Corrosion - Honeywell

www.honeywell.com
Corrosion – The New Process Variable
2004 Users Group Americas Symposium • Partners in Innovation
Corrosion is Part of the “Bigger Problem”
60% of plant engineers will
retire by 20101
Personnel actions cause $20B/yr
in avoidable costs in Petrochem²
More compliance, regulation
Improve
Process
Performance
Increase Asset
Effectiveness
Production processes
increasingly complex
Enhance
Business
Agility
Improve
People
Effectiveness
Must maintain safety, security
1. Source: Journal of Petroleum Technology
2. ASM Consortium
Higher business
volatility, faster decision
making
50% of maintenance not
needed, 10% harmful3
Supply chains more
integrated
3. Honeywell “Loopscout” studies
Automation Extends Beyond Process Efficiency
Honeywell’s Holistic View of Automation
• Improve Throughput
• Reduce Energy Costs
• Improve Quality, Reduce Waste
• Respond to Market Volatility
• Optimize What to Produce,
Where, When, at What Price
• Ensure Compliance
• Predict/Pre-empt Asset Failures
• Reduce/Avoid unplanned incidents
• Reduce Maintenance Costs
• Implement best work practices
• Enhance Security
• Turn data into actionable knowledge
Increasingly a Software/Knowledge Driven Business
Corrosion Facts & Figures
• $50B per year spent by the Global Process Industries on Corrosion
increasing due to aging plants, sour crude stocks, higher thru-puts
• 90% of Corrosion damage caused in only 10% of the time
conventional offline approaches can’t identify root cause & arlabor intensive
• 70-90% of all failures due to “local” corrosion
traditional approaches can’t detect local or pitting corrosion
• Major cause of costly downtime ….capacity loss
50% is planned but 50% is “unplanned”
• High inspection costs to try and find it
after the damage has been caused; little info on root cause
• Major component of maintenance & turnaround costs
could be significantly reduced with better real time data
• Safety & environmental risks
a corrosion “tachometer” is needed for the operator
• Optimize chemical inhibitor regime
via real time control vs offline methods today
Cyclohexane reactors explosion at
Flixborough in 1974
Delaware City refinery
Sulfuric Acid tank explosion in Jul.
2001
Pipeline Burst in Alberta Dec.
2004
What is Corrosion?
General Corrosion
Localized Corrosion
•
Corrosion is the loss of metal from an •
exposed surface in a corrosive
environment.
•
Corrosion rate expression:
•
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)
mmpy = K x ∆W
DxAxT
where:
K = constant
∆W = change in weight
D = density
A = area
T = time
•
This formula works only when corrosion
is uniform.
Localized Corrosion
Corrosive attack can be localized in
certain areas on the metal surface
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
Solution Selection Technology Alternatives
Indirect Methods
Direct Measurement
Passive Off-Line
Non-Destructive Testing
Analytical Data
• pH measurement
• Dissolved gas Measurement
• Metal ion counting
• Microbiological Analysis
• Weight loss coupons
• Ultrasonic Gauging
• Radiographic inspection (X-Ray and
Gamma Ray)
• Eddy Current
Operational Data Interpretation
Active On-line
• pH rate
• Flow rate
• Temperature
• Pressure
• ElectroChemical Noise (ECN)
• Linear Polarization Resistance (LPR)
• Harmonic Distortion Analysis (HDA)
• Electrical Resistance Measurement (ER)
• Electrical Field Signature Method (EFSM)
Strategic
Strategic
Focus
Focus
Preference for a Proven Differentiated Technology
Corrosion Measurement technologies (1)
•
Corrosion Coupons: Corr rate = K X Wheight Loss/surface/time
•
Ultrasonic testing (UT):
Sound Waves echo profile give an « image » of structures
thickness and alterations
•
Electrical Resistance (ER):
•
Electrochemical Noise (ECN):
Electrical resistance of an immersed electrode is
measured and comparred to a reference electrode
Measurement of small currents and voltages generated at the contact surface between
the corrosive solution and the vessel. Good for Pitting corrosion detection
•
Linear Polarisation Resistance (LPR):
Measurement of resistance to pulsed voltage between electrodes immersed in the
corrosive solution. The resistance calculated is inversely related to general corrosion
•
Harmonic Distorsion Analysis (HDA):
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.
Corrosion Measurement technologies (2)
•
Electrical Field Signature Method (EFSM)
Cumbersone technique that measures the distributed resistance via an array of pins
distributed on the surface of a certain length of a pipe
•
Thin Layer Activation (TLA):
Creation of small radioactive surface. Gamma
radiation intensity over time is an image of the corrosion effect.
•
Zero Resitance Ammetry (ZRA):
•
Accoustic Emission (AE):
•
Inductive Resistance Probes (IRP): Mass changes in the sensor element are
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
detected by measuring changes in the inductive resistance (Inductance) of a coil, located
inside the element.
Honeywell’s “Corrosion” solution Enabling Asset
Effectiveness
Honeywell
SmartCet
Patented online measurement of corrosive
activity by monitoring electrical properties of
the corrosion process.
Enabling
• Corrosion root cause analysis
• Closed loop control of corrosion rate
• Plant/Unit optimization
Integrated into Experion PKS
Transform Data into High Value Information
SmartCET ® – designed around SuperLPR™ technology
SmartCET provides on-line, real-time corrosion detection with evaluation of both
general and localized corrosion – Includes multiple techniques applied simultaneously
in the same package
Electrochemical
Noise (ECN)
For Pitting Factor and other parameters
related to localized corrosion
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
Honeywell InterCorr Technology & Services
Services
Systems
Software
®
Materials Consulting
Lab Testing
Analytical Services
Corrosion Diagnostics &
Control
On-line Real time
Sensing technology
Corrosion Prediction
Risk Assessment
Materials Selection
Asset Management
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
SmartCET® - Most Accurate Corrosion Rate & Pitting Detection
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
Accurate : Weight Loss Coupon = 2.965 mpy , SmartCET® = 2.9 mpy*
* Results of BASF study over 1.5 year operation
SmartCET® - Simple Data Trends – Correlation with Process
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
ƒ Reliable real-time corrosion rates
ƒ Distinguishes pitting
ƒ Enabling proactive corrosion control
ƒ
Process Control Improvement:
Optimizing process, chemical
treatment or unit operation
ƒ Identifying the “when” & “why” of
corrosion in the process
ƒ Use the DCS to reduce corrosion
damage/costs & increase profits
ƒ
SmartCET
SmartCET will
will NOT
NOT work:
work:
Non-conductive
Non-conductive oil
oil environments
environments
(naphthenic/sulfidic
(naphthenic/sulfidic corrosion)
corrosion)
SmartCET ® - in Petrochemical Industry
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
Probe Specifications - Standard or Custom
FACT! The best probe design gives the best data.
Honeywell matches probe design to the specific process applications.
Flange Probe Design & Assembly
The flange probe design installed currently on chemical plant, gas pipelines, oil
production pipelines is configurable to meet Customers’ materials specifications
and engineering tolerances.
SmartCET® online, real-time corrosion monitoring…..
100
0
Red Line
** mpy
mpy -- mils
mils per
per year
year
mmpy
millimeters
mmpy - millimeters per
per year
year
A “Tachometer” for the plant operator!
www.honeywell.com