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09337 Evaluation of Prediction Tool for Sour Water Corrosion Quantification and Management in Refineries

Product Number: 51300-09337-SG
ISBN: 09337 2009 CP
Author: Vishal Lagad, Russell D. Kane and Sridhar Srinivasan
Publication Date: 2009
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The Sour Water Joint Industry Program (JIP) has led to the development of new data and insights related to corrosion in H2S-dominated Ammonium bisulfide sour water systems, commonly found in a number of refinery processes. The JIP, termed as Sour Water Phase I, provided a new methodology and software prediction tool targeted towards predicting and quantifying corrosion in hydro-processing units, specifically reactor effluent air cooler (REAC) equipment and associated piping.

Based on comprehensive laboratory data, multiphase flow-modeling and numerical data interpolation, the Sour Water Corrosion Prediction Software (prediction tool) facilitates corrosion prediction, failure prevention, optimized material selection and safe operational practice as a basis for compelling cost saving and improved maintenance planning in refinery operations. This paper evaluates the efficacy of the JIP-based Prediction System when applied to real plant evaluation situations in a variety of refinery conditions. The paper also details appropriate methods of utilizing the data and functionality within the software tool to ensure optimized prediction accuracy. Case studies identifying pitfalls to avoid while using the software model are also provided along side comparison of predicted corrosion rates with measured rates from inspection. The case studies and trends presented demonstrate the importance of rigorous flow modeling and need for accurate characterization of effects of Ammonium Bisulfide NH4HS concentration and environmental parametric data variables in assessment of corrosivity of alkaline sour water systems.

Keywords: Reactor effluent air cooler, REAC, sour water corrosion, NH4HS, ammonium bisulfide, H2S, hydroprocessing, prediction model, refining, materials selection
The Sour Water Joint Industry Program (JIP) has led to the development of new data and insights related to corrosion in H2S-dominated Ammonium bisulfide sour water systems, commonly found in a number of refinery processes. The JIP, termed as Sour Water Phase I, provided a new methodology and software prediction tool targeted towards predicting and quantifying corrosion in hydro-processing units, specifically reactor effluent air cooler (REAC) equipment and associated piping.

Based on comprehensive laboratory data, multiphase flow-modeling and numerical data interpolation, the Sour Water Corrosion Prediction Software (prediction tool) facilitates corrosion prediction, failure prevention, optimized material selection and safe operational practice as a basis for compelling cost saving and improved maintenance planning in refinery operations. This paper evaluates the efficacy of the JIP-based Prediction System when applied to real plant evaluation situations in a variety of refinery conditions. The paper also details appropriate methods of utilizing the data and functionality within the software tool to ensure optimized prediction accuracy. Case studies identifying pitfalls to avoid while using the software model are also provided along side comparison of predicted corrosion rates with measured rates from inspection. The case studies and trends presented demonstrate the importance of rigorous flow modeling and need for accurate characterization of effects of Ammonium Bisulfide NH4HS concentration and environmental parametric data variables in assessment of corrosivity of alkaline sour water systems.

Keywords: Reactor effluent air cooler, REAC, sour water corrosion, NH4HS, ammonium bisulfide, H2S, hydroprocessing, prediction model, refining, materials selection
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