Corrosion Control In The Refining Industry
4-Day Classroom Course
Description
The Corrosion Control in the Refining Industry Course provides an overview of refinery process units and specific process descriptions, and focuses on the examination and identification of metallurgical problems that occur in process units. Students receive REFIN - COR 6.0 software which is a database of experiences, problems, and solutions encountered by refining industry corrosion engineers and includes minutes of meetings of NACE Committee TEG 205X (formerly T-8) on Refining Industry Corrosion from 1957 through 2002. This is information which can be used on-the-job and cannot be found anywhere else.
Who Should Attend
This course is geared toward those with a minimum of 1-2 years experience in refineries including: design engineers, process engineers, procurement agents, maintenance planners, service company representatives who support refineries, corrosion and equipment engineers, metallurgists, inspectors, and inspection supervisors.
Prerequisites
No prior training is required.
Course Highlights (include but are not limited to)
- Refinery Corrosion
- Failure Analysis-Techniques and Test Methods
- Materials of Construction for Refinery Applications
- Refinery Operations and Its Interactions with Corrosion
- Refinery Units/Processes-Crude Distillation/Desalting, Fluid Catalytic Cracking Unit, CLER Unit, Hydroprocessing Unit, Catalytic Reforming, Decoking Units
Corrosion Monitoring Methods in Refineries
Course Outline I. Corrosion and Other Failures
Introduction to Corrosion
Low-Temperature Refinery Corrosion
Low-Temperature Corrosion Principles
High-Temperature Refinery Corrosion
High-Temperature Corrosion Principles
High-Temperature Conditions
Corrosion/Failure Mechanisms
Metal Loss-General and/or Localized
Stress Corrosion Cracking
Hydrogen Blistering
Sulfide Stress Corrosion Cracking
Hydrogen Induced Cracking
Stress Oriented Hydrogen Induced Cracking
Hydrogen Cyanide
High-Temperature Hydrogen Attack
Metallurgical Failures
Grain Growth
Graphitization
Hardening
Sensitization
Sigma Phase
885 ° F (475 ° C) Embrittlement
Temper Embrittlement
Liquid Metal Embrittlement (LME)
Carburization
Metal Dusting
Decarburization
Selective Leaching
Mechanical Failures
Incorrect or Defective Materials
Mechanical Fatigue
Corrosion Fatigue
Cavitation Damage
Mechanical Damage
Overloading
Overpressuring
Brittle Fracture
Creep and Stress Rupture
Thermal Shock
Thermal Fatigue
Other Forms of Corrosion
Boiler Feedwater
Steam Condensate
Cooling Water Corrosion
Fuel Ash Corrosion
II. Failure Analysis in Refineries
Procedural Approach and Test Methods
Background Information
Initial Examination
Nondestructive Testing
Sectioning
Macroscopic Examination of Fracture Surfaces
Microscopic Examination
Fracture Appearance
Additional Testing and Analysis
Root Cause Analysis
Recommendations
III. Materials of Construction for Refinery Applications
The Role of the Corrosion Engineer
Corrosion Failures
Corrosion Testing Methods
Materials Selection Approach
Using Professional Consultants
Specifying Materials
National Standards
Company Standards
What the Designer Should Remember When Writing Specifications
Questions the Designer Should Ask to Control Quality
Fitness for Service
Refinery Materials of Construction
Introduction
Killed Steel
Steels
Carbon Steel
C-Mo Steels
Low-Alloy Steels
Cr-Mo Steels
Nickel Steels
Stainless Steels
Other Metals and Alloys
Non-Metallic Materials
Heat Treatment
Welding
IV. Refinery Operations and Overview
Refinery Operating Objectives
Refinery Process Overview
Process Interactions with Corrosion
V. Crude Distillation and Desalting
Introduction
Sources of Crude Oil
Composition of Crude Oil
Remaining Constraints
More About Crude Oil Composition
Crude Oil Pretreatment
Desalting
Preflash
Crude Distillation Unit
Operation of a Crude Distillation Unit
Corrosion in Crude Distillation Units
Columns
Exchangers and Piping
Fired Heaters
Other Corrosion Combating Measures
Blending
Desalting
Caustic Addition
Overhead pH Control
Corrosion Inhibitor
Water Washing
Corrosion Monitoring in Crude Units
Water Analysis (Overhead Corrosion Control)
Hydrocarbon Analysis
Corrosion Rate Measurement
On-Stream, Nondestructive Examination
VI. Fluid Catalytic Unit Corrosion and Metallurgical Damage
Process Description
Introduction
Hardware
Riser/Reactor
Regenerator
Flue Gas System
Fractionator
Corrosion Control in FCC Units
Materials of Construction
Damage Mechanisms and Suitable Materials
Reactors
Regenerators
Catalyst Transfer Piping System
Regenerator Reaction Mix Line, Main Fractionator, and Bottoms Piping
Flue Gas Systems
Inspection and Control Considerations
High-Temperature Oxidation
High-Temperature Sulfidation (H 2 S Attack)
High-Temperature Carburization
Polythionic Acid Stress Corrosion Cracking
Catalyst Erosion
Feed Nozzle Erosion
Refractory Damage
High-Temperature Graphitization
Sigma-Phase Embrittlement
885 ° F (475 ° C) Embrittlement
Creep Embrittlement
High-Temperature Creep
Thermal Fatigue
VII. Corrosion Control in Catalytic Light Ends Recovery (CLER) Units
CLER Process Description
Materials of Construction
Columns
Exchangers
Corrosion Problems:
Corrosion
Hydrogen Induced Damage
Inspection Techniques for Hydrogen Induced Damage
Prevention and Repair Techniques
Ammonia Stress Corrosion Cracking
Carbonate Stress Corrosion Cracking
Fouling/Corrosion of Reboiler Circuits
Corrosion Control Measures
Water Washing
Polysulfide Injection
Corrosion Inhibitors
Corrosion Monitoring
Hydrogen-Activity Probes
Chemical Tests
Corrosion Probes
VII. Sulfuric Acid Alkylation
Process Description
Reaction Section
Treating Section
Fractionation Section
Refrigeration Section
Materials of Construction
Materials and Corrosion Problems
Sulfuric Acid Corrosion
Acid Concentration
Acid Temperature and Velocity
Acid Dilution
Hydrogen Grooving
Feed Contaminants
Acid and Neutral Esters
Acid Carryover
Corrosion Under Insulation
Fouling Problems
Corrosion Control Measures
Reactor Section Corrosion
Tower Overhead Corrosion
Reboiler Corrosion and Fouling Control
Acid Tanks
Corrosion Control During Unit Shutdowns
Corrosion Under Insulation
Corrosion Monitoring
Inspection
Reaction Section
Treating Section
Fractionation Section
Refrigeration Equipment
Acid Tank
IX. Corrosion in Hydroprocessing Units
Hydroprocessing
Hydrotreating
Hydrocracking
Variations on Hydroprocessing
Common Corrosion Types in Hydroprocessing Units
High-Temperature Hydrogen Attack
High-Temperature H 2 S Corrosion-With Hydrogen Present
High-Temperature H 2 S Corrosion-With Little or No Hydrogen Present
Naphthenic Acid Corrosion
Ammonium Bisulfide Corrosion
Chloride Stress Corrosion Cracking
Failures Often Happen After Startup
Failures Happen at Predictable Points
Reactions with Stainless Steel
Polythionic Acid (PTA) Stress Corrosion Cracking
Stainless Steels Used to Prevent PTA
Other Methods Used to Prevent PTA SCC
Wet H 2 S Cracking
Sulfide Stress Cracking
Cracking: Hydrogen Induced and Stress-Oriented Hydrogen Induced
Material Property Degradation Mechanisms
Temper Embrittlement
Hydrogen Embrittlement
Selection of Materials
Reactor Loop -General
Reactor Feed System
Reactor Feed Furnaces
Reactors
Reactor Effluent System
Reactor Effluent-Distillation Feed Exchangers
Effluent Air Coolers
Effluent Air Cooler Inlet and Outlet Piping
Separator Vessels
Recycle Hydrogen System
Distillation Section
X. Catalytic Reforming
Introduction
Octane Number (RON)
Catalyst
Catalytic Reforming Process
Platformer (UOP)
Catalytic Reformer, Semi-Regenerative
Reactor Design
Corrosion Phenomena in Catalytic Reformers
HTHA
Stress Corrosion Cracking
Materials of Construction
Reactors
Exchangers and Piping
Fired Heaters and Other Equipment
Corrosion Control
Corrosion Monitoring
Inspection in Catalytic Reformers
XI. Delayed Coking Units-Corrosion, Materials, and Inspection
Considerations
Equipment and Operation of the Delayed Coking Unit
Corrosion and Other Problems in Delayed Coking Units
High-Temperature Sulfur Corrosion
Naphthenic Acid Corrosion
High-Temperature Oxidation/Carburization/Sulfidation
Erosion-Corrosion
Aqueous Corrosion
Corrosion Under Insulation
Thermal Fatigue, Temper Embrittlement of Cr-Mo Steels Used in Delayed Coking
Units
Inspection of Coking Units
General Inspection
Coke Drum Inspection
XII. Process Additives and Corrosion Control
Factors Affecting Corrosion
Acids
Temperature
Pressure
Flow
Turbulence
Material Selection
Methods to Mitigate Corrosion
Desalting and Caustic Injection
Water Washing
Acid Neutralization
Barrier Between Metal and Environment
Chemicals Used to Combat Corrosion
Filming Amines
Filming Formulation
Filmer Application
Treat Rates
Monitoring Filmer Performance
Neutralizing Amines
Polysulfides
Napthhenic Acid Corrosion Inhibitors
Application of Corrosion Inhibitors
XIII. Corrosion Monitoring Methods in Refineries
Introduction
Uses of Corrosion Monitoring
Corrosion Monitoring Techniques
Corrosion Coupons
Electrical Resistance Monitoring
Electrochemical Corrosion Monitoring
Linear Polarization Resistance
Potential Monitoring
Zero Resistance Ammetry (ZRA)
Electrical Impedence Spectroscopy (EIS)
Electrochemical Noise (EN)
Hydrogen Flux Monitoring
A Comprehensive Corrosion Monitoring Program
Corrosion Monitoring Sites
Corrosion Monitoring in Specific Process Units
Atmospheric Distillation Unit
Vacuum Distillation Unit
Fluid Catalytic Cracking Unit
Amine Treating Unit
Sour Water Stripper Units
Sulfuric Acid Alkylation Unit
Automated On-Line Monitoring
XIV. Refinery Injection Systems
Injection System Design Parameters
Engineering Practices
Process Design
Materials Selection Considerations
Inspection of Injection Point Locations
Location of Injection Point
Injection System Hardware
Chemical Storage Tanks
Chemical Injection Pumps
Additive Control Systems
Piping Systems
Injector
XV. Amine Treating
Refinery Amine Process Description
Tail Gas Units
Corrosion Phenomena
Corrosive Species
Amine Degradation
Cracking Phenomena
Corrosion Inhibitors
Materials of Construction
Corrosion Monitoring
Corrosion Control Measures
XVI. Sulfur Recovery Units
Sulfur Recovery Units
Sulfur Chemical Processes
Sulfur Recovery Process
Tail Gas Treating Unit
Incinerator
Cold Bed Adsorption (CBA) Unit
Corrosion Mechanisms
Sulfidation of Carbon Steels
Sour Environment Corrosion
Weak Acid Corrosion
Corrosion of Claus Units, by System
Feed Gas System
Corrosion Concerns
Mitigation of Corrosion
Inspections of the Feed Gas System
Reaction Furnace and Waste Heat Exchanger Systems
Corrosion Concerns
Mitigation of Corrosion
Inspections in the Reaction Furnace and Waste Heat Exchanger System
Claus Reactors, Condensers, and Reheat System
Corrosion Concerns
Mitigation of Corrosion
Inspections in the Claus Reactors, Condensers, and Reheat System
Liquid Sulfur Rundown Lines and Storage System
Corrosion Concerns
Mitigation of Corrosion
Inspections in Liquid Sulfur Rundown Lines and Storage System
Corrosion of CBA Units
Corrosion Concerns
Mitigation of Corrosion
Inspection of CBA Reactors, Condensers, and Piping
Corrosion of Tail Gas Treating Units
Burner and Mixing Chamber
Tail Gas Reactor and Waste Heat Exchanger
Water Quench and Re-Circulation Blower System
H 2 S Adsorption System
Corrosion in the Incinerator System
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