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    Acidizing_in_Process_Units_1734368384

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    Bhavesh Kanani
    Acidizing is a critical cleaning process for process units, especially those involving sensitive catalysts, but it poses hazards such as corrosion and handling of anhydrous HCl. An alternative method involves isolating equipment during repairs, maintaining inert conditions, and using pneumatic tests to eliminate moisture and rust, thus avoiding the need for Acidization. This approach not only enhances safety but also significantly reduces start-up time and has proven effective in high-performing refineries.

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    Acidizing_in_Process_Units_1734368384

    Uploaded by

    Bhavesh Kanani
    2 views2 pages
    Acidizing is a critical cleaning process for process units, especially those involving sensitive catalysts, but it poses hazards such as corrosion and handling of anhydrous HCl. An alternative method involves isolating equipment during repairs, maintaining inert conditions, and using pneumatic tests to eliminate moisture and rust, thus avoiding the need for Acidization. This approach not only enhances safety but also significantly reduces start-up time and has proven effective in high-performing refineries.

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    Acidizing is a critical cleaning process for process units, especially those involving sensitive catalysts, but it poses hazards such as corrosion and handling of anhydrous HCl. An alternative method involves isolating equipment during repairs, maintaining inert conditions, and using pneumatic tests to eliminate moisture and rust, thus avoiding the need for Acidization. This approach not only enhances safety but also significantly reduces start-up time and has proven effective in high-performing refineries.

    Copyright:

    © All Rights Reserved
    Download as PDF, TXT or read online from Scribd
    Download as pdf or txt
    2 views2 pages

    Acidizing_in_Process_Units_1734368384

    Uploaded by

    Bhavesh Kanani
    Acidizing is a critical cleaning process for process units, especially those involving sensitive catalysts, but it poses hazards such as corrosion and handling of anhydrous HCl. An alternative method involves isolating equipment during repairs, maintaining inert conditions, and using pneumatic tests to eliminate moisture and rust, thus avoiding the need for Acidization. This approach not only enhances safety but also significantly reduces start-up time and has proven effective in high-performing refineries.

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    Acidizing in Process units

    Most of the Process units are subjected to rigorous cleaning prior to commissioning of the
    units. This is particularly true when the process involves catalyst. Few catalysts are super
    sensitive to rust and moisture of the steel pipes used in the process. For the purpose general
    techniques used during commissioning of such units are buffing/ grit blasting/ flushing/
    cardboard blasting. These techniques, otherwise rendered to be reliable and proven,
    sometimes fail to meet the stringent most requirements of a few super sensitive catalyst for
    which rust/moisture remaining in micro pores acts as poison. Moreover, debris, if present,
    can plug control valves, column trays. Keeping all these in view, Licensors appropriately
    recommends a cleaning process called Acidization.

    Acidization involves handling of anhydrous Hcl and is thus deemed to be hazardous.


    Additionally, once acid is introduced in any circuit, it is possible that small portion of it remains
    locally in the piping loop rendering it a potential source of failure due to corrosion.
    Importantly, this may happen, despite very close monitoring during Acidization. While during
    the first-time commissioning, there is hardly any way to avoid this process, subsequent
    requirements during outage of such units can very well be eliminated. Good news is that the
    evolved process is safe, reliable and effective too.

    Subsequent requirement can come only if some repair/ replacement of equipment in the
    Reactor piping loop becomes necessary. In such eventuality, it is important to ensure that the
    equipment/ part of the circuit is effectively isolated from rest of the plant. While the plant
    except where work is required to be done, will be under inert atmosphere, the opened part
    will be exposed to atmosphere in a restricted manner.

    Let us take an example: Suppose Reactor Steam Heater (Reboiler) of an ISOM unit is to be
    repaired during outage of the unit (tube bundle replacement). This circuit falls under acidizing
    loop. Moisture/ rust particles will get generated once opened to atmosphere. Once the
    Reboiler is taken out of service isolation has to be done under positive Nitrogen pressure.
    At no point of time, the Reboiler shell side (connected to the Reactor) pressure shall be lower
    than tube side pressure. Shell side body to be spaded after bundle removal for preventing
    exposure to atmosphere. During retubing, cleanliness of the external part shall be ensured to
    minimise rust formation. After retubing, the assembly to be well preserved under inert
    condition wrapped up in polythene cover with Silica gel. Pneumatic test (with Nitrogen as
    fluid) shall be carried out rather than conventional hydrotest. All these will ensure
    that moisture, rust etc. are eliminated in the first place and thus the requirement of
    Acidization gets completely eliminated. Post box up of the equipment under inert condition,
    naphtha circulation to be resorted to, till the time the desired specification of Fe is reported
    in naphtha sample.

    For subsequent start-up of such unit post commissioning, following the above procedure in
    lieu of Acidization gives immense benefit. They are:
    1. Eliminate handling of hazardous Anhydrous Hcl
    2. Possibility of localised corrosion borne out of acid settling at any point in the piping
    loop
    3. Start-up time can be reduced substantially. For a 15Kbpsd ISOM unit start-up time can
    be reduced up to 4 days.

    Following the above procedure in lieu of Acidization, proved to be extremely beneficial in one
    of the high performing Indian Refinery.

    To summarise, one has to be circumspect about the methodology to be used for ensuring all
    process requirements are met. Safe and effective methodology are priorities and for that
    alternatives are to be dug out. That is the trigger point for safer and efficient operation and
    maintenance activity.

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