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Boilers are one of the most fundamental systems in refineries or processing plants. It is very critical to assess and control the conditions of boilers to avoid the operation failure. Scale and corrosions are major problems in the boiler. Boiler chemical treatment has been considered to be a cost-effective approach to prevent deposition formation and minimize corrosion in boilers to control feeding chemicals, tracers are used for monitoring chemical dosage levels. The usage of fluorescent tracers for dosage control and system diagnostics is a recognized approach for decreasing operator workload and improving system performance.
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The coatings industry has made widespread use of a variety of accelerated test methods to quickly and effectively evaluate coating performance. Such accelerated methods are advantageous for predicting coating system performance where real-time testing is impractical. For example, it is not practical to evaluate coatings in harsh environments where coatings are expected to last for decades when the pace of innovation and new coating development is faster than the test time would need to be. Therefore a variety of test methods exist to evaluate coatings on metal substrates, such as steel or aluminum. Coatings that will be subjected to corrosive environments require testing in environments to simulate the effects of corrosion, typically involving exposure to moderate salt concentration and elevated temperatures for a specified amount of time. Such tests, testing environments, and evaluation methods include ASTM B117,ISO 9227, and ISO 12944, to name a few.
The global cost of corrosion is estimated to be US$2.5 trillion, which is equivalent to 3.4% of the global GDP (2013). By using available corrosion control practices, it is estimated that savings of between 15 and 35% of the cost of corrosion could be realized; i.e., between US$375 and $875 billion annually on a global basis. These costs do not include individual safety or environmental consequences which can occur due to near misses, incidents, forced shutdowns (outages), accidents, etc.
This article will improve the existing literature and develop the corrosion industry by expanding the knowledge of the CPHM system. I will also show one of the ways to increase the safety, availability and operational efficiency of aircraft.
The production of sodium hydroxide (NaOH) can be carried out by the membrane, diaphragm or mercury process. The biggest difference between these processes, with regard to fluid composition, is that the caustic soda (NaOH) produced by the diaphragm process has a higher chloride content during its production process.
Such aggressiveness in the environment generally calls for the use of special materials to increase the useful life of the equipment and avoid unscheduled shutdowns in the production unit.
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.
Watermain failures are not often recognized as corrosion but are usually referred to merely as “watermain breaks” because watermain pipe appears sound prior to failure. Some of the causes of watermain breaks are poor design, improper installation, surge or water hammer, soil movement, manufacturing defects, impact, internal corrosion, and external corrosion. Figure 1 shows some of the possible causes of the DI pipe.
For decades, many asset owner/operators across the O&G value chain (and other critical industry segments) of upstream, midstream, & downstream have struggled to identify the root cause of fluctuating corrosion/erosion rates due to unreliable or infrequent data during various operating intervals on their most valuable of assets. This key missing data point has forced mechanical integrity teams, corrosion engineers, inspectors, and operations to, in many cases, make the best guess or hypothesize how to operate with a limited data set of information. In almost all cases, a time-based inspection or maintenance interval is used to gauge the useful lifetime of assets based on this limited data simply because these assets couldn’t give their owners a real-time health diagnostic of how they were doing … until now.