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This paper discusses current industry experience with CO2 Absorption systems. The evaluation of the
corrosion damage using API 579 Fitness-for-Service methodology along with recent industry application
is presented. Several different mitigation techniques are discussed to evaluate the available repair
procedures for CO2 Absorption system equipment. Examples are provided which show the repair process
and the results of the repairs for the ongoing fitness-for–service of these critical equipment items.
James R. Widrig
Quest Integrity Group, Boulder, Colorado, USA
Donald H. Timbres
D. & E. Consulting Inc., Fort Saskatchewan, Alberta, Canada
T
he Carbon Dioxide (CO2) Absorption and
Stripping Systems in Ammonia Plants are piping systems. Several papers on this subject have
critical equipment items to the plant opera- been reported at previous AIChE Ammonia Sym-
tion. The CO2 Absorption vessel is a vertic- posiums [1,2] Corrosion damage in this critical
al pressure vessel and typically is one of the largest equipment must be evaluated, monitored, and miti-
pressure vessels in the Ammonia Plant processing gated to safely and reliably operate this equipment.
a mixture of hydrogen, nitrogen, and carbon oxide
gases [Figure1]. Many of these vessels are con- Carbon Dioxide Corrosion
structed of carbon steels. The carbon oxide gases
are removed using various commercially available Carbon dioxide corrosion results when CO2 dis-
process solutions to produce a synthesis gas stream solves in water to form carbonic acid [H2CO3]. The
and carbon dioxide product stream. The aqueous acid generally lowers the pH and in sufficient
carbon dioxide rich environment of the absorber
Visible internal inspection of the vessel during a Section 4 of API 579/ASME FFS-1 Fitness–For–
shutdown is the most reliable method for locating Service (FFS) applies to the assessment of pressu-
corrosion. Internal inspection is often limited to the rized components subject to general metal loss re-
areas easily observed from manways and limited sulting from corrosion, erosion, or both corrosion
internal access. Removal of trays and structured and erosion. The assessment procedures use a
packing may be required to identify and fully un- thickness averaging (swimming pool profile) ap-
derstand the extent of corrosion in a system. This proach. When local thinned areas are found, the
inspection may become a critical path item for a procedures in Part 4 may produce conservative re-
plant turnaround and is especially true when unex- sults. Part 5 assessment procedures (use a river
pected corrosion is discovered. bottom profile) and can be used to reduce the level
of conservatism in the results. [Reference API
Examples of typical CO2 corrosion found during 579/ASME FFS-1]. The details of performing an
shutdowns are shown in Figures 2, 6, 7 and 12. API 579 / ASME FFS-1 assessment are provided
in these documents.
Fitness-for-Service One example of the API 579/ ASME FFS-1 as-
Once corrosion is discovered, the operator/owner sessment involves a Semi-Lean Absorption Tower
is faced with a decision on what needs to be done with the following design details.
to ensure continued safe and reliable operation of
the vessel and system. Local pressure vessel au- Inside Diameter, inches 120 (3.05 m)
thorities may be involved as well. Immediate con- Overall Height, feet 120 (36.6 m)
cerns are whether the equipment will need to be Design Pressure, psig 323 (2227 kPa)
shut down for repair or replacement, if the equip- Max. Design Temperature, 650 (343oC)
o
ment can be operated in the present condition until F
a future opportunity for repair, and what are the Nom. Wall Thickness, inches 1.3125 (33.3 mm)
options for repair. Maximum Allowable Stress, 17,500 (120 MPa)
psi
Localized corrosion in these systems can be affec- Shell Weld Joint Efficiency 1.0
tively evaluated using API 579/ ASME FFS-1 Fit- Specified Corrosion Allow- 0.125 (3 mm)
ness-for-Service criteria [3]. The results of this as- ance, inches
sessment are used by the operator/owner to Post Weld Heat Treatment Yes
determine the level of current risk and to determine Shell Material SA-516-70
a course of action for mitigation. Table 1 - Vessel Design Information
0.25-.3125”
A
Weld
Layers Clad
4 Plate
Figure 9 - Temper Bead Diagram • Determine the thickness and size of the strip
(Drawings not to scale) lining plates to be installed. The thickness and
size should be chosen based upon the size of
the entry, the diameter of the tower, and the
Strip Lining with Stainless Steel weight of the plates for handling within the
tower. For example a SA240-Grade 304L
The following points should be considered and in-
plate, 3/16 inches [4.76 mm] thick, with a
cluded in the repair procedures for the application
width and length of 16 inches [0.4 m] by 94
of the stainless steel strip lining in a CO2 Absorber:
inches [2.4 m], respectively will weight ap-
proximately 82 pounds [37 kg].
• Placement of solid stainless steel strip liner
• The spacing between strip lining plates should
plates straddling the corroded area in the ves-
be specified to minimize the size of the weld
sel. Determine the appropriate size for the strip
bead and gap between the plates.
lining.
• Following a layout of the cladding location and
• Strip lining shall be the butt welded design.
individual band locations, it is imperative to
Lap welded strip lining is not recommended.
verify the existing gap between the cladding
See Figure 10 below for a generic layout of the
and the base material. The gap at any location
butt welded lining concept.
between the clad plate and base material shall
be maximum 1/8 inch [3 mm].
• It is important that complete “tie-in” occur be-
tween the clad plate and base material around
the entire circumference of the each clad plate.
The “tie-in” of each clad plate is recommended
prior to completing the fill and cap weld layers
in the spacing between adjacent plates.
• A WPS/PQR meeting Section IX of the ASME
Pressure Vessel Code will be required for
General Design conditions of the CO2 Stripper During the repairs the area of the system that had
Tower are as follows: been previously repaired was inspected. The con-
Design Pressure, psig 43 (294 kPa) dition of the 2007 applied coating in 2008 indicates
Max. Design Temperature, 266 (130°C) that the life of the epoxy coating is significantly
o greater than one year of operation. It is understood
F
Nom. Wall Thickness, inches 1.34 (34mm) that the manufacturer also indicated that there
Specified Corrosion Allow- 0.125 (3.2mm should be no need to carry out a repair to the coat-
ance, inches ing applied within three years of operation. Based
Post Weld Heat Treatment Yes upon the visual inspection of the area previously
Shell Material ASTM A516 coated, the epoxy coating has performed very well
Grade 70 and appears to be a suitable long term solution to
ensure fitness for service of the stripper column to
In the specific example shown in the photographs prevent CO2 corrosion pitting in the semi-lean
[Figure 13], an alternative epoxy was being used aMDEA.
Conclusion
The evaluation of the corrosion damage in CO2
Absorbers systems using API 579/ ASME FFS-1
Fitness-for-Service methodology has been success-
fully applied in recent industrial applications.
Quest Reliability’s SignalTM Fitness-for-Service, is
a software product for performing fitness-for-
service and fracture mechanics analyses on fixed
and rotating equipment. Signal FFSTM allows the
user to perform both Level 1 and Level 2 assess-
ments and includes an advanced fracture mechan-
ics module to allow the user to perform limited
Level 3 assessments.