Saep 1026

Engineering Procedure
SAEP-1026 31 December 2016

Lay-Up and Preservation of Steam Generation Systems
Document Responsibility: Corrosion Control Standards Committee
Contents
1 Scope ................................................................ 2
2 Conflicts and Deviations .................................... 2
3 Applicable Documents ....................................... 2
4 Definitions and Abbreviations ............................ 4
5 Roles and Responsibilities ................................. 4
6 Selection of a Lay-Up Procedure ....................... 6
7 Short-Term Lay-Up ............................................ 8
8 Steam Lay-Up .................................................... 8
9 Wet Lay-Up ...................................................... 11
10 Dry Lay-Up....................................................... 13
11 Preservation..................................................... 15
12 Fire-Side Lay-Up .............................................. 16
13 Safety Precautions ........................................... 18
Revision Summary .................................................. 19
Appendix A –Lay-Up Decision-Tree ........................ 20
Previous Issue: 18 June 2015 Next Planned Update: 31 December 2019

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Contact: Debruyn, Hendrik Johannes (debruyhj) on phone +966-13-8800402
©Saudi Aramco 2016. All rights reserved.

Document Responsibility: Corrosion Control Standards Committee SAEP-1026
Issue Date: 31 December 2016
Next Planned Update: 31 December 2019 Lay-Up and Preservation of Steam Generation Systems
1 Scope
1.1 This procedure provides the minimum requirements for lay-up and preservation
(mothballing) of steam generation systems (fired boilers, water-tube boilers, fire-
tube boilers, waste heat boilers, and heat recovery steam generators). It covers
both new steam generating systems and existing steam generating systems.
1.2 This procedure aims to avoid or minimize the potential of corrosion damage,
i.e., oxygen pitting, corrosion fatigue, and/or under-deposit corrosion, associated
with idle steam generation systems. The intent is to minimize corrosion when
these systems are off stream for longer than 24 hours.
1.3 Auxiliaries in the preboiler water circuit (dearators, pumps, piping, valves, etc.)
shall be included in the lay-up scope of work covered by these procedures.
1.4 Any other equipment and piping, for example condensers and associated piping
in power plants, that can transport corrosion products into the boiler/steam
generator, or that could allow oxygen ingress into the boiler/steam generator
during start-up, shall also be included in the lay-up scope of work covered by
these procedures.
1.5 The steam header, critical piping, and equipment in utility steam generating
systems shall be laid up using SAES-A-007.
2 Conflicts and Deviations
2.1 Any conflicts between this Procedure and other applicable Saudi Aramco
Engineering Procedures (SAEPs), Saudi Aramco Engineering Standards
(SAESs), Saudi Aramco Materials System Specifications (SAMSSs), Saudi
Aramco Standard Drawings (SASDs), or industry standards, codes, and forms
shall be resolved in writing by the Company or Buyer Representative through
the Manager, Consulting Services Department of Saudi Aramco, Dhahran.
2.2 Direct all requests to deviate from this Procedure in writing to the Company or
Buyer Representative, who shall follow internal company procedure SAEP-302
and forward such requests to the Manager, Consulting Services Department of
Saudi Aramco, Dhahran.
3 Applicable Documents
The equipment lay-up and preservation covered by this procedure shall comply with all
Saudi Aramco Mandatory Engineering Requirements and industry codes and standards,
with particular emphasis on the documents listed below. Unless otherwise stated, the
most recent edition of each document shall be used.
Saudi Aramco: Company General Use
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3.1 Saudi Aramco References
Saudi Aramco Engineering Procedures

SAEP-302 Instructions for Obtaining a Waiver of a Mandatory
Saudi Aramco Engineering Requirement
SAEP-327 Disposal of Wastewater from Cleaning, Flushing,
and Dewatering Pipelines and Vessels
SAEP-1025 Chemical Cleaning of Steam Generation Systems
SAEP-1150 Inspection Requirements on Projects
Saudi Aramco Engineering Standards

SAES-A-004 General Requirements for Pressure Testing
SAES-A-007 Hydrostatic Testing Hydrostatic Testing Fluids and
Lay-Up Requirements
SAES-A-103 Discharges to the Marine Environment
SAES-A-210 Management of Pyrophoric Wastes
SAES-B-008 Restrictions to Use of Cellars, Pits, and Trenches
SAES-B-069 Emergency Eyewashes and Showers
Saudi Aramco General Instructions

GI-0002.100 Work Permit System
GI-0150.100 Hazardous Materials Communication (HazCom)
Program
Saudi Aramco Hazardous Waste Code (SAHWC)
Saudi Aramco Safety Management Guide

06-003-2013 Job Safety Analysis
Saudi Aramco Form

SA-924-4 Confined Space Entry
3.2 Industry Codes and Standards
American Society of Mechanical Engineers Boiler and Pressure Vessel Codes

ASME SEC VII Recommended Guidelines for the Care of Power
Boilers

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Electric Power Research Institute (EPRI)

TR 1004187 Cycle Chemistry Guidelines for Fossil Plants:
All-Volatile Treatment
TR 1004188 Cycle Chemistry Guidelines for Fossil Plants:
Phosphate Continuum and Caustic Treatment
4 Definitions and Abbreviations
All-ferrous Metallurgy: Steam generating circuit where all the equipment, piping, and
heat exchangers/condensers are constructed in carbon or low-alloy steel.
Blend-filling: A method of filling a vessel with chemical solution in which the

chemical concentrate (in liquid form) is metered into the filling line to maintain the
desired concentration level in the liquid entering the vessel.
Condensate: Water having a conductivity of less than 10 µS/cm.

DEHA: Diethyl Hydroxyl Amine
Hygroscopic: The phenomenon of attracting and holding water molecules from the
surrounding environment through either absorption or adsorption.
Inhibitor: A compound that retards or stops an undesired chemical reaction such as

corrosion or oxidation.
Lay-up: Preservation of a system, or equipment, for later use.

Mixed Metallurgy: Steam generating circuit where the equipment, piping, and heat
exchangers/condensers are constructed in a combination of carbon or low-alloy steel as
well as copper-base alloys.
QA & QC: Quality Assurance and Quality Control
VOS: Volatile Oxygen Scavenger
VPCI: Vapor Phase Corrosion Inhibitor
Water Wedged: Water overflowing vents.
5 Roles and Responsibilities
5.1 Project Management Team (PMT)
For new construction, PMT shall be responsible to:
5.1.1 Ensure the implementation of this standard and compliance with all

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requirements.
5.1.2 Facilitate and resolve any issues related to the implementation of these
procedures with other Saudi Aramco organizations.
5.2 Construction Agency
For new constructions, the Construction Agency shall be responsible to:
5.2.1 Ensure the implementation of this standard and compliance with all
requirements.
5.2.3 Provide all resources and materials required to implement these lay-up
procedures.
5.2.4 Implement, monitor, and conduct proper checks/tests for each lay-up
activity.
5.2.5 Regularly report all lay-up testing results to PMT.
5.2.7 Provide all records to PMT for each lay-up activity and shall be included
in the Project Records turnover to PMT at the end of the project.
5.3 Approval Authority (Proponent)
The lay-up procedures shall be approved by the Saudi Aramco Engineering

Superintendent (Proponent) or his designate.
Commentary Note:
Facility Corrosion Engineer should be involved in the review process to ensure

meeting the standard and facility requirement.
5.4 Inspection Authority
5.4.1 For new constructions, the responsible Projects Inspection Division

(PID), Inspection Department (ID), shall be the monitoring authority.
Complete list of responsibilities are provided in SAEP-1150.
5.4.2 For existing facilities, the proponent's Operations Inspection Units shall
be the authority monitoring the execution of the lay-up activities
according to these procedures.
5.5 Facility Operations
For existing facilities, the Plant Operations Foreman shall be responsible for
executing and adhering to these lay-up procedures.

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5.6 Facility Engineering
For existing facilities, Plant Engineering Supervisor shall recommend the

procedures to be used for the lay-up, and provide assistance to the Facility
Operations during lay-up activities.
5.7 Facility Maintenance
For existing facilities, Plant Maintenance Foreman shall provide the materials
necessary and personnel to perform the lay-up and/or preservation procedures(s).
5.8 Consulting Services Department (CSD)
5.8.1 CSD shall provide clarification, consultation, and technical support, as

needed, for the general requirement of this standard.
5.8.2 CSD shall only review and approve lay-up methods not specifically
discussed in this standard.
6 Selection of a Lay-Up Procedure
6.1 Both the water-side, and the fire-side of steam generating equipment shall be
protected against corrosion damage during idle periods. Refer to the decision-
tree diagram provided in Appendix A to guide the selection of the correct lay-up
procedure.
6.2 Short-Term Lay-Up
6.2.1 Short-term lay-up shall be performed if the steam generating system is

taken out of service for longer than 24 hours and will return to service
within 7 days. In these cases, as recommended in ASME SEC VII, no
major changes are required from normal operating conditions, with the
exception that the equipment shall be protected from air ingress.
6.2.2 Alternatively, if 103 - 413 kPa (15 - 60 psig) steam from an external
source is available, such steam can be continuously circulated inside the
idle boiler to keep all metal surfaces hot above the dew point.
6.2.3 The fire-side of the steam generating system shall also be protected
against corrosion. The fire-side lay-up shall ensure that the steam
generating system can be returned to service within 24 hours.
6.3 Intermediate and Long-Term Lay-Up
One of the following two methods shall be used to protect the water-side of the
steam generating equipment during intermediate lay-up (1 to 4 weeks) and long-
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term lay-up (1 to 6 months).
6.3.1 Wet lay-up

a) For all-ferrous metallurgy systems, wet lay-up shall be conducted
by filling most of the system with an alkaline solution with the pH
controlled between 9.2 and 9.6 (see EPRI TR 1004187 and
TR 1004188). Nitrogen pressurized up to at least 35 kPa (5 psig)
shall be used to prevent air ingress.
The use of wet lay-up in equipment with all-ferrous feed water
systems on oxygenated all-volatile treatment, AVT(O), should
generally be restricted to short-term protection. Extended wet lay-
up without a reducing agent could lead to pitting unless the
equipment is reliably capped with nitrogen and there is a means of
circulating the solution.
b) In mixed-metallurgy systems, wet lay-up shall be conducted by
filling the steam generating system with an alkaline reducing
solution (ammonia and hydrazine). Nitrogen pressurized up to at
least 35 kPa (5 psig) shall be used to prevent air ingress.
c) For units containing copper alloys, the pH of the feed water shall be
limited to 9.0 to 9.3. Higher pH values (> 9.3) would increase the
solubility of copper oxides.
6.3.2 Dry Lay-Up
Dry lay-up shall require draining all water from the boiler system while
hot, removal of all water, followed by pressurization with a moisture-free
inert gas or dehumidified air with a dew point of -1°C (30°F) at 35 kPa
(5 psig). The aim is to maintain a low-moisture environment in the
boiler system.
6.4 Preservation (Mothballing)
Preservation (mothballing) of a steam generating system shall be implemented

when the shutdown period is expected to exceed 6 months. This procedure
involves distributing a vapor phase corrosion inhibitor (VPCI) through the dried
boiler system, and then filling the system with nitrogen to at least 35 kPa (5 psig).
6.5 Fire-side Lay-Up
The fire-side lay-up procedure shall be used when the water-side of a steam
generating system is laid up using wet/dry lay-up or placed into long-term
preservation. The intent is to maintain external surfaces dry and clean.

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Sulfur-containing fuels can produce ash deposits that are acidic in nature and
can corrode boiler system surfaces on the fire-side. Such deposits are often
hygroscopic and when condensation takes place, low pH conditions can occur.
7 Short-Term Lay-Up
7.1 Ensure that the feed water chemistry is maintained at recommended parameters
before shutting the steam generating system down.
7.2 Supply nitrogen at all vents before the system pressure falls to zero as the steam
generating system is coming off line. Ensure that air ingress do not occur.
7.3 If the steam generating system pressure falls to zero before nitrogen can be
introduced, the steam generating system shall be fired again to re-establish
pressure. The superheaters and reheaters shall be thoroughly vented to remove
air before nitrogen is introduced.
7.4 All partly filled steam drums and superheater and reheater headers shall be
connected in parallel to the nitrogen supply.
7.5 If nitrogen can only be supplied to the steam drums, the nitrogen pressure shall
be higher than the hydrostatic head of the longest vertical column of condensate
that could be produced in the superheater.
8 Steam Lay-Up
8.1 Steam lay-up protects both the water-side, and the fire-side of the steam
generating system from corrosion. Ensure that the system can be returned to
service within 24 hours. For long term lay-up of economizers, see Sections 10
and 11.
8.2 Procedure
1. Shut down the steam generating system.
2. Inspect the system water-side and the fire-side.
3. If any deposits are present on the fire-side, neutralize, clean, and dry per
SAEP-1025, Section 11.
4. Size, and fabricate a suitable condensate collector (see Appendix C).
5. Ensure that the lower water wall header drains, superheater header drains,
and mud drum drains are connected to the condensate collection header.
6. Ensure that the condensate collection header is equipped with a suitable
level gauge, a pressure gauge, a sample point, a dial thermometer, and a
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steam trap. The steam trap shall be equipped with a by-pass line, and a
drain to sewer.
7. Size, and select steam traps to ensure complete removal of condensate from
the steam generating system. Connect the steam trap to the condensate
return system at a suitable location, as close to the steam generating
equipment as possible.
8. If a condensate collector is not used, then install steam traps, and bypasses
at each drain point.
9. Connect the steam supply line to the superheater outlet header at its
connection to the flash drum (knock-out drum).
10. For steam generating systems not equipped with superheaters, and equipped
with more than one safety relief valve, remove one safety relief valve, and
introduce the steam supply directly into the steam drum through a temporary
connection.
11. For steam generating systems not equipped with superheaters, and equipped
with only one safety relief valve, install a temporary Tee connection.
Install the safety relief valve at the vertical flanged, or screw connection.
Introduce the steam into the boiler through the horizontal flanged, or screw
connection. Installing a Tee to the boiler steam drum vent to inject steam is
also acceptable.
12. Provide vents at suitable points to remove gases. If the steam generating
system is not equipped with vents to atmosphere from the upper water wall
headers, remove one hand-hole plug from each header, and install a
temporary vent pipe and valve. Provide the upper water wall headers, and
the steam drum vents with reducers, and install 0.25", or 0.375" stainless
steel tubing for venting.
13. Provide temporary drains for lower water wall headers with no drains.
Remove a hand-hole plug (usually a screw plug on the lower part of the
header), and weld a suitable diameter pipe into it. Connect the pipe to a
steam trap, or condensate collector.
14. Provide temporary vents and valves for upper water wall headers not
provided with vents.
15. Close forced draft/induced draft fan inlet vanes, and seal the exhaust duct.
16. If the steam generating system is expected to be down for more than
3 months, inspect, repair, and clean the inside of all duct work, and the
stack. For long-term lay-up of economizers, see Section 10.

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17. Install a heavy duty waterproof cover on the stack, with a suitable ridge
arrangement to drain condensed water.
18. After completing all preparations, admit steam into the system. To avoid
thermal shock, control the entry of steam to raise the metal temperature
< 38°C per hour, until the temperature is stabilized.
19. After all produced condensate is removed from the lowest parts of the
steam generating equipment, raise the steam pressure to 171 kPa (25 psig).
Open the vents, and release pressure to purge all the air from the system.
Repeat this three times. Close the vents, and increase the steam pressure to
105 - 415 kPa (15 - 60 psig).
20. Examine and repair steam leaks at all temporary, and permanent
connections.
21. Regulate the pressure in the system for a minimum temperature of 100°C at
the lowest point, i.e., the condensate collector, or steam trap inlets. For steam
generating systems which have superheaters without drains to remove water,
maintain a minimum temperature of 120°C at the lowest point of the system,
or at the condensate collector.
8.3 Steam Generating System Maintenance during Steam Lay-Up

1. Analyze steam trap discharges periodically, for pH > 8.5, and conductivity
< 10 µS/cm, and if acceptable, connect into a collection header to the
existing condensate return system. If not acceptable, discard the condensate
into the sewer.
2. Request the laboratory to determine the oxygen content of the condensate
samples, daily for seven days. If the oxygen levels are higher than 20 ppb,
adjust the steam drum, and upper water wall header vents to remove the O2
and CO2. If necessary, add sufficient volatile oxygen scavenger (VOS) to
the steam source.
3. If the O2, and CO2 levels are at < 20 ppb, reduce sampling of the
condensate to once per week.
4. Ensure that a suitable water level is maintained in the condensate collector.
When a condensate collector is not used, examine steam traps at regular
intervals. Use drains installed to the steam trap system to prove that
condensate is not collecting in the lower headers, or mud drum.
5. In the event of a plant, or system failure resulting in the loss of steam
supply to the boiler, shut off steam inlet to the boiler. Once the steam
supply becomes stable, proceed as outlined in steps 18 to 21 of Section 8.2.

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6. During steam lay-up, keep the relief valve maintenance up to date, to enable
quick start up.
8.4 Before Returning the Steam Generating System to Service after Steam Lay-up
1. Shut off the steam supply to the steam generating system.
2. Allow the steam pressure to decay to 69 kPa (10 psig).
3. Open the steam drum vents to atmosphere.
4. Open the valve connecting the superheater to the flash drum (knock-out
drum).
5. Close all lower water wall header drain valves and mud drum drain valves.
6. When the pressure in the system is at zero gauge, isolate and disconnect the
steam supply.
7. Remove the temporary safety relief valve connections, and install the
permanent safety relief valves.
8. Remove all temporary upper, and lower water wall header drains, and
vents. Replace hand-hole plugs previously removed.
9. Remove the cover from the stack, and temporary seals used during the
lay-up period.
10. Ensure the safety relief valve maintenance is up to date, the steam
generating system hydrostatic test is complete (if applicable), the system
examinations are satisfactory, and that any auxiliaries and instrumentation
are operable.
11. Fill the steam generating system with clean condensate, and perform a
pressure test per SAES-A-004.
12. Drain the system to normal operating level.
13. Prepare the system for firing.
14. Test the steam generating system safety relief valves under steam pressure
before the system is placed in service at full operating pressure.
9 Wet Lay-Up
9.1 If this procedure is used for long term lay-up note that occasional firing may be
required (see paragraph 9.4.3 below).
9.2 Wet lay-up should only be used if the steam generating system has been
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designed with an external circulation system, and the water in the system can be
circulated using this.
9.3 Procedure
1. Drain the steam generating system and carry out all essential repairs.
2. Connect a nitrogen supply to the highest vent on the system.
3. Fill the steam generating system with condensate and inject an approved
oxygen scavenger (see Appendix D) to maintain residual concentrations of
200 mg/l to 400 mg/l. Use sulfites (sodium or ammonium) only for steam
generating system operating below 5170 kPa (750 psig) that have
superheaters with drains. Add morpholine, or morpholine plus
cyclohexylamine to adjust the pH between 10.0 and 11.0.
4. Shut off the water supply when it overflows from the steam drum, the
superheater inlet, and the outlet header vents, and a pressure of 35 kPa
(5 psig) is attained in the steam drum.
5. Maintain a positive pressure of at least 35 kPa (5 psig) in the system using
nitrogen.
9.4 Steam Generating System Maintenance during Wet Lay-up

1. Install an appropriate calibrated pressure gauge and ensure at least once a
day that the system pressure gauge reads >35 kPa (5 psig).
2. Take samples from the continuous blowdown line at least once a week.
Check the concentration of oxygen scavenger and the pH.
3. If the pH is not within the range of 10.0 to 11.5, and/or the concentration of
oxygen scavenger < 200 mg/L, drain sufficient volume and add the required
amount of dissolved chemicals. Open the vent and fire the pilot burners
until the water is heated to 60 - 70°C (140 - 160°F).
4. After cooling, introduce water and shut off the water supply when it
overflows from the steam drum, the superheater inlet, and the outlet header
vents, and a pressure of 35 kPa (5 psig) is attained in the steam drum.
5. Maintain a positive pressure (> 35 kPa/5 psig) in the system using nitrogen.
6. Circulate the system water once every two weeks for one hour.
9.5 Before Placing the Steam Generating System back in Service after Wet Lay-up
1. Relieve pressure.
2. Open the drum vents.
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3. Remove blinds in blowdown and drain lines.

4. Drain the system.
5. Drain the superheater section, and rinse with condensate, until the
conductivity of the water out of the superheater is within 10% of the
conductivity of the condensate being introduced to the steam generating
system.
6. Open the steam drum, mud drum, and all water wall headers, including
superheaters where installed.
7. Water flush with condensate and vent the steam generating system.
8. Ensure that the safety relief valve maintenance schedules are up to date,
the any hydrostatic testing is complete, the steam generating system
examinations are satisfactory, and that the system auxiliaries and
instrumentation are operable.
9. Fill the steam generating system with clean condensate and complete a
pressure test per SAES-A-004.
10. Drain the system to normal operating level.
11. Prepare and fire the steam generating equipment.
12. Test system safety relief valves under steam pressure before the steam
generating system is placed in service at full operating pressure.
13. Disposal of all wastewater shall be in accordance with SAEP-327.
10 Dry Lay-Up
10.1 Implement dry lay-up procedure if the steam generating system is to be laid up
for more than 3 months but less than 6 months.
10.2 Neutralize and clean the external fins of the economizers and then use the
procedure below. Note that the external fins of economizers can be efficiently
cleaned using CO2 pellet blast cleaning.
10.3 Procedure
1. Disconnect the steam generating system from load and fuel supply.
2. Drain the system under pressure to 138 - 172 kPa (20 - 25 psig).
3. Remove all water in the low areas of the steam and the mud drums
manually. Dry the steam generator, economizer, and the superheaters using

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hot air blowers, until there is no water visible and the relative humidity
(RH) inside the system is below 40%.
4. Install a suitable hygrometer to monitor the RH inside the system from the
outside.
5. Pressurize all wetted parts of the system with nitrogen to 35 kPa (5 psig).
6. Maintain a small flow of nitrogen through the condensers, turbine (if present)
and deaerator.
10.4 Steam Generating System Maintenance during Dry Lay-up

1. Keep the nitrogen line connected to the system.
2. Maintain pressure using a pressure regulator.
3. Check the RH and the nitrogen pressure daily.
4. Install an appropriate calibrated pressure gauge and ensure that the nitrogen
pressure is maintained at 35 kPa (5 psig).
5. Check for leaks, and eliminate these. Introduce nitrogen as required to
maintain the pressure above 35 kPa (5 psig).
4. Check the RH during the night, and in the winter months. Ensure that the
RH is below 40%. If not open, vent and introduce nitrogen to displace the
moisture until the RH is below 40%.
10.5 Before Placing the Steam Generating System back in Service after Dry Lay-up
1. Disconnect the nitrogen supply and open all system vents.
2. Remove temporary seals used during the lay-up period.
3. Ensure that safety relief valve maintenance schedules are up to date,
any hydrostatic testing is complete, system examinations are satisfactory,
and the system auxiliaries and instrumentation are operable.
4. Fill boiler with clean condensate and perform a pressure test per
SAES-A-004.
5. Upon satisfactory of the pressure test, drain the system to normal operating
level.
6. Prepare and fire the steam generator.
7. Test the system safety relief valves under steam pressure before the steam

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11 Preservation
11.1 Implement the preservation procedure if the steam generating system is to be

laid up for more than 6 months.
11.2 Neutralize and clean the external fins of the economizers and then use the
procedure below. Note that the external fins of economizers can be efficiently
cleaned using CO2 pellet blast cleaning.
11.3 Procedure
1. Disconnect the system from load and fuel supply.
2. Drain the boiler under pressure to 138 - 172 kPa (20 - 25 psig).
3. Remove all water in the low areas of the steam and the mud drums
manually. Dry the boiler, economizer, and the superheaters using hot air
blowers, until there is no water visible and the relative humidity (RH),
inside the boiler is below 40%.
4. Install a suitable hygrometer to monitor the RH inside the system from the
outside.
5. Apply vapor phase corrosion inhibitors (VPCI) in dry or aqueous form as
required to cover all internal surfaces of tubes, drums and headers. In dry
form VPCI may be applied by dusting, fogging or sprinkling. In aqueous
form VPCI may be applied by spray, brush, flushing or immersion.
6. For the internal surface of tubes and drum/headers with internal access, it is
preferable to apply VPCI in aqueous form, i.e., by flushing through the
equipment of by immersion. Use dicyclohexyl ammonium nitrate based
vapor phase corrosion inhibitors that are silicon-free (dee Appendix B).
Wear personal protection equipment and apply VPCI per manufacturer's
recommendations.
7. Close all openings except one small vent. Slowly displace the air inside the
steam generating system and the economizer with nitrogen. Monitor the
oxygen content and when it is displaced with nitrogen, close the vent and
maintain a nitrogen pressure of at least 35 kPa (5 psig). Post a notice
adjacent to each boiler access point stating that the boiler is under nitrogen
blanket.
8. Replace the VPCI every two years or as per manufacturer's recommendations.
11.4 Steam Generating System Maintenance while under Preservation

1. Keep the nitrogen line connected to the system.

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2. Maintain pressure using a pressure regulator.

3. Check the RH and the nitrogen pressure weekly.
4. Install an appropriately calibrated pressure gauge and ensure that the
nitrogen pressure is maintained at 35 kPa (5 psig).
5. Check for leaks, and eliminate these. Introduce nitrogen as required to
maintain the pressure to at least 35 kPa (5 psig).
6. Check the RH during the night and in the winter months. Ensure that the
RH is below 40%. If not open the vent, and introduce nitrogen to displace
the moisture until the RH is below 40%.
11.5 Before Placing the Steam Generating System back in Service after Preservation
1. Disconnect the nitrogen supply and open all system vents.
2. Flush to remove all traces of the VPCI and inspect the steam generator.
3. Chemically clean per SAEP-1025 if necessary.
4. Remove temporary seals used during the lay-up period.
5. Ensure that the safety relief valve maintenance schedules are up to date, any
hydrostatic testing is complete, that the system examinations are
satisfactory, and the system auxiliaries and instrumentation are operable.
6. Fill the system with clean condensate and perform a pressure test per
SAES-A-004.
7. Upon satisfactory pressure test, drain the system to normal operating level.
8. Prepare and fire the steam generator.
9. Test the system safety relief valves under steam pressure before the steam
12 Fire-Side Lay-Up
This procedure is not applicable with steam lay-up. Use only procedure steps 1 to 6 for
short term lay-up, and all the steps, for long term lay-up (longer than 3 months).
12.1 Procedure
1. Install necessary blinds in the main fuel lines, pilot gas line, and isolate the
igniters (if present).
2. Inspect the refractory and the tubes on the fire-side. If any deposit is

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present, neutralize, clean, and dry per SAEP-1025, Section 13. Seal all
refractory, and partially embedded tubes with bitumen.
3. Install new gaskets on all furnace openings, and manholes. Apply a sealing
compound on the gaskets of plate type covers.
4. Close stack blinds, seal the furnace, and cover the forced draft/induced draft
fan air inlet with plastic sheeting film, and tape completely, to prevent any
ingress of air.
5. Seal with plastic sheet, and tape, all inlet and exhaust ducts, observation
ports, and duct manways, to prevent entry of air.
6. Seal burner sight glasses tightly.
7. Dust or spray vapor phase corrosion inhibitor (VPCI) on all the exposed
metal in the fire-side. Use dicyclohexyl ammonium nitrate vapor phase
corrosion inhibitors that do not contain silicon (see Appendix B).
Apply VPCI per manufacturer's recommendations to get corrosion
protection up to 24 months.
8. Place electric heaters inside the firebox, and flue gas duct. Keep the metal
surfaces above ambient temperature to reduce moisture in the system.
Install ammeters outside the firebox to check the operation of the heaters.
9. Install a thermometer to check the temperature of the fire-side from outside.
Ensure that the thermometer entry location is tightly sealed.
10. Make all cable entries into the fire-side air tight.
11. Remove burners, clean, preserve with vapor phase corrosion inhibitor
(see Appendix B) and seal these.
12. Inspect, repair, and clean the inside of all duct work, and the stack. Dust, or
spray VPCI on all the exposed metal. Install a heavy duty waterproof cover
on the stack, with a suitable ridge arrangement to drain condensed water.
12.2 Maintenance during the Lay-up

1. Ensure that the temperature inside the fire-side is above the ambient.
2. Visually inspect after one month all the sealing used to isolate the fire-side
atmosphere. Correct any deficiencies. If conditions are satisfactory, then
extend the frequency of inspection to every three months, and then to every
six months.
3. Reapply the VPCI every two years or per manufacturer's recommendations.

Page 17 of 23
12.3 Before Placing the Steam Generating System back in Service after Preservation
1. Blow air through the fire-side to remove all traces of VPCI.
2. Chemically clean per SAEP-1025 if necessary.
3. Remove all temporary seals used during the lay-up period.
13 Safety Precautions
13.1 Consult LPD to provide safety consultations, audits, and to inspect the
operations, as necessary, to ensure compliance to company safety requirements.
13.2 All work shall be undertaken using work permits as governed by Saudi Aramco
GI-0002.100. Perform a job safety analysis (JSA), as per Saudi Aramco Safety
Management Guide #06-003-2013, for all lay-up or preservation activities to
ensure that hazards are identified and mitigated.
13.3 Protective clothing, respirator, and goggles should be worn during vessel entry
to avoid contact of lay-up chemicals with the skin, or eye; inhalation, or oral
ingestion.
13.4 Appropriate personal protective equipment shall be used when using nitrogen.
While nitrogen is not toxic, it displaces breathable air in confined spaces, as
defined in SAES-B-008, such as pipe trenches, vessel skirts, or vessels that can
lead to suffocation. Also, cryogenic nitrogen is harmful to personnel and all
skin contact shall be avoided.
13.5 Ensure that all nitrogen cylinders are in the upright position, firmly supported,
and that they have individual regulators. Also, install a safety relief valve to the
manifold to which the nitrogen cylinders are attached.
13.6 Follow procedures outlined in the Chemical Hazard Bulletins and Hazardous
Materials Communications Program (HazCom) labeling per GI-0150.100
provided by the Environmental Compliance Division, EPD, for handling,
storage, and mixing of the chemicals to be used for hydrostatic test water
treatment.
13.7 Blind fuel gas and pilot gas lines. Isolate igniters and do not enter the fire-side
until a CONFINED SPACE ENTRY (Form SA-924-4) permit is issued.
13.8 Disposal of all lay-up water shall be in accordance with the requirements of
SAEP-327, SAES-A-103, and the Saudi Aramco Hazardous Waste Code
(SAHWC). Disposal plans shall be part of all lay-up procedures.
13.9 Provide an eyewash station and emergency shower per SAES-B-069 at the
mixing site of the chemicals.
Page 18 of 23
13.10 Caution shall be taken in situations where pyrophoric iron sulfide, as defined by
SAES-A-210, might be present. Also, personnel shall not be exposed to fluids
containing hydrogen sulfide levels that will result in 10 ppmw in the air.
Refer questions concerning the safety of air and water to the General Supervisor,
Workplace Environment Division, EPD.
Revision Summary
1 November 2011 Revised the "Next Planned Update." Reaffirmed the contents of the document, and reissued
with editorial revision to remove “Brand” Name.
18 June 2015 Editorial revision to change the document responsibility and primary contact person.
31 December 2016 Major revision to ensure that all steam generating equipment are covered.
Amended the scope of this document to cover all steam generating equipment.
Added references to ASME SEC VII and Electric Power Research Institute (EPRI) technical
reports.
Added a section titled “Short-Term Lay-Up” covering a period of more than 24 hours but less
than 7 days.
Added a decision-tree that is based on expected time out of service to facilitate the selection
of the correct lay-up procedure.
Added specific requirements to govern “Wet Lay-Up” based on the metallurgy of the steam
circuit.
Restricted the use of vapor phase corrosion inhibitors (VPCI) to compound that are silicon-
free.

Page 19 of 23
Appendix A - Lay-up Decision-Tree

Page 20 of 23
Appendix B - MSG Numbers of Lay-up Materials
Product Name SAP MM

Adhesive duct tape for sealing openings, securing
1000205777
plastic protective film, etc.
Liquid Ammonia (Ammonium Hydroxide) 1000178423
Catalyzed sodium sulfite liquid 1000186446
Cyclohexylamine plus Morpholine 1000183543
Dicyclohexyl Ammonium Nitrate Powder (VPCI) 1000183807

1000185091
Diethyl Hydroxyl Amine (DEHA)
1000186446
1000062846
Electric heaters 1000062852
1000062880
Film, plastic 4 mil polyethylene film for protection
1000216006
of equipment
Morpholine 1000184683
Nitrogen (cylinder) 1000184763
Soda Ash (Sodium Carbonate) 1000186131

Page 21 of 23
Appendix C - Boiler Drainage under Steam Lay-up

Page 22 of 23
Appendix D - Approved Oxygen Scavengers
Feed ratio
Scavenger Name Formula
scavenger/O by wt.
Carbohydrazide CH6N4O 23
DEHA C4H11NO 3
Hydroquinone C6H6O2 4
Methy Ethyl Ketoxime CH3(NOH) C2H5 5.4
Sodium Sulfite Na2SO3 8
Catalyzed Sodium
Na2SO3 8
Sulfite
Ammonium Bisulfite NH4HSO3 8
Calculation of Oxygen Scavenger Requirement
Use the following steps:

a) Calculate the mass of oxygen in solution.
b) Multiply the mass of oxygen in solution (a) by the feed ratio.
c) Add additional 200 mg/liter in excess.
d) Take into account the concentration of the oxygen scavenger in the supplied chemical.
Example:
How much ammonium bisulfite (45%wt concentration) will be required to treat 10,000 liter of
water containing 8 mg/liter of dissolved oxygen?
[(8 x 10,000 L x 8 mg/L) + 10,000 L x 200 mg/L] / 0.45

(feed ratio x volume x oxygen content) + (volume x residual scavenger concentration) / concentration
= (640,000 mg + 2,000,000 mg) / 0.45
= 5,866,666 mg
This is approximately 6 kg of 45% wt. ammonium bisulfite solution is required.

Page 23 of 23

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What is the purpose and scope of this procedure?

What is the purpose and scope of this procedure?

What are the different types of lay-up procedures covered?

What are the different types of lay-up procedures covered?

Engineering Procedure

SAEP-1026 31 December 2016

Appendix A –Lay-Up Decision-Tree ........................ 20

Previous Issue: 18 June 2015 Next Planned Update: 31 December 2019

©Saudi Aramco 2016. All rights reserved.

2 Conflicts and Deviations

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

Saudi Aramco Engineering Standards

Saudi Aramco General Instructions

Saudi Aramco Hazardous Waste Code (SAHWC)

Saudi Aramco Safety Management Guide

Saudi Aramco Form

3.2 Industry Codes and Standards

American Society of Mechanical Engineers Boiler and Pressure Vessel Codes

Saudi Aramco: Company General Use

Electric Power Research Institute (EPRI)

4 Definitions and Abbreviations

Blend-filling: A method of filling a vessel with chemical solution in which the

Condensate: Water having a conductivity of less than 10 µS/cm.

Inhibitor: A compound that retards or stops an undesired chemical reaction such as

Lay-up: Preservation of a system, or equipment, for later use.

Water Wedged: Water overflowing vents.

5 Roles and Responsibilities

5.1 Project Management Team (PMT)

For new construction, PMT shall be responsible to:

Saudi Aramco: Company General Use

5.2 Construction Agency

For new constructions, the Construction Agency shall be responsible to:

5.2.5 Regularly report all lay-up testing results to PMT.

5.3 Approval Authority (Proponent)

The lay-up procedures shall be approved by the Saudi Aramco Engineering

Facility Corrosion Engineer should be involved in the review process to ensure

5.4 Inspection Authority

5.4.1 For new constructions, the responsible Projects Inspection Division

5.5 Facility Operations

Saudi Aramco: Company General Use

5.6 Facility Engineering

For existing facilities, Plant Engineering Supervisor shall recommend the

5.7 Facility Maintenance

5.8 Consulting Services Department (CSD)

5.8.1 CSD shall provide clarification, consultation, and technical support, as

6 Selection of a Lay-Up Procedure

6.2 Short-Term Lay-Up

6.2.1 Short-term lay-up shall be performed if the steam generating system is

6.3 Intermediate and Long-Term Lay-Up

term lay-up (1 to 6 months).

6.3.1 Wet lay-up

6.3.2 Dry Lay-Up

6.4 Preservation (Mothballing)

Preservation (mothballing) of a steam generating system shall be implemented

6.5 Fire-side Lay-Up

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

8.3 Steam Generating System Maintenance during Steam Lay-Up