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Assessing operating limits for C-0,5Mo steel in high temperature H2 service (case study)
Case study:
C-0,5Mo in high temperature H2
Coker distillate hydrotreating unit Commissioned in 1975 C-0,5Mo steel piping Reactor feed line Reactor outlet line Desulph. line (by-pass line) Satisfactory performance No history of cracking (HTHA) Unit optimisation/debottlenecking Increased operating temperature Increased H2 partial pressure
Case study:
C-0,5Mo in high temperature H2
Current Line
Pressure (bar) 46 Temp. (C) 265 pH2 (bar) 29 Pressure (bar) 51
Proposed
Temp. (C) 300 pH2 (bar) 35
44 46 (20)
16 29 (20)
51 51 (20)
20 35 (20)
Case study:
C-0,5Mo in high temperature H2
High temperature hydrogen attack (HTHA) Dissociation of hydrogen H2 = 2H Thermally driven Carbide reaction 4H + MC = CH4 + M Results in: Decarburization (high temperatures; lower pH2) Cr-Mo steels Internal fissuring/cracking (higher pH2) CS; C-0,5Mo; Cr-Mo steels
Case study:
C-0,5Mo in high temperature H2
Nelson curves (G.A Nelson - Shell Development Co) Collection of experience with high temperature hydrogen Temperature-hydrogen partial pressure curves showing experience with different steels Paper presented to API in 1949 Various updates 1950s & early 1960s. Update in 1965 More curves C-0,5Mo raised by 50F
Case study:
C-0,5Mo in high temperature H2
API 941 (Steels for Hydrogen Services at Elevated Temperatures and Pressures in Petroleum Refineries and Petrochemical Plants) 1st Edition: July 1970 Based on Nelsons 1965 curves + 2,25Cr-1Mo 2nd Edition: June 1977 Lowered curve for C-0,5Mo Failures in conditions around the curve 3rd Edition: May 1983 More C-0,5Mo failures (catalytic reforming units) 4th Edition: April 1990 More industry failures of C-0,5Mo 1977 curve removed & presented separately Caution on use of C-0,5Mo
Case study:
C-0,5Mo in high temperature H2
Case study:
C-0,5Mo in high temperature H2
Line
Reactor feed Reactor outlet
pH2 (bar) 29 16
pH2 (bar) 35 20
Case study:
C-0,5Mo in high temperature H2
Disadvantage of curves in API 941 Does not indicate ageing effects HTHA is also time dependent Single parameter PV was developed relate time, pH2, temperature API 581 Appendix I: HTHA Technical Module PV = log(pH2) + 3,09 x 10-4 (T) (log(t) +14) pH2 hydrogen partial pressure in kgf/cm2 (1 kgf/cm2 = 14,2 psia) T temperature in K (K = C + 273) t time (age) in hours
Case study:
C-0,5Mo in high temperature H2
Carbon & low alloy steel susceptibility to HTHA (API 581)
Critical PV factors Material High susceptibility
PV m 4,70 PV m 4,95 PV m 5,60 PV m 6,00 PV m 6,53
Medium susceptibility
4,61 < PV [ 4,70 4,87 PV [ 4,95 5,51 < PV [ 5,60 5,92 < PV [ 6,00 6,45 < PV [ 6,53
Low susceptibility
4,53 < PV [ 4,61 4,78 < PV [ 4,87 5,43 < PV [ 5,51 5,83 < PV [ 5,92 6,36 < PV [ 6,53
No susceptibility
PV [ 4,53 PV [ 4,78 PV [ 5,43 PV [ 5,83 PV [ 6,36
Case study:
C-0,5Mo in high temperature H2
Susceptibility to HTHA: C - 0,5Mo steel (annealed) Reactor inlet (Hydrogen partial pressure = 35 bar)
360.0 350.0 340.0 330.0 Temperature (C) 320.0 310.0 300.0 290.0 280.0 270.0 260.0 0 5 10 15 20 Plant Age (years) High Suceptibility Medium Susceptibility Low Susceptibility Current plant age 25 30 35 40
Case study:
C-0,5Mo in high temperature H2
Susceptibility to HTHA: C - 0,5Mo steel (normalised) Reactor Inlet (Hydrogen partial pressure = 35 bar)
460.0 450.0 440.0 430.0 Temperature (C) 420.0 410.0 400.0 390.0 380.0 370.0 360.0 0 5 10 15 20 Plant Age (years) High Susceptibility Medium Susceptibility Low Susceptibility Current plant age 25 30 35 40
Case study:
C-0,5Mo in high temperature H2
Susceptibility to HTHA: C - 0,5Mo steel (annealed) Reactor Outlet (Hydrogen partial pressure = 20 bar)
380.0 370.0 360.0 350.0 Temperature (C) 340.0 330.0 320.0 310.0 300.0 290.0 280.0 0 5 10 15 20 Plant Age (years) High Susceptibility Medium Susceptibility Low Susceptibility Current plant age 25 30 35 40
Case study:
C-0,5Mo in high temperature H2
Susceptibility to HTHA: C - 0,5Mo steel (normalised) Reactor Outlet (Hydrogen partial pressure = 20 bar)
500.0 490.0 480.0 470.0 Temperature (C) 460.0 450.0 440.0 430.0 420.0 410.0 400.0 0 5 10 15 20 Plant Age (years) High Susceptibility Medium Susceptibility Low Susceptibility Current plant age 25 30 35 40
Case study:
C-0,5Mo in high temperature H2
Conclusions Uncertaincies about metallurgical condition Annealed vs normalised Piping systems: unlikely to be normalised Reactor inlet Restrict temperature to 275C @ pH2 = 35 bar Low susceptibility Reactor outlet Restrict temperature to 315C @ pH2 = 20 bar Low susceptibility Change of materials (1,25Cr-0,5Mo) if higher temperatures are required
Appendix 9 Naphtenic acid corrosion Studies at Eni Technologie Roberto Riva Eni
Background
Opportunity crude oils are cheap, but potentially corrosive because they may contain naphthenic acids and a high concentration of sulphur. Chemical analysis alone cannot predict their corrosivity; still, the total acid number (TAN) and the content of sulphur are key parameters. There is a subtle interaction between naphthenic acids and sulphur, which can be described by a simple model. At 1) 2) 3) a fixed concentration of naphthenic acids the model predicts naphthenic acid corrosion at low S content inhibition of naphthenic acid corrosion at intermediate S content sulphidic corrosion at high S content.
Experimental procedure
Rotating specimen (9% Cr, 1% Mo) in a sealed autoclave at 340C. Two kinds of oil: 1) Ural crude oil (1.5% wt sulphur, TAN=0.2) 2) lubricant base oil (3.8ppm wt sulphur, TAN=0.16). Acidity is increased through addition of a mixture of synthetic naphthenic acids (Fluka 70340, average molecular weight 230). Evaluation of the rate of corrosion through weight loss after cleaning. Evaluation of the weight of corrosion product deposited on the surface of the metal: difference between weight after test and after cleaning.
Reportedly, a different appearance corresponds to the attack of either corrosive agent: - Sulphidic corrosion leads to the formation of sulphidic corrosion scales. - No surface corrosion products after naphthenic acid corrosion.
Low sulphur content Average weight of corrosion products (5 tests with various TAN values) 1.1 mg/cm2
Corrosion rate
1,20 1,00 0,80 0,60 0,40 0,20 0,00 0 5 10 15 20 total acid number (mg KOH/g oil)
High sulphur (Ural) low sulphur (DW05) Poli. (low sulphur (DW05))
NACI index
50,00 40,00 NACI index 30,00 20,00 10,00 0,00 0 5 10 15 20 total acid number (mgKOH/g oil) Ural (high sulphur content) DW05 (low sulphur content) Poli. (DW05 (low sulphur content))
Conclusions
The experiments have confirmed the interaction between sulphur and naphthenic acids. The results are roughly in agreement with the model given in the literature. Very high concentrations of naphthenic acids (TAN 10) were required for the onset naphthenic acid corrosion. Such behaviour is surprising even for 9% Cr-1% Mo steel, which is quite resistant to naphthenic acids . Far lower concentrations (TAN 0.5) are potentially corrosive in refinery plants. The experimental set-up probably needs modifying, if plant conditions are to be reproduced.
Appendix 10 Naphtenic acid corrosion A neural network approach S. Trasatti University of Milan
Neural Network
Mathematical model simulating neuronal activity of the human brain. Its an Artificial Intelligence System enables us to embed structured human knowledge into workable algorithms. NN learns the weights of the correlation between input and output data apparently not connected by any model (training step)
Target: to predict output from input not used in the training step and to obtain information on the involved mechanism
TAN Flow Rate Temperature %S Crude oil type Two phase flow Metallurgy
T (F) 70 330 70 600 400 455 455 375 400 560 560 560 450 500 500 560 500 662 550 550 698 698
Flow rate (m/s) 0,9 0,9 0,9 0,9 0 0 0 0 0 0,8 0,8 0,8 0,9 0 0,1 0 0 6 7 7 3 3
Exposure Time (h) 210 152 210 66 120 82 82 164 120 82 65 93 74 48 6 48 48 24 24,5 28 72 72
TAN 1 1 1 1 18,1 9 17,7 46,1 8,85 13,2 23,1 8,2 29,2 0,74 4,5 20 20 2,9 7,2 7,2 2,35 2,35
%S 0,3 0,3 0,3 0,1 0,1 0,1 0,1 0,1 0,1 0,1 0,1 0,1 0,1 0,1 0 0 0 0,4 0,4 0,4 1,1 1,1
%Cr 12,43 12,43 0,03 0,03 7,09 7,09 7,09 9,03 9,03 9,03 9,03 17,46 18,59 0,03 0,03 0,03 17,4 0,25 0,03 0,03 1,5 18,7
%Mo 0 0 0,01 0,01 0,58 0,58 0,58 1,08 1,08 1,08 1,08 2,02 0,18 0,01 0,01 0,01 2,06 0,2 0,01 0,01 0,45 3,13
Corr.Rate (mpy) 0,7 2,6 0,6 9,4 15,4 24,4 42,2 9,2 19,4 35 159 0,3 1,2 3,3 46 320,6 1,8 13,4 425 262 27 2
Variables
Parameter Min . Temperature (F) Pressure (atm) Flow Rate (m/s) Exposure Time (hours) TAN S_% Cr_% Mo_% Corrosion Rate (mpy) 70 1 0 6 0 0 0.01 0 0 725 69 7 768 46.1 4.17 20 4.64 425 Process Process Process Process Crude oil Crude oil Plant Plant Process Input Input Input Input Input Input Input Input Output Max. Variable type use
Dis tribuzione de lle fre que nze de lla variabile "Te m pe ratura" 45 Frequenza dei campioni [%] Frequenza dei campioni [%] 40 35 30 25 20 15 10 5 0 80 160 240 320 400 480 560 Clas s i di te m pe ratura [F] 640 720 800 0.5 0.0 1.0 0.0 4.7 0.5 16.8 11.4 27.0 38.1
90 80 70 60 50 40 30 20 10 0
Dis tribuzione de lle freque nze de lla variabile "Exposure Tim e" 76.7
21.3
0.5 400
0.0 500
0.0 600
0.0 700
0.5 800
Clas s i Expos ure Tim e [h] Dis tribuzione delle fre que nze de lla variabile "Flow Rate " 100 Frequenza dei campioni [%] 90 80 70 60 50 40 30 20 10 0 1.2 2.4 3.6 4.8 6 7.2 Clas s i di Flow Rate [m /s e c]
Distribuzione delle frequenze della variabile "Corrosion Rate"
Dis tribuzione de lle fre que nze de lla variabile "Pre ss ione " 100 Frequenza dei campioni [%] 90 80 70 60 50 40 30 20 10 0 20 40 60 Clas si Pres s ione [Atm ] 80 7.4 0.0 3.2 89.4
88.6
0.2
6.4
0.2
3.2
1.2
78.5
9.9
6.2
2.7 180
1.2 225
0.5 270
0.2 315
0.5 360
0.0 405
0.2 450
45
90
135
6.2
Distribuzione delle frequenze del "Crom o in percentuale" 50 Frequenza dei campioni [%] 45 40 35 30 25 20 15 10 5 0 2.5 5 7.5 10 12.5 Classi di Crom o [%] 15 17.5 20 1.2 5.0 7.2 0.0 12.1 12.6 17.1 44.8 Frequenza dei campioni [%] 80 70 60 50 40 30 20 10 0
68.6
6.2
7.2 0.0
11.9 0.0 2.25 2.7 2.7 3.15 2.0 3.6 0.0 4.05 0.7 4.5
0.45
0.9
1.35
1.8
Normalizing range
Parameter
Temperature (F) Pressure (atm) FlowRate (m/s) Exposure Time (hours) TAN %S %Cr %Mo
Input min.
390 1 0.09 6 0.5 0.1 0.1 0.1
Input max.
750 69 7 150 47 4.1 18 4.4
Output min.
0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1
Output max.
0.9 0.9 0.9 0.9 0.9 0.9 0.9 0.9
Corr.Rate (mpy)
425
0.1
0.9
Value
7.433
%
22.66
Sum%
22.66
Press
5.168
15.76
38.42
Temp
4.471
13.63
52.06
ExpTime
4.421
13.48
65.54
FloRate
3.364
10.26
75.79
Mo_Perc
3.327
10.14
85.94
Cr_Perc
2.792
8.513
94.45
S_Perc
1.820
5.548
100
200
Sample number
8 9 3 1
100
Sample nuimber
8 9 5 1
C orrosionR [m y] ate p
300
Ca lculated
200
2 R = 0.58
100
E xperim ental
8 7 3 1
Validation step
C s R [m y] orro ion ate p
450 400 Corrosion Rate [mpy] 350 300 250 200 150 100 50 0 1 6 11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96 101 106 S ple num am ber 0 0 100 200 E xperim ental 300 400 t_C peed orrS C peed orrS 300 Calculated
2 R =0.68
C rros nR [m y] o io ate p
400
200
100
8 9 5 1
Validation step
80 C o rro s io n R a t e ( m p y ) 70 60 50 40 30 20 10 0 1 2 3 4 5 6 TAN
Temp. (F ) 400-650 Press. (atm) 1,00 FlowRate (m/s) 0,00 ExpTime (hours) 48,00 TAN da 2,00 a 10,00 %S 0,10 %Cr 0,03 %Mo 0,01
10
11
Validation Step
Temp. (F ) 644.0 644.0 644.0 644.0 644.0 644.0 644.0 644.0 644.0 644.0 644.0 644.0 644.0 644.0 Press. (at m) 19.0 22.0 20.0 28.0 18.0 18.0 25.0 16.0 37.0 18.0 16.0 19.0 25.0 20.0 FlowRate (m/s) Exp.Time (ore) TAN %S %Cr %Mo Corr.Rate (mpy) Corr.Rate predetta 3.2 3.2 3.2 1.9 1.9 1.9 1.9 1.9 1.9 1.9 1.9 1.9 1.9 1.9 228.0 72.0 84.0 108.0 96.0 108.0 104.0 180.0 163.0 108.0 168.0 168.0 168.0 168.0 1.2 1.2 4.9 4.9 4.9 4.9 4.9 10 9.8 5.4 5.4 9.9 14.8 14.8 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 0.1 8 8 8 8 8 8 8 8 8 8 8 8 8 8 1 1 1 1 1 1 1 1 1 1 1 1 1 1 7.5 24.4 29.5 36.6 21.6 19.7 37.4 15.3 26.4 3.9 2.4 13 40.5 35.4 20.13 26.07 45.84 21.73 33.93 31.86 25.08 50.33 26.45 34.05 29.73 46.13 61.55 57.4
Appendix 11
The NACE Italy , section of NACE INTERNATIONAL, organizes on the occasion of the recognition in Genoa what capital European of the culture 2004, his 2 ^ annual conference. How custom, such conference is established to introduce, to discuss, to divulge, the connected problems to the technology of the corrosion. The involvement of peoples that work with prevention and control of the corrosion is combined to the exhibition of products and services from the working Societies in the sector. The papers interest all the sectors of the technology of the corrosion involving her thematic to it correlated (Research, Corrosion, Corrosion Control, Coating, Cathodic Protection, NDE, Metallurgy, Materials and Services). Continuous evolution of technology calls us to give an exhaustive contribution : scientific, university, production and commercial, without forgetting the normative and institutional aspects. The partecipation to the Conference becomes essential factor knowledge for deepened of this technology and remains the principal way to update the technicians that operated, to varied levels, in the different areas of the industry. The Firms that present products and/or services have the possibility to intend and to introduce theirs last novelties in technological terms, doing grow the market and contributing so to an effectiveness cultural popularization.
Italia Section
presents
with sponsorship of
Organizing Committee
Chairman Nace Italia Carmelo Aiello Eni Group Raffineria di Gela Gela (CL) Tel: 0933 842485 Email: carmelo.aiello@eni.it Treasurer Mario Celant Pipeteam Via Resistenza 2 20070 - Vizzolo Predabissi (MI) Tel: +39 (0)2 98232820 Email: mario.celant@pipeteam.com Vice-Chairman Alberto Lauro Istituto Italiano della Saldatura Lungobisagno Istria, 15 16141 Genova Tel: 010 8341354 E-mail: alberto.lauro@iis.it
Abstracts deadline : May 31, 2004 Papers deadline : September 30, 2004 The language is italian but the oral presentation can be in english. The abstracts, extended abstracts and complete papers must be in .doc format and sent it at under following addresses so like the Firms that want presented them products or services. Istituto Italiano della Saldatura Lungobisagno Istria 15 16141 Genova Alberto Lauro Tel. 010 / 8341354 Fax 010 / 8341353 e-mail : alberto.lauro@iis.it Franco Lezzi Tel. 010 / 8341372 Fax 010 / 8367780 e-mail : franco.lezzi@iis.it
Secretary Massimo Cornago ENI E & P Via Emilia, 1 20097 S. Donato Milanese (MI) Tel: 02 52063405 EFC WP15 Corrosion in the Refinery Industry 9 March 2004 Minutes of E-mail: massimo.cornago@agip.it