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Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
CONTENTS
1
Scope
Aim/purpose
Responsibilities
Procedure
4.1
4.1.1
4.1.2
4.1.3
4.1.4
Mechanical cleaning
Cleaning with air
Cleaning with steam (for steam networks only)
Cleaning with water
4.2
4.3
Cleaning preparation
4.4
4.5
4.6
4.6.1
4.6.2
4.6.3
4.6.4
4.7
4.7.1
4.7.2
4.7.3
4.7.4
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
4.8
4.8.1
4.8.2
4.8.3
4.8.4
4.9
4.9.1
4.9.2
4.9.3
4.9.4
4.10
4.11
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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1.0
Scope
This Process Engineering guide covers Best Practices in Ammonia Plant Pre-commissioning; Piping and vessels flushing and cleaning procedures,
and shall apply to all GBH Enterprises (GBHE) process engineers
worldwide.
2.0
Aim/purpose
This procedure applies generally to the cleaning and flushing of
underground and above ground pipelines, tanks and vessels which shall
be performed for process reasons during pre-commissioning. Special
instructions for the system will be fixed by a detail procedure.
The purpose of flushing and cleaning lines and vessels is to remove loose
foreign matter, production residues and surface protection substances
from the inside of line and vessels (welding rods, sand, earth, pebbles,
nuts and bolts, tools, rags, oil and greasy films, etc.) in order to avoid line
blockages, damage to sensitive components such as orifice plates,
turbine, compressors, pumps impellers, valve seats and so on.
3.0
Responsibilities
The responsibilities are given in the work instructions to the plant operator,
standard engineering procedures preparation of commissioning, working
step, network cleaning, flushing and purging.
Procedure
4.1
Quick decompression
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b)
c)
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Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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d)
e)
f)
4.3
Cleaning preparation
The following principles shall apply:
Whenever possible, the cleaning fluid shall flow from top to bottom.
The diameter of the outlet pipe may be at least two thirds of the
diameter of the line to be cleaned, and at least as large as the inlet
pipe.
Main headers shall be cleaned first (i.e., before their connecting lines).
Large diameter pipes shall be cleaned before small diameter ones.
Dead ends shall be avoided or, if not possible, cleaned separately.
Fragile devices included in the network (all flanged valves, turbine-type
flowmeters, orifice restrictions, etc.) shall be removed (see section
4.4).
Protection of the devices in the vicinity of the network shall be carefully
studied in particular near the water (or air) outlet in order not to
damage electric motors or instruments with water or dirty air (see
section 4.5).
Existing block-valves on the lines to be cleaned shall not be used to
control an air flow as they could be damaged by erosion (due to the
high velocity of the fluid).
A special care shall be taken for vessels designed only for an
atmospheric pressure service, in order not to create, during washing, a
high pressure due to a water head.
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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4.4
4.5
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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4.6
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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In liquid process lines and water lines, the velocity shall be the
lowest figure between 3 to 4 m/s and the velocity obtained with 1.3
times the maximum process or water flow. The minimum velocity
shall be 2 m/s.
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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- Personal protection:
Protection of personnel carrying out the operation must be ensured by
suitable protective equipment, i.e. gloves, boots, coveralls, goggles, etc.
4.6.2.10 Preparation of documents and notice to commissioning
-
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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In the gas process lines, the velocity shall be the lowest figure
between 60 m/s and the velocity obtained at 1.3 time the maximum
process flow rate. The minimum velocity shall be 30 m/s.
The total volume of the network shall be estimated and the time required
to raise the pressure up to 6 bars with the compressor(s) shall be
calculated.
Mechanical design pressure limits are to be considered.
4.7.2.3 Determination of the network pressure and maximum allowable
pressure
If the quick decompression method is used, the air pressure in the network
shall never exceed 6 bars. It should also be checked that all pipes and
vessels of the network are designed to withstand a pressure of 6 bars.
If the network cannot withstand a pressure of 6 bars, the pressure shall be
carefully studied and specified in order that the maximum allowable
pressure in the system is never exceeded.
If a rupture disk is to be installed on a large diameter pipe, the set
pressure of the disk shall be carefully calculated in order to limit the
energy released when bursting occurs to an acceptable level (in particular
with regard to recoil effect).
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For pipes above DN 250 especially the first blowing will take place with the
network pressurized at only 2-3 bars.
4.7.2.4 Sketch of the network to be cleaned
Identical to 4.6.2.4 only the lines to be flushed will be colored yellow.
4.7.2.5 Location of air inlets and outlets
A site review shall be made to determine the possible air inlets, the
possible outlets, and the necessary temporary pipes (avoid hose pipes
when possible). Detailed drawings shall be prepared if necessary,
and the required equipment to be supplied and installed (pipes, valves,
gaskets) shall be determined.
4.7.2.6 Opening means
Where the quick decompression method has been selected, the pressure
release can be obtained by:
-
In the first case, the flow rate may be roughly adjusted, if necessary, and
the valve may be closed in case of emergency; in the second case, no
control is possible.
Due to the high velocity involved, the quick opening valve might be eroded
if it is used in an intermediate state (i.e. not completely opened).
Therefore, whenever possible, the valve shall be completely open.
4.7.2.7 Fragile devices to be removed
Same as for water flushing (see item 4.4 und 4.6.2.7).
Attention shall be paid to tray manholes and other internals of the vessels
used as air capacities (quick decompression method).
4.7.2.8 Quality of air
The quality of air shall comply with the design basis.
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
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Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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4.7.2.9 Safety
The safety rules and instructions must be strictly obeyed.
Due to the high forces generated at the air outlet, the following particular
precautions shall be taken for blowing operations:
- Period of time for blowing:
Generally air blowing will take place after normal working hours.
- Restricted area:
An area of at least 30 meters around the outlet points will be roped off
during the release of air.
- Work permit:
Any air blowing operation shall be subject to specific work permits
according to the safety procedure.
- Space between flanges at the outlet:
To obtain the desired space without hammering, spacers (pieces of tube
of a diameter slightly larger than the bolts), or pile of washers, may be
installed on bolts fixed by two nuts between the two flanges in two holes
diametrically opposed (see figure below). Other fixing systems are also
possible.
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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- Restraints:
The flanges(s) at the air outlet shall be fixed by means of shackles and
cables or slings. For diameters larger than DN100, at least four cables
shall be used. The second end of the cable shall be fixed rigidly to the
structures (see figure below).
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
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- Blanks:
Blanks shall be rigidly fixed to the flanges by bolts and nuts in order
to prevent them flying off when opening the quick opening valve or
when the rupture disk blows out.
- Environment protection:
The large quantities of dirty air released during the flushing carries
particles of sand, rust. welding rods, .etc. which could damage
nearby equipment. Therefore adequate protection has to be
installed.
- Personnel protection:
Protection of personnel carrying out the operation must be ensured
by suitable protective equipment, i.e. ear protection, gloves,
coveralls, goggles as a minimum.
4.7.2.10 Preparation of documents and notice to commissioning
Identical to 4.6.2.10.
4.7.3 Performing air blowing
Once all preparation work is completed the commissioning engineer shall
inspect, the site (and check specially that all protections are installed: pipe
restraints, clamps, supports, protection of equipment in the vicinity of air
jets) and obtain the clearance of the safety engineer. Once satisfied he
shall give the authorization to start the air blowing operation.
4.7.3.1 Continuous blowing method
- Start the compressor (see particular procedure and vendor
requirements).
- Open the valves on the main header to be air flushed.
- Allow the air flow to enter the network up to the calculated flow rate
(check by difference at the outlet of the compressor, before and after).
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Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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b)
- The main advantage of steam over air is the embrittlement of pipe wall
deposits, especially millscale, caused by temperature changes between
blowings and the subsequent contraction of the piping or equipment
causing a cracking effect on pipe wall deposits.
- Steam blowing is a HAZARDOUS OPERATION:
Very high forces are generated at the steam outlet. Therefore, specific
safety procedures must be closely adhered to; generally steam blowing
operations shall be done when most of the other works in the area have
been stopped, personnel which will stay in the area should be
informed/warned before blowing, hearing protection is mandatory.
4.8.2 Preparation for steam blowing
Note: Before the detailed preparation work starts, a meeting shall
organized with GBHE and the customer commissioning representatives to
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Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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- There is little point in using a target plate during the initial steam
blowings, these plates should be installed when the exhaust steam
appears to be clean.
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Proceed as follows:
- If the exhaust steam appears to be clean install a target plate and steam
blow the system.
- Examine the plate at the end of the steam blowing.
- If the plate has became eroded and pitted, easily seen by a matt gray
appearance and surface pitting, continue steam blowing.
- Mark each plate and store in a safe place for comparison.
- The target plate surfaces will become brighter after each subsequent
blowing.
- When the plate surface remains bright it will be possible to count the
number of impact pits per blow caused by large dirt or rust particles.
- When the plate remains unmarked it may be assumed that the piping is
clean.
- If requested, submit the series of target plates to the equipment vendors
representative for his scrutiny and final approval.
- Ensure no dirt is re-introduced into piping during re-assembly following
steam blowing.
In the case that target plates will be used, note that wet steam may produce a
"matting" effect on a polished target plate which can be misleading. In this case
look for pitting marks as a general guideline.
When the equipment is considered to be clean, and / or meets the equipment
vendors representative requirements, etc., allow the piping to cool, drain
condensate from low points and, if necessary, carry out a drying procedure.
Reassemble the piping taking care not to reintroduce dirt into the equipment.
Commissioning engineer shall assess if the desired cleanliness has been
reached and give the authorization to stop the steam blowing operation.
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Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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The pressure shall be carefully studied and specified in order that the
maximum allowable pressure in the system is never exceeded.
4.9.2.4 Sketch of the network to be cleaned
A sketch of the network to be cleaned shall be specially drawn for the
cleaning operation (P&IDs will be used for this purpose).
The following color code may be used:
- Blue with flags: lines to be chemical cleaned
- Green: items to be removed
- Pink: flanges to be disconnected
- Orange: items to be isolated
Blinds used for chemical cleaning operations, if they are necessary they
will be indicated and numbered with a red color. Installation and removal
of blinds shall be followed up by commissioning by the mean of a blind list.
Installed blinds shall be tagged and equipped with a visible handle painted
red.
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4.9.2.9 Safety
The safety rules and instructions must be strictly obeyed.
The following particular precautions shall be taken for chemical cleaning
operations:
- Period of time for flushing:
Generally chemical cleaning operations will take place during normal
working hours.
- Restricted area:
An area of at least 5 meters around the system will be roped off or closed
off during the cleaning operation.
- Work permit:
Any chemical cleaning operation shall be subject to specific work permits
according to the safety procedure.
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- Restraints:
Wherever necessary, the pipes shall be rigidly fixed to avoid damage to
the lines, equipment and people nearby.
- Environment protection:
Adequate protection of the devices in the vicinity of the system and water
outlet has to be installed in order not to damage equipment, electric
motors or instruments with chemical solution or water.
- Personal protection:
Protection of personnel carrying out the operation must be ensured by
suitable protective equipment, i.e. gloves, boots, coveralls, goggles, etc..
4.9.2.10 Preparation of documents and notice to commissioning
- A work permit shall be issued for each cleaning operation according to
the safety procedures.
- Notice to the commissioning team shall be sent together with colored
P&ID(s).
4.9.3 Performing a chemical cleaning
Once all preparation works are completed the commissioning engineer
shall inspect the site and give the authorization to start the chemical
cleaning operation.
Cleaning operation will be performed by circulating the chemical solution
for a predestined time.
To check the flow rate if no flowmeter is installed, a pressure gauge can
be installed at the inlet of the system to be cleaned (downstream of the
inlet valve) and the flow then adjusted by acting on the inlet valve till the
head loss equals that calculated for the required velocity.
The flow / discharge pressure curve of the pump can also be used to
check the flow rate (make sure the pump runs at its normal speed).
The temperature of the cleaning solution shall be approx. 50 to 70 C.
When the complete system has been cleaned satisfactorily, the circuit
shall be emptied chemical solution.
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Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
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Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com
Refinery Process Stream Purification Refinery Process Catalysts Troubleshooting Refinery Process Catalyst Start-Up / Shutdown
Activation Reduction In-situ Ex-situ Sulfiding Specializing in Refinery Process Catalyst Performance Evaluation Heat & Mass
Balance Analysis Catalyst Remaining Life Determination Catalyst Deactivation Assessment Catalyst Performance
Characterization Refining & Gas Processing & Petrochemical Industries Catalysts / Process Technology - Hydrogen Catalysts /
Process Technology Ammonia Catalyst Process Technology - Methanol Catalysts / process Technology Petrochemicals
Specializing in the Development & Commercialization of New Technology in the Refining & Petrochemical Industries
Web Site: www.GBHEnterprises.com