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CORROSION CONTROL IN THE REFINING INDUSTRY

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CourseTopics

ThefollowingtopicsareincludedinCorrosionControlintheRefiningIndustry:

• CorrosionandOtherFailures• CrudeDistillationandDesalting• FluidCatalyticCrackingUnit• CrackedLightEndsRecovery(CLER)Units• HydrofluoricAcidAlkylationUnits• SulfuricAcidAlkylationUnits• CorrosioninHydroprocessingUnits• CatalyticReformingUnits• DelayedCokingUnits• AmineTreatingUnits• SulfurRecoveryUnits• ProcessAdditivesandCorrosionControl• CorrosionMonitoringMethodsinRefineries• RefineryInjectionSystems• MaterialsofConstructionforRefineryApplications• RefineryOperationsandOverview• FailureAnalysisinRefineriesChapter1:CorrosionandOtherFailuresIntroduction.Low-TemperatureRefineryCorrosionLow-TemperatureCorrosionPrinciplesCorrosionRatesandPolarizationTemperatureandConcentrationLow-TemperatureConditions.High-TemperatureRefineryCorrosionHigh-TemperatureCorrosionPrinciples.LinearRateLawParabolicRateLaw.High-TemperatureConditions.

Corrosion/FailureMechanisms.MetalLoss—Generaland/orLocalizedCorrosion.GalvanicCorrosionPitting.CreviceCorrosionIntergranularAttack.Erosion-Corrosion.HydrogenChloride.AmmoniumBisulfide(NH4HS)CarbonDioxide.ProcessChemicals.OrganicChloridesAluminumChloride.SulfuricAcidHydrofluoricAcid.PhosphoricAcid.Phenol(CarbolicAcid)Amines.Atmospheric(External)Corrosion.CorrosionUnderInsulation(CUI)High-TemperatureSulfideCorrosion(WithoutHydrogenPresent)High-TemperatureSulfideCorrosion(WithHydrogen)NaphthenicAcidCorrosion.High-TemperatureOxidation.StressCorrosionCracking(SCC)ChlorideStressCorrosionCracking(ClSCC).AlkalineStressCorrosionCracking(ASCC).CarbonicAcid(WetCO2)PolythionicAcidStressCorrosionCracking(PTASCC)AmmoniaStressCorrosionCracking(NH3SCC).WetH2SCrackingHydrogenBlistering.SulfideStressCracking(SSC)HydrogenInducedCracking(HIC)StressOrientedHydrogenInducedCracking(SOHIC).HydrogenCyanide(HCN)SCCPrevention.InspectingforWetH2SDamage.High-TemperatureHydrogenAttack(HTHA).MetallurgicalFailures.GrainGrowthGraphitizationHardeningSensitization.SigmaPhase.

885°F(475°C)Embrittlement.TemperEmbrittlementLiquidMetalEmbrittlement(LME).CarburizationMetalDustingDecarburizationSelectiveLeachingMechanicalFailures.IncorrectorDefectiveMaterialsMechanicalFatigue..CorrosionFatigueCavitationDamage.MechanicalDamageOverloadingOverpressuring.BrittleFractureCreep.StressRupture.ThermalShock.ThermalFatigue.OtherFormsofCorrosion.BoilerFeedWaterCorrosionSteamCondensateCorrosion.CoolingWaterCorrosion.FuelAshCorrosion.Chapter2:CrudeDistillationandDesaltingIntroduction.SourcesofCrudeOil.CompositionofCrudeOil..RemainingConstraintsMoreaboutCrudeOilCompositionCrudeOilPretreatment.Desalting.PreflashCrudeDistillationUnit.OperationofaCrudeDistillationUnitCorrosioninCrudeDistillationUnits.Columns..ExchangersandPiping..FiredHeaters.OtherCorrosionCombatingMeasuresBlending.Desalting.CausticAddition.OverheadpHControl.CorrosionInhibitor.WaterWashing.

CorrosionMonitoringinCrudeUnits.WaterAnalysis(OverheadCorrosionControl)HydrocarbonAnalysisCorrosionRateMeasurement.On-Stream,Non-DestructiveExaminationOptionalTeamExerciseChapter3:FluidCatalyticCrackingUnitsIntroduction.Hardware.Riser/ReactorRegenerator.FlueGasSystem.FractionatorCorrosionControlinFCCUnitsMaterialsofConstructionDamageMechanismsandSuitableMaterialsReactorsRegenerators.CatalystTransferPipingSystem.ReactionMixLine,MainFractionator,andBottomsPiping.FlueGasSystems.InspectionandControlConsiderationsHigh-TemperatureOxidationHigh-TemperatureSulfidation(H2SAttack)High-TemperatureCarburization.PolythionicAcidStressCorrosionCrackingCatalystErosionFeedNozzleErosion.RefractoryDamage.High-TemperatureGraphitization.SigmaPhaseEmbrittlement885°F(475°C)Embrittlement.CreepEmbrittlementHigh-TemperatureCreepThermalFatigue.OptionalTeamExerciseChapter4:CrackedLightEndsRecoveryUnitsCLERProcessDescriptionMaterialsofConstructionColumnsExchangersCorrosionProblemsCorrosionHydrogenInducedDamageInspectionTechniquesforHydrogen-InducedDamagePreventionandRepairTechniques.AmmoniaStressCorrosionCrackingCarbonateStressCorrosionCracking..Fouling/CorrosionofReboilerCircuits

CorrosionControlMeasures.WaterWashingPolysulfideInjectionCorrosionInhibitors.CorrosionMonitoringHydrogen-ActivityProbes.ChemicalTests.CorrosionProbes.Chapter5:HydrofluoricAcidAlkylationUnitsIntroduction.HFAlkyProcessDescriptionMaterialsofConstruction...Columns.Exchangers.Piping.BoltingCorrosionProblemsCorrosionHydrogenInducedDamage.InspectionandMitigationCorrosionControlMeasures.CorrosionMonitoring.CorrosionProbes.Chapter6:SulfuricAcidAlkylationUnitsIntroductionProcessDescription.ReactionSectionTreatingSectionFractionationSectionRefrigerationSectionMaterialsofConstruction.MaterialsandCorrosionProblems.SulfuricAcidCorrosion.AcidConcentration.AcidTemperatureandVelocity.AcidDilution.HydrogenGrooving.FeedContaminants.AcidandNeutralEstersAcidEstersNeutralEsters.AcidCarryover.CorrosionUnderInsulation.FoulingProblemsCorrosionControlMeasures

ReactorSectionCorrosionTowerOverheadCorrosionReboilerCorrosionandFoulingControl.AcidTanksCorrosionControlDuringUnitShutdownsCorrosionUnderInsulation(CUI).CorrosionMonitoringInspection.ReactionSectionTreatingSectionFractionationSectionRefrigerationEquipment.AcidTank.Chapter7:HydroprocessingUnitsIntroductionHydroprocessingHydrotreatingHydrocrackingVariationsonHydroprocessingTypesofCorrosionCommoninHydroprocessingUnitsHigh-TemperatureHydrogenAttackHigh-TemperatureH2SCorrosion–WithHydrogenPresent.High-TemperatureH2SCorrosion–WithLittleorNoHydrogenPresentNaphthenicAcidCorrosionAmmoniumBisulfideCorrosionChlorideStressCorrosionCracking(SCC)FailuresOftenHappenAfterStartupAdditionalConsiderationswithStainlessSteelPolythionicAcid(PTA)StressCorrosionCrackingStainlessSteelsUsedtoPreventPTAOtherMethodstoPreventPTASCCWetH2SCrackingSulfideStressCracking(SSC)HydrogenInducedCracking(HIC)andStress-OrientedHydrogenInducedCracking(SOHIC)MaterialPropertyDegradationMechanismsTemperEmbrittlementHydrogenEmbrittlementSelectionofMaterialsReactorLoop–GeneralReactorFeedSystemReactorFeedFurnacesReactorsReactorEffluentSystemReactorEffluent–DistillationFeedExchangers

EffluentAirCoolersEffluentAirCoolerInletandOutletPipingSeparatorVesselsRecycleHydrogenSystemDistillationSectionhapter8:CatalyticReformingUnitsIntroductionOctaneNumber(RON)CatalystCatalyticReformingProcessesCatalyticReformer,Semi-RegenerativeReactorDesignCorrosionPhenomenainCatalyticReformersHighTemperatureHydrogenAttack(HTHA)StressCorrosionCrackingMaterialsofConstructionReactorsExchangersandPipingFiredHeatersandOtherEquipmentCorrosionControlCorrosionMonitoringInspectioninCatalyticReformersChapter9:DelayedCokingUnitsIntroductionEquipmentandOperationoftheDelayedCokingUnitCorrosionandOtherProblemsinDelayedCokingUnitsHigh-TemperatureSulfurCorrosion.NaphthenicAcidCorrosionHigh-TemperatureOxidation/Carburization/SulfidationDecokingHeaterTubesErosion-CorrosionAqueousCorrosionCorrosionUnderInsulation(CUI)ThermalFatigue,andTemperEmbrittlementofCr-MoSteelsInspectionofCokingUnitsGeneralInspectionCokeDrumInspectionChapter10:AmineTreatingUnitsIntroductionTypesofAminesUsedRefineryAmineProcessDescriptionTailGasUnitsCorrosionPhenomenaCorrosiveSpecies

AmineDegradationCrackingPhenomenaCorrosionInhibitors.MaterialsofConstructionCorrosionMonitoringCorrosionControlMeasuresChapter11:SulfurRecoveryUnitsIntroductionSulfurRecoveryUnitsSulfurChemicalReactionsSulfurRecoveryProcess.TailGasTreatingUnitIncineratorColdBedAdsorption(CBA)UnitCorrosionMechanismsSulfidationofCarbonSteelsSourEnvironmentCorrosionWeakAcidCorrosionCorrosionofClausUnitsbySystemFeedGasSystem.CorrosionConcernsMitigationofCorrosionReactionFurnaceandWasteHeatExchangerSystemsCorrosionConcernsMitigationofCorrosionInspectionsintheReactionFurnaceandWasteHeatExchangerSystemClausReactors,Condensers,andReheatSystemCorrosionConcernsMitigationofCorrosionInspectionsintheClausReactors,Condensers,andReheatSystemLiquidSulfurRundownLinesandStorageSystemCorrosionConcernsMitigationofCorrosionInspectionsinLiquidSulfurRundownLinesandStorageSystemCorrosionofCBAUnitsCorrosionConcernsMitigationofCorrosionInspectionofCBAReactors,Condensers,andPipingCorrosionofTailGasTreatingUnitsBurnerandMixingChamber.ailGasReactorandWasteHeatExchangerWaterQuenchandRecirculationBlowerSystemH2SAdsorptionSystemCorrosionintheIncineratorSystemChapter12:RefineryInjectionSystems

IntroductionDefinitionsInjectionPointInjectionSystemnjectionSystemDesignInjectionSystemDesignParametersEngineeringPracticesProcessDesignMaterialsSelectionConsiderationsInspectionofInjectionPointLocationsLocationofInjectionPointCo-InjectantsInjectionSystemHardware.ChemicalStorageTanksChemicalInjectionPumpsAdditiveControlSystemsPipingSystemsInjector.Chapter13:ProcessAdditivesandCorrosionControlIntroductionFactorsAffectingCorrosionAcidsTemperaturePressure.FlowTurbulenceMaterialSelectionMethodstoMitigateCorrosionDesaltingandCausticInjectionWaterWashing.AcidNeutralization.BarrierbetweenMetalandEnvironmentChemicalsUsedtoCombatCorrosion.FilmingAminesFilmerFormulationFilmerApplicationTreatRatesMonitoringFilmerPerformanceNeutralizingAminesPolysulfidesNaphthenicAcidCorrosionInhibitors.ApplicationofCorrosionInhibitorsChapter14:CorrosionMonitoringinRefineriesIntroductionUsesofCorrosionMonitoring

CorrosionMonitoringTechniques.CorrosionCouponsElectricalResistanceMonitoringElectrochemicalCorrosionMonitoringLinearPolarizationResistancePotentialMonitoringZeroResistanceAmmetry(ZRA.ElectricalImpedanceSpectroscopy(EIS)ElectrochemicalNoise(EN)HydrogenFluxMonitoring.AComprehensiveCorrosionMonitoringProgramCorrosionMonitoringSitesCorrosionMonitoringinSpecificProcessUnitsAtmosphericDistillationUnit(ADU)VacuumDistillationUnit(VDUFluidCatalyticCrackingUnit(FCCU)AmineTreatingUnit(ATU)SourWaterStripperUnits(SWSUSulfuricAcidAlkylationUnit(SAU).AutomatedOn-LineMonitoring.Chapter15:MaterialsofConstructionforRefineryApplicationsTheRoleoftheCorrosionEngineerProblemDefinitionCorrosionFailuresCorrosionTestingMethodsMaterialsSelectionApproachUsingProfessionalConsultants.SpecifyingMaterialsNationalStandardsCompanyStandardsWhattheDesignerShouldRememberWhenWritingSpecificationsQuestionstheDesignerShouldAsktoControlQualityFitnessforServiceRefineryMaterialsofConstructionIntroductionKilledSteelSteels.CarbonSteelC-MoSteelsLow-AlloySteelsCr-MoSteelsNickelSteelsStainlessSteelsMartensiticStainlessSteelsFerriticStainlessSteelsAusteniticStainlessSteelsPrecipitationHardeningStainlessSteelsDuplexStainlessSteels

SpecialtyStainlessSteelsCastIronsGrayCastIronsDuctileIronsHigh-SiliconCastIronsNickelCastIronsOtherMetalsandAlloysCopperandItsAlloysNickelAlloysAluminumTitaniumandItsAlloysNon-MetallicMaterials.RefractoriesPlasticsThermosettingResinsHeatTreatmentNormalizationAnnealingQuenching.StressRelievingSolutionHeatTreatmentSpecializedHeatTreatmentsWhattheDesignerShouldKnowAboutHeatTreatments.HeatTreatmentVerification.HeatTreatmentforWelds.PreheatPostweldHeatTreatment.NormalizingWeldingTheNatureofWelding.WeldingDecisionsWeldingProcessesShieldedMetalArcWelding(SMAW)GasMetalArcWelding(GMAW)GasTungstenArcWelding(GTAW)SubmergedArcWelding(SAW)WeldingProceduresandWelderQualificationInspectionofWeldingElectrodesandFillerMetalChapter16:RefineryOperationsandOverviewIntroductionRefineryOperatingObjectivesRefiningProcessOverviewProcessInteractionswitChapter17:FailureAnalysisinRefineries

IntroductionProceduralApproachandTestMethodsBackgroundInformationInitialExaminationNondestructiveTesting.SurfaceDepositAnalysisFieldMetallographicReplication(FMR)HardnessTestingChemicalAnalysisMagneticParticleInspection(MPI)WetMethod.DryMethodDyePenetrantTesting(PT)Sectioning.MacroscopicExaminationofFractureSurfaces.MicroscopicExaminationFractureAppearanceDuctileFractureBrittleFractureFatigueFractureshCorrosionStressCorrosionCrackingCreepRuptureFailuresAdditionalTestingandAnalysis.MechanicalTestingApplicationofFractureMechanicsRootCauseAnalysis.Recommendations