PREFACE The Mothball Manual is a source for information for mothballing buildings and equipment in Saudi Aramco. The manual was compiled from information furnished from Saudi Aramco's technical personnel and input from U.S. Company experts. It is meant to be a guideline for mothballing equipment and facilities and as such does not give specific directions for each piece of equipment. Additional information including a chapter on instrumentation will be furnished as it becomes available. In this way it is hoped this manual can be kept up to date and therefore be of maximum use. If you require further information or assistance regarding this manual, please contact Roger Sarathy at 875-3520. I.F. AL-ADEL, Coordinator Corrosion Control Division Consulting Services Dept. Signed _______________________

AER 2365

TSI 51-156

SAUDI ARAMCO MOTHBALL MANUAL

FOR OILFIELD PRODUCTION PROCESSING AND REFINING EQUIPMENT I INTRODUCTION 4 II PHILOSOPHY OF MOTHBALLING 5 III CORROSION OF MOTHBALLED EQUIPMENT AND PIPELINES 9 IV PLANNING OF MOTHBALL PROCEDURES 13 V PROTECTIVE MATERIALS FOR MOTHBALLING 15 VI GUIDELINES FOR MOTHBALLING OF SPECIFIC EQUIPMENT AND FACILITIES 22 1. WELLS 22 2. PIPELINES 26 3. VALVES 39 4. PRESSURE VESSELS 43 5. TANKAGE 49 6. HEAT EXCHANGER EQUIPMENT 56 7. ROTATING EQUIPMENT 62 8. ELECTRIC EQUIPMENT 82 9. AIR CONDITIONING SYSTEMS 92 10. FLARE SYSTEMS 94 11. BOILERS AND FIRED HEATERS 96 12. BUILDINGS 102 VII MONITORING AND MAINTENANCE DURING MOTHBALLING 106

VIII APPENDIX 107 A. Extracts from Exxon Refinery Mothballing Guide for Saudi Aramco. 108 B. Recommended mothballing materials in SAMS. 119 C. Product Information 120 Boiler Lay-up Procedures - Refer to GI-403.001 1 121

TSI 51-156

SAUDI ARAMCO MOTHBALL MANUAL

CHAPTER I

INTRODUCTION This manual provides basic guidelines and recommendations for the preparation of detailed procedures for mothballing buildings, oilfield production, processing, and refining equipment. Due to long range forecasts for crude production In-Kingdom, some buildings, operating plants and pipeline systems are being considered for mothballing for a period of 3 - 10 years. Various plants and facilities have already been mothballed for 2 1/2 years and may remain mothballed for an additional 5 to 10 years. Saudi Aramco's recent investigation of mothballed facilities, plants and pipeline systems have indicated various mothballing procedures have given satisfactory results, whereas others are considered unsatisfactory. The basic guidelines and recommendations in this manual are not mandatory. They are based on the experience gained over the last few years in mothballing buildings, oilfield production and processing equipment in Saudi Arabia and the US Companies. The manual has been reviewed by Technical Specialists of Saudi Aramco and each of the U.S. Companies.

CHAPTER II

PHILOSOPHY OF MOTHBALLING

OBJECTIVES The need for mothballing occurs when the operation of a plant or facility is not currently needed to achieve Saudi Aramco's objectives. Quite often, the plant and/or equipment that is involved is very costly in terms of capital investment or replacement value. It is in Saudi Aramco's interest to put the equipment in such state that it can be maintained in good condition at a minimum cost. When operational requirements dictate the return of the facilities and the equipment to active service, it is desirable to accomplish this with minimum cost, time and effort. Therefore, the objectives of mothballing can be stated as follows: 1 Preservation of the buildings and equipment without a significant loss of useful operating

life and without excessive costs. 2. The continuation of the preservation state with a minimum of maintenance attention. 3. Recommissioning with a minimum cost and delay. The protection of shutdown equipment is always a compromise between cost of preservation, effectiveness in preventing deterioration and the ease with which the plant can be reactivated. Selecting the optimum mothballing procedure requires an economic evaluation of alternatives. The length of shutdown anticipated is important to this evaluation. The expected recommissioning time, however, is the most significant factor. The value of the equipment involved and the cost of maintenance are also necessary for a complete determination of the economics. The following definitions are used in this manual for mothballing equipment for different periods of downtime. Downtime Start-up Time Short Term Mothball 1/2 - 3 years Less than 3 months Long Term Mothball Over 3 years 6 to 12 months Minimum first cost Mothball Over 5 years 1 to 2 years TABLE 1, General Categories for Mothballing - page 7, provides a comparison of basic differences between short term, long term and minimum first cost mothballing. The above definitions are not applicable for mothballing buildings. Refer to Chapter VI section 12 which addresses building preservation.

Factors Influencing Mothballing Procedures The following factors have an important influence on the choice of mothballing procedures for a certain piece of equipment or a facility: 1. Recommissioning Time Time available for recommissioning is the significant factor in selecting a mothballing

procedure. Equipment disassembly and remote storage may reduce deterioration but significantly increase startup cost and duration. Using a hydrocarbon for a mothballing medium may also increase start-up time when internal inspection and/or hydrotesting is required prior to start-up.

2. Length of Shutdown Facilities which will be idle less than six months require little more than the normal turn-

around precautions. Such short-term layup is not covered in this Mothball Manual. Mothballing for more than six months requires more preparation and observance of specific precautions (minimum first cost mothballing is an exception).

3. Climate Equipment can deteriorate rapidly in warm, humid climates while corrosion is less in dry

environments. Sea coast locations vary in corrosivity, depending on temperature, humidity and prevailing winds. Saudi Arabia has a variety of climates. The southern area, in general, has a relatively dry climate and equipment in this area is subject to less external corrosion than equipment located in the more humid Northern area and in offshore fields. On the other hand, equipment and facilities located in the Southern area suffer more from the effects of sand than equipment and facilities located in the Northern area.

4. Nature of Product Internal protection needed for pipeline systems and pressure vessels varies with the

nature of the product. Mothballing pipelines used for dry sweet gas or dry crude is less costly and less complicated than mothballing pipelines used for wet crude, seawater or raw well water.

5. Relating Mothballing Cost to Replacement & Maintenance Costs The economics of a mothballing procedure must be considered. More extensive initial

mothballing expenses may reduce routine maintenance costs and/or equipment deterioration. If the cost of mothballing, recommissioning, and maintaining the equipment in a mothballed state is nearly equal to the cost of replacement or if the equipment is or may become obsolete, it should be a candidate for abandonment.

6. Possibility of Obsolete Technology After Being Brought Back into Service Considerations should be given to the possibility that certain equipment (especially

instrumentation) will be obsolete at the end of the mothball period. Obsolete in this context means that spare parts and/or competent servicing is either unavailable or excessively expensive.

7. Availability and Cost of Maintenance Personnel A specific piece of equipment, such as an electric motor driven pump, mothballed within

an operating plant can be routinely inspected and serviced by the plant operators with little additional cost/effort. The same pump located on an offshore GOSP which has been mothballed in its entirety would not routinely have personnel available to perform frequent mothball maintenance checks.

8. Availability of Protective Media The availability of the protective media for mothballing must be considered. For

example, nitrogen may be generated within one facility and be the obvious choice as an inert media while another location may not have nitrogen readily available; however, dry, sweet gas or dry crude may be convenient to use as an inert media.

9. Storage Facilities Availability of local (plant) storage facilities may encourage inside storage of equipment

such as small pumps, instruments, etc. rather than leaving them in place. 10. Security Measures to Control Loss of Equipment Measures to control reutilization of mothballed equipment should be part of a mothball

procedure. In most cases, equipment reutilization (cannibalization) should be discouraged in short-term mothballing, strictly controlled in long-term situations and actively encouraged in minimum first cost mothballing.

11. Time Required for Mothballing It may take significant time to develop an appropriate mothball plan for a facility. The

implementation of different mothballing techniques requires different times. If time is unavailable for proper planning and execution of mothballing procedures, more costly solutions should be expected.

Table 1 - General Categories For Mothballing

Short Term Long Term Minimum First Mothball Mothball Cost Mothball Time out of service 1/2 to 3 years Over 3 years Over 5 years Time to restart Less than 6 to 12 1 to 2 years (Snap back time) 3 months months (Major reconstruction) Mothballing Cost Medium High Low Mothballing Significant Some None Maintenance Cost Cannibalization Not permitted Strictly controlled Encouraged Restart Cost Low Medium High Only for Cathodic Electric Power Required Yes Yes Protection,Lights & Communications Instrument Air On or Off Not available Not available Control House A/C On usually Off usually Off Instrument Power On usually Off usually Off

CHAPTER III

CORROSION OF MOTHBALLED EQUIPMENT AND PIPELINES

GENERAL Oilfield equipment including that used in oil, gas and water production, as well as processing and transportation facilities, is designed for operational conditions of pressure, temperature and flow. When such equipment is shutdown, it can experience far more damage in a short time period than in several years of normal operation. Operating corrosion rates of less than 3 mpy can suddenly increase to 100 mpy during shutdown periods. While relatively high corrosion rates may be tolerated for short term shutdowns, they are unacceptable in mothballed facilities. A. EXTERNAL CORROSION 1. Cathodic Protection Cathodic protection systems must remain active for mothballed equipment to

retain its expected life. 2. Insulated Lines/Vessels Insulated systems are normally at a relatively constant temperature during routine

operation which prevents moisture accumulation beneath the insulation. Without moisture there is minimal corrosion and therefore many insulated pipes and vessels have no protective paint or coating; however, in the presence of variable ambient temperatures, moisture may penetrate insulation and cause severe corrosion of the underlying steel if it is uncoated or unpainted. When an insulated facility is mothballed, it should be determined if underlying steel is protected via a coating. For short-term mothballing of coated or non-painted system, the insulation should be inspected and repaired to reduce the probability of moisture penetration. For both short-term and long-term mothballing of insulated unpainted systems located offshore or in shoreline facilities, annual inspection of the insulation and underlying steel (via exposed windows) is recommended. Insulated painted systems should be inspected every two years. If corrosion is detected insulation should be removed and the damage repaired. For insulated unpainted systems strong consideration should be given to removing the insulation from the piping and/or vessels undergoing long-term mothballing in offshore and humid areas since it is unlikely that corrosion will be avoided in these locations; however, it is recommended that insulation be left in place over coated/painted systems in all locations.

3. Paint Systems Paint systems should be maintained for short-term and long-term mothballing for

corrosion prevention and/or aesthetics. No paint maintenance should be considered in minimum cost mothballing.

4. Sand Control Drifting sand will cover plant equipment not designed or protected for buried

service and therefore may limit access to the facility. If wet salts are contained in the sand, a highly corrosive environment may occur. In general, however, drift sand is dry and will cause only minor damage to piping/vessels etc. Since the cost of the damage may be small compared to the costs involved in removing the sand. sand control efforts should be limited to those required to maintain facility/equipment access for routine mothball maintenance. Sand removal for protection against corrosion should always be justified from an economic standpoint.

B. INTERNAL CORROSION 1. Wet Systems Equipment mothballed with free water present in the mothball media are 'wet

systems'. The presence of water causes concern because of three possible mechanisms for corrosion attack: oxygen, acid, and sulfate reducing bacteria (SRB).

• Oxygen -- metal exhibits anodic and cathodic sites. Iron dissolves at the

anode when an electrolyte (water) is present. During this reaction, hydrogen is formed at the cathode which may eventually stifle the reaction (polarization). When oxygen is present, however, it combines with this hydrogen and allows the reaction to continue (depolarization). The initial oxygen dissolved in a water-filled vessel or pipeline will be consumed very quickly (in the corrosion process) and does not do significant damage while continued oxygen (air) ingress in a wet system will significantly increase corrosion rates. Air plus sulfides left in mothballed systems can give polythionic acids which are very corrosive and damaging to stainless steel.

Organic corrosion inhibitors added to the mothballing fluid are ineffective

in controlling damaging corrosion in the presence of oxygen. Oxygen ingress must be prevented in a wet system since oxygen scavengers in the mothballing fluid will rapidly be consumed if continued oxygen ingress is allowed.

• Acid -- H2S and/or CO2 from sour crude or in produced water can cause water in these systems to become acidic. With the exception of sulfur handling areas, severe acid attack is not anticipated in Saudi Aramco's mothballed facilities.

• SRB -- sulfate reducing bacteria can become active in water systems that

contain less than 10% dissolved salts and are oxygen free. These bacteria populations can cause pitting corrosion by producing acid; however, they require sufficient water to cause significant damage. In mothballed systems containing only a small amount of water (i.e. a gas filled system which has been drained but not dried), SRB's will cause insignificant damage.

Water can be made biocidal via high pH (above 10) or use of chemical biocides.

If both biocides and oxygen scavengers are used, a check must be made on their compatibility. Using high pH (above 10) water will prevent bacterial attack throughout an extended mothball period. Since chemical biocides will degrade over time their initial concentrations must be calculated and enough biocides added to last throughout the mothball period or the biocides must be recharged based on corrosion monitoring and bacterial population assessment. Biocides presently in use have a half-life of about 6 - 9 months. Biocides are more effective in killing free floating bacteria than bacteria 'hidden' under slime and/or scale on the pipe or vessel wall. Water systems that have been in operation for an extended period of time often have established SRB colonies. In such cases, biocides even in very high concentrations will not sterilize these systems. In systems which have not been in operation, biocides added to the initial fill fluid may give sterilization, thus retreatment after biocide degradation is unnecessary.

2. Dry Systems Equipment mothballed with the moisture content of the media controlled to avoid

corrosion are known as 'dry systems'. Dryness can be specified as a dewpoint or in terms of relative humidity. In general, severe corrosion will not occur without "free water" present. Setting a dewpoint below what can be expected for ambient temperature (e.g. + 30 deg F) conditions will ensure that free water will not be present. In relatively insensitive equipment, such as pipelines, tanks and vessels, this specification is sufficient. Equipment which previously contained high salt content fluids, however, will retain a layer of salts on the metal surfaces. These salts are hygroscopic and can cause corrosion without freewater. In this case the equipment should either be cleaned prior to mothballing (water washed, steamed out or chemically cleaned) or the specified dewpoint should be lowered to -40 deg F. Equipment containing electrical contacts (e.g., instrumentation), thin walled exchanger tubing and machined surfaces is very sensitive to damage from minor corrosion. A very dry atmosphere (-30 deg F dew point) or a controlled relative humidity of 40 percent is required to ensure protection of sensitive equipment.

3. Ambient Systems Ambient systems are essentially dry systems with the dewpoint or relative

humidity uncontrolled. If the temperature drops below the dewpoint of the air and condensation occurs, the condensate will reevaporate when the temperature rises above the dewpoint. In the relatively dry climate surrounding onshore facilities in Saudi Arabia, ambient mothballing may provide a good solution for equipment which is not sensitive to corrosion.

CHAPTER IV

PLANNING OF MOTHBALL PROCEDURES

It is recommended that a Mothball Team be established to develop specific procedures for mothballing and recommissioning. This task force should be selected from experienced maintenance, engineering and operating personnel who will be assigned to write specific mothball procedures for the related facilities and/or pipe-systems in their responsible area. The initial objectives of the task force should be: 1. Identify mothballing options and alternatives, using this Mothball Manual for guidelines. 2. Obtain feedback on recent plant mothballing problems. 3. Recommend the general philosophy to be followed in mothballing (short-term, long-term,

or minimum first cost) the subject facilities. 4. Provide mothball cost estimates, recommissioning costs and option comparisons. 5. Obtain Management approval of philosophy and selected option. 6. Write specific procedures for initial mothballing, inspection/maintenance and

recommissioning. 7. Clearly define the assumptions used for developing the procedures and define the

responsibility for ensuring that the assumptions do not change. Several different technical specialties may be required to develop a complete mothball

procedure for a facility. These specialties would include electrical, instrumentation, rotating equipment, corrosion,inspection, vessels/piping/exchangers, petroleum engineering and utilities. The mothball team should be organized to develop procedures based on each individual's functional specialty rather than on administrative areas.

Any routine mothball inspection/maintenance required should be an integral part of the

mothball procedure with responsibility for record keeping during the mothball period and third party audit procedure clearly established. Since mothballing is often accompanied by manpower reductions and personnel transfers, ensuring that the maintenance tasks specified are performed continuously throughout the mothball period is difficult.

Because the economics involved in mothballing will normally be based primarily on

poorly defined assumptions, the requirement or value of a short recommissioning period and the expected downtime must be established (more often assumed) in order to develop cost effective procedures. After these basic assumptions are made, the choice of specific procedures will often be made from uncertain probabilities. For example, a system can be dried effectively or be left water filled with oxygen excluded and SRB's controlled over a 'long' period. Every one or two years a review of assumptions used and procedures in effect is required to ensure a system is effectively mothballed.

CHAPTER V

PROTECTIVE MATERIALS FOR MOTHBALLING

A. INERT MEDIA In order to make an environment virtually noncorrosive during the mothball period, one

can choose a number of alternatives. These vary from (a) monitoring positive pressure of the process fluids to (b) replacement of corrosive process fluids with an inert media. Inert is defined as a media which is noncorrosive for oilfield applications and may include:

1. Nitrogen (N2) Nitrogen is an inert gas and is available as bulk, liquified nitrogen, type II; and

gaseous nitrogen, type 1 grade C class 1 per Fed. Spec. BB-N-411b. The later is provided in cylinders (180 SCF; cost $10 each) equivalent to $0.06/SCF gaseous N2.

Experience with mothballed plants indicates some maintenance effort is required

to ensure nitrogen pressure. Nitrogen (or other dry gases) tend to dryout and degrade packing material and flange gaskets; therefore, these must be checked regularly in order to control leakage which can be detected with a leak detector or a soap solution. When leaks are detected, valves must have packing tightened or replaced and flanges and/or threaded connections must be sealed. Intervals between repressurizing will increase with time from four to eight months, perhaps longer. Using a liquid N2 source is recommended if available.

The advantages of using nitrogen are:

• nonflammable and nontoxic. • readily available in bulk as liquified nitrogen type II and gaseous nitrogen

type I. Disadvantages are:

• tends to dry out seals and packing • leaks must be controlled

2. Dry Sweet Fuel Gas Dry means no free water is initially present or will condense from the gas during

the mothball duration. Normally a maximum dew point is specified with the specification adjusted to match the mothball requirements.

The advantage of using dry fuel gas is:

• inexpensive and readily available at certain locations Disadvantages are:

• flammable • can form explosive mixture with air • more expensive than nitrogen in some locations • leaks must be controlled • tends to dry out seals and packing

3. Dry Air Dry air is an excellent mothball media if the system is initially dry or can be

thoroughly dried during the mothballing process. The system should be maintained at a dewpoint of +30 deg F or lower or the relative humidity controlled to 40 percent or less.

The advantages of using dry air are:

• nonflammable • nontoxic • no problems with disposal • facilitates internal inspection

The disadvantages are:

• may be expensive • positive pressure may be difficult to maintain • if very low dew point is required, it may dry out seals • may form explosive mixture with hydrocarbons

4. Other Hydrocarbons Hydrocarbons such as diesel, kerosene or nominally dry crude are good protective

materials although they sometimes need the addition of corrosion inhibitors to ensure protection against any water which may be present in the system at the time of mothballing. Hydrocarbons tend to wet flange gaskets and valve packing which expands the material and seals against leaks. Since leaks are easily detected, timely remedial action can be taken to prevent loss of these mothball media. Some water may settle out from these liquid hydrocarbons, and monthly draining at low points is recommended until no further water is found. Quarterly check for water should be conducted thereafter.

The advantages of using hydrocarbons are:

• Saudi Aramco's experience in their use, (depending on location). • readily available • reusable (in some locations)

Disadvantages are:

• flammable • disposal problems (depending on location) • Toxic • Hydrojetting will be required before recommissioning to remove sheets of

rust formed on the metal due to the water present in the hydrocarbons 5. Water While water is normally not considered inert, with proper conditioning it may be

used to mothball systems and an acceptable corrosion rate can be maintained. The use of water for long term mothballing is questionable since biocides, added to prevent the growth of sulfate reducing bacteria, decompose with time. This allows SRB colonies to grow and they may present a pitting problem. If the mothballed facility is recommissioned before the biocide has been allowed to decompose, a biocide disposal problem may be encountered because even a low concentration of these chemicals can pose an environmental hazard. A system mothballed with water should also be kept under positive pressure (nitrogen or sweet gas) to prevent pitting damage caused by oxygen (air) ingress.

The advantages of using water are:

• inexpensive • readily available

The disadvantages are:

• possibility of pitting corrosion by SRB • disposal problems if biocide is present • air ingress must be prevented by positive nitrogen or gas pressure

6. Ambient Air Ambient air is not inert since condensation can occur when the ambient

temperature drops significantly. When the temperature rises again, however, the condensed water will evaporate. In the onshore areas, the percentage of time that free water exists in a system due to condensation may be relatively short and even high corrosion rates during that period are acceptable. Ambient air mothballing allows inspection of the facility and, if corrosion is occurring, corrective measures may be taken.

The advantages of using ambient air:

• inexpensive • readily available • accessibility of equipment to inspection • nonflammable

The disadvantages are:

• condensation of water will cause corrosion

Table 2 - Materials For Mothballing

Advantages And Disadvantages

Mothball Media Cost Availability Advantages Disadvantages

1. Motrpgem (N2) Bulk $2.80/liq gal Available in tank Safe, nontoxic, Dries out gaskets; $0.03/SCF truck, contaner nonflammable, pressure maintenance or cylinders noncorrosive, required ease of disposal 2. Fuel Gas Depends on Depends on Inexpensive where Flammable; may be location location available easy corrosive in presence disposal of moisute 3. Dry Air (dew Depends on Readily available Nontoxic, non- May be costly point +30 deg F amount and in most locations corrosive in to -40 deg F source; lower absence of the dew point the moisture; easy more expensive disposal; non- flammable; facilities inspection 4. Other hydro- Depends on Depends on May already be Flammable, may have carbons including location location present at disposal problems dry crude and locations (process diese fluid) 5. Water Inexpensive Depends on Relatively nontoxic Sensitive to air where available location (if biocide free); (oxygen) ingress; nonflammable potential SRB corrosion 6. Ambient Air Least expensive Facilities Inspec- Corrosion tion low cost uncontrolled

B. PROTECTIVE COATINGS Coating metal surfaces provides a protective barrier between the metal and the

environment and therefore allows the equipment to be placed in an ambient environment of air and/or water where it provides added insurance from corrosion.

A coating can be a relatively permanent industrial maintenance type paint or a rust

preventative grease or oil. The application of permanent coatings (epoxy, paint, etc.) is generally not recommended for mothballing because of the cost involved; however, insulated vessels or piping which have the insulation stripped and are unpainted may be an exception. Rust preventative greases and oils are relatively inexpensive to apply and remove but generally provide protection for only 6 to 18 months. Vapor phase inhibitors (VPI) are more effective in small enclosures and vessels where vapor leakage is minimum. VPI's which vaporize effectively in warm climates have a limited life (one to two years per vendor's literature), but, they may also render the enclosed atmosphere toxic.

A listing of coating materials, and stock numbers is shown in Appendix B. C. HOUSINGS AND COVERINGS Protective housings and coverings may be applied to reduce deterioration from the

environment. These may be plywood boxes constructed over rotating equipment, tape coverings over exposed motor/pump shafts, or polyethylene bags over instruments (inside only). If this type of protection is vapor tight, it keeps dust, sand, rain, dew and salts from exposed surfaces. Coverings will also retard oxidation or 'drying out' of greases or oils applied to machined surfaces. Covering of motor, turbine, and compressor air inlets and taping over applied protective greases is recommended. Polyethylene film should not be used outdoors because it deteriorates rapidly. If the equipment is designed for outside exposure, constructing box enclosures and/or using plastic bags is generally not encouraged.

A listing of covering materials sealants and their stock numbers is shown in Appendix B. D. COCOONING Both internal and external surfaces can be protected by proper storage of equipment in

covered and, if required, conditioned-air enclosures. The equipment can be moved to environmentally controlled storage, or in situation where this is not feasible, a cover can be installed over the equipment in place. A noncorrosive environment can be maintained within the cover by using a patented CocoonTM method which utilizes a network of wire over which PVC is sprayed.

The environment is maintained by circulating controlled-humidity (40%) air between the

Cocoon and the surface of the protected equipment. Since this air is also circulated inside the equipment, both internal and external protection is provided. Automatically controlled air driers maintain moisture content below the corrosion level. The "Cocoon" method enables immediate recommissioning.

The initial cost for Cocooning expensive rotating equipment in Saudi Arabia is estimated

to be 1-3 percent of its capital cost. This cost will vary with the location (offshore or onshore), and configuration of the equipment.

CHAPTER VI

GUIDELINES FOR MOTHBALLING OF

SPECIFIC EQUIPMENT AND FACILITIES 1 WELLS 1.1 Basic Considerations Wells are separated into the following types for mothballing considerations: 1. Oil Wells 2. Water Wells 3. Gas Wells Sand encroachment at well heads should be monitored periodically and sand

removed when it restricts well access. Routine annulus pressure surveys and x-mas tree valve maintenance should be continued on mothballed wells, and the wells should be blinded at the wellhead with on-plot piping treated as part of the well flowline or lateral (TABLE 3).

1.2 Oil Wells No action is required for mothballing oil wells since shut-in oil wells are

generally under positive pressure which excludes oxygen ingress, water in wet wells sinks to the bottom, and the gas phase in some fields is sour but not very aggressive in the absence of oxygen.

1.3 Water Wells A. Potable Water Wells:

• Free flowing: Positive pressure in the well will prevent oxygen ingress and severe corrosion attack. Adding chemical inhibitors or biocides or displacing the well with diesel is not recommended due to potential toxicity problems on start-up.

• Non-free flowing: Nitrogen purge (cycle pressure to 30 psig two

times) and leave with 30 psig pressure to exclude oxygen. No pressure monitoring or repressurizing is recommended. Oxygen ingress (breathing) is expected to be minimal during short or long-term mothball. Chemical or oil addition is not recommended due to potential toxicity problems.

B. Non-Potable Water Wells (Injection and/or Supply) Oxygen Ingress

• Free flowing: Oxygen ingress into supply wells will be effectively controlled by positive wellhead pressure. Injection wells may lose their pressure after an extended period and may require nitrogen purging for long-term mothballing. A pressure survey is recommended with quarterly surveys for the first year and annual surveys thereafter.

• Non-free flowing: Nitrogen purge (cycle pressure to 30 psig two times) and leave

with 30 psig pressure to exclude oxygen. No pressure monitoring or repressurizing is recommended since oxygen ingress (breathing) is expected to be minimal.

Chemical treating/fluid displacement: Adding corrosion inhibitor or biocide to the well

bore fluid is advantageous since it will aid in reducing corrosion and reduce the possibility of SRB attack during the mothballing period. A concentration of 300 ppm of a filming amine corrosion inhibitor and 300 ppm quarternary amine biocide is recommended. Retreatment after three or more years may be required (based on corrosion monitoring) for long-term mothballing. For minimum first cost mothballing, retreatment is not recommended since SRB attack is a potential problem and not a certainty.

A second option is to displace the water in the well bore partially or fully with inhibited

diesel. This will better protect the tubulars from corrosion and avoid SRB and the need for retreatment. An additional recommissioning cost will be incurred for diesel filled injection wells since the diesel should not be injected into the formation and therefore must be backflowed or, in some cases, circulated out of the well.

Corrosion Monitoring: Semi-annual coupon analysis, sessile and planktonic SRB count,

and water analysis for total iron are recommended to track the success of the mothball program in both short-term and long-term mothballing. These analyses are not recommended for wells that have water displaced by diesel.

1.4 Gas Wells Deep, sour gas wells should be mothballed by shuting in with diesel or inhibited brine.

Cap gas wells should be mothballed with inhibited diesel or inhibited brine for long-term and minimum first cost mothballing. Both should be shut-in with no treatment for short-term mothballing.

Table 3-A

Wells

Mothballing

Facility Short Term Long Term Minmum First Cost

1. Oil Wells - Shut in under - Same as short term - Same as short term positive pressure 2 Water Wells - Remove submersible pumps, preserve and store a. Potable water - No treatment - No treatment - No treatment wells - free flowing b. Potable water - Purge with N2 - Same as short term - Same as short term wells - - Lease with 30 psig non-free flowing pressure - Do not treat with chemicals or oil c. Non-potable - No treatment - No treatment - No treatment water wells- May require N2 free flowing purging Maintenance/ - Purge with N2 - Same as short term - None Monitoring if needed - Annual pressure - Semi annually with survey well head coupons and SRB count Recommissioning - None - None - Replacement of tubular Concerns goods as required

Table 3-B

Wells

Mothballing

Facility Short Term Long Term Minmum First Cost

d. Non-potable - Purge with N2 - Same as short term - Same as short term water wells - Leave with 30 psig non-free flowing pressure - Treat with inhibitor or biocide (300 ppm) - Treat with inhibited diesel Monitoring/ - Semi annually with - Same as short term - None Maintenance well head coupons - Retreat with inhibitor and SRB count or biocide 3 year interval Recommissioning - None - None - Replacement of tubular concerns goods as required 3. Gas Wells a. Deep, sour gas - Shut in with inhibited - Same as short term - Same as short term wells brine or diesel b. Cap gas wells - Shut in - - Shut in with inhibited - Same as long term - No treatment diesel or inhibited brine

2 PIPELINES 2.1 Basic Considerations Pipelines are divided into the following types: Flowlines Crude Transmission Lines Wet Gas Transmission Lines Dry Gas Transmission Lines NGL & Hydrocarbon Condensate Lines Water Supply/Injection Lines Utility Lines

• Potable Water • Steam and Steam Condensate • Fire Water • Instrument Air

In general pipeline protection during mothballing relies on the exclusion of

oxygen and/or free water from the line. Where the line is left water filled, some provisions for SRB control is required (pH adjustment, chemical biocide treatment, Presence of high salinity e.g. flowlines). Cathodic protection systems, if present, must be left in operation.

2.2 Flowlines (Trunklines) Flowlines should be shutin under positive pressure (about 5 psig) to prevent

oxygen ingress. If lines lose pressure the leak should be stopped and repressurized with nitrogen, hydrocarbon gas or crude. When checking for positive pressure the liquid head should be taken into account with checks performed at both ends of the flowlines.

Because water will separate from the crude over a period of time, the high salinity

(above 10%) of the produced water will prevent SRB growth and exclusion of oxygen should control corrosion to an acceptable rate. Corrosion can be further reduced, by injecting a water soluble filming amine type corrosion inhibitor (200 ppm) into the flowline prior to shutdown, or alternatively, the flowline fluid may be displaced with inhibited 'dry' crude back-flowed from the GOSP (the effectiveness of water displacement via this relatively low velocity backflowing is questionable). Experience with shutting in flowlines without chemical inhibition has been quite good; however, the majority of our experience has been with relatively dry

flowlines where only isolated failures have occurred. Therefore, on

recommissioning, hydrotesting all flowlines shut-in longer than one year is recommended. Flowlines should not be hydrotested immediately prior to or during mothballing since residual hydrotest water can be far more damaging than wet crude.

2.3 Crude Transmission Lines Corrosion can take place where free water separates from the oil and will increase

in the presence of deposits -- sand, sludge, scales. Therefore if facilities are available, freewater and deposits should be removed by scraping the line prior to mothballing. (Installing facilities expressly to scrape the line for mothballing is not economic). When scraping is not possible, flowing the line at a high velocity (greater than 3 ft/sec) in order to reduce accumulated water is recommended.

Corrosion mitigation in crude transmission lines relies primarily on preventing

oxygen ingress. The line should be fully isolated and mothballed full of crude and maintained with positive pressure (about 50 psig) to prevent oxygen ingress. Lines should be checked every six months in order to ensure the positive pressure is maintained. For short and long-term mothballing, repressurization with nitrogen, hydrocarbon gas or crude as required is recommended. The addition of corrosion inhibitors or biocides is not considered necessary since lack of oxygen and the natural inhibiting properties of the oil, will result in corrosion rates which should be acceptable. Not enough water will be present to support a damaging bacterial population.

As an option, hydrocarbon gas can be used to displace the crude in the line. In

general, this will not lessen the risk of corrosion since this is dictated by the success of the water removal/cleaning operation.

2.4 Wet Gas Transmission Lines Like crude transmission lines, corrosion mitigation in wet gas lines depends on

preventing oxygen ingress and reducing the free water content of the line. Scraping prior to mothballing is recommended. Because these lines do not benefit from the inhibiting properties of crude oil, it is recommended coating the line with inhibitor prior to shut-in, by slugging inhibited diesel gel between two scrapers. A nominal pressure should be maintained in the shut in line by nitrogen or hydrocarbon gas. Corrosion should be monitored on a semi-annual basis by the use of coupons.

As an alternative, the line may be dried and filled with dry gas or nitrogen,

Although this will reduce the risk of corrosion, it is not generally considered necessary; however, in long, large diameter undersea lines it may be worth the added protection due to high repair/replacement costs of these facilities.

2.5 Fuel Gas Transmission Lines Fuel gas transmission lines should not have an internal corrosion problem during

mothballing. However, some pitting is to be expected at low spot due to condensed moisture. Scraping is recommended prior to mothballing (where facilities exist) to ensure the lines do not contain free water.

2.6 NGL and Hydrocarbon Condensate Lines Dry NGL or condensate lines may be shut-in under nominal positive pressure

since the product is non-corrosive. If facilities exist, these lines may be scraped prior to mothballing in order to ensure the absence of free water.

Wet NGL or condensate lines should be scraped if possible prior to shut-in. It is

recommended that a filming amine type corrosion inhibitor be added for short and long-term mothballing or as an alternative, the line may be dried and filled with dry hydrocarbon gas or nitrogen. As with wet gas transmission lines, this will reduce the risk of corrosion but this alternative is not recommended in most cases.

2.7 Water Supply/Injection Lines Successful mothballing of water supply/injection lines requires the prevention of

oxygen ingress. Bacterial corrosion control is also a real potential problem. Scraping is recommended prior to mothballing since corrosion is likely to form under deposits.

For short-term mothballing the water should be treated with a filming amine type

corrosion inhibitor. A high concentration 50-100 ppm of a water soluble type is preferred; although oil soluble, water dispersible products generally are better film formers, they are likely to separate under stagnant conditions. In addition to the corrosion inhibitor, a biocide treatment is recommended. Because biocides degrade fairly quickly (half-life 6-9 months), information on the particular product's degradation and minimum effective concentration (usually 50 - 100 ppm) is required in order to determine its initial concentration.

For long-term mothballing, bacterial control can be ensured by replacing the

treated water when the biocide has degraded to an ineffective level and the corrosion rate and the bacterial population counts indicate an upward trend. In general, this will not be as cost effective as displacing the water with hydrocarbon gas or nitrogen and mothballing the line as a wet gas line. Consideration may also be given to draining and drying the line and using dry air or dry gas as a mothballing medium.

Biocide treatment should be deleted for minimum first cost mothballing.

Although this will increase the risk of corrosion via SRB's, routine corrosion monitoring with coupons for SRB attack will help reduce concern. It must be understood, however, that severe corrosion may occur in parts of the line and not on the coupons. Oxygen ingress must be prevented in the minimum first cost case (otherwise the facility has been abandoned) and scraping and corrosion inhibitor are recommended as being cost effective.

Coupon monitoring, SRB counts (both planktonic and sessile) and, where

applicable, biocide residual testing is recommended every six months for water filled systems.

2.8 Utility Lines 2.8.1 Potable Water Potable water lines should be drained and, if possible blown dry since

residual water trapped in the system will result in corrosion and probably require line repair. Displacing the water with nitrogen will reduce the risk of corrosion but may not be cost effective in small systems. Chemicals are not recommended due to toxicity problems on start-up. If the line is left filled with water, oxygen must be excluded and corrosion via biological attack is possible.

2.8.2 Steam and Steam Condensate Hot steam lines should be blown with air and shut-in since the line's heat

will dry the line and Additional protection may be gained by using nitrogen in addition corrosion will be minimal in dry air. to the air but, unless the nitrogen is readily available, this insurance seems unwarranted.

Hot condensate lines may also be blown dry and effectively preserved.

Water in cold condensate lines should be displaced with nitrogen. They can be left full of water and oxygen excluded. However, removal of the water is preferred. Oil and/or oily corrosion inhibitors are not recommended in these systems.

2.8.3 Fire Water Fire water systems should be shut-in as is and oxygen ingress prevented. 2.8.4 Instrument Air Instrument air is dry and not corrosive. These systems can be shut-in

without special measures.

Table 4-A

Pipelines

Mothballing

Facility Short Term Long Term Minimum First Cost 1. Flowlines General General General - Keep C.P. in operation - Same as short term - Same as short term - Do not remove sand dunes - Do not hydrotest lines prior to mothballing - Add a water soluble - Back flow dry crude - Add inhibitor to crude filming amine type with inhibitor from corrosion (200 ppm) GOSP with WCHF to crude (wet or dry) - Shut-in and - Shut-in under positive repressurize same pressure (about 5 psig) as short term - If needed, repressurize with nitrogen hydro- carbon gas or crude - Back flow inhibited dry crude from GOSP with WCHF if water cut is 30 percent or more Recommissioning - None - None - Pitting expected at concerns low points

WCHF - Wet Crude Handling Facilities

Table 4-B

Pipelines

Mothballing

Facility Short Term Long Term Minimum First Cost 2. Crude - If facilities are avail- - Same as short term - Same as short term Transmission Lines able, scrape to remove free water and deposits Alternatives - Leave line full with - Scrape to remove crude under positive water and sludge pressure (about 50 - Displace crude in 50 psig) line with nitrogen gas - Do not add corrosion preferred) inhibitor or biocide - Maintain positive pressure Monitoring/ - Check pressure - Check Pressure - None Maintenance every 6 months every 6 months if - If needed, repressurize dry gas procedure with nitrogen, hydro- is used carbon gas or crude Recommissioning - None - None - Pitting expected at concerns low points - Replacement likely

Table 4-C

Pipelines

Mothballing

Facility Short Term Long Term Minimum First Cost 3) Wet Gas - If facilities are avail- - Same as short term - Same as short term Transmission able, scrape to Lines remove free water and deposits Alternatives - Coat line with a slug - Scrape to remove of inhibited diesel gel water and sludge - Displace wet gas - Add 3 phase inhibitor with nitrogen or dry fuel gas - Shut in under - Shut in under positive pressure positive pressure Monitoring/ - Check pressure - Same as short term - None Maintenance every 6 months - Check only - If needed, repressurize - pressure every with nitrogen or dry gas 6 months if nitrogen - Semi annually or dry gas procedure corrosion monitoring is used with coupons Recommissioning - None - None - Replacement likely concerns

Table 4-D

Pipelines

Mothballing

Facility Short Term Long Term Minimum First Cost 4) Fuel Gas - If facilities are - Same as short term - Same as short term Transmission Lines available, scrape to remove free water and deposits - Shut-in under positive pressure Monitoring/ - Check pressure - Same as short term - None Maintenance every 6 months - If needed, repressurize with nitrogen or dry gas Recommissioning - None - None - Pitting expected at concerns low points

Table 4-E

Pipelines

Mothballing

Facility Short Term Long Term Minimum First Cost 5) NGL and - If facilities are - Same as short term - Same as short term Condensate Lines available, scrape to remove free water Alternatives A) Dry - Shut-in under - Evacuate and fill positive pressure with nitrogen or dry fuel gas B) WET - If facilities are avail- - Same as short term - Shut in under postive able, scrape to pressure remove free water Alternatives - Add a filming amine - Evacuate and fill type corrosion with nitrogen or inhibitor dry fuel gas - Shut in under positive pressure Monitoring/ - Check pressure - Same as short term - None Maintenance every 6 months - If needed, repressurize with nitrogen or dry sweet gas - Semi annually corrosion monitoring with coupons Recommissioning - None - None - Pitting expected at concerns at low points

Table 4-F

Pipelines

Mothballing

Facility Short Term Long Term Minimum First Cost 6) Well Water Supply - If facilities are - Same as short term - Same as short term and Injection Lines available, scrape to - Replace treated - Do not treat with biocide remove deposits water when biocide treat with biocide - Treat with a filming has degraded to - Prevent ingress of amine type corrosion ineffective level oxygen inhibitor and/or biocide depending upon the water source Alternatives - A high concentration - Displace the water (50 - 100 ppm) of a with hydrocarbon water soluble type gas and mothball is preferred the line is as a wet - Prevent oxygen gas line ingress or - Displace the water with air - Dry the line - Lay-up with nitrogen dry air or dry sweet gas Monitoring/ - Semi annually coupon - Same as short term - None Maintenance monitoring SRB counts where applicable and biocide residual testing Recommissioning - None - None - Replacement likely concerns

Table 4-G

Pipelines

Mothballing

Facility Short Term Long Term Minimum First Cost 7 Utility Lines a) Potable Water - Drain lines and - Same as short term - Same as short term below dry if possible - Do not treat with chemicals - Prevent ingress of oxygen if lines cannot be drained Alternative - Displace water with nitrogen Monitoring/ - None - None - None Maintenance Recommissioning - None - Some pitting - Replacement likely concerns expected if lines lefter water filled b) Steam and - Drain lines and blow - Same as short term - Same as short term Steam dry with air or nitrogen Condensate - Shut in lines - Do not treat with oil and/or oily corrosion inhibitors Monitoring/ - Check every 6 months - None - None Maintenance if oxygen ingress is prevented

Table 4-H

Pipelines

Mothballing

Facility Short Term Long Term Minimum First Cost Recommissioning - None - Some pitting is - Replacement likely concerns expected if lines not properly drained, dried and effefitively preserved c) Fire Water - Leave full - Same as short term - Same as short term - Shut in - Prevent oxygen ingress Monitoring/ - None - None - None Maintenance Recommissioning/ - Replacement likely - Same as short term - Same as short term concerns d) Instrument Air - Shut in without - Same as short term - Same as short term special measures Monitoring/ - None - None - None Maintenance Recommissioning - None - None - None concerns

3 VALVES 3.1 Basic Considerations 3.1.1 General The mothballing procedures for the preservation and maintenance of

valves are dependent mainly on the size and type of valves, and the recommissioning period specified. Mothballing procedures will involve one of the following :

1) Preservation of the entire valve including those with hydraulic,

pneumatic or electric actuators. 2) Preservation of the valve in-line, but with some vulnerable

components removed and stored in a controlled atmosphere. 3.1.2 Types of Valves The following types of valves are considered: 1. Gate Valves 2. Ball Valves 3. Check Valves 4. Plug Valves 5. Butterfly Valves 6. Safety Valves 7. Relief Valves 8. Pressure Control Valves 9. Air Relief Valves 3.1.3 Some Specific Concerns and Considerations 3.1.3.1 The majority of valves are installed in process-piping and/or

process pressure vessel equipment. A smaller number of valves, in general larger in size and

expensive, are installed in pipelines (Crude or Gas transmission lines).

3.1.3.2 When a plant or facility is mothballed, valves should

normally not be removed and, they will be internally subjected to the mothballing media in the connected piping.

3.1.3.3 Preservation of valves in situ has the following advantages:

- No dismantling costs - No indoor storing costs - No identification problems - Most valves, located in a processing facility are an

integral part of the process equipment and its associated piping and will be subjected to the selected lay-up.

- Snap-back period for recommissioning will be relatively short.

- The disadvantage of valves in situ are: - Replacement of components, such as soft sealing, will

generally be required after long-term mothballing is terminated. These components can be easily replaced, however and spares should be made available from stock when termination of mothballing is expected.

3.1.3.4 Covering valves and/or actuators with plastic bags is

generally ineffective and not recommended, because the plastic bags or polyethylene wrappings deteriorate rapidly, and they will collect sand and moisture.

3.1.4 Recommendations 3.1.4.1 Internal preservation - Treat valves the same as connected piping or pipelines. - Leave valves, where applicable in (half) open position. - Drain valves when applicable and feasible. 3.1.4.2 External preservation - Lubricate and grease stem bearings. - Stroke after greasing (2 or 3 times). - Leave in (half) open position. - Tighten packing. - Coat machined surfaces with rust preventative SAMS

stock item 26-007-230/240 or equivalent. - Coat stem and stem threads with Denso paste plus

Denso tape. - Fill gear-boxes with R.P.oil (V.P.I.). - Leave diaphragm actuator in place. They should be

recalibrated during commissioning and replaced at that time if necessary.

- Remove oil, coat, and store piston actuators. 3.1.5 Monitoring Maintenance

3.1.5.1 Short Term Mothballing - Do not stroke - Determine if packing requires re-tightening when

checking pressure of the mothballing medium. - Add Denso paste/tape or equivalent if required. 3.1.5.2 Long Term Mothballing - Same as Short Term, but discontinue

onitoring/maintenance after three years. 3.1.5.3 Minimum First Cost Mothballing - Monitoring/maintenance is not recommended.

Table 5

Valves

Mothballing

Facility Short Term Long Term Minimum First Cost Internal - Same as connected - Same as short term - Same as short term piping External - Lubricate and grease - Same as short term - Same as short term - Stroke after greasing - Leave in half open position - Wrap with Denso tape and - Coat stem with Denso paste - Do not wrap valves with plastic sheets or bages Monitoring/ - Semi annually - Same as short term - None Maintenance - Add Denso paste - Discontinue as required monitoring after - Do not stroke three years Recommissioning - None - Replacement of - Same as long term concerns seat, gears or actuators likely

4 PRESSURE VESSELS 4.1 Basic Considerations 4.1.1 General Pressure vessels, which are part of the process equipment, generally

contain hydrocarbon products which can be either sweet or sour, dry or wet.

The process side of the pressure vessels require specific mothballing

procedures when the pressure vessels are mothballed for Short-Term, Long-Term or Minimum First Cost Mothballing.

Mothballing procedures involve one of the following: 4.1.1.1 Preservation of the entire pressure vessel in situ, using the

same lay-up medium as selected for the connected process piping.

4.1.1.2 Preservation of the entire pressure vessel in situ, but using a

different lay-up medium than was selected for the connected process piping. For this option, pressure vessels must be isolated from associated piping with blinds.

4.1.2 Some Specific Concerns and Considerations 4.1.2.1 The majority of pressure vessels are made of carbon steel.

Some are simple in construction and others, such as desalting traps in desalting facilities or columns in refineries, are complicated.

4.1.2.2 Some pressure vessels are made of stainless steel or cladded

carbon steel, while some are made of carbon steel with an internal coating. These types of pressure vessels, when mothballed, present different concerns than pressure vessels made of carbon steel and without an internal coating.

4.1.2.3 Pressure vessels will normally not be removed from a plant

and stored elsewhere when a plant is mothballed. The removal of the pressure vessels to other plants is encouraged when plants are mothballed at Minimum First Costs.

4.1.2.4 Preservation of pressure vessels includes internal protection

and external protection. In general, external corrosion and/or

pitting is not expected providing normal paint schedule is continued.

4.1.2.5 Some pressure vessels are externally insulated, which may

give reason for concern when vessels will be mothballed for Long Term.

The insulation should be removed when serious corrosion on

the steel surface is expected to occur or is revealed during monitoring.

The external steel surface should be coated with a suitable

paint after removal of insulation. 4.1.2.6 Lay-up mediums for pressure vessels are:

• Nitrogen • Diesel, with or without inhibitor • Dry-air • Ambient air

4.1.2.7 Dry fuel gas is recommended with care as a lay-up medium because it can form explosive mixtures with air.

4.1.2.8 It is recommended that the liquid from all pressure vessels be

drained prior to mothballing. 4.1.2.9 Recommissioning concerns: Significant amount of loose and

flaky rust will be present on all metal surfaces due to water present in diesel and oxygen in nitrogen. Hydro-jetting will be required before recommissioning.

4.1.3 Recommendations 4.1.3.1 Internal Preservation for Short and Long Term Mothballing - Drain liquid - Clean vessel, including boot-legs - Isolate vessel from connected piping if required - Fill with diesel or purge with nitrogen - Seal vessel and maintain 5 psig nitrogen pressure for

one year - Check quarterly if water has collected - Continue

checks after one year, annually

- Check diesel leakage semi-annually and tighten gaskets or threaded connections when needed - Discontinue checks after one year

4.1.3.2 External Preservation for Short or Long Term Mothballing - Non-insulated vessels require no special treatment - Continue normal paint schedule as required - Insulated vessels should be protected by sealing off all

openings in the weather jacket with plastic tape or mastic putty (Denso or equal type). Provisional windows may be cut in the insulation to enable monitoring of the underlaying steel surface. The windows should be sealed off effectively.

- Remove insulation if steel surface is corroding - Paint steel surface in accordance with Saudi Aramco

Paint Manual 4.1.3.3 Internal Preservation for Minimum First Cost Mothballing - Drain liquid - Purge with ambient air (avoid any fire hazards) - Close vessel - Do not steam out - Do not repair - Monitoring/maintenance not required 4.1.3.4 External Preservation for Minimum First Cost Mothballing - Insulated and non-insulated vessels do not require

special treatment - Discontinue normal paint schedule - Do not remove insulation - Monitoring/maintenance not required 4.1.3.5 Preservation of the Process Side by Continuous Dry-air Purge Technically it is feasible to preserve the process side of

pressure vessels and associated pipe work by purging them with dry air.

With this option, dry instrument air - with a maximum

relative humidity of 40 percent - should flow continuously through the process equipment and connected piping. The dry air can be supplied by instrument air compressors.

Instead of purging with dry air, the process equipment can

also be internally preserved by circulating the dry air (40% relative humidity) through the process equipment and connected piping. This can be achieved by flowing the air in a closed circuit through an air-drier equipped with a fan. This option can be applied for short or Long Term Mothballing. It is, however, only recommended for use in plants or facilities which have been installed but not operated with hydrocarbon products.

The advantages of using this option are:

• Nonflammable • Nontoxic • No problems with disposal • Facilitates internal inspection • Process side of pressure vessels and associated piping

will not corrode The disadvantages are:

• Fans and air-driers are required (initial cost is expensive)

• Weekly monitoring of fans and air-driers is required • Electric power is required

Table 6-A

Pressure Vessels

Mothballing

Facility Short Term Long Term Minimum First Cost Internal - Drain liquid - Same as short term - Drain liquid - Fill with diesel or - Purge with ambient air - Purge with nitrogen - Close or dry air Monitoring/ - Semi annually for - Same as short term - None Maintenance diesel leakage or - Maintain 5 psig pressure for one year - Then discontinue monitoring Recommissioning - None - None - Pitting expected at low concerns spots where water can collect External a) Non-Insulated - None - None - None Vessels Monitoring/ - Continue normal - Same as short term - None Maintenance paint schedule Recommissioning - None - None - Pitting and/or general concerns corrosion expected - Surface repair likely

Table 6-B

Pressure Vessels

Mothballing

Facility Short Term Long Term Minimum First Cost External b) Insulated - Seal off all openings - Same as short term - None Vessels in weather jacket with plastic tape or mastic putty (Denso paste) Monitoring/ - Semi annually - Same as short term - None Maintenance - Remove insulation if steel surface is corroding - Paint steel surface Recommissioning - None - None - Pitting and/or general concerns corrosion expected - Surface repair likely

5 TANKAGE 5.1 Basic Conditions 5.1.1 General The following types of tanks should be considered when mothballing

equipment: - Floating roof storage tanks for hydrocarbon products at ambient

temperature. - Cone roof storage tanks for hydrocarbon products at ambient

temperature. - Cone roof storage tanks for water. - Cone roof storage tanks for chemicals. Mothballing procedures involve one of the following: A. Floating Roof Tanks 1) Preserve the entire tank in situ, but with crude level full or

such that roof legs are 6 inchs from the tank bottom (Long and Short Term only).

2) Leave tank empty, without monitoring and without

maintenance (Min. First Cost only). B. Cone Roof Tanks - Hydrocarbon 1) Preserve the entire tank in situ, leaving the tank empty, and

using desiccant as lay-up medium (Short or Long Term). 2) Preserve the entire tank in situ, leaving the tank empty,

without desiccant and without monitoring/maintenance (Min. First Cost only).

C. Cone Roof Tanks - Water Preserve the entire tank in situ, leaving the tank empty, after

cleaning and drying (Short or Long Term or Min. First Cost). No monitoring/maintenance for Min. First Cost mothballing.

D. Cone Roof Tanks - Chemicals

Preserve the entire tank in situ, leaving the tank empty, after cleaning and purging (Short or Long Term or Min. First Cost). No monitoring/maintenance for Min. First Cost mothballing.

5.1.2 Some Specific Concerns and Considerations 1) Floating roof tanks and cone roof tanks are made from carbon

steel. These tanks, when mothballed, will present no concerns for external corrosion, provided normal paint schedule is continued. (Short and Long Term).

2) Floating roof tanks, in light product service when left empty,

present little concern for internal corrosion, provided all internal surfaces are sprayed periodically (once/year) with oil fuel No. 5 or No.6.

3) Floating roof tanks in heavy product service, when left empty,

present little concern for internal corrosion. If needed, internal surfaces may also be sprayed with oil fuel.

4) Cone roof tanks for hydrocarbon products are of concern when

maintenance is discontinued. General corrosion is expected and internal or external repair is likely. (Min. First Cost mothballing).

5) Cone roof tanks for water should be left empty when mothballed

for Short Term - Long Term and Min. First Cost. General corrosion is expected, and internal and external repair is likely when normal painting schedule is discontinued (Min. First Cost Mothballing).

6) Cone roof tanks for chemicals should be left empty when

mothballed for Short Term - Long Term and Min. First Cost. General corrosion is expected when normal painting schedule is discontinued (Min. First Cost).

5.1.3 Recommendations 5.1.3.1 Preservation of Floating Roof Tanks for Short or Long Term

Mothballing - Empty tank with roof on legs. - Spray on all internal surfaces with fuel oil No. 5 or No.

6 for tanks on light product service. - Continue normal painting schedule, externally.

5.1.3.2 Preservation of Floating Roof Tanks for Minimum First Cost Mothballing

- Recommendations for long term may be applied - Discontinue paint maintenance 5.1.3.3 Preservation for Cone Roof Tanks (Hydrocarbon) for Short

or Long Term Mothballing - Empty tank and open manways - Steam out, clean and dry - Use desiccant and breather valves - Replace desiccant semi annually if desiccant is installed - Continue normal painting schedule 5.1.3.4 Preservation of Cone Roof Tanks (Hydrocarbon) for

Minimum First Cost Mothballing - Empty tank - Steam out and clean tank - Purge with air or nitrogen - Seal tank - Do not install desiccant - Discontinue monitoring and maintenance 5.1.3.5 Preservation of Cone Roof Tanks (Water) for Short or Long

Term Mothballing - Empty tank - Clean and dry - Continue normal painting schedule 5.1.3.6 Preservation of Cone Roof Tanks (Water) for Minimum First

Cost Mothballing - Empty tank - Clean and dry - Discontinue monitoring and maintenance 5.1.3.7 Preservation of Cone Roof Tanks (Chemicals) for Short or

Long Term Mothballing - Drain the chemical product in 55 gallon drums and use

elsewhere - Purge with air or nitrogen, if required to remove toxic

vapors

- Continue normal painting schedule 5.1.3.8 Preservation of Cone Roof Tanks (Chemicals) for Minimum

First Cost Mothballing - Drain the chemical product in 55 gallon drums and use

elsewhere - Purge with air or nitrogen, if required to remove toxic

vapors - Discontinue monitoring and maintenance

Table 7-A

Tankage

Mothballing

Facility Short Term Long Term Minimum First Cost 1. Floating Roof - Leave full of crude or - Same as short term - Same as short term Tanks - Lower crude level Alternatives - Empty tank with roof on legs Monitoring/ - Continue normal - Continue normal - None Maintenance schedule painting schedule - In light product service and at low level, all internal surfaces to be sprayed with No. 5 or No. 6 oil fuel Recommissioning - None - None - General corrosion concerns expected if tank is empty - Internal & external repair likely

Table 7-B

Tankage

Mothballing

Facility Short Term Long Term Minimum First Cost 2. Cone Roof Tanks a) Hydrocarbon - Empty tank and open - Same as short term - Same as short term manways - Do not install desiccant - Steam out if required - Purge with air or N2 to remove flammable or toxic vapors or gases - Install desiccant Monitoring/ - Continue normal - Same as short term - None Maintenance painting schedule - Replace desiccant semi annually Recommissioning - None - None - General corrosion expected - Internal and external repair likely

Table 7-C

Tankage

Mothballing

Facility Short Term Long Term Minimum First Cost Cone Roof Tanks b) Water - Empty tank - Same as short term - Same as short term - Clean and dry Monitoring/ - Continue normal - Same as shor term - None Maintenance painting schedule Recommissoning - None - None - General corrosion expected concerns - Internal and external repair likely c) Chemicals - Empty tank - Same as short term - Same as short term - Purge with air or N2 if required to remove toxic vapors - Drain product in 55 gallon drums and use elsewhere Monitoring/ - Continue normal - Same as short term - None Maintenance painting schedule Recommissioning - None - None - None concerns

6 HEAT EXCHANGER EQUIPMENT 6.1 Basic Considerations 6.1.1 General The following types of heat exchanger equipment are considered for

mothballing: - Shell and Tube exchangers - Fin-Fans (Air coolers) - Evaporate Coolers (Combinaire) The above types of heat exchanger equipment in general form part of the

process equipment, and mothballing procedures for pressure vessels would therefore also be applicable to heat exchanger equipment.

Mothballing procedures involve one of the following: 1) Preservation of the entire heat exchanger equipment in situ while

using the same lay-up medium as selected for the connected piping.

2) Preservation of the entire heat exchanger equipment in situ, but using a different lay-up medium as selected for the connected piping.

6.1.2 Some Specific Concerns and Considerations 1) The specific concerns and considerations are also applicable to

heat exchanger equipment. 2) When mothballed at Minimum First Cost, there is concern for

recommissioning of tubes in Shell and Tube heat exchangers and for tubes, fans, belts and motors installed in Fin-Fans. Replacement is likely.

3) Wooden downcomers, installed in cooling towers, are of concern when mothballed and not removed. It is recommended the water system be circulated weekly when Short Term Mothballing is required. The wooden downcomers should be removed when Long Term or Minimum First Cost Mothballing is required.

6.1.3 Recommendations 6.1.3.1 Preservation of Shell and Tube Heat Exchangers for Short

Term, Long Term and Minimum First Cost Mothballing - Remove free water

- Treat as pressure vessels - Monitoring and maintenance remain the same as for

pressure vessels - Recommissioning concerns remain the same as for

pressure vessels, but tube replacement likely when mothballed at Minimum First Cost.

6.1.3.2 Preservation of Fin-Fans for Short Term or Long Term

Mothballing - Remove free water - Treat tubes internally installed in Shell and Tube heat

exchangers - If Fin-Fans are located offshore and mothballed for

Long term, spray tubes externally with inhibited R.P. oil.

- Block fans from rotation (Short Term only) - Leave belts installed - Do not treat - Fill gearboxes with R.P. oil (V.P.I.) - Treat fan motors as small motors - Check semi annually for diesel leakage or maintain 5

psig nitrogen pressure for one year - Check semi annually R.P. oil in gear box and refill

when required - Discontinue monitoring after 1 year 6.1.3.3 Preservation of Fin-Fans for Minimum First Cost Mothballing - Treat tubes internally as for Short Term - Do not treat tubes externally - Do not block fans - Leave belts installed - Do not treat - Treat gear boxes as for Short Term - Treat fan motors as for Short Term - Discontinue monitoring and maintenance 6.1.3.4 Preservation of Evaporate Coolers for Short Term or Long

Term Mothballing A) Cooling Tower with Plastic Downcomer - Stop circulating system - Drain basin - Discontinue monitoring/maintenance

B) Cooling Tower with Wooden Downcomer - Add Algacide to basin and circulate water weekly

to keep wood wet - Consider removal of wood and drain basin (Long

Term only) - Check circulation system semi annually if water is

circulated weekly - Discontinue monitoring/maintenance after 1 year 6.1.3.5 Preservation of Evaporate Coolers for Minimum First Cost

Mothballing - Drain basin - Do not remove plastic downcomer - Remove wooden downcomer - Discontinue maintenance - General corrosion is expected and replacement of

plastic downcomer and circulation system is likely

Table 8-A

Heat Exchangers

Mothballing

Facility Short Term Long Term Minimum First Cost 1. Shell and Tube - Remove free water - Same as short term - Same as short term - Treat as pressure vessels Monitoring/ - Same as pressure - Same as short term - None Maintenance vessels Recommissioning - None - None - Pitting and/or general concerns corrosion expected - Tube replacement likely 2. Fin-Fans a) Tubes - Internal - Treat as 1) - Same as short term - Same as short term b) Tubes - External - None - Spray with inhibited - None R.P. oil (offshore only) c) Fan-Blades - Block fan from - None - None rotation d) Belts - None - None - None

Table 8-B

Heat Exchangers

Mothballing

Facility Short Term Long Term Minimum First Cost Fin-Fans e) Gear Box - Fill with R.P. oil - Same as short term - Same as short term (V.P.I.) f) Fan Motor - Treat as small motors - Same as short term - Same as short term Monitoring/ - Semi annually for - Same as short term - None Maintenance diesel leakage or - Maintain 5 psig pressure for one year - Check R.O. oil in gear box and refill - Discontinue monitoring after 1 year Recommissioning - None - None - Fitting and/or general concerns corrosion expected - Replacement of tubes, fans, belts and motors likely

Table 8-C

Heat Exchangers

Mothballing

Facility Short Term Long Term Minimum First Cost 3. Evaporate Coolers a) Cooling Tower - Add algacide and - Consider removal - Same as long term Wooden circulate weekly of wood Downcomer to keep wood wet - Drain basin (Combinaire) b) Cooling Tower - Drain basin - Drain basic - Drain basin Plastic Down comers Recommissioning - None - None - General corrosion expected concerns

7 ROTATING EQUIPMENT 7.1 Basic Considerations 7.1.1 General A) The mothballing procedures for the preservation and maintenance

of rotating equipment are dependent mainly on the size and type of equipment and the recommissioning period specified. Mothballing procedures will involve one of the following:

1) Preservation of the entire rotating equipment in situ. 2) Preservation of the rotating equipment in situ, but some

vulnerable components to be removed and stored in a controlled atmosphere.

3) Preservation of entire rotating equipment indoors in a

controlled atmosphere. 7.1.2 Types of Rotating Equipment The following equipment is considered rotating equipment: 1. Centrifugal Pumps 2. Reciprocating Pumps 3. Submersible Pumps 4. Chemical Injection Pumps/Metering Pumps 5. Centrifugal Compressors 6. Reciprocating Compressors 7. Gas Turbines 8. Steam Turbines 9. Gear Boxes 10. Hydraulic Variable Speed Couplings 11. Torque Convertors 12. Tank Mixers 13. Diesel Engine 14. Emergency Diesel Generators 7.1.3 Some Specific Concerns and Considerations 1) Shutdown of a plant or facility with rotating equipment is complex

and demanding, and a mistake in the selection of the mothball procedure can result in the deterioration of expensive equipment.

2) Idle equipment is very sensitive to internal and external corrosion and will deteriorate quickly if not satisfactorily preserved. The exclusion of moisture is essential to avoid pitting and oxidation of critical components such as gear teeth, bearing journals, shaft seals, blading, etc.

3) Sand ingress into the close clearance components in rotating

equipment, such as shaft labyrinths, bearings and seals, is another concern. Equipment must be properly sealed during the mothball period to prevent ingress of sand and or sand dust since this could cause seizure/damage.

4) Large, centrifugal type rotating equipment, such as the injection

pumps, process gas compressors, gas and steam turbine drivers, sometimes has slender and heavy shafts. These shafts are susceptible to "creep" (a permanent or semi-permanent bend or sag in the shaft) if the shaft of an idle machine is not turned periodically. For this reason, equipment manufacturers advise that spare rotors for such machinery be turned periodically (monthly to quarterly) or that the rotor be stored vertically if turning is not possible.

Note: If a rotor is to be turned while in its casing, the journal

bearings must have a lubricant film; otherwise damage will occur. Rust preventive oil provides adequate lubrication. Because of leakage across the clearance between shaft and bearing/seal, periodic rotor rotation assures that the rotor maintains a complete protective coating of rust preventative when the casing can only be partly filled with rust preventative.

5) A large number of high horsepower pumps which are subject to

rotor sag are installed at Saudi Aramco. For example, 4000 HP (3000 psig operating pressure) multi-stage horizontal centrifugal pumps (Ingersoll-Rand and Sulzer) are installed at the desalting facilities. Pumps (Weir) of similar design are used for water-injection and are even larger in capacity than brine injection pumps (15,000 HP -3000 psig operating pressure).

The cartridge type design of these pumps is such that shaft,

impellers, diffusors, head flange, bearing brackets and seals can be easily removed from the pump barrel and the unit stored in a vertical position. It is recommended the cartridge be removed as one unit from the pump barrel and stored indoors when a long lay-up period is required.

If stored indoors, such rotors should be coated with a thick coating of rust preventative (solvent cut-back type) and then hung vertically. Storage outdoors (possibly adjacent to the machine) is also an approved method. In this case, the rotor can be immersed in a vertical position within a container fabricated from large diameter steel pipe filled with rust preventative oil.

6) Frequent starting of gas turbines will shorten turbine rotor and

stator/blading life. Therefore, mothballing procedures should avoid firing of the turbine.

7.1.4 Mothball Media Selection Considerations 1) In general, machinery's internal surfaces can be coated with rust

preventatives by circulating the oil through the equipment and/or oil piping by using the lube/seal oil pumps. Another method is sealing of the openings on the casing and filling to the top with rust preservative, and, if necessary, draining to shaft height should leakage across the shaft/bearing be a concern.

2) All internal spaces of rotating equipment should be filled with

either an inert gas, (N2) rust preventative film, or an inert fluid to prevent corrosion damage to the machine surfaces and internal walls of the equipment.

3) See Appendix E & G for available rust preventatives. 4) Most rust preventative solvents (cut-back type) exposed to the

atmosphere will last for a maximum of one year. Thus, if shutdown is to go beyond this period, rust preventatives must be reapplied and coating repairs may be needed.

5) ISO 46 for heavier grade oil with the addition of Vaprotec UPI

should be used as rust preventative oils in large systems. Deisel Engine oil CD SAE 30 or SAE 40 grades are suitable in smaller systems.

6) Critical components such as bearing and journals, crankcase,

coupling, reservoir, cylinders of rotating equipment are best protected by rust preventatives. Journal sections which are monitored by proximity vibration displacement probes should also be protected by rust preventative to avoid pitting corrosion of these highly polished surfaces.

7) The recommended media for protection of machinery internals for

lay-up of mothballed equipment are listed in Table 9.

7.1.5 Mothballing Options The following options are considered for the preservation of rotating

equipment: 1. Storage The ideal mothballing procedure for most rotating equipment

would be to store the equipment in a suitable warehouse where dry air with a relative humidity of maximum 40% can be maintained. Unfortunately, this is not particularly feasible for large equipment.

Rotating equipment which is relatively small and useable

elsewhere should be removed from the processing facility and stored in a warehouse under controlled conditions such as dry air. This option is only considered viable for skid mounted proportioning pumps, diesel engines, submersible pumps and rotating equipment where economics favor indoor storing for long term mothballing.

A disadvantage of this type of storage is the risk of damage during

dismantling and transport of the equipment to storage. 2. Insitu When complete processing facilities, such as onshore and

especially offshore GOSP's are to be mothballed, first consideration must be given as to whether the equipment can be effectively protected in situ.

Preservation of rotating equipment in situ has the following

advantages: - No dismantling costs - No indoor storing costs - No identification problems. Equipment stored indoors may

not be easily traced after 5 - 10 years lay-up if improperly tagged.

- Use of the same lay-up medium in certain cases, a pump or compressor, located in a processing facility is an integral part of the process equipment and its associated piping, and will be subjected to the same selected lay-up medium, such as instrument air purge or nitrogen blanket.

- No special equipment required. Removal of these pumps or compressors may require specially made drop-in spools for

replacing the removed pumps or compressors. Considerable time may also be required to realign these machines to their drivers during the snap back period.

- Snap-back period for recommissioning will be relatively small.

The disadvantages are: - Large rotors may loose their straightness if they cannot be

rotated periodically. If a spare rotor is available and has been properly stored, the snap back period will not be jeopardized. Bent rotors may need to be returned to the manufacturer for rework and this could impact on snap back period if no spare rotor is available.

- Replacement of components such as bearings and seals will generally be required after mothballing is terminated. However, these can be easily replaced and spares should be available from stock.

- Equipment left in situ is exposed to the ambient atmosphere and protection of internals by using greases, rust preventative oils, vapor phase inhibitors, or other long-lasting preservatives is required.

- If the rotor is not removed, the shaft/casing gaps at the bearing housings should be sealed with a silicone caulk, and taped so that the casing can be filled completely with rust preventative media. This option provides full protection of rotating equipment which does not need to have their rotors periodically turned during a long shutdown period; however, periodic inspection and maintenance still may be required.

7.1.5 Preparation Procedures Prior to Shutdown The following steps shall be followed prior to undertaking any

preservative action to the rotating equipment: 1. Stop all rotating equipment and insure the facility is not operating. 2. If applicable, de-energize and lock out all breakers in the 34.5 kV,

13.8 kV, 4.16 kV, 2.4 kV switchgears and 480 V MCC's for electric motors and emergency diesel generators.

Note: Some breakers will remain in service to provide electrical

power to fire-water pump motors and/or air compressors.

Refer to Electrical Equipment, Chapter VIII for detailed Mothballing Procedures and Guidelines for Electric Motors and Emergency Diesel Generators.

3. Flush and drain all rotating equipment when applicable. 4. Purge with nitrogen if hydro-carbon gases are present or are

believed to be present. 5. Isolate pumps or compressors from line (if required). 6. Remove and preserve coupling or spacer between

pump/compressor and driver to facilitate rotating of rotor (if required).

7. Properly tag and store spacer and/or coupling parts. 8. Isolate gear box between pump/compressor and driver when

applicable. 9. Remove and preserve rotors along with seals and bearings (if

required). 10. Install end covers on casing openings if rotors have been removed. 11. Seal ventilation openings. 12. Fit turn bars on rotors if rotors remain in case. Do not weld bars

on rotor shaft. 13. Provide electric motors with a warning that they are "Energized" or

"De-energized" and provide other rotating equipment with warning when space heaters have been installed.

14. For each piece of rotating equipment, prepare a complete listing of

mothballed status and procedure as defined by Saudi Aramco General Instruction Manual GI Number 1000.250. (Appendix F)

7.3 Guidelines for Mothballing Specific Rotating Equipment 7.3.1 Centrifugal Pumps - Refer to TABLE 10 and Paragraph 7.1.3 7.3.2 Reciprocating Pumps - Refer to TABLE 10 7.3.2.1 General

Reciprocating pumps of various sizes are used by Saudi Aramco to pump slop-oil, sludge and similar products. Large units, such as 350 HP Wheatley pumps, are used in stripper service offshore. Some small size pumps are installed on portable skids. This makes transport to and from a storage warehouse convenient.

7.3.3 Submersible Pumps - Refer to TABLE 10 7.3.3.1 General Sumbersible pumps are only used in shallow water supply

wells. Generally, water from these wells is less aggressive than water from deep water wells (Wasia and Biyadh formations). Remove submersible pumps from the wells and store in a warehouse using the following procedure.

- Carefully pull riser-columns and pump from the wells. - Wind electric cable on a reel. - Disassemble airline tubing and discard (low dollar

value). - Check the electric motor to determine if it is provided

with a mercury seal. Note: The motors of submersible pumps from Byron

Jackson have a mercury shaft seal. Because spilled mercury presents a health hazard to servicing personnel, special steps are required to prevent spillage of mercury before the motor is laid horizontally.

(See instruction manual of Byron Jackson.) - Note: It is recommended services be obtained from

Byron Jackson when pump and motor must be removed from well. This company has a service station In-Kingdom. Byron Jackson Services should also overhaul the pump and motor as required and prepare them for indoor storage.

- Disassemble pump submersible type from motor and disconnect cable from motor.

- Drain and clean pump and prepare for indoor storage. - Store in vertical position. - Drain all the water from balance chamber and

pressurematic balance tube (be careful that the oil is not

drained) and plug the balance chamber. Clean the electric motor and prepare for indoor storage.

- Store the motor in a vertical position. - Tag the pump and motor in such a way that they can be

reassembled as one original unit. 7.3.4 Chemical Injection Pumps/Metering Pumps - Refer to TABLE 10 7.3.4.1 General In general, chemical injection pumps and metering pumps are

small in size and capacity. Two options for the preservation of these pumps are presented-one for skid-mounted pumps and one for pumps permanently installed.

Skid-mounted - Store indoors. - Drain and clean pump then lubricate all rotating or

moving parts, including driver. - Do not disconnect pump from driver and do not remove

instrument or meters from the equipment. - Store as one unit. - Tag properly. - Treat same as reciprocating pump. Preserve in Situ (for Short Term) - Displace the chemicals in the injection lines with diesel

oil and fill the chemical tanks with diesel. - Fill the injection pumps with rust inhibiting oil. - Do not remove the injection quills. 7.3.5 Centrifugal Compressors - Refer to TABLE 10 7.3.5.1 General All types of centrifugal compressors when preserved in situ

for a long term period will require periodic maintenance. The rotor, if not turned periodically, will exhibit permanent sag. The rotor should be removed and stored indoors in a vertical position if possible. The rotor should also be placed in the original shipping canisters (if available) under a dry nitrogen blanket which will need to be turned periodically if mounted horizontally. Oxidation of the shaft, bearings,

blades and seals can be prevented by completely coating all metal surfaces with a rust preventive coating.

7.3.6 Reciprocating Compressor - Refer to TABLE 10 7.3.6.1 General Various large size reciprocating compressors are installed at

Saudi Aramco facilities. It is recommended that compressors be left in situ and be protected internally and externally for short or long term mothball period. Storage of the complete unit indoors is not recommended or feasible.

7.3.7 Gas Turbines - Refer to TABLE 10 7.3.7.1 General Because removal of complete units for indoor storage is not

physically possible, the equipment must be preserved in situ when long term mothballing is required. If the rotors cannot be turned periodically, it is recommended that the HP and LP rotors be removed and placed vertically in indoor storage in order to prevent rotor sag.

Mothballing options are as follows: Option 1. Preserve in situ Short or Long Term - Blank inlet and exhaust sections. - Remove the load coupling and preserve indoors. - Turn on the lube oil system on a monthly basis and

rotate both the HP and LP shafts 1 1/4 or 2 1/2 turns each time by ratcheting or hand barring.

- Fill all oil systems to maximum levels with rust preventative oil.

- Circulate all oil systems in order to wet all system surfaces.

- Seal breathers and other openings to the oil systems. - Over grease anti-friction bearings and linkages till fresh

grease appears externally. - Circulate preheated air. Option 2 - Preserve in Situ - Rotor(s) removed and stored

indoors

- Remove rotor(s) from the gas turbine and store indoors in a vertical position preferably in a canister.

- Protect the machine internally and externally as recommended in Option 1.

- Use heater, dessicant on VPI fog, to keep moisture out of blocked turbine interior.

7.3.8 Steam Turbines 7.3.8.1 General Saudi Aramco operates various steam turbines (200 to 10,000

HP) as drivers. Store the small steam turbines in situ if these machines are to

be mothballed for long periods and do not remove rotors. Large steam turbines should be left in situ. Removal of the

rotor(s) depends on its sensitivity to sag and whether it can be turned periodically. Treat these large steam turbines as Centrifugal Compressors.

7.3.9 Gear Boxes 7.3.9.1 General Gearboxes are classified as (1) gears lubricated by oil in the

case and (2) gears that have forced feed lubrication. The case should be completely filled with a rust preventive medium, and in order to prevent oil leakage, caulked and taped along the shaft and bearings. It is not necessary to turn the rotors.

7.3.10 Hydraulic Variable Speed Couplings 7.3.10.1 General Hydraulic variable speed couplings are mainly used for crude

loading pumps and can vary in size and capacity from a few hundred horsepower to 14000 HP.

This type of rotating equipment is very complicated and it is

not recommended that any components be removed from these machines when short or long term mothballing is required.

Small hydraulic variable speed couplings can be stored in situ outdoors; however, large speed couplings should be preserved in situ. Draining and flushing of these pieces of equipment is recommended whether the equipment is stored ndoors or preserved in situ. Internal protection of this equipment shall be achieved by partly filling the case with R.P. Vaprotec.

The recommended options is: Preserve in Situ - Disconnect hydraulic variable speed coupling from

motor and pump. - Drain and flush completely. - Seal off all openings. - Fill case partly with R.P. Vaprotec (See Appendix E) 7.3.11 Torque Convertors 7.3.11.1 General Torque convertors are generally installed between a start

motor and a gas turbine train. Lay-up for torque convertors are practically the same as those for hydraulic variable speed couplings. It is not recommended that the start motor and gas turbine be disconnected from the torque convertors since reinstallation is a complicated procedure.

7.3.12 Tank Mixers Tank mixers should be left on layed-up storage tanks. Long term

protection against oxidation and corrosion is very difficult; therefore, it is recommended these mixers be replaced when storage tanks are re-commissioned. If needed, the storage tanks can also be used for quite some time without operating tank mixers.

7.3.14 Diesel Engines Diesel engines that are not used to drive emergency diesel generators,

should be properly preserved or used elsewhere. Skid-mounted or truck-mounted diesel engines can be preserved indoors or insitu for short or long term mothballing. For either short or long term mothballing, the procedures described for reciprocating compressors should be followed.

7.3.15 Emergency Diesel Generators

Emergency diesel generators for operating firewater pumps, air-

conditioning and navigation lights (offshore) should be left operable as standby units and maintenance should be performed per normal schedule.

Table 9-A

Preservation Media For Machinery/Internals

Mothball Equipment Centrifugal Reciprocating Pumps Term Service Pump Casing Cylinders Crankcase a) Water 1) R.P. Oil 1) R.P. Oil 1) R.P. Oil Short b) Hydrocarbon 1) R.P. Oil 1) R.P. Oil 1) R.P. Oil 2) Crude a) Water 1) R.P. Oil 1) R.P. Oil 1) R.P. Oil Long b) Hydrocarbon 1) R.P. Oil 1) R.P. Oil 1) R.P. Oil 2) Crude NOTES on Available Media: - R.P. = Rust Preservation (Oil or Solvent Cutback Types) - N2 = Nitrogen - Diesel (Inhibited) or Crude Oil - X = Not applicable

Table 9-B

Preservation Media For Machinery/Internals

Mothball Equipment Reciprocating Pumps Term Service Cylinders Crankcase Pulsation Bottles Centrifugal a) Water X X X X Short b) Hydrocarbon 1) R.P. Oil 1) R.P. Oil 1) R.P. Coating & 1) R.P. Oil Treat as Piping 2) N2 a) Water X X X X Long b) Hydrocarbon 1) R.P. Oil 1) R.P. Oil 1) Treat same as 1) R.P. Oil Recip. 2) N2 Compressor Short Term

Table 9-C

Preservation Media For Machinery/Internals

Mothball Equipment Steam Gas Gear Boxes and Term Service Turbines Turbines Hyd. Couplings a) Water X X X Short b) Hydrocarbon Treat same as 1) Seal + Preheated 1) R.P. Oil Centrifugal Preheated Air + Compressor Operate Oil System Short Term + Turn Monthly a) Water X X X Long b) Hydrocarbon Treat same as Treat same as Gas 1) R.P. Oil Centrifugal Turbine Short Term Compressor Short Term

Table 10-A

Rotating Equipment

Mothballing

Machinery Type Short Term Long Term Min. First Cost 1) Centrifugal Pumps a) Submersible - Remove and use - Same as short term - Same as short term elsewhere b) Vertical Can - Leave in situ - Same as short term - Same as short term - Do not turn - Caulk and tape shaft/casing gaps - Fill casing with R.P. Oil or grease - See Appendix B Additional steps - Install temporary cover over coupling area c) Horizontal Type - Treat same as 1B - Same as short term - Same as short term Lesser Than 4,000 H.P. Greater Tan - Leave in situ - Remove rotor and - Leave in situ 4,000 H.P. store vertically - Turn shaft monthly - Caulk and tape - Do not turn - Fill casing to shaft shaft/casing gaps height with R.P. Oil - Fill bearing housings - Fill casing and bearing - Same as short term to normal level with housing fully with R.P. Oil - Install temporary - Same as short term - Same as short term cover over coupling area - See Appendix B - Same as short term - Same as short term

Table 10-B

Rotating Equipment

Mothballing

Machinery Type Short Term Long Term Min. First Cost 2) Centrifugal Compressors a) Process Gas - Leave in situ - Remove and store - Leave in situ - Fill casing with N2 if no manpower - Do not turn shaft/ or fill casing to shaft to turn shaft or to casing gaps height with R.P. Oil operate lube/seal oil - Fill casing and - Operate lube/seal systems bearings with oil systems monthly - Fill casing with R.P. Oil R.P. Oil - Turn shaft monthly - If rotor not removed, - See Appendix B for block in oil piping to additional steps bearings so can be filled with R.P. oil, turn shaft monthly - See Appendix C for additional steps b) Refrigeration - Same as 2(a) short - Same as 2(a) short - Same as 2(a) for term term minimum first cost c) Instrument Air - Leave in situ - Same as 2(a) for long - Same as 2(a) for - Operate lube/seal term minimum first cost monthly - See Appendix B for additional steps - Purge casing with N2, dry air or fill casing to shaft height with R.P. Oil

Table 10-C

Rotating Equipment

Mothballing

Machinery Type Short Term Long Term Min. First Cost 3) Gas Turbines - Leave in situ - If utilities or manpower - Leave in situ - Operate lube oil are not available to - Do not turn shaft systems monthly operate lube system - Block in oil to - Blind suction and and turn shafts, remove bearings discharge flanges and store rotors - Block in suction and install air pre-heater - Block suction and discharge flanges - Turn shaft monthly discharge flanges and and install air - See Appendix B for install air pre-heater pre-heater additional steps whether rotor removed or not - If motor not removed, block oil to bearings and turn shaft monthly - See Appendix B for additional steps 4) Gears - Grease or fill bearing - Reove and store rotors, - Leave in situ housing with R.P. Oil if can't seal shaft/ - Do not turn shaft - Fill casing to shaft casings - Seal shaft/casing height with R.P. Oil - If can seal shaft/ and completely - Leave in situ casing, fill casing with R.P. Oil - Turn shafts monthly fully with R.P. Oil - See Appendix B for - Do not turn rotors additional steps

Table 10-D

Rotating Equipment

Mothballing

Machinery Type Short Term Long Term Min. First Cost 5) Reciprocating Compressors a) Utility Air - If instrument air - Do not turn - Leave in situ required keep - Remove cylinder - Do not turn shaft compressor in suction valves and - Remove cylinder service, otherwise fill cylinder with suction valves and do not operate. R.P. Oil fill cylinder with - If not operated, - Fill crank case R.P. Oil remove cyclinder completely with - Seal off distance suction valves and R.P. Oil piece openings fill cylinder with - Seal off distance R.P. Oil piece openings - Turn shaft monthly - See Appendix B for - Fill crank case with additional steps R.P. Oil. Seal off distance piece openings - See Appendix V for additional steps b) Gas Lift - Leave in situ - Remove piston and - Leave in situ - Remove suction rod and store - Do not turn shaft valves and fill - Do not rotate - Remove suction cylinder and crank - Remove suction valves valves and fill shaft with R.P. Oil and fill cylinder and cylinder with - Turn shafts monthly crank case R.P. Oil. - See Appendix B for - See Appendix B for - Fill crank case fully additional steps additional steps with R.P. Oil - Seal off distance - Seal off distance piece openings piece openings

Table 10-E

Rotating Equipment

Mothballing

Machinery Type Short Term Long Term Min. First Cost 6) Reciprocating Pumps - Remove suction - Remove suction valves - Leave in situ valves and fill and fill cylinder with - Do not turn shaft cyclinder with R.P. Oil - Remove suction R.P. Oil - Fill crank case with valves and fill - Turn shaft monthly R.P. Oil cyclinder with - See Appendix B for - Do not turn shaft R.P. Oil. additional steps - See Appendix B for - Fill crank case fully additional steps with R.P. Oil 7) Steam Turbines a) Lesser than - Leave in situ - Leave in situ - Same as long term 1,000 H.P. - Turn shaft monthly - Do not turn shaft - Fill casings and - Fill seal casing/shaft bearings with R.P. gap and casing with Oil to shaft height R.P. Oil b) Greater than - Leave in situ 1,000 H.P. - Operate lube system - Remove and store - Leave in situ monthly cylinder and - Fill seal shaft/casing - Do not turn shaft - Fill casing with N2 or and casing with - Fill seal shaft/ fill partly with R.P. R.P. Oil casing and casing fully with R.P. Oil NOTE: R.P. = Rust preservative oil with vapor phase inhibitor added. Note rust preservative oil should have viscosity of

approximately 220 - 300 SSU at 100 deg F plus Vaprotec or SAE 30/SAE 40 Crankcase oil.

8 ELECTRICAL EQUIPMENT 8.1 Basic Considerations 8.1.1 General The mothballing guidelines for the preservation and maintenance of

electrical equipment are dependent mainly on the size and type of equipment, the required mothballing term and the time required for recommissioning. Mothballing procedures will involve one of the following:

1) Preservation of entire electrical equipment in situ. 2) Preservation of entire electrical equipment indoors in a

controlled atmosphere. 8.1.2 Types of Electrical Equipment The following equipment is considered electrical equipment: 1. Transformers 2. Motors 3. Substations and Switchracks 4. Cables 5. Batteries and Battery Chargers 6. Generator and Associated Facilities 7. Instrument Power Supply 8. Junction Boxes Conduit Systems Cable Trays 9. Security Lights 8.1.3 Some Specific Concerns and Considerations 1. Mothballing of electrical equipment, such as motors and

transformers, is complex and demanding and a mistake in the selection of the mothball procedure can result in the deterioration of expensive equipment.

2. Some electrical equipment, when idle, is very sensitive to

internal and external corrosion and will deteriorate quickly if not satisfactorily preserved.

3. The exclusion of moisture is essential to any protection program

to avoid oxidation of critical components such as bearings, shaft seals and insulation material, etc.

4. Sand ingress into the close clearance components in electric

motors and/or junction boxes is also a concern. 5. As in large centrifugal type rotating equipment, shafts of large

motors are susceptible to "Creep", if not turned periodically. 6. The majority of transformers, motors, and battery chargers can

be preserved for Short or Long Term without recommissioning concern, providing the equipment remains energized.

7. When mothballed at Min. First Cost in situ, electrical equipment

will quickly deteriorate if electric power is switched off. 8.1.4 Mothballing Options The following options are considered for the preservation of electrical

equipment which can be removed: 1) Store transformers, motors, batteries, battery chargers and UPS

inverters in a suitable warehouse. Unfortunately, this is not particularly feasible for large motors and transformers. Then the electrical power supply should be preserved only, for the following:

a. Plant incoming power transformers. b. 34.5 kV switchgear and transformers. c. 13.8 kV switchgear and transformers. d. 4.16 kV switchgear and transformers. e. 2.4 kV switchgear and transformers. f. 480 V control centers and lighting transformers and

lighting panel boards. 8.1.6 General Procedures The following steps shall be followed prior to undertaking any

preservative actions to the electrical equipment: 1) Stop all rotating equipment and insure the plant is not operating. 2) De-energize all breakers in the 34.5 kV, 13.8 kV, 4.16 kV, 2.4

kV switchgears, 480 V MCC's and distribution/lighting panel-boards.

Note: Some breakers will remain in service to provide

electrical power to the equipment indicated in paragraph 10.1.5.

3) All de-nergized breakers should be padlocked and tagged,

indicating that connected equipment has been mothballed. 8.1.7 General Electrical Preparation Procedures - De-energize equipment prior to mothballing. - Clean equipment internally with air-hose. - Clean and dry terminal housings, boxes and control cabinets. - Clean, dry and tighten all power and control connections. - Apply light coat of petroleum jelly on exposed terminals. - Replace any damaged or missing parts and hardware. - Repair or replace leaking cabinet door seals and junction box

gaskets. - Check doors and covers for tight fit. - Tighten all loose hardware. - Place silica gel in boxes, enclosures, housings and panels. - Tighten and re-anchor loose conduits. - Repaint corroded or damaged areas on equipment exterior. - Repaint corroded conduit and junction boxes near the mothballed

equipment. - Energize space heaters. - Energize equipment that is to remain in service during the

mothballing period. - Protect and seal all cable ends from weather and mechanical

damage. - Apply Denso or equivalent on junction box fasteners. 8.2 Guidelines and Recommendations for Mothballing Specific Electrical Equipment. 8.2.1 Transformers Short Term - Long Term - Min. First Cost - Clean and dry insulators. - Check operations of trips. - Energize transformers which are required during mothballing

period. - Check oil level and fill. - Repair seats and oil leaks. - Test oil and record data. - Add additional nitrogen, when applicable, to ensure pressure of 2

- 5 psig. - Remove debris around transformers semi-annually. - Check oil level and fill semi-annually. - Repair leaks.

- Replace silica gel (desiccant) semi-annually. - Store transformers (Min. First Cost Mothballing) . 8.2.2 Motors Short Term - Long Term - Min. First Cost A. Motors less than 600 V - 200 HP - Energize space heaters (if available) (Short Term - Long

Term). - Shut off power and leave in situ (Min. First Cost

Mothballing only). B. Motors greater than 600 V - 200 HP - Energize space heaters. - Block air-inlet. - Use space heater. - Install space heater ammeter (if not already available). - Shut off power and leave in situ (Min. First Cost

Mothballing only). - Check oil level in bearing housing semi-annually. - Check operation of space heater semi-annually. - Replace silica gel (desiccant) semi-annually. - Rotate periodically. 8.2.3 Substations and Switchracks Short Term - Long Term - Min. First Cost - Deenergize any part of switchgear or rack that will not be used

during the mothball period. - Wrap and seal current and potential transformers which will not

be used or store transformers (Min. First Cost only). - Clean and grease fuse clips with contact lubricating grease

(SAMS No. 14-800-125). - Place petroleum jelly on any movable or rusting part, such as:

wheels, contacts, trip and cranking mechanism and disconnect fingers.

- Padlock all breakers, which will not be used, in "OFF" position. - Tag all padlocked breakers indicating that connected equipment

has been mothballed. - Check switchgear/rack and building heating system. - Place silica gel or desiccant inside cubicles which are not

equipped with space heaters (Short and Long Term only).

- If available, activate space heater (Short and Long Term only). - Energize and tag breakers which are required for activating space

heaters. - Do not activate space heaters when equipment is mothballed at

Min. First Cost. Indoor (Short and Long Term only) - Seal any open holes in switchgear cabinets, especially in the floor. - Energize switchgear and building heating system. Outdoor

(Short and Long Term only) - Remove and tag all protective relays of breakers which will not

be used and store indoors. - Energize switchgear of rack space heaters. - Tarpaulin switchgear of racks, but allow air ventilation at bottom. Guidelines for Monitoring/Maintenance (Short and Long Term only) Three Months: - Remove debris around outdoor switchgear/rack. - Ascertain operating of space heaters and heating system. - Ascertain operating of breakers providing power to equipment

that are kept energized during the mothballing period. Six Months: - Replace silica gel inside cubicles. Two Years: - Test and calibrate relays that are still in service. - Clean main bus and breaker contacts that are still in service. 8.2.4 Cables Short Term - Long Term - Min. First Cost - Deenergize all cables which are not used during mothballing. 8.2.5 Batteries - Battery Chargers - Inverters Short Term - Long Term A. Batteries (Lead-Acid Type)

- Clean battery terminals and apply light coat of non-oxidizing grease.

- Clean outside of battery cases with baking soda solution. - Wipe off any acid spills. - Apply light coat of petroleum jelly to battery rack

hardware. Units in service - Check proper electrolyte level and density. - Measure and record individual cell voltages. Units not in service - Drain electrolyte and store. - Store battery. B. Battery Chargers - Keep energized if batteries remain in service and if A/C

is on and properly maintained. - De-energize if batteries do not remain in service and store. C. Inverters - Shut down. Guidelines for Maintenance Three Months: - Check electrolyte level and density of batteries in service. - Ascertain operating of battery charger. - Check charge rate. 8.2.6 Batteries - Battery Chargers - Inverters Minimum First Cost - Disconnect batteries and chargers and leave. - Shut down inverters. - Discontinue maintenance. 8.2.7 Generators and Associated Facilities

Short Term - Long Term - Min. First Cost (Exciters - Relays - Regulators) - Energize space heaters (Short and Long Term only). - Leave in situ, but do not activate space heaters (Min. First Cost

only). Guidelines for Maintenance (Short and Long Term only) Three Months: - Remove debris around equipment. - Ascertain operating of space heaters. - Check tarpaulin. - Rotate periodically. 8.2.8 Instrument Power Supply Short Term - Long Term - Min. First Cost - Do not keep power on unless A/C is on (Short and Long Term).

Abandon and discontinue monitoring (Min. First Cost only). 8.2.9 Junction Boxes - Conduit Systems - Cable Trays Short Term - Long Term - Remove dirt from box fasteners. - Apply Denso or equivalent on box fasteners. - Check semi-annually if Denso is to be reapplied. 8.2.10 Junction Boxes - Conduit Systems - Cable Trays Minimum First Cost - Do not apply Denso on box fasteners. - Abandon. 8.2.11 Security and Perimeter Fence Lights Short Term - Long Term A. Offshore:

- Keep energized. - Continue monitoring/maintenance. B. Onshore: - Keep energized. - Continue monitoring/maintenance. 8.2.12 Security and Perimeter Fence Lights Minimum First Cost A. Offshore: - Keep energized. - Continue monitoring/maintenance. B. Onshore: - De-energize all outdoor lighting circuit breakers and

abandon. - Discontinue monitoring/maintenance.

Table 13-A

Electric Equipment

Mothballing

Equipment Short Term Long Term Min. First Cost 1) Transformers (Cathodic Protection Rectifiers) a) Less than 600V - Energize (follow same - Same as short term - Leave in situ procedure as normal energized operation) b) Greater than 600V - Energize (follow same - Same as short term - Leave in situ procedure as normal energized operation) 2 Motors a) Less than 600V - Energize with space - Same as short term - Shut off and leave (lesser than heaters (if available) in situ 250 HP b) Greater than 600V - Energize with space - Same as short term - Shut off and leave (greater than heaters (mandatory) in situ 250 HP) - Block air-inlet - Install space heater ammeter (if not already available - Rotate periodically 3) Substations and Switchracks a) Less than 600V - If available activate - Same as short term - Leave in situ but do space heater not activate space heaters b) Greater than 600V

Table 13-B

Electric Equipment

Mothballing

Equipment Short Term Long Term Min. First Cost 4) Cables - Proect (seal) all cable - Same as short term - Same as short term ends from weather and mechanical damage 5) Batteries a) Chargers - Keep energized if - Same as short term - Abandon AC is on and properly maintained b) Inverter - Shut down - Shutdown - Shutdown 6) Generator and - Energize with - Same as short term - Leave in situ but do Associated Facilities space heaters not activate space (Exciters-Relays- - Rotate periodically heaters 7) Instrument Power - Keep power on if - Same as short term - Abandon Supply AC is on 8) Junction Boxes - Apply Denso or - Same as short term - Abandon Conduit (Systems equivalent on box Cables Trays) fasteners 9) Security Lights a) Offshore - Keep energized - Keep energized - Keep energized b) Onshore - Keep energized - Keep energized - Abandon

9 AIR CONDITIONING SYSTEMS Air conditioning will often be left in operation during short term mothballing to prevent

instrumentation degradation. Window Units Remove from window or wall openings and seal openings with plywood and tape. No

special precautions are required for the unit, but removal will improve the building sealing and reduce the temptation for unauthorized removal/use.

Control Air Handling Systems A. Packaged units -- Disconnect electrical supplys, seal off the outside air inlet and

leave in place. B. Split systems -- Disconnect electrical supplys, seal off outside air inlet and drain

freon (return to storage). Mothball components (i.e. compressor, motor) as specified equipment.

Table 14

Air Conditioning Systems

Mothballing

Facility Short Term Long Term Min. First Cost 1) Window Type - Remove and seal - Same as short term - Remove and seal openings with plywood openings with ply- and tape wood and tape - If control rooms are - Control rooms provided with window included type A.C., leave in place and operate 2) Central Systems a) Packaged - Disconnect electrical - Seal air openings - Same as short term - Same as short term - Leave in place b) Split Systems - Disconnect electrical - Same as short term - Same as short term - Seal air openings - Drain freon (return to storage) - Treat component as specific equipment using nitrogen purge Monitoring/ - Semi annually - Same as short term - None Maintenance pressure check Recommissioning/ - None - None - Large packaged concerns units may require replacement

10 FLARE SYSTEMS Flare systems should be isolated from the flare tip and the in-plant portion mothballed as

in-plant piping. (Relief systems should remain in service where plant vessels/piping contain hydrocarbon gas or liquid). Ground flare tips should be covered to prevent the accumulation of rainwater. Bottom, lowpoint drains should be left open for ground and elevated flares to drain firewater.

Table 15

Flare Systems

Mothballing

Facility Short Term Long Term Min. First Cost 1) Ground Flares - Isolate flare system - Same as short term - Same as short term from flare tips - Treat in-plant portion as in-plant piping and process vessels - Cover flare tips - Leave bottom low point drains open 2) Elevated Flares - Isolate flate stack - Same as short term - Same as short term from piping - Treat-in plant portion as in-plant piping - Relief system to remain in service where plant vessels-piping contain hydrocarbon gas or liquid - Leave bottom low point drains open Monitoring/ - In-plant portion as - Same as short term - Same as short term Maintenance in-plant piping Recommissioning - None - Replacement pilot - Extensive repair concerns tip likely and/or replacement likely

11 BOILERS AND FIRED HEATERS 11.1 Basic considerations 11.1.1 General The mothballing guidelines for the preservation and maintenance of

boilers and fired heaters are dependent on the required mothballing term and the recommissioning period specified.

Guidelines of the various lay-up procedures for mothballing boilers in a

steam generating plant are provided by the General Instruction Number 403.001.

This General Instruction provides mothballing procedures for Short

Term and Long Term mothballing only and does not provide guidelines for mothballing of boilers at Minimum First Cost.

Lay-up procedures for mothballing fired heaters (furnaces) are generally

less complex than for boilers, but common to the preservation of both are Stacks - Burners - Refractory and External Structure.

11.1.2 Some Specific Concerns and Considerations 1. The main concern in shutting down and mothballing the fire-side

of a boiler or fired heater is the potential for acid attack by condensed sulfur compounds on the refractory, its anchoring system and the casing plate. Since heater (furnace) casings operate below the acid dew point temperature, it may be assumed acid corrosion will occur.

Thus, repairs may be needed at shutdown (Short and Long Term

only). 2. The extent of such repairs are dependent on the type of fuel fired

and on the age of the unit. Fired heaters and fireboxes in high sulfur fuel service for over 10 - 12 years may need replacement of a majority of its refractory. (Short and Long Term). Newer units may need no repair work at all. (Short and Long Term).

11.1.3 Guidelines for Mothballing Boilers (Short Term and Long Term) - Use dry storage procedures as outlined in paragraph C7.302 of

"Care of Power Boilers, Section VII of the ASME Boiler and Pressure Vessel Code".

- Follow Boiler - Lay-up Procedures as outlined in Saudi Aramco General Instruction Number 403.001 (where applicable).

- Cap stack(s) - Remove and store burners - Open all manways and if possible sidewall wall headers - Install air eductors on the manway of the mud drum and steam

drum - Open firebox and manually clean down radiant tubes.

Wash/neutralize tubes externally with carbonate solution if fuel contains greater than 0.5 wt % sulfur

- Decoke tubes internally - Wash internally with soda ash if tubes are austenitic steel - Protect tubes internally the same as connected piping - Dry out refractory if tubes are externally washed (use burner) Optional: apply space heater - Maintain normal paint schedule for the external structure Monitoring/Maintenance - Replace silica gel semi annually in mud drums and steam drums - Check semi annually for diesel leakage (if applicable) - Maintain 5 psig pressure on tubes (nitrogen - if applicable) - Check space heater(s) if installed Recommissioning Concerns - Short Term - None - Long Term - Repair of refractory likely 11.1.4 Guidelines for Mothballing Boilers In general, the same procedures are recommended for mothballing

boilers short term as are recommended for Long Term. But for minimum first cost mothballing note the following exceptions:

- Do not cap stack(s) - Do not remove burners - Do not wash tubes externally - Do not decoke tubes internally if tubes are ferritic steel - Discontinue normal paint schedule on external structure - Discontinue monitoring and maintenance Recommissioning Concerns - General corrosion and acid attack to the refractory expected

making replacement likely.

- Some corrosion attack in boiler and tubes expected Repairs likely 11.1.5 Guidelines for Mothballing Fired Heaters (Short Term - Long Term) - Cap stack(s) - Remove and store burners and Seal openings - Wash tubes externally with carbonate solution if fuel contains

greater than 0.5 wt % sulfur - Decoke tubes internally if necessary - Wash internally with soda ash if tubes are austenitic steel - Protect tubes internally as connected piping (Diesel - Nitrogen -

fuel gas) - Dry out refractory if tubes are externally washed (use burner) Optional: apply space heater - Maintain normal paint schedule for the external structure Monitoring/Maintenance - Check semi annually for diesel leakage (if applicable) - Maintain 5 psig pressure on tubes (nitrogen - if applicable) - Check space heater(s) if installed Recommissioning Concerns - Short Term - None - Long Term - Repair of refractory likely 11.1.6 Guidelines for Mothballing Fired Heaters (Minimum First Cost) In general the same procedures are recommended for Minimum First

Cost mothballing of fired heaters as were recommended for Short and Long Term Mothballing, but with the following exceptions:

- Do not cap stack(s) - Do not remove burners - Do not wash tubes externally - Do not decoke tubes internally if tubes are ferritic steel - Do not use space heaters on refractory - Dry out only if tubes are

externally washed - Discontinue normal paint schedule on external structure - Discontinue monitoring and maintenance Recommissioning Concerns - General corrosion and acid attack to the refractory expected.

- Replacement of refractory and repairs or replacement of burners and tubes likely

Table 16-A

Fired Heaters

Mothballing

Facility Short Term Long Term Min. First Cost 1) Stack - Cap - Cap - No action 2) Burners - Remove and store - Same as short term - No action - Seal openings - Leave in situ 3) Tubes a) External - If more than 0.5 WT - Same as short term - No action % sulfur, wash tubes b) Internal Austenitic - Decoke if necessary - Same as short term - Same as short term - Soda ash wash - Protect as connected piping (diesel, N2 fuel gas) c) Internal Ferritic - Decoke if necessary - Same as short term - Same as short term - Protect as connected piping (Diesel, N2 fuel gas)

Table 16-B

Fired Heaters

Mothballing

Facility Short Term Long Term Min. First Cost 4) Refractory - Dry out if tubes are - Same as short term - Dry out if tubes are externally washed are externally (use burner) washed - Optional: Space heater 5) External Structure - Maintain normal - Same as short term - No action paint schedule Monitoring/ - Semi annually for - Same as short term - None Maintenance diesel leakage - Maintain 5 psig pressure on tubes - Check space heater if installed Recommissioning - None - Repair of refractory - General corrosion concerns likely and acid attach to the refractory expected - Replacement likely

12 BUILDINGS 12.1 Basic Considerations 12.1.1 General Prior to mothballing, an economic analysis should be made of the

options available for disposition of the excess building e.g. reuse within Saudi Aramco, reuse by a Non-Saudi Aramco Agency, mothball, abandon in place or demolish. Facilities Planning Department can assist in the economic analysis, including cost estimates for the options.

Chapter 2 of this manual describes the philosophy of mothballing

generally common to Saudi Aramco plant and buildings. In the case of plant, three levels of mothballing are relevant; short-term, long-term and minimum first cost. Due to the different nature of buildings, only one level of mothballing is applicable and is referred to in this chapter as simply 'mothballing".

12.1.2 Mothballing consideration will involve also the following: 1. Economic justification comparing costs of preservation,

maintenance and recommissioning to the cost of demolision and rebuilding.

2. Fire, safety and health hazards in keeping the building unoccupied.

3. Effect of environment (wind, rain, humidity, heat and pollutants) and biological effects on the building and contents. The major natural environmental damage expected to mothballed buildings will come from water. If plumbing is correctly shut off and the building sealed against rain, no serious damages are likely.

4. Security requirements. Vandalism can be a major problem in mothballed buildings. If the facility is securely sealed (and fenced where appropriate) the risk of vandalism is minimized.

12.2 Environmental considerations Temperature fluctuations, rain exposure, moisture absorption, chemical alteration

of the masonry units and the mortar, elastic and plastic strains all acting in many combinations alter the appearance, weather tightness and strength of buildings. Some of the problems arise by wood-boring insects and wood-destroying fungi which proliferate in damp or dry conditions and cause the deterioration of plaster, gypsum board, insulation, carpets etc. besides wood. Chlorides, carbon dioxide, sulfur dioxide and oxides of nitrogen present in the atmosphere may also cause deterioration of the cement in concrete, carbonates in limestone, exposed iron in rebar, aluminum in conduits, metal siding and trim. Electrical wiring may be

damaged by rodents if they are permitted to enter mothballed buildings. Entry of birds, bats and other animals will also cause damage to the building interior and contents.

12.3 Some specific concerns and considerations 12.3.1 The exclusion of water or high humidity (i.e. over 40%) is essential for

any protection program to avoid corrosion and biological damage to the various components within the building. Heating and air conditioning systems, plumbing, sewage and fire water systems should all be drained of water completely and dried for mothballing.

12.3.2 Condensation of moisture under the roof and in other enclosed spaces

should be mitigated by proper ventilation or by preventing moisture entry from outside into a dry building.

12.3.3 Excessive heat built up inside buildings should be avoided by blocking

the sun entering the building through glass windows. 12.3.4 All accumulations of flammable or combustible waste or rubbish and

food should be removed from the building and the interior of the building should be disinfected.

12.3.5 Protection against the entry of poisonous sewer gas, animals, vermins

and vandals should be made to avoid damage to the building and its contents during the mothballed period.

12.4 Preparation for mothballing 12.4.1 A thorough inspection of the building should be made by a qualified

civil inspector for structural integrity, weather proofing, damage to the exterior and interior walls, roof, flooring, framing, insulation, doors, windows and ventilation outlets. An entomological survey should be done to determine the pest control treatment required prior to mothballing.

Based on inspection and survey findings remedial work may be

necessary to protect the building from the environmental considerations stated in paragraph 12.2.

12.4.2 A written procedure should be developed for each building listing the

inventory, actions to be taken for preservation and protection, and the periodic monitoring responsibilities by inspection and security.

12.5 General procedures

The following actions should be completed to mothball buildings. 12.5.1 Clean the inside, remove all food, rubbish and combustible waste. 12.5.2 Shut off electricity, gas, and water supply. 12.5.3 Drain all water from supply, return and disposal lines including fire

water lines, water heaters and storage tanks. 12.5.4 Dry utility water systems with compressed air. 12.5.5 Block off sewer outlets and seal. 12.5.6 Disconnect service to computer and communication systems at the

switching station. 12.5.7 Block off all ventilation and other openings that permit air circulation.

Install rodent proof screens and disinfect the entire building, per entomological recommendations.

12.5.8 Board up all windows and exterior doors except one entrance for

periodic monitoring inspection. 12.5.9 Ensure that the building is weatherproof and paint exterior walls if made

of wood or metal siding, per normal maintenance schedule. 12.6 Mothballing associated equipment For mothballing air conditioning systems, utility systems, electical equipment,

water tanks etc. which are associated with the building refer to the appropriate sections in the Saudi Aramco Mothball Manual.

12.7 Guidelines for monitoring/maintenance 12.7.1 Buildings which are mothballed require periodic inspection and security

checks every 3 months for the first year and annualy thereafter. 12.7.2 Monitoring inspections should include both exterior and interior checks

of the building and the external condition of the associated equipment. Proper safety precautions should be followed in entering mothballed buildings for inspection.

Table 18

Buildings

Mothballing

Facility Mothballing Actions 1) Exterior walls a) Concrete, Brick, Stone No action b) Wood, Metallic siding Maintain normal paint schdule 2) Weather proofing roof, windows, doors, other Inspect and repair as necessary openings 3) Ventilation systems Block off to prevent air circulation inside building 4) Utility water systems Drain & dry with compressed air 5) Sewer systems Block sewer outlets & seal 6) Air conditioning/Heating Systems See Table 14 7) Electrical systems including lighting, alarms a) Shut off power emergency, power, elevators, etc. b) See also Tables 13A and 13B 8) Fire fighting equipment a) Leave in place b) Do not service 9) Carpets Disinfect 10) Communication/computer equipment Disconnect service 11) Flamable & combustible materials, food, rubbish a) Remove from premises b) Shut off gas supply 12) Exterior doors and windows a) Block off direct sun light entering the building b) Board up all windows and doors c) Leave one entrance for inspection 13) Protection against infestation, rodents, vermins a) Disinfect interior and vandals b) Cover openings with insect proof c) Lock, barricade, secure all doors, windows and openings d) Install fence if necessary 14) Security lighting and power Decide on a case by case basis Monitoring/Maintenance Check security, inspect inside & outside every 3 months for the first year and check annually thereafter. Recommissioning concerns None

CHAPTER VII

MONITORING AND MAINTENANCE DURING MOTHBALLING

Monitoring and maintenance of oilfield production processing and refining equipment

depend on the objectives of mothballing. The objectives and factors influencing the mothball procedures are listed in Chapter II.

It has been established that monitoring and maintenance are significant for Short Term

Mothballing, some monitoring and maintenance will be required for Long Term Mothballing, and low or no maintenance costs are dictated for mothballing at Minimum First Cost.

Availability and cost of maintenance personnel are important factors when equipment is

mothballed for Short and Long Term. As explained in Chapter II, short-term lay-up of equipment and facilities idle less than six

months requires little more than the normal turn-around precautions. Recommendations A Mothball Task force Team should be established for each facility in a specific area

(field) to develop specific procedures for mothballing and recommissioning. This task force should be selected from experienced maintenance, engineering and

operating personnel who will write the mothball procedures for the related equipment and facilities or pipe systems in their area of responsibility.

Planning of the Mothball Procedures should be in accordance with the guidelines

recommended in Chapter IV. It is recommended that "Inspection Guidelines for Mothballed Equipment" - Saudi

Aramco Drawing No. DE-321351 be used as a check list for establishing the frequency of inspection and maintenance requirements during mothballing.

In addition to the guidelines, as given in Chapter IV, it is strongly recommended that a

special party audit team be established to verify mothballing records and results in all areas where facilities have been mothballed. This special audit team should report their findings directly to Saudi Aramco's Management periodically. This procedure will enable Saudi Aramco's Management to determine recommissioning terms for mothballed facilities as required.

APPENDIX

A. Extracts from the Exxon Refinery Mothballing Guide for Saudi Aramco. B. Recommended mothballing materials in SAMS. C. Product information. D. Boiler Lay-up Procedures - GI-403.001. E. Storage Preservation of Machinery - Issued by EXXON Chemical Company Baytown,

Texas

APPENDIX A

Extracts from the Exxon Refinery Mothballing Guide for Saudi Arabian Oil Company.

December 1982

Legend: X - Applicable requirement AA - As applicable to equipment NA - Not applicable to equipment NO - Not required or desired Note: TECTYL is a trade mark of Valvoline Oil Company, a division of Ashland Oil, Inc. Utility Centrifugal Compressor Process Services Air/N2 ____________________________________________________________________________________________ High Horizontally Barrel Sundyne Speed Type Split Split Screw Axial Flow (vertical) Package Couplings 1) All couplings (hubs, spacers, keys) X X X X X X spacers, keys) should be coated TECTYL 506 and store in warehouse Casing 1) Flush internals of heavy polymers AA AA AA AA AA NA 2) Store stage diaphram assembly NO X NA X NO NA (or bladed carrier) in warehouse, clean and coatwith TECTYL 506 3) Coat upper half of casing internals X X X X NO X (which do not have casing vents) with TECTYL 930 4a) Install an oil filler pipe connection X X X X X X on casing at convenient location and such that filler pipe iletat slightly higher elevation than top of casing 4b) If casing is separate of bearing X X X X X X housing, install an oil filler pipe also at bearing housings Utility 5) Blind suction and discharge nozzle X X X X X X flanges 6) Blind the coupling housing flange X X X X NA X 7) Blind or plug all casing openings, X X X X X X including those on bearing housing

Utility Centrifugal Compressor Process Services Air/N2 ____________________________________________________________________________________________ High Horizontally Barrel Sundyne Speed Type Split Split Screw Axial Flow (vertical) Package 8) Fill compressor casing with X X X X X X TECTYL 930 using filler pipe per 4a,b (bearing, seal and coupling housing will fill up also). Vent trapped air from casing (where possible) to be sure all internals become coated with TECTYL 930 9) When level in filler pipe indicates X X X X X X casing is full, screw on cap over filler mouth. Extend length of filler pipe as necessary to provide adequate volume for thermal expansion of TECTYL due to ambient temperature changes 10) Coat all exposed sliding or X X X X X X machined surfaces, pins, studs and threaded connections on casing and its support pedestal with TECTYL 890 11) For machines which have integral NA NA NA NA NA X interstage coolers, the gas side will be filled with TECTYL 930 when the compressor casing is filled (as required in earlier step) 12) Integral gear boxes should also NA NA X NA X X be filled completely with TECTYL 930 when the compressor casing is filled 13) Note - where shafts protrude NA NA NA NA X NA through the casing, a teflon gasket should be installed (to prevent TECTYL leakage from the casing or rain leaking into casing) 14) Lube oil systems and reservoir AA AA AA AA NA X mounted in machinery baseplate shall be protected per section covering "Lube & Seal Oil Systems" 15) Store inlet filter in warehouse NA NA AA AA NA X

Utility Centrifugal Compressor Process Services Air/N2 ____________________________________________________________________________________________ High Horizontally Barrel Sundyne Speed Type Split Split Screw Axial Flow (vertical) Package 16) Blank off suction/discharge silencers NA NA X AA NA AA aftercoating metal surfaces with TECTYL 890 17) Drain all casing cooling water jackets NA NA AA NA NA AA and plug. Leave valved drain connection cracked open slightly 18) Protect all instrumentation and X X X X X X control panels as described in separate section covering Instrumentation

Service Reciprocating Compressor (excluding driver) Process Gas Utility (Air/N2) 1) Remove the following: cylinder valves, unloaders, and rod packing. X X Coat with TECTYL 506 and store in warehouse. 2) Blind opening at rod packing box. X X 3) Blind compressor gas inlet and discharge casing connections, X X after filling cylinder and gas passages completely with TECTYL 930. (Allow some space for thermal expansion.) 4) Do not clean or coat cylinder cooling passage, only flush with X X water, drain and air dry. Plug inlet cooling passage. (Leave low point drain cracked open and wire valve in this position (permits self draining of any atmospheric condensation). 5) Blind opening at wiper ring adjacent to crosshead compartment. X X 6) Fill crankcase and crosshead compartment completely with X X TECTYL 930. Install a valved vent (at high point if possible) to permit addition of TECTYL later if required. 7) Blank off pulsation bottles and knock out drums after coating X X with TECTYL 930 (fill and then drain vessels). 8) Coat intercooler/aftercooler gas passages (not water passages) X X with TECTYL 930 by filling and draining. Blank or plug all connections on these components. Keep low point drain valve on water side slightly open and wire valve in this position (water side need only be flushed and air dried). 9) Fill all lubricators, lube pumps and filter on compressor frame X X with TECTYl 930. Plug all connections and vents. 10) Coat flywheel with TECTYL 890 and cover with guard. X X 11) Coat all exposed shafts and linkages with TECTYL 890. X X Cover crank shaft opening from compressor with tape. 12) Remove all gear type couplings (hubs, spacers, keys) and X X pack of non-lube type couplings. Coat with TECTYL 506 and store in warehouse. 13) Protect all instrumentation and control panels described in X X separate section covering Instrumentation.

Horizontally Mounted Service (Vert.& Horiz.Split) Vertical Mounted Hydro- Caustic Four Four Single Multi0 Centrifugal Pumps carbon Acid Water Stages Stages Stage Stage 1a) Flush pumps and drain casing. X X X X X X X 1b) Neutralize step required X AA AA AA AA 2) Fresh water flush and air dry all cooling jackets AA AA AA AA AA AA AA 3) Remove rotor and store in warehouse (coat with TECTYL 506 and mount vertically if possible to avoid need to rotate). Blind shaft openings on casing. Coat bearings & seals and store also. AA AA AA NO X NO NO 4) Blind shaft openings on bearing housing if pump rotor is being stored. AA AA AA NO AA NO NO 5) Fill pump casing with TECTYL 930,gas oil or glycol completely (leave room only for thermal expansion). Make sure stuffing box filled. X X X X X X X 6) Plug cooling water jackets (bearing and stuffing box) but keep low point drain valve cracked open slightly. AA AA AA AA AA AA AA 7) Coat space where shaft protrudes through bearing or stuffing box housings with TECTYL 890 and cover with tape. Insert tape between bearing shield (labyringth seal or deflector disc) and bearing cover. (See Attachment) X X X X X X X 8a) Remove gear type couplings(hubs, spacer keys) and coat with TECTYL 506. Store in warehouse. AA AA AA AA AA AA AA 8b) Remove disc pack of non-lube type coupling. Coat and store in warehouse AA AA AA AA AA AA AA

Horizontally Mounted Service (Vert.& Horiz.Split) Vertical Mounted Hydro- Caustic Four Four Single Multi0 Centrifugal Pumps carbon Acid Water Stages Stages Stage Stage 9) Coat all exposed machine surfaces (shafts,pedestal support) with TECTYL 890 X X X X X X X 10) Fill bearing housings completely with all purpose EP-1 (grease) or heavy oil. X X X X X X X 11a) Note: Pumps with rotors installed do not require rotation. AA AA AA X AA X X 11b) Note: Mechanical seals and shaft packing are not being removed for pumps which have rotors installed. AA AA AA X AA X X 12a) Blind suction and discharge pump flanges if pump casing will be filled with TECTYL 930. AA AA NA AA AA AA AA 12b) Close pump suction and discharge block valves if pump casing and confined piping will be filled with gas oil. AA AA NA AA AA AA AA 12c) Close pump suction and discharge block valves if pump casing and confined piping will be filled with antifreeze water solution. NA AA X AA AA AA AA 12d) Keep pump suction and discharge block valves open if pump casing and confined piping will be purged with inert gas. AA AA AA AA AA AA AA

Reciprocating Proportioning Gear or Steam Motor or Injection Screw Positive Displacement Pumps Driven Driven Type Type 1) Flush and drain pump casing. X X X X 2) Neutralize step required (if caustic or acid) AA AA AA AA 3) Blind suction and disch. nozzles of pumps, liquid end. X X X X 4) Remove and coat all valves and plate covers on liquid end with TECTYL 506 and store in warehouse. X X X X 5) Fill liquid end with TECTYL 930. Bar rotor or piston to coat all surfaces. Allow some space for thermal expansion of TECTYL. X X X X 6) Fill steam end with TECTYL 930. Bar piston and then drain TECTYL. Install steam end valves after coating with TECTYL 930. X NA NA NA 7) Coat internals of safety relief valves (which are integral with pump) with TECTYL 930. NA AA AA AA 8) Coat all joints where shaft protrudes from casings with TECTYL 890. Cover with tape. X X X X 9) Coat exposed piston rod, shafts, and machined parts with TECTYL 890. X X X X 10) Fill bearing housing and gear box with all purpose EP-1 grease. NA X X X 11) Fill packing lubricator with TECTYL 930 or all purpose EP-1 grease. X X NA NA 12) Remove gear type couplings (hubs, spacers and keys), cost with TECTYL 506 and store in warehouse Disc pack for non-lube type couplings should be coated and stored in similar manner. NA AA AA AA

Applicable to all type Fans & Blower Compressors Generator Drives Special General Gear Units (Separate Boxes) Purpose Type Purpose Type 1) Loosen end covers containing shaft labyrinth oil seal from drive and driven end of gear box. Insert teflon rope packing around shafts and bearing to provide a positive shaft seal with gear box. Retighten end covers. X X 2) Blind all oil supply and drain connections on box. X X 3) Replace casing vent with valved pipe which extends just above casing top (serve as refiller). X X 4) Fill casing completely with TECTYL 930, making sure level is above gear elements and within the new filler piping. Leave space for thermal expansion and close filler valve. X X 5) Coat all exposed shaft surfaces with TECTYL 890. X X 6) Gear type couplings (spacer, keys, hubs) should be removed and stored in warehouse. Coat these parts with TECTYL 506. Disc pack for non-lube type couplings should be removed, coated with TECTYL 506 and stored in warehouse. X X

Aircraft Industrial Derivative Heavy Duty Gas Turbines Type Type 1) Purge fuel system and gas passages. Drain all cooling water passages completely. X X 2) Remove gasifier section (aircraft derivative) clean, store in warehouse in container provided by manufacturer. Protect unit per manufacturer's instructions. X NA 3) Remove power turbine section (aircraft derivative) clean and store in warehouse. Protect with TECTYL 506. Protect per manufacturer instructions. X NA 4) Aircraft gasifier and power turbine rotors to be rotated per manufacturers instructions. X NA 5) Remove axial compressor rotor assembly (heavy duty type). Clean and coat with TECTYL 506 and store in warehouse per manufacturer's instructions. NA X 6) Remove power turbine rotor assembly (heavy duty type). Clean and coat with TECTYL 506 and place in warehouse per manufacturer's instructions. NA X 7) Heavy duty axial compressor and power turbine rotor assemblies to be rotated per manufacturer's instructions. NA X 8) Remove electronic overspeed protection and governors and store in warehouse per manufacturer's instructions. X X 9) Coat fuel piping stop valves, spray nozzle, with TECTYL 930. AA X 10) Blind flanges to oil (control, lube), air, fuel connections to gas turbine frame. Plug all vents. X X 11) Remove flame out sensors and store in warehouse per manufacturer's instructions. Plug openings. X X 12) Clean all stationary blading in axial compressor and turbine sections, inlet air box to axial compressor. Spray coat of TECTYL 930 to all these interior parts and surfaces. Isolate these sections by installing blind at inlet air box and exhaust gas duct scroll. NA X 13) Blind sections of piping for control and lube oil between machine frame and oil reservoir. 14) Protect accessories (gear boxes, oil system, startup drives, and couplings) per applicable attached instructions covering these types of equipment. X X 15) Remove inlet air filter cartridges and discard. Spray coating of TECTYL 930 to all latches, bolting, rollers, bearings. Protect any motor drives per instructions covering this specific item. X X 16) Coat all hydraulic cylinders internally with TECTYL 930 and block in. X X

Aircraft Industrial Derivative Heavy Duty Gas Turbines Type Type 17) Spray coat all adjustable nozzle control linkages with TECTYL 506. Grease all fittings with a vendor's recommended lubricant. AA X 18) Coat all machined surfaces on support pedestals and exposed bolting with TECTYL 890. X X 19) Low point drain valve for cooling passages should be cracked open slightly and valve handle tied to this position. X X 20) Protect all instrument and control panels as described in separate section covering these items. X X

Appendix B - Recommended Mothballing Materials In SAMS*

A. LUBRICANTS 1. Grease Compounds - Rust Inhibitive for pumps, air compressor crankcases and

other applications where these procedures specify the use of - SAMS 26-007-230/240* or

2. TECTYL 506 for protection of exposed shafts and other machined surfaces -

SAMS 09-611-830 3. Grease, Ball Valve, Cameron 31545-27-1, for lubrication of ball valves - SAMS

26-009-107 4. Lubricant, Anti-seize, Anti-seize Compound for threaded fasteners - SAMS

26-011-067 5. Ball Bearing Grease, for use in antifriction bearings of all types - SAMS

26-004-330 6. Crank-case Oil, (Diesel Engine Oil), Use as R.P. oil - SAMS 26-005-130/140 Option 1: Add 5 percent Vaprotec to engine oil Option 2: Use turbine oil and add Vaprotec as R.P. oil (1 gram Vaprotec to 20 grams turbine oil) 7. All purpose Grease EP1 - SAMS 26-004-130 B. OTHER MATERIALS: 1. Paper, Greaseproof, for wrapping exposed shafts and other machined surfaces

after they have been greased - SAMS 29-486-485 2. Tape, for sealing openings, securing plastic protective films - SAMS 27-216-219 3. Silica Gel, desiccant for protecting equipment from moisture - SAMS 27-580-824 * SAMS - Saudi Aramco Material System. The SAMS stock numbers are shown.

Appendix C - Product Information

1. TECTYL Products 2. Denso Paste

TECTYL 506

A product of Valvoline Oil Company, Division of Ashland Oil, Inc. What it is TECTYL 506 is a solvent cutback, wax base, corrosion preventive compound. The dry film is firm, amber, waxy translucent. Benefits Easy Application TECTYL 506 is formulated for easy application by spray, dip or brush. Low Cost Protection TECTYL 506 is a one coat rust preventive. The thin film provides high coverage and

low cost protection. Long Term Protection TECTYL 506 is excellent for long term protection of metallic surfaces against corrosion

in either indoor or outdoor exposure and during domestic and international shipments. TECTYL 506 provides outstanding external protection of machinery,machine rolls, machine tools, automotive parts, dies,tubing,and spare parts. TECTYL 506 has a dielectric (insulating) strength of approximately 1000 volts per dry mil of film thickness and therefore protects electrical connections and helps prevent galvanic corrosion.

Surface Preparation The maximum performance of TECTYL 506 can only be achieved when the metal

surfaces to be protected are clean and dry. Remove dirt, rust, scaling paint and other contaminants before applying 506.

Application Ensure uniform consistency prior to use. Continuous stirring or thinning is generally not

required. If product thickens due to cold storage or loss of solvent during use, add only aliphatic mineral spirits and only if necessary to restore consistency. Apply at 10-30 deg C. (50-95 deg F.) by spray, dip or brush.

Coverage The theoretical coverage is 650 sq.ft/gallon (16 sq meters/liter) at the recommended dry

film thickness of 1.3 mils (32.5 microns). Material losses during application will vary and must be considered when estimating job requirements.

Removal TECTYL 506 can be removed if necessary with mineral spirits, or any similar petroleum

solvent or vapor degreasing. TECTYL 506 can be removed from fabrics by normal dry cleaning procedures. Avoid using chlorinated or highly aromatic solvents when removing from painted surfaces as these solvents may adversely affect paint.

Lab Data English Metric Flash, PMCC, Min. 100 deg F 37.8 deg C Specific Gravity @ 60 F (15.6 C), Typical 0.88 0.88 Recommended Dry Film Thickness 1.3 mils 32.5 microns Theoretical Coverage, Typical 650 sq ft/US Gallon 16 sq meters/Liter Approximate Air Dry Time 77 F deg (25 deg C) 1 hour 1 hour High Temperature Flow Point, Typical 300 deg F 149.5 deg C Low Temperature Flexibility, Typical 10 deg F 22.5 deg C (90 bend.No flaking or cracking) Accelerated Corrosion Tests: 5% Salt Spray (Hours) (A) *ASTM B-117 @ 1.3 mils. Typical (2x4x1/8 in.Polished Steel Panels) 2000 hours - (B) *DIN 50021 @ 32.5 microns, Typical (125x200mm. DIN 1623 Panels) - 165 * ASTM (American Society for Testing and Materials) * DIN (Deutsche Industrie Norman) CAUTION TECTYL 506 cures by solvent evaporation. If applied to the interior of an enclosed vessel adequate ventilation is required for cure and to ensure against formation of an explosive atmosphere. For further information, consult Technical Bulletin 173.

TECTYL 890

A product of Valvoline Oil Company, Division of Ashland Oil, Inc. What it is TECTYL 890 is a solvent cutback, asphaltic base corrosion preventive compound. The dry film is firm, black asphaltic type. Benefits Easy Application TECTYL 890 is formulated for easy application by spray or brush. Low Cost Protection TECTYL 890 is a single coat rust preventive. The film provides high coverage and low-

cost protection. Long Term Protection TECTYL 890 is excellent for long term protection of metallic surfaces against corrosion

in either indoor or outdoor exposure and during domestic and international shipments. TECTYL 890 provides outstanding outdoor protection. TECTYL 890 is primarily designed for the protection of non-precision parts such as exterior surfaces, nuts, bolts, large chains and cables. TECTYL 890 will not corrode brass, cadmium, zinc, magnesium, aluminum or steel.

Surface Preparation The maximum performance of TECTYL 890 can only be achieved when the metal

surfaces to be protected are clean and dry. Remove dirt, rust, scaling paint and other contaminants before applying TECTYL 890.

Application Ensure uniform consistency prior to use. Continuous stirring or thinning is generally not

required. If product thickens due to cold storage or loss of solvent during use, add only aliphatic mineral spirits and only if necessary to restore consistency. Apply at 5-30 deg C (40-95 deg F) by spray, dip or brush.

Coverage The theoretical coverage is 450 square feet per U.S. gallon (11 sq meters/liter) at the

recommended dry film thickness of 2.6 mils (65 microns). Material losses during application will vary and must be considered when estimating job requirements.

Removal TECTYL 890 can be removed if necessary with mineral spirits, or any similar petroleum

solvent. TECTYL 890 can be removed from fabrics by normal dry cleaning procedures. Avoid using chlorinated or highly aromatic solvents when removing from painted surfaces as these solvents may adversely affect paint.

Lab Data English Metric Flash, PMCC, Min. 100 deg F 37.8 deg C Specific Gravity @ 60 F(15.6 C),Typical 0.92 0.92 Recommended Dry Film Thickness 2.6 mils 65 microns Theoretical Coverage. Typical 450 sq ft/U.S. Gallon 11 sq.meters/Liter Approximate Air Dry Time 77 deg F(25 deg C) 1.5 hour 1.5 hour High Temperature Flow Point, minimum 175 deg F 79 deg C Low Temperature Adhesion,Scratch Test, Pass Pass No Flanking at 0 deg F Accelerated Corrosion Tests: 20% Salt Spray (Hours), Typical (A) Fed.STD 791, Method 4001 @ 2.6 mils, Typical 600 hours - (B) Weather-o-Meter @ 2.6 mils, typical 1,200 hours - * ASTM (American Society for Testing and Materials) Applicable U.S. Military Specification; MIL-C-16173D, Grade 1, MIL-P-116 Preservative, Type P-1. CAUTION TECTYL 890 cures by solvent evaporation. If applied to the interior of an enclosed vessel adequate ventilation is required for cure and to ensure against formation of an explosive atmosphere. For further information, consult Technical Bulletin 173.

DENSO PASTE PROPERTIES

Composition : Saturated petroleum hydrocarbon (petrolatum), napthenic oil, inert fillers (slate or

china clay), passivating agents (tannin, amines). Characteristics : Non-drying. Non-hardening. Impervious to water. Highly resistant to mineral

acids, alkalis and salts. Temperature Limit : 131 deg F (55 deg C) max. Density : 26 cu. in/lb (925 cm3/kg). Flash Point : 450 deg F (232 deg C) min. per ASTM D-92. Fire Point : 550 deg F (288 deg C) min. per ASTM D-92. Flammability (Denso Tape) : Flame Spread Index 22 per ASTM E-162. Film Thickness : 0.1 in (2.5 mm) min. recommended when not overlaid with Densotape. Spraying : Heavy duty airless spray unit (e.g. De Vilbiss Model UB 1 and APA/663.

Compressor capacity 15 CFM at 50-80 psi (normal spray pressure 40 psi). Packing : 500 mg tubes, 3.2 kg (7 lb) cartons. 25.4 kg (56 lb) drums.

USE OF DENSO PASTE FOR CORROSION PROTECTION OF NUTS AND BOLTS Denso Paste is a petrolatum base gel containing siliceous fillers and organic rust preventatives. It is closely related to familiar Denso Tape for which it is used as a primer. These products have been successfully used for atmospheric corrosion protection for many decades. Although both of these products are judged capable of providing long-term corrosion protection of exposed hardware, Denso Paste is better suited for the intended application. Denso Paste has a butter-like consistency like light grease and can be applied by various techniques, including airless pray. Importantly, it can be put on with a minimum of surface preparation. All that is necessary is that loose rust be removed which can be achieved by simple wire brushing. When used as a protective coating (rather than as primer), the minimum recommended film thickness is about 0.10 inch (2.5 mm). Denso Paste is impervious to water and quite resistant to acids, alkalis and salts. It remains soft and flexible even after extended weathering. Though quite easily damaged due to its softness, it is sufficiently tough to survive atmospheric storm conditions. The upper temperature limit is 55o C but more heat resistant formulations could be developed for hot climates. One great advantage of petroleum base putty over bitumens, pitches, asphalt, etc is easy of removal. Denso Paste can be removed by scraping and solvent wiping. The easiest method for extensive applications is by steam blasting. However, there would be no need to remove Denso Paste before recommissioning, not even on hot flanges because, if used as recommended, the small quantities involved are not considered a personnel or fire hazard.