Mothballing

 Using VCI (newest, claimed to be the most efficient)

 Nitrogen

o the release of special VpCI molecules from a source — whether it be packaging,

powder, coating or additive material. The vapor abilities of VpCIs allow these
protective molecules to diffuse throughout an enclosed space until they reach
equilibrium. The VpCIs condense on metal surfaces, forming a hydrophobic layer
that neutralizes the electrical surface potential of the metal and protects it from
corrosive forces. If the protective layer is damaged, VpCIs present in surrounding
voids are attracted to the exposed metal and soon replenish the molecular
barrier.
o VpCI technology has the advantage of working in three phases: the liquid phase,
the vapor phase, and at the air-water interface. While traditional protective
methods typically work only when applied directly to a metal surface, the multi-
phase ability of VpCIs gives it greater flexibility and effectiveness. For example,
VpCIs fogged into equipment void spaces can protect even hard to reach areas
without direct contact application. Equipment partially filled with fluids can
benefit from VpCI additives that not only protect metals in contact with the liquid,
but also diffuse throughout the surrounding void space to protect metal surfaces
above the level of fluid.
o The versatility of VpCI means it can be applied to many different kinds of
equipment and plant systems. Turbines, pumps, compressors, boilers,
generators, gears, and valves all benefit from VpCI protection. Even the return on
protecting electrical control boxes can be a significant but sometimes overlooked
savings. VpCIs can work directly in lubricating and hydraulic systems, water
systems and air systems, as well.
o VpCIs are typically very easy to remove or may not need to be removed at all if
selected properly. This is an important cost savings in itself. Instead of requiring
hours of labor to clean a sticky protective substance
off a part, removing VpCI protection is often just a matter of unwrapping a
protective VpCI film, using an alkaline cleaner to easily spray off a VpCI
removable coating, or doing nothing. For example, removable coatings can often
be left on equipment due to a thin clear surface layer that will not interfere with
equipment operations. This translates into lower environmental disposal costs
and quicker installation of replacement parts with less hassle and downtime.
 Dehumidification


Nitrogen mothballing is a maintenance procedure used for equipments to

prevent corrosion of the equipments during their idle time. The basic principle is
to fill up idle equipments with an inter gas, commonly nitrogen, so as to remove
air, oxygen, moisture etc. to prevent these elements from corroding the
equipment walls.

When process equipments are not in use, they are drained, vented,
depressurized, purged and sealed. If these equipments are sealed with
atmospheric air inside them, then the equipment walls are in constant contact
with atmospheric oxygen which can slowly react with the metal walls to produce
oxides leading to corrosion. Moist atmospheric air is hugely responsible for
metal wall corrosion. Also atmospheric air usually contains microorganisms
which can flourish on the equipment walls causing fouling. Hence for long
period of idle time, it is desired that to isolate the equipment walls from air and
this can be achieved by nitrogen mothballing.

When an equipment is filled with nitrogen for mothballing, it has to be

pressurized and sealed from atmosphere. So the provision to seal off the
equipments is essential for nitrogen mothballing. After pressurizing the
equipment with nitrogen, the system must be tight enough to maintain that
pressure.

The nitrogen used for mothballing must have very little oxygen and moisture
contents (typically less then 1% wt).

Prior to mothballing, all the components and interior spaces of the equipments
must be properly drained, dried, sediments or deposits should be removed.

Nitrogen mothballing is considered an active procedure for corrosion control.

This means that the presence of nitrogen has to be continuously monitored
using pressure measurement instrumentation.

Prior to pressurizing the equipment with nitrogen, it is necessary to effectively

purge the system with nitrogen. Purging is done by cycles of pressurization by
nitrogen followed by venting until the oxygen concentration is reduced to less
than 1%.

The former method is dangerous, expensive and high-maintenance, requiring daily monitoring
to check nitrogen levels. Inevitable nitrogen leakage requires nitrogen replenishment.

Corrosion can’t occur when parts are stored in environments with

relative humidity below 40%

Tanks, pressure vessels and pipework. In all cases ensure these

are 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. Provide a small flow and arrange for some simple
telltale mechanism to show pressure, flow and level of humidity
(e.g., indicator cards).

Keep the temperature at 30-40C

Slightly positive pressure +0.5 psig (see arabian monitoring check). Some says 5-
10 psig. Install gauges for monitoring.

Depending on volume and the service of the system my first choice would be to initially purge it with
nitrogen to remove any O2 and then pack it with Nitrogen to a low pressure (2-3Psi) , maintain this with a
bottle rack and regulator.  I would be wary of using nitrogen from a membrane system as they are still
quite high in O2.  

This means - isolate, drain, vent, purge and inertize all vessels, rotating equipment and piping, and
maintain it under slight positive pressure. Ideally use Nitrogen because it is not flammable. In normal
circumstances one could also use dry fuel gas, but since you are facing potential security problems it is the
best if you keep your systems free of anything that can burn or explode. I'm thinking that even leaving the
entire plant exposed to atmospheric air (after purging) is a better option than filling it with fuel gas. No
real damage should happen within 1-2 months if equipment is open to ambient air.

Reference:

- MTI publication 34, Guidelines for the  Mothballing of Process Plants

- API Guide for Inspection fo Refinery Equipment, Chapter XVIII-Protection of Idle Equipment, 3rd Edition.
Apr-1982
- Cortec Corp., Temporary Protection, Lay-up and Mothballing Equipment, Systems and Plant

1989 by NACE for MTI, softcover, 128 pages, 2 figures, 3 tables. ISBN 1-877914-00-2

NBIC code RB-3238 (1998 Interpretations):

INTERPRETATION 98-03
Subject: RB-3238 Interrupted Service
1998 Edition with the 1995 Addendum

Helium Leak Testing- A combined nitrogen purge with a helium leak test is used in the commissioning
and start-up of onshore and offshore process.