Taking Preservation ‘Upstream’: Where Does Your Preservation Plan Start?
July 11, 2024
Getting approved to implement a preservation program at an oil and gas facility or other industrial plant is a huge step toward saving money, increasing efficiency, and promoting reliable uptime. However, if the preservation plan does not start far enough upstream, users may still unexpectedly encounter rusty parts when they go to install a critical spare or asset. To avoid these unwanted surprises and maximize effectiveness, Cortec® recommends starting the preservation plan farther “upstream.”
‘Rewind’ the Rust Story
When mothballing an industrial plant or preserving inventory that has been sitting on outdoor racks for years, workers cannot just start applying corrosion inhibitors. If the components have already rusted, workers must “rewind” the story to the point where parts are clean and usable again. Otherwise, even the best preservation package will not magically make a rusty valve or other part ready to use on demand with minimal downtime. Furthermore, corrosion inhibitors must have clear access to the metal surface for the best results. A layer of rust- or even dirt or grime—will tend to block the action of corrosion inhibitors so they cannot form a protective molecular layer on the metal surface. A full “clean, protect, preserve” routine will solve this problem.
Metal parts should be cleaned with a Cortec® VpCI®-41x Series cleaner to remove dust and grime prior to rust removal, if needed. These alkaline cleaners contain corrosion inhibitors to protect against flash rusting from the exposure of metal to a corrosive environment. If many rusty parts need restoration, it is a good idea to set up a rust removal station with three stages: a tub of rust remover (e.g., VpCI®-422 or VpCI®-426), a tub of rinse water, and a tub of VpCI®-41x Series cleaner. The size of the tubs should be based on the size of the parts being restored. The same rust removal solution can be used many times and is an excellent option when hundreds of parts are being restored. At times it will be necessary to circulate these products through a component such as a heat exchanger. After the rust is removed and the components have been properly cleaned and dried, preservation can proceed as normal by wrapping assets in VpCI® Films and adding VpCI® Emitters within as needed.
Go Back up the Supply Chain
While large-scale restoration projects are commonly needed at industrial facilities to preserve hundreds of thousands of dollars’ worth of inventory or mothball the entire plant, it is better if this step can be avoided completely. The secret is to move farther “upstream” in the supply chain. This is especially true for greenfield projects where custom components gradually arrive onsite but may not be installed immediately. If the supplier has not taken proper precautions, the equipment may have already rusted on its way across the ocean. Or it could rust while sitting out in the open yard for months or years waiting to be installed. By specifying that suppliers follow specific preservation materials and procedures, end users can ensure their deliveries arrive in good condition and are preserved until needed, avoiding unwelcome surprises that could delay their startup date or leave them without necessary spares. Some commonly recommended supplier activities include hydrotesting with VpCI®-649, fogging with CorroLogic® Fogging Fluid VpCI®-339, and heat shrinking in VpCI®-126 HP UV Shrink Film or MilCorr® VpCI® Shrink Film (depending on the severity of the environment).
Enjoy the Benefits of ‘Upstream’ Preservation
Methods and materials vary from case to case, but the important steps are to “rewind” the rust that has already started and recommend specific preservation activities to equipment suppliers. In these ways, workers can ensure effective preservation and preempt many time consuming rust problems that could otherwise arise “downstream.” Contact Cortec® for specific advice on your preservation needs and to enjoy the benefits of starting your preservation plan farther “upstream”!
Keywords: preservation, preservation plan, restoration of rusty parts, rust removal, how to remove rust, upstream preservation, Cortec, VpCI, rust prevention, corrosion inhibitors
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