The contents of this section applies to the main items of rotating machinery, where associated motors, instruments and electrical items are concerned reference should be made to the relative sections.
Where vendors provide recommendations for site storage and protection these are to be followed and take precedence over the recommendations contained in this section.
Where prolonged site storage is involved, which is not under the control of vendors concerned, equipment guarantees are invalidated. However most vendors offer a site re-furbishing service after which equipment guarantees are re-instated. Clients are recommended to employ this type of service wherever necessary.
A warm, clean, dry and vibration free environment in a secure under cover storage area is required. Recommended environment conditions are temperature range of 15°C to 30°C and a humidity of between 30 to 40%.
Machinery to be stored in level and up-right position.
Machinery transportation supports and temporary stiffeners to be checked for soundness and repaired where necessary.
Ensure all name plates and Tag labels are intact and secure.
Centrifugal Compressors/Blowers
Large centrifugal compressors require extensive and detailed preservation. Machinery of this type is complex and a detailed program of protective measures must be undertaken. The environmental effect on a compressor that is to remain in an operating position must be considered. (Protection by a roof, installed in open air). Refer to vendor's instructions.
Due to the heavy weight of compressors, storage in areas remote from field positions should be avoided. A compressor which is not resting on a foundation must be supported the full length of its frame to prevent any possible sag or distortion. Support can be provided by a frame of welded structural steel members. Units shall be protected with tarpaulin covers.
Generally, vendor's packaging allows for 6 months storage. If prolonged storage is necessary intermediate inspections are to be considered. Every six months, suction and discharge shipping covers and bearing caps are removed and a thorough investigation of the internals is to be made. If any signs of corrosion are found, corrective measures are to be taken and inspections varied accordingly (take care of sealing compressor after inspection).
Half yearly internal inspections are to be performed on all items shipped loose in accordance with above, except for items sealed in plastic bags, if no visual corrosion is apparent.
The level of preservation will be designed for unheated or outdoor storage. It is required to place a waterproof cover over all equipment and crates continuously. The following is required:
The first inspection shall be done immediately after transportation to the storage area. This shall include, but is not limited to, inspection for visible external damage to equipment or crates, indication of moistures and or oxidation and degradation of applied preservative compounds. The presence of any such signs shall require a thorough inspection of all equipment. Each month thereafter, all humidity indicators shall be inspected.
The interval for subsequent inspections shall be every six months.
The compressor shall be disassembled and all internals shall be brushed with Shell Ensis Oil 158 with VSI 8325. Dip all journal and thrust bearing assemblies or parts in Shell Ensis Oil, turn to remove air pockets, drain and reinstall in unit. Use multiple strips of denso tape placed over top of journals to take up all bearing clearance when cover is bolted down. Place a tag on the outside of the unit stating:
The coupling end of the shaft shall be treated with Shell Ensis 158 and taped with denso. All bearing vents shall be taped with Denso tape and closed.
The intent is to completely seal the unit and prevent pockets of water such as at bolt holes. All openings shall be covered with plastic caps or metal covers. Use 3 mm thick metal covers for all flanged openings. Use plastic caps on small size pipe, NPT holes, dowel and other holes. Rubber shall be used between metal cover and flanges. The edges of all flange covers shall be taped with denso to the flange. As a minimum, bolts will be used in half the number of holes on all flanges. (Minimum to be four bolts per flange).
Suction and discharge nozzle openings shall be blanked as described above. Attach a dehumidifier and operate until drain stops dripping. Each section shall be dehumidified on re-entry type units. Desiccant bags will be provided on the inside of the covers and shall be immediately placed in the unit and unit sealed. The amount of desiccant required is 1.2 units per cubic foot of internal volume to be protected.
Special duty compressors, e.g. for oxygen or chlorine service, shall be preserved by inert gas filling in combination with desiccants. The application of inert gas blanket can also be considered to other centrifugal machines. Allow for a small flow due to seal leakage.
For air blowers, cap the intake stack to avoid rain and humidity ingress.
The shaft shall be rotated regularly leaving the shaft in another position, (if applicable). Follow vendor's recommendation of available.
Shell Ensis Oil H shall be used as lube oil during the testing if the console. Add 2% VSI 8235.
Drain oil from unit after satisfactory completion and approval of all testing requirements.
Inspect and clean suction screens.
Coat all exposed unpainted surfaces and flexible couplings and valve steams, etc. except stainless steel parts with Shell Ensis 158.
Spray carbon steel internals which are parts of the pump driver assembly with Shell Ensis Oil H (with 2% VSI 8235).
Remove and discard filter cartridges and wash inside of filter housing with solvent, then apply Shell Ensis Oil H (with 2% VSI 8235).
Install new filter cartridges in all filter housings.
Paint unit in accordance with applicable specification.
Operate the lube oil system weekly for 30 minutes.
The water cooling system shall be drained. Dry and spray with VPI 280 solution. Close all connections carefully.
For electric motors see 9.10.
Sound enclosure to be inspected periodically or stored in the warehouse.
For other elements refer to relevant paragraphs.
The following procedure is intended for safeguarding centrifugal pumps, rotary displacement pumps, reciprocating pumps, rotary vacuum pumps and axial pumps. It shall be checked against vendor's recommendations.
Verify that the bright external parts are all coated with Shell Ensis MD (twice) followed by Shell Ensis HB.
For pumps working in hydrocarbon service internal parts shall be flushed with Shell Ensis Oil H with addition of 2% VSI 8235. Repeat every six months. Rotate shaft during flushing. For vertical pumps spray internals with Shell Ensis Oil H. For pumps in water service spray internals with VPI 280 solution, repeat every six months. Close pump completely to allow vapor accumulation.
Bearing house: Follow vendor's recommendation. Fill as high as possible with Shell Ensis Oil H with addition of 2% VSI 8235. Rotate the shaft periodically. Plug vents.
Separately lubricated gears for high speed vertical pumps shall be drained and filled with Shell Ensis Oil H added with 2% VSI 8235. The oil shall be applied by circulation flushing, spraying or brushing. Whatever the treatment, all openings shall be closed thoroughly afterward.
If the pump is to be stored outdoors or installed at service location, protect with plastic sheets to minimize ingress of dirt, dust, etc.
Break all pipe connections and suction and discharge flanges and close all openings. When the pump is to be maintained in a field position, ensure that the suction and discharge valves are closed and blanked off after protective fluids have been applied.
When single mechanical seals are used, the complete mechanical seal remains within the stuffing box chamber. Pour Shell Ensis Oil H with 2% VSI 8235 through the circulation and quench connections and turn pump shaft manually several times while filling with preservative. Check O-ring compatibility with oil. Verify whether all connections are plugged.
Where double mechanical seals are used, plug the lower stuffing box drain and fill with Shell Ensis Oil H with 2% VSI 8235. Slowly rotate the shaft to ensure complete coverage of internal surfaces. Mask clearance between seal gland and shaft to prevent direct from entering the seal cavity. Verify in the manufacturer's instructions whether the rings of the seals are oil resistant.
If the pump will be shipped with the seal not installed, the seal will be stored in the warehouse and installed shortly before precommissioning. The seal cavity shall be filled with Shell Ensis with 2 % USI 8235).
Where conventional packing is used, loosen the packing gland and remove all packing. Coat the interior of the stuffing box with light grease. Repack the pump with a nonmetallic packing and retighten the packing glands slightly. Tag the pump to indicate that the service packing has been removed. Care shall be taken to repack the pump with the service packing at precommissioning.
Wrap the exposed pump shaft with Denso tape. At the points where the shaft enters the pump casing and the bearing housing, carefully wrap to seal off the openings. Allow for regular shaft rotation by hand, leaving shaft in fresh position on each occasion.
Cover all outer exposed surfaces with either paint or a suitable rust preventative (Shell Ensis MD or Autoseal 1894).
For electric/motor drive refer to 9.10.
The sound enclosure shall be inspected periodically for mechanical damage, or stored in the warehouse.
Coupling: Treat gear ring teeth as described under "bright parts" and wrap in denso tape after treatment. Treat coupling hub and spacer as described under "bright parts" and have them wrapped in plastic sheeting and tagged and stored in warehouse. Verify oil filling of installed coupling every six months and have VSI 8235 added.
Reciprocating Pumps: In addition to the above, the following instructions shall be observed to protect reciprocating pumps:
Reciprocating injection or metering pumps should preferably be stored in warehouse.
Remove the valve cover plate from the liquid end of the pump.
Remove a valve from each end of each cylinder on the liquid end.
Fill all cylinders with Shell Ensis Oil.
Apply Shell Ensis Oil to all valves and valve covers.
Fill all lubricators with oil.
Have the crank-case unit filled with Shell Ensis oil H with addition of 2% VSI 8235.
Rotate the pump for a few minutes every 2 months
Refer to vendor's recommendations.
Oil-lubricated bearings shall be drained and filled with Shell Ensis Oil 158 and run for a short while to ensure complete coverage, after which all openings are closed. Grease-lubricated bearings shall be cleaned and re-greased with the appropriate grease, turned and closed thoroughly.
Separately lubricated gears shall be drained while hot and then filled with Shell Ensis Oil 158 which is circulated for a while. Where circulation is impracticable, the oil shall be applied by flushing, spraying or brushing. If complete oil coverage cannot be realized, small bags with Shell VPI 280 shall be used. Whatever the treatment, all openings shall be closed thoroughly afterwards.
Refer to vendor's recommendations.
Large reciprocating compressors require extensive and detailed preservation. A thorough inspection and a detailed program of protective measures must be foreseen. A compressor that is to remain in an operating position in open air will require special attention for external corrosion. Before assembly all parts will be thoroughly checked for any sign of corrosion.
Due to the heavy weight, compressors will be installed quickly on their foundations. A compressor which is not resting on a foundation must be supported to prevent any possible sag or distortion. Support can be provided by a frame of welded structural steel members. Generally manufacturers packaging allows for six months storage. If prolonged storage is required intermediate inspections are to be considered.
For the preservation, the following general rules are recommended:
Fill all lubricators completely full of oil, Shell Ensis Oil H with 2% VSI 8235, to prevent rusting of the pumping parts, rotate lubricators to fullness with oil. Also fill the crank case.
Remove stuffing box, and wiper rings of the compressor. Clean in a suitable solution. Apply a coating of a satisfactory rust preventive and wrap in a waterproof paper or place in a plastic container. A rust preventive may be grease or oil with a high viscosity. Identify the stuffing box to ensure reassembly in their original position.
Have the main shaft rotated according to manufacturers recommendations.
Remove the inlet and discharge valves from the compressor cylinders, clean, and apply a coating of Shell Ensis Oil H with 2% VSI 8235. Completely coat the valve bores and piston rods with a spray or other suitable means while the valves are removed. If piston rods are not stainless steel, consideration shall be given to removing the piston and rod. These shall then be coated, wrapped and boxed. The rod must be properly supported to prevent bowing.
Replace all valves in their original position and tighten in place.
Seal muffler vents or cover them with plastic.
Reciprocating compressors are provided with some Shell Ensis Oil H with 2% VSI 8235 and are run on "no load" or turned by hand until the oil is fully distributed. This is repeated according manufacturers recommendations. Separate lubrication systems should be drained and filled with Shell Ensis Oil H with 2% VSI 8235 prior to the above-mentioned treatment.
In case of doubt as to whether all internal parts are reached by the oil, small bags with Shell VPI 280 should be placed in the vicinity of the parts concerned or 2% VSI 8235 added to the oil and the parts closed. Mark the number of bags on red tags on the outside of the equipment.
Clean and apply protective coating to all small auxiliary equipment, relief valves, piping filters, and the like.
A periodic inspection should be made if compressors remain idle for a considerable time. Small surfaces on cylinder bores, crankshafts, bearing journals, piston rods, crossheads, and the like should be wiped free of protective coatings to determine their condition. When protection appears to be satisfactory, the same care as originally used in the application of the protective coating must be used in covering the exposed surfaces.
If there is any sign of rust or corrosion on any of the aforementioned parts, they should be wiped clean and dry and the protective coating reapplied.
Refer to vendor's recommendations.
Large turbines require a detailed program of protective measures. The environmental effect on a turbine that is to remain in an operating position must be considered. (Protection by a roof/open air).
Due to the heavy weight of turbines, storage in areas remote from field positions should be avoided. A turbine which is not resting on a foundation must be supported the full length of its frame to prevent any possible sag or distortion. Support can be provided by a frame of welded structural steel members. Units shall be protected with tarpaulin covers.
Generally manufacturer's packaging allows for six months storage if prolonged storage is required.
Half yearly internal inspections are to be performed of all shipped items.
The level of preservation will be designed for storage unheated or outdoor. It is required to place a waterproof cover over all equipment and crates continuously. The following is required.
The first inspection shall be done immediately after transportation to the storage place. This shall include inspection for visible external damage to equipment or crates, indication of moistures and or oxidation and degradation of applied preservative compounds. The presence of any such signs shall require a thorough inspection of all equipment. Each month thereafter, all humidity indicators shall be inspected.
The interval for subsequent inspections shall be every six months.
All bright surfaces of any component parts of the governing system, such as reset linkages, valve levers, piston rods, etc., shall be preserved with Shell Ensis Oil 158.
Both the rotor and guide-blade carrier shall be internally preserved with nitrogen with the turbine casing and the bearing housings closed. A spray of VPI 280 can be given. Alternatively a nitrogen blanket can be applied if practical.
Lube and control oil piping, mounted prior to the test stand trial run and used during the latter, shall not be preserved. Oil piping mounted to the unit after the trial run shall be preserved.
Prefabricated oil pipes that are field mounted shall be pickled and preserved and sealed with plastic covers on both sides. Piping shipped to site in the usual way shall not be preserved.
The oil reservoirs and baseplates containing an oil reservoir shall be internally (oil chamber) protected with Shell Ensis 30 (with addition of 2% VSI 8235). The lube oil system shall be operated weekly for 30 minutes.
For outdoor storage of the unit prior to putting into operation, the above preservation procedure remains valid and the unit shall moreover be protected with tarpaulin covers.
All referred preservation, internal and external must be removed before operating the unit. Follow instructions for products used.
Separately shipped gauges shall be capped, cleaned and carefully wrapped and packed in cellulose cushioning material (CCM).
Vibration pick-up and other vendor devices shall be cleaned, carefully wrapped and packed in cellulose cushioning material (CCM).
The same recommendation applies for electrical devices.
Labyrinths - coat with Shell Ensis Oil H with 2% VSI 8233.
Tools: Coat unpainted surfaces with Shell Ensis H with 2% VSI 8235.
For all other miscellaneous items, coat unpainted surfaces with Shell Ensis 30.
All loose remaining coupling parts to be coated with Shell Ensis Oil followed by Shell Ensis HB wrapped in denso tape and packaged separately.
Coat unprotected interior surfaces by spraying or brushing structural members with a gas oil with 2 % VSI 8235.
For floating roof tanks, all unpainted surfaces exposed to open air shall be protected with Shell Ensis 30 or 158 or Shell Autoseal 1835:
Avoid damaging of floating roof seals by covering with tarpaulins or equal.
Close all manholes with gasketed covers, but do not obstruct breathing.
Leave floating roof drains open. Verify periodically for pluggings and support roof in high position. Inspect periodically for water ingress.
Maintain the tank exterior according to the plant maintenance painting program or maintain the weather seals on insulated tanks. Pay special attention to seal between tank bottom and foundation to avoid water ingress under tank bottom.
Refer to vendor's recommendations. These shall be handled under the main "SYSTEM" in which they are integrated.
Dry the equipment and keep it dry.
Make sure no rain or atmospheric humidity can enter the equipment.
Ensure that the intake stack is capped and closed.
V-belts shall be stored in the warehouse and installed at precommissioning in conjunction with the vendor representative.
Oil-lubricated bearings shall be drained and filled with Shell Ensis Oil 158 and shall be run for a short while to ensure complete coverage, after which all openings are closed. Grease-lubricated bearings shall be cleaned and re-greased with the appropriate grease, turned and closed thoroughly. The internal parts shall be sprayed with Shell Ensis Oil 158.
Sound enclosures shall be inspected for mechanical damage.
Separately lubricated gears shall be drained while hot and then filled with Shell Ensis Oil 158 which is circulated for a while. Where circulation is impracticable, the oil shall be applied by flushing, spraying or brushing. If complete oil coverage cannot be realized, small bags with Shell VPI 280 shall be used. Irrespective of any treatment, all openings shall be closed thoroughly afterwards.
