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In any operating facility, the integrity of flare or relief lines should always be closely maintained, as it is one of the most important safeguards during plant upsets or emergency conditions. The most common damage mechanism in acid flare lines is acid gas dew point corrosion”. Corrosion in such systems is often dependent on fluid stagnation, especially in the presence of acidic water, during idle conditions.The intent of this paper is to shed light on the efforts done in a gas treatment facility to identify different root causes that impacted or accelerated Acid Gas Dew Point Corrosion. These included design deficiencies, equipment integrity, and process challenges. Moreover, the paper provides findings and recommendations to avoid the occurrence of similar events in acid flare lines.
From day to day, Robots advance from testing in labs to operating in the outside world. Theindustrial application of Robotic technologies continually increases, providing unique solutions fordifferent challenges. Flare System is an important and critical equipment required for continuoussafe operations for any petrochemical plant addressing proper burning of excess hydrocarbongases, unusable gases which cannot be recovered or recycled, and gas flaring protects againstthe dangers of over-pressure. This paper discusses the different types of robotic inspection,advantages, and limitations based on actual site demonstrations. As an innovative case, here tointroduce actual business case for close aerial inspection and surveying technique to avoidpolyethylene plant shutdown and providing a reliable inspection technique for on-stream integrityevaluation for the flare tip. Drones, formally known as unmanned aerial vehicles (UAVs), are aflying robot that can be remotely controlled, and offer an innovative inspection method launchedbetween 2006-2008 for Engineering professional aerial inspection and surveying using RemotelyOperated Aerial Vehicles (ROAVs). The visual inspection detection accuracy of (ROAV) offerhigher than the normal visual inspection and easily approach all the flare structure from fourdirections. Drone inspection cost is competitive considering the cost of maintenance to dismantlethe flare tip. Drone inspection can be used to assess the elevated flare parts for any seriouslydamage in order to define a clear maintenance scope ahead of shutdown.
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A case history where an ethoxylated thio-phosphate ester was successfully used to mitigate low temperature naphthenic acid corrosion in a high total acid number condensing overhead system in which a traditional imidazoline corrosion inhibitor failed.
Hydrocracking and other refinery hydroprocessing units have a common goal to convert organic sulfur compounds to hydrogen sulfide (H2S) that can be removed, thereby producing low-sulfur refinery products. Corrosion and equipment degradation risks range from high-temperature hydrogen attacks (HTHA) to ammonium bisulfide and ammonium chloride corrosion in the downstream heat recovery and fluid separation equipment.This paper provides an overview of corrosion management principles that can be applied to reduce operating risks in new and existing units, focusing equipment susceptible to ammonium bisulfide (NH4HS) and ammonium chloride (NH4Cl) corrosion. Best practices for materials selection, as well as designing for corrosion management through adequate provision of corrosion management related instrumentation and sampling points are covered.