Appendices Meeting 11 Sept 2019

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Appendix 1

List of participants

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


Participants EFC WP15 meeting 11th September 2019 Seville (Spain)

NAME SURNAME COMPANY COUNTRY


Al Aithan Jehad Saudi Aramco SAUDI ARABIA
Al Musharfy Mohamed ADNOC Refining Research Center UNITED ARAB EMIRATES
Bateman Colin IGS UK
Bhamji Imran TWI UK
Chmielarski Jarema Armacell POLAND
Claesen Chris J Nalco Champion BELGIUM
De Landtsheer Gino Borealis BELGIUM
Dean Frank Ion Science Ltd UK
Demma Alessandro Omnia Integrity SPAIN
Dodelin Laure Total Refining & Chemicals FRANCE
Escorza Erick Tenaris Dalmine ITALY
Fischbacher Peter Emerson Automation Solutions ITALY
Fullin Luna Tenaris Dalmine ITALY
Gregoire Vincent Equinor NORWAY
Hasek David ATI Metals USA
Hofmeister Martin Bayernoil Raffineriegesellschaft mbH GERMANY
Holmes Briony TWI UK
Houlle Patrice Patrice Houlle Corrosion Service - MTI FRANCE
Höwing Jonas Sandvik SWESEN
Kawakami Tadashi Nippon Steel European Office GERMANY
Kus Slawomir Honeywell UK
Lasarte Carlos Combustión, Energía & Ambiente, S.A. SPAIN
Lee Chi-Ming TWI UK
Lheureux Mathieu NEOTISS FRANCE
Lorkin David Ionix Advanced Technologies UK
Lucci Antonio Rina Consulting ITALY
Maddi Mohamed ADNOC Refining UNITED ARAB EMIRATES
Madeddu Enrico SARTEC SARAS ITALY
Magel Chis PPG Protective & Marine Coatings UK
Magel Chris PPG Protective & Marine Coatings BELGIUM
Monnot Martin Industeel FRANCE
Olahova Natalia Kubota Materials CANADA
Onodera Yoichi Mitsui & Co Ltd JAPAN
Prencipe Roberta Rina Consulting ITALY
Rangel Pedro CEPSA SPAIN
Rodriguez Jorva Javier CEPSA SPAIN
Ropital François IFP Energies nouvelles FRANCE
Schempp Philipp Shell Deutschland Oil GmbH GERMANY
Serra Mario SARLUX ITALY
Sharma Prafull Corrosion RADAR UK
Soltani Askar South Pars Gas Complex IRAN
Suardi Edoardo SARLUX ITALY

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


Suleiman Mabruk ADNOC Refining Research Center UNITED ARAB EMIRATES
Surbled Antoine A.S – CORR CONSULT FRANCE
Tabaud Frederic BP RTE NETHERLANDS
Ulm Philipp Bayernoil Raffineriegesellschaft mbH GERMANY
Van Rodijnen Fred Oerlikon metco GERMANY
Shell Global Solutions International
van Roij Johan B.V. NETHERLANDS
Vlad Gogulancea LUKOIL Neftochim Bourgas JSC ROMANIA
Zhang Jian-Zhong SABIC UK
Zlatnik Ivan MITSUI & Co Deutschland CZECH REPUBLIC

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


Appendix 2

EFC WP15 Activities

(Francois Ropital)

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


EFC Working Parties
http://www.efcweb.org

• WP 1: Corrosion Inhibition
• WP 3: High Temperature
• WP 4: Nuclear Corrosion
• WP 5: Environmental Sensitive Fracture
• WP 6: Surface Science and Mechanisms of corrosion and protection
• WP 7: Education
• WP 8: Testing
• WP 9: Marine Corrosion
• WP 10: Microbial Corrosion
• WP 11: Corrosion of reinforcement in concrete
• WP 12: Computer based information systems
• WP 13: Corrosion in oil and gas production
• WP 14: Coatings
• WP 15: Corrosion in the refinery and petrochemistry industry
(created in sept. 96 with John Harston as first chairman)
• WP 16: Cathodic protection
• WP 17: Automotive
• WP 18: Tribocorrosion
• WP 19: Corrosion of polymer materials
• WP 20: Corrosion by drinking waters
• WP 21: Corrosion of archaeological and historical artefacts
• WP 22: Corrosion control in aerospace
• WP 23: Corrosion reliability of Electronics
• Task Force on Corrosion in CO2 Capture Storage (CCS) applications
• Task Force on atmospheric corrosion

EFC WP15 annual meeting 11 September 2019 Seville - Spain


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Presentation of the activities of WP15

European Federation of Corrosion (EFC)


• Federation of 29 National Associations

• 21 Working Parties (WP) and 1 Task Force

• Annual Corrosion congress « Eurocorr »

• Thematic workshops and symposiums

• Working Party meetings (for WP15 twice a year)

• Publications

for more information http://www.efcweb.org

EFC WP15 annual meeting 11 September 2019 Seville - Spain


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EFC Working Party 15 « Corrosion in Refinery » Activities
http://efcweb.org/WP15.html

Chairman: Francois Ropital Deputy Chairman: Johan Van Roij

Information Exchange – Forum for Technology


Sharing of refinery materials /corrosion experiences by operating company
representatives (ie corrosion atlas).
Sharing materials/ corrosion/ protection/ monitoring information by providers

Eurocorr Conferences : organization of refinery session and joint session with


other WPs (2020 Brussels-Belgium, 2021 Budapest-Hungary, 2022 Berlin-
Germany)

WP Meetings
One WP 15 working party meeting in Spring,
One meeting at Eurocorr in September in conjunction with the conference,

Publications - Guidelines

Education – qualification – certification


List of "corrosion refinery" related courses on EFC website ?
Proposal
EFC ofmeeting
WP15 annual courses within2019
11 September Eurocorr ?
Seville - Spain
3

EFC Working Party 15 « Corrosion in Refinery »

List of the WP15 spring meetings :

10 April 2003 Pernis - NL (Shell)


8-9 March 2004 Milan -Italy (ENI)
17-18 March 2005 Trondheim- Norway (Statoil)
31 March 2006 Porto Maghera - Italy (ENI)
26 April 2007 Paris - France (Total)
15 April 2008 Leiden -NL (Nalco)
23 April 2009 Vienna - Austria (Borealis)
22 June 2010 Budapest - Hungary (MOL)
14 April 2011 Paris - France (EFC Head offices)
26 April 2012 Amsterdam - NL (Shell)
9 April 2013 Paris - France (Total)
8 April 2014 Mechelen - Belgium (Borealis)
14 April 2015 Leiden -NL (Nalco)
26 April 2016 Paris - France (Total)
13 April 2017 Frankfurt - Germany (EFC Head offices)
3 May 2018 Dalmine - Italy (Tenaris)
10 April 2019 Roma - Italy (Rina CSM)

EFC WP15 annual meeting 11 September 2019 Seville - Spain 4

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Publications from WP15
•EFC Guideline n° 55 Corrosion Under Insulation
A revision is in progress by a task force

•EFC Guideline n° 46 on corrosion in amine units


A revision is in progress by a task force

• Best practice guideline on corrosion in sea water cooling systems (joint document
WP9 Marine Corrosion and WP15)
In progress by a task force

•Future publications – task forces : suggestions ?


•best practice guideline to avoid and characterize stress relaxation cracking ?

EFC WP15 annual meeting 11 September 2019 Seville - Spain


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Information :
Future conferences related to refinery corrosion

15-19 March 2020


CORROSION 2020 NACE Conf Houston Texas

6-10 September 2020


EUROCORR 2020 Brussels Belgium

19-23 September 2021


EUROCORR 2021 Budapest Hungary

4-8 September 2022


EUROCORR 2022 Berlin Germany

Look at the Website: www.efcweb.org/Events

EFC WP15 Spring meeting 10 April 2019 Roma - Italy


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Best practice guideline on corrosion
in sea water heat exchangers systems
1- Introduction M. Suleiman (chapter leader)

2- Main seawater heat exchangers systems and other uses, M. Suleiman (chapter
leader), V. Bour-Beucler (contributor)

3- Seawater environment: aggressivity, living organisms, deposits and scale formation,


pretreatment A.M. Grolleau (chapter leader) . M. Suleiman

4- Different forms of corrosion in sea water heat exchangers systems (galvanic, crevice,
erosion…) A.M. Grolleau (chapter leader), F. Ropital

5- Biocide treatments (chlorination) – how they can affect the corrosion resistance V.
Bour-Beucler (chapter leader) A.M. Grolleau, P. Bleriot

6- Corrosion and scale inhibitors P. Bleriot (chapter leader)

7- Corrosion tests A.M. Grolleau (chapter leader)

EFC WP15 annual meeting 11 September 2019 Seville - Spain


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Best practice guideline on corrosion


in sea water heat exchangers systems
8- Materials used A. Surbled (chapter leader)
Carbon steels and coating and concrete A. Surbled F. Dupoiron
Stainless steels D. Thierry, A.M. Grolleau A. Philipp
Nickel base alloy D. Thierry, A.M. Grolleau , A. Philipp
Copper alloys A.M. Grolleau
Aluminium, Titanium alloys A. Surbled F. Dupoiron
Plastics , composites, non metallic J.M Daubenfeld, M. Suleiman

9- Corrosion protection J.Z. Zhang (chapter leader)


Material selection to avoid galvanic corrosion J.Z. Zhang
Coatings J.Z. Zhang
Corrosion control by use of cathodic protection A.M. Grolleau, J.Z. Zhang

10-Maintenance and tube cleaning F. Dupoiron (chapter leader) J.Z. Zhang A.


Surbled,

11- Control and monitoring, inspection techniques A. Surbled (chapter leader)

EFC WP15 annual meeting 11 September 2019 Seville - Spain


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EFC Working Party 15 « Corrosion in Refinery » Activities
Who is an EFC member
To be an EFC member you (individually or your company, university) has to be
member of one of 29 national EFC "member societies". Your company or university
can now also an affiliate member.

For example:
in Norway: Norsk Korrojonstekniske Forening
in France: Cefracor
in Germany: Dechema or GfKORR
in UK: Institute of Corrosion or IOM or NACE Europe
in The Netherlands: Bond voor Materialenkennis
in Poland: Polish Corrosion Society
.................
You will find all these information on www.efcweb.org or in the EFC Newsletter

Benefits to be an EFC member:


- 20% discount on EFC Publications and NACE Publications
- reduction at the Eurocorr conference
- Access the new EFC web restricted pages (papers of the previous Eurocorr
Conference) via your national corrosion society web pages
EFC WP15 annual meeting 11 September 2019 Seville - Spain
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Appendix 3

Integrity operating window in amine units

(Askar Soltani)

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


Integrity operating window in amine
Askar Soltani

South Pars Gas Complex, Inspection Department, Asaluyeh, Iran


[email protected]

Introduction
One of the most challenging issues in amine units is to find out the basic culprit and
prove its effect as the main corrosive component. However corrosive agents such as
HSAS (Heat Stable Amine Salts), amine degradation byproducts, oxygen ingress and acid
gases can play the main role in corrosion scenario in amine units but there is another
hidden player which sometimes stands in safe side and takes no responsibility of not being
within the limits of IOW (Integrity Operating Window) as shown in figure 1, and doesn't
accept its role in this kind of corrosion. After observing severe corrosion in the bottom of
regenerator and also the reboiler of AGE unit, it was decided to conduct a root cause
analysis by further internal inspection in other trains, reviewing the operational conditions
and also amine solution laboratory analysis. Comparing operational conditions in
different amine treating units revealed that the rich amine inlet temperature into the
regenerator column was lower than the design value due to the problems in lean/rich cross
exchangers. In order to compensate the low temperature in the top portion of the stripper
column the operator increased steam rate into the reboiler and the elevated temperature
Figure 2: Some important IOW in amine units
was exceeded the maximum allowable temperature for steam which increased the
probability of thermal degradation of amine in the bulk solution. Lab results revealed that
the amine was degraded and the content of HSAS were considerable. Comparing the
corrosion extent in different amine treating units revealed that however amine solution in
all of the trains were degraded but the corrosion was observed in trains with poor
operating conditions (i.e. low temperature of rich amine feeding into the regenerator
column).

Methods
To investigate the root causes of amine corrosion two methods followed:
• Internal closed visual inspection
• Laboratory analysis of amine solution
A closed visual inspection was conducted in the first overhaul of the AGE (Acid
gas Enrichment) unit in sulfur recovery plant. Severe corrosion with more than 3
mm of metal loss was observed on the bottom portion of the regenerator column Figure 3: Comparative plots of amine specification in different amine treating units
(from the bottom dish end up to the chimney trays) and also on the side
locations of the regenerator reboiler and some parts of weir plate. Further
internal inspections were conducted in six other trains in gas sweetening units in
order to compare the conditions from corrosion points of view. The corrosion
Results
was observed in only one of these trains. Samples were taken from suspected Results of internal inspection and laboratory analysis were as following:
amine solutions in order to do more laboratory analysis. Comparative lab results • However almost all the amine solutions in different treating units were
in different amine units have been illustrated in figure 3. degraded but corrosion was occurred only in 2 number of trains with
more deviation in rich amine inlet temperature to the stripper column
• Corrosion in the reboiler was more severe compared to the regenerator
bottom
• Considerable amount of DEA in the amine solution of AGE unit revealed
thermal degradation of amine due to elevated temperatures because of
excessive steam flow during a short period of time
• In corroded units the concentration of formate and acetate anions were
considerably more than other trains
• It seems that acetate anion compared to formate and succinate is less
effective on corrosion in amine units

Conclusions
Conclusions from our research categorizes as following:
• Comparing the corrosion extent in different amine treating units revealed that however
amine solution in all of the trains were degraded but the corrosion was observed in
trains with poor operating conditions (i.e. low temperature of rich amine feeding into
the regenerator column).
• Due to the safety problems, retrieving the corrosion coupons is not applicable during
the operation of amine units, so we need to have an applicable inspection plan in
reasonable intervals. But a big question arises here and that is what interval is reliable
before the corrosion occur after the last inspection? Is it reliable to plan future
inspection based on the last inspection history ? This question has a simple response
which highlights the necessity of establishing and implementing an IOW program for
amine operational parameters. This is a reliable troubleshooting recommendation.
• Without having an appropriate IOW, the RBI program would not have its required
efficiency in maintaining the integrity of equipments and it is not enough to plan the
future inspections only on prior records and prior history of the equipments and
understanding of the process conditions
• Our experience showed us, a continuous monitoring of process conditions is required
Figure 1: Comparison of corrosion extent in different amine treating units: a) Chimney tray to prevent premature failures. Inspection intervals needs to be modified based on the
area of GTU1, b) Chimney tray area of GTU 3, C) Chimney tray area of GTU4, d) Chimney changes in the operational conditions and this is an IOW program which is able to
tray area of GTU 5, e) Chimney tray area of GTU 6 , f) Chimney tray area of SRU help the inspector in this regard.

www.postersession.com
Paper ID: 227316 www.postersession.com
Appendix 4

CUI, practical approach from a coating


perspective

(Chris Magel)

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


9/13/2019 6:39:08 AM

CUI, practical approach from a coating


perspective

Content

• Corrosion under insulation and approach


• Testing of coatings serving under insultation
• Clarification of the CUI coating range
• Typical systems

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Corrosion under insulation

CUI is defined as the external corrosion of piping and vessels that occurs when water gets trapped
beneath insulation. CUI damage takes the form of localized corrosion in carbon and low alloy steels.
Factors that affect CUI include

• Duration, frequency of exposure to moisture


• Corrosivity of the aqueous environment
• Condition of protective barriers (cladding, coating,…)
• Design
• Temperatures ( -4°C to +175°C // also outside this zone!)
• Cyclic temperatures??
• Insulation type
• Climate
• Site maintenance practice
• General environment (proximity of saltwater, cooling towers,…)

API 583

PPG HI-TEMP™ heat-resistant coatings 3

Corrosion under insulation

Gaps exist in cladding Via rain, water enters the • Water boils at the pipe
• Damage system down to the insulation • Electrolytes in the water
• Poor sealing and steel. concentrate
• Improper fit • Steam condenses when it
• All cladding leaks eventually reaches the cladding

Pipe Pipe Pipe

Insulation Insulation Insulation

Cladding Cladding Cladding

PPG HI-TEMP™ heat-resistant coatings Very Aggressive Corrosion 4

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Corrosion under insulation

• Nothing stays hot forever


• Water under cladding is never completely expelled
• Additional water can enter damaged cladding
• Electrolytes in the water may concentrate
• Eventually the insulation becomes saturated or will hold water (depending on insulation)

The substrate will corrode if not properly protected

FOTOS

PPG HI-TEMP™ heat-resistant coatings 5

Corrosion under insulation

It is important to take all aspects of the application into account as they all are equally important to
reduce the problem of corrosion under insulation. The most important aspects are

a. Sheeting
• correct sheeting selected
• correct application
• correctly sealed
a.
b. Insulation
• reduced or no water uptake (water repellant)
• very limited chloride content
• designed to serve the purpose (not more, not less)

c. Coating b.
• suited for the temperature range
• immersion resistant c.
• able to serve under cyclic temperature conditions, intermittent boiling water.
• easy to repair if damaged
•must be able to withstand a worst case scenario

PPG HI-TEMP™ heat-resistant coatings 6

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Corrosion under insulation

Protective coating

• Select the correct coating: This is the LAST


barrier to the steel!
• Define temperature range,
• Define possible surface preparation
• Select coating which serves the goal!
• Weigh coating cost up to expected service
life!

ALL OPERATING CONDITIONS SHOULD BE CONSIDERED, INCLUDING OUT OF SERVICE


STATE WHEN SELECTING THE CORRECT PROTECTIVE SYSTEM

PPG HI-TEMP™ heat-resistant coatings 7

Testing of coatings that serve under insulation

• No specific test standard until last month


• Several guidelines addressing the subject of CUI

• API 583
• EFC WP13 and WP14
• These a very detailed documents addressing all aspects in mitigating CUI
starting from the design phase.
• All “last barriers” towards the steel are addressed (wrapping, TSA, coating)
• general approach towards coatings (“conventional coating”)
• NACE 0198-2010
• Standard practice document (control of corrosion under thermal insulation
and fireproofing materials)
• Defines typical recommended generic coating systems based on different
temperature zones

PPG HI-TEMP™ heat-resistant coatings 8

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Testing of coatings that serve under insulation

PPG HI-TEMP™ heat-resistant coatings 9

Testing of coatings that serve under insulation

Test standard published in DECEMBER 2018 under committee ISO TC 67 WG 11 (ISO19277)


Standard defines:
• CUI environments
• Temperature ranges
• Specific testing to be done depending on the environment like
• Neutral salt spray
• Water condensation test
• Immersion test (if applicable)
• Thermal cycling test
• Specific CUI test (Houston pipe test/PPG CUI chamber test,…this is still to be defined

Classification Minimum Peak Temperature Range Description


CUI-1 -45⁰C -45⁰C 60⁰C Wet
CUI-2 -45⁰C 60⁰C 150⁰C Warm
CUI-3 -45⁰C 150⁰C 204⁰C Hot
CUI-4 -45⁰C 204⁰C 450⁰C Very Hot

PPG HI-TEMP™ heat-resistant coatings

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Testing of coatings that serve under insulation

Typical test methods for elevated temperature coatings


• ASTM B-117:
• Salt Fog Chamber 3500–4500 hours
• ASTM 2485:
• This test ensures adhesion based on CTE after severe thermal shock
• ASTM 2402:
• Mass loss is critical in determining the porosity and longevity of a coating

Specific CUI test methods


• Shell Test; Cyclic Wet / Dry Immersion Testing 16 weeks
• Modified Houston Pipe Test 21-30 days
• ASTM G189
• PPG HTC CUI Chamber Test (1008 hours, 252 cycles)

Other tests only focus on dry exposure and/or thermal shock.

PPG HI-TEMP™ heat-resistant coatings 11

Testing of coatings that serve under insulation

PPG CUI Chamber Test 2008

Uses ASTM G189 as a model


• For simplicity the insulation is omitted
• Temperature control: ambient to 250°C
• Consistent and repeatable results.
• The chamber environment can be totally controlled
Approvals: Shell Oil 2008, Aramco 2010

Method B:
• 5% NaCl solution
• Set wet/dry cycle time [4 hours]
• 42 day duration [252 cycles] 1008 hours
• Internal temp 350°F [179°C]
• Steam-out immersion temp 212°F [100°C]

PPG HI-TEMP™ heat-resistant coatings

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Testing of coatings that serve under insulation

PPG HI-TEMP™ heat-resistant coatings

Positioning of PPG CUI coating range

CUI solutions can be classified by generic type, temperature or type of application


Generic Type Temperature Type of application
• Epoxy Glass Flake • Insulated assets can be • New build (NB)
• Epoxy Phenolic exposed to extreme conditions • Maintenance & Repair (M&R)
• Multipolymeric ranging from -196°C to 650°C

Generic type discussions are


usually held by asset owners and The operating temperature of the M&R scenarios might require from
engineering companies. insulated asset will determine the your solution to be surface
Depending on the assets, they type of technology needed for tolerant, applicable by brush or
specify technologies that will give certain job roll, one-component material.
the best protection and contribute NB scenarios will require blast
to extending the life cycle of the cleaned surfaces and a coating
assets less prone to mechanical
damages

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Positioning of PPG CUI coating range

Legend Best fit for use


Suitable for use
Not suitable for use

NB /
min SURFACE
M&R PREP
-46°C (- 121°C 204°C 232°C 760°C
-196°C (-321°F) 50°F) -18°C (0°F) (250°F) 149°C (300°F) (400°F) (450°F) 316°C (600°F) 482°C (900°F) 650°C (1200°F) (1400°F)

Epoxy Phenolic SA2.5

Epoxy (imm) ST2

MP copolymer ST3

MP hybrid SA2.5

IMPM ST2

17

Typical systems

INORGANIC ZINC

STRENGTHS WEAKNESSES

• High temperature limits • Thin film coating (75µm)


• Good sacrificial corrosion protection • Corrosion can occur with zinc
• SP0198 CS-8 as a bulk shop primer and consumption in corrosion cell
when used - a top coat is recommended • Will not survive long in wet environments
• Thermal shock and cycling may reduce life
expectancy
• May suffer “reverse galvanic” corrosion
between 60 and 80⁰C
• SA2,5 absolute minimum

Not recommended

PPG HI-TEMP™ heat-resistant coatings

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Typical systems

TSA

STRENGTHS WEAKNESSES

• Mechanical bond to substrate • SA2.5 absolute mimimum


• High durability • Limited suitability for maintenance
• High temperature limits • Coefficient of thermal expansion not
• Automated application possible matched to substrate. Can lead to stress in
thermal cyclic conditions
• costly

PPG HI-TEMP™ heat-resistant coatings

Typical systems

EPOXY AND EPOXY PHENOLIC

STRENGTHS WEAKNESSES
• Very good chemical resistance • SA2.5 absolute mimimum
• High durablity • Limited suitability for maintenance
• Hard and durable coatings • Coefficient of thermal expansion not
• Provides extremely good corrosion matched to substrate. Can lead to stress in
protection in immersion service thermal cyclic conditions
• Temperature limitations

PPG HI-TEMP™ heat-resistant coatings

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Typical systems

INORGANIC COPOLYMER – HYBRID COPOLYMER - IMPM

STRENGTHS WEAKNESSES
• Large temperature range • Slightly higher initial cost
• CTE matches almost the substrate, so • Moderate chemical resistance (PH5 to 10)
thermally durable • Good but not best solution below 120°C
• Can whithstand thermal cycling
• Can whithstand thermal shock
• Surface tolerant (ST2)
• Easy to apply
• Hot application possible!

PPG HI-TEMP™ heat-resistant coatings

10
Appendix 5

Design of probes to evaluate the performance of


the different options of coatings to be used
under insulation
(Carlos Lasarte)

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

The Control of Corrosion Under Thermal Insulation and Fireproofing Materials

Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials
Location

Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

Polyethylene

Polyethylene

Power plant

Ammonia

Polyethylene
VC monomer
PVC Polystyrene

Chlorine-Soda Olefins 1& 2 Gas desulphurizer

Effluents

Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

Evaluation - Characterization of the Macro


and Micro Environments in each area of the
plants to select the best coating options Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

The test of the various options of coatings in each critical


area of the plants, to select the best performance
Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

... To achieve the best possible protection, with


the best cost-benefit ratio, in each plant area

Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials
... But we had neglected the
protection of pipes and equipment
under thermal insulation.

Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials
A high percentage of equipment and pipes are thermally insulated.
The Facilities, with more than 35 years usually do not have
Metallic Surface Protective Coatings

For Different Reasons the Vapor Barrier and Waterproofing Covers Fail.
Once the Thermal Insulation System Becomes Permeable to
the Humidity of the Environment, the Metallic Surface begins a Wet Corrosion
Process, which will basically depend on the Operation-temperatures
Cycles and the Pollution Levels of the Environment.

Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

Typical misuse of thermally insulated equipment and pipes

Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

At that time:
References on Corrosion Problems Under Thermal Insulation
Technical Committee Report
NACE International Task Groups

 T-6H-31 Coating for Carbon and Stainless Steel Under Insulation

 T-5A-30 Corrosion Under Thermal Insulation

Reporte:
“A State–of–Art Report of Protective Coatings for Carbon Thermal Insulation
and Cementitious Fireproofing – última emisión: Marzo 1996”

How to Select the best Protective Coating Option?


Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

How to Select the best Protective Coating Option?


To evaluate the various options of
protective coatings, to be used under
thermal insulation, the ASTM
standards were searched and since a
specific design was not found, a test
tube was designed to achieve an
evaluation with accelerated results

Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

EXPOSURE CONDITIONS

Nipples Material: ASTM-53 GrB Insulating Materials Used:


 Fiberglass
Coatings
 Mineral Wool
 Inorganic Zinc (silicate)
 Calcium Silicate
 Silicone Aluminiun
 Aluminium Metallized

Surface Preparation: SSPC-SP5

“Saline Chamber” 4% p/v


Thermal Cycles 12 hours
Maximum temperature 150 ºC
Minimum temperature 30 ºC

Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

Al Silicona Al Metalizado

Zinc Inorgánico Carlos Lasarte


Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

RESULTADOS:
Probeta Tiempo de Relación Vs.
Exposición Blanco

Blanco 120 horas ………..


Insulating Performance
Control
Coating
Al Silicona 816 horas 6.8
Calcium Silicate Best

Zinc 1.104 horas 9.2


Fiberglass Intermedium
Inorgánico
4.800 horas
Al > 40 Mineral Wool Deteriorated most
sin ningún daño
Metalizado

Aluminium-Silicone and Inorganic Zinc failed by blistering first in combination with Mineral Wool

Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

Almost immediately the results were used in


the painting of the heating jacket of a
polymerization reactor (Polystyrene),
making use of the combination: Inorganic
Zinc and Fiberglass, with apparent good
results after inspection done two years later.

It was necessary to implement


protections against misuse by
operators, who had to walk on
the insulation to act some valves

The rehabilitation process


continued with the
insulated pipes, located in
areas - very high humidity
microenvironments

Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

The next protection system to be


implemented was the one used in the
structures covered with fire protection system

Carlos Lasarte
Corrosion Under Insulation (CUI)
thermal insulation and fireproofing materials

Using Chlorinated Rubber paint for direct protection of steel structures


and sealing of fire protection cement

Carlos Lasarte
Muchas Gracias por su Atención

Carlos Lasarte
Phone-WhatsApp +34-625898225
Skype: carlosluislasartev
[email protected]

Carlos Lasarte
Appendix 6

Overview of the research done recently at TWI

(Che Ming Lee)

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


Appendix 7

CorrosionRADAR CUI monitoring and


prediction system - Recent case studies

(Prafull Sharma)

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


CUI Monitoring System
and Predictive Corrosion
Management: Case
Studies

www.corrosionradar.com EFC Work Party 15


Annual Meeting
A Cranfield University Spinout September 11th 2019
Seville, Spain
Inspection 4.0
A NEW ERA OF ASSET INTEGRITY

Inspection 1.0 Inspection 2.0 Inspection 3.0 Inspection 4.0


Manual observation, Visualisation, Automated,
Statistics, RBI
Leaks NDT instruments Analytics, Prediction

Manual Automated

Detection Prediction

Reaction Prevention

CorrosionRADAR Ltd. 2
Problem
HIDDEN CORROSION

Oil & Gas Chemical Industry Corrosion Under Insulation (CUI)

Renewable Energy Civil & Construction

CorrosionRADAR Ltd. 3
Corrosion Under Insulation
WHAT IS THE FUTURE

Imagine an ideal world with no CUI

Prevention
(Coatings, Insulations, Metallurgy..)

Monitoring
(NDT, Sensors, Data)

CorrosionRADAR Ltd. 4
Solution
THE CURRENT PRACTICE

CURRENT PRACTICE
REACTIVE MAINTENANCE
WHERE?
HUMAN PERIODIC WHERE • Labour Intensive
• Unscheduled Shutdowns
JUDGEMENT + MANUAL
• Safety Risk
GUESSED RISK INSPECTION WHEN • High cost

CORROSION UNDER Cost of CUI in Oil and Gas > £3.5B Annual spent on CUI
INSULATION
IDEAL PRACTICE
PREDICTIVE MAINTENANCE

WHERE • Minimal labour effort


AUTOMATED
CONTINUOUS • Scheduling Maintenance
RISK •
MONITORING Improve safety
PROFILING WHEN • Reduce cost
WHEN?

CorrosionRADAR Ltd. 5
Solution
CORROSIONRADAR TECHNOLOGY

DETECT CONNECT PREDICT

Distributed Corrosion & Moisture Sensors Long-Life Battery Powered Predictive Asset Management
Long Range Coverage Remote Wireless Communications Asset life extension
Cost Effective Installation Continuous Monitoring Effective Risk Management
Covering Complex Pipe works Dashboard for Actionable Intelligence Historical Data & Analytics

CorrosionRADAR Ltd. 6
Principle
ELECTROMAGNETIC GUIDED WAVE RADAR
Wave reflection time-of-flight locates the corrosion on sensor

CorrosionRADAR Ltd. 7
CorrosionRADAR System
SPECIFICATIONS - SENSORS
Technology Fundamental:
The CorrosionRADAR (CR) technology is based on Guided-wave
Electromagnetic principle and embedded sensors inside the insulation.
CR sensors are designed in such a way to carry an electromagnetic wave
unaffected by the field complexities (flanges, bends, pipe support, …).
Thanks to the sacrificial layer of the sensors, the locations prone to
corrosion activity can be pinpointed as the sensor reacts to a potential
corrosive environment surrounding the monitored asset. The sacrificial
layer of the sensors can be made out of various different materials and
close to the material of the asset.
The data obtained from CR sensors can be used as a “Risk Profiling Tool”
to enhance and optimise the RBI maintenance programs.

Material of CR Sensors
Most commonly used sensors are made out of carbon steel, however,
other sensor materials are also available. Moreover, in the case of
difference between CR sensor material to the asset’s material, corrosion
correlation approach can be used.

Sensors Type Corrosion Sensor Moisture Sensor

Sensor Length Up to 100m Up to 50m

Temperature Range -50 to +300 0C -50 to +200 0C

CorrosionRADAR Ltd. 8
CorrosionRADAR System
SPECIFICATIONS - ELECTRONICS

Dimensions 284x245x169 Mass (kg) 11.2 Kg


(mm) excl.
antenna
Ports 1x power cable Power 220V AC
2x SMA requirements

ATEX EXd Zone1 IP rating IP66


certification Group2
Connectivity/ Cellular, Wi-Fi, Ambient -20 to +60
Data transfer WirelessHART, temperature
LoRa range (°C)

CorrosionRADAR Ltd. 9
CorrosionRADAR System
SPECIFICATIONS – ONLINE DASHBOARD

CorrosionRADAR Ltd. 10
Towards Asset Digitalisation
DIGITAL TWIN OF ASSET INTEGRITY

100% Pipe length coverage for assets digitalisation and enabling digital twins

CorrosionRADAR Ltd. 11
CR Use Cases
Helical
Configuration

Line
Configuration
Mesh
Configuration

CR is pioneering the distributed sensing approach for corrosion sensing

Long-range Unaffected
by Complex Cost Effective
Embedded & Modular
(each sensor unit Geometries for Mass
Sensors can cover up to (e.g. vessels, pipe Deployment
1 km) bends, flanges...)

CorrosionRADAR Ltd. 12
Installation Configurations

CorrosionRADAR Ltd. 13
Case Study A
PRODUCTION COLUMN CORROSION MONITORING (ATEX)

CorrosionRADAR Ltd. 14
Case Study A
CUSTOMER’S FEEDBACK

Source: https://www.sitech.nl/tech-update/columbus-egg-for-corrosion-under-insulation
CorrosionRADAR Ltd. 15
Case Study B
CORROSION DETECTION

In a six month trial in a chemical plant in EU, CR system has successfully detected, located and continuously
monitored a corrosion activity on a pipe, manholes and a vessel
Example of identified location by CR
system where visual inspection
confirmed the presence of corrosion on
the asset and the CR Sensor.
Having the ability to continuously
monitor corrosion activity and having
access to the data remotely can
enhance and reduce maintenance
budgets by conducting targeted
inspections.

Benefits

✔ Confidence in the ability of CR


Sensors to react to a corrosive
environment.

✔ Confidence in the ability of CR


CRL002 – Vertical Pipeline
Systems to accurately locate
Hours corrosive environments.

CorrosionRADAR Ltd. 16
Case Study B
CORROSION PROGRESSION MONITORING

In a six month trial in a chemical plant in EU, CR system has successfully detected, located and continuously
monitored a corrosion activity on a pipe, manholes and a vessel
Propagation of Corrosion Example of progression of corrosion
along the CR sensor length. Visual
inspection confirmed the analysis and
showed the progression of corrosion on
the CR Sensor.
The ability to not only detect and locate
but also continuously monitor the
progression of corrosion can provide
valuable information and assist
decision making processes of
maintenance team on the ground and
increase the safety of the assets.

Benefits

✔ Continuously monitoring the


progression of the corrosion.

CRL002 – Vertical Pipeline ✔ Increasing the safety of assets by


Hours avoiding loss of containment
events.

CorrosionRADAR Ltd. 17
Case Study C
MOISTURE MONITORING SYSTEM
Figure (A) (A) (B) Figure (B)

Installation of CR Installation of the pre-


corrosion sensors on a fabricated insulation
3 inch pipe using cable around the pipe and
ties the corrosion sensor

Figure (C) (C) (D) Figure (D)

Installed CR Nodes Moisture sensor is


Corrosion sensor
(electronic) driving CR placed inside the pre-
Moisture and fabricated insulations
Corrosion sensors and installed at a fixed
distance from the pipe

Moisture sensor

CorrosionRADAR Ltd. 18
Case Study C
MOISTURE MONITORING SYSTEM

Moisture
sensor data
analysis
and Detected water ingress points
correlation at 22 metres location

with historical
weather data
rainfall (mm)
Amount of

CorrosionRADAR Ltd. 19
Data Driven RBI
BENEFITS TO RBI METHODOLOGY

Saving CUI management cost by at least 30%


£0.5m to £1m per year per refinery.

£2.8m Annual Budget £2.0m

CorrosionRADAR Ltd. 20
Summary
CORROSIONRADAR SYSTEM

• CorrosionRADAR embedded sensor technology


• Monitoring for early detection of corrosion under insulation
• Insulation Moisture monitoring for prediction and prevention of CUI

Detect early
CorrosionRADAR Ltd. 21
Heading
SUB HEADING

Enabling Smarter Assets

CorrosionRADAR Ltd
Future Business Centre
King’s Hedges Road
Cambridge, CB4 2HY
[email protected]
www.corrosionradar.com
Appendix 8

Technical economic feasibility study for the


adoption of Thor™115 pipes in Refinery
Furnaces

(Luna Fullin, Erick Escorza)

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


EFC WP15 Corrosion Refinery Industry

Sevilla – September 11th, 2019

Thor™115 Pipes
in Refinery Furnaces

L. Fullin – Product Engineer


E. Escorza – Product Senior Director

The information in this electronic mail is not intended to constitute professional or any other type of advice and is provided on an “as is” basis. No warranty is given. Tenaris has not independently
verified any information –if any- provided by petitioner in connection with, or for the purpose of, the information contained hereunder. Petitioner acknowledges and agrees that the use of the
information is at user’s own risk and Tenaris does not assume any responsibility or liability of any kind for any loss, damage or injury resulting from, or in connection with any information provided
hereunder or the use thereof. Tenaris products and services are subject to the Company’s standard terms and conditions or otherwise to the terms resulting from the respective contracts of sale,
services or license, as the case may be. Unless specifically agreed under such contract of sale, services or license, if petitioner requires Tenaris to provide any warranty or assume any liability in
connection with the information provided hereunder, any such warranty or liability shall be subject to the execution of a separate written agreement between petitioner and Tenaris. The information
in this electronic mail is confidential and shall not be reproduced or disclosed in any form or by any means whatsoever, without prior permission from Tenaris. For more complete information please
contact a Tenaris's representative or visit our website at www.tenaris.com. ©Tenaris 2019. All rights reserved.

1 September 13, 2019


Agenda
 Introduction of Fired Heater Furnaces and Damage Mechanisms

 Metallurgy and Properties of Thor™115 and P9

 Life Model Development:


• Mechanical Data
• Creep Data
• Corrosion Data

 Model Layout and Validation with Real Cases

 Economic Evaluation and Benchmark Between Thor™115 and P9

 Conclusions

2 September 13, 2019


Agenda
 Introduction of Fired Heater Furnaces and Damage Mechanisms

 Metallurgy and Properties of Thor™115 and P9

 Life Model Development:


• Mechanical Data
• Creep Data
• Corrosion Data

 Model Layout and Validation with Real Cases

 Economic Evaluation and Benchmark Between Thor™115 and P9

 Conclusions

3 September 13, 2019


Fired Heater Furnaces - Design
 P5 and P9 steel grades typically
 Process conditions:
• Up to 600°C  creep regime
• Low pressures, up to 35 bar

Piping Design based on:


 Static stability

σapplied ≤ S adm

 Creep life

tdesign ≤ tcreep

4 September 13, 2019


Fired Heater Furnaces – Damage Mechanisms

EXTERNAL PIPE SURFACE INTERNAL PIPE SURFACE


 Oxidation  Carburization: embrittlement, thermal
insulation
 Mechanical cleaning / erosion
 HT Sulphidation (Sulphur compounds, NAC)

5 September 13, 2019


Agenda
 Introduction of Fired Heater Furnaces and Damage Mechanisms

 Metallurgy and Properties of Thor™115 and P9

 Life Model Development:


• Mechanical Data
• Creep Data
• Corrosion Data

 Model Layout and Validation with Real Cases

 Economic Evaluation and Benchmark Between Thor™115 and P9

 Conclusions

6 September 13, 2019


Metallurgy and Properties: P9 and Thor™115
GRADE 9:
introduced in 1940-1960 to improve corrosion resistance; martensitic microstructure

THOR™115:
Tenaris new martensitic steel for high temperature applications:
Improved steam oxidation resistance vs. 9Cr grades
Creep properties better than grade 91
Friendly in manufacturing and welding

C Mn Si Cr Mo V Nb N
Gr.9 0.1 0.4 0.6 9.0 1.0 - - -
Thor™115 0.1 0.4 0.4 11.0 0.5 0.2 0.04 0.05

 Both are ferritic steels, with similar thermal expansion and thermal conductivity.

7 September 13, 2019


Agenda
 Introduction of Fired Heater Furnaces and Damage Mechanisms

 Metallurgy and Properties of Thor™115 and P9

 Life Model Development:


• Mechanical Data
• Creep Data
• Corrosion Data

 Model Layout and Validation with Real Cases

 Economic Evaluation and Benchmark Between Thor™115 and P9

 Conclusions

8 September 13, 2019


Life Model Development – Mechanical Data
Strength Data:
 P9: Table A-1 of ASME B31.3
 Thor™115: ASME BPVC.CC.BPV.S3-2017 Code Case 2890

Allowable Stress [MPa]


140
P9 - ASME B31.3
120

100 Thor115 - CC2890

Stress [MPa]
80
60

40

20
0
450 500 550 600 650 700
Temperature [°C]

 Conventional creep initiation: T=575°C (P9: 520°C)


9 September 13, 2019
Agenda
 Introduction of Fired Heater Furnaces and Damage Mechanisms

 Metallurgy and Properties of Thor™115 and P9

 Life Model Development:


• Mechanical Data
• Creep Data
• Corrosion Data

 Model Layout and Validation with Real Cases

 Economic Evaluation and Benchmark Between Thor™115 and P9

 Conclusions

10 September 13, 2019


Life Model Development – Creep Data
CREEP DATA:
 P9: API 530 Table F.31
 Thor™115: creep tests database

Larson Miller Parameter [LMP] to correlate the remaining material life [tcreep] with operating temperature [T]
and applied stress [σapplied ] (API 530 and API 579):

T=600°C

Thor™115 lasts 90
times more than P9

11 September 13, 2019


Life Model Development – from Stress to Hardness
In fired heaters over-tempering of the
material causes:
 carbides precipitation
 boundary cavity formation
 Hardness decrease (martensite structure
vanishes)  S adm decreases

M23C6 carbides evolution in both alloys at similar LMP

Hardness values of new material and crept


specimens tested at 600°C were correlated to the
exposure conditions through LMP (σ):

12 September 13, 2019


Agenda
 Introduction of Fired Heater Furnaces and Damage Mechanisms

 Metallurgy and Properties of Thor™115 and P9

 Life Model Development:


• Mechanical Data
• Creep Data
• Corrosion Data

 Model Layout and Validation with Real Cases

 Economic Evaluation and Benchmark Between Thor™115 and P9

 Conclusions

13 September 13, 2019


Life Model Development – Corrosion Data
EXTERNAL OXIDATION
API 571 and API 581 report Oxidation Rates (OR) vs. Temperature for several material classes :
 9Cr: 1 mpy at 600°C
 12Cr: 1 mpy at 600°C
INTERNAL SULPHIDATION
 Modified Mc Conomy curves (API 571 and API 581) report 9Cr and 12Cr Corrosion Rates (CR9Cr > CR12Cr).
 Thor™115 was already tested and compared with P9 in similar corrosion environments:
TAN 3.0 - 360°C Corrosion Rates vs. Material
5
2
Accelerated Corrosion Rate [mm/y]

Accelerated Corrosion Rate [mm/y]


4,5
4 1,8
P5
3,5 P5
1,6 P9
3
P9
2,5 Thor115
1,4
2 Thor 115
1,5 1,2
AISI 410
1
1
0,5
0
0,8
0 2000 4000 6000 8000 10000 12000 P5 P9 Thor™115
pH2S [ppm]
1. Pilot Plant at ENI (Venezia – Tech) - Tests in 2. HGO hydrotreating pilot plant at ADNOC Refining
naphthenic and sulphidic environment Research Center
14 September 13, 2019
Agenda
 Introduction of Fired Heater Furnaces and Damage Mechanisms

 Metallurgy and Properties of Thor™115 and P9

 Life Model Development:


• Mechanical Data
• Creep Data
• Corrosion Data

 Model Layout and Validation with Real Cases

 Economic Evaluation and Benchmark Between Thor™115 and P9

 Conclusions

15 September 13, 2019


Model Layout
CREEP DESIGN:
 σapplied in furnaces is low  the design condition tdesign ≤ tcreep can be disregarded, low creep damage

STATIC DESIGN:
 The applied stress increases due to thickness (WT) reduction caused by oxidation and corrosion:

PD
σapplied=
2WT

WT=WT0 –(OR + CR) t

 The allowable stress decreases with time (overtempering) as described by LMP law:

S adm= S 0 f (LMP)

16 September 13, 2019


Model Validation – Real Case
A real case was used to verify the model, comparing P9 and Thor™115:

High Safety Margin


granted by Thor™115 in
the same conditions

FURNACE DATA:
• Position: radiant coil
• Material: P9
• T=587°C
• OD=88.9 mm
• wt=5.5 mm
• P=20 bar
The model sets the P9 component life at 20.5 years.
• OR=0.04 mm/y
From the service history, the coil was replaced after 22 years of service. • CR=0.0 mm/y

17 September 13, 2019


Agenda
 Introduction of Fired Heater Furnaces and Damage Mechanisms

 Metallurgy and Properties of Thor™115 and P9

 Life Model Development:


• Mechanical Data
• Creep Data
• Corrosion Data

 Model Layout and Validation with Real Cases

 Economic Evaluation and Benchmark Between Thor™115 and P9

 Conclusions

18 September 13, 2019


Economic Evaluation: Shutdown Costs

Refineries shutdowns are scheduled as follows:

 For creep controls:


• After 100 kh +/-10% (10-12 years)
20 days
• Every 50 kh +/-10% (4-5 years)
stoppage
• In case of defects, reduced schedule (1.5
years)

 Furnaces clean up:


• Every 2-2.5 years

 General Refinery Turnaround for maintenance:


45-60 days
• Every 4-5 years
stoppage

19 September 13, 2019


Shutdown Costs
 Loss of Refinery production:
Loss of production = Refining Net Margin x Furnace Output
with
𝐓𝐨𝐭𝐚𝐥 𝐑𝐞𝐟𝐢𝐧𝐞𝐫𝐲 𝐒𝐚𝐥𝐞
Refining Net Margin:
𝐂𝐫𝐮𝐝𝐞 𝐂𝐨𝐬𝐭 + 𝐎𝐩𝐞𝐫𝐚𝐭𝐢𝐨𝐧𝐚𝐥 𝐂𝐨𝐬𝐭

Considering the last Refining Net Margin trend,


the expected value is around 1-3 USD/barrel

Furnace Outputs vary depending on the


furnace and are around 200 ton/h

 20 days shutdown = about 600 – 1000 K$


(if 100% furnace production lost)

20 September 13, 2019


Shutdown Costs
 Recoil costs:
20-50 ton of pipes = 100 – 200 K$ (material costs)
 Thor™115 cost ≈ 1.1 P9 cost

Additional costs: dismantling, rebuilding, manpower, scaffolding, safety, recommissioning

 Inspection costs:
1 furnace NDT cost = 10 - 20 K$

21 September 13, 2019


Economic Assessment

30 k$ up to 1000
k$

Failure

The initial investement P9 replacement introduces additional costs:


of Thor™115 is 11% loss of production, inspection,
higher than P9 construction, material substitution
22 September 13, 2019
Agenda
 Introduction of Fired Heater Furnaces and Damage Mechanisms

 Metallurgy and Properties of Thor™115 and P9

 Life Model Development:


• Mechanical Data
• Creep Data
• Corrosion Data

 Model Layout and Validation with Real Cases

 Economic Evaluation and Benchmark Between Thor™115 and P9

 Conclusions

23 September 13, 2019


Conclusions
 Fired heater furnaces are adopting P9 steel grade despite elevated temperatures

 Crudes have increased sulphur content and TAN, turning corrosion more critical

 Thor™115 steel grade has better performance with respect to P9 in terms of:

• Static and Creep resistance

• Oxidation resistance

• High Temperature Sulphidation resistance

 The technical and economical comparison has shown high advantage to adopt Thor™115 in Furnaces
application:

• Higher safety margins

• Low initial cost difference

• Reduced maintenance costs

24 September 13, 2019


Appendix 9

Utilization of Permasense sensors in refineries

(Peter Fischbacher)

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


Rosemount Wireless Permasense
Non-Intrusive Corrosion/Erosion
Monitoring Solutions to Enhance
Operational Profitability

Online Corrosion Monitoring Update

EFC WP15 Corrosion Refinery Industry


11th September 2019 Meeting

Emerson Automation Solutions – Milano / Italy


PETER FISCHBACHER – [email protected]
Industry Challenges – Missing Asset Health Data Means Your Plant Is
Not Being Driven to Its Maximum Capability

More variable feedstock quality

Process & Treatment optimization Increased Margin


Longer runs between maintenance Operational Certainty
solutions

Tighter H&S regulations

Tighter CAPEX budgets

Shortage of experienced inspectors

Leaks/loss of
containment
Conservative
operations – poor
profitability
Top Downstream Applications and Solutions
• Opportunity feedstock – real time online corrosion data, effective and efficient asset
integrity management, continuous production corrosive feedstock, payback within weeks

• Process optimisation – root cause analysis to minimise or even eliminate process


attributed corrosion including material selection, to maximise production uptime, 25 to 50
sensors per unit operations, payback within weeks

• Extended equipment life span and planned shutdown – understanding of corrosion


behaviour to implement self regulation asset management system, determine planned
shutdown period, 25 to 50 sensors per unit operations, payback within weeks

• Unmanned operations/reduction of OPEX – to minimise human intervention especially to


hazardous, inaccessible area or unmanned platform resulting in improved safety and
reduction of operational cost, 25 to 50 sensors per platform, payback within months

• Treatment optimisation – monitor effectiveness of chemical injection, optimise chemical


consumption and minimise inevitable corrosion, 15 to 25 sensors per unit operations,
payback within months
Organic Chloride Contaminated
Crude Oil Challenge

20
Druzhba Pipeline - Chlorine Contaminated Crude Oil
• Between April and June 2019, Central and
Eastern Europe experienced interrupted
deliveries of crude via the Druzhba pipeline
• Crude oil in the Druzhba pipeline was
contaminated by organic chlorides
• Varying levels of organic chlorides of up to
150ppm
• Need for blending strategies & real time
corrosion monitoring
• Petrochemical industry having the fear of
contaminated feedstock from the refineries

Emerson Confidential 5
Refining case study: The contaminated crude oil corrosion monitoring
challenge

• Contaminated oil accelerates the corrosion process


– organic chlorides: residues from chemicals used for well stimulation in the upstream oil production

• Expected to cause corrosion when process liquid condenses

• 4 units instrumented: ~50 sensors each


– 3x crude distillation units
– 1x isomerization unit

Emerson Confidential 6
Case Study: Crude Unit Monitoring
• ~50 sensors per unit 30
• Corrosion monitoring used to
evaluate mix rate of 4
contaminated to
uncontaminated crude
6

• Risk areas:
1. Condensation in overhead line
• Before and after inhibitor 2
injection
• Large area
2. High temperature crude
3. Sidecuts 6

Emerson Confidential 7
Caste Study: Track record in monitoring crude units for organic chlorides

• Another North American customer monitors distillation unit overhead system


• Period marked by the red dot showed markedly higher corrosion rates than normal
• Crude type was not unusual and had been processed previously
• No unusual process measurements
• Samples of the crude oil were analysed in
lab
– Result: high (and unusual) level of organic
chlorides
• Customer now routinely tests every import
of crude for organic acids to pre-empt any
corrosion problems

Emerson Confidential 8
Case Study: Isomerization Unit Monitoring
• ~50 sensors per unit
• Monitoring corrosion caused by
10
condensation
27

• Risk areas:
1. Post-reaction mixture gradually
cooling down
2. Vapours/fumes from stabilizer 8

Emerson Confidential 9
Benefits of Online Corrosion Monitoring for Organic Chlorides
• More profitable blending strategy – higher chloride content

• Avoiding unplanned shutdowns

• Safer operations

Emerson Confidential 10
Refinery Case Study
Amine Unit Corrosion
Monitoring
Overview of Corrosion Issues in Amine Units
• Corrosion in amine units can be divided in
two types

– Wet acid gas corrosion of carbon steel from the


reaction of CO2 and H2S with iron through a thin
liquid film;
– Amine solution corrosion of carbon steel in the
presence of aqueous amine

• Key variables for assessing amine unit


corrosion
Figure above shows the predicted variation of corrosion rates for carbon
– Acid gas loading steel with amine acid gas loading and velocity. This shows that, as would
– Velocity and wall shear stress be expected, high rich amine H2S loading combined with high velocity
results in higher corrosion rates.
– Temperature
– Impurities and heat stable amine salts
– CO2 to H2S ratio
– Choice of amine type
Amine Unit Process Overview

Corrosion issues
– High gas loading
– Heat stable salts
– Amine degradation
– Oxygen contamination

Corrosion is uniform and not so localised


– Fewer measurements needed to represent
entire system
– Elbows, bends, tees, exchanger shells
– Lower temperature application, ET210s
Permasense Solution for Amine Units
Permasense Solution for Amine Units
• Continuous wall thickness measurement
sensors are ideally suited to monitor
corrosion in the highest risk areas of amine
units

• The monitoring data enables engineers to


– Reliably determine if corrosion is taking place
– Supporting the management of unit integrity
between planned shutdowns
– Understanding the correlation between corrosion
rates and process conditions
– Optimizing corrosion monitoring prevention &
mitigation measures
Case Study: Preventing Unplanned Outages – Amine unit

1 ■ Refinery with four amine absorber / regeneration trains


■ All similarly configured, all stainless steel – corrosion NOT
expected
• Much faster and unexpected corrosion in train 4
- 1 year to retirement even in stainless !
2
• High CO2 content feed due to preferential routing of FCC
off-gas to train 4
• Carbonic acid attack mechanism
3 • Feeds redistributed to dilute effect of CO2 corrosion across
trains and extend run length

Early warning & enable decision making on process


42 mpy optimization to extend equipment life span
4
Case Study: Amine Regenerator – Process Optimization
 Historically controlled amine
dump/top-up to heat stable salts
level of ≤1

 Opex savings from fewer amine


changes – targeted 1.5, then 2

 Reboiler outlet corrosion


monitored

 Rising corrosion rate trend over


time corresponding to increasing
heat stable salts content

 Trade-off operating cost saving


against equipment replacement
cost
Commercial Impact of Amine Unit Shutdowns
• The commercial impact of an amine system outage on a given plant will depend on the type of
plant, its specific configuration and the feed quality, but is often significant

• Amine units often operated at significantly higher processing rates and amine H2S loading
– This causes limits in the flexibility that the processing facility has to shut down the amine system for repairs in
the event of a corrosion-induced leak, as the risk of H2S gas evolution

• Without storage for rich amine, the facility is forced to limit the H2S load on the amine system
by, for example:
– Change of feedstock (heavy, high sulphur crudes changed to light, lower sulphur, and more expensive
feeds),
– Reduced production rate (lower natural gas feed rate to a gas processing platform or onshore plant)
– Change of production mode (yielding high sulphur, raw gas oil to storage for
Sensor Mounting

53
Sensor Installation Examples
Sensor Installation Examples
Emerson solutions help meet future business
demands safely

Reduce OPEX safely SAVE $100,000s

GENERATE $$
Optimize operations MILLIONS

AVOID SPENDING/LOSSES $$$


Avoid major incidents TENS OF MILLIONS+
Appendix 10

A new hydrogen flux monitor with inspection


and multipoint extended monitoring capabilities

(Frank Dean)

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


Eurocorr 2019
Seville 11 Sept 2019
WP15 meeting

Hydrosteel 6500
A new hydrogen flux monitor with
extended monitoring capability.

Frank Dean, consultant


[email protected]

Measure corrosion and hydrogen damage. In real time. Non-intrusively.


Ver. 190907
DATE
Unrivalled Gas Detection ionscience.com
Hydrogen permeation schematic

Hydrogen activity H activity


at an entry face
is the ‘engine’
for flux
H concentration
measured on the
external face

H permeation
H entry H2 exit
H segregation
H H
H H
H2 H H H2 H
H2 H+ H H
H H H H
H+ H H
H H H H H2
H HH
H+ H2

Air
(Oxide,
coatings)
(Scale,

inhibitors)`
coatings,
fluid
Corrosive

ionscience.com
Copyright Ion Science Ltd, 2010
Principle of operation

...increases the H2 concentration in air by c...

Detector exhaust
pump

Capillary  Flux J = F x c / A
...in a well
defined flow of
air F...
Steel surface
Collector
direction of air flow

Hydrogen captured from a well defined area, A...


ionscience.com
Method and devices patented, manufactured and supplied by Ion Science Ltd, UK
Main industrial interests in hydrogen flux
Corrosive wall loss …and hydrogen damage (HIC)

T. Batzinger, A May, C. Lester, K. Kutty , P. Allison, 16th World Conference on W.Bruckoff et.al., Corrosion ‘85, Paper 389, NACE conference series,
NDT, 2004, Montreal, Canada Boston, Mass. 1985.

ionscience.com
Refinery corrosion detected with Hydrosteel
Fuel gas
Other gases Amine unit Refinery fuel
Claus sulfur plant Sulfur
Gas processing Merox treaters LPG, butanes Corrosion Key:
Gas Gas H2 Gas H2 amine
Light Isomerate sour
Atmospheric distillation
Hydrotreater Isomerisation
naphtha
ammonium bisulfide

PRODUCTS OUT
Gas H2
CRUDE FEED IN

Gas H2
Heavy naphtha Catalytic Reformate HF
Hydrotreater Gas H2 reformer NAC/sulfidic
Jet fuel Merox Jet fuel

Hydrocrack
Kerosene treater and/or Hydrocracked gasoline
Gas H2 Kerosene

er
Diesel oil
Diesel oil Diesel oil
Hydrotreater Gas
Butenes Alkylate
Atmospheric Alkylation
gas oil Heavy vac. gas
oil Gas Pentenes
Evacuated non- Gas H2
condensibles Gas H2 naphtha FCC gasoline
Atmospher
ic bottoms

Hydrotreater
FCC feed

FCC
distillation

Light vac. Hydrotreater FCC gas oil


Vacuum

Gas Fuel oil


gas oil

Heavy vac. Coker naphtha


Delayed
coker

gas oil
H2S to sulfur plant
Vacuum Coker gas oil
Sour waters

stripper
residuum

water
Sour
Petroleum
Asphalt coke
air blower Asphalt
steam
Stripped water
CO2
Natural gas Hydrogen H2
Steam plant
ionscience.com
Multipoint spot measurements: episodic crack risk

Historic HIC damage To identify a HIC


Liquid level at
0 0 0 0 time of conditions,
0 measurement
0 0 episode, at least
0
3 two monitoring
15 5 points are
53 27 23 15
14 required
6
0
Overhead condenser. Numbers
indicate flux in pL/cm2/s 0

ionscience.com
Copyright Ion Science Ltd, UK
Multipoint spot measurements: high temperature corrosion (1)

ionscience.com
Multipoint spot measurements: high temperature corrosion (2)

Flux monitor
data for up to a
few months at
multiple points at
a few points will
assure full
realisation of
corrosion severity
over a typical
corrosion epoch

ionscience.com
Multipoint spot measurements: HIC risk
Start of inhibitor dosing

250 Automated
monitoring of
200 flux at multiple
points would
H2 flux [pL/cm² s]

150 save time.

100

50

0
18/12/05 28/12/05 7/1/06 17/1/06 27/1/06 6/2/06 16/2/06 26/2/06
Date

ionscience.com
Multipoint spot measurements: hydrogen bakeout

F
Automated
E
monitoring of
G
D flux at multiple
3.00 points would
ppm.cm: assure full
= 1.2 ppm
from 2.5 cm bakeout.
depth.

C
Direction of
delamination H
growth

A B

ionscience.com
C.N.Brown, M.J.Carroll, F.W.H.Dean, J.H.Harrison, A.Kettle, Corrosion 2004, NACE, Paper 04478 .
8
Overview of Hydrosteel 6500 5
7
[1] Ruggedised field analyser with program operation and 1 11
data monitoring capability. 10
[2] New 150 mm high sensitivity probe
9
[3] New 60 mm low sensitivity probe
[4] Steel clad flexible sample conduit – up to 10 m length
[5] Four ports for sequential flux monitoring
[6] Staubli® connectors afford easy pneumatic fitting to
ports. 2
[7] Battery charge connector.
[8] USB connector for data download and program 3
upload. 4
6
[9] Robust push button finger operation
[10] Large display with backlight
[11] Provision for wireless communication and
networking
ATEX certification.

ionscience.com
Application features and benefits of Hydrosteel

• wide dynamic range


• fast response
• simple to use
• no consumables
• usually no surface prep
• adapts to pipe > 3.5”
• operates upside down
• useable to 500 oC
• monitors up to four locations for up to three months

• measures active corrosion and crack risk, non-intrusively

ionscience.com
Hydrosteel 6500: spot flux kit

Conduit SR large roaming probe

LR large roaming probe

Analyser and harness

Copyright Ion Science Ltd, UK ionscience.com


Hydrosteel 6500 spot monitoring
Simultaneous flux measurement evaluation liquid in/out gas in gas out T
Shot blast to Butyl rubber
SA 2.5 std seals
Add 4 L NACE B soln
(pH 3.6), mag flea,
stock H2S

6.7 in dia, 9 mm wall


seemless C steel pipe

Acrylic end
piece
ionscience.com
Repeatability on probe detachment at single site

F.W.H.Dean, A.Witty, A.Zanre, Corrosion 2017, Paper 9694, NACE, Houston 2017 . ionscience.com
Co-trending of flux (1)
F.W.H.Dean, A.Witty, A.Zanre, Corrosion 2017, Paper 9694, Conference Series, NACE, Houston 2017.

Automated
monitoring of
flux at multiple
points would
ensure more
accurate and
assured
realisation of
corrosion severity
and save time.

F.W.H.Dean, A.Witty, A.Zanre, Corrosion 2017, Paper 9694, NACE, Houston 2017 . ionscience.com
Co-trending of flux (2)

Automated
monitoring of
flux at multiple
points would
ensure more
accurate and
Flux ratio

assured
realisation of
corrosion severity
and save time.

F.W.H.Dean, A.Witty, A.Zanre, Corrosion 2017, Paper 9694, Conference Series, NACE, Houston 2017. ionscience.com
Multipoint spot measurements (vertical profile)

Flux was not


subject to vertical
variance, even at
the liquid level

F.W.H.Dean, A.Witty, A.Zanre, Corrosion 2017, Paper 9694, NACE, Houston 2017 . ionscience.com
Data interpretation
Sour corrosion
In assessing sour corrosion, flux measurements are most reliable where corrosion is contingent
on removal of corrosive scale. Such corrosion occurs in distillation units, overhead, eg in
condensers, fin-fan units, coolers and sour flare lines. It can be very severe (>500 pL/cm2/s)
and is often associated with hydrogen damage (see separate slide). It is usually episodic,
occurring typically after equipment installation, inspection, or sometimes during process
changes (eg air ingress, water washes, pH changes). Typically, >5 pL/cm2/s indicates some
corrosion activity, and 100 pL/cm2/s moderate corrosion. The chart below may also be used to
assess corrosion under deposits, eg in amine units.
Please contact Ion Science for further details.

1 10 100 1000 10000


Flux-thickness, pL/cm/s
Insructions: Multiply flux in pL/cm2/s by test site thickness in cm, to obtain a flux-thickness in pL/cm/s. Look along
bottom of chart for corrosion rate. Note corrosion flux correlation varies in a complex way with other corrosion variables,
not least temperature. This makes the correlation very approximate.
eg, flux = 20 pL/cm2/s, thickness = ½ in = 1.25 cm => flux-thickness = 25 pL/cm/s. Corrosion rate is very approximately
0.2 mm/yr, 8 mil/yr.

ionscience.com
For indication only. Copyright © Ion Science 2008. All rights reserved.
Data interpretation
HF acid corrosion
5 pL/cm2/s indicates very low but definite HF corrosion. 300-500 pL/cm2/s is common,. HF is
used to catalyse the formation of high octane gasoline – alkylate – from smaller olefins in HF
alkylation units. The alternative catalyst – sulfuric acid – also causes corrosion but provides a
much weaker flux signal. HF corrosion is very widespread and continuous. There is probably
some temperature dependency for corrosion-flux correlation not shown on the chart.

1 10 100 1000 10000


Flux-thickness, pL/cm/s

Instructions: Multiply flux in pL/cm2/s by test site thickness in cm, to obtain a flux-thickness in pL/cm/s. Locate this value on the x-axis
and corresponding approximate corrosion rate.
eg, flux = 200 pL/cm2/s, thickness = 2 cm => flux-thickness = 400 pL/cm/s. Corrosion rate is approximately 0.5 mm/yr, 8 mils/yr.

ionscience.com
For indication only. Copyright © Ion Science 2008. All rights reserved.
Data interpretation
Naphthenic acid and sulfidic corrosion
A few 10’s of pL/cm2/s indicate active corrosion. A few thousand pL/cm2/s have been registered in very acid corrosive streams. ‘Naphthenic
acid’ is in fact a large family of acids found in crude oil. Corrosion generally occurs at pipe bends and reducer sections. The correlation
below is based on lab experiments and some field data. The chart is also applicable to other acidic corrodants above about 150 oC, 300 oF.
Please contact Ion Science400 for further technical information.
0.02
mm/yr
0.05
350 mm/yr
0.1 mm/yr
Temperature, C .

0.2 mm/yr
o

300
0.5 mm/yr

1 mm/yr
250
2 mm/yr

5 mm/yr
200

10 mm/yr

150
10 100 1000 10000
Flux-thickness, pL/cm/s
Instructions: Multiply flux by test site thickness in cm to obtain a flux-thickness. Locate this value on the x-axis. Look up
temperature on the y-axis. The corrosion rate through mild steel is demarcated between lines.
ionscience.com
For indication only. Copyright © Ion Science 2008. All rights res
Data interpretation
Hydrogen cracking
Generally, hydrogen cracks are initiatied in poor quality, non-sour service steels, and welds, at activities as low as 10000 bar, whereas sour
service steels can withstand at least 1,000,000 bar. After cracks have appeared, much lower activities are needed to propagate them, indeed,
any flux may contribute to further crack growth.
Iso-hydrogen activity contour map
400 752

350

300
Temperature (deg C)

250

200

150

100

50

0 32
1 10 100 1000 10000
Steady state flux (pl/sqcm/s) x thickness (cm)

Instructions: Using the hydrogen activity expressed in bar obtained in step 1. See S.Al-Sulaiman, A.Al-Mithin,
A.Al-Shamari, M.Islam, S.S.Prakash, ‘Assessing the possibility of hydrogen damage in crude oil processing
equipment’, Corrosion 2010, Paper 10176, Conference series, NACE, Houston, 2010 . ionscience.com
Conclusions

A new Hydrosteel analyser is introduced:


• More robust probes
• Extended monitoring capability
• Multiple point monitoring

Please contact
[email protected]
If interested.

Thank you for your attention

ionscience.com
Appendix 11

“Corrosion Software Sensor” – A New


Framework to utilize the power of process
data and prediction tools

(Slawomir Kus)

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


“CORROSION SOFTWARE SENSOR”
A NEW FRAMEWORK TO UTILIZE THE POWER OF
PROCESS DATA AND PREDICTION MODELS
AGENDA

“Software sensor”
➢ General concept
➢ Structure, Requirements, Scalability
Application case study (EU Refinery)
➢ General information
➢ Implementation approach
➢ Outcomes
Summary & Discussion

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved. 1


FROM “STATIC” TO “REAL-TIME” CORROSION QUANTIFICATION – HISTORICAL VIEW

Velocity <30m/s

Y N
• “Consensus”
• Arbitrary correction factors Use CR from Tables CR x5

70-80s XX • In several areas found misleading about expected


API RP581, 932B corrosion rate (NH4HS, sulfidic/Nap acid)

Corrosion Rate vs % Cr Alloy


T = 600 F

• Based on extensive studies on specific corrosion 160


H2S Interaction with TAN 5.5 Oil No added
H2S - NAT =
4.6

mechanisms 140

120

• Utilizing modern IT systems to generate multiparametric 100


0.5% H2S -

CR, mpy
NAT = 4.6
80

90s XX corrosion modelling framework 60

• Field-proven
40

“Static” software 20
5% H2S -

models 0
0 5 10 15
NAT = 4.6

% Cr Alloy

• Combining “static” models and “live” data streams from


Process Historian
• Automated predictions are following process changes
XXI
• High level analytics with “live” Corrosion/Inspection
Prediction in KPI’s
real time

“SOFTWARE SENSOR” CONCEPT Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved. 2
SOFTWARE AS A CORROSION SENSOR – CONCEPT

“Software corrosion sensor” is a scalable and


adaptive IT framework designed to glean
process driven corrosion insights and provide
process-corrosion relations in real time.

The software sensor platform utilizes “live”


process data streams available in the Historian
and proven corrosion models to deliver
Inputs II
quantified corrosion info:
- corrosion rate Corrosion/Inspection
- flow parameters (WSS, flow pattern) - Coupons (manual)
- ER (manual/auto)
- LPR (manual/auto)
- UT (manual/auto)
Software sensor can also provide:
- real time KPI’s
- real time integrity overview
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
3
HOW DOES IT WORK?

- Real or virtual server

- Network Level (3.5 or 4)

- Security and user access

- OPC connectivity

- DA (data access)

- HDA (historic data access)

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.4


WHAT INFORMATION IS NEEDED?

Process Control/Instrumentation/Systems
• Process Flow Diagrams • Tags for Instruments/Measurements
• Process and Instrumentation Diagrams (P&IDs) • Tags for Lab data
• Operating Conditions • Tags for results (if needed)
• Best Instruments/Measurements representing • Calculated Tags
circuits conditions • If flow estimates are needed
• Sampling points for Lab analyses • If Eng. Unit conversions are needed

Inspection/Corrosion IT/Systems
• Corrosion Loops (Corrosion Control Documents) • OPC Connectivity
• Piping Circuits • User & Admin access/permissions
• Inspections, Thickness Monitoring Locations • Backups & Maintenance
(TML) and Thickness data • Network Architecture
• Piping Isometrics, Materials, Diameters,
Initial/Design Thicknesses
• Sampling points for Lab analyses
• Corrosion Failure History
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
TIMING AND RESOURCES

Services:
• “static” modelling
• Configuration table

Hardware/ software
Windows 2012 R2; SQL Server 2012 R2

Data
SQL Server Reporting Services; IIS (Web Server);
OPC server license
Processor: Two Quad Processors, 3GHz, 64-bit (x64) Typical timing: 1-3 months
RAM: 16 gigabytes (GB) (start-commissioning) / based
Hard disk drive: 500GB on unit size and complexity

Typical refinery manpower required:


2 engineers for 1-2 weeks
Start
(corrosion/process & IT)
Software Sensor
Commissioning

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved. 6


SCALABILITY
HT/HC/SWS
CDU OH
• 50-100 Soft Points
• 3-6 Hardware • 100-200 Soft Points
• 2-6 Analysis/Lab • 2-5 Hardware
NH4Cl
HCl(aq) • 3-6 Analysis/Lab

CDU
NH4HS

REGENERATOR OH
Sulfidation
NH4HS
NAP Acids

Refinery Corrosion Framework Amine Corrosion

• 300-600 Soft-Sensor Points

VDU
• x number of materials
• c.a. 20 Hardware points AMINE
• 6-10 months effective project time Sulfidation
NAP Acids
• 50-100 Soft Points
• 4-8 Hardware
• 100- 200 Soft Points
• 3-6 Analysis/Lab
LEGEND: • 2-5 Hardware
Sulfidation – available models
• 1-3 Analysis/Lab Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
SOFTWARE SENSOR IMPLEMENTATION – CASE STUDY

Goals: Details:
• Location: EU Refinery
➢ Deliver a process-integrated
• HVGO Line
solution for real time, quantified
• 5Cr material
corrosion rates and process
• 15 modelling points – 45 Tags in
correlations in HVGO line.
Historian
➢ Show utilization of Corrosion as - Pipe MoC Corrosion rate per JIP – 15
a process variable (PV) and Tags (update every 10min)
- 1-D Average MoC Corrosion Rate – 15
present potential for real-time Tags (daily update)
corrosion management purposes - Predicted Wall Thickness – 15 Tags (daily
in CDU/VDU update)
• +200 tags saved in Prediction Server
• Historian – OSI/PI
• Prediction Model – Predict Crude

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved. 8


TASK 1 - SELECTION OF MODELLING POINTS – HVGO (EXAMPLE)

RT-2

RT-3

RT-14 RT-13
RT-4
RT-11

RT-5
RT-15 RT-12 HVGO Pumps
HVGO Pumps
RT-1 100-P1XX/a/b/c
100-P1XX/a/b/c

RT-6 RT-8

Exchangers
RT-9
100S1XA/B RT-10
Column CX
RT-7

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved. 9


TASK 1.1 - “OFFLINE” MODELLING TO CONFIRM HOT SPOTS

Measured parameter DCS Tag from DCS Unit


Temp in CX near outlet of HVGO 100-TI-0xxx-23 269 degC
HVGO Hot circulation flow 100-FIC-00x6 59 m3/h
HVGO PA flow 100-FIC-00x6 515 m3/h
HVGO return temp (measured in CX) 100-TI0115-xx 248 degC

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved. 10


TASK 2&3 – IMPLEMENTATION & SUPPORT

Task 1
Task 2: Software Implementation
Modelling Outcome

IT Infrastructure

Functional Design

Detailed Design (IT)

Software Installation

Detailed Design (Config)

11
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
TASK 2&3 – IMPLEMENTATION & SUPPORT

Task 1
Task 2: Software Implementation
Modelling Outcome

IT Infrastructure

Functional Design

Detailed Design (IT)

Software Installation

Detailed Design (Config)

Soft. Configuration

Training

Task 3: Consulting & Support

12
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
SOFT-SENSOR FRAMEWORK OUTPUT

Real time Support Inspection CR for different


corrosion status Planning MoCs

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved. 13


SOFT-SENSOR FRAMEWORK OUTPUT
Real Time Corrosion Status

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved. 14


SOFT-SENSOR FRAMEWORK OUTPUT

Support Inspection Planning

Real time Support Inspection CR for different


corrosion status Planning MoCs

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved. 15


SOFT-SENSOR FRAMEWORK OUTPUT

Corrosion Rates For Various Materials

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved. 16


LIVE TRENDING

• “Live” & historical trending from Real Time Framework level


• 10min update rate
• Process vs Corrosion Rate (predicted and measured – if any available)
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved. 17
LIVE TRENDING

Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved. 18


SUMMARY
➢ “Software Sensor” concept provides the next generation of predictive insights
for real time, intelligent corrosion analysis
➢ Combines stand alone modelling, “live” process data and corrosion
measurements
➢ Real Time Modelling Framework provides quantified insights into corrosion risk
and identification of corrosion hot spots in key refinery units
➢ “Software Sensor” Framework delivers the following features:
➢ Real-time Assessment of corrosion “hot-spots”
➢ On-line corrosion-process correlations (corrosion as one of PVs)
➢ Real-Time Corrosion KPIs
➢ High-level overview of Unit/Refinery Integrity status

➢ Analytical Framework is easily scalable to expand coverage in critical areas in


key refinery operating units
Honeywell Confidential - ©2019 by Honeywell International Inc. All rights reserved.
Appendix 12

Infra Red Thermography: a reliable,


Fast and helpful method in corrosion
detection

(Askar Soltani)

Minutes of EFC WP15 Corrosion in the Refinery Industry 11 September 2019


Infrared Thermography
A reliable, Fast and helpful method in corrosion detection

Presented By: Askar Soltani


IR thermography has been applied in different industries as a useful
method. Unfortunately in oil and gas industry it is not being applied as
a useful instrument to detect corrosion, however it can be used as a
helpful instrument beside UT measurements to detect corroded areas
or areas in the pipe or vessels which hard scales precipitation is likely
to occur. Hereafter some IR thermal images have been indicated
which reveals operating problems detected by thermal cameras.

IR scan of inlet piping to three air cooler headers


[Ref.: NACE paper no. 10362]
IR scan at water injection point
[Ref.: NACE paper no. 10362]

IR scan of a sound steam trap [Ref.: Irinfo.org]


IR scan of a failed steam trap [Ref.: Irinfo.org]

During our PPM check, severe corrosion detected by UT measurements. It


was hard to prove the reliability of UT measurements and declare with
100% of confidence that the pipe has been corroded severely and it needed
to shut down the unit in order to cut and inspect the pipe. So, the
inspection team decided to conduct a complementary non-destructive
method in order to make sure of the extent of corrosion. IR thermography
was done and IR thermal images revealed significant temperature gradient
in some parts of the pipe. Cutting the pipe approved our hypothesis. Here
after thermal images and also pictures of pipe after cutting have been
indicated.
Fig 1: Results of UT measurements on 10 inch equalizer pipe in slug catcher indicated
Severe metal loss in this pipe

Fig 2: IR image which indicates some parts of pipe has higher temperature compared to other parts
(approx. 10 degree C temperature difference in the pipe is obvious), After cutting the pipe we
observed that the sections of the 10 inch pipe with similar temperature to the main 42 inch pipe had
no scale inside them, however the parts with higher temperature were full of scales.
Fig 3: IR thermal image of the 10 inch line indicating the high
temperature in this section of pipe. After cutting the pipe, it
was full of scale. So, thermal imaging was able to be used as a
complementary non-destructive tool beside UT measurement
to determine the corroded areas.

Our experience indicated that IR thermography can be used as a


helpful complementary non-destructive method beside UT
measurements in order to detect corroded areas in the pipes of oil and
gas industries.

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