Smart non-stop oil exchanger cleaning: CIP pilot in Gachsaran
Why is CIP essential for oilfields?
In challenging operating environments such as the oilfields of the south, every minute of downtime is costly. Traditional cleaning of exchangers requires disassembly, time-consuming operations, and safety risks. In contrast, Cleaning In Place (CIP) offers the following benefits:
- Performing cleaning without opening the equipment
- Significantly reducing downtime
- Increased equipment reliability
- Saving maintenance and repair costs
- Maintaining stability in oil production
First successful CIP pilot in the oilfields of the south
In the Gachsaran Desalination Unit No. 2, for the first time in southern Iran, CIP was successfully implemented on an oil-to-oil heat exchanger. This project was carried out with the technical cooperation of Abrizan Industrial Research Company and using specialized chemical solutions of the “Mitreh” brand.
The technical results were remarkable:
- Reduction of ΔP (pressure drop) from 4.5 bar to 0.5 bar
- Measurable improvement in heat transfer
- Maintaining the metallic integrity of the equipment without corrosion
What factors made this success possible?
This project was not just a chemical operation, but the result of a combination of in-house technical knowledge, smart chemicals and careful operational planning:
- Design of a custom formulation based on the composition of the deposits identified in the laboratory
- Use of Mitreh anti-scalers and descalers with high solubility in oil environments
- Close cooperation between the operations, maintenance and engineering units
- Continuous monitoring of process parameters during operation
According to the CEO of Gachsaran Oil and Gas Production Company, “This pilot is an effective step towards smart maintenance of equipment and strengthening internal capacity.”
Can CIP be extended to other units?
Yes. The success of this pilot showed that the CIP method, with appropriate technical adjustments, can be implemented in other process units in the oil-rich southern regions — including boilers, water injection systems, and other heat exchangers. This approach is especially valuable in units where operational downtime entails high costs.
How to implement CIP for your equipment?
Successful CIP implementation requires four key steps:
1. Sampling and laboratory analysis of sediments (by aquaponics specialists)
2. Selection of the optimal chemical formulation (appropriate to the type of sediment and equipment material)
3. Design of an operational scenario without disrupting the main process
4. Controlled implementation and monitoring of results in real time
Mitreh’s chemical solutions for CIP include acid/alkaline descalers, post-corrosion inhibitors, and targeted co-solvents that are compatible with oil and gas industry standards.
Conclusion: From downtime to productivity
The successful implementation of CIP in Gachsaran was not just a project, but a model for the future of smart maintenance of industrial equipment in Iran. By using customized solutions from Abrizan and Mitre chemicals, you can increase the efficiency of your equipment and protect its useful life without stopping the unit.
If you need expert advice to identify the type of scale or the optimal selection of chemicals, Abrizan company specialists with more than 20 years of experience in advanced laboratories are ready to provide customized solutions to various industries.
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Physical and chemical descaling methods
In industries such as oil, gas and petrochemical, there is always an attempt to prevent the formation of deposits using different methods in equipment such as heat exchangers and boilers. In this field, a lot of money is spent on chemical materials and additives. But most industrial heat exchangers are exposed to sedimentation due to various reasons such as the low quality of water in different areas. These deposits are mostly formed in the pipes of the converters. In order to reduce the losses caused by sedimentation, the converter must be continuously monitored and cleaned.
Sediment formation in boilers
Boiler feed water should be free of hardness. Sometimes, due to the short or improper operation of the hardness device or the failure to regenerate the resins in time, some hardness enters the boiler feed water. Increasing the water temperature in the boiler reduces the solubility of water solutes. The water near the hot surfaces becomes saturated and the conditions for deposition of less soluble substances are provided and eventually sediment is formed.
Remove the sediment solution Mitreh
Mitreh is a superior solution for dealing with scale in various industries. Mitreh scale removal solution, a revolutionary product from Abrizan Industrial Research Company, is an efficient alternative to traditional scale removal methods. This product offers a comprehensive solution to the scale problem in various industries by overcoming the limitations of existing physical and chemical methods.
Coastal freshwater sediment removal (MED)
One of the methods of producing fresh water for industrial use is the use of multi-stage thermal desalination plants to desalinate seawater. Due to the high content of soluble and insoluble compounds in seawater and the high temperature shock in desalination packages, sedimentation in these packages is unavoidable. For this reason, periodic sediment removal from desalination plants should be performed.
Sediment and problems caused by it in facilities
When water is used as a thermal fluid, the salts and hardness in the water are separated due to the temperature shock and settle on the surfaces, forming deposits. These deposits are one of the most important factors of erosion and corrosion in heating and cooling installations.
Methods to prevent sediment formation
The most important method for preventing sediment formation is to improve the quality of water used in various industries. This method is carried out in various forms such as sedimentation, filtration, deaeration, degreasing, using the under-water rinsing method, and softening the water used.
Descaling of marine equipment
Marine equipment deposits, which are mostly calcium and magnesium, act as an insulator between the metal surface and the water and cause the metal temperature to increase, resulting in reduced engine cooling. Marine equipment descaling plays a significant role in reducing costs, including fuel consumption, equipment maintenance, washing, etc.
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