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21 JUNE 2012
Source:R.D.Kane,ChemicalEngineering,June2007
Itshallbeincludedinthedetaileddesignstageofplantandfacilities. CorrosionRiskAssessment(systembysystembase)
1) 2) 3) 4)
3. 3
Developmentofcorrosionmonitoringplan
1) 2) 3) 4)
Positionswherewaterwillcondense,poolorimpinge.
Accessfittingshouldbelocatedaminimumdistanceofsevenpipediameters downstreamandaminimumofthreepipediametersupstreamofanychangesinflow causedbybends,reducers,valves,orificeplates,thermowells,etc. causedbybends reducers valves orificeplates thermowells etc Ifaccessfittingsareinstalledinpairsthereshouldbeaminimumdistanceof1m(3ft) betweeneachfitting. Ifthemonitoringdevicesareintrusiveandcompriseaprobeandacouponholder the Ifthemonitoringdevicesareintrusiveandcompriseaprobeandacouponholder,the probeshouldbelocatedintheupstreamfittingtominimizeturbulencearoundthe secondmonitoringdevice.
Positionswherethereareconcentrationsofcorrosivespecies. Positionswhereabruptchangesoccursuchasplantmetallurgy,processfluids,etc.
Positionswhereprocessstreamchangesuchaspressure,temperature,flowrate,etc. areprevalent.
Positionswherefromexperiencethehighestcorrosionrateswouldbeexpected.
LOCATIONS - GUIDELINES
NACERP0775
In lines handling wet gas water can accumulate at changes in the line elevation as depicted in Figure 8 In gas, 8. Corrosion may be accelerated where water has accumulated. Coupons in such systems must be located where they will be waterwet to correlate with corroding areas. Coupons located in the vapor phase could indicate only slight corrosion when waterwet areas are corroding severely.
PROBE LOCATION
theneedtoshutdownthefacility. th dt h td th f ilit
Forsystemsoflessthan10bar(g)(150psig),lowpressureDN25(NPS1)
retrievaltool;otherwise,theaccessfittingisunusable.
Seawaterinjectionandcooling system Producedwatertreatmentandinjectionsystems q Aquifer water Effluentwater Boiler feedwater andstreamcondensate Multiphaseflowwithwater Unstabilized crudeoil Hydrocarbongas Fractionationunits,CDU, andpipework FCCU,reactorcolumns FCCU reactorcol mns Solventextractionunits,amine/caustictreaters and piping Vacuumtowers,regenerators,processunits,and pp pipework Storagevessels/tanks withseparatedwaterbottoms
4 1 3 X X X X X X X
X X X X X X X X X
X X 2 2 2 X X X X X X X
X X X X X X X
X X X X
pH6
Source: BP GP 06-70
Nonintrusive
MONITORING METHODS
Corrosion coupon
LPR probe
Bioprobe for monitoring bacteria Source: Alabama Specialty Products, www.metalsamples.com Electrical resistance probe
17
18
NACERP0497:aminimumexposureduration(h)=50/[expectedcorrosionrate(mm/y)] Shutdownsorprocessinterruption
ASTM G58
35 ppm
25 ppm
CORROSION COUPONS
Advantages Inexpensive,easilyapplied Couponmadeofmaterialssimilartopipeorvessel Visualinspectionidentifiesmodeofcorrosion attack Samplesavailableforscale orsurfacedeposit analysis Sources ofmicrobiologicaldata Applicable toallenvironments Disadvantages Corrosionrate averagedoverexposuretime Corrosionratecalculationassumesuniform corrosion Datagenerationslow(longexposuretimes) Requiresinsertion andretrievalunderpressureorat aturnaround
Straycurrentcorrosion
Corrosioninoxygenrich(aerobic)soil
Microbiologicallyinfluencedcorrosion Inanaerobicsoil 25
O
2000
Si S Ca Fe
1
MIC
1000
Al
2
0 3000 0 3
Inorganiccorrosion
2000
O Fe Ca Si
1000
0 0 1
S
2 3
keV
Ratioofmaximumlocalizedcorrosionratetogeneralcorrosionratedeterminedbymass g y loss(pittingfactor)
PittingofSS Velocityacceleratedcorrosion
Percentofcorrosionaffectedareaonthecoupon
L R A
Velocity shield
ER PROBE
ER PROBE
Recommendedmeasurementinterval
ER PROBE
Advantages Directmeasurementofmetal loss Disadvantages Sensitivetothermal change
Willworkinmostenvironments:doesnotrequire Corrosionrate calculatedasuniformcorrosion. continuousaqueous phase Noinformationonlocalizedcorrosion (suitableformultiphase,nonaqueousenvironments) (suitableformultiphase non aqueousenvironments) Quickerresponsethancorrosioncoupons Continuously loggedprobesgivehighqualitydata (loggingrateaslowas5min) (trendsandchangesincorrosionactivity) Meter outputisincumulativemetalloss.Slopeof dataneededtocalculatedcorrosionrate Highsensitivitytypeprobeis available. (Takreer RRE#2) Noncorrodingelementscanbeusedaspure N di l t b d erosionmonitor. Manual readingssubjecttosignalnoise (probeconnections) Crevicecorrosioncanoccuronpoorlyconstructed flushtype probes Requiresinsertionandretrievalunderpressure whichcanhavesafetyimplications Requires severaldaystodetermineareliable corrosionratetrend Adverselyaffectedbyconductivesulfidefilm Ad l ff t db d ti lfid fil corrosionproductswhereH2Sispresent
APPLICATIONS OF ER PROBE
Oilandgasproduction Gassweetening,storage,andtransportationsystems Reneriesandpetrochemicalplants Inhibitorevaluation/optimizationprograms Powerplantsforcoolingwater,feedwater,andscrubbersystems.In
SAND PROBE
Eapp Ecorr
ic
ia
io,a
c
log i g
iapp =ia ic =icorr (e2.303E/ e2.303E/ ) =icorr (2.303E/a +2.303E/c) =2.303icorrE(a +c)/ac =icorrE/B S SternGearyequation G i
c
LPR PROBE
Givesinstantaneouscorrosion rates Onlyusedinconductive, aqueoussolutions Basedonthecurrentflow betweentwoormoreelectrodes Requiresthesurfacetobecome polarizedandcurrentresistance ismeasured. Sometimesprobehasa referenceelectrodeaswell.
LPR PROBE
Advantages Rapidmeasurementofcorrosivity Sensitivetoanyprocesschanges:flow, pressure,temperature,etc. Disadvantages Generalcorrosionratesindicativeoftrendrather thanabsolute Continuouswaterphaserequired Probesaresusceptibletofoulingbydepositsor hydrocarbonphase. Nolocalizedcorrosioninformation
OTHER TECHNIQUES
ElectrochemicalImpedanceSpectroscopy(EIS) ElectrochemicalNoise(EN) ZeroResistanceAmmetry(ZRA)
GALVANIC PROBE
DOmonitoringinEastTexas WaterInjectionStation
NDTmethods
RT IMAGE - EXAMPLE
54
HYDROGEN PROBE
Waterchemistryparameters
Dissolvedsolidsanalysis(APIRP45) Metalioncorrosionanalysis(NACERP0192 ironcountanalysis) Dissolvedgasanalysis O2,CO2,H2S Testkitsorlaboratoryanalysis
BacterialMonitoring
Planktonic bacteria(APIRP38 SRB) bacteria(APIRP38SRB) Sessilebacteria(NACETM0194)
ChemicalAnalysis
Methods
Wateranalysis(overhead) pH Fecontent Chlorides(waterinoverheadreceiver) baseforoptimizationofcaustic ( ) p injection/blendingofcrudes Hardness CWquality,precipitationatoverhead(waterwashing) Hydrocarbonanalysis Residualtestoffilminginhibitor(35ppm) d l ffl hb Metalanalysisofoil(forNACcontrol) Corrosionratemeasurements ERprobe LPRprobe overheadreceiverwaterdrum Corrosioncoupon NDT(onstream) ( ) UT,RT Whenthereisaconfirmedorsuspectedproblems
LPR ER
Atsitesofcondensationofacidicchlorideinthedistillatedrumbootandtheejectorintercondenser collectordrum. Areassusceptibletonaphthenicacidcorrosion(NAC,500700F)suchasVDUpreheater,shellandtraysof tower,transferline,columnsidestripper,gasoilcircuits. tower transferline columnsidestripper gasoilcircuits Inregionsofcondensationfoundinsideofthecolumn. Highsulfurcorrosion(bottom) Hightemperaturecylindricalelementprobesoftheretractabletypes
Reactor®enerator g
Corrosionprobes
ChemicalTest
CN andSCN contentinwastewaterstream pH(highpressurecondensate)forwaterwashcontrol Condenser/coolerbunldes (highpHcorrosionofCualloys) Heatexchangereffluentsingascompressionsystem Debutanizeroverheadsystem,etc. Sourwaterlines Differentelevationoftheabsorber/strippertower Vapor/liquidinterfaceareaofthehighpressureseparatordrum
Corrosionprobes
HydrogenmonitoringProbe
67
Use of Portable CorrosometerTM Instrument for M f Measuring Corrosion of Shell-side of Heat Exchanger i C i f Sh ll id f H t E h
Ar blowing (+ NaCl 16%) Air blowing (+ NaCl 16%) Ar blowing g Air blowing
mm/yr r
0.200 0.175 0.150 0.125 0.100 0 100 0.075 0.050 0.025 0.000 22 24 26 28 30 32 34 36
EG:water 60:40
EG:water 78:22
38
40
42
water %
RiverWaterAnalysis
ChemicalTreatment
Program
CycledWater
Analysis
ON-LINE MONITORING
MONITORING STRATEGY
CORROSION AS A PROCESS CONTROL VARIABLE!
REFERENCES
1) 2) 3) ) 4) 5) 6) 7) 8) 9) 10) 11) 12) 1) 2) 13) 14) 15) 16) ) 17) 18) 19) R.D.Kane,ChemicalEngineering,June2007,34. CoursebookforCorrosionControlintheRefiningIndustry,NACEInternational,July2011. SurveyofCorrosionCostinJapan,CommitteeonCostofCorrosioninJapan,JapanSocietyofCorrosionEngineering(JSCE), S fC i C i J C i C fC i i J J S i fC i E i i (JSCE) March2001. AlabamaSpecialtyProducts,www.metalsamples.com. NACERP0775,Preparation,Installation,Analysis,andInterpretationofCorrosionCouponsinOilfieldOperations,2005. NACERP0497,FieldCorrosionEvaluationUsingMetallicTestSpecimens,2004. ASTMG4StandardGuideforConductingCorrosionCouponTestsinFeldApplications ASTMG46StandardGuideforExaminationandEvaluationofPittingCorrosion ASTMG102StandardPracticeforCalculationofCorrosionRatesandRelatedInformationfromElectrochemical Measurements. CoursebookforCorrosionBasics,NACEInternational,Jan2003. P.R.Roberge,HandbookofCorrosionEngineering,McGrawHill,2000. P.A.Schweitzer,CorrosionofLiningsandCoatings CathodicandInhibitorProtectionandCorrosionMonitoring,CRCPress, 2007. NACEPublication3T199TechniquesforMonitoringCorrosionandRelatedParametersinFieldApplications,NACE International,1999. NACEPublication3D170ElectricalandElectrochemicalMethodsforDeterminingCorrosionRates,NACEInternational ApplicationNoteAN107,CorrosionMonitoringinCrudeUnitDistillationColumns,Rohrback Cosasco Systems,Inc.,April1990. J.Gutzeit,CrudeUnitCorrosionGuide ACompleteHowToManual,PCC,2004. ApplicationNoteAN109,CorrosionMonitoringinFluidCatalyticCrackers(FCC),Rohrback Cosasco Systems,Inc.,April1990. K.Wold andR.Stoen,MonitoringInternalCorrosioninPipelins,ASTMEIndiaOil&GasPipelineConference,GOA,February , g p , p , , y 2011. OperatingManualforModelCET5000,SeriesSmartCET CorrosionMonitoringTransmitter,Honeywell,July2006. P.Collins,HydrocarbonProcessing,March2012,35. GuidanceonPracticeforCorrosionMonitoring,EngineeringTechnicalPracticesGP0670,BPGroup,2005.
QUESTIONS?