20 Preservation of Piping Materials

PRESERVATION of PIPING
MATERIALS
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What is Preservation
PROTECT THE OBJECTS AWAY FROM

UNWANTED FOREIGN SUBSTANCES

Preserve – Why ?
Many of the items may be required to be kept in

stores or lay down yards for many months or
years. It shall therefore be essential that proper
methods of storage and preservation be applied so
that items do not deteriorate, loose some of their
properties and become unusable due to
atmospheric conditions

NO PRESERVATION
Tend to change or deviate from their properties
Sometime unfit for use
may not be able to fulfill intended functions

MATERIALS IN OUR WARE HOUSE
MECANICAL
 Metallic Materials
 Non-Metallic Materials
 Metallic Material
 Carbon steel
 Alloy steel
 Stainless steel & etc.
 Non-Metallic Material
 Plastic
 Rubber
 GRE & GRP
 Nylon (Polymer Material)
 PTFE
 Non-Asbestos & etc.

METALLIC MATERIAL PRODUCTS
 Pipes  Structures
 Pipe Fittings  Vessel Equipments
 Valves  Lifting Equipments &
 Steel Plates Accessories
 Flanges  Pumps
 Spades & spectacle  Bearings
 Gaskets  Spare Parts
 Stud Bolts  Hydraulic Hoses

NON-METALLIC PRODUCTS
 Spare Parts
 Gaskets
 O-rings
 Different type of filters
 GRE & GRP Pipes
 Plastic Products

FACTORS INFLUENCING DETERIORATION
Nature
 Moisture / Humidity
 Dust
 Water / Rain
 Atmospheric Temperature
Technical
 Unfavorable storage conditions
 Wrong storage method
 Passage of time

DAMAGES DUE TO NATURE
 Rusting of iron
 Corrosion
 Cracking of paints
 Hardening of rubber

CORROSION
Corrosion relates to deterioration of metal surfaces due to reason other than
mechanical ones and deliberate destruction of iron parts and even pitting of
aluminum utensils are example of corrosion.
Corrosion is usually caused when one of more of following conditions prevail

(i) When materials are exposed to harmful gases in the industrial town.
(ii) When materials are in continuous contact with water in the presence of air.
(iii) When materials are exposed to solutions of acids, alkalis or salts.
RUST
Rust is compounding formed by the oxidation of iron in the presence of moisture.
The term “Rust” is restricted to iron and steel only. While the term “Corrosion” is
applicable
to all metals.

PICTURES

CHEMICAL CHARACTERISTICS OF CORROSION
Chemical Characteristics Effects

pH Low pH may increase the corrosion
rate; high pH may protect pipes and
decrease corrosion rates.
Dissolved oxygen (DO) Increases the rate of many corrosion
reactions.
Chlorine residual Increases metallic corrosion
Total dissolved solids (TDS) High TDS increases conductivity
and corrosion rate.
Chloride, sulfate High levels increase corrosion of
iron, copper, and galvanized steel.
Hydrogen sulfide (H2S) Increases corrosion rates.

EFFECTS OF NATURE
Temperature :
 Diurnal changes in temperature may induce stress due to differential
expansion and result in failure of stores where two or more materials are
used.
 Diurnal changes in temperature may also result in dew formation and
subsequent
corrosion
 Dew formation results in failure of electrical/electronic equipment
 Plastic, polymers & Rubber materials become hard at high temperature.
 Rubber, certain polymers and metal like molybdenum and zinc die-casting
become brittle at low temperature

 Paint coatings become crack due to high temperature

 Increase in moisture may cause corrosion of metallic parts
 Loss in insulation of electrical/electronic instruments/equipment
 Oxygen and ozone cause oxidation and oxidation degradation in many

compounds. These reactions are accelerated in presence of moisture
and
light
 Dusts are sediment on the materials and observe the water particles
from
humid / moisture and make the material as wet condition and initiate the
corrosion.
Uniform Corrosion
Pitting Corrosion
(Localized)
Wide Pitting
Types of Corrosion
Corrosion
Inter granular
Corrosion
Galvanic Corrosion
Interfacial Corrosion
DAMAGES DUE TO TECHNICAL
 Unfavorable storage conditions
Some of the materials shall be kept under climatic control store. This
kind of material we stacked in out side of WH means it will unfit for
use.
Example:
Electronics goods stored in Lay down Yard
 Wrong storage method
Materials are to be stored separately as per their characteristics.

Example :
SS materials stored with CS & Alloy materials.
 Passage of Time
Materials were stored for longer time it may be become unfit for use.
FIRST IN FIRST OUT.
PICTURES

PRESERVE - WHEN
 New Goods received by WH
 After Quality Inspection
 Stacked Goods in WH become dusty/rusty
 Before stacking of returned materials to WH

Preserve
the
Materials

TO DO FIRST
Before preservation the following activities to be carried

out
 Cleaning
 Visual Inspection
 If any rust or corrosion found locally, remove by manually and

clean
again
 If it’s more, go for chemical Cleaning
 Ensure it’s free from dust, rust & corrosion

CLEANING BY HAND/MANUAL
 Washing with water/solvents, scrubbing with wire brush or rags or rubbing with sand paper or emery cloth may
carry
out cleaning and degreasing.
Note:
SS wire brush shall be use for SS materials
List of Solvents
 WD 40
 Kerosene
 Carbon tetrachloride
 Caustic soda or soda ash
 White Spirit
Note:
Hand gloves shall be use while handling solvents by Hand
After the material has been cleaned and rust free material should be thoroughly dried by one of following
methods
before preservative coating is applied.
 Blow hot air.
 Blowing dry compressed air, and
 Wiping with clean rags
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of the above methods are possible, it may be dried in the hot sun (if the weather is clear). 24
CLEANING BY CHEMICALS
 Dust, Rust & Corrosion can be removed by chemicals also.
 The corroded materials are immerged in the chemical solution bath and sock for some time. During the socking
time
the chemical react with the rust and remove the rust from the surface.
 After that the treated material shall be treated with diluted solution to stop the chemical reactions.
 The same wash with water and dry after cleaning.
Types of Chemical cleaning

 Cold Method
 Hot Method
The Following Chemicals are use for chemical cleaning.
 Trichloroethylene (Vapour Immersion)

 Hot Alkaline Solution
 Phosphoric Acid-Cold immersion

ADVANTAGES & DISADVANTAGES OF
HAND & CHEMICAL CLEANING
Hand Method Chemical Method
Advantages: Advantages:
 Simple Process  High production
 Low Cost  Less Lead time
 Less equipments required  High Quality
 Less area is enough
 Disposal of wastage is easy Disadvantages :

 Less fumes  Complicated Process
 High Cost
Disadvantages:  More equipment required
 More Lead time  More area required
 More man power  Disposal of wastage is difficult
 Low quality

PRESERVATION OF PIPE AND FITTINGS
 All Pipe and fittings to be clean before preservation.

 Preservative coatings to be applied on the surface and wrap with waterproof
paper or VPI paper is a cheap method of protection. However, the material
protected in this way should be stored under cover.
 End caps shall be placed at the ends.
 Pipes are stored in rack or on the wooden pallet / piece above 100mm from
the ground level. (One end slightly raised).
 All fittings of 2” and below un packed and stored under roof.
 SS pipes shall be covered with cloth or tarpaulin in yards.
 All tubes are stored in side the ware house.

PRESERVATION OF VALVES
 Check rust preventive coat on body, hand wheels, butts welded

ends/flanges
and by pass tubes, if not applied, apply the same.
 Rest the valve upright on wooden pieces,
 Protect unpainted surface of valve components like stem, yoke, bush etc.
with
grease or preventive oil.
 Keep valves always with disc/wedges closed.
 Proper polythene bag covering for actuators and motor Assy. to be applied.
 Valves ends/flanges opening are to be plugged with PVC caps.

 Due to non-availability of covered area, certain heavy valves can be stored
in
open yards, concrete and after providing necessary rust preventing
coatings.
PRESERVATION BLINDS AND SPADES
 All Blinds & spades to be clean before preservation.
 End caps shall be placed at the ends.
 Preservative coatings to be applied on the surface and wrap with

waterproof
protected in this way should be stored under cover
 For over 8” Blinds & spades no need of end capes, but maintain 25mm gap
between the two items by wood strip.

END CAPS
Picture

PRESERVATION OF STUD BOLTS & GASKETS
 All Stud bolts to be clean before preservation.
 Preservative coatings to be applied on the surface and wrap with
waterproof
protected in this way should be stored under cover.
 Gasket shall be stored as same received condition.
 Big size gaskets should not be stored on the small size gaskets.
 Gaskets always stored in horizontal position.

Columns/Heavy Beams/Girders/Structural Steel (Open
Yards)
 Laid over suitable supports such that flange of the section rests on support.
 Multi support at proper intervals to avoid sagging.

 Machine faces of the column pieces as well other surface are to be applied
with rust preventing oil coating.
 No other materials to be kept over the columns.
 Other structural components shall be kept above the ground on suitable
supports

PROTECTIVE COATING AGENTS
 Mineral Jelly
 Beeswax
 Grease
Shell Products:
 Shell Ensis Oil (grade N)
 Shell Ensis Compound CA
 Shell Ensis Fluids

STORAGE AND PRESERVATION OF RUBBER
GOODS
Main factors causing deterioration of rubber goods are
 Light; particularly sunlight rich in ultraviolet rays
 Air flow
 Ozone
 Heat
 Organic solvents and oil
 Acid and alkalis
 Mechanical stress, strain, sharp bends and folds
 Dust
Main symptom of deterioration is development of tackiness and softness,
crack development, surface crazing, brittleness, loss of shape, fungal
growth
and tendering of rubberized fabric.
PICTURES
JG

Precautions For Storage Of Rubber Goods, Which
Shall Prolong Their Useful Life
 Storage room should be of permanent construction, dark and cool as far
as
possible.
 Its temperature should not increase 27° C.
 Ventilation should be restricted to minimum to avoid airflow as they supply
fresh oxygen. A slow circulation of cool air is desirable.

 Mechanical strain and distortion to rubber should be avoided during
storage
 Contamination with grit, dirt and dust should be avoided
Note :
General methods of preservation and any specific instruction from
manufactures for preservation shall additionally be followed.

STORAGE HYGIENE
Cleanliness:
All Stores rooms must of swept daily and cobwebs are removed. Cracks
and crevices must be filled up. If possible saw dust shall be spread over the
floor before sweeping. It stops spreading of dirt and dust in the air and
subsequently accumulating on the storage racks and materials lying on
them.
Ventilation
Air must be allowed to circulate freely throughout the storage area. The
only exception is in respect of rubber articles where ventilation has to be
restricted to a slow natural circulation of air. Free aeration helps in keeping
the stores and stores rooms dry, and prevent accumulation of heat within the
stocks, bundles and stores.

PERIODIC INSPECTION OF PRESERVATION
Proper preservation shall be ensured by storekeeper/custodian who

shall work under guidance of user departments.
User departments shall also extend full cooperation in this regards

and visit stores from time to time to assess implementation and
advise in the matter.


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PRESERVATION of PIPING

Copyright of INSERT COMPANY NAME HERE 4/29/2019 1

PROTECT THE OBJECTS AWAY FROM

Copyright of INSERT COMPANY NAME HERE 4/29/2019 2

Many of the items may be required to be kept in

Copyright of INSERT COMPANY NAME HERE 4/29/2019 3

Tend to change or deviate from their properties

Sometime unfit for use

may not be able to fulfill intended functions

Copyright of INSERT COMPANY NAME HERE 4/29/2019 4

Copyright of INSERT COMPANY NAME HERE 4/29/2019 5

 Valves  Lifting Equipments &

 Steel Plates Accessories

 Spades & spectacle  Bearings

 Gaskets  Spare Parts

 Stud Bolts  Hydraulic Hoses

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 Different type of filters

 GRE & GRP Pipes

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 Wrong storage method

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Corrosion is usually caused when one of more of following conditions prevail

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Chemical Characteristics Effects

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 Plastic, polymers & Rubber materials become hard at high temperature.

become brittle at low temperature

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 Oxygen and ozone cause oxidation and oxidation degradation in many

Materials are to be stored separately as per their characteristics.

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 New Goods received by WH

 After Quality Inspection

 Stacked Goods in WH become dusty/rusty

 Before stacking of returned materials to WH

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Before preservation the following activities to be carried

 If any rust or corrosion found locally, remove by manually and

 Ensure it’s free from dust, rust & corrosion

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 The same wash with water and dry after cleaning.

Types of Chemical cleaning

The Following Chemicals are use for chemical cleaning.

 Trichloroethylene (Vapour Immersion)

 Phosphoric Acid-Cold immersion

Copyright of INSERT COMPANY NAME HERE 4/29/2019 25

 Low Cost  Less Lead time

 Less equipments required  High Quality

 Less area is enough

 Disposal of wastage is easy Disadvantages :

Disadvantages:  More equipment required

 More Lead time  More area required

 More man power  Disposal of wastage is difficult

Copyright of INSERT COMPANY NAME HERE 4/29/2019 26

 All Pipe and fittings to be clean before preservation.

 SS pipes shall be covered with cloth or tarpaulin in yards.

 All tubes are stored in side the ware house.

Copyright of INSERT COMPANY NAME HERE 4/29/2019 27

 Check rust preventive coat on body, hand wheels, butts welded

 Valves ends/flanges opening are to be plugged with PVC caps.