crude unit overhead automated corrosion control · “corrosion window” ... monitoring on...
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DETECT
DETERMINE
DELIVER
©Copyright 2010 Nalco Company. All rights reserved
Crude Unit OverheadAutomated Corrosion Control
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DETECTDETERMINEDELIVER
Opportunity Crude Processing
Refinery Tank Farm
Wharf
Terminals
Atmospheric Tower
Desalter
Brine
WWTP
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DETECTDETERMINEDELIVER
Automating Crude Overhead Monitoring
• Start with ovhd water analysis
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DETECTDETERMINEDELIVER
Its all about
90/10““Corrosion WindowCorrosion Window””
90% of the corrosion in a 90% of the corrosion in a crude overhead circuit crude overhead circuit
occurs in 10% of the timeoccurs in 10% of the time
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DETECTDETERMINEDELIVER
Overhead Corrosion Automation
Undetected excursions resulting in annual exchanger failuresUndetected excursions resulting in annual exchanger failures
KPI in spec 100% of time ?
KPI Cl 25ppm
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DETECTDETERMINEDELIVER
Overhead Corrosion Automation
Undetected excursions resulting in annual exchanger failuresUndetected excursions resulting in annual exchanger failures
KPI Cl 25ppm
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DETECTDETERMINEDELIVER
Alpha analyzer data5-Months
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DETECTDETERMINEDELIVER
Weekend Upset
Saturday evenings upset takes until
Monday midnight to correct
•Data not captured in operators log
Sat Sun Mon
Estimated 2Estimated 2--6 mils lost over 2 days6 mils lost over 2 days
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DETECTDETERMINEDELIVER
Data allows troubleshooting … 90/10
Crude RelatedTransient Corrosion Excursion Identified
Chloride SpikepH Drop
Fe (corrosion ) increase
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DETECTDETERMINEDELIVER
Impact of Continuous Monitoring on Corrosion
• In manual mode: with more frequent data corrosion was reduced by 60%60%
5.7 mpy during initial 3 months
3.5 mpy during last 6 months
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DETECTDETERMINEDELIVER
Use Analyzer for continuous monitoring and REAL TIME process chemical control
TargetspH 6.5
Chloride 25 ppm
Iron 0.5 ppm
Nalco On-LineAnalyzer
Neutralizer based on pH
Control caustic in crude based on chloride, or customer-set limit
Automation Project Objectives
Filmer based on iron
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DETECTDETERMINEDELIVER
Anticipated Value
• Improved Reliability• Reduce Total Cost Operation• Improved corrosion performance• True picture of actual unit performance • In-depth interrogation of upset conditions• Real time caustic/chloride control
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DETECTDETERMINEDELIVER
Anticipated Value
• Predictive analysis of chloride based of crude diet and rates
• Improved control (tighter control of KPI’s)• Better understanding of system limits• Improved control and safer operation at
the limits• 24/7/365 reporting thru real time
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