Sabp A 025 PDF

Best Practice
SABP-A-025 6 January 2009

Corrosion Control in Vacuum Distillation Units
Document Responsibility: Materials & Corrosion Control Standards Committee
Saudi Aramco DeskTop Standards
Table of Contents
1 Scope and Purpose………………………………... 2

2 Conflicts and Deviations………………..………... 2
3 References…………………………………………... 2
4 Definitions and Abbreviations……….……...…... 3
5 Process Considerations………………………...... 3
5.1 Process Description…..………………..……... 3
5.2 Process Flow Diagram…….……………..…... 4
5.3 Corrosive Species…………….…………..…... 6
6 Damage Types……………………………….……... 8
6.1 Damage Mechanisms………………….…..…. 8
6.1.1 High Temperature Attack……….…… 8
6.1.2 Wet H2S Damage……………….……. 8
6.1.3 Underdeposit Corrosion…………..…. 9
6.1.4 Erosion Corrosion…………..……..…. 9
6.1.5 Acid Corrosion………………….….…. 9
6.2 Damage Locations………………….……..….. 9
7 Corrosion Control Options………………..……. 11
7.1 Design Aspects………………….………….... 11
7.2 Materials Selection………………….……..… 11
7.3 Chemical Inhibition………………….……..… 12
7.4 Process Variables………………….……..…. 13
8 Corrosion Monitoring………………….………… 15
8.1 Techniques………………….………………... 15
8.2 Locations………………….………………….. 16
8.3 Inspection………………….………………….. 16
8.4 Stream Analysis………………….…..………. 17
Appendix I – Best Practice Limits………....…….……. 18

Appendix II – Team Members &
Technical Contributors………………….……. 19
Previous Issue: New Next Planned Update: TBD

Page 1 of 19
Primary contacts: Mansour A Al-Zamil (966-3-8760316) or Olavo C. Dias (966-3-8760254)
Copyright©Saudi Aramco 2009. All rights reserved.

Document Responsibility: Materials and Corrosion Control Standards Committee SABP-A-025
Issue Date: 6 January 2009
Next Planned Update: TBD Corrosion Control in Vacuum Distillation Units
1 Scope and Purpose
This SABP provides guidelines that will improve the integrity of vacuum distillation
units through a fundamental understanding of the damage mechanisms, process
parameters, inspection techniques, corrosion monitoring, analytical needs and corrosion
control options. It is based on current industry practices and field experiences in Saudi
Aramco vacuum distillation units.
2 Conflicts and Deviations
If there is a conflict between this Best Practice and other standards and specifications,
please contact the Coordinator of ME&CCD/CSD.
3 References
This Best Practice is based on the latest edition of the references below:
3.1 Saudi Aramco References
Saudi Aramco Engineering Procedure

SAEP-1135 On-Stream Inspection Administration
Saudi Aramco Engineering Standards

SAES-L-132 Material Selection for Piping Systems
SAES-L-133 Corrosion Protection Requirements for Pipelines,
Piping, and Process Equipment
Saudi Aramco Best Practice

SABP-A-015 Chemical Injection Systems
3.2 Industry Codes and Standards
American Petroleum Institute

API RP 570 Inspection, Repair, Alteration and Rerating of In-
Service Piping Systems
API RP 571 Damage Mechanisms Affecting Fixed Equipment
in the Refining Industry
International Organization for Standardization

ISO 15156 Petroleum and Natural Gas Industries Materials
for Use in H2S-Containing Environments in Oil
and Gas Production
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3.3 Publications
Understanding Vacuum System Fundamentals – G. R. Martin, J. R. Lines and
W. Golden, Hydrocarbon Processing, Volume 73, No. 10 (1994)
Understanding Ejector Systems Necessary to Troubleshoot Vacuum Distillation-
J. R. Lines, Hydrocarbon Processing, Volume 73, No. 10 (1994)
Improve Vacuum Heater Reliability- A. Garg, Hydrocarbon Processing, Volume
78, No. 3 (1999)
Vacuum Tower Overhead System Corrosion Control – Baker Petrolite Bulletin –
6/1999
Crude Unit Corrosion Guide – Joerg Gutzeit, PCC Process Corrosion
Consultants, 2006
Corrosion in Petroleum Refining and Petrochemical Operations – ASM Metals
Handbook, Volume 13C, ASM International, Materials Park, Ohio
Chevron Corrosion Manual - CSD/ME&CCD Live Link site
4 Definitions and Abbreviations

API American Petroleum Institute
ASME American Society of Mechanical Engineers
ASTM American Society for Testing and Materials International
CS Carbon Steel
Cr Chromium
HVGO Heavy Vacuum Gas Oil
LVGO Light Vacuum Gas Oil
HVD Heavy Vacuum Diesel
mpy Mils per Year (40 mpy = 1 mm/yr)
Mo Molybdenum
NACE National Association of Corrosion Engineers
PTB Pounds per thousand barrels of crude oil
SCC Stress Corrosion Cracking
SS Stainless Steel
TML Thickness Measurement Location
5 Process Considerations
5.1 Process Description
The vacuum distillation unit takes the atmospheric column tower bottoms and
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separates it into residuum and gas oil fractions. The feed from the crude units
vary from Arab light crude oil to Arab heavy crude oil based on the availability
and the asphalt demand. Consequently, operating conditions of the vacuum
units are adjusted. The vacuum unit feed normally is hot; however, cold feed
option exists in case of shortage in reduced crude production.
The vacuum column pressure allows heavy hydrocarbons to vaporize by

decreasing the boiling point to produce vacuum diesel, vacuum gasoil (VGO) that
is further upgraded to valuable products through hydroprocessing units like the
hydrocracker or fluidized catalytic cracking. The heavy asphaltic material of the
vacuum column bottom is fed to the asphalt oxidizer or sent to fuel oil blending.
The table below provides a comparison of vacuum distillation units in Saudi

Aramco refineries.
Table 1 – Comparison of Vacuum Distillation Units in Saudi Aramco
Refinery Ras Tanura Riyadh Jeddah

VDU2: 15 MBD (current),
Current: 155 MPD Current: 49 MPD 18 MBD (design)
Capacity
Design: 136 MPD Design: 40 MPD VDU5:14 MBD (current),
14 (design)
Current : Current: Current:
70%AL+30% AH 100% AL VDU2: AL, VDU5: AH
Feed
Future (2013): Future: Future potential:
100% AL AL + Khurais AL VDU2: 100% AH
VDU2:
LVGO, HVGO, LVGO, HVGO, Slop Wax.
Products LVGO, HVGO
HVD VDU5:
VGO, Slop Wax.
Overhead Ejectors In Parallel In Parallel In Series
Overhead Receiver Seal Drum Hotwell (Vessel) Hotwell (Concrete)
5.2 Process Flow Diagram
The figure below shows a typical process flow diagram for the vacuum
distillation unit. It has the following sections:
Charge Section
The atmospheric residuum is pumped to a series of heat exchangers before
entering the charge heater where it is heated from 740-780F. Some thermal
degradation can take place in the radiant tubes that can lead to coking 0.12-0.24 in
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(3-6 mm) and at the end of the cycle, typical 2-4 years. This requires
conventional steam/air or mechanical decoking. At low throughput, a stratified
flow regime may develop dry areas that would increase corrosion. At higher flow
rates, over-firing in the fired heater may result in overheating and oxidation of the
coils. Some refineries are using velocity steam to minimize the residence time in
the tubes at the expense of fuel firing. The fired heaters in Saudi Aramco have a
horizontal tube layout and use natural draft.
Vacuum Distillation Column

The combined heater coils outlet, partially vaporized, flows from the transfer
line and enters the vacuum column flash zone via a vane inlet device feed
distributor. Superheated steam is injected into the column bottom to strip off
any light hydrocarbons. The yield of vacuum distillate is solely determined by
flash zone conditions pressure (20-38 mm Hg vacuum) and temperature (740-
780F). Any change of flash zone pressure is compensated by changing the
heater outlet temperature. The feed flashes and is separated into light and heavy
fractions. The vaporized gas oil travels up through multiple layers of structured
or random packing which is wetted by spraying wash oil via spray nozzles. The
vacuum gasoil is recovered in the upper sections by condensation. Filters are
used in the circulating reflux streams to prevent spray nozzle blockages.
The heavy asphaltic material residence time in the vacuum bottom is minimized
to reduce cracking and it is quenched to 675-700F by circulating cold reflux to
the column boot. The dirty wash oil above the flash zone is collected and
recycled back to atmospheric column bottoms or mixed with the vacuum bottom
and diverted to the oxidizer, Demex unit or fuel oil blending tank.
Vacuum Overhead System

The overhead of the column include non condensable hydrocarbons, water,
hydrocarbons gases, H2S and possible O2 from air leakage. Chemical injection
(neutralizer) is used in some refineries to adjust the condensate water pH. The
vapors are routed to ejectors with corresponding condensers.
The reduction of pressure is achieved by multiple stage ejectors set system.

Each ejector set consists of two ejectors with variable load, which passes high
velocity jet steam through nozzles and across an open suction chamber. A
recycle line from the ejector is routed back to the top of the column to control
the top pressure. Vacuum vapors are drawn through ejector nozzles, mixes with
steam and cooled down in the condensers. They are transferred via dip legs to a
receiver. Vacuum is preserved by maintaining the barometric legs from ejectors
sealed by a level of condensate. The receiver sour water is pumped for desalting
or to the sour water stripper unit, while non condensable gases are routed to
waste gas burner in the heater or to the flare. The hydrocarbon condensate is
diverted to slop or recycled back with the crude feed to the unit.
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Figure 1 – Schematic of a Typical Vacuum Distillation Unit
5.3 Corrosive Species
A discussion of the specific corrosive compounds follows:
Sulfur Compounds – Corrosion is primarily caused by hydrogen sulfide, a

decomposition product of organic sulfur compounds. These compounds begin
to decompose at around 500F and corrosion rates increase exponentially up to
700F. Saudi Aramco Standard SAES-L-132 stipulates a temperature limit of
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536F for carbon steel use. However, based on industry guidelines, API RP 571
proposes 500F and API RP 939C (yet to be officially issued at the time of
writing this best practice) will recommend 473F. At this time, it is proposed to
use a threshold limit of 473F. Beyond this, low-alloy or stainless steels shall be
used based on metal temperature and process severity.
Naphthenic Acids – Occurs in certain crude oils and these become corrosive
when the temperatures exceed 450F, although, attack has been observed as low
as 350F. Maximum corrosion generally occurs between 520F-535F. This
has not been a problem with Saudi Arabian crudes.
Hydrogen Sulfide – originates with reactive sulfur in the reduced crude that are
decomposed at the higher temperatures of the vacuum heater (compared to the
atmospheric heater) to form H2S. It goes up the vacuum column, combines with
steam condensate and can corrode the column dome, overhead condensers,
steam ejectors, vacuum receivers and the interconnecting piping.
Hydrogen Chloride –about 10% of the magnesium chloride and 90% of the
calcium chloride in the desalted crude end up in the reduced crude. All the
magnesium chloride and 5% of the calcium chloride react with steam in the
vacuum heater to form HCl vapor. This combines with condensate upstream of
the ejectors and can lead to low pH and severe corrosion. Other sources of
chloride include entrained seawater in shipping tanker reduced crude and waste
products containing organic chlorides added to the feed.
Oxygen – enters the system with air leaking from flanges, seals in valves, pumps
& sight-glasses, condensers and during shutdowns. Poorly deaerated steam can
also be a contributor. Oxygen accumulates in dead spaces and accelerates
corrosion reactions. It can also react with H2S to form elemental sulfur and
inorganic polysulfide deposits that accumulate on the condenser shell side.
Neutralizer Hydrochloride(R-NH2.HCl) - A mist of this compound can form

when liquid organic neutralizer is added to the in the vacuum overhead line or
into the line leading to the ejectors for pH control. With sufficient condensate, it
will dissolve and create no problems.
Ammonium Chloride – Certain residual organic nitrogen compounds in the

reduced crude are converted to ammonia in the vacuum heater. This moves up
in the vacuum column and converts to corrosive ammonium chloride in the
presence of HCl vapors. This also occurs if ammonia is used as a neutralizer in
the vacuum column overhead.
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6 Damage Types
The main areas of corrosion susceptibility are the heater tubes, column internals and the
overhead circuits. Areas operating above 475F are subject to high temperature
sulfidation that require alloying to minimize attack. This is especially true in areas of
high turbulence. Corrosion in the overhead system is primarily the combination of H2S,
HCl and oxygen at low pH values. In general, vacuum overhead corrosion is less than
the crude overhead which sees most of the corrosives.
6.1 Damage Mechanisms
6.1.1 High Temperature Attack
Piping and Vessels – are subject to sulfidation in the presence of

mercaptans and H2S gas which are corrosive to carbon and low alloy
steels. Sulfidation is primarily caused by H2S and other reactive sulfur
species as a result of thermal decomposition. The corrosion rate is a
function of the alloy composition, temperature and concentration of
sulfur. Alloys containing 5-9% Cr are often sufficient but 12% Cr or
304 SS are also used at higher sulfur levels.
Heater tubes - can be subjected to overheating, carburization and

thinning due to coking and sulfidation. This is particularly true if the
feed contains asphalthenes that tend to settle out in the tubes. Most plants
use the decoking process at the end of the cycle (based on high tube skin
temperatures) to prevent material damage. Metallurgy upgrades (e.g.,
going from 5 Cr to 9 Cr) can help if sulfur levels increase over time.
6.1.2 Wet H2S Damage
This occurs when carbon steel is exposed to a minimum of 50 ppm H2S

and liquid water such as in the vacuum overhead circuit. It can manifest
itself in four forms – Hydrogen Blistering, Hydrogen Induced Cracking
(HIC), Stress Oriented Hydrogen Induced Cracking (SOHIC), and
Sulfide Stress Cracking (SSC). The key factors are environmental
conditions (pH, H2S levels, contaminants and temperature), material
properties (hardness, microstructure, strength) and tensile stress level
(applied or residual). ISO 15156 provides guidance on fabrication.
6.1.3 Underdeposit Corrosion
Fouling that leads to corrosion is prevalent in the condensers on the shell

side (overhead vapors) and tube side (from the cooling water). In
addition to corrosion, there is decreased heat transfer and increased
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ejector vapor load that can cause ejectors to break operation. The
primary types of underdeposit corrosion are as follows:
Chloride salt deposits - ammonium chloride and neutralizer

hydrochlorides formed when acids are neutralized in the overhead
system. With steam, these salts cause underdeposit corrosion.
Corrosion products - are formed when condenser and ejector systems are
exposed to air during extended shutdown periods. These products flake
off and tend to foul and corrode downstream equipment.
Sulfur deposits - generally corrode vent gas compressors. As polysulfides,

they can either be corrosive or protective.
Water deposits - Fouling occurs at velocities below 3 ft/sec, and from

formation of CaCO3 scale at temperatures above 140F (summer time).
Condenser tube sides and channel boxes are frequent fouling targets.
6.1.4 Erosion Corrosion
Most ejector erosion problems are caused by excessive steam velocities

and take the form of an etched striated pattern and lake type erosion
corrosion in the nozzles and diffusers. Other erosion concerns are:
 Gouging corrosion of the nozzle’s diverging diffuser section due to
poor steam deaeration and treatment
 Droplet impingement of the inlet diffuser section due to wet steam
formed at low exhaust temperatures ( < 250-300F)
6.1.5 Acid Corrosion
Corrosion due to low pH is the most common problem in the overhead

system. Cracking in the vacuum column results in acidic components
that include HCl, H2S, light organic acids, CO2 and SOx. These can
combine with condensed steam to form acidic components that can
aggressively attack carbon steel metallurgy. Generally, this will require
the use of neutralizers to elevate the pH. This type of attack is more
prevalent in the diplegs after the ejectors and is also found sometimes in
the receiver vessels downstream.
6.2 Damage Locations
The figure below provides the different damage mechanisms and their locations.
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Figure 2 – Location and Types of Damage Mechanisms
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7 Corrosion Control Options
7.1 Design Aspects
Velocities
When the maximum fluid velocities in the vacuum heaters and transfer piping
exceed 200 ft/sec, a minimum of 5-9 Cr metallurgy are used to prevent severe
erosion corrosion. All Saudi Aramco refineries use 9 Cr heater tubes
metallurgy. For the transfer piping to the vacuum column, Jeddah and Riyadh
refineries use 5 Cr while Ras Tanura uses 9 Cr.
Fouling
By-pass piping becomes necessary to allow for periodic cleaning and repairs of
the condenser bundles especially in seawater service. This can be in addition to
periodic backwashing.
7.2 Materials Selection
The materials choice for the vacuum unit high temperature sections depends
primarily on the sulfur content of the reduced crude feed. Per the original
design, carbon steel components are used for operating temperatures below
500F and 5-9 Cr for temperatures above 500F for sulfidation resistance.
However, as discussed in 5.3, this limit is being lowered to 475F.
Specific locations where alloys can be employed are discussed below.
Heater Tubes
Due to the high sulfur levels in Arabian crudes, 5-9 Cr tubes are necessary in the
radiant section to prevent sulfidation. Carbon steel is frequently used for the
convection section bare tubes. However, for finned tubes it may be necessary to
upgrade to 5 Cr due to potential sulfur attack and difficulty of inspection.
In 2003, Riyadh refinery found success after changing the design from side firing
to bottom firing to minimize coking and sulfidation that plagued the old heater.
Vacuum Column
The use of 12 Cr (405 or 410S SS) clad internals and tray components are
necessary for high sulfur crudes where temperatures exceed 475F. The most
susceptible locations are above the feed tray. On rare occasions, the top heads
have suffered corrosion possibly due to organic acids and this has been resolved
by utilizing a 316L SS lining.
Overhead Condensers
If process controls do not give adequate life to carbon steel tubes, more
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corrosion resistant materials can be used such as admiralty brass, 70-30 CuNi,
Monel and Titanium Grade 2. Where chloride pitting of Titanium is a concern
(>250F), Titanium Grade 7 is used. Coatings are generally helpful for channel
boxes and tubesheets (thick film) and can also be an option for the tubes (see
SAES-H-001, Section 7.3, I and consult with CSD Coatings group).
The original metallurgy for the condenser tubes was admiralty brass for all the
refineries. However, due to corrosion problems in sea water service, Ras
Tanura changed to super austenitic stainless steel 254SMO (6% Mo) and
Jeddah has used copper nickel with success. Riyadh refinery continues to use
admiralty brass – however, they use treated sewage water.
Receiver drum (seal drum, hotwell or vacuum sump)

The standard construction material is carbon steel. However, Ras Tanura has
recently gone to a new coated seal drum as a result of corrosion and is awaiting
a T & I for evaluation.
Diplegs
These can be subjected to acidic attack form chlorides and sulfides even with the
use of neutralizers. Internally coated pipe and non-metallic are options (Contact
ME&CCD for materials selection). Jeddah refinery has successfully used non-
metallics since 1997 to resolve this problem. Ras Tanura has recently faced
corrosion problems with the original legs.
Piping and Valves

For sour crude lines operating above 475F, piping is upgraded to 5-9 Cr. To
prevent shock condensation of dilute acids, all lines leading to the ejectors
should be insulated.
The conventional 12 Cr steel valve trim is adequate for carbon steel or 5 Cr steel
bodies. For austenitic stainless steel, trim can be either a matching composition
or Stellite (Cobalt based) weld overlay for erosion resistance.
Pumps
Due to turbulence, more corrosion occurs in pumps. Carbon steel is a typical
selection for pump cases and impellers at temperatures below 475F. For higher
temperatures for resisting sulfidation, 5-9 Cr cases and 12 Cr or CA6NM (12 Cr,
4 Ni, 0.7 Mo) impellers have been used.
7.3 Chemical Inhibition
Neutralizer addition can become necessary to control the pH from 5.5 to 6.5.
The pH control is also influenced by effective tank settling, desalting and caustic
additions in the crude unit. Feed of the neutralizer is ideal ahead of each stage
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of condensation. The preferred method is to provide additions downstream of

each ejector stage and control the pH independently. In special cases, where the
use of motive (wet) steam is unavoidable, the injection with motive steam is
recommended to provide pH elevation. However, this has to be done carefully
to ensure there is no chloride salt deposition and subsequent severe corrosion.
For systems requiring direct additions to the condensers, a minimum of 15 pipe
diameters ahead of the condenser inlet or pipe elbows is suggested for adequate
mixing in the vapor phase.
In some cases, neutralizer injection is accompanied by filming amine inhibition.

This may lead to fouling problems if insufficient hydrocarbon liquids are
condensed to remove excess inhibitor.
Ras Tanura tried discontinuing the use of neutralizer (into the column) and used
caustic in the crude unit for pH control in early 2008. However, the pH control
was ineffective. They plan to change the injection to the vacuum overhead line
in the next T & I. Jeddah refinery adds neutralizer (3-5 ppmv) to each steam
ejector and have been able to control the pH to acceptable levels. Riyadh
refinery does not add any neutralizer and have had good success.
7.4 Process Variables
Feed Changes
Variations in feed and vacuum column revamps can have a direct impact on
reliability. In Ras Tanura, processing of higher rates of Arab Heavy crude
containing asphalthenes contributed to heater tube coking, thinning and
carburization- decoking is currently done every two years. Jeddah refinery has
also seen signs of coking soon after decoking during the T & I that has required
careful monitoring and control.
High Sodium Content in Product

This occurs when excessive amounts of caustic are used in the crude units to
reduce overhead chlorides. Sodium is a significant catalyst deactivator in the
Hydrocracker. Increased use of neutralization amines and minimization of
caustic usage is recommended to maintain proper specifications.
Sulfur Levels
The charts below depict the effect of changes in sulfur levels and how it impacts
the corrosion rates and materials of construction. Note that the changes are
parabolic. In Saudi Aramco, there has been a gradual increase in the crude oil
sulfur levels over the years and hence, increased corrosion.
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Figure 3 – Modified McConomy Curves Showing Effect of

Temperature on Corrosion of Various Steels and Stainless Steels
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Figure 4 – Effect of Sulfur Content on Corrosion Rates Predicted by Modified

McConomy Curves in 290-400C (550 – 750F) Temperature Range
Source: J. Gutzeit, Process Industries Corrosion – The Theory and Practice, NACE 1986
Overhead System
Hydrogen sulfide and hydrogen chloride are the main variables here but this can
be complicated by the air leakage, the presence of wet steam and excessive
steam velocities. The main control is pH of each condenser dipleg which is
normally maintained from 5.5 to 6.5. When air leakage occurs, corrosion and
scaling of both steel and copper alloys can be severe. Wet steam can lead to
corrosion in the ejectors while high steam velocities cause erosion.
Jeddah refinery also maintains Cl at 10-30 ppm and Fe at <2 ppmv in addition
to pH control. Without neutralizer additions, the pH goes down to 3.
8 Corrosion Monitoring
8.1 Techniques
Coupons and Probes

Retractable coupons can give reliable data under turbulent and laminar flow
conditions. Probes offer the advantage of continuous data collection without the
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need for frequent replacements. Water cooled tubular sensing probes and weight
loss specimens are available to force and measure effects of shock condensation.
If there is pitting or turbulence, the thin probe element used can fail by fatigue.
Generally, corrosion coupons are removed on a 6-12 month frequency or sooner

if high corrosion rates are observed either from past coupon/probe data or the
On Stream Inspection (OSI) analysis. Coupon data needs to be supplemented by
inspection to confirm the results.
Non-intrusive
Recently, non-intrusive corrosion monitoring technology has improved and
become more reliable to monitor corrosion in systems where intrusive
techniques cannot be used such as in high velocity and high pressure locations.
Most of these technologies are currently under evaluation.
Infrared
The use of infrared thermography is recommended to check for heater tubes
overheating. Riyadh refinery uses this technique if there is flame impingement.
Ras Tanura feels that specialty cameras could make this an effective tool.
8.2 Locations
Typical locations for monitoring are:

 Vertical rundown piping (each dipleg) between the condenser and the
receiver drum ( seal drum, hotwell or vacuum sump)
 Horizontal vapor line between the vacuum column and the first set of
condensers – probes are preferred.
8.3 Inspection
Equipment
Susceptible equipment includes those exposed to high temperatures and the
vacuum overhead system that includes the condensers, ejectors, diplegs and the
receiver drum (seal drum, hotwell or vacuum sump). Other areas of concern are
pump impellers in the vacuum overhead. Visual inspection, random ultrasonic
thickness (UT) and wet fluorescent magnetic particle testing (WFMPT) are
commonly used to check for localized corrosion and environmental cracking.
Baseline readings need to cover four quadrants per API RP 570, paragraph 5.5.2.
Ensure that the TMLs cover the full length of the equipment such as top head,
nozzles, shell (top, mid & bottom) and the bottom heads per SAEP-1135 and
API RP 570.
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For the overhead condensers, inspect tube inside diameters by using borescope,
UT or advanced NDT techniques. For carbon steel tubes, consider MFL
(Magnetic Flux Leakage), LOTIS (Laser Optic Testing Inspection System) and
IRIS (Internal Rotary Inspection System) inspections while eddy current testing
can be used for stainless steel tube inspections.
Piping
The most vulnerable areas are the high temperature and the vacuum unit
overhead piping circuits. Various techniques such as random ultrasonic
thickness (UT), UT shear wave (UTSW) of welds and radiography (RT) are
used to detect metal loss, weld preferential corrosion and fine cracking. The
following is recommended if scattered low readings are found in the circuit:
 Re-verify the OSI readings showing low thickness measurements.
 If still low, inspect using UT grid scanning, RT survey or P-scan to establish
the corrosion rate and profile. Note that high temperature UT mapping or a
T & I may be required if temperatures are > 140F.
 Re-calculate the remaining life and apply SAEP-1135 to establish future
inspection frequency and extent.
8.4 Stream Analysis
The table below provides a summary of the recommended analysis.
Table 2 – Typical Analysis, Frequency, Limits and Methodology
Variable Location Frequency Limit Methodology
pH Each dipleg water Daily 5.5 to 6.5 pH meter

Chloride Each dipleg water Daily 10-30 ppm Dionex/Mettler
Iron Receiver drum Weekly < 1 ppmw Colorimeter/ICP
Sulfide Receiver Drum If necessary - -
Ammonia Each dipleg water If necessary - -
Revision Summary
6 January 2009 New Saudi Aramco Best Practice.
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Appendix I – Best Practice Limits
LOCATION TARGET
COMMENT
OR VARIABLE OR LIMIT
1.0 Overhead Piping
Velocity 75 feet/second Target value
1.1
(Carbon Steel) < 100 feet/second Mandatory limit
Usually, hydrogen induced cracking
1.2 Metallurgy Carbon steel
resistant steel is not used (per SAES-L-133)
2.0 Neutralizer ( also see SABP-A-015)
Positive displacement
2.1 Pump Ensure that size is appropriate
metering pump
2.2 Filter Strainer Preferred. 100 mesh typical
Treatment rate is adjusted to give required
2.3 Treatment rate
overhead receiver pH (typical 3-5 ppmv)
Neutralizer must be injected into the
At each dipleg
overhead system and not into the column
2.4 Injection location
>5 pipe dia. from the Strongly preferred to minimize damage on
downstream elbow. downstream elbow
Retractable Allows maintenance on-stream
12 o’clock Normal orientation
2.5 Quill design
Inject in center third of Ensures even distribution away from pipe
stream. walls
2.6 Quill metallurgy Hastelloy C-2000, B-2 Monel should not be used
3.0 Corrosion Monitoring
Operations data, laboratory results,
3.1 Data correlations chemical injection rates, OSI and any
probe/coupon data.
Injection point API RP 570 &
3.2 Essential
inspection Inspection Alert 001/97
3.3 Coupons < 5 mpy
3.4 Probes < 5 mpy Electrical resistance or MicroCor probes
Operations data, laboratory results,
3.5 Data correlations chemical injection rates, OSI and any
probe/coupon data
Injection point API RP 570 &
3.6 Essential
inspection Inspection Alert 001/97
3.7 Coupons < 5 mpy
3.8 Probes < 5 mpy Electrical resistance or MicroCor probes
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Appendix II – Team Members & Technical Contributors
Team Members
Mansour A. Al-Zamil CSD/CTU
Olavo C. Dias CSD/CTU
Abdulkareem A. Al-Dabass P & CSD/DTU
Khalid J. Al-Anazy ID/IEU
Rakan A. Al-Shammary CSD/MEU
Faris O. Al-Dawoud JRD/IU
Mohammed A. Al-Ibrahim RTR/NFU
Mohammad R. Al- Badri RRD/IU
Technical Contributors
Robin D. Tems CSD/CTU
Maher S. Al-Khashram CSD/N&PCU
Abdelhak Kermad CSD/MEU
Don R. Hixon RTR/IU
Tushar V. Merchant RRD/OEU
Abdulgader M. Seyed ID/IEU
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Best Practice

SABP-A-025 6 January 2009

1 Scope and Purpose………………………………... 2

Appendix I – Best Practice Limits………....…….……. 18

Previous Issue: New Next Planned Update: TBD

Copyright©Saudi Aramco 2009. All rights reserved.

1 Scope and Purpose

2 Conflicts and Deviations

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

Saudi Aramco Engineering Standards

Saudi Aramco Best Practice

3.2 Industry Codes and Standards

American Petroleum Institute

International Organization for Standardization

4 Definitions and Abbreviations

5.1 Process Description

The vacuum column pressure allows heavy hydrocarbons to vaporize by

The table below provides a comparison of vacuum distillation units in Saudi

Table 1 – Comparison of Vacuum Distillation Units in Saudi Aramco

Refinery Ras Tanura Riyadh Jeddah

5.2 Process Flow Diagram

Vacuum Distillation Column

Vacuum Overhead System

The reduction of pressure is achieved by multiple stage ejectors set system.

Figure 1 – Schematic of a Typical Vacuum Distillation Unit

5.3 Corrosive Species

A discussion of the specific corrosive compounds follows:

Sulfur Compounds – Corrosion is primarily caused by hydrogen sulfide, a

Neutralizer Hydrochloride(R-NH2.HCl) - A mist of this compound can form

Ammonium Chloride – Certain residual organic nitrogen compounds in the

6.1 Damage Mechanisms

6.1.1 High Temperature Attack

Piping and Vessels – are subject to sulfidation in the presence of

Heater tubes - can be subjected to overheating, carburization and

6.1.2 Wet H2S Damage

This occurs when carbon steel is exposed to a minimum of 50 ppm H2S

6.1.3 Underdeposit Corrosion

Fouling that leads to corrosion is prevalent in the condensers on the shell

Chloride salt deposits - ammonium chloride and neutralizer

Sulfur deposits - generally corrode vent gas compressors. As polysulfides,

Water deposits - Fouling occurs at velocities below 3 ft/sec, and from

6.1.4 Erosion Corrosion

Most ejector erosion problems are caused by excessive steam velocities

6.1.5 Acid Corrosion

Corrosion due to low pH is the most common problem in the overhead

6.2 Damage Locations

Figure 2 – Location and Types of Damage Mechanisms

7 Corrosion Control Options

7.1 Design Aspects

7.2 Materials Selection

Specific locations where alloys can be employed are discussed below.

Receiver drum (seal drum, hotwell or vacuum sump)

Piping and Valves

7.3 Chemical Inhibition

of condensation. The preferred method is to provide additions downstream of

In some cases, neutralizer injection is accompanied by filming amine inhibition.

7.4 Process Variables

High Sodium Content in Product

Figure 3 – Modified McConomy Curves Showing Effect of

Figure 4 – Effect of Sulfur Content on Corrosion Rates Predicted by Modified

Coupons and Probes

Generally, corrosion coupons are removed on a 6-12 month frequency or sooner