Professional Documents
Culture Documents
: 26071-V7A-A-331-07A/B-WHB-01-00070
PO NO : 26071-131-PO-MBF0-00007
REVISION LOG
HOLD LIST
Project :
Client : RDMP-JO BALIKPAPAN Sheet 4 of 38
TABLE OF CONTENTS
Page
1 INTRODUCTION ..................................................................................................................................... 6
11 ATTACHMENTS ...................................................................................................................................23
RDMP-JO – PERTAMINA Doc. No.: 1211-0-Q-155
RDMP- UNIT V Date: 21/09/2020
Balikpapan, Indonesia Rev.: 000
Page: 6 of 38
1 INTRODUCTION
This document specifies the requirements and gives recommendations for the preservation of
equipment and piping staying idle up to HRSG s. It contains procedures for short term and long
term preservation of specific items of plant and components parts.
After HRSG first firing the preservation procedures described in O&M manual 26071-V7A-A-331-
07A/B-WHB-01-00001 (1211-0-A-500) will be applied.
This document refers to equipment supplied by Macchi destined to Balikpapan Refinery and
composed by No. 2 HP + 2 MP HRSG and relevant accessories
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:
presence of operating plant which could affect environmental conditions;
coastal areas with presence of salty environment;
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.
RDMP-JO – PERTAMINA Doc. No.: 1211-0-Q-155
RDMP- UNIT V Date: 21/09/2020
Balikpapan, Indonesia Rev.: 000
Page: 7 of 38
2 REFERENCE DOCUMENTS
The following documents shall be taken as reference.
Macchi Doc. 26071-V7A-A-331-07A/B-WHB-01-00071 (1211-0-Q-156) “Shop preservation
procedure”
Macchi Doc. 26071-V7A-A-331-07A/B-WHB-01-00069 (1211-0-Q-150) “Painting
Specification”
Supplier’s manual in Macchi doc. 26071-V7A-A-331-07A/B-WHB-01-00002 (1211-0-A-501)
“Technical Catalogue”.
Macchi Doc. 26071-V7A-A-331-07A/B-WHB-01-00001 (1211-0-A-500) “Operating and
Maintenance Manual”
3 EQUIPMENT PRESERVATION
This document defines the recommendations relevant to preservation in the following project
stages:
At workshop/assembling yard before shipment (by Macchi).
Before erection from equipment arrival at jobsite (by erection company).
During erection (by erection company).
After erection completion up to commissioning (by erection company).
4 PRESERVATION MATERIALS
For other general uses dedicated to preservation and maintenance, here below are summarized
/ suggested the products to be used.
(greased)
Plugs Plastic
Temporary blinds Plywood
Tectyl 5350W or SHELL ENSIS FLUID V or
Protective oil
equivalent
Lubricant Teflon Spray based AREXONS System TT163 or equivalent
Self Amalgamating tape Densolen E10 or PIB 2504
Solid Lubricant Paste Molykote 1000 or Jet Lube 550
Corrosion inhibitor emitter CORTEC VpCI-105 or equivalent
Plastic protection sheet Heat shrink-wrap METALBOLD or equivalent
Corrosion inhibitor for pressure parts Protecsol 770P
Desiccant Silica gel
For the preservation maintenance to be carried out at site, it is allowed to use equivalent
materials with equivalent features.
The list of product is only indicative and could be extended upon the need in site.
Notes:
[1] In case desiccants are used (e.g. Silica gel), desiccant materials shall not be in direct contact
with metallic surfaces and shall be placed onto wood trays inside the items.
[2] Products required for preservation maintenance to keep initial preservation even for period
longer than 12 months and/or to restore initial preservation in case damages occurred during
transportation from arrival port to site/storage at site are NOT included in Macchi scope of
supply.
[3] Products required for preservation during erection & commissioning are NOT included in
Macchi scope of supply.
RDMP-JO – PERTAMINA Doc. No.: 1211-0-Q-155
RDMP- UNIT V Date: 21/09/2020
Balikpapan, Indonesia Rev.: 000
Page: 9 of 38
7 SAFETY INSTRUCTIONS
(1) When open the steam drum manholes and/or remove the blinds on steam/water lines,
use all necessary PPE such as mask, gloves and goggles (refer to MSDS attached to
this procedure) since corrosion inhibitor (Protecsol 770P) has been used for shipping
preservation as per document 26071-V7A-A-331-07A/B-WHB-01-00071 (1211-0-Q-156)
RDMP-JO – PERTAMINA Doc. No.: 1211-0-Q-155
RDMP- UNIT V Date: 21/09/2020
Balikpapan, Indonesia Rev.: 000
Page: 10 of 38
GENERAL NOTES:
Lay-up method
shop preservation
procedure #1
procedure #2
procedure #3
procedure #4
procedure #5
procedure #6
procedure #7
remarks
Location Lay-up period Note 1
HRSG loose
parts not yet
up to 12 months
erected
waterside
> 12 months Note 2
up to 2-3 weeks
fireside
> 2-3 weeks
Note 1: the lay-up period is referred to the time elapsed from HRSG arrival at jobsite.
Note 2: In case the HRSG erection activities don't start within 12 months from HRSG
arrival provide to re-apply the shop preservation according to Macchi document
No. 26071-V7A-A-331-07A/B-WHB-01-00071 (1211-0-Q-156)
RDMP-JO – PERTAMINA Doc. No.: 1211-0-Q-155
RDMP- UNIT V Date: 21/09/2020
Balikpapan, Indonesia Rev.: 000
Page: 12 of 38
m) Insulated parts where people tend to step shall be protected on top with 10 mm plywood.
n) All precaution shall be taken to avoid damages to painted items and insulation materials.
o) Particular precautions shall be taken in case site sandblasting is carried out. Equipment
shall be protected and sealed to prevent sand entering in the circuits.
p) Maintain always good housekeeping during all activities.
10.1 INTRODUCTION
The recommendations outlined in this section are for general guidance and should be used to
develop the preservation procedure required for each item or group of similar item.
Specialist advice should be sought from plant owner on the preservation of items not specifically
indicated in this section.
Lay-up method
shop preservation
procedure #1
procedure #2
procedure #3
procedure #4
procedure #5
procedure #6
remarks
Location Lay-up period Note 1
commissioning
HRSG before
up to 5 days
waterside up to 3 months
> 3 months
up to 2-3 weeks
fireside up to 3 months
> 3 months
Note 1: the period is referred to the time elapsed from HRSG erection completion.
As a general rule, for medium and long period before starting any preservation activities
Stop all rotating equipment and ensure the facility is not operating;
De-energize and lock out all breakers;
Isolate equipment from line;
Remove and preserve coupling or spacer between the fan and driver to facilitate rotating of
rotor;
Properly tag and store spacer and/or coupling parts;
Provide electric motors with a warning that they “Energized” or “De-energized”;
Provide equipment with warning when space heaters have been installed;
All exposed shafts and polished surfaces shall be thoroughly cleaned and protected with a
rust preservative (e.g.: Tectyl 506-EH or equivalent);
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. Proper lubrication of bearing shall be confirmed before manual rotation.
Cover and seal with plastic sheets the suction side to prevent entrance on contaminants.
11 ATTACHMENTS
Page 1 of 3
ATTACHMENT #1
GENERAL NOTES:
a) For shop preservation of all HRSG pressure parts refer to Macchi document 26071-V7A-A-331-07A/B-WHB-01-00071 (1211-0-Q-156(
b) Once HRSG is arrived in site, tarpaulins shall be applied during all storage period.
c) During preservation period, if inspections to pressure parts internals are required, proper procedure for confined spaces shall be applied. Assure proper ventilation before entering and verify by means of an analyzer that the oxygen content is 20.5-21% vol.
NOTES
1) If the storage period will be extended over 12 months check every 30 days the conditions of pressure parts external surfaces
2) The integrity of shop applied tarpaulins, if provided, has to be verified. If the boiler/equipment is shipped with external temporary preservation or shop applied painting, after 6 months the preservation integrity shall be checked and, in case of damages, restored. Particular warning shall be addressed to possibility of
water collection.
3) Internally protected with corosion inhibitor PROTECSOL 770P
4) All ends of the TEE-BOX will be closed with tarpaulins or wooden sheets
5) Leave the materials in their shipment packages during storage. Do not remove blanking devices (where provided).
6) Vessels, equipment and piping of austenitic stainless steel shall be thoroughly checked because deposits, eventual pockets of water can lead to serious corrosion. Water containing a concentration of chlorides may precipitate stress corrosion cracking or pitting.
7) If the storage period will be extended over 12 months check every three months the conditions of pressure parts external surfaces
8) When the materials reach the jobsite they will be stored according to the following features: ambient temperature 20°C ± 5°C - relative atmospheric humidity 60 ± 10%
Page 2 of 3
ATTACHMENT #1
10) Place on concrete floor or dry ground floor, properly supported keeping suitable distance from floor, to avoid any contact with possible water/mud
Page 3 of 3
RDMP-JO – PERTAMINA Doc. No.: 1211-0-Q-155
RDMP- UNIT V Date: 21/09/2020
Balikpapan, Indonesia Rev.: 000
Page: 27 of 38
The short term HRSG preservation (≤ 3 months) of the fire side may be carried out as follows:
1) Install necessary blinds in the main fuel lines and pilot gas line.
2) Thoroughly inspect the flue gas side. If deposits are found out on the tubes external
surfaces provide to remove them by compressed air.
3) The HRSG should then be isolated from external environment to reduce as much as
possible the entry of air.
4) Seal the enclosures, GT exhaust gas inlet, flue gas outlet with plastic sheets and tape
completely to prevent entry of 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) Distribute hygroscopic chemicals (e.g. silica gel or equivalent), along flue gas path, at the
amount of 1 kg at cubic meter (in accordance with supplier instructions). Do not place
chemicals directly in contact with metals.
7) Carry out periodical inspection of chemicals.
8) Follow supplier instructions for their substitution or regeneration.
9) All Dampers shall be closed to avoid, as much as possible, draft effect and contact with
ambient air
RDMP-JO – PERTAMINA Doc. No.: 1211-0-Q-155
RDMP- UNIT V Date: 21/09/2020
Balikpapan, Indonesia Rev.: 000
Page: 28 of 38
The long term HRSG preservation (> 3 months) of the fire side may be carried out as follows:
1) Install necessary blinds in the main fuel lines and pilot gas line.
2) Thoroughly inspect the flue gas side. If deposits are found out on the tubes external
surfaces provide to remove them by compressed air.
3) Install new gaskets on all enclosure openings and access doors.
4) Close dampers, seal the HRSG 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 man
ways to prevent entry of air.
6) Remove the pilot burners and flame scanner and seal tightly the openings.
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) Install a thermometer to check the temperature of the fire side from outside. Ensure that the
thermometer entry location is tightly sealed.
9) Make all cable entries into the flue gas side air tight.
10) Keep humidity below 50%. Take readings of temperature, relative humidity on regular basis.
RDMP-JO – PERTAMINA Doc. No.: 1211-0-Q-155
RDMP- UNIT V Date: 21/09/2020
Balikpapan, Indonesia Rev.: 000
Page: 29 of 38
The short term HRSG preservation (≤ 3 months) of the HRSG water side may be carried out as
follows only if the pressure parts erection activities have been completed:
1) Drain completely the HRSG immediately after hydrostatic test.
2) Special care is paid to drain fittings, measuring instruments connection lines, water levels,
etc.
3) The residual water in pressure parts (if any) can be eliminated using cycle of
pressurization/depressurization at 3 kg/cm2g. Best performance will be obtained using
Nitrogen.
4) Check all surfaces are in clean conditions. Inspect steam and water drum conditions; where
necessary wipe off residual water (if any).
5) Place corrosion resistant trays (e.g. wood) inside each drum to avoid any contact with
metallic surfaces. The trays will be supported to allow air circulation under them.
6) Distribute hygroscopic salts (e.g. silica gel) on the trays in the quantity of 1 bag of 250 g. per
1 m3 of volume at full capacity (Quantity of desiccant shall be in according supplier
recommendations). Close drains, manholes, vents, etc.. The HRSG volume is 64.3 m3.
7) Check periodically the conditions of chemicals and restore it.
8) Follow supplier instructions for their substitution or regeneration.
RDMP-JO – PERTAMINA Doc. No.: 1211-0-Q-155
RDMP- UNIT V Date: 21/09/2020
Balikpapan, Indonesia Rev.: 000
Page: 30 of 38
This procedure shall be applicable in Site when HRSG pressure part activities have been
completed and Hydrotested.
The long term HRSG preservation (> 3 months) of the HRSG water side may be carried out as
follow.
1) Drain completely the HRSG from lower part opening HRSG steam drum vents immediately
after hydrostatic test.
2) Special care is paid to drain fittings, measuring instruments connection lines, water levels,
etc.
3) Open steam and water drum and manually remove residual water.
4) The residual water in pressure parts (if any) can be eliminated by nitrogen pressurization
3 kg/cm2g.
5) Drain from HRSG bottom parts.
6) Check that the relative humidity is lower than 40%. If not, it will be necessary to repeat
nitrogen pressurization. Pressurization with nitrogen and quick opening of drain valves will
improve water removal.
7) Flush the HRSG with nitrogen, using the steam drum vent nozzle, to blow out completely
the air contained (typically 5 volumes of nitrogen). The amount of the residual oxygen in the
gas vented from HRSG and superheater drains must be checked. When its concentration is
lower than 2% in every venting point, it is possible to bottle-up the HRSG. The HRSG
volume is: 64.3 m3.
8) Seal the HRSG after gas filling. Keep constantly the protective gas under low pressure of
0.3 kg/cm2g
9) Apply warning plates in proximity of HRSG manholes and access doors to prevent anybody
to enter while in preservation.
10) Daily check the nitrogen pressure.
RDMP-JO – PERTAMINA Doc. No.: 1211-0-Q-155
RDMP- UNIT V Date: 21/09/2020
Balikpapan, Indonesia Rev.: 000
Page: 31 of 38
The short term HRSG preservation (≤ 3 months) of the water side may be carried out as follows.
1) Add demineralized and deaerated (if available) water to fill-up all the maximum possible
volume.
2) Add 500 ppm of Oxygen Scavenger, sufficient alkalinizer agent (typically ammonia) to rise
pH up to 10.
3) Pressurize with nitrogen using the steam drum vent nozzle. Keep nitrogen pressure at
0.3 kg/cm2g
4) After one week the HRSG water has to be tested to verify the chemicals concentrations, pH
and residual oxygen water. If pH decrease below 9.5 add alkalinizer agent
5) Periodically check the nitrogen pressure and restore water level if necessary.
1) HRSG Module
a) Weld on the blanked nozzles of the upper headers the nitrogen temporary filling
connections complete of temporary interception valves. The connections already
provided for shop corrosion inhibitor injection shall be used for this purpose.
b) Weld on the blanked drain nozzles of each bank the temporary vent connections
complete of temporary interception valves.
c) Flush banks with nitrogen, using the nitrogen temporary filling connections, to blow out
completely the air contained (typically 5 volumes of nitrogen). The amount of the
residual oxygen in the gas vented from HRSG drains must be checked. When its
concentration is lower than 2% in every venting point, it is possible to bottle-up the
HRSG. The total water volume is
Module #1: 18.9 m3.
Module #2: 7.2 m3.
d) Seal banks after gas filling. Keep constantly the protective gas under low pressure of
0.3 kg/cm2g
e) Apply warning plates in proximity of HRSG manholes and access doors to prevent
anybody to enter while in preservation.
f) Periodically check the nitrogen pressure.
RDMP-JO – PERTAMINA Doc. No.: 1211-0-Q-155
RDMP- UNIT V Date: 21/09/2020
Balikpapan, Indonesia Rev.: 000
Page: 33 of 38
2) Steam drums
a) Check all surfaces are in clean conditions.
b) Place corrosion resistant trays (e.g. wood) inside the drum to avoid any contact with
metallic surfaces. The trays will be supported to allow air circulation under them.
c) Distribute hygroscopic salts (e.g. silica gel) on the trays in the quantity of 1 bag of 250
g. per 1 m3 of water volume at full capacity. Close manholes.
d) Steam drum volume is 30.8 m3.
e) Check periodically the conditions of chemicals and restore it.
f) Follow supplier instructions for their substitution or regeneration.
Alternatively preservation with nitrogen could be used.
NOTE 1: HRSG loose pressure parts preservation validity before starting erection
activities is 12 months.
PROCEDURE 7 – HRSG LOOSE MODULES (FLUE GAS SIDE) NOT YET ERECTED
This procedure will be followed for the HRSG flue gas side preservation in case the HRSG
modules remain in the storage area as delivered.
1) Modules M1, M2
a) Check all surfaces are in clean conditions.
b) If required perform the preservation maintenance by cleaning/removing the eventual
rust present on the surfaces and apply again the protective coating according to
Macchi doc. No. 26071-V7A-A-331-07A/B-WHB-01-00069 (1211-0-Q-150)
NOTE: in case of HRSG erection activities are interrupted at an intermediate phase, the
HRSG flue gas side shall be put in preservation. Please contact Macchi technical
department to define in detail the suitable preservation procedure to be followed
according to the erection progress.
RDMP-JO – PERTAMINA Doc. No.: 1211-0-Q-155
RDMP- UNIT V Date: 21/09/2020
Balikpapan, Indonesia Rev.: 000
Page: 35 of 38
4.4 Storage
If the machine is not installed immediately upon receipt and is fitted with antifriction bearings,
rotate the shaft of the fan manually or in a similar manner for several turns, once every 2 or 3
weeks.
This way, the grease inside the bearings will cover any less protected parts of the bearing,
also preventing condensation.
Lock the impeller to prevent any accidental rotation due to air draughts
If the Centrifugal fan is fitted with drive belts, we recommend reducing the belt tension by
slightly loosening the turnbuckles.
The belts must be tensioned properly shortly before starting the machine.
Periodically, check the condition of the parts to avoid surface oxidation.
After long periods of inactivity, the machine must be commissioned by HDF S.r.l. technical staff
or by technical staff authorised by HDF S.r.l., ensuring that:
the conditions and characteristics of the Centrifugal fan before storage have been kept
unchanged;
there are no signs of corrosion on the frames;
here are no signs of breakage due to improper storage;
the electrical connections are efficient and there are no damaged cables;
the pneumatic connections are efficient and there are no broken pipes;
that all safety devices installed, tested manually are efficient.
Code: HDF_M_C_EN_2020_07_R08
This document is the exclusive property of HDF S.r.l. Any reproduction thereof, either whole or in part, is forbidden Page 39 of 96
FRESH AIR FAN - PRESERVATION AT SITE
3. HANDLING
The packages, as well as the unpacked equipment, shall be carefully handled to avoid damages
during handling.
Suitable hoisting / lifting equipment shall be used based on the weight / dimension and physical
characteristics of the items.
For packaged equipment, each package shall clearly indicate the positioning of lifting points.
Please refer to Packing List for details on dimensions and weights.
For unpackaged equipment, each piece of equipment is provided with suitable lifting lugs.
Please refer to G.A. drawings for details on dimensions, weights and location of lifting lugs.
All packages are thoroughly inspected prior to shipment. Regardless, rough handling en-route may
damage the packages and equipment. The receiving party must thoroughly inspect all packages
from possible damages. Any damaged parts are the responsibility of the carrier and should be
reported to him immediately upon arrival.
Boldrocchi shall be notified in writing immediately of any damages, lost or undelivered parts.
5. STORAGE UP TO 12 MONTHS
Above preservation as per par. 1 will guarantee outdoor storage up to 12 (twelve) months under
below conditions: