Fixed Equipment Inspection Manual

INSPECTION
STRATEGY # 8:

Section 8.0

Appendix E
Inspection Strategies

NAPHTHENIC ACID CORROSION

WHEN IT OCCURS

Occurs above 350F when neutralization number of hydrocarbon

exceeds the threshold of 1.5 to 2 mg KOH/gm. Neutralization
number is measured in the refinery laboratory per ASTM D-664,
potentiometric titration technique.

SUSCEPTIBLE ALLOYS

Carbon steel, C-Mo, Cr-Mo, and the 18-8 Cr-Ni stainlesses (such as
types 304, 321 and 347) are all subject to attack.

RESISTANT ALLOYS

Molybdenum-containing stainless steels such as Types 316, 317,

and Inconel 625 resist corrosion.

WHERE ATTACK
OCCURS

Attack can occur in crude units and downstream plants that receive
hot, high neut # feed. Contact between feed stock and catalyst in
hydrotreater reactors will immediately destroy the naphthenic acids.

APPEARANCE OF
CORROSION

Very severe and localized at points of high velocity such as pump

impellers and control valves (including piping just downstream).
Corrosion is fairly uniform in liquid-packed lines. Bends and areas
of turbulence will be corroded more rapidly in mixed phase lines
due to the higher velocity. See attached Figure.
In columns and vessels during shutdowns, visually inspect inlets,
flash zones, trays and outlets for sidecut draws. Verify with UT
thickness measurements as naphthenic acid corrosion can leave a
shiny, scale free appearance.

OTHER CHARACTERISTICS OF CORROSION

Threshold neutralization number for Types 321 and 347 is higher

than for carbon steel but has not been firmly established. H2S may
reduce naphthenic acid corrosion rates.

INSPECTION
TECHNIQUES

Inspect piping by RT and/or UT scanning per the attached figure.

Devote attention to piping downstream of pumps and control
valves. Also bends, tees, reducers, and other probable
turbulent/high velocity areas. There is no particular tendency for
corrosion to occur in dead legs.
Vessels and exchangers also require visual and UT inspection.
Inspection frequencies must be increased if neutralization number of
feed rises, or if evidence of naphthenic acid corrosion is noted.

NDE PROCEDURES

April 1994

UT scanning per Chev-UT-2.

UT thickness measurement per Chev-UT-1.
RT thickness measurement per Chev-RT-1.
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Fixed Equipment Inspection Manual

Section 8.0

Appendix E
Inspection Strategies

CERTIFICATION

The Plant Inspector or Analyst responsible for Naphthenic Acid

Corrosion inspection will pass a written test on this corrosion
phenomena.

REFERENCES

Ploetz, J. C.; Naphthenic Acid Corrosion Guidelines 9/7/90

CRTC
Chevron Corrosion Prevention Manual Vol. 2, Sections 3100 and
3300
Baker, K. C.; Inspection for Naphthenic Acid Corrosion 5/7/93
El Refinery

DATE WRITTEN

April 1994

July, 1993

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Fixed Equipment Inspection Manual

April 1994

Section 8.0

Appendix E
Inspection Strategies

E-IS08-3