CORROSION CONTROL IN THE REFINING INDUSTRY

Improve Your Working Knowledge of Corrossion Control with Expert Specialist 25th - 29th August 2014, Kuala Lumpur, Malaysia
Case Studies, Discussion, Simulation Learning and many Practical exercises!

Petrosync Lecturer
Yousuf Memon B.E.
Plant Inspection & Corrosion Control Consultant

Major Corrosion Projects
Over 35 years of experience in upstream & downstream oil & gas industry
CEO of Reliance Swift Veritas (Pvt) Ltd. Director of Petrosult & Unimart Specializing in corrosion & integrity management systems execution and training

Prepared Policies for Corrosion Monitoring Systems & Corrosion Inhibitor Injection System for Total ABK. Prepared Corrosion Management System for Jeddah Oil Refinery Presented technical paper on Failures in Refinery Overhead of Atmospheric Distillation Column.

Masterclass Overview

Petroleum Refineries are perusing sustained approach from identification of corrosion and material failure issues to long-term corrosion control approaches. However, the risks to corrosion failures are still evident in the refineries. The course covers key topics pertaining to refinery processes, corrosion issues, corrosion monitoring and corrosion control methods.
Supported by

Masterclass Objectives • To provide understanding various petroleum refinery processes including CDU. Invest a small amount of your time to prepare before attending the course to ensure maximum learning PetroSync follows a rigorous selection process to ensure that all expert trainers have first-hand. WHY YOU SHOULD ATTEND PETROSYNC’S EVENTS To ensure that all objectives of the course matches yours. etc. Hydrocracker. FCC. simulations. not theoretical academic lectures PetroSync training focuses on practical interactive learning tools and techniques including case studies. refinery equipment. ery processes. • To provide understanding of corrosion monitoring techniques used in different units of the To provide understanding of corrosion prevention methods mainly corrosion control chemicals • injection at different stages of refinery processes. up-to-date and practical knowledge and are leaders of their respective industrial discipline . material degradation and various damage mechanisms involved in the refinery. Platformer. group discussions.Specially Designed For This course is geared toward those with a minimum of 1-2 years experience in refineries including: • • • • • • • • • design engineers process engineers procurement agents maintenance planners service company representatives who support refineries corrosion and equipment engineers metallurgists inspectors inspection supervisors. scenarios. petroleum refinery. • To provide understanding of common material construction and metallurgy used in petroleum • To provide understanding of common corrosive environment encountered in petroleum refin• To provide understanding of refinery-specific corrosion problems. all PetroSync programs are developed after intensive and extensive research within the industry PetroSync programs focus on your immediate working issues to ensure that you are able to apply and deliver immediate results in real work situations Application and implementation of industry knowledge and experience are the drivers for our course design. Amine Units. practical exercises and knowledge assessments during the course.

Non-destructive Examination • Materials of Construction of FCCU • • • • • • • • • • • • • • • • • • Corrosion in FCCU Regenerator Reaction Mix Line Main Fractionator Bottoms Piping Flue Gas Systems High-Temperature Oxidation High-Temperature Sulfidation (H2S Attack) High-Temperature Carburization Polythionic Acid Stress Corrosion Cracking Catalyst Erosion Feed Nozzle Erosion Refractory Damage High-Temperature Graphitization Sigma-Phase Embrittlement 885° F (475° C) Embrittlement Creep Embrittlement High-Temperature Creep Thermal Fatigue • Materials of Construction of CDU DAY 2 SECTION 4 1 1 • Corrosion Control in Crude Distillation Units • Desalting • Caustic Addition • Corrosion Control in FCC Units • Damage Mechanisms and Suitable Materials • Reactors . Kuala Lumpur. Malaysia 1 DAY 1 1 SECTION 1 Refinery Operations & Overview • Refinery Operating Objectives • Refinery Process Overview • Overhead pH Control • Corrosion Inhibitor • Control Washing Fundamentals Metallurgy & Corrosion Other Damage Mechanism SECTION 2 Vacuum Distillation Unit (VDU) SECTION 5 Fluid Catalytic Unit (FCCU) • • • • • • • • • • Process Description Riser/Reactor Regenerator Flue Gas System Fractionator Type selection Fouling behavior/mitigation Tube Insert Technologies Header types High Fin tube types Common Metals & Alloys Used in Refinery • • • • • • • • • Killed Steel Steels Carbon Steel C-Mo Steels Low-Alloy Steels Cr-Mo Steels Nickel Steels Stainless Steels Other Metals and Alloys Thermal & Mechanical Aspects SECTION 3 1 Crude Distillation Unit • Sources of Crude Oil 1 • Composition of Crude Oil • Remaining Constraints •3 Crude Oil Pre-treatment • Desalting • • • • • • • • • Corrosion in Crude Distillation Units Columns Exchangers and Piping Fired Heaters Corrosion Monitoring in Crude Units Water Analysis (Overhead Corrosion Control) Hydrocarbon Analysis Corrosion Rate Measurement On-Stream.CORROSION CONTROL IN THE REFINING INDUSTRY 25th .29th August 2014.

• Regenerators • Catalyst Transfer Piping System SECTION 6 Catalytic Light Ends Recovery Unit (CLERU) Units • • • • • • • • • • • • • • • • • • • CLER Process Description Materials of Construction Columns Exchangers Corrosion in CLERU Hydrogen Induced Damage Inspection Techniques for Hydrogen Induced Damage Prevention and Repair Techniques Ammonia Stress Corrosion Cracking Carbonate Stress Corrosion Cracking Fouling/Corrosion of Reboiler Circuits Corrosion Control Measures Water Washing Polysulfide Injection Corrosion Inhibitors Corrosion Monitoring Hydrogen-Activity Probes Chemical Tests Corrosion Probes • • • • • • • • • • • • • Fouling Problems Corrosion Control Measures Reactor Section Corrosion Tower Overhead Corrosion Reboiler Corrosion and Fouling Control Acid Tanks Corrosion Under Insulation Corrosion Monitoring Reaction Section Treating Section Fractionation Section Refrigeration Equipment Acid Tank SECTION 8 Hydroprocessing Units (HPU) • • • • Hydroprocessing Hydrotreating Hydrocracking Variations on Hydroprocessing DAY 3 SECTION 1 7 1 1 Sulfuric Acid Alkylation Unit (SAAU) • • • • • 3 1 Process Description Reaction Section Treating Section Fractionation Section Refrigerator Section • Materials of Construction • • • • • • • • • • Corrosion in SAAU Sulfuric Acid Corrosion Acid Concentration Acid Temperature and Velocity Acid Dilution Hydrogen Grooving Feed Contaminants Acid and Neutral Esters Acid Carryover Corrosion Under Insulation • Corrosion in HPU • Hight-Temperature Hydrogen Attack • High-Temperature H2S CorrosionWith Hydrogen Present • High-Temperature H2S CorrosionWith Little or No Hydrogen Present • Naphthenic Acid Corrosion • Ammonium Bisulfide Corrosion • Chloride Stress Corrosion Cracking • Failures Often Happen After Startup • Failures Happen at Predictable Points • Reactions with Stainless Steel • Polythionic Acid (PTA) Stress Corrosion Cracking • Other Methods Used to Prevent PTA SCC • Wet H2S Cracking • Sulfide Stress Cracking • Temper Embrittlement • Hydrogen Embrittlement • • • • • • • Materials of Construction of HPU Reactor Loop-General Reactor Feed System Reactor Feed Furnaces Reactors Reactor Effluent System Fouling/Corrosion of Reboiler Circuits .

com . Semi-Regenerative Reactor Design SECTION 12 Sulfur Recovery Units (SRU) • • • • • • • • • • • • • • • Sulfur Recovery Units Sulfur Chemical Processes Sulfur Recovery Process Tail Gas Treating Unit Incinerator Cold Bed Adsorption (CBA) Unit Corrosion Mechanisms Sulfidation of Carbon Steels Sour Environment Corrosion Weak Acid Corrosion Corrosion of CBA Units Burner and Mixing Chamber Tail Gas Reactor and Waste Heat Exchanger Water Quench and Re-Circulation Blower System H2S Adsorption System 1 • Corrosion I CRU • HTHA • Stress Corrosion Cracking • • •3 • Materials of Construction Reactors Exchangers and Piping Fired Heaters and Other Equipment 1 1 • Corrosion Control • Corrosion Monitoring DAY 4 SECTION 10 1 Delayed Coking Units (DCU) • • • • • • • • • Equipment and Operation of the Delayed Coking Unit High-Temperature Sulfur Corrosion Naphthenic Acid Corrosion High-Temperature Oxidation/Carburization/Sulfidation Erosion-Corrosion Aqueous Corrosion Corrosion Under Insulation Thermal Fatigue Temper Embrittlement of Cr-Mo Steels DAY 5 SECTION 13 Refinery Corrosion Prevention Methods Process Additives and Corrosion Control • • • • Factors Affecting Corrosion Acids Temperature Pressure IN-HOUSE SOLUTIONS SAVE COST • IMPROVE PERFORMANCE • REDUCE RISK PetroSync understands that in current economic climate. The training can be tailored to meet your specific needs at your preferred location and time. If you like to know more about this excellent program.• • • • • • Reactor Effluent-Distillation Feed Exchangers Effluent Air Coolers Effluent Air Cooler Inlet and Outlet Piping Separator Vessels Recycle Hydrogen System Distillation Section SECTION 1 11 Amine Treating Unit (ATU) • • • • • • • • • • Process Description Tail Gas Units Corrosion Phenomena Corrosive Species Amine Degradation Cracking Phenomena Corrosion Inhibitors Materials of Construction Corrosion Monitoring Corrosion Control Measures SECTION 9 Catalytic Reforming Unit (CRU) • • • • • • Octane Number (RON) Catalyst Catalytic Reforming Process Platformer (UOP) Catalytic Reformer. We will meet you anywhere around the globe. This excellent training can be conducted exclusively for your organization. please contact on +65 6415 4500 or email general@petrosync. getting an excellent return on your training investment is critical for all our clients.

• Flow • Turbulence • Material Selection • • • • • • • • • • • • • • Methods to Mitigate Corrosion Desalting and Caustic Injection Water Washing Acid Neutralization Barrier Between Metal and Environment Chemicals Used to Combat Corrosion Filming Amines Filming Formulation Filmer Application Treat Rates Monitoring Filmer Performance Neutralizing Amines Polysulfides Napthhenic Acid Corrosion Inhibitors • Electrochemical Corrosion Monitoring • Linear Polarization Resistance • Potential Monitoring •1 Zero Resistance Ammetry (ZRA) • Electrical Impedence Spectroscopy (EIS) • Electrochemical Noise (EN) • Hydrogen Flux Monitoring • • • • • • • Atmospheric Distillation Unit Vacuum Distillation Unit Fluid Catalytic Cracking Unit Amine Treating Unit Sour Water Stripper Units Sulfuric Acid Alkylation Unit Automated On-Line Monitoring SECTION 15 • Application of Corrosion Inhibitors SECTION 14 Refinery Injection Systems • • • • • • • • Materials Selection Considerations Location of Injection Point Injection System Hardware Chemical Storage Tanks Chemical Injection Pumps Additive Control Systems Piping Systems Injector Corrosion Monitoring Methods in Refineries • • • • Uses of Corrosion Monitoring Corrosion Monitoring Techniques Corrosion Coupons 1 1 Electrical Resistance Monitoring Petrosync Quality Limited Attendees The course has limited seats to ensure maximum learning and experience for all delegates. This will provide you with a deeper and more long-term understanding of your current issues. High Quality Course Materials Printed course manual will provide you with working materials throughout the course and will be an invaluable source of reference for you and your colleagues afterward. Interactive Training You will be attending a training designed to share both the latest knowledge and practical experience through interactive sessions. Program Schedule 08:00 – 09:00 09:00 – 11:00 11:00 – 11:15 11:15 – 13:00 13:00 – 14:00 14:00 – 15:30 15:30 – 15:45 15:45 – 17:00 17:00 Registration (Day1) Session I Refreshment & Networking Session I Session II Lunch Session III Refreshment & Networking Session II Session IV End of Day . This certificate is proof of your continuing professional development. You can follow course progress on your laptop with soft copies provided. Certificate of Attendance You will receive a Certificate of Attendance bearing the signatures of the Trainer upon successful completion of the course.

fertilizer plants. Corrosion Inhibitor Injection. Joshi worked in the areas of Plant Design. Yousuf Memon has been working for • ADCO • & ASME Sec. Gas sweetening plants.and distant learning Toyoin-house. petroleum refineries. in corrosion & integrity management systems industry. Durr GMBH  and Thermax limited…etc. Pressure vessel.in Off shore produc on facili es. ZADCO • Fauji Power • AD-MERKBLATTER • API Bri sh Standard BS 5500 Mechanical Integrity remained his areas of expertise such as. including in-service inspec on of Plant equipments. such as: Coatings. Protective • OMIFCO interacted with leading mul na onal giants. • API 620. Fer lizer Client List Yousuf Memon is the CEO of Reliance Swift for Veritas (Pvt) Ltd. • PARCO • Engro Fertilizer He also delivers public training courses. Piping systems and Tank-farms Refineries. Yousuf Memon B. specialized • UEP • DPL execution and training. Engineering  Mitsubishi Heavy Industries • Asia Petroleum • Engro Polymers courses on Corrosion Control. Indonesia. Oil terminals.1. Mr. power • GASCO • FODCO codes plants for several years. Material Performance Evaluation.Ch. • QP • Engro Powergen Plant.I. His is well known expert in over 35 years of experience upstream & downstream oiland & gas • BP • DEWA the following codes. Heat exchangers. with plants. • PSO FFC Non Destructive Testing (Conventional Advanced).Petrosync Lecturer Mr. Plant Inspection & Corrosion Control Consultant more than 38 years. Petrochemical plants. Risk-Based Inspection.) Pakistan Engineering Council (PEC) Skill & Expertise • • • • • • • • Piping Inspection Oil & Gas Refinery NDT Metal Fabrication Power Plants Plant Inspection • • • • • • • • Risk Based Inspection API 510 API 570 Desalination Plants Boilers Petroleum Refinery Natural Gas Petrochemicals • • • • • • • • Material Selection Metallurgy Corrosion Control Protective Coatings Damage Mechanisms Fertilizers Petrochemical Petroleum . • TUV NORD • DUBAL  Balcke –upstream. fabrica on. Cathodic Protection System. Professional Affiliations National Association of Corrosion Engineers (NACE) The American Society of Mechanical Engineers (ASME) American Society of Quality (ASQ) American Educational Society of Surface Finishing (AESF) American Institute of Chemical Engineers (A. Joshi has worked with several mul & na onal companies worldwide and was. and downstream oil gas industries. Plant Inspection & Mechanical Integrity to Umm-Al-Nar Re finery local PT. Fitness-For-Services. • involved / • PAPCO Monitoring. Failure Analysis.E. Material Selection. • API 510. PUSPETINDO. Corrosion Mr. chemical plants. B 31. Power plants. VIIIoil Div. etc and international midstream. API 570 and API 653 • ASME B 31. API 650 • HUBCO national international & gas exploration. Different areas • ASME IX plants • andTEMA desalination of •Sec. Inspec on.3 petrochemical plants. 1 and Div 2. E.

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