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Precleaning & Passivation of Heat

Exchnagers
Introduction:
All new equipment or equipment taken out for maintenance in cooling water
system should be precleaned to remove grease, oil, corrosion products, mill
scale and dirt. Clean surface enable corrosion inhibitors to establish a
uniform protective passivation flm. Failure to remove debris can result in
deposition on critical heat exchanger surfaces during start up. assivation of
the metal reduces the initial corrosion reaction that occurs at start up and
facilitates the establishment of corrosion inhibitor programme. !ith
traditional pre cleaning method separate pre flming "passivation# step is
recommended to promote a rapid formation of protective flm to retard
corrosion of the metal surfaces.
re$cleaning procedures non$negotiable since passivation procedures are
only e%ective on clean metal surfaces
assivation of carbon steel heat exchangers is so important that it should be
a non$negotiable part of start$up. lants may choose to conduct passivation
procedures by isolating a single heat exchanger or circulating chemicals in
the entire cooling water circuit, depending on the number of new heat
exchangers or the number of new tubes.
AquaChemie precleaning and passivation programme safely remove
deposits, corrosion products and leave passivated metal surfaces.
Advantages:
&. Cleans heat transfer surfaces and hence ensures maximum heat transfer.
'. recleaning ensures that no debris or loose corrosion product is left which
can block tubes or deposit on heat transfer surfaces during operation.
(. assivation ensures that metal surfaces are not directly exposed to
corrosive )uid and hence prolong equipment life.
*. assivation to certain extent protects equipment from corrosion during
upsets like low p+, +ydrocarbon leak etc,
Prepared By : Surjeet Kumar
Uncleaned & Unpassivated CS Surface Precleaned & Passivated
CS Surface
Procedure:
Degreasing/ Dirt Removal
&. Flush system with potable water till water at outlet of exchanger is
visually clean and -.. of outlet water is equal to -.. of inlet water.
'. Add surfactant/ chelating agent to remove oil 0 grease and loose products
at recommended dosage level and circulate for & hour.
(. 1rain circulating solution completely.
*. 2epeat step ' 0 ( again. .tep ' should be continued for ' hours.
Passivation
&. Add polymeric dispersants at recommended dosage in circulation tank.
'. Add passivation chemical at recommended dosage in circulation tank.
(. 3aintain p+ in range of 4.4 5 6.7 by using mild acids. 8t is recommended
to use acid corrosion inhibitors.
*. Circulate above solution for 9 hours.
4. 1rain passivation solution completely from heat exchanger.
Prepared By : Surjeet Kumar
6. -horoughly )ush heat exchanger with Cooling !ater.
:. 8mmediately after through )ushing heat exchanger should be taken in line
within '* hours.
9. -o speed up passivation procedure following actions can be taken;
$ 3aintain circulating water temperature of :4 5 97 1eg C.
$ +igher dosing of polymeric dispersant is done to keep passivation
chemicals in soluble form.
$ Circulation should be done for * 5 4 hours.
Time ine for Completing Precleaning & Passivation:
!e"uirements:
&. -ank for circulation
'. Circulation ump
(. Flexible +oses and adapter connections
*. +eating arrangement for maintaining temperature
4. 8nlet 0 <utlet connections isolation valve
6. Chemicals for precleaning 0 passivation
Prepared By : Surjeet Kumar
A"uaChemie Specialt# Services for Precleaning &
Passivation:
&. 3echanical systems for precleaning 0 passivation.
'. Chemicals for precleaning 0 passivation.
(. .upervision of complete activity along with required analysis to ensure
precleaning and passivation.
*. -ests to ensure proper precleaning and passivation.
4. Complete precleaning 0 passivation report for record and future
reference.
The center and right pipes sho$ incomplete pretreatment and passivation%
Preferred is the pipe at left
Prepared By : Surjeet Kumar
Important &ote:
&. Chemical requirement is calculated based on circulation loop volume.
'. Chemical requirement 0 procedure varies with 3<C of exchangers.
(. Closed cooling systems equipment precleaning and passivation procedure
is di%erent from open cooling system.
*. assivation should be done in supervision of technical expert to avoid any
damage to equipment during process.
Prepared By : Surjeet Kumar