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Power and Sugar Plant Layup

August 26, 2011


Sugar, Power and fertilizer plants undergo planned shutdown every year for the purpose of maintenance.

There may be several reason why some equipments in Power Plants/Refineries or the whole unit has to be idled or shutdown temporarily or for extended period viz:

  • For maintenance or repair
  • Due to excess capacity
  • As standby in case of breakdown
  • Partial shut down due to excess capacity
  • Hold until start up
  • Extended cold standby(ECS)

All equipment, when not in operation, must be preserved in the ‘As Left’ condition till there is a

need to activate them. When needed, they should be capable of going ‘On-Line’ immediately.

The equipments begin to rust and corrode while in storage or during plant layup or even when in operation due to excess moisture presence in the air.

Moisture accelerates the rate of corrosion leading to :

  • Deterioration & decrease in life of parts and components.
  • Malfunctioning of equipments.

Rate of corrosion accelerates, when Relative Humidity crosses the critical level of 40%.Above this level industrial pollutants, like sulphur-di-oxide also enhances the corrosion rate as  corrosion is faster when surfaces are exposed to polluted air in combination with high relative humidity.

General Recommendation:

During shutdown Relative Humidity should be maintained at 15%-30% RH at 24ºC (75ºF) and during operation at less than 35% RH at ambient temperature to minimize the loss due to corrosion.

TDS Solution:

TDS plant layup services is meant to protect expensive equipments like Turbines, Chillers, Power Generators, Boilers, navigation rooms, Condensers & Panels etc. from corrosion through dehumification.

Prevention from corrosion damage through dehumidification:

Dehumidification involves drying the air by removing undesired moisture. Removal of moisture from the storage area lowers the relative humidity of the area, effectively arresting corrosion and microbial growth. During equipment storage proper dehumidification, ensures minimum deterioration of all internal systems.

Power plants idled for maintenance or repair can be effectively protected from corrosion, by blowing dry-air through the steam side as well the generator winding.

Dehumidified air keeps components such as boilers, condensers, turbines, rust free when the plant is shut down. In certain cases shutdown can go on for a whole year.

In case of fossil fuel power station, layup can be due to furnace or boiler repair or less expensive power becoming available, from alternate source, During such periods – a flow of dry-air in the facility prevents rusting and other harmful moisture related problem.

TDS application finds great usage in hydel power plants. Dehumidification services are used for equipment storage even when the plant is under construction and also during annual shutdown.

TDS provides desiccant based dehumidifiers, which offers ideal solution to moisture/ humidity control during storage. This helps in preventing costly repairs and emergency outage. Along with dehumidifiers TDS provides condensing unit, blower, ducts and skilled manpower for services on RENT.

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