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11359 Corrosion Failures in Atmospheric Residue-Desulphurizer Unit after the Revamp (ARDS)

Picture for 11359 Corrosion Failures in Atmospheric Residue-Desulphurizer Unit after the Revamp (ARDS)
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Product Number: 51300-11359-SG
ISBN: 2011 11359 CP
Author: Sunil V. Vipat, Anil K. Ray, Mutlaq al Enezi and Musaed Al Arada
Publication Date: 2011
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An Atmospheric Residue De-sulphurizer Unit was revamped in year 2004 with a new online catalyst replacement technology process for increasing the operating run length, as well as capacity, of the unit. This paper describes three corrosion case studies which were a direct result of the revamp of the unit and inadequate understanding of the corrosion mechanisms / degradation expected due to process / capacity changes. The first case history is an exchanger tube sheet and components which experienced corrosion due to high temperature sulfidation1. The second case history addresses erosion of an inlet nozzle elbow and bulging / thinning of the impingement plate in the high pressure cold separator vessel (HPCS Vessel). The third case history documents high temperature sulphidation1 corrosion on diesel stripper inlet piping and a connected tower liquid inlet nozzle which was caused by an increase in operating fluid temperatures resulting in high corrosion rates. Based on these case histories, a thorough re-evaluation of the unit has been under taken using RBI methodology and is expected to result in revised inspection plans and intervals.

KEYWORDS: Erosion, corrosion, velocity, high temperature sulphidation, fouling, thinning, bulging, impingement
An Atmospheric Residue De-sulphurizer Unit was revamped in year 2004 with a new online catalyst replacement technology process for increasing the operating run length, as well as capacity, of the unit. This paper describes three corrosion case studies which were a direct result of the revamp of the unit and inadequate understanding of the corrosion mechanisms / degradation expected due to process / capacity changes. The first case history is an exchanger tube sheet and components which experienced corrosion due to high temperature sulfidation1. The second case history addresses erosion of an inlet nozzle elbow and bulging / thinning of the impingement plate in the high pressure cold separator vessel (HPCS Vessel). The third case history documents high temperature sulphidation1 corrosion on diesel stripper inlet piping and a connected tower liquid inlet nozzle which was caused by an increase in operating fluid temperatures resulting in high corrosion rates. Based on these case histories, a thorough re-evaluation of the unit has been under taken using RBI methodology and is expected to result in revised inspection plans and intervals.

KEYWORDS: Erosion, corrosion, velocity, high temperature sulphidation, fouling, thinning, bulging, impingement
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