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Personnel actions cause $20B/yr in avoidable costs in Petrochem Higher business volatility, faster decision making
Reduce/Avoid unplanned incidents Implement best work practices Turn data into actionable knowledge
Delaware City refinery Sulfuric Acid tank explosion in Jul. 2001 Pipeline Burst in Alberta Dec. 2004
What is Corrosion?
General Corrosion
Localized Corrosion
Corrosive attack can be localized in certain areas on the metal surface This is caused by the formation of local anodes and cathodes on the metal surface 70 to 90 percent of corrosion failures are due to localized corrosion (e.g. Pitting) Pitting tends to occur where materials are stressed or when their structure has changed (welding, Bends, clamps)
Corrosion is the loss of metal from an exposed surface in a corrosive environment. Corrosion rate expression:
mmpy = K x W DxAxT where: K = constant W = change in weight D = density A = area T = time
What is Corrosion?
Corrosion tends to happen where: Water separates from oil Water and corrosives condense from the gas phase Corrosives concentrate due to evaporation Water is trapped or stagnant Fluid are highly turbulent, impinge or flash
Localized Corrosion
Localized Corrosion
Direct Measurement
Passive Off-Line Non-Destructive Testing Weight loss coupons Ultrasonic Gauging Radiographic inspection (X-Ray and Gamma Ray) Eddy Current Active On-line
ElectroChemical Noise (ECN) Linear Polarization Resistance (LPR) Harmonic Distortion Analysis (HDA) Electrical Resistance Measurement (ER) Electrical Field Signature Method (EFSM)
Alternating voltages are applited to an arrangement of 3 electrodes and resultant currents, primary frequencies and harmonics are analyzed. This technique is used in combination with LPR.
Creation of small radioactive surface. Gamma radiation intensity over time is an image of the corrosion effect.
Current measured between 2 corrosion sensors. Used mainly for Galvanic current monitoring strategicaly positionned microphones on a structure to listen the noise generated by stressed structures under corrosion
Inductive Resistance Probes (IRP): Mass changes in the sensor element are
detected by measuring changes in the inductive resistance (Inductance) of a coil, located inside the element.
Enabling Corrosion root cause analysis Closed loop control of corrosion rate Plant/Unit optimization
Electrochemical Noise (ECN) Linear Polarization Resistance (LPR) Harmonic Distortion Analysis (HDA)
For accurate Corrosion Rate and other parameters related to general corrosion
Features: automated data acquisition and analysis cycle (data update every 7 min.) low power requirements; can be applied in hazardous areas simple interface to SCADA, process control, process information management systems
Services
Systems
Software
Materials Consulting Lab Testing Analytical Services Corrosion Diagnostics & Control
HONEYWELL InterCorr also provide value added solutions along with online, real-time corrosion monitoring
Plant Corrosion Survey Review historical corrosion data, failure, maintenance record, replacements Determination of monitoring points / probe configurations Review and interpretation of monitoring data Process correlation Plant diagnostics Expert Consultation Material selection Failure Analysis Process Correlation Simulation Corrosion modeling Corrosion prediction Analysis of operating Conditions Sensitivity studies Process projections
Corrosion Rate
(Smart Corrosion Evaluation Technology)
Pitting Factor and corrosion diagnostics data Configuration Options On-board data storage Hardwire or Wireless Digital or analog output Class I, Div 2 or non-IS
Simple trend views Data logging Export to spreadsheets Online Data Options Direct to DCS or data historian via 4-20mA, HART, RS-485,RS-232, others
The SmartCET Differentiators - Corrosion/Pitting Detection & Asset Life Monitoring Accurate Corrosion Monitoring: Applicable to all conductive fluid environments Reliable real-time corrosion rates Distinguishes pitting Enabling proactive corrosion control
Process Control Improvement: Optimizing process, chemical treatment or unit operation Identifying the when & why of corrosion in the process Use the DCS to reduce corrosion damage/costs & increase profits
SmartCET SmartCET will will NOT NOT work: work: Non-conductive Non-conductive oil oil environments environments (naphthenic/sulfidic (naphthenic/sulfidic corrosion) corrosion)
Oilfield Applications: Crude Oil Flow Lines Seawater Injection Systems (Biofouling/MIC) Produced Water Systems Offshore Gas Flow Lines Field Gas Gathering Systems Gas Transmission Pipelines Multi-Operator Gas Transmission Erosion-Corrosion During Sand Washing Carbon Dioxide and Hydrogen Sulfide Pipelines Gas Processing Applications: Inlet Stabilization Amine Plant Compression Utilities Dehydration and Refrigeration Hydrogen Processing Operations
Refinery Applications: Distillation and Overhead Systems Sour Water & Amine Systems Sulfuric/Hydrofluoric Acid Alkylation Units Desalting Units Heat Exchangers FCCU Steam Cracker/Caustic Skid Flue/Tail Gas Systems Chemical Processing Applications: Corrosion in Sulfuric Acid Systems Pitting of Stainless Steel in an Ammonia Stripper Pitting of Welds in Process Liquor Process Modification Trials High/low Temperature Corrosion in Acid Regeneration Plant Corrosion in Gasification Processes
100
Red Line
* * mpy mpy -- mils mils per per year year mmpy mmpy -- millimeters millimeters per per year year
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