Vappro Vbci: Mothballing Reference Book for Onshore and Offshore Equipment

By Nelson Cheng PhD HRF

This Vappro VBCI mothballing reference guidebook provides guidelines for protecting infrastructure, equipment, and expensive capital assets during lull period for both onshore and offshore industries.
Protecting the said complex and expensive infrastructure and equipment from destructive corrosion during system lay-up and mothballing is a critical concern for future reactivation.
Preserved infrastructure is also more valuable in the event of sale of the asset as it prevents the drastic depreciation value of the capital assets due corrosion.
This Vappro VBCI mothballing reference book main principal of concerns is mechanical, electrical, water handling systems and the combination of materials associated with these systems all of which require a concise approach to corrosion control.
Corrosion of these components occurs for several reasons within an idle plant or equipment. In an idle condition, plants and associated equipment are subject to temperature fluctuations, water condensation and other conditions that cause corrosion to occur. Under certain combinations of conditions, corrosion can be very rapid. Without adequate control, corrosion can cause several problems during activation of the preserved equipment.

• Language: English
• Publisher: Partridge Publishing Singapore
• Release date: Mar 9, 2021
• ISBN: 9781543763690

Book preview

Copyright © 2021 Nelson Cheng PhD (H.C.) HRF; Dr Benjamin Valdez Salas. All rights reserved.

All rights reserved. No part of this book may be used or reproduced by any means, graphic, electronic,

or mechanical, including photocopying, recording, taping or by any information storage retrieval system

without the written permission of the publisher except in the case of brief quotations embodied in critical

articles and reviews.

www.partridgepublishing.com/singapore

Because of the dynamic nature of the Internet, any web addresses or links contained in this book may

have changed since publication and may no longer be valid. The views expressed in this work are solely

those of the author and do not necessarily reflect the views of the publisher, and the publisher hereby

disclaims any responsibility for them.

ISBN

ISBN: 978-1-5437-6368-3 (sc)

ISBN: 978-1-5437-6370-6 (hc)

ISBN: 978-1-5437-6369-0 (e)

03/08/2021

37827.png

Preface

Corrosion is a pernicious phenomenon that appears in engineering materials, infrastructure assets, and industrial equipment exposed to the atmosphere, water, and soil. The aim of this book is to produce a body of knowledge on the theory and practice of vapour corrosion inhibition so it can be used in the selection of corrosion inhibitors to prevent and/or minimize corrosion in natural environments and industrial facilities.

Corrosion inhibitors are employed in different forms such as emitters, pellets, powders, films, paints, aerosols, and aqueous and solvent solutions, depending on their chemical composition: organic or inorganic.

They are also applied impregnated on papers or plastics; closed in pouches and sachets, or added to coatings and paints to form a barrier against the attack of corrosion agents. They are employed in many vital industries: automotive, offshore/onshore, water, military, marine, manufacture, oil and gas, electronics, and concrete structures. Vappro VBCI corrosion inhibitors are a special group of corrosion inhibitors which are related to the advanced field of ‘green chemistry’. The use of Vappro Volatile biocorrosion inhibitors (VBCIs) as expanded rapidly in the last decades, and they are frequently mentioned in the relevant literature and in professional congresses and conferences organized by international and national corrosion associations.

The mothballing reference guidebook was designed for ease of reference for corrosion engineers, rigs superintendents, and plant managers for both onshore and offshore industries when mothballing equipment or capital assets during lull period.

Special thanks to Dr Benjamin Valdez Salas, Dr Michael Schorr Weiner, Dr Nicola Nadev, Dr Ernesto Beltran Partida, Dr Juan Ricardo Salinas Martinez, and Mr Patrick Moe for their contributions towards the completion of this book.

Profile of Co-Authors

Dr Benjamin Valdez Salas

Dr Benjamin Valdez Salas was the director of the Institute of Engineering (2005–2013), Universidad Autonoma de Baja California, Mexico. He has a BSc in chemical engineering, an MSc and PhD in chemistry, and is a member of the Mexican Academy of Science and the National System of Researchers in Mexico. He was the guest editor of Corrosion Reviews, in which he produced two special issues on corrosion control in geothermal plants and the electronics industry. He is a full professor at the University of Baja California. His activities include corrosion research, consultancy, and control in industrial plants and environments. He has published more than 350 publications with almost 2,000 citations. He received a NACE Distinguished Service Award. He has been a member of NACE for 30 years. He is the current technical adviser of the Magna Think Tank Group.

Dr Roumen Zlatev

Full-time researcher in the Engineering Institute of the Autonomous University of Baja California, UABC, Mexicali, Mexico. Master’s degree in electrochemistry from the Institute of Chemical Technology, Sofia, Bulgaria, and PhD degree from the National Polytechnic Institute of Grenoble, (INPG), Laboratory of Electrochemistry and Physical Chemistry of Materials and Interfaces (LEPMI), Grenoble, France.

He received the NACE International Award for outstanding contributions in the field of electrochemistry, corrosion, and materials science and for the education of future professionals. Member of the Mexican Academy of Science and level II in the National Researcher Systems in Mexico. He has published more than 100 papers in recognized journal and hold several patents in the electrochemistry and corrosion fields.

Dr Nicola Nadev

Dr Nicola Nadev received the PhD degree in physics from the Institute of Solid State Physics, Bulgarian Academy of Sciences, in 1990. He is a professor of semiconductor physics and head of the laboratory semiconductors, microelectronics, and nanotechnology with the Institute of Engineering, Universidad Autonoma de Baja California, Mexico. His research interests include nanostructured materials, semiconductors, and semiconductor device technologies.

Dr Ernesto Beltrán-Partida

Dr Beltrán-Partida obtained his bachelor’s degree in biological and pharmaceutical chemistry and his PhD in biomaterials sciences both with honours from the Universidad Autonoma de Baja California, Mexico. He is member of the Science and the National System of Researchers in Mexico and professor of biomaterials science, tissue engineering, microbiology, and molecular biology at the Institute of Engineering of Autonomous University of Baja California Mexico. He has authored different peer-reviewed articles and a book chapter. He is a member of the Magna Think Tank Group.

Dr Rogelio Arturo Ramos Irigoyen

Mechanical electrical engineer with a specialty in electronics from the engineering faculty of the Autonomous University of Baja California where he obtained the degree with honourable mention. He is a doctor of engineering with honourable mention, member of the National System of Researchers SNI I, and member of the evaluation committees of research and technological development projects for CONACYT.

He has 25 years of experience as an academician. Postgraduate coordinator and researcher at the UABC Institute of Engineering and General Coordinator of the master’s and doctorate program in Sciences and Engineering of the UABC from 2013 to 2016 and academic coordinator for the PNPC of CONACYT Mexico. His current research line is the field of corrosion and advanced materials, virtual instrumentation in the fields of computational vision, instrumentation, and control. Some of its most recent innovative technological developments are virtual instrumentation for computational vision applied in localized corrosion, unique in its type; and colorimetry applications in corrosion studies. Participant in national and international congresses, indexed journals with articles in electrochemistry; vision, speech recognition and instrumentation; and electronic control and book chapters.

Dr Mario Alberto Curiel Alvarez

M. A. Curiel was born in Mexicali, Baja California, Mexico in 1983. He is an electrical engineer in the area of control and instrumentation from the faculty of engineering of the Autonomous University of Baja California in 2005. He obtained his PhD in materials science and engineering from the Institute of Engineering of the same university in 2010. Dr M. A. Curiel did a postdoctoral project in the area of thin films of advanced materials in the Center of Nanosciences and Nanotechnology of the National University of Mexico. Now he is a full professor of the Corrosion and Advanced Material Group and director of the Institute of Engineering at the Autonomous University of Baja California working in research projects related to semiconductors, microelectronics, and nanomaterials, focused in advanced microscopy techniques for materials characterization. Dr Curiel is author and co-author of 42 articles, 3 book chapters, and 1 international invention.

Patrick Moe

Patrick Moe is the senior technical manager of Magna International Pte Ltd. He has a BSc in industrial chemistry, GradDip and MSc in environmental engineering. His key responsibilities at Magna International are as follows: assisting the CEO in research and development of new products, finding out customers’ needs and developing customized new products, helping in synthesizing new compounds by making appropriate modifications of known methods, recommending and implementing methods to increase the quality of products and service, and managing hazardous raw materials.

Dr Nelson Cheng, PhD (honoris causa)

Nelson Cheng, PhD (HC) HRF graduated as a marine engineer under the United Nations Development Program Scholarship and received his doctor honoris causa from the Universidad Autonoma de Baja California, Mexico. He is also the senior honorary research fellow with the Institute of Engineering of Autonomous University of Baja California. He is recognized as Singapore’s leading inventor and the Singaporean with the highest number of patents from the Intellectual Property Office of Singapore. He owns several worldwide patents, including VBCI Mineral Stone Paper.

He has invented more than 500 chemicals, lubricants, and anti-corrosion products with more than 230 products assigned with NATO stock numbers and marketed in more than 30 countries. He is the inventor of several technologies for corrosion protection, including Vappro VBCI (vapour corrosion inhibitors) and Vappro CRI (concrete rebar inhibitor), molecular reaction surface technology (MRST), colloidal corrosion inhibitors (CCI), and heat-activated technology (HAT).

He has written more than 130 research papers and technical journals published in National Association of Corrosion Engineers (NACE), International Journal of Emerging Technology and Advanced Engineering (IJETAE), International Journal of Current Trends in Engineering & Technology (IJCTET), Cambridge University Press, Acedemia.edu, ResearchGate, and IntechOpen. He has and co-authored and co-edited two books: Disinfectants and Its Efficacy in Combating Infectious Diseases and VBCI Corrosion Inhibitors.

Nelson has received and accorded several accolades, including the 2020 World Star President Gold Awards; 2020 Asia Star Asia Packaging Federation 2020 Awards and Singapore Star Packaging Awards for green and sustainable packaging products; 2015 Winner of the Asia Packaging Award; Top 10 Most Inspiring Entrepreneur 2015; Winner of the Global Star, Asia Star and Singapore Star Packaging Awards 2014, 2015, 2016, 2017, and 2018; Top Entrepreneur Award—Singapore Small Medium Business Association; Asia Excellence Award 2014; and Top 20 Innovation Award 2013 from Small Medium Business Association.

He is a member of the Society of Tribologists and Lubrication Engineers (STLE), American Chemical Society (ACS), World Corrosion Organization (WCO), and European Federation of Corrosion (EFC).

Meet the Editors

Picture-2-Dr%20Benjamin.jpg

Dr Benjamin Valdez Salas was the director of the Institute of Engineering (2006–2013), Universidad Autonoma de Baja California, Mexico.

He has a BSc in chemical engineering, an MSc and PhD in chemistry, and is a member of the Mexican Academy of Science and the National System of Researchers in Mexico. He was the guest editor of Corrosion Reviews, in which he produced two special issues on corrosion control in geothermal plants and the electronics industry. He is a full professor at the University of Baja California. His activities include corrosion research, consultancy, and control in industrial plants and environments. He has published more than 350 publications with almost 1,000 citations. He received a NACE Distinguished Service Award. He has been a member of NACE for 26 years. He is the current technical director of Magna Group of Companies and head of the Magna Think Tank Group.

Picture-3-Dr%20Nelson.jpg

Nelson Cheng, PhD (HC) HRF, graduated as a marine engineer under the United Nations Development Program Scholarship and received his doctor honoris causa from the University of Baja California (UABC). He is also the senior honorary research fellow with the Institute of Engineering of Autonomous University of Baja California. He is recognized as Singapore’s leading inventor and the Singaporean with the highest number of patents from the Intellectual Property Office of Singapore. He owns several worldwide patents, including VBCI Mineral Stone Paper.

He has written more than 130 research papers and technical Journals published in National Association of Corrosion Engineers (NACE), International Journal of Emerging Technology and Advanced Engineering (IJETAE), International Journal of Current Trends in Engineering & Technology (IJCTET), Cambridge University Press, Acedemia.edu, ResearchGate, and IntechOpen. He has co-authored and co-edited two books: Disinfectants and Its Efficacy in Combating Infectious Diseases and Vappro VBCI Corrosion Inhibitors.

Nelson has received and accorded several accolades, including the 2020 World Star President Gold Awards; 2020 Asia Star Asia Packaging Federation 2020 Awards and Singapore Star Packaging Awards for green and sustainable packaging products; 2015 Winner of the Asia Packaging Award; Top 10 Most Inspiring Entrepreneur 2015; Winner of the Global Star; Asia Star and Singapore Star Packaging Awards 2014, 2015, 2016, 2017, and 2018; Top Entrepreneur Award—Singapore Small Medium Business Association; Asia Excellence Award 2014; and Top 20 Innovation Award 2013 from Small Medium Business Association.

Contents

Chapter 1

1.0 INTRODUCTION

1.1 CORROSION PREVENTIVE CLASSES

1.2 SAFETY

1.3 DESCRIPTIONS OF CORROSION PREVENTIVE CLASSES

1.3.1 CLASS A—Vappro 818 VBCI Solvent Fluid or Vappro 872 VBCI Penetrating Fluid

1.3.2 CLASS B—Vappro 869 VBCI GREASE

1.3.3 CLASS C—Vappro 868 VBCI Wax

1.3.4 CLASS D—Vappro 886 VBCI Water-Based Hard Coating

1.3.5 CLASS E—Vappro 852 VBCI Additives for Hydraulic Fluid and Vappro 850 Oil Additives

1.3.6 CLASS F—Vappro 848/849 VBCI POWDER

1.3.7 CLASS G—VAPPRO VBCI 826, 826S, 826SK, 826MW, 825 VBCI PE PLASTIC WRAPS

1.3.8 CLASS H—Vappro 01, VAPPRO 05, and VAPPRO 10 FOAM EMITTER

1.3.9 CLASS I—DESICCANTS AND VBCI (Vappro VBCI Pak and Vappro VBCI Pouches)

Chapter 2

2.0 BUDGETARY DELIBERATION FOR MOTHBALLING

2.1 SURVEY OF EQUIPMENT CONDITION BEFORE MOTHBALLING

2.1.1 Internal Inspection

2.1.2 Exterior Inspection

2.1.3 Mechanical Equipment

2.1.4 Electrical Equipment

2.1.5 Structural

2.1.6 Piping

2.2 IDLE PERIOD

2.3 DEPLOYMENT OF STAFF/SIT REQUIREMENT

2.3.1 Staff Considerations

2.3.2 Site Requirements

2.4 MAJOR COST ITEMS—MOTHBALL PROGRAM

2.5 WHAT EQUIPMENT SHOULD BE PROTECTED?

2.5.1 Field-Erected Equipment

2.5.2 Heat Exchangers

2.5.3 Piping

2.5.4 Fired Heaters

2.5.5 Boilers and Associated Equipment

2.5.6 Mechanical Equipment

2.5.7 Reactors, Mixers, and Autoclaves

2.6 PRESERVATION OF PROCESSING EQUIPMENT

2.6.1 Scope

2.7 PROCESS VESSELS AND TANKS

2.7.1 Stainless Steel and Non-Ferrous Metals

2.7.2 Carbon Steel

2.8 DRIVES

2.8.1 Gear Cases

2.8.2 V-belt drives

2.8.3 Bearings and Bushings

2.8.4 Couplings

2.9 AGITATORS, CENTRIFUGES, AND MIXERS

2.9.1 Carbon Steel

2.9.2 Gear Cases

2.9.3 V-Belt Drives

2.9.4 Bearings and Bushings

2.9.5 Couplings

2.9.6 Mechanical Seals and Packing

2.10 HYDRAULIC SYSTEM, LUBRICATING OIL SYSTEMS, AND OIL RESERVOIRS

2.11 SCREWS, BOLTS, THREADS, AND MECHANISMS

2.12 STACKS

2.13 INSTRUMENTS

2.14 Electrical Equipment

2.14.1 Flare Systems

2.15 EQUIPMENT NOT PROTECTED

Chapter 3

3.0 PROTECTION SYSTEMS AND PLANT EXPERIENCE

3.1 FILM TYPE

3.1.1 Thin Film

3.1.2 Thick Film

3.1.3 Hard Film

3.1.4 Wrapping Materials

3.1.5 Cocooning

3.2 GREASES AND OIL

3.2.1 Oils

3.2.2 Greases

3.3 VOLATILE BIOCORROSION INHIBITORS (VBCIs)

3.4 ALTERNATION OF THE ENVIRONMENT

3.4.1 Dehumidification

3.4.2 Air Conditioning

3.4.3 Heat

3.4.4 Desiccants

3.4.5 Other Drying Media

3.4.6 Neutralization

3.4.7 Antifreeze

3.5 INERT ATMOSPHERES

3.6 MULTICOMPONENT SYSTEM

3.7 PLANT EXPERIENCE

3.7.1 Plastic Wrap

3.7.2 Flanges

3.7.3 Safety Valves

3.7.4 Electrical Equipment

3.7.5 Storage Yards

3.7.6 Insulation

3.7.7 Equipment Removal

3.8 SUMMARY OF PLANT EXPERIENCE

3.9 LAY-UP OF POWER EQUIPMENT

3.9.1 Scope

3.10 GENERAL

3.11 BOILERS

3.11.1 BOILERS, WATER SIDE—WET METHOD

3.11.2 BOILERS, WATER SIDE—DRY METHOD

3.11.3 BOILERS, FIRESIDE—COLD METHOD

3.11.4 BOILERS, FIRESIDE—HOT METHOD

3.12 VAPOURIZERS

3.12.1 VAPOURIZERS, DOWTHERM SIDE—DRY METHOD

3.13 TURBINES

3.13.1 Short-term lay-up

3.13.2 Charged Systems

3.13.3 Uncharged Systems

3.14 GENERATORS

3.15 FANS

3.16 PUMPS

3.16.1 Stainless Steel and Non-Ferrous Metals

3.16.2 Carbon Steel

3.17 DEAERATORS

3.18 CONDENSERS, HEAT EXCHANGERS, AND AIR EJECTORS

3.19 PIPING

3.20 REFRIGERATION MACHINES

3.21 Heat Exchangers

3.21.1 Long-Term Lay-Up

Chapter 4

4.0 TESTING OF PROTECTIVE COMPOUNDS

4.1 CORROSION TESTS

4.1.1 Coupon Preparation

4.1.2 Application of the Preservative

4.1.3 Corrosion Test

4.1.4 Adherence and Protection Test

4.1.5 Chemical Analysis

4.1.6 Elastomers and Gaskets

4.1.7 Removal of Preservatives

4.2 PROCEDURES OF PLACING NEW EQUIPMENT UNDER PROTECTIVE STORAGE

4.2.1 Scope

4.3 GENERAL

4.4 PROTECTION OF PIPES AND VALVE FITTINGS

4.4.1 Corrosion Inhibitor Applied by Dipping

4.5 TANKS, PRESSURE VESSELS, AND COLUMNS

4.6 HEAT EXCHANGERS AND SPARE HEAT EXCHANGER TUBE BUNDLES

4.7 ELECTRICAL EQUIPMENT

4.7.1 Electric Motors—Definition of Equipment Status Storage Environment

4.7.2 General and Short-Term Storage

4.7.3 Long-Term Storage

4.7.4 Maintenance during Short- or Long-Term Storage

4.7.5 Preparation for Service

4.7.6 Indoors Storage—Controlled Environment

4.7.7 Indoor Storage Partially Controlled Environment

4.7.8 Outdoor Storage

4.8 INSTRUMENTS

4.8.1 Shipping Containers

4.8.2 Electric and Electronic Instruments

4.8.3 Field-Mounted Instruments Not Equipped with Electrical Connectors

4.8.4 Control Valves, Orifice Flanges, Level Chambers, Venture Tubes, Back-Pressure Regulators, Pressure-Reducing Valves, Etc.

4.8.5 Instrument Panels

4.9 FANS AND BLOWERS

4.10 AIR COMPRESSORS

4.10.1 Turbine Drive

4.10.2 Gasoline or Diesel Engine Drive

4.11 GEARBOXES AND SPEED CHANGERS

4.12 MECHANICAL EQUIPMENT

4.12.1 General

4.12.2 Stainless Steel

4.12.3 Carbon Steel

Chapter 5

5.0 INERT GAS PURING AND MOTHBALLING OF FIELD STORAGE OF EQUIPMENT

5.1 PURGE AND FILL

5.2 CONTINUOUS PURGE

5.3 MONITORING

5.4 PROTECTIVE FIELD STORAGE OF DRILLING EQUIPMENT AND PIPELINES

5.4.1 Scope

5.5 GENERAL

5.5.1 Lubricating Films

5.5.2 Touch-Up

5.5.3 Covering with Tarpaulin

5.5.4 Index of Drilling Equipment Categories

5.5.5 Suggested Order for Tasks

5.6 AC BLOWER UNITS

5.7 AC COMPRESSORS

5.8 ACCUMULATOR UNIT

5.9 AIR COMPRESSORS

5.10 AIRTEMP AC CONDENSING UNIT

5.11 ANCHOR WINCH

5.12 ANNULAR PREVENTER

5.13 AUXILIARY BRAKE AND COOLING SYSTEM

5.14 BOP HANDLING SYSTEM

5.15 BLOWER AND MOTORS FOR ROTARY DRIVE, DRAW WORKS, AND MUD PUMPS

5.16 BULK TANKS

5.17 CHEMICAL EXTINGUISHING UNIT

5.18 CRANES

5.19 CROWN BLOCK

5.20 DEEP-WELL PUMPS

5.21 DEGASSER

5.22 DERRICK SHALE SHAKER

5.23 DESANDER

5.24 DIRTY LUBE PUMP, BILGE PUMP, DRILL-WATER PUMP, AND DIESEL FUEL PUMP

5.25 DRAW-WORKS

5.26 DRILL PIPE AND COLLARS

5.27 DRILL-WATER TANKS

5.28 FUEL OIL TANKS

5.29 HOOK BLOCK

5.30 KELLY SPINNER

5.31 MAIN ENGINES

5.32 MUD AGITATORS

5.33 MUD CLEANER

5.34 MUD CLEANER AND DESANDER

5.35 MUD PUMPS AND MUD TANK SYSTEM

5.36 POTABLE WATER TANKS

5.37 COLD START DIESEL

5.38 QUARTERS

5.39 RAM PREVENTER

5.40 ROTARY TABLE

5.41 ROTARY TRANSMISSION

5.42 SCR (Silicon-Controlled Rectifier)

5.43 SEWAGE TREATMENT PLANT

5.44 SKIDDER UNIT

5.45 SLANT AND ELEVATING SYSTEM

5.46 SPINNING WRENCH

5.47 SPRING SLIPS

5.48 SUPER CHOKE

5.49 ENGINE

5.50 SWIVEL

5.51 TUGGERS

5.52 WASHING MACHINE

5.53 WATER MAKER

5.54 WIRELINE ANCHOR

5.55 PIPELINES

5.55.1 Low-Flow Bypass Piping or dead legs

5.55.2 Road Crossings and Casings

CHAPTER 6

6.0 MECHANISM OF VAPPRO VBCI

6.1 STAGE 1

6.2 STAGE 2

6.3 STAGE 3

6.4 STAGE 4

6.5 HOW VBCI WORKS

CHAPTER 7

7.0 PROTECTION PROGRAM FOR 24 MONTHS

7.1 SHUTDOWN CONSIDERATIONS

7.2 CORROSIVE ENVIRONMENTS

7.2.1 Acid Service

7.2.2 Alkaline Service

7.2.3 Organic Compounds

7.2.4 Pyrophoric Materials

7.2.5 Sulphur-Oxy (Polythionic) Acids

7.3 WATERLINES

7.4 INSULATION

7.5 PIPING, VALVES, AND FITTINGS

7.5.1 Carbon and Low-Alloy Steel Materials

7.5.2 Piping, Valves, and Fitting (Underground)

7.5.3 Austenitic Stainless Steel and Other High Alloys

7.5.4 Lined Low-Alloy Steel Pipe

7.6 FLARE SYSTEM

7.7 HEAT TRACING

7.8 PROCESS VESSELS AND TANKS

7.8.1 Stainless Steel and Non-Ferrous Alloys

7.8.2 Carbon Steel

7.8.3 Reactors

7.8.4 Towers, Spheres, and Bullets

7.9 COOLERS AND EXCHANGERS

7.9.1 Cooling Towers

7.9.2 Spray Coolers

7.9.3 Finned Air Coolers

7.9.4 Plate Exchangers

7.9.5 Shell and Tube Exchangers

7.10 STORAGE TANKS

7.11 ROTATING EQUIPMENT

7.11.1 Centrifugal Pumps

7.11.2 Reciprocating Pumps

7.11.3 Mechanical Seals and