www.honeywell.

com

Corrosion The New Process Variable

2004 Users Group Americas Symposium Partners in Innovation

Corrosion is Part of the Bigger Problem

60% of plant engineers will
retire by 20101

Personnel actions cause $20B/yr

in avoidable costs in Petrochem

More compliance, regulation

Improve
Process
Performance

Increase Asset
Effectiveness

Production processes
increasingly complex

Enhance
Business
Agility
Improve
People
Effectiveness

Must maintain safety, security

1. Source: Journal of Petroleum Technology

2. ASM Consortium

Higher business
volatility, faster decision
making

50% of maintenance not

needed, 10% harmful3
Supply chains more
integrated

3. Honeywell Loopscout studies

Automation Extends Beyond Process Efficiency

Honeywells Holistic View of Automation

Improve Throughput
Reduce Energy Costs
Improve Quality, Reduce Waste

Respond to Market Volatility

Optimize What to Produce,
Where, When, at What Price

Ensure Compliance

Predict/Pre-empt Asset Failures

Reduce/Avoid unplanned incidents

Reduce Maintenance Costs

Implement best work practices

Enhance Security

Turn data into actionable knowledge

Increasingly a Software/Knowledge Driven Business

Corrosion Facts & Figures

$50B per year spent by the Global Process Industries on Corrosion
increasing due to aging plants, sour crude stocks, higher thru-puts
90% of Corrosion damage caused in only 10% of the time
conventional offline approaches cant identify root cause & arlabor intensive
70-90% of all failures due to local corrosion
traditional approaches cant detect local or pitting corrosion
Major cause of costly downtime .capacity loss
50% is planned but 50% is unplanned
High inspection costs to try and find it
after the damage has been caused; little info on root cause
Major component of maintenance & turnaround costs
could be significantly reduced with better real time data
Safety & environmental risks
a corrosion tachometer is needed for the operator
Optimize chemical inhibitor regime
via real time control vs offline methods today

Cyclohexane reactors explosion at

Flixborough in 1974

Delaware City refinery

Sulfuric Acid tank explosion in Jul.
2001
Pipeline Burst in Alberta Dec.
2004

What is Corrosion?
General Corrosion

Localized Corrosion

Corrosion is the loss of metal from an

exposed surface in a corrosive
environment.

Corrosion rate expression:

This is caused by the formation of local

anodes and cathodes on the metal
surface

70 to 90 percent of corrosion failures

are due to localized corrosion (e.g.
Pitting)

Pitting tends to occur where materials

are stressed or when their structure has
changed (welding, Bends, clamps)

mmpy = K x W
DxAxT
where:
K = constant
W = change in weight
D = density
A = area
T = time

This formula works only when corrosion

is uniform.
Localized Corrosion

Corrosive attack can be localized in

certain areas on the metal surface

What is Corrosion?
Corrosion tends to happen where:
Water separates from oil
Water and corrosives condense
from the gas phase
Corrosives concentrate due to
evaporation
Water is trapped or stagnant
Fluid are highly turbulent, impinge
or flash
Localized Corrosion

Localized Corrosion

Solution Selection Technology Alternatives

Indirect Methods

Direct Measurement
Passive Off-Line
Non-Destructive Testing

Analytical Data
pH measurement
Dissolved gas Measurement
Metal ion counting
Microbiological Analysis

Weight loss coupons

Ultrasonic Gauging
Radiographic inspection (X-Ray and
Gamma Ray)
Eddy Current

Operational Data Interpretation

Active On-line

pH rate
Flow rate
Temperature
Pressure

ElectroChemical Noise (ECN)

Linear Polarization Resistance (LPR)
Harmonic Distortion Analysis (HDA)
Electrical Resistance Measurement (ER)
Electrical Field Signature Method (EFSM)

Strategic
Strategic
Focus
Focus

Preference for a Proven Differentiated Technology

Corrosion Measurement technologies (1)

Corrosion Coupons: Corr rate = K X Wheight Loss/surface/time

Ultrasonic testing (UT):

Sound Waves echo profile give an image of structures

thickness and alterations

Electrical Resistance (ER):

Electrochemical Noise (ECN):

Electrical resistance of an immersed electrode is

measured and comparred to a reference electrode

Measurement of small currents and voltages generated at the contact surface between
the corrosive solution and the vessel. Good for Pitting corrosion detection

Linear Polarisation Resistance (LPR):

Measurement of resistance to pulsed voltage between electrodes immersed in the
corrosive solution. The resistance calculated is inversely related to general corrosion

Harmonic Distorsion Analysis (HDA):

Alternating voltages are applited to an

arrangement of 3 electrodes and resultant currents, primary frequencies and harmonics
are analyzed. This technique is used in combination with LPR.

Corrosion Measurement technologies (2)

Electrical Field Signature Method (EFSM)

Cumbersone technique that measures the distributed resistance via an array of pins
distributed on the surface of a certain length of a pipe

Thin Layer Activation (TLA):

Creation of small radioactive surface. Gamma

radiation intensity over time is an image of the corrosion effect.

Zero Resitance Ammetry (ZRA):

Accoustic Emission (AE):

Inductive Resistance Probes (IRP): Mass changes in the sensor element are

Current measured between 2 corrosion sensors.

Used mainly for Galvanic current monitoring
strategicaly positionned microphones on a structure to
listen the noise generated by stressed structures under corrosion

detected by measuring changes in the inductive resistance (Inductance) of a coil, located

inside the element.

Honeywells Corrosion solution Enabling Asset

Effectiveness
Honeywell
SmartCet

Patented online measurement of corrosive

activity by monitoring electrical properties of
the corrosion process.

Enabling
Corrosion root cause analysis
Closed loop control of corrosion rate
Plant/Unit optimization

Integrated into Experion PKS

Transform Data into High Value Information

SmartCET designed around SuperLPR technology

SmartCET provides on-line, real-time corrosion detection with evaluation of both
general and localized corrosion Includes multiple techniques applied simultaneously
in the same package

Electrochemical
Noise (ECN)

For Pitting Factor and other parameters

related to localized corrosion

Linear Polarization
Resistance (LPR)
Harmonic Distortion
Analysis (HDA)

For accurate Corrosion Rate and other

parameters related to general corrosion

Features:
automated data acquisition and analysis cycle (data update every 7 min.)
low power requirements; can be applied in hazardous areas
simple interface to SCADA, process control, process information management
systems

Honeywell InterCorr Technology & Services

Services

Systems

Software

Materials Consulting
Lab Testing
Analytical Services
Corrosion Diagnostics &
Control

On-line Real time

Sensing technology

Corrosion Prediction
Risk Assessment
Materials Selection
Asset Management

HONEYWELL InterCorr also provide value added solutions

along with online, real-time corrosion monitoring
Plant Corrosion Survey
Review historical corrosion data, failure, maintenance record, replacements
Determination of monitoring points / probe configurations
Review and interpretation of monitoring data
Process correlation
Plant diagnostics
Expert Consultation
Material selection
Failure Analysis
Process Correlation Simulation
Corrosion modeling
Corrosion prediction
Analysis of operating Conditions
Sensitivity studies
Process projections

SmartCET - Most Accurate Corrosion Rate & Pitting Detection

Corrosion Rate
(Smart Corrosion Evaluation Technology)

Pitting Factor
and corrosion diagnostics data
Configuration Options
On-board data storage
Hardwire or Wireless
Digital or analog output
Class I, Div 2 or non-IS

Accurate : Weight Loss Coupon = 2.965 mpy , SmartCET = 2.9 mpy*

* Results of BASF study over 1.5 year operation

SmartCET - Simple Data Trends Correlation with Process

Simple trend views

Data logging
Export to spreadsheets
Online Data Options
Direct to DCS or
data historian via 4-20mA,
HART, RS-485,RS-232,
others

The SmartCET Differentiators - Corrosion/Pitting Detection

& Asset Life Monitoring
Accurate Corrosion Monitoring:
Applicable to all conductive fluid
environments
Reliable real-time corrosion rates
Distinguishes pitting
Enabling proactive corrosion control

Process Control Improvement:

Optimizing process, chemical
treatment or unit operation
Identifying the when & why of
corrosion in the process
Use the DCS to reduce corrosion
damage/costs & increase profits

SmartCET
SmartCET will
will NOT
NOT work:
work:
Non-conductive
Non-conductive oil
oil environments
environments
(naphthenic/sulfidic
(naphthenic/sulfidic corrosion)
corrosion)

SmartCET - in Petrochemical Industry

Oilfield Applications:
Crude Oil Flow Lines
Seawater Injection Systems (Biofouling/MIC)
Produced Water Systems
Offshore Gas Flow Lines
Field Gas Gathering Systems
Gas Transmission Pipelines
Multi-Operator Gas Transmission
Erosion-Corrosion During Sand Washing
Carbon Dioxide and Hydrogen Sulfide
Pipelines
Gas Processing Applications:
Inlet Stabilization
Amine Plant
Compression
Utilities
Dehydration and Refrigeration
Hydrogen Processing Operations

Refinery Applications:
Distillation and Overhead Systems
Sour Water & Amine Systems
Sulfuric/Hydrofluoric Acid Alkylation
Units
Desalting Units
Heat Exchangers
FCCU
Steam Cracker/Caustic Skid
Flue/Tail Gas Systems
Chemical Processing Applications:
Corrosion in Sulfuric Acid Systems
Pitting of Stainless Steel in an Ammonia
Stripper
Pitting of Welds in Process Liquor
Process Modification Trials
High/low Temperature Corrosion in Acid
Regeneration Plant
Corrosion in Gasification Processes

Probe Specifications - Standard or Custom

FACT! The best probe design gives the best data.
Honeywell matches probe design to the specific process applications.

Flange Probe Design & Assembly

The flange probe design installed currently on chemical plant, gas pipelines, oil
production pipelines is configurable to meet Customers materials specifications
and engineering tolerances.

SmartCET online, real-time corrosion monitoring..

100

Red Line

** mpy
mpy -- mils
mils per
per year
year
mmpy
millimeters
mmpy - millimeters per
per year
year

A Tachometer for the plant operator!

www.honeywell.com