TODAYS WEAK global economy is forcing closure

and immobilization of plant and equipment worth

billions of dollars. Unfortunately, such actions usually are done hastily and typically against a background
of acrimony. Even worse, they can diminish or even
destroy the value of assets and preclude the possibility
of reactivating them once business rebounds.
Two major plant dismantling/second-hand equipment vendors recently told me that when the decision
to shutdown comes most companies remove anything
that could present an immediate danger and essentially close the doors and walk away from millions of
dollars worth of equipment. Leaving assets as is to
deteriorate can make them suitable only for scrap in
just a matter of months. Yet, its a fact that an unused
plant if properly prepared for shutdown and left in
fairly good condition can retain much of its value.
Engaging in a well-planned process of deactivation/
mothballing can pay off whether the intention is
eventual reactivation or sale of assets.
In my experience through three boom/bust cycles in
the process industries and oil well drilling, 75% of idled
plants or rigs eventually were reactivated in some form.
The bottom line is that while it only should cost 5% of
plant replacement value (PRV) to reactivate a well-preserved unit, restarting an inadequately mothballed plant
will cost 20+% of PRV. This often is a deal breaker.

So here, well look at what should be done and

describe specific products and techniques. None of
these are new or experimental therere 40+ years of
documented experience for some.
THE APPROACH

Its essential to have a clear view of how to mitigate if

not defeat the constant foes of galvanic/bio corrosion, mold, mildew, etc. While much depends on
local conditions, wetter and colder environments
pose greater challenges for handling humidity, while
blowing dust is an issue in high desert regions.
A useful analogy in developing a strategy is to consider how plants fend off fire hazards by removing one of
the fire triangles three elements i.e., heat, fuel source
and oxygen. The three corresponding elements for agerelated deterioration are a driving force such as galvanic
action, a conducting medium or electrolyte, and oxygen.
The fundamental approach to stopping or slowing deterioration is to remove one or more of the three.
In simple terms we aim to do the following:
separate dissimilar metals;
protect surfaces that could be attacked with a
covering, even if only a few molecules thick;
dry out or remove the conducting medium (Corrosion cant occur when parts are stored in environments with relative humidity below 40%); and
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will withstand temperature extremes, thermal shock,

differential substrate movement and impingement, even
when sprayed onto webbing to form a cocoon.
Ten frequent errors can damage or even doom a plants prospects:
Volatile phase/corrosion inhibitors (VPI/VCI). Such
1. Not treating news of an impending shutdown as a knock
materials generate protective vapors even at room temdown blow rather than a knock out one. With adequate
perature. They come in a number of convenient forms,
preparation, it can be turned into just another blow. In todays
including time-release vaporizers, sprays, plastic bags
global marketplace just about anything can happen.
and films, powders, oil additives (see VSI below) and
2. Not allocating responsibility to an individual beforehand for
coatings. They are adsorbed (just a few molecules
writing a list of possible scenarios during tough times. This
thick) onto metallic surfaces of equipment and can
person should have enough clout to implement the chosen
prevent corrosion for up to two years.
strategy whether the fatal scene develops suddenly or slowly
They are solid or liquid at room temperature.
unfolds.
While many chemical compounds are in use, the
3. Not making sufficient funds available to execute the initial
most common form of VPI is a salt of an amine and a
shutdown and preservation strategy.
weak acid. Research has shown that they work by dis4. Not choosing the right type of long-term equipment caretakassociation of the amine and the acid; the two volatile
ers. Those selected often are security or ex-supervisory types
components then recombine on the metal surfaces.
rather than experienced operators/craftsmen with intimate
While most VCI are environmentally friendly and
knowledge of the equipment.
create no safety hazards for employees, some are sus5. Not remembering to maintain state and local operating
pected of being harmful. Most contain no toxic subpermits grandfathered ones might be unobtainable in the
stances such as nitrates, chromates or volatile organic
future if allowed to lapse.
compounds (VOC). (Note: products containing VOC
6. Not removing all process materials. Dealing with even innocushouldnt be used in combination with a desiccant.)
ous materials left in a unit long-term likely will cost five times
Vapor space inhibitors (VSI). These concentrates
more than at initial shutdown. Plus, the current operations
can be added to lubricating oil systems (internal compeople are familiar with all the hazards, while those in the
bustion engines, etc.) when equipment isnt going to
future might not be.
be completely filled. They essentially boil at ambient
7. Not seeking expert advice on equipment preservation, resulttemperatures to exclude air, leaving an oily residue.
ing in not getting the best bang for the buck.
Heat-shrinkable desiccant plastic films. Such films
8. Not involving the hourly workforce in the shutdown and mothcontaining desiccants are ideal for enclosing individuball plan. Experience actually has shown that involving operaal machines that have been cleaned and dried.
tors and mechanics can very much improve both the quality
VCI-covered polyethylene films. These suit wrapping
of the shutdown plan and its execution.
individual smaller components.
9. Not keeping good records and not clearly marking and keepChemical oxygen scavengers. These are added to
ing track of what has been done to preserve an item of equipfresh water used to displace more-corrosive liquid in
ment during deactivation, making it too easy for the reactivatsystems that cant be effectively cleaned or dried out.
ing crew (a different group of people) to miss that a filter, line
Chemical inhibitors. Incorporated into liquids, they
blind, internal component, etc., has been removed or added
remove unwanted products while preferentially inhibitwith serious consequences at startup.
ing their attack on the body of the container. (Anti10. Not keeping safety programs and routine audits active to
freeze sometimes used in mothballing contains them.)
avoid accidents. Idle plants with small crews operating at a
Desiccants. Numerous solids can absorb water
very relaxed tempo can be dangerous places.
from gases (air) or liquids.
Biocides. Such materials prevent microbial growths
in water and fuels like gasoline and diesel fuel.
eliminate any oxygen and sources of chemical
Sacrificial anodes. Made of materials such as magor biological attack.
nesium or aluminum, they are used in tanks that cant
Materials and equipment we can use are:
be drained of their contents.
Liquid protective waxes and liquid polyvinyl chloride
Dehumidifiers. Such equipment removes moisture
(PVC) coatings. These can be sprayed onto any clean
by one of two methods, the refrigeration principle or
dry surface to protect it. Light waxes are chosen for
two-cycle rotary (wheel) heated desiccant absorption.
surfaces where a subsequent removal process such as
(Numerous companies make all the products menhigh-pressure washing might damage the substrate.
PVC will form a tough, flexible and waterproof skin that tioned above. For a comprehensive list, e-mail me.)

Avoid Common Mistakes

SEPTEMBER 2009

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CP0909_19_23_Design.indd 20

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Getting started

Couple a long-term strategic approach with a series of

medium-term tactics; detailed plans are needed. First
guesstimate how long the shutdown is probably going to
last and whether the plant most likely will be restarted,
sold as a complete unit or disposed of piecemeal.
Consider every item or class of equipment individually and detail a specific initial storage/mothball technique plus a methodology for ongoing maintenance.
The individuals doing the deactivation often arent
those wholl be doing the reactivation so encourage
them to visibly identify various components and equipment state, even if only by using chalk or felt tip pen.
Before we go further into mothballing, permit a
small digression about the practice of pirating parts
from an idle unit. It can wreak havoc or worse. I vividly
recall the impact on a major U.S. chemical manufacturer I was involved with. After it shut down a product line
in the 1960s, other operations on site began to purloin
parts. When the market recovered four years later, little
of the plant was left to restart. The company was forced
to exit the market for that product. So, in your preservation plan explicitly prohibit removal of parts.

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Now, lets get into how to properly deal with

specific equipment and hardware. For purposes of
this article, lets consider a plant in the central U.S. or
Europe that could restart in from six to nine months
to perhaps several years. What follows is only a guide
and isnt intended to be comprehensive and detailed.
Tanks, pressure vessels and pipework. In all cases
ensure these are as clean and dry as possible. Insert
line blinds to create manageable zones that can be
slightly pressurized (0.5+ psig) using nitrogen or dry
air. Provide a small flow and arrange for some simple
telltale mechanism to show pressure, flow and level of
humidity (e.g., indicator cards).
For large enclosures, use an appropriate-capacity
commercial dehumidifier or maybe even consider a
total tented enclosure. For vessels, tanks and containments that must be kept full of liquid, employ some
form of oxygen scavenger or anti biological growth
chemical (see Boilers). If a pipework system contains
any traps, remove their internals and clear all strainers.
Boilers. These can be laid up using long-term dry
or wet hydrazine methods. The latter involves leaving
the wet-side, i.e., boiler, economizer and superheater,
full of treated feed water (dosed with 15% hydrazine, a proprietary solution, and pH adjusted to raise
alkalinity to a minimum pH of 8.3) and supplying the
fireside with heated air with desiccant as a backup.
Both waterside and fireside points should have
new gaskets, except for furnace hot-air entry inspection and exit points.
Pumps, engines, compressors and machinery. To minimize internal corrosion, close off all vents and openings
and completely fill the casing with the manufacturers
recommended lubricant. Alternatively, add VPI in the
correct proportion to the lubricating oil.
For large compressors, turbines, etc., use a portable
filtration cart with water-absorbing elements to remove
any free water in existing oil soon after shutdown.
For diesel and gasoline engines, drain fuel systems
and add biocide to remaining fuel.
To minimize external corrosion, spray either a
light wax or liquid PVC on unpainted surfaces.
Instruments and controls. Maintain the driest possible conditions for both electronics and external field
devices, including sensors, transmitters and valves, by
strategically placing desiccant packages and sealing
the enclosures. Supplement this by putting small
containers of VCI powder wherever possible they
wont adversely affect electronics.
Instruments that would normally be in contact
with process materials should be removed, cleaned,
protected and marked for immediate local storage.

8/24/09 11:11 AM

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Electrical enclosures. Seal and insert bags or wraps

desiccants and containers of VCI. Alternatively,
heat using individual strip or built-in heaters.
Motors and generators. Clean exterior, grease and
apply protective covering. Lift carbon brushes from
commutators/slip rings. Where sleeve-type bearings are
fitted, add VPI concentrate to the lubrication system. Include packets of desiccants if completely sealing a unit.
Periodically, nominally monthly, exercise equipment
by rotating it several times and leaving it at a different
(90) angle. Where humidity controls have been set,
monitor these at least weekly; check chemical controls
every three months. Long-term lay-up also requires regular monitoring of motor/generator internal resistance
(meggar), and tank oxygen and humidity levels.
Auxiliaries. Dont forget that in most cases fire pro-

tection systems and alarms still need to be maintained

and powered up fires are common in dried-out
wooden cooling towers. If batteries normally are used,
disconnect them and smear terminals with petroleum
jelly. Fully charge vented-type lead-acid batteries, then
drain and flush them with distilled water.
Dont squander assets

It makes sense to think strategically about plant deactivation. Proven techniques can preserve the functionality and value of assets. Proper mothballing can pay
off substantially whether an operating company aims
to eventually restart, sell or dismantle a plant.
BERNIE PRICE is CEO of Polaris Veritas Inc., a Houston-based
consulting group. E-mail him at Polarisver@aol.com.

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