Rae Enterprise

Ref :Date:To,
M/s Anand Seamless Tubes Pvt Ltd.
Ahmedabad
Attn :- Mr. Kedar Choksi
Subject :- Audit of Pickling Process at your Works and Investigation of Rusting On
Finned Tubes.
Dear Sir ,
We are pleased to submit herewith the reports for audit of Pickling Process at your works at
Indrad carried out on 05/12 and 06/12.
We hope the reports are useful . Kindly feel free to contact us for any further queries
Thanking You ,

For,
Rae Enterprise
Ashwin Joshi
(Propreitor)

Rae Enterprise
Consultant Surface Coating applications

GF 10,Panchratna,Nr. Parivar Char Rasta ,Waghodia Dabhoi Ring Road,vadodara

3ace 90025
Tel/Fax-+91-265-2521852,Cell-9824231852 , Email-raeenterprise@gmail.com
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Rae Enterprise
FINAL PICKLING PROCESS FOR CARBON STEEL AND
ALLOY STEEL TUBES

SR.NO

PROCESS

REQUIRED
PARAMETERS

OBSERVATION

REMARKS

Pickling of Tubes in
Hydrochloric Acid

HCl + inhibitor +
surfactant in soft
plain water - of
15% 20 %
concentration

SURFACE must
be free from rust.

OK

Cleaning Of The tubes

With high Pressure Water
Jet

Cleaning of the
tubes with water
pressure jet at
pressure of min
70 bar

Surface should
be wet and free
from any
rust,scale and
water breaks.

OK

Neutralization of the tubes

to remove acid traces

Borax +
neutralization
agent + plain
water

No acid should
get carried over.

OK

Oiling In Dewatering type

rust preventive oil

Rust preventive
inhibitors + MTO
based petroleum
product

Tube surface
must be
completely
wetted and
covered with R P
Oil.

OK

Rae Enterprise
Consultant Surface Coating applications

GF 10,Panchratna,Nr. Parivar Char Rasta ,Waghodia Dabhoi Ring Road,vadodara

3ace 90025
Tel/Fax-+91-265-2521852,Cell-9824231852 , Email-raeenterprise@gmail.com
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Rae Enterprise
INVESTIGATION REPORT FOR THE REASONS FOR
RUSTING ON FINNED TUBES
Investigation for the reasons for rusting of Finned Tubes
1)
2)
3)
4)
5)
6)
7)
8)
9)

WO No :- EXP I/502
Tube Material :- Carbon Steel (DIN 17175 St 35.8 )
Tube Diameter :- 38.1mm OD
Tube Thickness :- 3.76 mm THK.
Fin Material :- Carbon Steel Welded on Bare tubes
Fin OD :- 63.5mm OD
Fin Thickness :- 1.25 mm THK.
OIL used :- IPOL make Dewatering Type RPSB 101 grade oil
Packing Material :a. Hessian Cloth Embedded with VCI paper on one Side.
b. VCI Plastic.
c. Water Proof Hessian Cloth
d. All ends Sealed with VCI cello tape

After going through the photographs sent by the client and samples observed at M/s Anand
Seamless Tubes Pvt Ltd .have come to the following
1_ Problem :1) Rusting On Tubes
a. Heavy On few Tubes.
b. Light On Few tubes ( Spotting or Localized ).
c. Few Tubes Without any Rusting .
2_ Observation :2) The Pickling Process and records audited and found to be in accordance with the
standard recommended process.
3) Random Sampling Done on Chemical Baths and found o be within the specifications.
4) Dewatering Properties of oil checked
5) Packing Material used and found to be in order
3_ Conclusion :1) From our observation we can conclude the following
a) The process has been carried out satisfactorily
b) Following may be the reasons for the rusting behavior on the tube
a. Both ends of the tubes are having bend which might have resulted in to
accumulation or Improper draining of the solutions in process leading to
improper cleaning and washing.

Rae Enterprise
Consultant Surface Coating applications

GF 10,Panchratna,Nr. Parivar Char Rasta ,Waghodia Dabhoi Ring Road,vadodara

3ace 90025
Tel/Fax-+91-265-2521852,Cell-9824231852 , Email-raeenterprise@gmail.com
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Rae Enterprise
b. Due to improper Draining suspended particles from the neutralization bath
may have settled in the tubes causing reaction with residual acid resulting
in to formation of neutralized powder during the transit.
c. The Rust Preventive oil used might have less De Watering characteristics.
This resulted in oil not reacting properly wherever water/other chemicals
were deposited. This might have affected to the corression protection life
of the oiled tube.
4_ Recommendations / Suggestions
1) The process normally carried out is OK for Straight and U tubes
2) For such Tubes with bent both ends the following suggestion can improve the
process
a. Tilting of the Tubes at an angle equivalent to the bending angle so as the
bend potion Is at more angle than the angle of the plain. This should be made
applicable on all Pickling Processes
# 100 % inspection of such type of awkward shape tubes after Pickling and
Oiling and ensuring that no residual solution gets left over as well as
complete surface must gets treated and oiled.
b. Addition of one more post neutralization bath with Ph maintained above 7 Ph
to ensure 100% removal of traces of any acids , reaction salts and other
suspended particles from the tubes.
c. Usage of more neutralizer with better solubility and filtering if required
ensuring no solid suspended particles remains in the in the neutralization
tank.
d. Air agitation or Forced agitation of the bath solution with educators in the
Neutralization bath and Post Neutralization bath to ensure proper miscibility
of neutralizer and proper cleaning.
e. Mimimised neutralized water carried over in to Dewatering oil bath.
f.

Frequent removal of water from the Dewatering oil tank.

g. Usage of Oil with higher Dewatering Characteristics as well as better

corrosion protection for the longer transit periods with harsh environments.
For Rae Enterprise
Ashvin Joshi

Rae Enterprise
Consultant Surface Coating applications

GF 10,Panchratna,Nr. Parivar Char Rasta ,Waghodia Dabhoi Ring Road,vadodara

3ace 90025
Tel/Fax-+91-265-2521852,Cell-9824231852 , Email-raeenterprise@gmail.com
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Rae Enterprise
END OF REPORT

Rae Enterprise
Consultant Surface Coating applications

GF 10,Panchratna,Nr. Parivar Char Rasta ,Waghodia Dabhoi Ring Road,vadodara

3ace 90025
Tel/Fax-+91-265-2521852,Cell-9824231852 , Email-raeenterprise@gmail.com
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