Corrosion Monitoring and Control in Refinery Process Units (51300-97512-Sg)

512
CORROSION MONITORING AND CONTROL

IN REFINERY PROCESS UNITS
Alec Groysman
Oil Refineries Ltd.

P.O. Box 4
31000 Haifa, Israel
Avihu Hiram
HIRAM - Process Control Eng. Ltd
22 Martin Buber St
34861 Haifa, Israel
eMail:hiram@netvision.
net.il
ABSTRACT
This paper describes the experience gained in corrosion monitoring in the overhead
systems of three crude dktillation units of a refinery in Haifa, Israel.
The data of electrical resistance (ER) probes, connected to an on-line data acquisition
system were compared with the mass loss method and chemical analysis of accumulated sour
water tier condensation in the overhead system,
SEM & EDS anrdysis of films and deposits formed on the coupons showed that iron
sulfide with impurities of chlorides are responsible for the comosion extent. The corrosion was
less than 5 MPY when a uniform tenacious iron sulfide tilms of 10-50 microns thickness were
formed. The severe corrosion occurred when deposits and non-uniform films of more than 80100 microns thickness were formed.
Special attention was given to ER probes which were connected on-line to the process
units and enabled the operators to react immediately to any change in corrosion rates.
KEYWORDS: corrosion monitoring, crude distillation unit, mass loss method
(coupons), electrical resistance @R) probes, on-line corrosion monitoring
system, Distributed Control System (DC S), accumulated condensed sour water.
Copyright
01997 by NACE International. Requests for permission to publish this manuscript in any form, in part or in whole must be made in writing to NACE
International, Conferences Division, P.O. Box 218340, Houston, Texas 77218-S340. The material presented and the views expressed in this
paper are solely those of the author(s) and are not necessarily endorsed by the Association. Printed in the U.S.A.
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Paper No.
Crude oil contains different species which while beii

into substances corrosive to alloys.
processed reacted or converted
Water is condensed during the production processes and gases like hydrogen chloride
(I-ICI) and hydrogen sulfide (H,S) are dissolved in this water, various salts (chlorides,
sulfides, hydrosulfides) and oxide-hydroxide deposits formed on the metal surhces result in
severe corrosion in the overhead system of the crude distiition unit. Air coolers, heat
exchangers, condemers and pipes made of carbon steel suffkr km general corrosiorq
pitting corrosio~ and under deposit corrosion.
Prevention of corrosion damage and possible detrimental eflkcts on the environment
depend on knowledge of the corrosion situation at the units, that is corrosion behavior of
metallic equipment, especially their corrosion rates and corrosion forms.
Various types of corrosion monitoring methods were recommended fix follow-up in
the overhead system of dkdlation units [1,2]. We did not tind literature comparing the
various types of monitoring results and how ef%ctive it is in evaluating real time corrosion.
SEM & EDS method is widely used for the identitlcation of corrosion products [3],
but we did not find in the literature, how this method is particularly used fir the chemical
idedfkation of corrosion products and morphology of coupons surfhces f.iom the
overhead system.
Given this apparent lack of well published basis for using various corrosion
monitoring techniques, we attempted to use our practical experience to define ways how to
utilize these tools to monitor Real Time Corrosion in the Equipment.
Corrosion follow-up in the overhead systems of three crude distillation units consisted
of on-line monitoring with ER-probe measurements, long-term mass loss coupon
mewurements, visual examination of coupons, identification of deposits fbrmed on CQupons
and investigation of coupons surt%cesby means of SEM & EDS, and chemical analysis of
accumulated condensed sour water.
The collected intlmnation is analyzd by experts and conclusions are drawn as of the
required changes in the anti-corrosion treatment program The datz their treatment, the
analysis and the conclusions are presented in a periodic report by the corrosion engineer to
the management, to the operation people, to the maintenance and to the technical services.
Some of the information is also presented in an on line tiormation system and are made
available to all concerning stti.
These also serve the goal of improving anti-corrosion meSSUre$ prediction of
equipment service Ii@ decision of needed maintenance and shutdown period.
512/2
INTRODUCTION
PROCEDURE
A. MASS LOSS (ML) METHOD
Retractable corrosion probes with coupons were used, The mass loss of coupons
made of a carbon steel (the same material the corrosion of which we want to monitor) strip
specimen and their corrosion rates were measured every 40-60 days. The exposure period
depended on the corrosion, In some cases, where the corrosion rate was too low to be
measur@ we had to extend this period up to 190 days.
After the retraction of the coupons, hydrochloric acid (5%) with organic corrosion
inhibitor was used for cleaning coupons surthces from corrosion products and W.
Analytical weighing was used for definition of the mass loss of the specimen.
B. ELECTRICAL RESISTANCE (ER) METHOD
Retractable ER-probes were used fix measuring changes of electricrd resistance of
sensor made of carbon steel wire or cylinder and thus corrosion rate. The ER-probes were
located m close proximity to the corrosion coupons, close to the wall of heat exchangers or
pipes as possible. The measuring of changes in the electrical resistance of the sensor was
done by portable device or continually monitored by an on-line monitoring (acquisition)
system.
The corrosion rates were
versus Measuring time.
calculated
from the slope of line Dial reading of ER-probe
The on-line monitoring included also data collecting systeq calculations, performing
and utilization of received data.
C. CHEMICAL
ANALYSIS OF ACCUMULATED
CONDENSED
SOUR WATER
The chemical analysis of corrodents (pH, chlorides, sulfldes, sulfhtes) and corrosion
product (iron) in accumulated water was carried-out five times a week by means of
conventional laboratory methods. The data of pH measurements under laboratory
conditions were compared with on-line pH-meters which are mounted in the process
streams as part of the operating monitoring and control system. The data obtained in the
laboratory were also made available to the techuical team.
D. VISUAL EXAMINATION
OF COUPONS
Visual inspection of coupons surthces was done every 40-60 or 190 days, tier
removing from the places of their mounting in the system
The presence of tilm and deposits fbrmed on the coupons surfhces, their unifiorrnity,
pits or other corrosion phenomena or damages were descrii.
512/3
EXPERIMENTAL
device for measmhg non-conductive or non-magnetic ilhns on the iron. Some expertise and
experkme needed in order to make out the important tits which should be considered in
the anti-corrosion efforts.
E. THE IDENTIFICATION
OF CORROSION
PRODUCTS
ON THE COUPONS
The chemical composition of corrosion products, films and other deposits formed on
coupons surhces as well as morphology of these surfhces after removing of deposits was
M
by IIBXUIS
of SEM & EDS. The device JSM-5400 of JEOL was used fix these
purposes.
RESULTS AND THEIR DISCUSSION
The arrangement of corrosion probes in the overhead systems of a typical crude

distillation units is presented m Figure 1. The general scheme of corrosion monitoring logic,
the relationship betsveen its various methods and its posslMlities are descrii
in F~e 2.
I. CHEMICAL ANALYSIS
OF ACCUMULATED
SOUR WATER
h chemical analysis of accumulated sour water formed after condensation of

overhead gases from the atmospheric dihlhtion colurnm+ has been used for many years to
make out the details about corrosion behavior in the overhead systems. The chemical
analysis of the corrodents (p~ chlorides, sulfides, suliktes) and the corrosion product
(dissolved iron mainly) give relatively fhst and reliable picture of both sides of the
corrosion system. These data fimilitate improving neutralization and inlrdition treatment in
the overhead system and improving the desalting process of the crude.
The chemical data of accumulated sour water do not reflect exactly the real corrosion
situation in the overhead system. The tit reason is that the most vulnerable place from the
corrosion point of view is situated in the air coolers and condensers - heat exchangers
where the shock condensation is taking place (see Figure 1). It is clear that there are
di.tlierences between pH, corrodent content in the overhead (m the place of shock
condensation) and below in the accumulated water drum (the water sampling place for the
chemical analysis). The second reason is that the iron content in sour water does not always
reflect real corrosion situation. For example, iron sulfide formed on the surhce of carbon
steel may dissolve as a result of pH changes or concentrations of other species and not as a
result of a corrosion process.
The chemical data enable the indication of corrosion situation and general Mormation
in the overhead system. It is acceptable to run the system with pH values of 5.5-6.5 subject
to cldondes and iron content lower than 20 ppm and 0.5 ppm respectively. Information
about corrodents and corrosion product content enable improving anti-corrosion treatment.
51214
The film and deposit thickness on the specimen was measured by means of special
The chemical method gives qualitative rather than quantitative information of the
corrosion situAon. Therefore the metal loss coupons, visual examinatio~ identification of
corrosion products and iilrns and ER - probes were utilized to complete the picture of the
corrosion in the overhead system of the crude distillation units.
II. MASS LOSS (ML) METHOD
This method is descriid in literature [4,5]. There is no universal method for

corrosion follow-up. Every method has advantages and d~vantages,
limits and benefits.
Mass loss method enables memwing the average corrosion rate over a period. Visual
-on
enables detining the presence of deposits and pits. The salt deposits on the
coupon aurt%cesshows the necessity of increase washing m the overhead system.
Chemical identiktion
of films and deposits firmed on the surf%cespecimen enables

ascertaining corrosion mechanisms, that is the causes of corrosion process and thus
Cbinkh@ or preventing its spreading.
The results of mass loss method corrosion follow-up that have been collected for the
last two years are presented in F3.
The strip coupons show the corrosion situation only in the places of its mounting. The
corrosion situation may dif.lkrin the other places of the system. Therefore the more coupons
we insert in the overhead system the better picture we are going to get of the real
corrosion situation.
The exposure period of coupons dependa on the expected corrosion rate values,
There is no sense in taking measurements and hence having no mea.ni@d value when the
corrosion rates are too low to determine. The exposure period for coupons was first set to
30 days and then extended up to 60 days and 190 days when corrosion rates were low
(thousandths and hundredths mdy), m order to receive reliable and correct data. The
obtained data show that corrosion rate of carbon steel before the air cooler is higher than
tier its heat exchangers (see Fw. 3).
This tit
indicates that condensation occurs kefore air cooler.
One should note that corrosion rate in some cases is twice the permissible value
(accepted, dangerous or limiting). This permissible corrosion rate was determined as 0.11
nnrdy (5 MPY) for the carbon steel tube bundles of air coolers, heat exchangers and
condensers. It is very important to achieve a correct interpretation of mass loss coupon
51215
High changes of pH values as well as content of chlorides and iron in sour water
indicate an unstable conditions in processing and as a result bad corrosion behavior. In
spite of this, there is no iniiormation about the real corrosion rates and the actual corrosion
forms. There is no way to forecast, km the chemical analysis of the sour water only, the
tube service life and shut-down periods.
0.7 * 2.336 Lnrn/15y = 0.11 MM/y(5 my),

where 0.7 - wear and tear coefficient, that is the maximum percent (70??) that
thickness of tubes are allowed to be diminished up to its replacement. It means that
corrosion rate up to 0.11 nudy is acceptable.
This value cotildes with the one NACE recommendation as an accepted low
corrosion rate for the equipment in the oil industry [4].
SEM & EDS analysis of corrosion products and films formed on coupons
In addition to corrosion rate values, coupons enable defining corrosion form and
mechanism based on surfhce state (morphology) and chemical identification of films and
corrosion products formed.
General corrosion with uniform tilms, and pitting corrosion under non-unifbrm films
and deposits have been found.
The ardysis of corrosion products made by means of SEM & EDS, showed the
presence of iro~ suli%r, oxyg~ s.msll quantity (traces) of chloride and sometimes even
bromide (Figures 4,5).
The obtained data point out that iron suliides (probably FeS and some other forms
FeJ+.) covering the carbon steel surfiwe are responsible for the formation of protective iihn,
The presence of nitrogen in the films is problematic because of its likely small
quantities and close energy with oxygen atom The presence of nitrogen suggests a possible
inhibitive film formation by mans of filming amine. The chloride akaline salts are generally
water soluble. In spite of this, traces of chlorides were found in the deposits and films (see
Figure 4). The presenm of bromides in the deposits in some cases (see F~e
5) maybe
explained by the usage of W
tankers with sea water during the transportation of cmde
oil.
TIE pits formed under films and deposits on the coupons surfhces can be explained
by the presence of non-unifbrm iron sulfide ilm or ammonium and amine chloride deposits.
If this film were perfkct, tiorm and tenacious not more than 50 microns of thickness, the
corrosion was less than 5 MPY (0.1 1 mndy).
When deposits and non-uniftmn films of 100 microns and more were formed, the
coupons, arranged in the air cooler and condensers were severely corroded. Generally pits
51216
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data. The thickness of tube bundles m many cases is 2.336 mm. The planned Me of air
coolers, condensers and heat exchangers m refineries is 15 years [6]. Thus the accepted or
permissible corrosion rate for this equipment is:
If this film were perfect, the galvanic pair does not work, therefore corrosion is negligible. If
this tl.hnwere non-unifiorm and impmfkct, the corrosion agents ingress in impmtkctions and
severe pittii corrosion occurred under ilms.
The presence of annnonia or amines and chlorides m the overhead system results in
the formation of ammonium and amine chloride deposits which may hydrolyze with
formation of hydrochloric acid under deposits.
The pH values decrease to 2-3 and results in corrosion under deposits and m its turn
pitting corrosion. The corrosion rate under deposits can be as nmch as 100 times as the
general corrosion rate. In order to prevent the formation of these deposits, ammonia usage
is mininimd and generous water wash is applied. The deposits consisted of chloride salts on
the coupon surfhces is an indicator of wash quality.
In cases where the deposits and sediments were consisted of iron sulfides water wash
could not be effbctive, because the sulfide salts are not water soluble.
The mass loss method has some limitations.
Corrosion coupons examination are unable to ditlkrentiate between long term steady
corrosion rates and corrosion which has occurred rapidly over a short period of time, due to
upsets or other events.
This method gives the overall average corrosion rate during some, usually long
period. If corrosion rate was low (thousandths mm/y), the exposure time should be
prolonged up to as long as halfa year and it is impossible to retrieve any data during all this
Verylong period.
The other deficiency is that a lot of time has to be spent for preparation of coupon
specimen surfhces befbre and after exposure, and fir calculations. Not every one can use
this method and highly skilled and well traiued people are needed to get meaningiid data.
The use of ER-probes overcomes most of these drawbacks.
IIL ELECTRICAL
RESISTANCE
(ER) METHOD
A. Manual registration method.
Retrievable ER-probe was mounted parallel to mass loss coupons in the overhead
system of the crude distillation unit. A portable device was used for registration of the
changes of wire sensor electrical resistance [7]. Corrosion rates were calculated according
to slope of an average line dial reading of ER-probe - exposure time (Figure 6).
51217
were Rmned under non-unifbrm films and deposits. The iron sulfide iilm is cathodic to iron.
ER-method gives results considerably quicker, aud less effimts are needed m
comparison to the mass loss method.
Properly selected ER-Probes enable data to be read close enough to give instant
information about events m the ER-probe litk. The various results may be received for the
M%rent periods (Figure 7). Phenomena like sudden reversing the corrosion process might
be indicated R values go to the opposite direction - decreasing @ii
8). Finding
reasonable explanation for this phenomena is always problematic. One of the explanations
for such fluctuations is that protecting tlrns on the sensor surilice are formed and destroyed
periodically. Another possibility is the periodic formation of films with various electrical
conductivity. If the memring period taken is long (the same period as fbr mass loss
method) then identical results are received.
As a rule the corrosion rates are lower when measuring periods are longer (see Fig.
8). The similar results may be received by means of the mass loss method. When the
exposure period of coupons is increased the average corrosion rate is diminkhed. Generally
this relationship occurs when dependence of specimen mass loss versus time is descrii
by
a curve with saturation (Fii
9). This phenomenon often occurs when carbon steel is
under neutral or near neutral solutions. Comparison of the results received by means of two
methods, mass loss and E~ during long-term periods shows their fidl codhnity (Figure
lo).
B. On-line corrosion monitoring.
A number of ER-probes with 4-20 ma output as a fimction of R changes were

installed m the overhead of two crude distillation units (see F1). The installation of
these devices gave us the ability to measure and monitor the corrosion rates m and around
the places they were mounted at, to get accurate - real time fked back data about the
process and from the anti-corrosion measures taken - all these to reduce the time needed to
react to changes in the plant (processing) and to minimim the corrosion damages.
ER-method is one of the corrosion monitoring ways which better enables operators to
know the exact and real situation of the equipment with regards to the corrosion and decide
quicker how to improve the treatments such as desalting, maintaining the right process
conditions and the right parameters of the anti-corrosion program injection of soda and
other types of neutdimrs, inhibiting agents etc.
The philosophy of on-line ER corrosion monitoring incMes the data collecting
syst~
their treatment @ormiag
interpretation.
the calculation),
51218
utilization the data and theii
Curve fitting by regression analysis was carried out for the data received from this
device.
The outputs of these probes are monitored via the existing DCS
(Honeywell/TDC3000) and are also sent to the Plant Mormation System (PI) where they
are analyzed. Figure 11 shows these data as collected and stored within the PI System. The
PI System enables easy access to the history data base with every simple PC which is
connected to the local net or by dialing-in tiom remote PCs. Bringing this intbrmation onto
the PC makes possible the manipulating with all kind of analysis tools not only from within
the PI System but from outside it on other systems which might be available on any PC in
the network (e.g. commercial available spreadsheets and various Stattilcal software).
Performing the cakulations. Based on the field imtrume nt readings corrosion rates
are calculated by means of WRmmtiation of received data regarding given period. In order
to make mean@@d calculations it is essential to fist tilter the noise from the data. A
number of approaches were practiced.
The simplest way is to take all the readings that were collected within the Mormation
System and find the regression line which best fits the data (Figure 12).
Another technique which is more suitable fbr on-line calculations is Mtering by
averaging over periods of time and making the corrosion calculations between separated
averages. There are two parameters to adjust in the application of this algorithm the length
of the period to be averaged to give representing values and the time to separate between
these tsvo values (Figure 13).
The calculated corrosion rates are depended on measured period and these data are
presented for various periods (Figure 14). The title of each trend rndicates how many hours
were averaged and what is the d-e
in time between these averages. The calculation was
done continuously and the results were stored in the system history.
Long periods (longer than 30 days) give integral corrosion rate values coinciding with
the data of mass loss method but the latter does not allow to follow changes in corrosion as
it happens during this period. on-line ER data allow adyzing during various small periods
(Figure 14). These data reflect process changes as it reflects the corrosion and enables the
experts to find the reasons for these upsets and to try to improve or elimiuate the causes and
minimiz the corrosion damages.
4. Actual Equipment Inspection Data
After four years of service actual equipment inspection of heat exchanger tubes was
taken at planned turnaround.
51219
The analog signals (4-20 ma) are sent from the probe are proportional to the uncorroded matter left and are calibrated to give an indication of total corrosion of the steel
sensors in microns.
The general condition of the tubes sties

was good, but shallow pits of various size
were discovered under the thick deposits. The pits on the tubes were very mild and of no
dangerous for the on going service of the heat exchangers. These pits required no special
attention and no speci6c action to be taken
The actual equipment inspection findiis
matched the available on line monitoring
data.
The ability to react i%stto the signals given by the on line monitoring system enabled
the anti-corrosion program to be adjusted in real time and helped to maintain the equipment
under good service conditions.
CONCLUSIONS
1. The experience of corrosion monitoring in the overhead system of the crude distillation
units in the reiinery has been described.
2. Mass loss coupons and ER-probes showed good coincidence.
3. On-1ine, real time ER monitoring with data acquisition system data analysis and
calculations allowed following the corrosion and to react immediately and accurately to
minimim the damages.
4. The combination of these methods enabled anti-corrosion program included crude
desalting, neutralization and inhibitio~ to be optimize~ to be more precise and more
efficient. Wfi these data it is possible to better predict tube service life and to plan the
maintenance shut-down p$XiOdS.
5. SEM & EDS analysis showed that iron sultide films and deposits of variable content
were formed on the coupons installed in air coolers aud condensers in the overhead of
the atmospheric cohmms.
6. The corrosion was less than 0.11 mudyr ( 5 MPY) when a uniform tenacious iron
sulfide films of 10-50 microns thickness were fbrmed. The severe corrosion occurred
512110
The tube bundles in the overhead atmospheric unit are under reduction conditions
~zs
atmoS@e@
during
nod
operation. men the equipment is opened for inspection
they are exposed to normal atmosphere (with oxygen), and oxidation processes immediately
take place. The black deposits of iron sultide inside the air cooler becomes reddish iron
hydroxides within several hours after opening of the cooler. Therefore it is important to
have the inspection of the tube bundle done as soon as it is opened to the atmosphere.
Visual exarnination had been done immediately afler opening the heat exchangers. The tubes
were found to be covered with black deposits of various thickness. The chemical analysis
showed the deposits consisted of iron sulfides and iron oxides. These deposits were
removed by water jet, and tube surt%cewas then visually inspected.
Wns of more than 80-100 microns thickness were
7. The actual equipment inspection iindings showed general good condition of tubes
bundles and thus matched the available on line monitoring data,
8. The availab@ of on-line corrosion monitoring system enabled better look after anticorrosion treatment and made the overall program much more successfid.
REFERENCES
1. Russel C. Strong, Raymond A. Stephenso~ Ara J. Bagdaaar@ James E. Feather,

Robert B. Hti Crude Unit Corrosion and Corrosion Control, CORROSION/96,
1996).
paper no. 615, @otiOQ TXNACE Internatio~
2. Milton P. Ramo% Luiz A. Corre% On-Line
Overhead
System,
Internatiod
1995).
CORROSION/95,
Corrosion
paper no. 335,
Control in Refinery
(Houstonj TXNACE
3. Thomas Mebrahtuj K.J. Del Rossij SEM and XPS Characterization of the Carbon
Steel SurfSee Paasivation Film in Anhydrous
Hydrogen Fluoride Media,
CORROSION/95, paper no. 341, (Housto~ lXNACE Internatio@ 1995).
4. RP 0775-87 NACE. Preparation

Interpretation
and Installation
of Test Data in Oiltleld Operations.
5. ASTM G4-84. Standard Method for Conducting

Equipment.
6. R.A. White and E.F. Ehrnke, Materials
Facilities (NACE, 1991), p.131.
of Corrosion
and
Corrosion Coupon Tests in Plant
Selection
for Refineries
7. RP 0189-89 NACE. On-Line Monitoring of Cooling Waters.
512/11
Coupons
and Associated
when deposits and non-tiorm

formed.
C.I.
111
tl.66
116.
N-
CJ.
t+leutralizi~_q
- Corrosion
Amine
Inhibitor
0.]63
~_401
U. 1336
E-4(I1
42.
ATM
G13LUMN
0.869
0.;26
0.;30
0.;23
-1
c-419{2
c-419/l
1
)1(
0. 0!0
b+)
mm~ear
LAST CTIEEK
0.063
O.030
30-Jan-95
00:00:00
0.023
03-kug-94
00:00:00
II
E
F
o
o.n69
O. 026
0.010
03-lmg-94
00:00:00
30-JEm-95
00:00:00
Figure
1 . Atmospheric
0.036
Naphtha
37.
and
F-403
(+
* M Line Monitoring
@ Corrosion Probes
overhead
512112
corrosion
accumulator
Water
Separator
6.5 PH
monitoring
system
NH3 N
robe
Manual
On Line
Coupons
Chemical
alysis of
Condensed
Sour Water
Corroderd%
ER -
Inspection
Mass loss
of
equipment
Visual
Deposita,
Corrosion
Rate,
Pits
Deposits,
Pits
examination
Corrosion
rat
IsQ! W!21
Prognosis of
-E
equipment,
Tube Service
life,Shut-down
periods
Figure 2 . Scheme of corrosion monitoring.
512113
n
B ElK1
Visual
0.28
14+
0.26
0.24
0.22
0.2
0.18
0.16
0.14
0.12
c
.-o
IJl
0
L
c1
5 MPY
0.1
0.08
0.06
0.04
0.02
0
.03.94
Before
Figure
oir
3.
Corrosion
rate
.ooIer
After
vs
time.
condenser
NV-1005522-D5J2Q3, downloaded on 1/3/2016 5:48AM - Single-user license only, copying/networking prohibited.
NH, ~ C.I.
c
0
u
n
t
s
Fe
c
)~.
78
Zn
123456
10 11 12 13 14 15 16 17 18 19 20
E%ergy (keV)
1200
1100
1000
900
800
Fe
c
0
u
n
t
s
700
6(IO
500
400
300
200
Fe
o
100
a
1234567
Figure
4.
Fe
891011121314
Energy
EDS spectra
of film on coupon
inside
of air cooler.
512/15
151617181920
(keV )
(a)
and
sediments
(b)
Fe
150
1401
1301
1201
11OI
c 100(
0
90(
: ~o(
u
70(
60(
50C
400
300
200 s
Fe
100
Fe
Cu
.J~,
Br
1234567
12 13 14 15 16 17 18 19 iO
E?nerg~ (k~;)
Figure
5.
EDS spectrum
of
film
on coupon
512116
after
air
cooler.
160
510
/
500
490
480
470
460
450
/
440
430
) * 0,365
K =(aR/~t
420
10 MPY
7.3
MPY
410
400
390
380
370
o
10
20
30
30,12.93
Figure 6.
Dial reading
ER-probe
40
50
- 08.03.94
vs
time.
60
70
Days
(t)
520
390
380
370
360
AC:
350
0,05 r In/v
.-c
-0
0
1!
340
330
320
c
310
10
20
30
40
50
60
02.09
Figure
7.
Dial
reading
ER-probe
vs
time.
70
- 30.12,93
80
90
100
I1O
120
Days
400
135
D
130
125
120
I
115
110
105
100
95
II
10.12-30,12.92
0,10 mm/y
10,12-10,01,93
0,06 mlI1/y
I 10.12 -19.01,9310
.02 mm/y
20
30
90
85
10
10,12.92
Figure
$.
Dial
reading
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Corrosion Monitoring and Control in Refinery Process Units (51300-97512-Sg)

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Corrosion Monitoring and Control in Refinery Process Units (51300-97512-Sg)

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512

CORROSION MONITORING AND CONTROL

Oil Refineries Ltd.

Crude oil contains different species which while beii

processed reacted or converted

A. MASS LOSS (ML) METHOD

from the slope of line Dial reading of ER-probe

The arrangement of corrosion probes in the overhead systems of a typical crude

h chemical analysis of accumulated sour water formed after condensation of

This method is descriid in literature [4,5]. There is no universal method for

of films and deposits firmed on the surf%cespecimen enables

indicates that condensation occurs kefore air cooler.

0.7 * 2.336 Lnrn/15y = 0.11 MM/y(5 my),

A. Manual registration method.

A number of ER-probes with 4-20 ma output as a fimction of R changes were

utilization the data and theii

The general condition of the tubes sties

matched the available on line monitoring

Wns of more than 80-100 microns thickness were

1. Russel C. Strong, Raymond A. Stephenso~ Ara J. Bagdaaar@ James E. Feather,

4. RP 0775-87 NACE. Preparation

5. ASTM G4-84. Standard Method for Conducting

Corrosion Coupon Tests in Plant

7. RP 0189-89 NACE. On-Line Monitoring of Cooling Waters.

when deposits and non-tiorm

Figure 2 . Scheme of corrosion monitoring.

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NV-1005522-D5J2Q3, downloaded on 1/3/2016 5:48AM - Single-user license only, copying/networking prohibited.

NV-1005522-D5J2Q3, downloaded on 1/3/2016 5:48AM - Single-user license only, copying/networking prohibited.

and corrosionrate vs exposuretime,

Mass Loss, mm/y

$2. O9-O2.l 1 4 12.9309.03.$4

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NV-1005522-D5J2Q3, downloaded on $1%1

Figure 42. Dial reading and linear regression.

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6 HmrS / & Ilays

---- .___; ---$

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