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1.1 GENERAL
If a boiler is taken out of operation for either a short or a long period, adequate precautions must
be taken in order to prevent corrosion during shutdown.
It shall be highlighted that the climatic conditions play an important role in determining the rate of
corrosion for unprotected equipment. In particular the rate of corrosion may increase in areas
where the atmosphere has high humidity and contains corrosive contaminants.
In general the selection of preservation type shall be also based on:
¾ presence of operating plant which could affect environmental conditions;
¾ coastal areas with presence of salty environment;
¾ sand and dust.
For reference here below is shown a curve which indicates the correlation between the relative
humidity and the corrosion rate of metal surface.










For steam generator both water side and fire side must be protected against possible corrosion
damage during idle period.
In the case that idle period is less than five days for water side and fifteen days for fireside, no
preservation procedures are deemed necessary.
This “grace” period could be longer in case of favourable environmental conditions (to be verified
case by case).
The water-side preservation can be carried out either with the wet or the dry method.
The dry method preservation is based on nitrogen filling under light pressure.
Macchi recommends also the dry method when the air temperature could be below +5°C and
wet preservation is not applicable.

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The wet preservation is based on the neutralization of the dissolved oxygen existing in the boiler
water by adding suitable chemicals, and pressurization with nitrogen.
The preservation period has been divided in:
¾ SHORT-TERM preservation up to 3 months
¾ LONG-TERM preservation more than 3 months
The following diagram indicates the preservation procedure to be applied for pressure parts and
for fire side care.

Each time the boiler is put out of service, the flue gas side must be
preserved according to the procedure #1 or #2 as applicable (refer to
preservation chart). Indeed if the boiler is not properly preserved the
ambient temperature variation between day and night facilitates the
condensation of the air humidity and this water is absorbed by the
refractory castings. Consequently the excess of water in the castings
can lead to corrosion on the tubes embedded in the refractory.

1.1.1 Preservation selection chart

















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1.2 PRESERVATION PROCEDURES

1.2.1 Safety precautions

Before to perform the preservation procedures on the flue gas water sides it is necessary to
adopt the following safety requirements:
1) The boiler is out of service, depressurized and cooled at ambient temperature.
2) The firing system has been put in safety conditions.
3) Before to enter in the boiler flue gas side and water side verify, by means of an analyzer,
that the oxygen content is 19.5-20.5% vol.
4) Before to proceed with the boiler preservation verify that the damper on air side is closed.

Preservation activities may require the access of a confined space, the use
of hazardous chemicals and/or toxic/asphyxiating gas, electric equipment,
etc…dedicated PTW procedures to be respected
During preservation period, if inspections to steam drum internals are
required, be sure to vent completely the nitrogen and assure proper
ventilation before entering the drum.
When nitrogen is vented to atmosphere, do not draw near the vent zones for
not breathing this gas.

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1.2.2 Procedure #1 – Fireside preservation (short term)

The short term preservation of the boiler fire side (” 3 months) may be carried out as follows:
1) Install necessary blinds in the main fuel lines and pilot gas line.
2) Inspect refractory and tubes on fire side. Acid type external deposits, if found, shall be
removed from surfaces. Normally pressurized (and alkalized) water or steam lances are
necessary to properly clean the tube surfaces.
After tubes are cleaned they shall be rinsed with an alkalized water (for example 1%
Na2CO3) to neutralize any residual acid components from the ash deposit. After the final
rinse (when pH of rinsing water > 8) it is very important that all the surfaces be thoroughly
dried.
NOTE: in the case of sulphur free fuel or ash free fuel firing point No. 2 is not applicable.
3) Install new gaskets on all furnace / combustion chamber openings and access doors.
4) Seal the furnace, combustion air inlet, flue gas outlet with plastic sheets and tape
completely to prevent ingress of air. All holes shall be closed to avoid, as much as possible,
draft effect and contact with ambient air.
5) Protect pilot burner and flame scanners by applying a corrosion inhibitor on wirings and
wrapping the equipment with glass fibre aluminium coat and seal with tape. Seal tightly the
openings. Seal the burner sight glasses tightly (if applicable).
6) Prior to close the last opening distribute hygroscopic chemicals (e.g. silica gel or
equivalent), along air/flue gas passages and inside the furnace, at the amount of 1 kg per
cubic meter (for different chemicals refer to supplier instructions). Do not place chemicals
directly in contact with metals. Carry out periodical inspection of chemicals.
7) Follow supplier instructions for their substitution or regeneration.
8) Monitor humidity inside furnace / combustion chamber through dedicated instrument; it must
be below 50%.
9) In case despite all precautions in place atmospheric moisture condensates on the tubes /
ductworks install hot air blower as for 10.2.3 clause 7 to 11).

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1.2.3 Procedure #2 – Fireside preservation (long term)

The long term preservation of the boiler fire side (> 3 months) may be carried out as follows:
1) Install necessary blinds in the main fuel lines and pilot gas line.
2) Inspect refractory and tubes on fire side. Acid type external deposits, if found, shall be
removed from surfaces. Normally pressurized (and alkalized) water or steam lances are
necessary to properly clean the tube surfaces. After tubes are cleaned they shall be rinsed
with an alkalized water (for example 1% Na2CO3) to neutralize any residual acid
components from the ash deposit. After the final rinse (when pH of rinsing water > 8) it is
very important that all the surfaces be thoroughly dried.
NOTE: in the case of sulphur free fuel or ash free fuel firing point No. 2 is not applicable.
3) Install new gaskets on all furnace / combustion chamber openings and access doors.
4) Close stack blinds, seal the furnace, and cover the FD fan air inlet with plastic sheets and
tape completely to prevent entry of air.
5) Seal with plastic sheet and tape all inlet and exhaust ducts, observation ports and duct
manways to prevent entry of air.
6) Remove the pilot burner, flame scanners and seal tightly the openings. Seal the burner
sight glasses tightly. Wrap the burner cone (furnace side) with plastic sheet and tape.
7) Place electric heaters (or other systems) inside the furnace and flue gas duct. Keep metal
surfaces above ambient temperature to reduce moisture in the system. Install ammeters
outside the furnace to check the operation of the heaters.
NOTE: for installation of heaters consult specialized company.
8) Keep humidity below 40%. Take readings of temperature, relative humidity on regular basis.
9) Install a thermometer to check the temperature of the fire side from outside. Ensure that the
thermometer entry location is tightly sealed.
10) Make all cable entries into the fire-side air tight.
11) Place in the flue gas duct and economizer silica gel or equivalent.
12) If the lay-up period is longer than 6-12 months the need for application of VCI or rust
prevention product on the fire side tubes will be evaluated in relation to the environmental
conditions severity.


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1.2.4 Procedure #3 – Waterside wet preservation (short term)

The wet preservation is based on the neutralization of the oxygen contained in the boiler water.
The neutralization is obtained by means of the addition of suitable chemicals.
The use of hydrazine is not recommended because this product is carcinogenic. On the contrary
it is recommended the use of volatile products equivalent to hydrazine. We advise against the
use of non-volatile products.

The use of sulfite as oxygen scavenger is not allowed

The boiler (economizer, evaporating tubes and the superheater) has to be filled with deaerated
water containing suitable chemicals to neutralize the dissolved oxygen contained in water.
The short term boiler preservation (” 3 months) of the water side may be carried out as follows.
For the wet preservation of the water side of a boiler it is recommended to follow this procedure:
1) Let cool the boiler.
2) Open the following valves:
™ Saturated steam line vents (tag No. 113, 114).
™ Main steam line drains (tag No. 121, 125).
3) Close the following valves:
™ Main steam stop valve and its by-pass (tag No. XV-500, 010).
™ Continuous blowdown line isolation valve (tag No. 172).
™ All sampling lines isolation valves (tag No. 130, 131, 173).
™ Start-up vent valves (tag No. 007, HV-500).
™ All steam traps isolation valves.
4) Connect the nitrogen temporary filling line to the connection provided on the saturated
steam line vent.
5) Fill the boiler with deaerated water and inject an oxygen scavenger (volatile type) to
maintain a residual concentration in the range 200 ppm to 400 ppm. Add sufficient
alkalinizer agent (typically ammonia or morpholine) to adjust the water pH between 10 and
11. The superheater is filled with deaerated water too.
6) Stop the boiler filling when the water overflows from saturated steam line vent and from
main steam line drain. Close all vents and the drain valves previously opened.

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7) Pressurize with nitrogen at 0.3 bar(g). It is important to pressurize the boiler to avoid air
entry.
8) Once a day check the nitrogen pressure
9) After one week the boiler water has to be tested to verify the concentration of oxygen
scavenger and the pH.
10) If the pH decreases below 9.5 and/or the concentration of oxygen scavenger < 200 ppm,
add required amount of chemicals by partially draining the boiler (opening one drain each
time during refilling) and then fill it up again with fresh conditioned water.

1.2.4.1 Re-start after wet conservation

To re-start the boiler proceed as follow:
1) Disconnect the nitrogen temporary filling line and install the blind flange on the relevant
connection.
2) Remove all items added on flue gas side as for 10.2.2 and restore it as for normal operation
3) Open saturated steam line vents (tag. No. 113, 114).
4) Open the drain valve (tag No. 013, 015) to restore the normal start-up level.
5) Open superheater and main steam line drains (tag No. 163 to 166).
6) Proceed with the boiler cold start-up as described in chapter 7 “start-up”.

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1.2.5 Procedure #4 – Waterside dry preservation (long term)

The long term boiler preservation (> 3 months) of the water side may be carried out by filling with
nitrogen (N2).
The procedure for nitrogen filling is the following:
1) Isolate boiler from rest of plant. Install blinds.
2) Before to drain completely the boiler check that the following valves are opened:
¾ Saturated steam line vents tag No. 113, 114
¾ Start-up vent tag. No. HV-500
¾ SH steam lines drains tag. No. 163 to 166
3) Before to drain completely the boiler check that the following valves are closed:
¾ Main steam stop valve tag. No. MOV-500
¾ Main steam stop valve by-pass tag. No. 010
¾ Desuperheater control valve tag. No. FV-502
¾ Continuous blowdown, intermittent blowdown and sampling lines isolation valves
¾ BFW line to economizer isolation valve tag. No. FV-500, 006
4) Connect the nitrogen temporary filling line to the connection provided on the saturated
steam line vent.
5) Drain completely the boiler and the economizer by opening the following valves:
¾ Boiler drain valves tag. No. 013, 015, 159 to 162
¾ Economizer drain valve tag. No. 168, 169
After draining install a spectacle blinds on 525-MC-0-523-M1BDFA-Q in correspondence
with module limit.
6) In order to speed-up the draining introduce nitrogen or compressed air at a pressure of
7 bar(g). When the draining has been completed leave the drain and vent valves slightly
open for three weeks in order to evacuate eventual water residuals. Special care shall be
paid for draining fittings, measuring instruments connection lines, water level, etc. The
residual water in pressure parts can be eliminated using cycles of
pressurization/depressurization at 3-5 bar(g). Best performance will be obtained using
nitrogen.

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NOTE: The boiler, SH and economizer drain valves shall be operated in order to remove
the humidity that condenses when nitrogen is introduced inside the pressure parts. This will
improve the oxygen removal from pressure parts.
7) Check that the relative humidity is lower than 40%. If not, it will be necessary to repeat
air/nitrogen pressurization cycles. Pressurization with nitrogen and quick opening of start-up
vent valve will improve water removal.
8) Provide to flush the boiler with nitrogen (typically five boiler volumes).
For flushing the status of the following valves will be:
¾ Nitrogen filling line valve: Opened
¾ Saturated line vent valve: tag No. 113 Opened
¾ Drain of SH steam line tag No. 119 Opened
¾ Main steam line isolation valve tag No. 011 Closed
¾ Main steam stop valve tag. No. MOV-500 Opened
¾ Saturated line vent valve: tag No. 114 Closed
The amount of the residual oxygen in the gas vented from boiler and SH line must be
checked. When its concentration is lower than 2% in every venting point, it is possible to fill
the boiler with protective gas. The boiler total volume is 44 m³.
NOTE: the term “venting point” is referred not only to the vents themselves but also to all
drains from which the nitrogen can be discharged.
9) Seal the boiler after gas filling; keep constantly the protective gas under low pressure of
0.3-0.4 bar(g).
10) Apply warning labels in proximity of boiler manholes to prevent anybody to enter while in
preservation.
Although nitrogen is not toxic, it is an asphyxiating gas that can cause
a rapid death.
11) Periodically check the nitrogen pressure.

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1.2.5.1 Re-start after dry preservation

To re-start the boiler proceed as follow:
1) Vent to atmosphere the nitrogen contained in the pressure parts through the steam drum
and SH steam line vents.
2) Disconnect the nitrogen temporary filling line and install the blind flange on the nitrogen
connection.
3) Remove all items added on flue gas side as for 10.2.3 and restore it as for normal
operation. Remove the spectacle blinds installed on the lines
4) Fill the boiler as described in paragraph 6.3 “boiler filling”.
5) Proceed with the boiler cold start-up as described in chapter 7 “start-up”.

1.3 AUXILIARY EQUIPMENT PRESERVATION

This paragraph outlines general requirements for auxiliary equipment preservation to be carried
out at site. They are not intended to substitute the sub-vendors prescriptions. The detailed
instructions of sub-vendors, included in doc. No. XXX-A-501 “Boiler Auxiliaries Technical
Catalogue”, shall be followed in addition.

Auxiliary equipment preservation requires several different activities to be

carried out by specialized personnel based on the equipment at hand. PTW
procedures to be followed

1.3.1 General preservation criteria

The following general requirements shall be observed, when applicable:
¾ All openings shall be sealed to prevent the ingress of water;
¾ Waterproof case liners shall be used as an over wrap if the items are susceptible to damage
from rain or salt spray but do not require total protection;
¾ Polyethylene is not a vapor barrier and shall not be used to enclose or seal
equipment
¾ For Vessels, piping in stainless steel 316 (or better) no external and internal corrosion
protection is required.
¾ Bolts used for temporary blinds, if any, shall not cause corrosion on equipment (galvanized
or stainless steel bolts shall be used).

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¾ Machined and untreated carbon steel surfaces to be coated with rust preservative or a rust
protective wax.
¾ All uncoated studbolts / nuts shall be coated with grease or other suitable rust preservative.
¾ Lubricate door hinges (if provided), grease nipples and fastener.
¾ In case desiccant are used (i.e. Silica gel), desiccant material shall not be in direct contact
with metallic surfaces and shall be placed onto wood trays inside the items.
¾ During preservation period temperature and relative humidity shall be recorded regularly.
¾ Stainless steel equipment must be dried and thoroughly cleaned on both the inside and
outside and must be coated with a thick plastic based water-resistant coating.

1.3.2 Pipes and pipelines

The preservation of piping, in general, relies on the exclusion of oxygen and/or free water from
line. The protection, also, are dependent mainly on the size, on the type and material.
All piping internals shall be clean and free from debris, dirty, humidity and any foreign material.
As a general recommendation, all the lines connected to the boiler are treated with Nitrogen as
per boiler preservation; while for the interconnecting piping out of the boiler battery limit it has
been foreseen only to seal the flanges and or the blinds.

1.3.3 Valves and line accessories

Follow LOTO and dedicated procedures

The in line preservation of the valves consist in protecting both the internal surface and the
external one. In addition to the general criteria, the following instructions shall be respected.
¾ Drain valves when applicable and feasible.
¾ All ball valves shall be preserved in open position.
¾ Gate valve shall be preserved in closed position.
¾ Globe valve shall be preserved in open position.
¾ Lubricate and grease stem bearings with Teflon lubricant type.
¾ Stroke after greasing (2 or 3 times) if feasible.
¾ Tighten packing.
¾ Coat machined surfaces.
¾ Any drain holes shall be covered with tape.
¾ The stems/yokes shall be protected as a minimum with rust preservative.
¾ Protect valve handle / operator / actuator with plastic sheet water-resistant.

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1.3.4 Rotating equipment

Follow LOTO and dedicated procedures

These suggestions shall be applied to rotating machinery such as forced draft fan and driver(s).
For these types of equipment, the exclusion of moisture is essential to avoid pitting and oxidation
of critical components such as gear teeth, bearing journals, shaft seals, blading, etc.
Moreover these equipment must be properly sealed to prevent ingress of sand or sand dust
since this could cause seizure/damage.
The Preservation of the rotating equipment is made directly at site; in same cases where it is not
possible to proceed with an acceptable extent of protection it could be decided to remove and
store some components (i.e. electrical motor, rotors, ...) in a controlled atmosphere.
As a general rule, for medium and long period before starting any preservation activities
¾ Stop all rotating equipment and ensure the facility is not operating.
¾ De-energize and lock out all breakers.
¾ Isolate equipment from line.
¾ Remove and preserve coupling or spacer between the driven machine and driver to facilitate
rotating of rotor.
¾ Properly tag and store spacer and/or coupling parts.
¾ Provide electric motors with a warning that they “Energized” or “De-energized”.
¾ Provide equipment with warning when space heaters have been installed.
¾ All exposed shafts and polished surfaces shall be thoroughly cleaned and protected with a
rust preservative (e.g.: Tectyl 506-EH or equivalent).
¾ Manual rotation of shafts at weekly intervals is recommended. Rotation through a minimum
of 3½ complete turns. The position of the shaft at rest should be advanced by a ¼ turn each
time.
¾ Cover and seal with plastic sheets the suction side to prevent entrance on contaminants.

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1.3.5 External insulation

Prior to conduct any preservation activities the insulation shall be inspected. Depending on the
results of the inspection, the following measures are advised to prevent external corrosion due to
the possible ingress of water.
Short term and long term preservation
¾ On plants which are painted underneath the insulation, the insulation may be left intact for
long term periods providing it is reasonably sound and in good condition, and ends are
sealed. Insulation which is unsound, or considered susceptible, should be removed and
made good.
¾ One meter of cold insulation on vertical piping, which is not provided with vapor stops,
should be removed at the low points in order to drain condensed water out of the insulation.
¾ On plants which are not painted underneath the insulation and where a comparatively larger
proportion of the insulation may not be in good condition, consideration should be given to
removing all unsound insulation and painting the metal surfaces thus exposed.
¾ Generally, insulated columns, vessels and exchangers are more susceptible to exterior
corrosion through deterioration of the insulation than is insulated piping on plant standing
idle for 5 year or longer.

1.3.6 Electrical and electronic equipment

Preservation of electrical and electronic equipment is dependent mainly on the size and type of
equipment. It involves the preservation of entire equipment assembled and where it is not
possible to proceed in this direction, the protection consists in storing the entire
electrical/electronic equipment indoors in a controlled atmosphere.
Minimizing the moisture is essential to avoid oxidation of critical components. Sand/dust ingress
into the close clearance components in electric motors and/or junction boxes is also a concern.
The majority of transformers, motors, etc. can be preserved for short and long term without re-
commissioning concern, providing that the equipment remain energized.
In situ preservation is the first consideration that it must be taken when processing facilities are
completed. In this case these special instructions shall be applied.

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1.3.6.1 General
¾ De-energize equipment.
¾ Clean equipment internally with air-hose.
¾ Energize space heaters (if provided).
¾ Energize equipment that is to remain in service during the preservation period.
¾ Put inside equipment exposed to humidity porous bags of VCI or VCI emitters, or desiccant
(silica gel).
¾ Spray VCI on wiring and electronics.
¾ Close door and openings and seal it.
¾ Check tightness of cable glands.
¾ Electrical equipment to be wrapped in glass fiber aluminium cloth and sealed with tape.

1.3.6.2 Cables, Boxes and Cabinets

¾ Clean and dry terminal housings, boxes and control cabinets.
¾ Clean, dry and tighten all power and control connections.
¾ Protect and seal all cable ends from weather and mechanical damage.
¾ Cable entries and pneumatic tubing shall be sealed with approved stopping plugs.
¾ Junction boxes, switch boxes and electrical cabinets shall be supplied with an appropriate
amount of desiccant inside and sealed from water ingress. Notice shall be attached
indicating the presence of desiccant.
¾ Protect equipment by wrapping in glass fiber aluminium cloth and sealed with tape.

1.3.7 Burners
For both short and long preservation the burners will remain installed on the boiler.
¾ Short term preservation
¾ Protect pilot burner and flame scanners by applying a corrosion inhibitor on wirings and
wrapping the equipment with glass fibre aluminium coat and seal with tape. Seal tightly
the openings. Seal the burner sight glasses tightly (if applicable).

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¾ Long term preservation

¾ It is suggested to remove the flame scanners, the pilot burners and the flexible hoses.
¾ After dismantling inspect and clean thoroughly the components and store them in
warehouse.
¾ Inspect, clean, lubricate where required and apply rust prevention oil on the equipment.
Put the burners auxiliaries on pallets, cover with plastic sheet and store in warehouse

1.3.8 Instrument equipment

For instrumentation, minimizing the moisture is essential to avoid oxidation of critical
components. Sand/dust ingress into the close clearance components in electric motors and/or
junction boxes is also a concern.
The majority of instruments can be preserved for short and long term without re-commissioning
concern, providing the equipment remains energized.
In situ preservation is the first consideration that it must be taken when processing facilities are
completed. In this case these special instructions shall be applied.

Fluid under pressure!

¾ Drain the eventual fluid still present in the primary connections and close the interception
valves.
¾ Check the tightness of the cable glands.
¾ For long period storage apply/fasten a 6 mm plywood board to all glasses in
instrument/panel fronts and cover with aluminium glass fiber cloth and tape. For panel
fronts, a wooden frame for corner protection shall be installed in addition to the front panel.
¾ Aluminium sheeted glass fiber cloth wrapped with tape, shall be used to envelope pressure
gauges, local electronic transmitters, panels, junction boxes, temperature instruments.
¾ Protect instruments internal parts by means of VCI (Vapor Corrosion Inhibitor).
¾ All wired instrument equipment containing electronic components shall be protected with
vapor corrosion inhibitor VCI according to Manufacturer’s instructions.
¾ All openings in hydraulic/pneumatic tubing shall be provided with steel caps/plugs of
material compatible with the metallurgy of the component being capped or plugged (if any).
Non-metallic plugs shall not be used.

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¾ Gaskets/O-rings on instrument equipment to be greased with acid free Vaseline.

¾ Level gauge glass to be protected with wooden strip and covered.
¾ Relief valves to be covered.
¾ Flow sight glasses to be protected with wooden blanks and covered

1.3.9 Motor operated valves

Follow LOTO and dedicated procedures

1) Apply on the stem a rust prevention oil
2) Check the tightness of the cable glands
3) Protect the actuator with plastic sheet
4) For detailed information refer to manufacturer instructions.

1.3.10 Control valves

Follow LOTO and dedicated procedures

1) Apply on the stem a rust prevention oil
2) Close the instrument air valves
3) Check the tightness of the cable glands
4) Protect the actuator with plastic sheet
5) For detailed information refer to manufacturer instructions.

1.3.11 Pneumatic shut-off valves

Follow LOTO and dedicated procedures

1) Close the instrument air valves
2) Check the tightness of the cable glands
3) Protect the actuator with plastic sheet
4) For detailed information refer to manufacturer instructions.

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1.3.12 Safety valves

Follow LOTO and dedicated procedures

1) Apply on the stem a rust prevention oil
2) Seal with plastic sheets and tape the discharge pipe or the outlet of the silencer to limit the
entry of air inside the boiler pressure parts
3) Protect with plastic sheets.
4) For detailed information refer to manufacturer instructions.

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