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Chemical
Cleaning at
Upstream &
Downstream
701-JA/JB
Isomerization unit, March, 2015
of
Table of Contents
1 Executive Summary:........................................1
2 Chemical Cleaning Procedure:.........................2
3 Description of Chemical Cleaning Activity:.......3
4 Lineup/Drawings:.............................................4
5 Lab results:......................................................6
6 Recommendations:..........................................6
1 Executive Summary:
Chemical cleaning of lines is important to remove dirt, rust or scale
from ferrous metals which can cause corrosion, ultimately the loss of
equipments or lines. It is usually necessary when a new compressor
is to be commissioned. Prl is going to install a new makeup
Hydrogen gas compressor (701 JA/JB) for an isomerization unit. So,
it is recommended by the vendor to perform pickling at upstream &
downstream of compressor before commissioning of compressor. For
an implementation of this activity we took a tank of having 64 ft 3
volume (1800L) with a pump discharged the tank liquid in the closed
circuit & after filling the system with liquid completely the remaining
liquid returned to the tank. It became like a closed circuit so that the
maximum result of chemical cleaning achieved in less time. First of
all, we took raw water in the tank to check the pump performance.
After fully satisfied with the pump performance. We took a
condensate in the tank as per procedure & started the circulation
into closed circuit also to found out any leakage that might occur
before adding strong acids for pickling. After cleaning of lines at
upstream & downstream of compressor 701-JA with condensate
thoroughly for 2 hours. Added 22 cans of HCl (770 Kg) in the
tank with strength found 9.8 wt% in lab results & 7.0 kg of
corrosion inhibitor (Tomamine Inhibitor 60Q Surfactant) to
reduce the acid attack on the material. Circulation started at 10:40
hrs. The first sample send to lab at 11:15 hrs. & iron found 2850
ppm and ended at 13:50 hrs. when iron stabilized at 1400 ppm.it
took almost 3 hrs. HCl tank drained and filled with condensate,
circulation with condensate stopped after 45 minutes & tank again
drained. Caustic solution of 2.5 wt% prepared in fresh condensate
in order to neutralize spent acid in lines. Circulation with caustic
started at 15:10 hrs. & completed at 16:25 hrs. when HCl strength in
caustic solution found nil. In the end, made a solution in condensate
with 10 cans (300 Kg) of phosphoric acid having strength of 3
wt%. Phosphoric acid circulation started at 16:55 hrs. & stopped at
18:10 hrs. After completing task of chemical cleaning successfully.
Nitrogen purging carried out one by one from different points (local
1
drain, dead ends) & it took almost one hours to finish the activity of
Nitrogen blanketing.
Condensate Flushing:
After draining the HCl tank completely & safely, filled the tank with
condensate & flushing the lines for 45 min.
Nitrogen Purging:
At the end of all the activities of cleaning, Nitrogen purging planned
to dry the wet lines & the remaining liquid that might present in the
lines removed easily. A connection from Nitrogen storage vessel was
taken and set it at pump discharge gauge point by removing a
gauge. 16 Kg/cm2 pressurized Nitrogen was used to drain the liquid
from all low points of system. One by one all local drains & dead
ends opened to remove the liquid. When no liquid was coming out
from the lines but nitrogen. The activity completed, initial level of
Nitrogen in vessel was 1100 L. Consumption was nearly 500 L.
4 Lineup/Drawings:
Figure: 1
Figure: 2
Figure: 3
5 Lab results:
Time
Sample
Iron (ppm)
5.5
5.4
2850
9.8
2840
13:00
9.7
1400
13:30
1410
0.15
NIL
10:55
11:15
11:45
15:25
16:00
HCl
SOLUTION
NaOH
SOLUTION
6 Recommendations:
The centrifugal pump used for circulation should maintain a
velocity of not less than 10 ft/sec.
Lines should be properly drained and dried enough to avoid
any chemical carryover.
Carefully checkout the lineup as acid leakage may result in
serious accident.
Chemical transferring pump should be properly checked before
using it to transfer concentrated acid.