of the ground.
Equipment transportation supports or saddles will be checked for soundness and repaired as
necessary.
This equipment is designated "open area storage" category, but must be provided with complete
tarpaulin covering with free ventilation.
Ensure all nameplates are intact and secure.
4.2 Protection
Stainless steel (alloys containing more than 10% chromium) equipment, components and
materials shall be externally protected as follows:

Under cover.
Not in contact with the soil or with porous supports such as raw wood. Sound protective
coatings, subject to periodical inspection, are acceptable alternatives to covered storage.

In addition, austenitic stainless steel shall not be exposed to salt water, salt spray or salty
atmosphere.
4.2.2 Columns/pressure vessels can be internally preserved either by maintaining them under
nitrogen pressure or by making use of vapor phase corrosion inhibitors.
4.2.3 Site personnel shall be familiarized with the risk of nitrogen containing equipment (refer
9.3.2).
4.2.4 Austenitic stainless steel items can be internally protected in accordance with the following
preservation method:

Shop installed gaskets and blind flanges shall remain unremoved until installation of piping.
Maintenance of a nitrogen blanket on austenitic stainless steel is imperative.
The nitrogen gas pressure in the equipment shall be checked regularly.
If the pressure is below 0.5 bar(g), a refill with dry nitrogen is required. The oxygen content
shall be less than 2 % by volume measured at the flushing outlet which shall be a maximum
distance from the flushing inlet. The refill shall not start before nitrogen pressure is at 0.1
bar(g). When a pressure of less than 0.5 bar(g) is recorded, close monitoring is required (at
least one a week).
When depressurizing is required during erection of equipment, it is imperative that the
nitrogen blanket immediately be restored when this action is completed. Equipment shall be
absolutely dry before refill can start. Temporary covers to avoid ingress of water are
mandatory.
If the equipment is to reinspected, safety precautions are to be taken. Refer to Site Safety
Procedures.

4.2.5 All columns/pressure vessels not referred to in 9.4.2.4 above can be protected in
accordance with the following preservation method.
4.2.6 Vapor Phase Corrosion Inhibitors
Shell VPI 280 spray or bags can advantageously be used for the internal protection of engines,
bearings, turbines, heat exchangers, pipes, drums, small tanks and identical equipment,
preferably in non-hydrocarbon services. Equipment in hydrocarbon service shall be sprayed with
Shell Ensis oil 30 with addition of 2% VSI 8235. For both vapor phase inhibitors refer to Shell
recommendations. The equipment shall be closed thoroughly to allow vapor accumulation .
Inspection at regular intervals is required at least every three months.
4.2.7 For all pressure vessels not protected in accordance with 9.4.2.4, temporary covers of
nozzles or openings shall be removed, machined flange faces shall be cleaned and reprotected
with suitable rust preventative, covers shall be repaired where necessary, then replaced and
secured. Non-suitable covers will be replaced by wooden covers or equal.
4.2.8 All exposed bolts and flanges shall be coated with a heavy grease.
4.2.9 Verify openings for non-installed instruments. These shall be plugged or blanked off.
4.2.10 For equipment installed in elevated positions attention shall be paid to lightning
protection: the earthing connection shall be made early.
5. Storage Tanks
Corrosive attack in storage tanks appears in varying degrees throughout all parts. Atmospheric
corrosion will occur on external surfaces and is easily detected by visual inspection. For external
corrosion, prompt and effective remedial action may be taken. Internal corrosion will require a
regular and careful inspection.
The procedure practised in preparing tanks and vessels during idle periods shall be given special
consideration.
5.2 Protection
Before entering any tank or equipment, it is necessary to take certain special safety-precautions.
Refer to site safety procedures.
Inspect through available openings overhead parts for loose purlins, or any other object which
might fall and cause personal injury. If nitrogen blanketing is foreseen on a tank the best internal
protection will be obtained by applying the blanket soonest.
The following procedures can be used for protecting almost any type of tank against
deterioration:

If necessary dry the walls (consider use of heat guns);

Coat unprotected interior surfaces by spraying or brushing structural members with a gas oil
with 2% VSI 8235. For floating roof tank all unpainted surfaces exposed to open air shall be
protected with Shell Ensis 30 or 158 or Shell Autoseal 1835;
Avoid damaging floating roof seals by covering with tarpaulins or equal.
Close all manholes with gasketed covers, but breathing not to be obstructed.
Leave floating roof drains open. Verify periodically for pluggings and support the roof in
high position. Inspect periodically for water ingress.
Maintain the tank exterior according to the plant maintenance painting program or maintain
the weather seals on insulated tanks. Pay special attention to the seal between tank bottom
and foundation to avoid water ingress under the tank bottom.
Check cathodic protection periodically.

6. Heat Exchangers
6.1 Air-Cooled Heat Exchangers
Refer to vendor's recommendations.
The following are recommendations that can be used for protecting finned air coolers:
 Pump light oil through the tubes. Drain and seal or spray internally with Shell Ensis H oil
with 2% VSI 8233 and cap.
Open, drain the tubes, dry and close. Fill with inert gas 0.5 bar(g). Verify pressure
periodically.
Spray the exterior parts with a suitable rust preventive such as Shell Ensis Oil 158.
Coat bolts with a heavy grease such as Shell Rhodina.
Damaging of finned tubes has to be prevented. Therefore leave the tube bundles in the
storage area for as long as possible, properly protected by means of steel plates covering the
protection screen of the bundles. These plates shall be reinstalled when tube bundles are
fitted and shall be removed during precommissioning activities.

Motors shall have separate preparation and follow up as described under motors (9.10).
Operating mechanisms on the louvers shall be coated with a heavy grease such as Shell Rhodina,
to ensure operability when put to service. Operate louvers periodically and verify functioning.
Since airfin coolers are generally installed at elevated positions, attention shall be paid to connect
earthing at an early stage for lightning protection.
Since deformation of louvers may result in blocking of louver vanes, care should be taken during
bolting up. Protection steel plate shall only be removed prior to final installation.
During installation of fans and prior to operating, grease-lines shall be loosened at the bearing
ends and be pumped through until clean grease comes out of the grease line ends.
Fans
The fan blades and blade insert reinforcement shall be protected by Shell Ensis Oil 158 or
Autoseal 1894.
If idle time exceeds two years, grease will be changed and ball joints checked/regreased.
Protect the hubs from infiltration of dust, sand and water. Protect the bearing discharge screws
by grease and cover these with rubber bands or denso tape.
The fan shall be rotated periodically.
V-Belts shall be stored in a loose condition in a dry stock room away from direct heat and
sunlight.
They will be properly tagged for identification and installed only shortly before
precommissioning.
Enclosed Gears
Separately lubricated gears shall be filled with Shell Ensis Oil 158 with 2% VSI 8235. The oil
shall be applied by circulating, flushing or brushing. All openings shall be closed thoroughly
afterwards.
6.2 Shell and Tube Heat Exchangers
Refer to vendor's recommendations.
The exchanger shall be drained and dried. Blank off all nozzles and plug all vents and drains.
Coat all exposed bolts and flanges with heavy grease (such as Shell Rhodina). Determine the
exterior protective measures as dictated. Provide when specified nitrogen pressure of 0.5 bar(g).
Verify blanket pressure.
If nitrogen supply is impractical, dry air can be used combined with moisture absorbents. The
equipment shall be pressurized as for nitrogen. Every month the moisture absorbent shall be
checked and replaced if required. Location of moisture absorbent shall be noted so that it can be
removed easily and completely when the commissioning is started. Other methods can also be
selected in conjunction with client representative.
7. Special Equipment
7.1 General
Where vendors provide recommendations for site storage and protection, these are to be followed
and take precedence over the following recommendations.
Where prolonged site storage is involved, which is not under the control of vendors concerned,
equipment guarantees are invalidated. However, most vendors offer an on site re-furbishing
services after which equipment guarantees are re-instated. Clients are recommended to employ
this type of service wherever necessary.
Where special equipment includes rotating machinery, motors, instruments, etc., the relevant
sections of this document will apply.
7.2 Storage
A warm, clean, dry and vibration free environment in a secure under cover storage area is
required. Recommended environment conditions are temperature range of 15C to 30C and a
humidity of between 30 to 40%.
Equipment and motors to be stored in a level and upright position.
Equipment transportation supports and temporary stiffening to be checked for soundness and
repaired as necessary.
Ensure all nameplates are intact and secure.
7.3 Protection
All damaged mark/tag numbers to be re-instated and maintained.
All 'bright parts' on machinery to be inspected and re-greased/rust protected where necessary and
maintained throughout storage period.
All protection blanks on flanged connections to be repaired where necessary and maintained.
All threaded connections inspected and re-greased/rust protected where necessary and re-
plugged.
Where special equipment is provided with moisture absorbents these are to be replaced with a
fresh charge immediately after receipt at site storage area and the protective seals/membranes re-
instated. The moisture absorbents to be recharged at regular intervals thereafter.
Mixing Equipment
Refer to vendor's recommendations.
Shafts, propellers and other blank parts shall be sprayed or brushed with Shell Ensis fluid HB.
All threaded connections shall be plugged and threads coated with rust preventatives where
necessary.
Oil-lubricated bearings shall be filled with Shell Ensis Oil 158 and rotated to ensure complete
coverage, after which all openings are closed. Grease-lubricated bearings shall be cleaned and
greased with the appropriate grease, turned and closed.
Separately lubricated gears shall be filled with Shell Ensis Oil 158. The oil shall be applied by
circulation, flushing, spraying or brushing. If complete oil coverage cannot be realized, small
bags with Shell VPI 280 shall be used.
Whatever the treatment, all openings shall be closed thoroughly afterwards. Some manufacturers
recommend the seal to be removed or to ship with no seal installed. Verify this per item.
Loading Arms
Refer to vendor's recommendations. Loading arms can be protected as follows:

Close all openings tightly with gasketed cover.

Pressurize with an inert gas.
Close the inert-gas inlet and leave the equipment blanketed with inert gas at 0.5 bar(g).
Apply same procedure for jacket.
All exposed bolts and flanges shall be coated with a heavy grease during preservation.
Determine the appropriate external protective measures as dictated by local conditions.
Verify insulation and painting as per recommendation.
Cover joints with a heavy grease (such as Shell Rhodina) to avoid water penetration.

Conveyors/Elevators
Refer to vendor's recommendations.
Bearing Brackets
Oil-lubricated bearings shall be drained and filled with Shell Ensis Oil 158. Run for a short while
to ensure complete coverage and then cover all openings. Lubricated bearings shall be cleaned,
greased with the appropriate grease and dried thoroughly.
Gear Boxes
Gear boxes shall be drained and filled with Shell Ensis Oil 158 by circulation, flushing, spraying
or brushing. If complete oil coverage cannot be carried out, then small bags with Shell VPI 280
shall be inserted. All openings shall be closed thoroughly afterwards.
Machined Parts
Couplings, shafts, rollers and all blank machined parts shall be solvent cleaned and coated with
Shell Ensis fluid HB. Coating shall be applied in accordance with the supplier's requirements.
Exposed chains shall be cleaned, grease coated, wrapped in waxed paper and tagged for
identification. V-belt pulleys shall be oiled on the bore to avoid rusting.
Sound Enclosures
Until they can be assembled around the equipment, the sound enclosures shall be stored in the
warehouse, or under cover, not in contact with soil. Sound enclosures already installed at the
vendor shop shall be preserved.
After assembly inspect periodically for mechanical damage (see Reference 9.13.3).
If a sound enclosure is installed over equipment preserved by a nitrogen blanket, safety
precautions are to be taken, (see Reference 9.13.4).
Boiler Feedwater system
Refer to vendor's recommendations.
This covers the following type of equipment.

Deaerator
Dosing units
Demineralizer (BFW Treating unit)

The equipment shall be moved as soon as possible to its foundation. If this is not practical it shall
be stored in a suitable area, preferably protected from the elements and in any case on timbers.
Resins for ion exchangers shall be stored outside the equipment and protected against humidity
and frost (See vendors instructions). Special attention shall be paid to avoid mechanical damage
of the linings.
Deaerators
Refer to Pressure Vessels (9.4).
Spray internally with VPI-280 solution, close off carefully.
Dosing Units
The equipment shall be protected from the ingress of water. All tank drains to be kept open.
Suction pipes of dosing pumps shall be capped and kept filled with water, with 50-100 ppm
hydrazine as oxygen scavenger (do not use sulphite). Alternatively provide nitrogen blanket.
Demineralizers
Refer to Pressure Vessels (9.4).
Rubber lined equipment shall be protected against exposure to direct heat or radiation by the sun,
or kept full of water. In this case allow for thermal expansion by opening the vent. Be careful of
mechanical damage to the lining. Resins shall be put in the equipment only shortly before
precommissioning. Refer to vendors instructions.
Weighing Equipment
Refer to vendor's recommendations.
Check structural members in accordance with the coating specification to ensure adequate
protection. Various components shall be checked in accordance with the relevant paragraphs of
this procedure.
Internal Combustion Engines
Refer to vendor's recommendations. For the preservation of these engines the cooling water
system is drained and dried with dry air or nitrogen. Fuel tanks are drained and blanketed with
nitrogen if practical. Care shall be taken regarding nitrogen accumulation under sound enclosures
(see Reference 9.13.4). All oil systems shall be drained with Shell Ensis Motor Oil or equivalent
of adequate viscosity (SAE 10 - SAE 50).
Spark Plugs/Electrical Accessories
Fuel injection nozzles shall be removed and the openings in the cylinders plugged. A small
amount of Shell Ensis shall be sprayed into each cylinder through the spark plug or injection
nozzle openings. Additional Shell Ensis shall be sprayed into the cylinders each time the
crankshaft is rotated, in accordance with the vendor's recommended schedule. Electrical
accessories such as magnets, which can be damaged by moisture, shall be protected from
condensation or humidity.
Batteries may be shipped wet or dry and subsequently treated at site as per the manufacturer's
instructions. The batteries shall be disconnected if feasible and the battery connections coated
with vaseline or the manufacturer's recommendations followed.
8. Rotating Machinery
8.1 General
The contents of this section applies to the main items of rotating machinery, where associated
motors, instruments and electrical items are concerned reference should be made to the relative
sections.
Where vendors provide recommendations for site storage and protection these are to be followed
and take precedence over the recommendations contained in this section.
Where prolonged site storage is involved, which is not under the control of vendors concerned,
equipment guarantees are invalidated. However most vendors offer a site re-furbishing service
after which equipment guarantees are re-instated. Clients are recommended to employ this type
of service wherever necessary.
8.2 Storage
A warm, clean, dry and vibration free environment in a secure under cover storage area is
required. Recommended environment conditions are temperature range of 15C to 30C and a
humidity of between 30 to 40%.
Machinery to be stored in level and up-right position.
Machinery transportation supports and temporary stiffeners to be checked for soundness and
repaired where necessary.
Ensure all name plates and Tag labels are intact and secure.
8.3 Protection
Centrifugal Compressors/Blowers
Large centrifugal compressors require extensive and detailed preservation. Machinery of this
type is complex and a detailed program of protective measures must be undertaken. The
environmental effect on a compressor that is to remain in an operating position must be
considered. (Protection by a roof, installed in open air). Refer to vendor's instructions.
Due to the heavy weight of compressors, storage in areas remote from field positions should be
avoided. A compressor which is not resting on a foundation must be supported the full length of
its frame to prevent any possible sag or distortion. Support can be provided by a frame of welded
structural steel members. Units shall be protected with tarpaulin covers.
Generally, vendor's packaging allows for 6 months storage. If prolonged storage is necessary
intermediate inspections are to be considered. Every six months, suction and discharge shipping
covers and bearing caps are removed and a thorough investigation of the internals is to be made.
If any signs of corrosion are found, corrective measures are to be taken and inspections varied
accordingly (take care of sealing compressor after inspection).
Half yearly internal inspections are to be performed on all items shipped loose in accordance
with above, except for items sealed in plastic bags, if no visual corrosion is apparent.
The level of preservation will be designed for unheated or outdoor storage. It is required to place
a waterproof cover over all equipment and crates continuously. The following is required:
The first inspection shall be done immediately after transportation to the storage area. This shall
include, but is not limited to, inspection for visible external damage to equipment or crates,
indication of moistures and or oxidation and degradation of applied preservative compounds.
The presence of any such signs shall require a thorough inspection of all equipment. Each month
thereafter, all humidity indicators shall be inspected.
The interval for subsequent inspections shall be every six months.
Compressor (including gearbox)
The compressor shall be disassembled and all internals shall be brushed with Shell Ensis Oil 158
with VSI 8325. Dip all journal and thrust bearing assemblies or parts in Shell Ensis Oil, turn to
remove air pockets, drain and reinstall in unit. Use multiple strips of denso tape placed over top
of journals to take up all bearing clearance when cover is bolted down. Place a tag on the outside
of the unit stating:
"REMOVE PLASTIC SHIMS AT JOURNALS BEFORE OPERATING UNIT"
The coupling end of the shaft shall be treated with Shell Ensis 158 and taped with denso. All
bearing vents shall be taped with Denso tape and closed.
Sealing the Casing
The intent is to completely seal the unit and prevent pockets of water such as at bolt holes. All
openings shall be covered with plastic caps or metal covers. Use 3 mm thick metal covers for all
flanged openings. Use plastic caps on small size pipe, NPT holes, dowel and other holes. Rubber
shall be used between metal cover and flanges. The edges of all flange covers shall be taped with
denso to the flange. As a minimum, bolts will be used in half the number of holes on all flanges.
(Minimum to be four bolts per flange).
Suction and discharge nozzle openings shall be blanked as described above. Attach a
dehumidifier and operate until drain stops dripping. Each section shall be dehumidified on re-
entry type units. Desiccant bags will be provided on the inside of the covers and shall be
immediately placed in the unit and unit sealed. The amount of desiccant required is 1.2 units per
cubic foot of internal volume to be protected.
Special duty compressors, e.g. for oxygen or chlorine service, shall be preserved by inert gas
filling in combination with desiccants. The application of inert gas blanket can also be
considered to other centrifugal machines. Allow for a small flow due to seal leakage.
For air blowers, cap the intake stack to avoid rain and humidity ingress.
The shaft shall be rotated regularly leaving the shaft in another position, (if applicable). Follow
vendor's recommendation of available.
Console Oil System and Unit Piping
Shell Ensis Oil H shall be used as lube oil during the testing if the console. Add 2% VSI 8235.
Drain oil from unit after satisfactory completion and approval of all testing requirements.
Inspect and clean suction screens.
Coat all exposed unpainted surfaces and flexible couplings and valve steams, etc. except
stainless steel parts with Shell Ensis 158.
Spray carbon steel internals which are parts of the pump driver assembly with Shell Ensis Oil H
(with 2% VSI 8235).
Remove and discard filter cartridges and wash inside of filter housing with solvent, then apply
Shell Ensis Oil H (with 2% VSI 8235).
Install new filter cartridges in all filter housings.
Paint unit in accordance with applicable specification.
Operate the lube oil system weekly for 30 minutes.
The water cooling system shall be drained. Dry and spray with VPI 280 solution. Close all
connections carefully.
For electric motors see 9.10.
Sound enclosure to be inspected periodically or stored in the warehouse.
For other elements refer to relevant paragraphs.
8.3.2 Pumps
The following procedure is intended for safeguarding centrifugal pumps, rotary displacement
pumps, reciprocating pumps, rotary vacuum pumps and axial pumps. It shall be checked against
vendor's recommendations.
Verify that the bright external parts are all coated with Shell Ensis MD (twice) followed by
Shell Ensis HB.
For pumps working in hydrocarbon service internal parts shall be flushed with Shell Ensis Oil
H with addition of 2% VSI 8235. Repeat every six months. Rotate shaft during flushing. For
vertical pumps spray internals with Shell Ensis Oil H. For pumps in water service spray internals
with VPI 280 solution, repeat every six months. Close pump completely to allow vapor
accumulation.
Bearing house: Follow vendor's recommendation. Fill as high as possible with Shell Ensis Oil H
with addition of 2% VSI 8235. Rotate the shaft periodically. Plug vents.
Separately lubricated gears for high speed vertical pumps shall be drained and filled with Shell
Ensis Oil H added with 2% VSI 8235. The oil shall be applied by circulation flushing, spraying
or brushing. Whatever the treatment, all openings shall be closed thoroughly afterward.
If the pump is to be stored outdoors or installed at service location, protect with plastic sheets to
minimize ingress of dirt, dust, etc.
Break all pipe connections and suction and discharge flanges and close all openings. When the
pump is to be maintained in a field position, ensure that the suction and discharge valves are
closed and blanked off after protective fluids have been applied.
When single mechanical seals are used, the complete mechanical seal remains within the
stuffing box chamber. Pour Shell Ensis Oil H with 2% VSI 8235 through the circulation and
quench connections and turn pump shaft manually several times while filling with preservative.
Check O-ring compatibility with oil. Verify whether all connections are plugged.
Where double mechanical seals are used, plug the lower stuffing box drain and fill with Shell
Ensis Oil H with 2% VSI 8235. Slowly rotate the shaft to ensure complete coverage of internal
surfaces. Mask clearance between seal gland and shaft to prevent direct from entering the seal
cavity. Verify in the manufacturer's instructions whether the rings of the seals are oil resistant.
If the pump will be shipped with the seal not installed, the seal will be stored in the warehouse
and installed shortly before precommissioning. The seal cavity shall be filled with Shell Ensis
with 2 % USI 8235).
Where conventional packing is used, loosen the packing gland and remove all packing. Coat the
interior of the stuffing box with light grease. Repack the pump with a nonmetallic packing and
retighten the packing glands slightly. Tag the pump to indicate that the service packing has been
removed. Care shall be taken to repack the pump with the service packing at precommissioning.
Wrap the exposed pump shaft with Denso tape. At the points where the shaft enters the pump
casing and the bearing housing, carefully wrap to seal off the openings. Allow for regular shaft
rotation by hand, leaving shaft in fresh position on each occasion.
Cover all outer exposed surfaces with either paint or a suitable rust preventative (Shell Ensis
MD or Autoseal 1894).
For electric/motor drive refer to 9.10.
The sound enclosure shall be inspected periodically for mechanical damage, or stored in the
warehouse.
Coupling: Treat gear ring teeth as described under "bright parts" and wrap in denso tape after
treatment. Treat coupling hub and spacer as described under "bright parts" and have them
wrapped in plastic sheeting and tagged and stored in warehouse. Verify oil filling of installed
coupling every six months and have VSI 8235 added.
Reciprocating Pumps: In addition to the above, the following instructions shall be observed to
protect reciprocating pumps:

Reciprocating injection or metering pumps should preferably be stored in warehouse.

Remove the valve cover plate from the liquid end of the pump.
Remove a valve from each end of each cylinder on the liquid end. Fill all cylinders with
Shell Ensis Oil.
Apply Shell Ensis Oil to all valves and valve covers.
Fill all lubricators with oil.
Have the crank-case unit filled with Shell Ensis oil H with addition of 2% VSI 8235.
Rotate the pump for a few minutes every 2 months.

8.3.3 Gear Boxes

Refer to vendor's recommendations.
Bearings
Oil-lubricated bearings shall be drained and filled with Shell Ensis Oil 158 and run for a short
while to ensure complete coverage, after which all openings are closed. Grease-lubricated
bearings shall be cleaned and re-greased with the appropriate grease, turned and closed
thoroughly.
Enclosed Gears
Separately lubricated gears shall be drained while hot and then filled with Shell Ensis Oil 158
which is circulated for a while. Where circulation is impracticable, the oil shall be applied by
flushing, spraying or brushing. If complete oil coverage cannot be realized, small bags with Shell
VPI 280 shall be used. Whatever the treatment, all openings shall be closed thoroughly
afterwards.
8.3.4 Reciprocating Compressors
Refer to vendor's recommendations.
Large reciprocating compressors require extensive and detailed preservation. A thorough
inspection and a detailed program of protective measures must be foreseen. A compressor that is
to remain in an operating position in open air will require special attention for external corrosion.
Before assembly all parts will be thoroughly checked for any sign of corrosion.
Due to the heavy weight, compressors will be installed quickly on their foundations. A
compressor which is not resting on a foundation must be supported to prevent any possible sag or
distortion. Support can be provided by a frame of welded structural steel members. Generally
manufacturers packaging allows for six months storage. If prolonged storage is required
intermediate inspections are to be considered.
For the preservation, the following general rules are recommended:

Fill all lubricators completely full of oil, Shell Ensis Oil H with 2% VSI 8235, to prevent
rusting of the pumping parts, rotate lubricators to fullness with oil. Also fill the crank case.
Remove stuffing box, and wiper rings of the compressor. Clean in a suitable solution. Apply
a coating of a satisfactory rust preventive and wrap in a waterproof paper or place in a plastic
 container. A rust preventive may be grease or oil with a high viscosity. Identify the stuffing
box to ensure reassembly in their original position.
Have the main shaft rotated according to manufacturers recommendations.
Remove the inlet and discharge valves from the compressor cylinders, clean, and apply a
coating of Shell Ensis Oil H with 2% VSI 8235. Completely coat the valve bores and piston
rods with a spray or other suitable means while the valves are removed. If piston rods are not
stainless steel, consideration shall be given to removing the piston and rod. These shall then
be coated, wrapped and boxed. The rod must be properly supported to prevent bowing.
Replace all valves in their original position and tighten in place.
Seal muffler vents or cover them with plastic.
Reciprocating compressors are provided with some Shell Ensis Oil H with 2% VSI 8235 and
are run on "no load" or turned by hand until the oil is fully distributed. This is repeated
according manufacturers recommendations. Separate lubrication systems should be drained
and filled with Shell Ensis Oil H with 2% VSI 8235 prior to the above-mentioned treatment.

In case of doubt as to whether all internal parts are reached by the oil, small bags with Shell VPI
280 should be placed in the vicinity of the parts concerned or 2% VSI 8235 added to the oil and
the parts closed. Mark the number of bags on red tags on the outside of the equipment.
Clean and apply protective coating to all small auxiliary equipment, relief valves, piping filters,
and the like.
A periodic inspection should be made if compressors remain idle for a considerable time. Small
surfaces on cylinder bores, crankshafts, bearing journals, piston rods, crossheads, and the like
should be wiped free of protective coatings to determine their condition. When protection
appears to be satisfactory, the same care as originally used in the application of the protective
coating must be used in covering the exposed surfaces.
If there is any sign of rust or corrosion on any of the aforementioned parts, they should be wiped
clean and dry and the protective coating reapplied.
8.3.5 Steam Turbines
Refer to vendor's recommendations.
Large turbines require a detailed program of protective measures. The environmental effect on a
turbine that is to remain in an operating position must be considered. (Protection by a roof/open
air).
Due to the heavy weight of turbines, storage in areas remote from field positions should be
avoided. A turbine which is not resting on a foundation must be supported the full length of its
frame to prevent any possible sag or distortion. Support can be provided by a frame of welded
structural steel members. Units shall be protected with tarpaulin covers.
Generally manufacturer's packaging allows for six months storage if prolonged storage is
required.
Half yearly internal inspections are to be performed of all shipped items.
Protection Level
The level of preservation will be designed for storage unheated or outdoor. It is required to place
a waterproof cover over all equipment and crates continuously. The following is required.
The first inspection shall be done immediately after transportation to the storage place. This shall
include inspection for visible external damage to equipment or crates, indication of moistures
and or oxidation and degradation of applied preservative compounds. The presence of any such
signs shall require a thorough inspection of all equipment. Each month thereafter, all humidity
indicators shall be inspected.
The interval for subsequent inspections shall be every six months.
All bright surfaces of any component parts of the governing system, such as reset linkages, valve
levers, piston rods, etc., shall be preserved with Shell Ensis Oil 158.
Both the rotor and guide-blade carrier shall be internally preserved with nitrogen with the turbine
casing and the bearing housings closed. A spray of VPI 280 can be given. Alternatively a
nitrogen blanket can be applied if practical.
Oil Piping (Internal Preservation)
Lube and control oil piping, mounted prior to the test stand trial run and used during the latter,
shall not be preserved. Oil piping mounted to the unit after the trial run shall be preserved.
Prefabricated oil pipes that are field mounted shall be pickled and preserved and sealed with
plastic covers on both sides. Piping shipped to site in the usual way shall not be preserved.
The oil reservoirs and baseplates containing an oil reservoir shall be internally (oil chamber)
protected with Shell Ensis 30 (with addition of 2% VSI 8235). The lube oil system shall be
operated weekly for 30 minutes.
Outdoor Storage
For outdoor storage of the unit prior to putting into operation, the above preservation procedure
remains valid and the unit shall moreover be protected with tarpaulin covers.
Cleaning for Operation
All referred preservation, internal and external must be removed before operating the unit.
Follow instructions for products used.
Controls
Separately shipped gauges shall be capped, cleaned and carefully wrapped and packed in
cellulose cushioning material (CCM).
Vibration pick-up and other vendor devices shall be cleaned, carefully wrapped and packed in
cellulose cushioning material (CCM).
The same recommendation applies for electrical devices.
Labyrinths - coat with Shell Ensis Oil H with 2% VSI 8233.
Tools: Coat unpainted surfaces with Shell Ensis H with 2% VSI 8235.
For all other miscellaneous items, coat unpainted surfaces with Shell Ensis 30.
Couplings
All loose remaining coupling parts to be coated with Shell Ensis Oil followed by Shell Ensis HB
wrapped in denso tape and packaged separately.
Coat unprotected interior surfaces by spraying or brushing structural members with a gas oil with
2 % VSI 8235. For floating roof tanks, all unpainted surfaces exposed to open air shall be
protected with Shell Ensis 30 or 158 or Shell Autoseal 1835:

Avoid damaging of floating roof seals by covering with tarpaulins or equal.

Close all manholes with gasketed covers, but do not obstruct breathing.
Leave floating roof drains open. Verify periodically for pluggings and support roof in high
position. Inspect periodically for water ingress.
Maintain the tank exterior according to the plant maintenance painting program or maintain
the weather seals on insulated tanks. Pay special attention to seal between tank bottom and
foundation to avoid water ingress under tank bottom.

Fans
Refer to vendor's recommendations. These shall be handled under the main "SYSTEM" in which
they are integrated.

Dry the equipment and keep it dry.

Make sure no rain or atmospheric humidity can enter the equipment.
Ensure that the intake stack is capped and closed.
V-belts shall be stored in the warehouse and installed at precommissioning in conjunction
with the vendor representative.

Bearings
Oil-lubricated bearings shall be drained and filled with Shell Ensis Oil 158 and shall be run for a
short while to ensure complete coverage, after which all openings are closed. Grease-lubricated
bearings shall be cleaned and re-greased with the appropriate grease, turned and closed
thoroughly. The internal parts shall be sprayed with Shell Ensis Oil 158. Sound enclosures shall
be inspected for mechanical damage.
Enclosed Gears
Separately lubricated gears shall be drained while hot and then filled with Shell Ensis Oil 158
which is circulated for a while. Where circulation is impracticable, the oil shall be applied by
flushing, spraying or brushing. If complete oil coverage cannot be realized, small bags with Shell
VPI 280 shall be used. Irrespective of any treatment, all openings shall be closed thoroughly
afterwards.
9. Fired Heaters, Steam Generators and Incinerators
9.1 General
The contents of this section applies to the main items of fired heaters, steam generators and
incinerators. Where associated motors, instruments and electrical items are concerned, reference
should be made to the relevant sections.
For preservation of steam boilers see Reference 9.13.5.
Where vendors provide recommendations for site storage and protection these are to be followed
and take precedence over the recommendations contained in the appendix.
Where prolonged site storage is involved, which is not under the control of vendors concerned,
equipment guarantees are invalidated. However, most vendors offer an on site re-furbishing
services after which equipment guarantees are re-instated. Clients are recommended to employ
this type of service wherever necessary.
9.2 A warm, clean, dry and vibration free environment in a secure under cover storage area is
required for Panels etc. Recommended environment conditions are temperature range of 15C to
30C and a humidity of between 30 to 40%.
Fired heaters and Incinerator parts to be stored in level and up-right position.
Fired heaters and Incinerator parts transportation supports and temporary stiffeners to be checked
for soundness and repaired where necessary.
When refractory lined steel sections of heaters, furnaces or boilers are stored outside care must
be taken that water can not enter between steel and refractory in order to avoid corrosion that can
cause cracking of refractory covers are mandatory.
Ensure all name plates and Tag labels are intact and secure.
9.3 Protection
The cleaned boiler shall be thoroughly drained, dried and can be protected as follows:

A gasketed cover on all manholes.

Close all other openings tightly.
Pressurize with nitrogen.
Close the inert-gas inlet and leave the vessel blanketed with inert gas at 0.5 bar(g).
All exposed bolts and flanges shall be coated with a heavy grease.
Determine the appropriate external protective measures as dictated by local conditions.
Ensure that the external surfaces have been painted, coated or insulated as per the
specification.

Boiler Feedwater Systems

See 9.7.
Header Boxes and Casing
Hinges on header doors, peepholes and access doors shall be coated thoroughly with a heavy
grease. Where seating surfaces of openings could corrode because of leakage of rain or moisture,
it is advisable to seal the doors with a readily removable mastic.
Burners
Treatment of this equipment is dependent upon the type of burner used, and some will require
more care than others. The movable parts shall be covered with heavy grease to protect threads
or adjusting mechanisms. Spray nozzles shall be removed, tagged and stored. Fuel supply
openings shall be blanked off and secured.
Combustion
Chamber If the combustion chamber is to be preserved, burner holes shall be closed. Protection
recommendations shall be checked with vendor's recommendations. Inert gas bleeding can be
carried out or moisture absorbents used. Selection shall be made in conjunction with vendor
representative.
Breeching and Ducts
For internal surfaces absorption of moisture during the idle period shall be minimized by closing
the ducts. Expansion bellows shall be inspected. Operating mechanisms on the dampers shall be
coated with heavy grease such as Shell Rhodina to ensure operability when in service. Operate
dampers periodically and verify functioning.
Refractory
Refractories shall be kept dry and free of frost at all times. Atmospheric moisture can be
excluded by capping stack and duct openings and by sealing locations where water or moisture
can enter. Refer to vendor's recommendations.
Tubes
All tubes shall be dried, the headers shall be closed and nitrogen blanket applied at 0.5 bar(g).
Nitrogen pressure shall be checked periodically.
Steel Stacks
The stacks shall be capped. External inspection of paint shall be in conjunction with the
specification. Particular attention shall be paid to ladders as these are safety items.
Fans
Refer to 9.8.3.6.
10. Electrical Equipment and Motors
10.1 General
Where vendors provide recommendations for site storage and protection, these are to be followed
and take precedence over the following recommendations.
Where prolonged site storage is involved, which is not under the control of vendors, equipment
guarantees are invalidated. However most vendors offer a re-furbishing service after which
equipment guarantees are re-instated. Such a service is outside normal Company contracts but
clients are recommended to take up this option where applicable at their own expense.
10.2 Storage
Electrical equipment must be stored in the warehouse.
220 and 110 volt electrical supply to be available adjacent to stored motors and equipment to
enable anti-condensation heaters and equipment to be energized where necessary. Equipment
transportation supports and temporary stiffening to be checked for soundness and repaired as
necessary.
Ensure all nameplates are intact and secure.
All motors to have shafts manually rotated frequently, at least once per week. This must not be
carried out with tools which will damage or mark motor shafts.
10.3 Protection
All damaged painted Mark/Tag Numbers to be reinstated and maintained.
All threaded entries to be plugged and threads recoated with rust preventatives where necessary.
All gland plates to be checked and reinstated where required.
Where moisture absorbents are included to protect equipment it should be replaced with a fresh
charge immediately on receipt in the site stores and replaced on a regular basis thereafter.
Motors
Motor bearings to be checked regularly to ensure grease is in good condition, should it harden or
be discolored the bearings should be cleaned out and regreased.
Motor condensate drain plugs to be removed periodically to remove any accumulated moisture.
Plugs to be replaced to avoid ingress of dust.
All bright metal parts, machined surfaces (i.e. shafts) to be coated with rust preventatives.
All 6000V. motors should have insulation resistance values measured and recorded every 3
months against climatic conditions at time of test. If the reading is not greater than 6 megohm an
approved method of drying out is to be undertaken to achieve acceptable resistance readings.
Connect anti-condensation heaters.
Transformers and Capacitors
Where units are supplied complete with insulation liquids/gases these should be checked on
arrival at Site. If level or pressure is not within vendor's tolerances, possible leaks should be
located and rectified. Monthly checks on level/pressure should be made and rectification work
carried out as necessary.
Any separately supplied insulation liquids should be stored on an incline, containers should not
be left stored in upright position.
Switchgear, Motor Control Centres, Inverters, Battery Charger Units, Etc.
Unless provided with anti-condensation heaters the equipment shall be removed from the
packing cases with the plastic coverings left in place and resealed where damage has occurred
during shipment.
Where anti-condensation heaters are fitted these shall be connected.
Spot insulation tests shall be carried out every 6 weeks and where readings are low an approved
drying out procedure shall be adopted to achieve acceptable resistance readings.
Batteries should be stored in an inactive area to avoid accidental breakage and seals should be
regularly checked for damage. Damaged seals shall be renewed in accordance with Vendors
instructions.
Nickel-cadmium and lead-acid batteries that have been shipped dry do not require maintenance.
Electrolyte levels in batteries that have been shipped wet should be checked and topped up as
required.
These batteries should also be given a re-freshing charge tri-monthly.
Cable
Measure and record gas pressure in low pressure gas filled cable when received and weekly
thereafter.
If falling pressure indicates a leak in cable, maintain same with dry nitrogen until leak is sealed.
Rotate reels of paper insulated lead sheathed cable 90 every 2 weeks to prevent migrating oil
from collecting at low points.
11. Instrumentation
11.1 General
Where vendors provide recommendations for site storage and protection these are to be followed
and take precedence over the following recommendations.
Where prolonged site storage is involved, which is not under the control of vendors, equipment
guarantees are invalidated. However most vendors offer a re-furbishing service after which
equipment guarantees are re-instated. Such a service is outside normal Company contracts but
clients are recommended to take up this option where applicable at their own expense.
11.2 Storage
A warm, clean, dry and vibration free environment in a secure under cover storage area is
required. Recommended environment conditions are temperature range of 15C to 30C and a
humidity of between 30 to 40%.
Instruments can be stored in the above environment for up to 4 months in their shipment cases.
However, where cases/packing have been opened the plastic coverings are to be retained and
resealed in the manner they were shipped.
Where moisture absorbents are included they are to be replace with the new charge on receipt on
site and further replaced at regular intervals thereafter.
Adjacent 220 and 110 volt supply made available for energizing equipment as necessary.
Panels to be stored up-right and level, any temporary transportation/strengthening supports to be
reinstated and maintained.
Threaded connections to be re-capped and rust protected, also maintained.
Ensure all Nameplates/Tags/Gland plates are intact and secure, also maintain.
11.3 Protection
Local Instruments
All openings shall be tightly plugged against entry of water.
Panel Instruments
The power pack units of the control panel racks shall be energized at monthly intervals. For
storage in original packing refer to recommendation of vendor.
Delicate Instruments as e.g.

panel instruments
distribution control components
racks with power supply and/or cards
computer racks and components
programmable controllers

will be stored in air conditioned spaces.

Instruments with Electronic Components as e.g.

transmitters
I/P converters, and others

will be stored shielded from direct sun radiation.

Safety Relief Valves and Control Valves
Refer to vendor's recommendations.
Safety valves shall be stored in the warehouse and either dummies installed in the line or the
lines blanked off.
The valves shall be stored indoors in a clean, dry environment. Avoid extreme temperatures and
humidity conditions.
Threaded connections to the capped and rust protected.
Ensure all Nameplates/Tags/Gland plates are intact and secure, also maintain.
For stainless steel safety valves special instructions should be followed.
Stainless steel (alloys containing more than 10% chromium) equipment, components, and
materials shall be protected as follows:

Indoor storage,
Not in contact with the soil or with porous supports such as raw wood. Protective coatings
are acceptable alternatives to covered storage.

In addition, austenitic stainless steels shall not be exposed to salt water or salt spray.
Internals of carbon steel relief valves are to be treated with Shell Ensis.
12. Piping
12.1 Storage
Particular attention shall be paid to inner cleanliness of piping. Prefabricated piping transported
to the construction site shall be laid down on supports. Adequate measures (such as capping)
shall be taken to ensure that piping is protected from the ingress of sand and foreign material.
Protective coatings shall be inspected periodically. All machined parts to be coated with Shell
Ensis fluid.
Stainless Steel
Stainless steel (alloys containing more than 10% chromium) equipment, components and
materials shall be protected as follows:

Under cover.
Not in contact with the soil or with porous supports such as raw wood. Protective coatings
are acceptable alternatives to covered storage.

In addition, austenitic stainless steel shall not be exposed to salt water or salt spray.
Consideration shall be given to pipelines integrated in a "SYSTEM" with a main piece of
equipment (exchanger, pump etc.) If this is the case they come under the responsibility of the
"SYSTEM" engineer when ready. The "SYSTEM" is drained, dried and a nitrogen blanket of
O.5 bar(g) applied. Nitrogen pressure is checked periodically.
12.2 Protection
Inspect painting and insulation periodically and take remedial action where required.
Bolts and Gaskets
Bolts shall be coated with heavy grease, such as Shell Rhodina. When the "SYSTEM" is being
prepared for precommissioning, after a prolonged shutdown, selective service testing shall be
considered and only those gaskets that fail shall be renewed.
Flanges
Machined parts shall be coated with Shell Ensis fluid during storage. After erection moisture
proof tape shall be wrapped around aperture of adjacent faces of flange joints. Shell Ensis fluid
SDC shall be applied to nuts and exposed threading of studs.
Valve Packings
Stuffing box packings are left intact during idle periods. If repacking after start-up would be very
cumbersome, packings can be replaced before precommissioning.
Pipe and Fittings
All piping shall be properly drained and dried after testing. Open flanges if required. For all lines
filling with nitrogen is recommended if prolonged standstill is forecasted, (especially for gas,
oxygen and chlorine lines). Alternatively dry air can be considered if nitrogen is impractical.
The dry air or inert gas system shall not contain oily matter or solid particles. After the
preservation treatment is finished the system shall be blanked off and the gas pressure of the
system checked periodically
Valves and Other Appurtenances
Valves and appendages, except instruments, are treated together with the "SYSTEM" they are
incorporated in and inspected valves shall be opened fully. Motor operated valves and hydraulic
valves are operated periodically. Exterior parts shall be coated, especially the threaded stem.
During idle periods no special care is given to valve packings.
For large piping systems installation of thermal relief valves can be considered when filled with
liquid.
Instruments
Special attention shall be paid instrument connections to be capped or plugged and spools to be
installed where required.
Lightning Protection
Special attention shall be paid at an early stage to lightning protection of elevated lines. Verify
the earthing connection.
13 References

Document
Title Level
Number
Standard Procedure for Material Control and
13.1 BN-CO-107 3
Warehousing
13.2 BN-G-Y008 Materials Quality Management 5
API Guide for Inspection of Refinery Equipment,
13.3
Section 18, point 18.2.2.4
API Guide for Inspection of Refinery Equipment,
13.4
Section 5
ASME Boiler and Pressure Vessel Code, Section 7,
13.5
Subsection C-7