The document discusses the solvent conversion process of a natural gas liquefaction plant from using MEA to various formulated amines to address issues like stress corrosion cracking and erosion corrosion. It describes how the plant initially used MEA but switched to UCARSOL CR-402 to prevent SCC, but then faced problems with erosion corrosion. Various efforts were made to address this using equipment modifications and operating parameter changes. Eventually the plant converted to using BASF aMDEA which resolved the corrosion issues based on the successful results of an 18-month test run.
The document discusses the solvent conversion process of a natural gas liquefaction plant from using MEA to various formulated amines to address issues like stress corrosion cracking and erosion corrosion. It describes how the plant initially used MEA but switched to UCARSOL CR-402 to prevent SCC, but then faced problems with erosion corrosion. Various efforts were made to address this using equipment modifications and operating parameter changes. Eventually the plant converted to using BASF aMDEA which resolved the corrosion issues based on the successful results of an 18-month test run.
The document discusses the solvent conversion process of a natural gas liquefaction plant from using MEA to various formulated amines to address issues like stress corrosion cracking and erosion corrosion. It describes how the plant initially used MEA but switched to UCARSOL CR-402 to prevent SCC, but then faced problems with erosion corrosion. Various efforts were made to address this using equipment modifications and operating parameter changes. Eventually the plant converted to using BASF aMDEA which resolved the corrosion issues based on the successful results of an 18-month test run.
The document discusses the solvent conversion process of a natural gas liquefaction plant from using MEA to various formulated amines to address issues like stress corrosion cracking and erosion corrosion. It describes how the plant initially used MEA but switched to UCARSOL CR-402 to prevent SCC, but then faced problems with erosion corrosion. Various efforts were made to address this using equipment modifications and operating parameter changes. Eventually the plant converted to using BASF aMDEA which resolved the corrosion issues based on the successful results of an 18-month test run.
I. INTRODUCTION II. STRESS CORROSION CRACKING WHEN USING MEA III. SOLVENT CONVERSION FROM MEA TO FORMULATED UCARSOL CR-402 IV. EROSION CORROSION WITH UCARSOL CR-402 V. EFFORTS TO OVERCOME EROSION CORROSION WITH UCARSOL CR-402 VI. SOLVENT CONVERSION FROM UCARSOL CR- 402 TO BASF aMDEA VII. CONCLUSIONS Introduction (Cont.)
? 1977 FIRST DROP OF LNG FROM TRAINS A AND B
? 1982 CONSTRUCTION OF TRAINS C AND D ? 1987 CONSTRUCTION OF TRAIN E ? 1991 CONSTRUCTION OF TRAIN F ? 1995 CONSTRUCTION OF TRAIN G ? 1997 CONSTRUCTION OF TRAIN H ? 2000 PLANT CAPACITIES : EIGHT TRAINS (A-H) LNG = 21.64 MM Tons/Year. LPG = 1.25 MM Tons/Year (Propane + Butane) Condensate = 10 MM Barrels/Year. Introduction (Cont.)
CO2 REMOVAL (AMINE) UNIT
ORIGINAL DESIGN (Trains A & B)
• Feed gas : 305,900 Nm3/h • CO2 content in feed gas : 5.88% vol. • Amine solution : MEA, strength max 20% wt. • Amine circulation rate : 740 m 3/h • Maximum CO2 slip : 50 ppmv • Use corrosion inhibitor
AFTER REVAMP (Trains A-D)
• Feed gas: 495,000 nm3/h • Maximum CO2 content in feed gas : 8% vol. • Amine circulation rate : 1200 m3/h • Maximum CO2 slip : 50 ppmv • Use corrosion inhibitor Introduction (Cont.)
CO2 REMOVAL (AMINE) UNIT
TO DRIER OVHD.COOLER
CARBON OVHD.ACC. TREATER OVHD.ACC.
OVHD.COOLER SURGE TANK MECH. FILTER 1G-6 WASH WATER 1G-1
AMINE STRIPPER CO2 ABSORBER LP STEAM TRIM COOLER FEED GAS
FINFAN COOLER
FLASH DRUM REBOILER CROSS BOOSTER EXCHANGER PUMP II. STRESS CORROSION CRACKING WITH MEA
TRAINS A & B • STARTUP WITH MEA SOLUTION IN 1977 • JANUARY 1986, FIRST CRACK INCIDENT IN AMINE STRIPPER ON THE LACE WELD WITHOUT STRESS RELIEF
TRAINS C & D • STARTUP WITH MEA IN 1983 • MAY 1986, CRACK WAS FOUND IN AMINE STRIPPER IN TRAIN C NEAR THE MIDDLE CIRCUMFERENTIAL WELD
JANUARY 1986 - MAY 1989
10 UNSCHEDULED SHUTDOWNS BECAUSE OF SCC III. SOLVENT CONVERSION FROM MEA TO UCARSOL CR-402
SOLVENT CONVERSION • TO PREVENT FURTHER LOSSES DUE TO SCC • CARRIED OUT IN THE PERIOD OF 1990-1991 (TRAINS A-D) • USED MEA WAS BURNED • TRAINS E/F STARTED UP WITH UCARSOL CR-402
RESULTS • NO SCC OCCURRED • REDUCED STEAM CONSUMPTION • CO2 SLIP IN TREATED GAS < 5 ppmv SOLVENT CONVERSION … (Cont.)
Operating Conditions with UCARSOL CR-
402 • AMINE STRENGTH 35% WEIGHT • AMINE CIRCULATION RATE 1050-1100 m3/h VELOCITY IN PIPING 5-6 ft/sec (1.5-1.8 m/sec) • MAXIMUM RICH LOADING 0.35 M/M • MAXIMUM LEAN LOADING 0.02 M/M • NO CORROSION INHIBITOR • ANTIFOAM INJECTION RATE 5-6 LITERS/DAY (50% Si-BASE AND 50% GLYCOL-BASE) IV. EROSION CORROSION WITH UCARSOL CR-402
IN 1995, LOST OF LNG PRODUCTION OPPORTUNITY
EQUIVALENT TO $24MM CAUSED BY: • REDUCED LNG RATE FOR REPAIR ONE BANK CROSS EXCHANGERS • SHUTDOWN AMINE UNIT AND LNG PRODUCTION USING CROSS LEAN GAS FROM OTHER TRAIN • EXTENDED DOWNTIME FOR EQUIPMENT REPAIR Erosion Corrosion ... (Cont.) Metal Content in Solution UCARSOL CR-402
140 Train E Train A Train B 120 Train C Iron Content (ppm)
• EROSION CORROSION OF THE CARBON STEEL CHANNEL BOX, FLOATING HEAD COVER, AND FIXED TUBESHEETS • THINNING OF 304 SS TUBES • SCALE FORMATION INSIDE TUBES
AMINE FLASH DRUM DAMAGE
• EROSION CORROSION ON INTERNAL WALL • POOR DESIGN OF INLET DISTRIBUTOR Erosion Corrosion ... (Cont.)
HEAT STABLE AMINE SALTS (HSAS)
• PRIMARILY ACETATE, GLYCOLATE, AND FORMATE
• MAXIMUM ALLOWABLE 0.25% WEIGHT • NEUTRALIZATION USING CAUSTIC CAUSE • OXYGEN INGRESS INTO THE SYSTEM • RETURNING LEAKING SOLUTION INTO THE SYSTEM PREVENTION • NITROGEN BLANKETING Erosion Corrosion ... (Cont.)
Lean Amine Side Corrosion
LOW-PRESSURE RELATED REGIMES SUCH AS:
• DOWNSTREAM CONTROL VALVE • INSIDE OF ELBOWS • INLET TUBES OF FIN FAN HEAT EXCHANGER V. EFFORTS TO OVERCOME UCARSOL CR-402 EROSION CORROSION
CHANGING OPERATING CONDITIONS
• INCREASE OPERATING PRESSURE OF AMINE FLASH DRUM • REDUCE THE RICH AMINE TEMPERATURE OUTLET CROSS EXCHANGER
EQUIPMENT MODIFICATIONS • PARTIAL UPGRADE PIPING MATERIAL FROM CS TO SS • IMPROVE DESIGN OF INLET DISTRIBUTOR AMINE FLASH DRUM AND AMINE STRIPPER • IMPROVE MECHANICAL SUPPORT OF AMINE STRIPPER INLET DISTRIBUTOR Amine Flash Drum
Liquid Wire Screen Level
Splash Baffle
Corrosion Areas
After Modification Before Modification with Perforated Pipe (A) (B) Efforts … (Cont.)
HIGHER AMINE STRENGTH
INCREASE AMINE CONCENTRATION FROM 35% WT TO
45-50% WT TO REDUCE AMINE CIRCULATION RATE
PROBLEMS • FOAMING IN CO2 ABSORBER VERY FREQUENTLY • AMINE STRIPPER LEVEL CYCLING • EXCESSIVE SCALE FORMATION IN STRIPPER REBOILER • EROSION CORROSION WAS STILL OBSERVED DURING INSPECTION AFTER ONE YEAR • STRENGTH WAS REDUCED BACK TO 35% WT VI. SOLVENT CONVERSION FROM UCARSOL CR-402 TO BASF aMDEA
SELECTION OF ALTERNATE SOLVENT
• Corrosion problem is the driving force for solvent conversion • Several alternate solvents were evaluated • Comparison study with reference plants using the alternate solvent in the U.S. And Europe
SELECTED BASF aMDEA
• Minimum equipment modification is a must • Test in one train for 18 months, with internal inspection after 12 months • Tighter guarantee figures: - 20 mpy max corrosion rate by coupon - 100 ppmw max iron content in solution - No defect found after one year test Solvent Conversion … (Cont.)
TEST PREPARATION FOR THE
SELECTED SOLVENT
• MAJOR EQUIPMENT INSPECTION FOR BASE LINE
• INSTALL TWO NEW BUNDLES OF CROSS EXCHANGER TO MEASURE TUBE THINNING RATE & SCALE FORMATION • INSTALL THREADED CONNECTIONS ON PIPING FOR COMPARISON WITH UCARSOL CR-402 • CHEMICAL CLEANING WITH CAUSTIC 2% WT (pH 12) • STEAM CONDENSATE FLUSHING FINISH Solvent Conversion … (Cont.)
NEW OPERATING CONDITIONS
• SOLUTION STRENGTH 40% WT
• AMINE CIRCULATION RATE : 750 m3/h, LIMITED BY CO2 SLIPPAGE INSTEAD OF RICH LOADING • NO CORROSION INHIBITOR • MAXIMUM RICH AMINE LOADING : 0.62 M/M • MAXIMUM LEAN AMINE LOADING : 0.03 M/M • ANTIFOAM INJECTION RATE 5 LITER/DAY (GLYCOL TO SILICON BASE 50:50) Solvent Conversion … (Cont.)
AMINE CIRCULATION RATE
• DESIGN AMINE CIRCULATION: 1200 m3/h
• THREE CIRCULATING PUMPS, TWO RUN • PUMP CAPACITY: 400-800 M3/H EACH • REQUIRED CIRCULATION RATE BY PROCESS: 750 M3/H • PUMP LIMITATION RUNNING 1 PUMP: LOW PLANT RELIABILITY RUNNING 2 PUMPS: CLOSE TO MINIMUM FLOW • TEMPORARY SOLUTION: INCREASE AMINE CIRCULATION RATE TO 850-900 m3/h Solvent Conversion … (Cont.)
IRON CONTENT IN aMDEA BASFSOLUTION
4 Fe content (ppmw)
0 Solvent Conversion … (Cont.)
ONE YEAR WARRANTY SHUTDOWN
• NEGLIGIBLE CORROSION ATTACK
• GOOD CONDITION OF THREE THREADED CONNECTIONS • NO THINNING TUBES IN CROSS EXCHANGER • NO SCALE FORMATION INSIDE CROSS EXCHANGER TUBES Solvent Conversion … (Cont.)
ADVANTAGES OF OPERATING WITH
BASF aMDEA
• AMINE CIRCULATION RATE
28% LOWER THAN UCARSOL CR-402 25% LOWER THAN MEA • CORROSION RATE 3 MPY MAX CORROSION RATE BY COUPON MEASURED EVERY 4 WEEKS FOR 6 TIMES • SOLVENT LOSSES 46% LOWER THAN UCARSOL CR-402 67% LOWER THAN MEA Solvent Conversion … (Cont.)
• MEA in 1977-1989: SCC occurred in CO2 Absorber and
Amine Stripper and caused 10 unscheduled shutdowns in January 1986 - May 1989 • UCARSOL CR-402 eliminated SCC but Erosion Corrosion was prominent. The suspected cause: CO2 liberation on rich amine side Vena contracta effect on lean amine side High linear velocity • Efforts to control erosion corrosion UCARSOL CR-402 : Changing operating conditions Modifying equipment Upgrading materials CONCLUSIONS
• Solvent conversion from UCARSOL CR-402 to BASF
aMDEA was successful. Meet the specified absorption capability Low corrosion rate by coupon Lower iron content in solution Lower steam consumption Lower solvent makeup • Lower amine circulation rate could not be maintained because of pump limitation. Evaluation is being continued.
4P Multiple Conventional Hydraulic Fracturing Modeling in Directional Wells. Historical Case Well PN3 1 Pumping Treatment Thru BLT Gas Lift Installation in Offshore Rigles
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