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STD-171 Preservation of Idle Static & Rotary Mechanical Equipment
STD-171 Preservation of Idle Static & Rotary Mechanical Equipment
JULY 1998
FOR RESTRICTED
CIRCULATION ONLY
Prepared by
OISD publications are prepared for use in the oil and gas industry
under the Ministry of Petroleum and Natural Gas. These are the
property of Ministry of Petroleum and Natural Gas and shall not be
reproduced or copied and loaned or exhibited to others without
written consent from OISD.
Though every effort has been made to assure the accuracy and
reliability of data contained in these documents, OISD hereby
expressly disclaims any liability or responsibility for loss or damage
resulting from their use.
The Oil Industry in India is 100 years old. Because of various collaboration
agreements, a variety of international codes, standards and practices have been in vogue.
Standardisation in design philosophies and operating and maintenance practices at a
national level was hardly in existence. This, coupled with feed back from some serious
accidents that occurred in the recent past in India and abroad, emphasised the need for
the industry to review the existing state of art in designing, operating and maintaining oil
and gas installations.
With this in view, the Ministry of Petroleum and Natural Gas in 1986 constituted a
Safety Council assisted by the Oil Industry Safety Directorate (OISD) staffed from within
the industry in formulating and implementing a series of self regulatory measures aimed at
removing obsolescence, standardising and upgrading the existing standards to ensure
safe operations. Accordingly, OISD constituted a number of functional committees of
experts nominated from the industry to draw up standards and guidelines on various
subjects.
The present document on " Preservation of Idle Static & Rotary Mechanical
Equipment", has been prepared by the Functional Committee on " Preservation of Idle
Static & Rotary Mechanical Equipment". This document is based on the accumulated
knowledge and experience of industry members and the various national and international
codes and practices. This document is meant to be used as supplement and not as a
replacement for existing codes and practices. It shall be borne in mind that no standard
can be a substitute for the judgment of a responsible qualified Engineer. Suggestions are
invited from the users after it is put into practice to improve the document further.
Suggestions for amendments to this document should be addressed to
The Coordinator
Functional Committee on
" Preservation of Idle Static & Rotary Mechanical Equipment",
Oil Industry Safety Directorate, 2nd Floor, “Kailash”,
26, Kasturba Gandhi Marg,
New Delhi - 110 001.
This standard in no way supersedes the statutory requirements of bodies like IBR,
CCE, Factory Inspectorate or any other Government Body which must be followed as
applicable.
FUNCTIONAL PANEL ON PRESERVATION OF IDLE STATIC &
ROTARY MECHANICAL EQUIPMENT
LEADER
MEMBERS
MEMBER COORDINATOR
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In addition to the above, various other experts from the industry contributed in the preparation,
review and finalisation of this document.
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S.No. CONTENTS
1.0 General
1.1. Introduction
1.2 Scope
1.3 Definition
1.4 Consideration for Selection of Protective System
2.0 Preservation of Idle Static Equipment
2.1 Preservation of Heat Exchangers
2.2 Preservation of Columns & Vessels
2.3 Preservation of Fired Heaters, Ducts and Stacks
2.4 Preservation of Equipment in Cooling Towers
2.5 Preservation of Atmospheric Storage Tanks
2.6 Preservation of Idle Boilers
2.7 Preservation of Pipelines
3.0 Preservation of Idle Rotary Equipment
3.1 Preservation of Idle Pumps
3.2 Preservation of Idle Compressors
3.3 Preservation of Steam Turbines
3.4 Preservation of Gas Turbine
3.5 Preservation of Diesel Engines
3.6 Preservation of Fans & Blowers
4.0 Preservation of Materials in Stores
4.1 Preservation of Heater Component
4.2 Preservation of Pipes, Pipe Fittings and Valves
4.3 Preservation of Heat Exchangers/Condensers/Coolers
4.4 Preservation of Plates
4.5 Preservation of Structural Steel
4.6 Preservation of Column Trays & Fittings
4.7 Preservation of Vessel & Exchanger Shell
4.8 Preservation of Refractory
4.9 Preservation of Spare Parts of Pumps and
Reciprocating Compressors
4.10 Preservation of Anti-Friction Bearings
4.11 Preservation/ Represervation of Components of Centrifugal
Compressor/Steam Turbine/Gas Turbine/Diesel Engine
4.12 Preservation Procedure for Equipment not Installed/
kept at Store
5.0 References
Annexure I
Commonly Used Preservative
OISD-STD-171
PRESERVATION OF IDLE STATIC
& ROTARY MECHANICAL EQUIPMENT
1.0 GENERAL
a) Preservation :
1.1. INTRODUCTION Preservation is safeguarding of
unattended and inactive equipment
Preservation of idle equipment from deterioration during their down
installed in the plant involves period.
safeguarding unattended and
inactive equipment from b) Coating :
deterioration during their down Coating means an application of a
period, generally above one month coat of preservative media like
arising out due to the reasons like paint, Oil or grease etc.,
feed problems, haulage problem,
major repairs, revamps, c) Surface Preparation :
modifications, retrofitting, etc. Surface Preparation includes
Deterioration of equipment during cleaning of the parent metal surface
periods of idling is usually caused for removing foreign particles like
by conditions entirely different from rust, scale, liquid etc., by
those that exist during operation. mechanical or chemical cleaning
Many deposits formed during techniques.
operations turn usually corrosive
under shutdown conditions. 1.4 CONSIDERATION FOR SELECTION
Moisture, oxygen, dirt, dust, OF PROTECTIVE SYSTEM:-
ultraviolet rays, extreme pressure
and temperature, corrosive A careful study should be undertaken
environment of coastal areas and before finalising a protection system.
closeness to other chemical plants, This should consider the type of
are the some of the factors causing equipment, its cost and ease of
deterioration. repair/replacement, period of
protection, rate of deterioration
Preservation of static and rotary expected and allowable deterioration
equipment and their spare parts, etc. Equipment, which can be shifted
which are required to be kept in easily, should preferably be moved to
store for prolonged periods, needs warehouse.
to be carried out to prevent their
deterioration, and as such Before going for protective measures,
preservation procedures for the following should be considered:
equipment/spares kept in store
should be adopted. New equipment a) Period of shutdown
received at plant/project site should
be preserved considering b) Allowable deterioration and rate of
manufacturer’s recommendations. deterioration
c) Fired Heaters, Ducts & e) All the exposed bolts and flanges to
Stacks be coated with grease.
b) Purge with nitrogen after ensuring c) When the external surface of the
that all the openings are sealed furnace/ducts/stack reveals paint
and leak free. Maintain a positive failure, it is advisable to touch up
pressure of 100 mm of water and maintain the paint on a regular
column. Alternatively spraying oil schedule. Sulphur deposits if
on the inner surfaces or filling and found, should be removed.
draining oil or placing desiccants
like bags of lime or silica gel may d) Refractory should be kept dry at all
be considered. the times to prevent any cracking
due to water ingress. The ingress
c) Remove the safety valves (bolted of atmospheric moisture should be
only) and close all the openings. avoided by proper capping of stack
Safety valves shall be stored and duct opening and by sealing all
indoors. those locations from where water or
moist air can seep in.
d) Coat all the exposed bolts anchor Supplementary heat or a desiccant
bolts, gaskets, flange faces with can also be considered.
grease/preservative oil.
2.4 PRESERVATION OF EQUIPMENT
e) Austenitic stainless steel IN COOLING TOWERS
components shall be suitably
passivated before exposure to The cooling tower consists of concrete
atmosphere in line with the basin, main structure of red wood, fan
procedure as laid down in NACE and fan motor. The conditions are more
Standard RP-01-70. severe when the cooling tower is in
operation than it is idle. Following
2.3 PRESERVATION OF FIRED preservation procedures should be
HEATERS, DUCTS AND STACKS adopted while cooling tower is idle.
In heaters when idle, corrosion may a) Drain and flush all the pipe lines.
take place either due to condensation
or chemical reaction of atmospheric b) Drain all water from the basin,
moisture with scale/deposits on the remove all debris, muck, etc. and
clean the basin thoroughly.
to exterior corrosion due to stagnant
c) Replace all unsatisfactory structural water on the roof. Following
members. Replace warped and procedures for preservation should be
missing slats. adopted.
d) Carryout repairs to the concrete a) The tank shall be made free of gas
walls and floors of the basin for and any residue. Extra precautions
cracks, loose concrete, slope of the shall be taken when pyropheric iron
floor, etc. sulphide or residue of leaded
gasoline are present.
e) Remove fan motor and protect it as
per OISD-146 (Preservation of idle b) All the loose scales on the internal
electrical equipment). surface of the tank should be
removed.
f) Drain the oil from gear box and refill
it with a high grade mineral oil. c) The internal surface should be
Clean the exterior surfaces of the coated with preservative oil by
gear reducer housing and paint spraying. Brushing can be used in
them. Wrap all exposed shaft with the case of structural members.
Plastic tape. Store the reducer in a
warm and dry area. d) All the manholes should be closed.
h) Cover the fan drive gear with a light f) Tanks located in areas subjected to
grease and water proof paper. windstorms of high velocity shall be
filled with an inhibited water.
i) Secure the fan blades to prevent
rotation and to provide supports. g) If the tank is with steam coils, the
codensate should be drained off and
In areas where it is undesirable or the steam coil should be positively
unnecessary to remove the fan drive blinded.
components, the fan should be operated
every 3-4 weeks and routine preventive h) The tanks isolated from service shall
maintenance be carried out. be externally inspected annually.
The dry wood of an idle cooling tower is i) In case of floating roof tanks, the
a serious fire hazard. Therefore, for idle floating roofs should preferably be
periods of about two months, a kept afloat by filling with inhibited
perforated hose should be laid around water and roof drains be kept open.
the tower and spray water periodically to Water accumulated on the roof tops
keep wood in wet condition all the time. due to rain etc, if any, shall be
For extended shutdowns, the plenium cleaned periodically.
and fill should be sprayed with a fire
retarding chemical and a biocide. 2.6 PRESERVATION OF IDLE BOILERS
The boiler should be cleaned and Nitrogen or other inert gas may also
inspected and then filled to the normal be used for storage purpose. A slight
water level. If deaerated water is not positive pressure of the gas is
available, dissolved gases should be maintained after the boiler has been
expelled by boiling water for a short filled to operating level with deareated
time with boiler vented to atmosphere. feed water.
The boiler water alkalinity should be
adjusted with caustic soda to a c) Superheater Storage
minimum of 400 PPM. Sufficient
Sodium sulfite should also be added In some boilers it is not possible to
to produce a minimum sulfite residual separate the superheater section from
of 100 PPM. After the boiler is cooled rest of the boiler. Accordingly, it is
and before a vacuum is created, the necessary to follow the same storage
unit should be filled completely with procedure for the superheater section
water and all connections closed. as for the other portions of the boiler.
Wet storage of drainable
superheaters is relatively simple while
wet storage of nondrainable NRV. Through this accumulator
superheaters is more complicated. In steam line, steam from the main
dry storage, care must be taken to steam header enter into MUD
remove all the moisture from the DRUM and get condensed and
nondrainable superheaters by hence the boiler will be under
reheating the superheaters sufficiently pressure without keeping the
to evaporate all the water. This may burners in service. About 3 to 5
be accomplished by means of a small Tonnes per hour of steam may be
fire in the boiler furnace. In some consumed in this way to keep the
cases it may be possible to dry the boiler as Accumulator- depending
nondrainable superheaters with hot air upon the insulation of the boiler.
diverted from the air heaters of one of
the operating boiler. Depending on the To keep the boiler as accumulator
actual design, there may be a choice
as to whether the dry air is directed a) Stop the burner/s
over the external surfaces or
internally. b) Stop the FD fan
h) Rotate the pump shaft every g) Clean and cover exposed rods
three to four weeks, leaving it in with grease.
a different position each time.
h) Fill all lubricators with oil.
i) Clean the exposed pump shaft
and protect with grease. II) Preservation of idle motor driven
Injection/Metering Pumps
j) Protect the shaft couplings by
filling them with grease or a) Open all vents and drains.
coating them with a rust
preventive. b) Remove the pump, clean, fill the
liquid chamber with a lubricating
3.1.2 Preservation of Reciprocating oil and fix back the pump.
Pumps.
c) Blind the suction and discharge
I) Preservation of idle steam/air valves
driven Reciprocating Pumps
d) In case of diaphragm type pump
a) Open all vents and drains on drain the hydraulic oil from the
both the liquid end and steam/air hydraulic chamber, flush and fill
end of the pump. the hydraulic chamber with a
lubricating oil.
b) Disconnect all pipe connections,
blind the suction, discharge and e) Drain the gear box oil; flush and
steam flanges/ air connections. fill the gear box with a lubricating
oil.
c) Remove the packing from the
stuffing box and coat the stuffing f) Close all vents and drains in the
box and rods inside the box with pump and gear box.
light grease. Repack the stuffing
box with a non-metallic packing g) For pumps with gland packing,
and re tighten the gland. remove the packing, coat the
interior of the stuffing box with
d) Remove the valve cover plate light grease, repack with a few
from liquid end of the pump and rings of ordinary non-metallic
slide valve cover from steam/air packing to avoid ingress of water
end. Remove a valve from each into the stuffing box and then
end of each cylinder on the liquid retighten the gland.
end. Flush the cylinders with a
cleaning agent. Fill all cylinders 3.2 PRESERVATION OF IDLE
with a suitable preservative oil. COMPRESSORS.
Fill the steam/ air cylinders with
The following procedure should be It should be rotated by 90
adopted for preserving idle degree position after 3 months.
compressors.
This procedure shall be
3.2.1 Preservation of idle centrifugal continued subsequently.
Compressors
For compressors which are
Whenever the centrifugal idle for a period over 6
compressor is required to be at months, the following
stand still for a prolonged shutdown preservation methods may be
of more than 3 months the following used.
method may be used for preserving
the compressor components. a) Blind off all process, oil supply and
oil drain openings
a) The compressor casing may be
charged with a low positive b) Remove the rotor and associated
pressure of dry nitrogen 50 to parts, such as bearing and seals
70 mm WG during the whole and diaphragms.
time of shutdown at stand still
condition for all the c) Preserve the removed parts with a
compressors which are not protective material as detailed in
provided with oil seals. For the Para 4.9
type of compressors, which are
provided with oil seals nitrogen d) Fill the compressor system with oil
supply, may be given after through a drain opening and
putting into operation the seal displace all air from the case by
oil system. However, if the venting and close all drain and vent
nitrogen pressure can be connections.
maintained around 70 mm WG
even without seal oil system in e) Fill the oil seal system with oil.
service, nitrogen supply can be
given without operating seal oil f) The water cooling system shall be
system drained, flushed and filled with
clean fresh water dozed with
b) The lube oil and seal systems anticorrosive chemical.
should be operated for half an
hour once a week to protect the g) Change water every six months.
system against corrosion.
3.2.2. Preservation of idle Reciprocating
c) The compressor rotor shall be Compressor.
rotated by turning gear or by
hand by the following The following procedures should be
procedures: adopted for preserving an idle
reciprocating compressor.
It should be rotated by 180
degree from the standstill a) Close and seal all frame
condition after three months openings to prevent
contamination of frame interior.
It should be rotated by 90
degree after 3 months. b) When the compressor
(lubricated as well as dry
It should be again rotated by lubricated) compressor is kept
180 degree after 3 months. idle for a period less than six
months, run the motor
driven/hand driven crank
mechanism lube oil pump for 10- assemble the valve covers.
15 minutes once in every week. Clean the valves and keep them
in plastic bags with dehydrator
While the crank mechanism lube oil
pump in operation, rotate the shaft f) When lubricated compressors
by a few revolutions at least once in are kept idle for less than 6
every two weeks. The shaft need months, wet the cylinder and
not to be stopped at previous packing with sufficient quantity of
locations. lube oil and also have 10-15
piston strokes at the same time.
c) When the compressor Repeat the operation once in
(lubricated as well as dry every two weeks.
lubricated) is kept idle for more
than six months fill up the g) When dry lubricated
crank case with enough suitable compressors are kept idle for
preservative oil to bring the oil less than 6 months, Seal all
level to the mark on the oil level holes of the cylinder, purge with
gauge window. Close all holes/ dry nitrogen and maintain a
opening of the crank case and pressure of about 100 mm WG.
purge the air inside the crank If nitrogen is not available, keep
case with dry nitrogen and keep sufficient quantity of dehydrating
a nitrogen pressure of about 100 agent such as silica gel and
mm WG. Run the lube oil pump close tightly. Check periodically
for 10-15 minutes and at the effectiveness of the dehydrating
same time rotate the shaft, by a agent.
few revolutions, manually or by a
barring jack. Avoid that the shaft h) When lubricated compressors
stops in previous position. and dry-lubricated compressors
Repeat the operation once in (for process that allow traces of
two weeks. In case dry nitrogen grease), are kept idle for more
is not available, introduce in the than 6 months, take out the
crank case a suitable quantity of pistons out of the cylinders.
dehydrating agent at such a Remove the piston rings and
location that it does not get rider rings. For metallic piston
soaked with oil during the rings, apply grease on the entire
running of lube oil pump. Check surface and keep them in sealed
the effectiveness of the polythene bags with dehydrator.
dehydrating agent periodically. Non metallic piston rings do not
require any special protection.
d) Apply suitable grease on the Clean thoroughly and apply
shaft end outside the crank case suitable grease inside the
and all other exposed surfaces. cylinder and the housing for
valves and packing. Seal all
e) For lubricated compressors holes of the cylinder, purge with
keep the compressor valves dry nitrogen and maintain a
immersed in suitable rust pressure of about 100 mm WG.
preventive oil. As an alternative If dry nitrogen is not available,
apply rust preventive oil on the keep sufficient quantity of
compressor valves and keep dehydrating agent such as silica
them in plastic bags with gel inside the cylinder and check
dehydrator. For dry lubricated the effectiveness of the
compressors remove the valves dehydrating agent periodically.
from cylinder, put sufficient Fill lubricators with lubricating oil.
quantity of dehydrating agent in For dry-lubricated compressor all
the valve chambers and traces of rust preventive grease
shall be removed before putting manual condensate drains of
into service. inter cooler and after cooler and
ensure all drain pipes are free.
i) When dry-lubricated Close the drains and reopen
compressors for process that do them only after the unit has
not allow traces of grease, are stopped.
kept idle for more than 6
months, the pistons, piston b) Remove the moisture trap flange
rings, valves and packing shall of the inter cooler and place
be degreased with thinners and sufficient quantity of moisture
kept in sealed polythene bags absorbing agent inside the
with dehydrator. Seal all holes moisture trap.
of the cylinder, purge with dry
nitrogen and maintain a pressure c) Close the flange hole of moisture
of about 100 mm WG. If dry trap airtight. Keep the flange
nitrogen is not available, keep separate in dry condition.
sufficient quantity of dehydrating
agent such as silica gel inside d) Close the manual drains.
the cylinder and check the
effectiveness of the dehydrating e) Rotate the compressor drive
agent periodically. shaft a few turns by hand once a
week.
j) Drain cooling water from cylinder
jackets, inter coolers and after f) Drain off the lubricating oil and
coolers wherever applicable. refill the oil sump with a suitable
preservative oil
k) Purge the piping with dry
nitrogen. Close all openings and g) Run the compressor on no load
maintain a nitrogen pressure of after first two months for at least
100 mm of WG. As an half an hour to ensure that the
alternative, close all openings normal working temperatures
tightly and keep inside the piping have been reached. Before
sufficient quantity of dehydrating running the compressor, remove
agent such as silica gel, in and discard the moisture
accordance with their absorbing agent and refit the
dimensions and shape. Check moisture trap flange.
the dehydrating agent
periodically. h) Proceed further as described
under steps (a) to (e) above
3.2.3 Preservation of idle oil free screw using a new moisture absorbing
type Air Compressor. agent.
The following procedure should be i) When the unit is standing idle for
adopted when the compressor kept an extended period the above
idle for a period up to two months mentioned procedure should be
the compressor should be run on repeated every six months.
no load once a week for approx. 10-
15 minutes j) Drain the cooling water, close
the inlet and outlet valves and fill
When the compressor kept idle for the line with fresh water.
more than two months, the following
steps should be adopted 3.2.4 Preservation of idle oil flooded
screw Compressor
a) With the compressor running on
LOADED condition open the
When the compressor is going to be The turbine rotor shall be rotated by
idle fore more than six months turning gear or by hand by the
following procedures:
a) Blind off suction and discharge
valves It should be rotated by 180
degree from the standstill
b) Drain the oil in the casing of the condition after three months
screw elements.
It should be rotated by 90
c) Flush and fill the casing of the degree after 3 months.
screw elements with a suitable
preservative oil. It should be again rotated by 180
degree after 3 months.
d) Close all drains and vents
It should be rotated by 90
e) Drain the cooling water, close degree position after 3 months.
the inlet and outlet valves and fill
the line with fresh water dozed This procedure shall be
with anticorrosive chemical. continued subsequently.
f) Rotate the compressor drive 3.4 PRESERVATION OF GAS
shaft a few turns by hand once a TURBINE
week.
The following procedure should be
g) Change the preservative oil adopted for preserving idle gas
every six months/one year as turbine
per schedule.
Machine already erected at site and
h) Change water every six months. the final commissioning of the
machine is expected to be longer
3.3 PRESERVATION OF STEAM than one month.
TURBINES
a) For a single shaft turbine,
a) The lube oil system and cranking has to be done for half
governing oil system shall be an hour once in a week keeping
either kept in service on a the lube oil system under
weekly basis or filled with a low operation. Apart from cranking of
positive pressure of dry nitrogen. HP shaft, Low pressure (LP)
shaft of two-shaft turbine has to
b) Dry nitrogen may be admitted be rotated manually for a few
into the turbine including all complete revolutions every week
steam spaces and gland sealing with help of suitable fixtures
through one of the pressure fitted with coupling hub in the
tapping points in the turbine direction of rotation keeping the
exhaust hood of turbine case. lube oil under operation.
This shall be done during a
period of minimum humidity and b) The lube oil has to be internally
air inside the turbine is to be circulated through a centrifuge
purged out completely. every day for 8 hours or
whatever time required to drive
c) Maintain a positive pressure of out the moisture/ dirt/ dust from
about 50 to 75 mm WG during the lubricating oil when the Gas
the idle time and monitor the Turbine is lying in idle condition.
same.
c) If the cranking is not possible by idle run the engine till the
motor not being provided with temperatures of cooling water and
electrical connections, in such lubricating oil reach the normal
case rotation of the machine to operating range.
be done manually using suitable
fixtures keeping the lube oil When the engine is kept idle for a
under operation. period more than six months the
following steps should be adopted.
d) The rotor in no case shall be
rotated without lube oil a) Start the engine, increase the
circulation. speed gradually up to 1200 rpm
or a fast idle, operate the engine
Machine already commissioned and with no load until the engine is
the idle period is longer than one thoroughly warm and then stop
month the engine.
a) The unit should be operated on b) Drain all lubricating oil from the
NO LOAD for at least 30 minutes oil sump and refill the oil sump
in every month to dry out any with suitable preservative oil.
moisture inside the ducting and
other components and to c) Drain coolant from cooling
recirculate the lubricating oil to system and thoroughly flush with
recoat the moving parts to clean water and suitable
prevent rust and corrosion. radiator cleaner. Refill the
cooling system with mixture of
b) The lube oil has to be internally water and suitable radiator
circulated through a centrifuge protector in the ratio
every day for 8 hours or recommended by the
whatever time required to drive manufacturer.
out the moisture/ dirt/ dust from
the lubricating oil when the Gas d) Fill two portable containers one
Turbine is lying in idle condition. with diesel and other with the
preservative oil mentioned in (b)
c) If the cranking is not possible by above
motor not being provided with
electrical connections, in such e) Start the engine with engine
case rotation of the machine to pulling fuel from the container
be done manually using suitable with diesel through the filter and
fixtures keeping the lube oil the injector drain line flowing into
under operation. the container with diesel. Once
the engine is running smooth at
d) The rotor in no case shall be idle, switch the fuel line to the
rotated without lube oil container with preservative oil.
circulation. Run the engine 5-10 minutes on
NO LOAD till it is observed that
3.5 PRESERVATION OF DIESEL the preservative oil is coming out
ENGINES from injector return line. Stop
the engine.
The following procedure should be
adopted for preserving an idle diesel f) Drain the oil sump, fuel filter and
engine when the diesel engine is fix back the drain plugs.
kept idle for a period less than
6 months, run the engine on load g) Turn fuel pump manual shut off
for 10-15 minutes once in a week. valve to ‘OFF’ position so that
If the engine cannot be run on load, the engine will not start.
components. Carry out
h) When the engine has become precommissioning checks.
cool, disconnect the inlet and
exhaust manifolds, spray iii) Flush cooling system.
suitable preservative oil into air
intake and exhaust outlets, iv) Refill the oil sump with clean
engine being turned by hand lubricating oil
during spray operation. Cover all
intake manifold opening with v) Adjust the injectors, valve
tape to prevent entry of dirt and and belts and check cylinder
moisture. Cover all engine head cap screws, filters, air
openings of cylinder block, oil filter and screens.
breather and crank case
including coolant inlets and vi) Pressurise the lubricating
outlets. All vents, dynamo, system about 1 Kg/ cm2
starter motor, magneto if any including turbo charger or
and air cleaners to be carefully supercharger prior to starting
sealed with water proof paper the engine.
and water proof adhesive tape.
vii) Run the engine with diesel
i) Loosen V belt tension. Remove on NO LOAD LOW IDLE for
rock lever covers and spray 5 minutes to flush the entire
preservative oil over rocker fuel system out of any
levers, valve springs & stems, preservative oil
guides, cross head and push
tubes. Replace cover. viii) Remove any foreign matter,
which may collect on screens
j) Do not rotate the crank shaft and strainers, before regular
after the above operations. operation of the engine.
k) Tag the Engine with date of When the diesel engine is kept in
treatment to indicate it has been store as a spare complete set and
treated with preservatives and likely to be unused for more than
should not be turned over. six months
ii) Remove all paper cover, d) The crank case should be filled
tape and wrappings and with suitable rust preventive
reinstall the dismantled
and should be filled up to the housing fully with fresh grease.
high oil level mark of crank ease Close all openings of the bearing
housing.
e) Connect a electrical motor driven
lube oil priming pump with f) In case of oil lubricated bearings
suction of the pump connected drain the oil. Flush and fill the
to the crack case drain point and housing fully with suitable grade
discharge connected to the inlet of fresh lubricating oil. Close all
of the lube oil filters openings of the bearing housing
g) Run the lube oil pump once in h) Drain the oil from gear box and
week to achieve the operating refill it with a high grade mineral
pressure inside the engine and oil. Clean the exterior surfaces of
then stop the pump. By this the gear box and paint them.
method all bearings, pistons Wrap all exposed shaft with
connecting rod, rocker arms, Plastic tape. Store the reducer in
valves, etc. will be lubricated a warm and dry. The gear box
rotor shall be rotated by the
h) After six months repeat the following procedures:
above procedure as per steps
(b) to (g) mentioned above It should be rotated by 180
degree from the standstill
condition after three months
i) Replace the preservative oil as
per schedule. It should be rotated by 90
degree after 3 months.
3.5 PRESERVATION OF FANS &
BLOWERS It should be again rotated by 180
degree after 3 months.
The following procedure should be
adopted for preserving idle fans and It should be rotated by 90
blowers degree position after 3 months.
a) Coat the interior of the casing This procedures shall be
and the impeller of the continued
fan/blower with a suitable rust
preventive. 4.0 PRESERVATION OF MATERIALS
IN STORES
b) Blind the suction and discharge
end of the fans/blowers. Moisture, oxygen and atmospheric
conditions are the main contributing
c) Close all openings in the factors causing deterioration.
casings. These may cause rusting, pitting of
surfaces and other forms of
d) Clean and coat the exposed deterioration. Proper identification
shaft with grease. system should be used for material
stored in the warehouse to avoid
e) In case of grease lubricated mixing. Procedure for preservation
bearings remove the grease, of stored material should be adopted
clean the bearing and bearing as follows.
housing and fill the bearing
draining position on a concrete
4.1 PRESERVATION OF HEATER surface either on steel racks or
COMPONENT: woody rafter placed in such a
position that rain water does not
4.1.1 HEATER TUBES: accumulate and affect pipes. Pipes
shall not be allowed to get
Both CS and low alloy steel heater submerged in ground or pool of
tubes can be stored outdoor on a water.
sloped concrete surface. These
tubes shall be kept either on steel Pipes/ pipe fittings shall be
racks or wooden rafter. Tubes shall protected with an external coat of
not be allowed to get submerged in black bituminous paint. Pipes shall
the ground or in contact with water. also be painted internally at the
Both the ends of tubes shall be ends, upto a length of 12" or as
suitably capped or plugged. CS practicable.
heater tubes shall be given a coat
of oil preservative externally Stainless steel pipes shall be stored
before stacking the tubes. 300 mm indoor on wooden rafters/ concrete,
length at each end of tube shall be separate from CS, with ends opened
coated with grease and water proof or plugged. The ink used for
wrapping paper where rolling marking, if any shall be free from
operation is performed. To avoid chloride, sulphur and lead.
chloride attack, it is preferable to
store Stainless steel heater tubes For pipes with threaded connection,
indoors on wooden rafter with both extra care shall be taken in
the ends plugged. protecting the threads by putting
plastic caps or wrapping with jute
4.1.2 Return Bends: cloth.
CS/ Low alloy steel cast plug type 4.2.2 Preservation of Flanges:
return bends should be stored in a
covered shed. Grease preservative Flanges with anticorrosive painting
shall be applied on all the machined shall be stacked on stands
and threaded surfaces. However /concrete or wooden sleepers with
other type of return bend can be their gasket seating surfaces at the
stored outdoors after applying bottom and covered with tarpaulin.
necessary protective coatings as All the flange gasket seating surface
given to heater tubes in downward must have a protective coating &
position to avoid any accumulation of extreme care must be taken during
water inside the bend. handling to avoid damage.
4.3.2 Tubes:
4.2.4 Preservation of Fasteners:
All the exchanger/ condenser tubes
Fasteners shall be kept indoors. shall be stored indoor on steel
Carbon steel and alloy steel racks. CS and alloy steel tubes shall
fasteners shall be stored in separate be coated with oil preservative or
bays after oil preservation spray. black bituminous paint whereas
Stainless steel fasteners do not brass/ stainless steel tubes do not
require any protection. require any preservative. Tubes
may be provided with tightly fitted
4.2.4 Preservation of Valves: HDPE/ PVC end caps.
d) All piping connections and openings g) Run the special oil pump for 15 minutes.
should be carefully plugged, blinded. While the oil circulates, turn the
compressor coupling by hand. The silica
e) Lubricated cylinders should be gel kept in the inter cooler moisture trap
lubricated by manually turning the force is to be removed before starting the lube
feed lubricator, which should be kept oil pump. After lubrication insert new
filled up with suitable preservative oil. silica gel.
Wherever the force feed lubricators are
not available apply suitable preservative h) Repeat the procedure mentioned in (g)
oil inside the cylinder surfaces. above once in six months