Push Operations Integrity Boundaries in Hydroprocessing Units

摘要

Honeywell Process Solutions has made available a new methodology to quantify and characterize sour water corrosion damage in refineries through introduction of its corrosion prediction software tool, Predict?-SW. Corrosion due to H2S-dominated Ammonium bi-sulfide sour water systems is a common problem in a number of refinery processes, especially in hydroprocessing unit reactor effluent air coolers (REAC) and associated piping. Based on extensive laboratory data, flow-modeling and numerical data interpolation, the Predict-SW system facilitates identification of unit integrity boundaries, failure prevention, optimized material selection (for new construction and revamping) and safe operational practice as a basis for compelling cost saving and improved maintenance planning in refinery operations. Case studies showing the efficacy of the tool and related value propositions have been detailed when applied to two separate hydroprocessing units. The predicted corrosion rates for the piping, using this software tool, were compared with actual field data. The results confirm the accuracy of the corrosion prediction model incorporated into the software tool, as well as demonstrate the need to incorporate rigorous flow modeling and effect of environment variables in assessment for corrosiveness of alkaline sour water systems. The case studies show the efficacy of using the Predict model to extend appropriate operational boundaries for hydroprocessing (versus those derived from more conventional approaches), as well as developing a methodology for inspection and maintenance through accurate quantification of corrosion and potential for damage.