Sabp A 015 PDF

Best Practice
SABP-A-015 1 July 2007

Chemical Injection Systems
Document Responsibility: Materials and Corrosion Control Standards Committee
Saudi Aramco DeskTop Standards

Table of Contents
1 Introduction............................................................................ 2
2 References............................................................................ 3
3 Definitions and Abbreviations................................................ 6
4 Chemical Injection Overview................................................. 7
5 Chemical Injection System Design...................................... 11
6 Chemical Injection Point Position........................................ 23
7 Chemical Injection System Inspection................................ 25
8 Management of Change...................................................... 25
9 Chemical Injection System Maintenance............................ 26
10 Injection Point Documentation............................................ 27
11 Safety.................................................................................. 28
12 Refinery Chemicals and Water Wash Injection................... 29
13 Upstream Facilities and Gas Plants Chemical Injection...... 47
14 Steam Generator Chemical Injection.................................. 51
15 Chemical Dosage Control................................................... 52
16 Chemical Injection Effectiveness........................................ 53
17 Strategies for Chemical Optimization.................................. 55
18 Quality Control of Chemicals............................................... 57
Appendix A.................................................................................. 58
Previous Issue: New Next Planned Update: TBD

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Primary contacts: Ahmed M. Al-Zahrani on 874-6132 or Ahmad S. Al-Omari on 874-7431
Copyright©Saudi Aramco 2007. All rights reserved.
Document Responsibility: Materials and Corrosion Control SABP-A-015
Issue Date: 1 July 2007
Next Planned Update: TBD Chemical Injection Systems
1 Introduction
1.1 Purpose
The intent of this best practice is to provide guidelines for the detailed design,
materials selection, quality assurance, operations and inspection of chemical
injection systems. The content is based on established industry guidelines and
field experience with their use in Saudi Aramco facilities.
Corrosion Technology Unit of Consulting Services Department has developed

this Best Practice to assist with improving and maintaining the mechanical
integrity of Saudi Aramco upstream and downstream facilities through the use
of the chemical injection systems.
1.2 Scope
This Best Practice covers chemical injection systems in all refining units,
including wash water and chloride injection in reformer units. All upstream oil
& gas processing facilities, transmission and producing pipelines and stem
generators chemical injection systems have been also covered. The chemical
injection system for sea water application is not covered in this document.
1.3 Conflicts with Mandatory Standards
In the event of a conflict between this Best Practice and other Mandatory Saudi
Aramco Engineering Requirement, please contact the supervisor of
CSD/ME&CCD/Corrosion Technology Unit for resolution.
1.4 Disclaimer
The material in this Best Practice document provides the most correct and
accurate design guidelines available to Saudi Aramco which complies with
international industry practices. This material is being provided for the general
guidance and benefit of the Saudi Aramco engineers and designers. Use of this
Best Practice in designing projects for Saudi Aramco, however, does not relieve
the designer from his responsibility to verify the accuracy of any information
presented or from his contractual liability to provide safe and sound designs that
conform to Mandatory Saudi Aramco Engineering Requirements. Use of the
information or material contained herein is no guarantee that the resulting
product will satisfy the applicable requirements of any project.
Saudi Aramco assumes no responsibility or liability whatsoever for any reliance

on the information presented herein or for designs prepared by Designers in
accordance with this Best Practice. Use of this Best Practice by Designers is
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intended solely for, and shall be strictly limited to, Saudi Aramco projects.
Saudi Aramco® is a registered trademark of the Saudi Arabian Oil Company.
Copyright, Saudi Aramco, 2007.
2 References
Unless stated otherwise, all Standards, Specifications and Codes referenced in this Best
Practice shall be the latest issued (including revisions, addenda and supplements) and
are considered a part of this Best Practice.
2.1 Saudi Aramco References
Saudi Aramco Engineering Procedure

SAEP-20 Equipment Inspection Schedule
Saudi Aramco Engineering Standards

SAES-A-205 Oilfield Chemicals
SAES-A-208 Water Treatment Chemicals
SAES-A-206 Positive Material Identification
SAES-A-301 Materials Resistant to Sulfide Stress Corrosion
Cracking
SAES-B-005 Spacing and Diking for Atmospheric and Low -
Pressure Tanks
SAES-D-109 Design of Small Tanks
SAES-G-006 Positive Displacement Pumps - Controlled
Volume
SAES-J-400 Temperature
SAES-L-105 Piping Material Specifications
SAES-L-110 Limitations on Pipe Joints and Components
SAES-L-132 Material Selection for Piping Systems
SAES-Q-005 Concrete Foundations
Saudi Aramco Materials System Specifications

31-SAMSS-009 Positive Displacement Pumps - Controlled
Volume
32-SAMSS-030 Manufacture of Small Tanks
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Saudi Aramco Library Drawings

DA-950035-001 2-inch high Pressure Access System Chemical
Injection and Corrosion Monitoring
DB-950175-001 Antifoulant Injection Point Details
DB-950176-001 Water Wash Injection Point Details
DB-950177-001 Caustic Injection Point Details
DB-950178-001 Neutralizing Amine Injection Point Details
DB-950179-001 Filming Amine Injection Point Details
Saudi Aramco Best Practice

SABP-A-016 Crude Unit Corrosion Control
Saudi Aramco Engineering Reports

SAER-2365 Saudi Aramco Mothball Manual
SAER-5941 Final Report and Guidelines on Crude Unit
Overhead Corrosion Control
Saudi Aramco Inspection Procedures

00-SAIP-07 Positive Material Identification Requirements
01-SAIP-04 Injection Point Inspection Program
2.2 Industry Codes and Standards
American Petroleum Institute

API RP 570 Piping Inspection Code Inspection, Repair,
Alteration, and Rerating of In-Service Piping
Systems
American Society of Mechanical Engineers

ASME B31.3 Process Piping
ASME B16.9 Factory-Made Wrought Buttwelding Fittings
Manufacturers Standardization Society of the Valve and Fittings Industry, Inc.

MSS SP-97 Integrally Reinforced Forged Branch Outlet
Fittings - Socket Welding, Threaded, and
Buttwelding Ends
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2.3 Other References

J. G. Willmon and M. A. Edwards, “Precommissioning to Startup: Getting
Chemical Injection Right”, SPE 96144, SPE Annual Technical Conference and
Exhibition, Dallas, Texas, 9 – 12 October 2005.
J. W. Palmer, W. Hedges and J.L. Dawson, “Use of Corrosion Inhibitors in Oil
and Gas Production: (EFC 39)”, Woodhead Publishing, 2004.
W. C. Fortt, E. S. Berm, R. C. Strong and Ma. Vegesi" Process Design of
Injection Systems" Corrosion 96, NACE International, Paper No. 587, 1996.
R. R. Konet; G.J. Honer and R.M. Thompson, “Implementation Strategies for
API RP 570 Injection Point Inspection Programs”, Corrosion 96, NACE
International, Paper No. 588, 1996.
R. C. Quinter, "Performance Verification of Injection Systems", Corrosion 96,
NACE International, paper No. 590, 1996.
J. Gutzeit, "Problems with Injection Facilities for Process Additives or Wash
Water", Corrosion 96, NACE International, paper No. 591, 1996.
P. R. Petersen, “The Use of Corrosion Inhibitors in the Refining Industry”,
Corrosion 96, NACE International, paper No. 594, 1996.
A. Bagdasarian, J. Feather, B. Hull, R. Stephenson and R. Strong, “Crude Unit
Corrosion and Corrosion Control”, Corrosion 96, NACE International, Paper
No. 615, 1996.
J. R. Rue and J. G. Edmondson, “Control of Salt-Initiated Corrosion in Crude
Unit Overhead Systems”, Corrosion 2001, NACE International, Paper No.
01538, 2001.
D. E. Powell, D. I. Ma’ruf, and I. Y. Rahman, “Field-Testing Corrosion
Inhibitors in Oil and Gas Gathering Systems”, Materials Performance, p. 42-45,
August 2002.
D. W. Alley and N. D. Coble, “Corrosion Inhibitors for Crude Distillation
Columns”, Materials Performance, p. 44-49, May 2003.
NACE International Publication # 3410: Refinery Injection and Process Mixing
Points (prepared by Task Group 174)
Nalco Best Practices
Chevron Best Practices
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3 Definitions and Abbreviations
Be°: Baumé is a scale used to measure the density of various liquids.
Catalyst: A material that aids or promotes a chemical reaction between other

substances but does not react itself. Catalyst increases reaction speed and can provide
control by increasing desirable reactions and decreasing undesirable reactions.
CCR: Continuous Catalyst Regeneration
CHB: Chemical Hazard Bulletin. CHB is an internal company document (available in

both English & Arabic) developed by Environmental Protection Department to provide
a standardized one-page summary of a material’s hazard ratings: health hazards, fire &
reactivity, handling, storage & disposal and first aid information for use in the handling
of hazardous materials. It is known also as Material Safety Datasheet, MSDS.
CRA: Corrosion Resistant Alloy
ER: Electrical Resistance
Fouling: Accumulation of deposits in condensers, exchangers, etc.
GOSP: Gas Oil Separation Plant
HPPT: High Pressure Production Trap
IPPT: Intermediate Pressure Production Trap
LPPT: Low Pressure Production Trap
LPR: Linear Polarization Resistance
LPI: Liquid Penetrant Inspection
MSDS: Material Safety Datasheet. MSDS is a document containing information on

hazardous ingredients, their properties, and precautions for use for a specific chemical
substance.
MPI: Magnetic Particle Inspection
NGL: Natural Gas Liquids
OSI: On-Stream Inspection
PMI: Positive Material Identification
PWHT: Post-Weld Heat Treatment
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QA/QC: Quality Assurance/Quality Control
RSS Report: Refinery Shift Superintendent Report
RT: Radiography Test
Stress Corrosion Cracking: (SCC) is the cracking induced from the combined
influence of tensile stress and a corrosive environment.
SARCOP: Saudi Aramco Refining Chemical Optimization Program
T&I: Test & Inspection
TDS: Total Dissolved Solids
RVL: Restricted Vendor List, generated by Saudi Aramco
“Typical” or “Target”: indicate desirable but not mandatory items
“Limit,” “Required,” “Shall,” and “Must”: indicate mandatory items
4 Chemical Injection Overview
Chemicals play an important role in the enhancement of oil and gas production and
processing. They control corrosion, prevent organic and inorganic deposits, aid in
phase separation, control microbial problems, control pH, scavenge oxygen and
neutralize chlorides.
Chemical injection philosophy depends primarily on the fluid composition, fluid

chemistry, operating pressures and temperatures, and to some extent the flow regime.
Depending on fluid characteristics and system materials, a wide range of chemicals
maybe injected into vessels and piping system to control corrosion. Chemical injection
is considered one of several corrosion mitigation methods such as coating, material
selection, cathodic protection, process control, use of CRAs, etc.
Chemical injection systems are an invaluable component of corrosion control systems

implemented in a variety of operating units. For example, one of the chemical
injections is corrosion inhibitor that is used to form a stable adherent film on the
internal surface of a pipe or vessel, which acts as a barrier between the equipment
surface and the corrosive media. Also, the injection system could be used to neutralize
or dilute the components of the process stream. Inhibitors can be added either as a
batch or as a continuous injection.
Chemicals can be applied through a variety of mechanisms. There are three typical
configurations of injection systems used in hydrocarbon production and processing:
retrievable (high pressure), retractable (low pressure) and fixed (high or low pressure).
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The retrievable system allows operators to undertake injection, retrieve, inspect and
maintain equipment while the system is under full operating conditions. The oil and gas
production industry from the wellhead through the GOSP generally employs retrievable
injection systems (Figure 1) that operate with high pressure access fittings. The unit
assembly consists of an access fitting, a solid plug, an injection nut, and an injection
tube (quill, cross head or perpendicular spray nozzle).
Figure 1 - Retrievable Type Injection System
The retractable type injection system (Figure 2) is commonly used in the refining
operations. A retractable quill style injector, which has a packing gland design, offers
the ability to remove and service the injector system during normal operations. This
design can be manually retracted from lines or other equipment operating at low
pressure.
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Figure 2 - Retractable Type Injection System
The fixed assembly (Figure 3) is recommended for use in a by-pass loop which can be
isolated, or in systems having frequent and regular shut-down, since system
depressurization is required during insertion and removal. The unit is ideally suited for
use in high pressure and/or hazardous applications where threaded fittings are not
recommended to avoid leakage. Process shutdown or process isolation is required for
installation and inspection. The unit assembly consists of a flange and an insertion rod
with an injection quill.
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Figure 3 - Fixed Type Injection System
Table-1 summarizes the configurations of chemical injection and their applications.
Table 1 - Injection System Styles
Configuration Pressure Range Facility

Retractable Low Refineries
Retrievable High Upstream Facilities
Fixed* All All
* While fixed systems could be employed in a wide variety of situations, their limited flexibility with
regard to serviceability and maintenance typically restricts their application to more extreme or
hazardous services.
The following factors can have significant impact on the safety, maintenance, operation,
and service life of the chemical injection system:
● Chemical solution being injected
● Concentration (both of the chemical being injected and the mixed chemical/process
stream, i.e., concentrated sulfuric acid injection into an RO water stream)
● Flow rates (both stream receiving the injection and the product injected)
● Viscosity
● Chemical hazard
● Materials of construction
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5 Chemical Injection System Design
A typical chemical injection system (Figure 4) should consist of a chemical supply

storage tank from which the chemical solution shall be pumped through piping or
tubing, as appropriate, to the point of application. Each chemical feed system shall
include controlled volume pumps, tanks, gauges, strainer, filter, pressure relief valves,
sight glasses and flow metering/monitoring devices, check valves, hand valves, a power
source for the pump and instrumentation to control the injection and to monitor its
effectiveness.
The chemical injection system must be well designed to accommodate the chemical
types and volumes that are considered necessary for efficient operation throughout the
project lifetime. All systems should be appropriately sized to handle the ‘worse-case’
scenarios.
Figure 4 illustrates a diagrammatic view of the main components of the chemical

injection skid.
Figure 4 - Chemical Injection System Simplified Drawing
5.1 Materials
Materials of construction for the chemical injection system components should

be carefully selected and shall be compatible with chemical solution and be
capable of withstanding maximum pump discharge line pressure and process
main pressure. Concentrated chemicals by themselves can be corrosive until
properly diluted by the produced fluids.
Chemicals identified as oilfield treatment chemicals, such as biocides, corrosion

inhibitors, scale inhibitors, demulsifiers, and boiler treatment chemicals shall use
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316L material as designated in SAES-L-132 for piping, tanks, and injection

quills. Other products which do not meet these guidelines, such as strong acids,
or inhibitors injected in refinery process systems, etc., shall be assessed on a
case by case basis in coordination with ME&CCD. Moreover, specific materials
for some applications have been addressed on their relevant sections on this Best
Practice. Non-metallic materials may be an acceptable alternative for certain
purposes if and only if allowed in specific sections of this document.
When handling chemical solutions where the solvent is water or when injecting
water streams, dissimilar metal flanged joints shall use insulation kits.
5.2 Chemical Storage Tank
The chemical storage tanks should be sufficiently sized so that re-filling is not
required every day. The size of chemical storage tank depends on their exact
application. Chemical storage tanks in offshore upstream operations are
normally sized for 3 months use. Chemical storage tanks in refineries are
usually sized to provide at least one month’s capacity. Some applications, such
as caustic (NaOH) in a refinery, may use local unit tanks that are made up on a
batch basis from a bulk supply. Such local unit tanks should have a minimum of
one day’s capacity.
The chemical tank shall be equipped with a fill nozzle, vent, discharge, level
instrument and drain. The chemical storage tank level should be monitored.
Tanks shall be reinforced to withstand all forces when full of liquid. Chemical
storage tanks should be flushed and cleaned when replacing chemical type.
Chemical tanks must be properly labeled as to the contents of the tank and its
hazards. Tanker connection should be accessible by road and must be clearly
identified with connected tank number and product. Unloading connections
shall be sealed, in order to prevent cross-contaminating chemical products, with
blind flanges or if fitted with quick connect systems, i.e., Kamlock, with plugs
or caps. Chemical tanks must be electrically grounded similar to any other tanks
in the plant. Also, the chemical tanker must be connected to the ground system
before starting chemical filling to the tank.
CHB (it is also known as MSDS) shall be located near the unloading
connections, in enclosures protected from direct sun, wind and rain. In general,
CHBs must be readily available to the workers who are exposed to the chemical
product.
Containment concrete slab and curb must be constructed around the tank to
contain its contents in the event of a spill or tank rupture. This concrete slab and
curb must be sloped toward a drainage system. It should be noted that, any new
chemicals should be included in the plants spill prevention controls. Spacing and
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diking of tanks shall be in accordance with SAES-B-005. Concrete foundations

for tanks shall be in accordance with SAES-Q-005.
Design of chemical storage tanks up to 1500 barrels capacity shall be in

accordance with SAES-D-109. This standard shall be used only by the design
engineer/contractor and shall not be attached to nor made a part of a purchase
order. Manufacture of these tanks shall be in accordance with 32-SAMSS-030.
This specification may be attached to and form an integral part of a purchase
order. Chemical tanks manufacturer shall be selected from Saudi Aramco
approved RVL list.
PORTA-FEED® containers, or similar tanks provided by other vendors, can be

used for some applications including temporary chemical applications or limited
space for construction a storage tank. Standard units are made of 304L or 316L
stainless steel. For products that are corrosive to stainless steel, there are plastic
and polyethylene units.
The PORTA-FEED® system contains a shuttle tank and a base tank (Figure 5).
The shuttle tank is used for the transportation of the product. The two tanks are
connected via the filling hose. Transfer of the product from the shuttle tank is
done automatically under the influence of gravity. The supplier fills a shuttle
tank with a product and delivers the filled tank to the facility. When the shuttle
tank empties it is disconnected and returned to the product supplier for reuse.
The supplier replaces the empty tank rather than refilling it on-site.
Figure 5 - PORTA-FEED® Base Tank (Source: Nalco Company)
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The preferred mode for a PORTA-FEED® location is to stack one on top of

another and drain the new one “shuttle tank” into the permanent site tank “base
tank”.
Some chemical tanks require nitrogen purge to exclude oxygen from the feed.
Some tanks require mixers, caustic tanks in particular. These mixers should be
nitrogen or mechanical. No air blowing is allowed for mixing purpose. Special
materials are required for special chemicals such as caustic and sulfuric acid.
The materials of construction should be per SAES-L-132.
Non-metallic tanks have been used for more than 25 years successfully in the
offshore Berri field. For new applications, seek the approval of
CSD/ME&CCD/MEU/ Non-Metallic Group.
5.3 Pump
Positive displacement pumps are frequently used for injection of chemicals into
a pressurized system. The positive displacement pump must be a metering type
with stroke adjustment to vary the chemical injection rate. It is important to
select a pump from Saudi Aramco approved manufacturers that meet the
required flow rate and pressure. The chemical injection pump needs only to be
slightly higher than the internal process stream pressure. So, the positive
displacement pump must be capable of generating sufficient injection line
pressure to overcome injection line losses, the process line operating pressure
and thus create the required pressure differential across the injection tube.
To ensure online chemical injection reliability and availability, back-up, or

secondary pump must be available in the event of pump failure or the need for
maintenance. For critical application, the chemical injection pumps shall be
provided with appropriate alarms and automated controls to provide immediate
switchover from running to standby pump, in case of pump failure. All pumps
must meet area classification.
SAES-G-006 and 31-SAMSS-009 defines the minimum mandatory

requirements governing the design and installation of positive displacement
pumps-controlled volume (chemical injection pumps).
5.4 Quill
Most of the failures that is related to the injection point have occurred
immediately downstream of the injection quill. Such failures have been
attributed to general corrosion attack of the concentrated product, which
attacked the pipe wall prior to the product being diluted by the produced fluids.
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Consequently, the use of internal injection tubes, as quills, atomizing nozzles,

etc., which direct the product into the process fluids, is required.
5.4.1 General Quill Design Criteria
The design of an injection quill is very critical. The quill should be

designed efficiently to disperse injected chemicals into a process stream
without allowing the injected chemicals to build up on the interior walls
of the pipe and without clogging the injection quill opening. The
injection quill must be sized to inject the desired amount of chemical.
The injection quill should be capable of injecting the chemical in such
way to effectively and intimately mix the chemical with the process
stream. Injection quills should be installed per approved design
drawings and inspector has to measure the injection quill insertion
lengths prior to the installation.
The quill design should be evaluated for possible stress, fatigue problems
and flow induced vibration. For new projects, stress calculations must
be performed and provided by the engineering contractor to determine
the optimum injection quill insertion length. These calculations should
be reviewed and approved by CSD. For any replacement quills, stress
calculations must also be performed and provided. Process stream flow
rate fluctuations, flow regimes, fluid viscosity and quill natural
frequency are essential variables affecting injection quill design. Natural
frequency and wake frequency calculations shall be performed on each
quill that will be installed in the field. The purpose of these calculations
is to prevent the quill from entering a resonant vibration in which fatigue
failure can occur. The wake frequency should be less than 80% of the
quill's natural frequency to guarantee no resonant harmonic vibration.
This can be determined by applying the thermowell calculations in
SAES-J-400 Paragraph 5.3.
5.4.2 Angled Face Quill Design
The style of the injection quill with open end shall has a bevel cut angle
with 45° as a minimum and 60° as a maximum. Angles less than 45°
would limit the influence of the scarf cut. The quill must include a slot
through a wall of the quill tip. The slot shall not be longer than the
length of the bevel. The slot is rectangular and is opposed to the angled
end.
The quill with angled face utilizes the turbulence created by its design, in
conjunction with the natural turbulence within the pipe, to accomplish
distribution of the injected chemical into the process stream. The
disadvantage of the quill with angled open end is that at low process
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stream flow rates there tends to be a concentration of the injected

chemical at the pipe wall surface below the injection point.
For liquid-phase stream, the quill should be installed in the pipe so that
the angled face of the quill faces the fluid downstream (Figure 6). While
for mixed and vapor phase streams, the angled face of the quill should
face the fluid upstream as shown in Figure 7.
45o-60o
Figure 6 - Proper Quill Alignment in a Liquid-Phase Stream
45o-60o
Figure 7 - Proper Quill Alignment in a Mixed and Vapor Phase Streams
The above mentioned design of quill tip is commonly used in upstream

facilities and can be used as an option for neutralizing and filming amine
injection system in addition to the side hole opening quill.
5.4.3 Caustic Injection Quill Design
Caustic Injection quill (Figure 8) shall not be fabricated using pipe with
welded end plate. Cracking around a circumferential fillet weld can
occur due to the difficulty of getting a sound weld in this restricted area.
So, caustic injection quill must be fabricated from solid Monel bar. The
design, materials, fabrication, examination, and testing of the fabricated
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Monel bar shall meet the requirements of ASME B31.3 “Process

Piping”.
Fabricating the caustic injection quill by boring a solid Monel bar is

considered as unlisted components in ASME B31.3. The ASME B31.3
Code defines unlisted components as components not in Tables 326.1,
A326.1, or K326.1 of the code.
The processes used to fabricate the caustic injection quill must be

reviewed for Code compliance. Some fabrication processes can cause
gross or local wall thinning. The absolute first stage in the process of
fabricating the caustic injection quill is to perform PMI on the bar
material to assure that the material is indeed Monel 400. Do not rely on
paperwork or bar stamping. The metallurgical condition of the bar
should be “annealed” which will give a yield strength in the range 25 to
50 ksi. The machining should be done in more than one pass. First a
rough cut is required followed by fine cutting. The objective is to avoid
work hardening the surface of the Monel. All machining should be done
with adequate lubrication. The quill must be examined in accordance
with the ASME B31.3.
Dimensions of the fabricated quill shall conform to those of comparable

listed components as practicable as possible (straight pipe). In any case,
dimensions shall be such as to provide strength and performance
equivalent to standard components except as provided in paragraphs 303
and 304 of ASME B31.3.
The pressure/temperature design of the fabricated caustic quill shall

provide the same safety margins as ASME B31.3. The Code states that
the pressure design must meet the requirements of paragraph 304.7.2.
The fabricated caustic injection quill may be used provided that it
conforms to a published specification or standard within the following
limitations:
1) The designer shall be satisfied that composition, mechanical
properties, method of manufacture, and quality control are
comparable to the corresponding characteristics of listed
components.
2) Pressure design shall be verified in accordance with paragraph 304
of ASME B31.3.
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The pressure design of the fabricated caustic injection quill shall be

based on calculations consistent with the design criteria of ASME B31.3.
These calculations shall be substantiated by one or more of the means
stated below (paragraph 304.7.2 of ASME B31.3) considering applicable
dynamic, thermal, and cyclic effects in paragraphs 301.4 through 301.10
of ASME B31.3, as well as thermal shock.
(a) Extensive, successful service experience under comparable
conditions with similarly proportioned components of the same or
like material.
(b) Experimental stress analysis, such as described in the Boiler
Pressure Vessel Code, Section VIII, Division 2, Appendix 6.
(c) Proof test in accordance with either ASME B16.9, MSS SP-97, or
Section VIII, Division 1, UG-101.
(d) Detailed stress analysis (e.g., finite element method) with results
evaluated as described in Boiler Pressure Vessel Code, Section
VIII, Division 2, Appendix 4, Article 4-1. The basic allowable
stress from Table A-1 shall be used in place of Sm in Division 2.
At design temperatures in the creep range, additional
considerations beyond the scope of Division 2 may be necessary.
(e) For any of the above, the designer may interpolate between sizes,
wall thicknesses, and pressure classes, and may determine
analogies among related materials.
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Figure 8 - Caustic Injection Quill Simplified Drawing
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5.5 Calibration Tube
Accurate calibration of chemical injection rate is essential to provide adequate

protection to the piping and equipment and to control the chemical consumption.
So, the injection system shall include provisions for pump calibration and flow
rate verification down stream of the metering pumps. A vented calibration tube
(graduated cylinder) in addition to the inline flow meter shall be installed on
each chemical injection pump which will provide an easy way to measure the
rate of flow of the chemical being injected. While the use of inline flow meters
is becoming more common, field installations may inject volumes as low as one
gallon per day. The costs of flow metering equipment in these cases exceed the
costs for chemical injection. So, the need for inline flow meter may not be
required for low volume injection. Tank consumption tracking or graduated
cylinder can provide the injection confirmation required in these situations.
Flow switches can be installed which shut the pump in on low flow and send an
alarm indicating low flow. Flow measurement data and alarms shall be sent to
the DCS.
A calibration tube is typically a clear tube with markings in milliliters,

gallons/hour (GPH) or gallons/day (GPD) as appropriate and used with a stop
watch to measure the flow rate. The tube should be placed on the suction side of
the injection pump with the necessary valves and fittings so the injection rate
can be checked any time by the operator. Main line chemical feed and
calibration tube shut off valve shall be ¼ turn ball valves and shall be positioned
so that the operator can easily and simultaneously operate both valves during
calibration.
Figure 9 - Calibration Tube Drawing
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Below is a simplified procedure in how to use the calibration tube to measure

the chemical flow rate:
1. With valve A open and the pump operating (Figure 9), open valve B
slowly until chemical level reaches the 0 mark.
2. Close valve A and begin timing with a stopwatch or wristwatch
secondhand.
3. At the one-minute mark, observe the chemical level. This is the actual
pump flow rate.
4. The graduated cylinder should be drained when it is not in use by closing
valve B and opening valve A.
5.6 Injection Line
Injection lines should be sized to allow for the efficient transfer of chemical and
stay within the working pressure of the material. All connections from the
chemical pump to the point of injection shall be hard piped. Flexible tubing in
certain portions can be used only if pressure and temperature limitations are not
exceeded. The distance between the chemical storage tank and the injection
point should be minimized as much as possible. All piping to the injection
pump and from the pump should be free draining towards the pump to avoid any
chemical stagnation.
5.7 Check Valve
Check valves must be installed on all chemical lines at the inlet line to the
injector to prevent the process fluid from pushing back into the chemical
injection line. Some of the line or fittings have built-in internal check valve. It
is recommended to install external ones. The internal check valves are not
reliable in case of internal corrosion that will damage the internal threads
causing the check valves to be disoriented and becoming useless. Also, the long
inspection intervals of these fittings, once a year during the plant PM shutdown,
will make them un-reliable.
5.8 Filter
Filters/Y-strainers must be placed between the chemical supply and the injection
pump. The size and type of the filter element will depend on the rate and type of
fluid that is to be pumped. Two separate filters with individual isolation valves
shall be provided where chemical injection can not be stopped for process
requirement such as demulsifier.
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5.9 Miscellaneous
Most of the chemical injection lines are small in size (less than 1-inch diameter
mostly) and they are not rigid, which can vibrates easily if not properly
supported. This continuous vibration, even if it was minor, would result in
pending fatigue failure in the chemical lines in the long run. As a result,
adequate support to these chemical lines must be provided.
Each injection point shall be installed with an isolation valve in case any repairs
are needed to chemical feed system. For retractable system, vent valve must be
installed to release pressure and drain any process fluid/gas that accumulates
after the quill is retracted from the process and the injection process valve is
closed.
A pressure relief valve must be installed on the pump discharge to vent fluid
back into the chemical tank or pump suction line if pressure builds up.
A pressure gauge for each pump discharge line must be installed.
A sight flow indicator is recommended to be provided close to the injection

point location as visual indication of chemical flow.
A pulsation damper, to ensure an even chemical application, shall be provided in

each pump discharge line and shall be sized to provide sufficient degree of
damping.
As per SAES-L-110 Section 8, seal welding of threaded joints is required when

deemed necessary by the Operating Organization for those locations and
services where an uncontrolled leakage would result in serious consequences for
the operation or safety of plant and personnel. Seal welding of all threaded
joints up to the first block valve is required in the following services and
applications:
● All hydrocarbons
● Boiler feed water, condensate, and steam systems utilizing ASME Class 300
and higher flange ratings
● Toxic materials such as chlorine, phenol, hydrogen sulphide, etc.
● Corrosive materials such as acid, caustic, etc.
● Oilfield chemicals (e.g., corrosion inhibitors, Demulsifiers, electrolytes, etc.)
● Piping which is subject to vibration, whether continuous or intermittent
As per SAES-A-206 Section 5 and 00-SAIP-007, PMI testing shall be

performed at a point in time that ensures proper alloy materials have been used
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in the fabrication of an identifiable assembly. Usually, this is done after

fabrication and immediately prior to fabrication to ensure completes testing of
the injection system components before their installation in the field.
The following information is needed to design an optimum injection system:

● System Parameters
Pipe/vessel diameter (also vessel length if applicable)
Line pressure
Fluid viscosity
Fluid density
Mass or volumetric flow rate
Working temperature
Clearance for the retrieval of the quills
● Chemical Parameters
Viscosity
Density
Temperature
Anticipated injection pressure
Mass or volumetric flow rate
Concentration of active ingredient
6 Chemical Injection Point Position
The injection point is installed through an opening in the wall of the pipeline. It should
be installed in location which can be accessed by the Operations. Adequate clearance
shall be available for insertion and removal of the quill.
The effectiveness of the chemical injection is heavily influenced by the location of the
injection point. The quill should be installed in pipe provided, of course, a sufficient
flow rate to promote distribution of the chemical solution. The turbulent flow at the
injection point should cause mixing of the injected chemical with the process stream.
The relative viscosity of injected chemical and the process stream play a major role in
mixing.
The injection tube tip shall be inserted within the center 1/3 of the pipe as shown in
Figure 10 that illustrates a side view of the chemical injector installed in a pipeline.
Generally, the most effective position for chemical injection is at the center of the pipe.
Highest fluid velocity is normally at the center of the line, therefore, injection at this
point is supposed to prevent concentration of the chemical at the edge where the
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velocity is low due to friction and will ensure efficient distribution of the introduced
chemical. It is imperative that any injected chemical is not directed at the equipment
wall where it could cause local corrosion attack and wall perforation. In large diameter
systems, it may be impossible to find a quill that can be either retractable or retrievable.
Therefore, for nominal line sizes of 36 inches and greater, insertion quill length shall
provide a tip location not greater than 35% of the nominal diameter measured from the
out side wall of the pipe while the minimum insertion must be no less than 6 inches.
If the line pipes are designed for regular scraping operations, protruding injection quill
must be removed before scraping begins. Installation of the protruding chemical
injection tubes in the scrapable line can be avoided by locating the injection point at
other locations such as lateral lines, etc.
Injection Tube
See Note
Proper insertion depth shall be
within center 1/3 of the pipe
Note: the most effective position for chemical injection is at the center of the pipe
Figure 10 - Quill Insertion Limits
The quill opening must be aligned parallel to the process flow with the correct opening
orientation, as illustrated in the previous section, when the injection tube assembly is
placed in the process pipe. Therefore, the orientation of the quill must be marked to
insure proper positioning of the quill opening once the injection tube assembly is
installed in the process pipe.
One of the recommended field practices, for high pressure injection system, is to
permanently mark, on the solid plug hex nut, the long side of the quill with a straight
line using a file, small hacksaw cut or waterproof paint marker. This convention should
be maintained if possible whenever the quill is reinstalled. The solid plug should not be
loosened in order to achieve orientation, as this may affect the plug seal in the access
fitting. This shall be part of an installation checklist signed off by the installer and
assigned inspector.
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7 Chemical Injection System Inspection
Monitoring and inspection are key activities in maintaining chemical injection system
integrity. Chemical injection systems must be inspected regularly, including the
injection point itself, downstream and upstream piping and equipment that may have
been affected.
Inspection frequencies should be determined by the type of mechanical/ physical

deterioration anticipated. The inspection frequency shall follow SAEP-20, paragraph
5.5.6.3. The NDT inspection shall be performed every three month for the new
installed quills and after T&I installation for the first year.
The need for more detailed inspection requirements for chemical injection system was
formally addressed industry-wide with the issuance of API RP 570 “Piping Inspection
Code Inspection, Repair, Alteration, and Rerating of In-Service Piping Systems”. As
stated in API RP 570, injection points are sometimes subject to accelerated or localized
corrosion from normal or abnormal operating conditions. So, API RP 570 recommends
more rigorous inspection of injection points due to the potential susceptibility to
accelerated or localized corrosion and these areas need to be inspected thoroughly on a
regular schedule. Moreover, inspection requirements can be found in 01-SAIP-04
“Injection Point Inspection Program”. This Saudi Aramco inspection procedure
provides guidelines to plant personnel on the injection point's identification, tracking
and monitoring. Refer to 01-SAIP-04 for more details.
8 Management of Change
The Management of Change (MOC) process shall be used to identify changes which
could impact the inspection plan for a particular injection point circuit. Changes to the
composition of the additive, location of the injection, and length of time the additive is
injected can occur frequently. This is especially important when a trial program for an
additive is initiated. Close communication between Operations, Engineering, and
Inspection personnel regarding these types of changes will help prevent the
development of problems due to an oversight in the inspection program. In addition,
the same type of communication on new installations will help improve the
effectiveness and minimize the cost impact of the inspection program by addressing key
issues such as materials selection, inspection access, and potential corrosion problems.
A detailed review of the methodology involved in performing an effective MOC is
beyond the scope of this best practice.
Below are some examples of work/changes requiring MOC approval:

● Use of different chemicals
● Change of chemical Manufacturer
● Process parameters
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● Locations of the injection point
● Routing chemicals to any sewer
● New chemicals being introduced
● Existing chemicals being mixed in different ways
● Quill replacement in kind to ensure updated construction drawings.
The success of the program depends on timely communication of changes made to

injection systems. Ideally any change in chemical type, injection rate, duration,
injection location or concentration should signal a need to analyze potential impact on
the inspection program.
9 Chemical Injection System Maintenance
The proper assembly and care of a chemical injection system is extremely important.
Establishing and following a thorough maintenance routine will aid in preventing any
problems. To ensure maximum performance, periodic checks and cleaning are
necessary for the injection quill. This cleaning practice can be done during the plant
shutdown.
All tubing connections, fittings, tanks, and pumps should be checked by the plant
operators on a daily basis. The injection fittings must be examined regularly for leaks
and thread damage. Injection fittings should be thoroughly cleaned at least once a year.
Installed filters should be disassembled, cleaned, and inspected on a regular basis for
contamination and damage. The frequency of inspection is dependent upon the fluid
injection rates; the higher the rates, the shorter the time between inspections. Filter
elements should be replaced if there are any signs of plugging or contamination. The
filter element can be flushed from the inside out with solvent. If any significant debris
is noted at any one time, the source must be identified and eliminated. The check valve
should be checked regularly to confirm that its seat is clean and seated correctly to stop
any back flow.
If a chemical injection system appears to be plugged or the flow restricted, stop

injecting immediately. Pull and inspect the filters for debris. If the injection system
does not respond to this treatment, stop pumping. Troubleshoot the chemical injection
system to identify the location of plugging and clean it. Continued pumping may only
increase the severity of the problem and possibly damage the system.
If any piping or equipment shuts down or is taken down for inspection or maintenance,
the chemical injection system related to this piping or equipment shall be stopped. This
will avoid concentration of the injected chemical at the injection site which can lead to
corrosion for the pumps, valves and piping system.
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If the chemical pump is to be stopped for an extended period in excess of 2 months, it is

recommended that the original chemical be displaced from the injection system by
flushing with an appropriate solvent. Stagnant chemical lying in the injection system
could cause plugging, and corrosion. Selection of solvent will be determined on a case
by case basis. Contact CSD/ME&CCD Corrosion Technology Unit for further
guidance. Proper mothballing of the chemical system including tanks and pumps shall
be considered based on the downtime period defined in Saudi Aramco Mothball Manual
(SAER-2365). This manual provides basic guidelines and recommendations for the
preparation of detailed procedures for mothballing piping and equipment.
If polymerization of a chemical is a problem when the system is suspended, then the

line shall be provided with drainage capability and the line drained immediately
following suspension of service. This shall be clearly stated in the OIM for the system.
The injection point isolation valve must not be closed without stopping the pumps,
because injection against a closed injection location valve will cause continual
operation of the PZV.
Records of maintenance activities, repairs and downtime for the chemical injection
system should be documented to develop appropriate maintenance strategies.
10 Injection Point Documentation
The injection system details shall be documented, including:

● Process operating window
● Anticipated conditions
● Equipment design
● Monitoring requirements
● Inspection requirements
Appendix A contains a sample form that can be used for documenting plant injection
point details. This form should be carefully filled out completely with as much detailed
information as possible for each injection point in the plant. It will help concerned
engineers/inspectors to make sure that all injection points are included in the inspection
program. This form will assist plant inspector to select the proper inspection techniques
and to optimize the inspection interval.
For caustic, neutralizing and filming amine injection points, all PMI performed must be
documented and logged in inspection files. Proved quill tip location and orientation
after installation and before startup by radiography shall be also retained by the plant
inspection. It is recommended that a digital photograph before installation to be taken
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for the quill tube inserted in the pipe so that the conditions and details of the quill can be
noted. This photograph should be documented in inspection files.
11 Safety
The purpose of warnings and cautions highlighted below is to call the operator’s
attention to possible danger of injury to personnel and/or damage to equipment, and
deserve careful attention and understanding. Safety precautions must be established
throughout any activities related to the chemical injection system operations including,
but not limited to the following:
● Safe operation for the retrieval equipment requires a minimum of two (2) trained
operators.
● The retrieval equipment shall not be used unless the crew performing the work has
been trained in its safe operation.
● All plant safety requirements and environmental regulations shall be followed.
● The media type, its pressure and temperature for the attended job shall be identified
before commencing the job.
● All the required personal protective equipment shall be provided and used when
checking the injector, i.e. hard hat, safety glasses, protective clothing, face shield,
safety gloves, breathing apparatus, etc.
● Any actions which could vary system pressure such as surges caused by opening
and closing of valves and chokes should be delayed until completion of the attended
job related to the chemical injection system operations.
● Enough clearance for safe operation around the attended location should be
established.
● Wind direction prior to starting operations involving hazardous products should be
noticed.
● Up-to-date CHBs shall be posted near all chemical storage tanks and unloading
sites.
● Ensure safe release of chemical to the environment by proper installation of
equipment, provision of ventilation and personnel protection.
● Every chemical injection skid shall be equipped with eye washes and showers side
to be used in case of any emergencies situation.
● Waste chemical shall be disposed in a safe place.
● For the retractable injector, be careful when breaking connections. Release the
pressure on the chemical line using the drain valve on the pump discharge. Be sure
to close the isolating valve on the process before inspecting the retractable injector.
Break the connection between the retractable injector and the isolating valve slowly
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and carefully to release any pressure. Verify that the valve is completely shut and
holding before removing the retractable injector. Never operate the retractable
injector without the external support frame.
● The operator should always position himself to the side when working on the
injector location.
The following sections (12, 13 and 14) describe the details of chemical and water wash
injection requirements in Saudi Aramco facilities with respect to design basis, injection
locations, and material of construction.
12 Refinery Chemicals and Water Wash Injection
Many different types of process additives are used to maintain reliability and optimal
performance of refinery operations. The types of injection chemicals used in refineries
are as varied as the intent and purpose of the programs they service. An additive can be
either a commodity chemical such as acid, caustic, methanol; or a proprietary chemical
such as neutralizing amine, filming amine, antifoulant and chloride. The additive can
be as simple as a water stream injected to dissolve salt deposits or to dilute corrosive
process components. Some of the major types of additives used in refineries are:
12.1 Caustic Addition in Crude Units
Caustic (NaOH) injection is used to reduce crude column overhead acid

corrosion, caused by hydrogen chloride (HCl). Caustic is injected at one or two
points in a Crude Unit. Caustic may be injected upstream of the desalters but it
is not recommended. It should be noted that, pH above 7.0 leads to tighter
emulsions and poor performance of the desalters while pH below 7 is better for
the desalter performance. Additionally, it is injected at a location between the
desalter and the fired heaters. The location of this second injection point varies
from refinery to refinery in Saudi Aramco’s operations. It may be injected
immediately downstream of the desalter or immediately upstream of the heaters.
12.1.1 Design Basis
The design is based on injecting up to 5 lb of NaOH (100%) per

1000 bbl of crude in the form of a 3 wt % aqueous caustic solution
mixed with sufficient bypassed crude to maintain an injection velocity
of 30 ft/sec, as a minimum for good mixing, into the main crude
stream. The following minimum velocities should be considered when
a caustic injection system is designed:
Caustic Injection Orifice Velocity, ft/sec 20
Slipstream Injection Orifice Velocity, ft/sec 20
Crude Velocity in Main Stream, ft/sec 7
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12.1.2 Injection Locations

● Downstream of the Desalter
Caustic injection downstream of the desalter is an effective method
to reduce overhead corrosion. Caustic injected at this location
must be thoroughly mixed with the crude stream. This is best
achieved by use of a crude slip stream and static mixer. The crude
slip stream should preferably be obtained from a location after the
desalter to eliminate undesalted crude from being reinjected into
the stream. In some cases, injection into the crude pump suction
has had an equally effective mixing role as using a slip stream.
Inadequate mixing can result in excessive fouling of heat
exchanger trains.
Caustic is usually injected at a low concentration, on the order of 1

to 5 weight percent (2 to 7 oBaume). This low concentration
requires a greater volume and aids in effective mixing with the
crude stream. The injection of a low concentration also reduces the
risk of caustic corrosion and caustic stress corrosion cracking. In
order to minimize fouling of the heat exchangers, it is critical that
caustic quality be strictly controlled. At refineries where there are
large fluctuations in caustic quality, heat exchanger fouling and
caustic stress corrosion cracking have occurred.
Piping and equipment downstream of the injection location must be

post weld heat treated (PWHT) to minimize the risk of caustic
stress corrosion cracking. However, even PWHT pipework is not
immune from cracking in high concentration caustic streams.
A Monel 400 quill is required for caustic injection at this location.

Such quills have an expected service life well in excess of ten
years.
The measured chloride content in the overhead accumulator water

controls caustic addition downstream of the desalters. The target
range is 10-30 ppm Cl- in the accumulator water. Currently, at
most Saudi Aramco refineries, operators adjust the caustic rate
when a chloride reading is out of specified limits. However, the
injection rate is usually limited to a maximum of 2 PTB (pounds
per thousand barrels) to prevent downstream fouling.
● Upstream of the Heater
Caustic injection upstream of crude heater is an alternative if and
only if heat exchangers downstream of the desalter experience
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severe fouling. However, there are increased risks from caustic

injection at these higher temperatures. For contrast, Shell’s Best
Practice specifically requires caustic injection at temperatures less
than 350°F. Nalco’s Best Practice limits caustic injection to a
temperature of less than 300°F. Caustic at elevated temperatures is
extremely corrosive and can corrode the injection quill or the pipe
wall itself if the quill is incorrectly positioned. Further, caustic
may cause caustic stress corrosion cracking of non-stress relieved
pipework and heater tubes. Injection of caustic at this location
requires precision engineering and operation. Caustic of consistent
strength and quality must be thoroughly pre-mixed with a slip
stream of crude, ensuring thorough mixing with the use of a static
mixer. Injection is achieved via Monel 400 pipework, valves, and
quill. The crude slipstream must be carefully monitored to ensure
that the caustic stream is not injected un-mixed into the main crude
line. The Monel 400 quill will experience some minor sulfidation
on the process side at these temperatures, in the region of very
approximately, 500°F.
12.1.3 Crude Bypass Stream
The most important consideration in the design of the crude bypass

stream is to establish a controlled flow which will maintain an injection
velocity of 30 ft/sec into the main crude stream. [It is assumed that the
velocity of the main crude stream at the point of injection will
normally be greater than 7 ft/sec].
In order to meet this objective, while at the same time limiting the
bypassed crude rate to less than 1% of the maximum expected crude
rate, three differently sized injection sections, as shown in Table 2, are
recommended to cover the range of crude unit capacities:
Table 2 - Crude Unit Charge Rate vs. the Slipstream Rate
Maximum Expected Crude Bypass Rate at 300°F,

Rate at 600°F, BPD BPD (GPM)
Over 100,000 940 (27)
60,000-l00,000 580 (17)
Under 60,000 300 (9)
It is obviously important to stop injecting caustic during crude flow

interruptions to avoid formation of a pool of concentrated caustic in the
carbon steel system. It is, therefore, strongly recommended that a low
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flow shutdown be installed to stop the caustic pump when the bypassed
crude rate decreases to less, than 85% of its design rate.
12.1.4 Requirements for Caustic Injection System
The detailed design of the caustic injection system is shown in the

Library Drawing # DB-950177. Table-3 summarizes the caustic
injection requirements. Refinery must have current as-built quill
detailed design drawings which also specify the quill materials of
construction. These drawings should be up-to-date and signed-off.
Table 3 - Caustic Injection Requirements

Variable/Location Target or Limit Comment
Spent caustic results in tramp compounds entering the
Source Fresh caustic only system and causing corrosion, fouling, emulsions, and
foaming.
Typical values. Dilute caustic aids mixing. Identical
1 to 5 wt % concentration must be provided. Variation in caustic
Caustic concentration
(2 to 7o Baume) strength injected to process stream is a major cause of
preheater fouling.
Essential. Measure the concentration of each and every
batch of caustic to be used in the plant prior to use. Data
must be stored in a permanent record. Injection of off-
Measurement Each batch specification caustic at one plant caused stress corrosion
cracking and an economic loss of over $1 million. Injection
of off-specification caustic at another plant caused excess
fouling.
Dilution water O2 < 20 ppb Stripped sour water is a good source.
Dilution water Cl- Zero Target.
Target. The larger the better to minimize batch make-up
operation and variation. Nitrogen blanket to exclude
Storage tank oxygen.
Mechanical mixers.
Strongly preferred. A dedicated line from the bulk caustic
tank to the unit day tank facilitates the correct dilution of
caustic. At least two plants that use a complex caustic
Caustic delivery to unit Dedicated line
header system have experienced major problems with
cross contamination and delivery of out-of-specification
caustic that resulted in major operational problems.
NACE recommends and 80% of the industry injects caustic
downstream of the desalter. The suction of the crude
booster pump is the normal location and assists efficient
Injection location caustic mixing. In cases where preheater fouling is an
issue, then caustic injection upstream of the heater is
allowable. Ras Tanura Plant 15 has had good long term
success with this latter methodology.
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Best practice of the majority of the industry. Shell restricts
caustic injection temperature to 350°F. Nalco’s Best
Practice restricts caustic injection to 300°F. Higher
temperatures can be used but only if fouling of preheat
exchangers or some other site specific need makes it
Injection temperature Maximum 350°F
essential. Fouling can be readily detected by
measurement of pressure drop across the preheater.
Higher temperature injection requires careful and
continuing attention to every detail as failures at higher
temperatures can be catastrophic.
Salt < 2 PTB, Caustic injection rates are fine tuned based on overhead
add 1 PTB NaOH chloride levels. Initial rates for a new unit follow the rules of
Salt 2-5 PTB, thumb provided. The maximum amount injected is limited
Quantity injected
add 1.5 - 2 PTB NaOH to less than 2 PTB NaOH. Amounts injected may be
limited further due to effects on downstream process such
Maximum 2 PTB Visbreakers, FCCUs, and hydrocrackers.
Saudi Aramco experience has demonstrated that this
Injection quill material Monel 400 material serves well whether the injection point is located
downstream of the desalter or upstream of the heater.
Only when the unit is The caustic injection quill can be removed only when the
down unit is down. The quill must be inspected at every T&I.
Positive Material Identification of the injection quill must be
performed on site on all quill fittings to verify metallurgy
PMI
upon the removal. This must be documented and logged
in inspection files.
Injection quill removal
Visual inspection supplemented by Magnetic particle
testing or penetrant testing should be conducted by the
plant inspection to determine the need for replacement.
NDT Ultrasonic Thickness measurement should be taken on all
quill fittings. The retirement thickness (Tmin) of the quill
should be calculated by the Inspection Department in
cooperation with the refinery Corrosion Engineer.
Field verification of pipe diameter and quill length to be
Injection quill must
Injection quill length confirmed before installation by operations, process
be the correct length
engineer, inspection and maintenance.
Use of a slip stream aids dispersion of the caustic and
Dilute caustic mixed helps to minimize caustic-caused corrosion problems. The
1:100 with crude slip slip stream is effectively mixed prior to injection using a
Injection slip stream stream Monel 400 static mixer. All caustic pipe and fittings shall
be Monel 400.
Installation of a The slip stream line should be fitted with a flowmeter for
flowmeter positive flow indication and appropriate restriction orifice.
Static mixer shall be used to ensure a homogenous
Static mixer
In-line Mixer mixture.
Monel 400 Use Monel 400 only.
Co-current with crude The quill should be installed in the pipe so that the hole of
Injection orientation
flow the quill faces the fluid downstream (Figure 8).
Shop QA/QC inspector must identify all materials to be
Quill construction PMI Monel 400 during fabrication. The PMI Results must be
documented and compared to the approved site drawings.
Page 33 of 58

A special welding procedure should be verified by CSD
Welding procedure
welding engineers.
Positive Materials Identification of the injection quill and all
slip stream pipe and fittings must be performed on site to
PMI
verify metallurgy. Material other than Monel 400 shall not
Quill installation be fitted.
Location of quill tip shall be proved after installation and
Radiography before startup by radiography. A permanent record of the
radiograph shall be retained by the refinery.
Correct positioning of the quill is critical. Therefore, a non-
Non-retractable with
retractable design shall be used. A match-mark indicator is
match-mark indicator
used to show the orientation of the quill opening.
Quill design Minimum schedule 80 The quill must be schedule 80 and/or thicker.
Drawings update / redlined and approved by CSD should
Latest revision available be archived and new drawings communicated to all
affected refinery personnel.
Required that the pipework, fittings, etc., be post weld heat
Crude pipework
PWHT for minimum of treated to prevent caustic stress corrosion cracking.
upstream of the
3 diameters upstream Failures due to Caustic SCC have occurred in Saudi
injection point
Aramco plants.
Required that the pipework, fittings, etc., be post weld heat
Crude pipework PWHT all piping
treated to prevent caustic stress corrosion cracking.
downstream of the systems and
Failures due to Caustic SCC have occurred in Saudi
injection point equipment.
Aramco plants.
The pipework upstream and downstream of the injection
location must be inspected as per API RP 570 and 01-
Crude pipework
NDT SAIP-04 for injection point. The frequency of NDT
inspection
inspection shall be increased to every three months for
newly installed quills for the first year of operation.
As communicated by the operation engineer on a daily
Operating procedures Caustic injection rate
basis and any deviations reported in RSS report.
12.2 Neutralizing Amine in Crude Units
Neutralizing amine is introduced into the crude unit overhead lines from the
atmospheric columns and vacuum columns to neutralize the acids that cause
very low pH and high corrosion rates at the water dew point. The objective of
injecting neutralizing amine is to control the pH in the overhead receiver water
at a pH of 5.5 to 6.5 which is the range commonly used in the industry.
However, some companies have adopted different ranges. Chevron uses a target
range of 7.5-8.0. This higher pH is achievable in systems using ammonia for
neutralization but is not cost effective in Saudi Aramco systems where a
neutralizing amine is used.
12.2.1 Design Basis
The neutralizing amine should be injected through an injection quill
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with steam to distribute and atomize the neutralizing chemical. This

method will fully disperse the neutralizer into the vapor stream and
will prevent neat chemical injection which could lead to under-deposit
and severe localized corrosion.
In order to have a good neutralizing amine injection the following

items shall be consider in the system design:
● All process-wetted parts, including the injector pipe with a quill tip
or nozzle, are constructed of Hastelloy C2000, B-2 or Inconel 625.
● The steam pressure should be in the range of 50 to 150 PSI.
● The steam should be trapped and filtered close to the injection
point.
● The steam injector equipment, valves and check valves in steam
side service should be rated for this service with steam.
● The neutralizer mixing tee should be as close to the injector as
possible.
● The mixing tee should be horizontal to or above the top of the
injection pipe to insure free uniform flow of the neutralizer.
● The neutralizer mixing tee and the chemical and steam lines should
be supported on adjacent structures to avoid placing excessive
strain on the chemical injector pipe and packing gland.
● Both the steam line and the neutralizer line shall have a check
valve to insure proper flow.
● Both the steam line and the neutralizer line should have a filter
(Y-strainer – 100 mesh) located near the steam injector to prevent
mill scale or other solid contaminates from fouling the injector pipe
or nozzle.
● The steam injector should be installed in the top or side of the
horizontal section of overhead vapor line, not the bottom.
● Using 316 stainless steel materials or better for the steam and
neutralizer line to the steam injector is recommended.
The neutralizer should be injected into of the crude column overhead

vapor line before any salts can form, and before any water can
condense. The neutralizing amine injection point should be located
near the top of the crude unit overhead line after the first elbow.
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12.2.3 Requirements for Neutralizing Amine Injection System
The detailed design of neutralizing amine injection system is shown in

the Library Drawing # DB-950178. Table-4 summarizes the
neutralizing amine injection requirements. Refinery must have current
as-built quill detailed design drawings which also specify the quill
materials of construction. These drawings should be up-to-date and
signed-off.
Table 4 - Neutralizing Amine Injection Requirements

Variable /Location Target or Limit Comment
Preferred. 100 mesh typical. The Y-Strainer should be
installed in both the steam line and neutralizer line
immediately before mixing, but at a location that can
Filter Y-Strainer easily be serviced (easily accessible from an existing
platform). This will reduce the problem with quill
blockage by preventing mill scale or other solid
contaminates from fouling the injector pipe or nozzle.
Treatment rate is adjusted to give the required
Enough to maintain pH in overhead receiver pH. The Nalco Strong Acid Test
Treatment rate the Overhead receiver from provides a method to calculate the target injection rate
5.5 to 6.5 that will assure neutralization of the first drops of
condensing acid.
Neutralizer must be injected into the overhead system.
Injection into the reflux is bad practice. For crude unit,
Injection location After 1st elbow preferred location is immediately downstream of the
first elbow if the outlet pipe is installed at the top of the
crude column.
> 5 pipe diameters from Strongly preferred to achieve proper mixing and to
downstream elbow. avoid erosion-corrosion on downstream elbow.
Neutralizer co-injection with the wash water without
nd
steam (downstream of the 2 elbow) can be
Co-injection with wash water
considered as an alternative on a case by case basis
with approval of CSD.
Injection point with steam to
be top side of line if entering
Injection orientation
on a horizontal portion of
line.
Co-current with the process The quill should be installed in the pipe so that the
stream flow. hole of the quill faces the fluid downstream.
Mixing Tee should be located at an elevation above
The mixing tee should be as
the injection point. The mixing tee should be
Mixing Tee close to the injector as
horizontal to or above the top of the injection pipe to
possible.
insure free uniform flow of the neutralizer.
Required. Use steam co-injection to ensure neutralizer
The steam used should be is vaporized and adequately dispersed. Use lowest
from 50 psi to 150 psi. pressure steam that meets design need. Inject into the
Steam co-injection
overhead at no more than 5 psi over stream pressure.
The steam should be trapped and filtered close to the
injection point.
Page 36 of 58

The slip stream line should be fitted with a flowmeter
Installation of a flowmeter for positive flow indication and appropriate restriction
orifice.
Steam injector equipment,
valves and check valves in Should be rated for this service with steam.
steam side service
Piping from and including Using 316L stainless steel or better tubing material is
Steam and neutralizer
the mix point with steam recommended. This tubing is clean and more
lines and fittings
shall be a compatible resistant to corrosion than mild steel that is commonly
metallurgy
material. used. Monel shall not be used for inhibitor service.
Should be installed on
Steam trap steam line close to
the mixing point
Quill design Retractable Mandatory. Allows maintenance on-stream.
12 o’clock Normal orientation.
Preferred to inject in the center of the stream to ensure
even distribution away from pipe walls. In large
Inject in center 1/3 systems it may be impossible to obtain a quill that can
of the stream be retractable, i.e., removed on-line and meet this
criteria. In this case, the minimum insertion into the
pipe flow must be no less than 6 inches.
Injection quills must be the correct length. Field
verification of pipe diameter and quill length to be
Injection quill length
confirmed before installation by operations, process
Nalco provide Hastelloy C-2000 quills. Hastelloy B-2
that was supplied previously is also a good choice.
Hastelloy C-2000, B-2 or
Quill metallurgy Monel shall not be used for inhibitor service. Any
Inconel 625.
existing stainless steel quills should be replaced at the
next T&I.
Quill installation Positive Materials Identification of the injection quill
PMI
must be performed on site to verify metallurgy.
Location of quill tip shall be proved after installation
Central with the pipework and before startup by radiography. A permanent
record of the radiograph shall be retained by the plant.
12.3 Filming Amine (Corrosion Inhibitor) (Crude Unit, Fractionation Columns

at Rheniformers and Visbreaker; and Debutanizer at Hydrocracker)
Filming amine is added to provide a protective film, or barrier, between the

metal surface and the corrosive liquids in the overhead system.
Injection rates are typically set to add the filmer at 3-5 ppm based on total
overhead naphtha rate. Filming amine should normally not be injected in
concentrated form. The product is injected into the overhead line through a quill
with a naphtha slipstream with a dilution between 50 and 100 naphtha to 1
inhibitor. Typically, naphtha dilution is provided to help the dispersion, at the
Page 37 of 58
injection point, and to dilute the concentrated filming amine that may be
corrosive to injection equipment.
12.3.1 Design Basis
The filming amine shall be injected through an injection quill with

naphtha to distribute the filming chemical. This method will fully
disperse the filming amine into the overhead stream and will prevent
neat chemical injection which can be corrosive at elevated temperature.
In order to have a good filming amine injection the following items

shall be consider in the system design:
● All process-wetted parts, including the injector pipe with a quill tip
or nozzle, are constructed of Hastelloy C2000, B-2 or Inconel 625.
● The filming amine mixing tee should be as close to the injector as
possible.
● The mixing tee should be horizontal to or above the top of the
injection pipe to insure free uniform flow of the filming amine.
● The filming amine mixing tee and the chemical and naphtha lines
should be supported on adjacent structures to avoid placing
excessive strain on the chemical injector pipe and packing gland.
● Both the naphtha line and the filming amine line shall have a check
valve to insure proper flow.
● The Y-Strainer must be installed in the naphtha slip stream line and
it is preferred for the filming amine line. The Y-Strainer shall be
located near the injector to prevent mill scale or other solid
● The injector should be installed in the top or side of the horizontal
section of overhead line, not the bottom.
● Using 316 stainless steel materials or better for the naphtha and
filming amine line to the injector is recommended.
The filming amine will typically be injected at several other locations

in addition to the crude unit over head including but not limited to:
● Fractionation Columns at Rheniformers
● Fractionation Columns at Visbreaker
● Debutanizer at Hydrocracker
Page 38 of 58
For crude units, the filming amine is typically injected immediately

downstream of the neutralizer separated by minimum space of 5D if
possible. However, Ras Tanura Refinery injects filming amine
upstream of fin fans.
12.3.3 Requirements for Filming Amine Injection System
The detailed design of filming amine injection system is shown in the

Library Drawing # DB-950179. Table-5 summarizes the filming
amine injection requirements. Refinery must have current as-built
quill detailed design drawings which also specify the quill materials of
Table 5 - Corrosion Inhibitor Injection Requirements

for Crude Unit Atmospheric Tower Overhead
The Y-Strainer must be installed in the naphtha slip
stream line and it is preferred for the filming amine
line. The Y-Strainer should be installed immediately
before mixing, but at a location that it can easily be
Filter Y-Strainer
serviced, that is, easily accessible from an existing
platform. This will reduce the problem with quill
blockage by preventing mill scale or other solid
Typical. Presently used in all Saudi Aramco crude
unites. An option is to evaluate water soluble
Corrosion Inhibitor Type Oil dispersible film former
products co-injected with the water wash with the
approval of CSD and SARCOP.
3 to 5 ppmv of total
Typical for normal operations. Depends on product
Injection rate naphtha product
used.
and naphtha reflux.
Typical. Most Saudi Aramco crude units inject
corrosion inhibitor downstream of the 1st elbow, if the
outlet pipe is installed at the top of the crude column,
and downstream of the neutralizing amine injection
After 1st elbow
point. Ras Tanura primary injection point is at the fin
fans. Secondary injection at the fin fans may be
Injection location appropriate for refineries with flow distribution
problems.
> 5 pipe diameters from
Rule-of-thumb (if possible).
neutralizer injection
> 5 pipe diameters Strongly preferred to achieve proper mixing and to
from downstream avoid erosion-corrosion on downstream elbow (if
elbow. possible).
Dilute inhibitor in naphtha stream. Flow
measurement on inhibitor and naphtha streams
100 naphtha to 1
Slip stream essential. 100 mesh screen required. The naphtha
inhibitor
stream can be taken from the reflux or other similar
source.
Page 39 of 58

The slip stream line should be fitted with a flowmeter
Installation of a flowmeter for positive flow indication and appropriate restriction
orifice.
Injection point with naphtha
to be top side of line if
entering on a horizontal
Injection orientation portion of line.
Co-current with the process The quill should be installed in the pipe so that the
stream flow hole of the quill faces the fluid downstream.
Mixing Tee should be located at an elevation above
The mixing tee should be as
the injection point. The mixing tee should be
Mixing Tee close to the injector as
horizontal to or above the top of the injection pipe to
possible.
insure free uniform flow of the neutralizer.
Piping from and including Using 316L stainless steel or better tubing material is
Naphtha and filming
the mix point with naphtha recommended. This tubing is clean and more
amine lines and fittings
shall be a compatible resistant to corrosion than mild steel that is commonly
metallurgy
material used. Monel shall not be used for inhibitor service.
Retractable Mandatory. Allows maintenance on-stream.
Preferred to inject in the center of the stream to
ensure even distribution away from pipe walls. In
Inject in center 1/3 large systems it may be impossible to obtain a quill
Quill design of the stream that can be retractable, i.e., removed on-line and
meet this criteria. In this case, the minimum insertion
into the pipe flow must be no less than 6 inches.
Nalco provide Hastelloy C-2000 quills. Hastelloy B-2
that was supplied previously is also a good choice.
Hastelloy C-2000, B-2 or
Quill metallurgy Monel shall not be used for inhibitor service. Any
Inconel 625.
existing stainless steel quills should be replaced at
the next T&I.
Positive Materials Identification of the injection quill
PMI
must be performed on site to verify metallurgy.
Quill installation Location of quill tip shall be proved after installation
and before startup by radiography. A permanent
Central with the pipework
record of the radiograph will be retained by the
refinery.
12.4 Water Wash in Refining Units
Water washing has been practiced in many refinery process units as a means of
preventing formation or removing fouling salt deposits and to dilute corrosives,
often in column overhead systems, hydrotreater reactor effluent systems, and in
the overhead of some fractionators.
Page 40 of 58
12.4.1 Design Basis for Water Wash Rates
Most water washes have been continuous. Intermittent washing has

been used in some applications for periodic removal of salt deposits.
Low water wash rates can be more harmful than beneficial. The water
rate must be high enough so that the bulk of the water does not flash at
system conditions when injected. Because many of the salt deposits
encountered in refining processes are hygroscopic, inadequate water
washing can lead to severe localized corrosion in certain
circumstances. The water wash rate must be sufficient to maintain at
least 25% of the total water injected as liquid water. Typically, for a
crude unit overhead, a wash water rate of 4 to 6% of total naphtha
stream volume is needed to meet this 25% liquid water requirement.
Many refinery process unites have used water wash as a corrosion

control method. The following are list of the water wash injection
locations which are:
● Crude unit atmospheric column overhead piping system
Water is usually injected in the overhead piping to help quench and

scrub the overhead vapors, dilute acids formed, and keep any salts
or acids from accumulating in the system.
● Hydroprocessing unit reactor effluent cooling trains
Ammonia and hydrogen sulfide gases, generated during

hydrotreating, combine to form ammonium bisulfide salts as the
reactor effluent stream cools down. To prevent plugging of
exchanger tubes, water is injected upstream of the salt formation
temperature (upstream of the effluent coolers) to remove
ammonium chloride or ammonium bisulfide deposits and to dilute
aqueous condensates containing these salts.
● Catalytic reforming unit
The typical injection point has been located upstream from the
point in the pretreater reactor feed/effluent exchangers where the
temperature allows deposition of ammonium chloride. Water is
injected on a continuous or intermittent basis to remove
accumulations of ammonium chloride salts.
Page 41 of 58
● Fluid catalytic cracking unit (FCCU) light ends recovery unit
Water wash is typically injected upstream of the fractionators

overhead condenser and upstream of interstage cooler to reduce
corrosion by dilution of the contaminants, such as hydrogen
sulfide, ammonia, and cyanide. Conditions in FCCU light ends
recovery units have been conducive to hydrogen blistering,
hydrogen induced cracking (HIC) and stress-oriented hydrogen
induced cracking (SOHIC) problems due to the hydrogen sulfide,
ammonia, and cyanide formed by the catalytic cracking reaction.
12.4.3 Requirements for Water Wash Injection System
The detailed design of the water wash injection system is shown in the
Library Drawing # DB-950176. Table-6 summarizes the water wash
Table 6 - Water Wash Injection Requirements

for Crude Unit Atmospheric Tower Overhead
Recycle water from the overhead receiver is the most
Source Overhead receiver.
common source.
Required. Oxygen in wash water results in major
O2 <20 ppb
corrosion damage.
Total dissolve solids (TDS) typically are in the region
TDS of 160 ppm in Saudi Aramco operations. Low figures
are preferable but not controllable.
Quality
Avoid the presence of tramp neutralizing amines if at
all possible. Neutralizers introduced with the wash
water help to control overhead receiver pH but do not
Tramp amines
help control pH in the first condensing drops of acid in
the overhead, if condensation occurs upstream of the
water wash.
For Crude unit: Preferred location is immediately
Should be based on dew
downstream of the second elbow after the crude
Injection location point location/deposit
column if the outlet pipe is installed at the top of the
forming location
crude column.
Target is to maintain at least 25% of the injected water
in the liquid phase after injection, so that solids may be
5 % volume of overhead washed through the system and the condensing
Injection rate
naphtha hydrochloric acid diluted. This water wash rate may
not be achievable with undersized or poorly designed
overhead receivers.
Page 42 of 58

Accurate measurement and control of wash water flow
Measurement and is essential especially in locations where on water feed
control is used to supply different parts of the system, such as
the overhead and the fin fans.
Spraying Systems Company, Wheaton, Illinois,
(www.spray.com) “Whirljet-CX” design, standard
Nozzle design
hollow cone nozzle has been used in some Aramco
refineries.
Co-current with the process Orient spray nozzle to spray downward along center
Nozzle orientation
stream flow. line of vapor line
Corrosion resistant alloys such as Hastelloy C-276 or
Inconel 625 are the materials of choice for this service
Hastelloy C-276, Inconel but only available in batches of 25 or more from the
Nozzle metallurgy
625 manufacturer. SS 316L and 316F have been used as
a less desirable alternative in crude unit overhead
systems. Rabigh Refinery uses alloy 600.
12.5 Chloride Injection
There are differences in operation between semi-regenerative and continuous

catalytic reformers. The differences are related to the amount of chloride
injected, to replace chloride lost from the catalyst during the run and maintain
catalyst activity, and whether the chloride is injected continuously.
Old reformer units use fixed bed reactors in series. Typically, four reactor beds
are used in a cascade arrangement. These units are referred to as semi-
regenerative catalytic reformers. Removing one bed at a time from service and
physically opening the reactor and removing and replacing the catalyst achieve
regeneration of this type of process.
Continuous Catalyst Regeneration (CCR) platforming is another catalytic

reforming process which is operated fairly dry to minimize stripping chlorides
from the catalyst and forming hydrochloric acid that is very corrosive. In CCR,
the catalyst is continuously withdrawn from the reactor then regenerated,
activated and fed back to the stacked reactor bed.
The chloride content of the catalyst must be kept in the range that is provided by
the catalyst supplier to maintain good catalyst activity and selectivity. To
maintain chloride on the catalyst at an optimum level as per catalyst supplier
recommendations (determined by catalyst sampling), and a moisture level in the
recycle gas (determined by on line recycle gas moisture analyzers), it is
necessary to continuously inject a solution of chloride, methanol, and reformate
as a dilution agent. The injection rate of each chemical required is expressed as
ppm wt% of material active ingredient based on the unit feed rate.
Page 43 of 58
12.5.1 Design Basis
The injection quill and as much of the related piping and valves as
possible have often been fabricated from Inconel 600 (UNS N06600),
which has sufficient nickel content to make it immune to chloride
stress corrosion cracking.
12.5.2 Injection locations

● Fixed Bed Naphtha Reforming Units (Semi-Regenerative
Catalytic Reformers)
In Semi-Regenerative Catalytic Reformers, solution of chloride is

injected continuously ahead of the reactors to replace chloride lost
from the catalyst during the run and maintain catalyst activity.
Sometimes methanol is added to maintain minimum water in the
recycle gas. Catalyst life is improved if a small amount of water is
present but not enough water to wash chlorides off the catalyst.
● Continuous Catalyst Regeneration (CCR) Platformer
In the CCR Platformer, solution of chloride is injected in the

platformer feed line. Chloride is also injected to CCR regenerator
in chlorination zone to keep the proper activity of the platformer
catalyst base function. The injection of chloride, from the chloride
storage tank, serves both platformer startup and CCR normal
operation.
12.5.3 Requirements for Chloride Injection System
Table-7 summarizes the chloride injection requirements. Refinery

must have current as-built quill detailed design drawings which also
specify the quill materials of construction. These drawings should be
up-to-date and signed-off.
Page 44 of 58
Table 7 - Chloride Injection Requirements

Ahead of the reactors in semi-
regenerative catalytic The chloride is continuously injected
reformers
In the platformer feed line of
The chloride is continuously injected
the first heater
Injection location The chloride is continuously injected to avoid any
Downstream from the heaters
possible buildup of chloride in the heater tubes
In the chlorination zone of The chloride is continuously injected to keep the
CCR regeneration tower proper activity of the platformer catalyst base function
Between the CCR Combined
The chloride is intermittently injected during start-up.
Feed Exchangers
The injection nozzle for chloride solution should be
Nozzle insertion Inject centerline of the pipe extended to the centerline of the pipe to assure proper
mixing and to protect against localized corrosion.
Stainless Steel 316L shall not be used for this service
since this alloy has been very susceptible to chloride
Nozzle metallurgy Alloy 600 (Inconel 600) stress corrosion cracking. Alloy 600 (Inconel 600) has
sufficient nickel content to make it immune to chloride
stress corrosion cracking.
12.6 Antifoulant Injection
Fouling deposits can degrade the operation of refinery process units in several
ways: restricting fluid flow, reducing heat transfer rates, shortening service life,
and compromising product quality. While fouling can be found throughout the
refinery, the most common problem area includes Condensate Fractionation Unit.
Fouling deposits can consist of inorganic materials, such as iron sulfide

corrosion by-products, and organic materials, such as agglomerated asphaltenes,
thermally degraded polymer, and coke. Deposits often contain a complex
mixture of organic and inorganic materials.
An antifoulant is a chemical additive which may be injected into a process

stream at low concentration to prevent the buildup of deposits on downstream
tube/shell exchangers. Because of the variety of complex mechanisms which
contribute to an overall fouling problem, no single balanced formulation is
effective for all fouling cases. Consequently, each fouling problem is highly
individual and dependent on many variables such as experience on similar
operating units, unit history, stream characterization, deposit analysis, and/or
laboratory screening. The use of antifoulants is often a matter of
experimentation to establish which compound is most effective. Then, the
success of an antifoulant application depends largely upon properly selecting the
Page 45 of 58
right antifoulant for the fouling problem at hand and determining what dosage
level is required to maintain fouling control.
12.6.1 Design Basis
The injection quill should be made out of 316L stainless pipe.
Common applications of antifoulants have included preheat exchangers

and furnaces in desalted crude, atmospheric bottoms, coker feed, or
hydroprocessing unit services. Treatment of FCCU slurry circuits, fuel
gas lines, pyrolysis gasoline, coker and FCCU light ends, and lube
extraction solvents has sometimes been performed depending on plant
operations.
12.6.3 Requirements for Antifoulant Injection System
The detailed design of the antifoulant injection system is shown in the

Library Drawing # DB-950175. Table-8 summarizes the antifoulant
Table 8 - Antifoulants Injection Requirements

Initial feed rate should be
determined by experience with
similar situations or laboratory
testing.
For example: 10 ppm of Nalco Thermogain EC3019A
Ongoing feed rates and chemical (Heavy aromatic Naphtha, Naphthalene) was
Injection rate performance verification found to be optimum injection rate for Condensate
should be determined by Fractionation Unit.
monitoring heat transfer
coefficients or fouling factors
across critical heat transfer
equipment.
Preheat exchangers and
furnaces in desalted crude, For example: downstream of condensate preflash
Injection location atmospheric bottoms, coker drum at condensate fractionation unit at Ras Tanura
feed, hydroprocessing unit Refinery.
services.
Overall heat transfer coefficient and pressure drop can
Fouling measurement
be used as values in quantitative evaluation of heat
and control
exchanger fouling.
Page 46 of 58

Retractable Mandatory. Allows maintenance on-stream.
Preferred to inject in the center of the stream to ensure
even distribution away from pipe walls. In large
Inject in center 1/3 of the systems it may be impossible to obtain a quill that can
Quill design stream be retractable, i.e., removed on-line and meet this
criteria. In this case, the minimum insertion into the
pipe flow must be no less than 6 inches.
Co-current with the process The quill shall be installed in the pipe so that the hole
Quill orientation
stream flow of the quill faces the fluid downstream.
the injection nozzle should be
Quill metallurgy made out of 316L stainless
pipe
13 Upstream Facilities and Gas Plants Chemical Injection
Management of corrosion, scale formation, oxygen content and microbial populations,

are essential in oil and gas production and processing systems. In addition, demulsifier
chemical is used in the GOSPs to assist in water-oil emulsion breaking/separation. The
injection of the inhibitor is a standard practice to control internal corrosion and scale
build-up in carbon steel equipment and piping. This strategy has been shown to be very
successful and cost effective.
13.1 Design Basis
Standard two-inch high pressure access fittings and injection quills are
commonly used in GOSPs, oil & gas processing facility and gas plants for
injecting typical oilfield treatment chemicals. High pressure access fittings are
designed to permit safe, relatively easy insertion and retrieval of injection quills
as well as other devices (such as coupons or monitoring equipment) while under
full operating pressure.
This type of injection quill can be removed for cleaning while system is under
pressure. The injection components, other than the access fitting body, shall be
made out of 316L stainless steel or better and shall be suitable for sour service
and meet the requirement of SAES-A-301, if injection is required into a sour
service process.
Access fittings for injection must be installed in straight run pipe. The fitting
must not be installed closer than a minimum of two pipe diameters downstream
of a bend, valve or reducer and there must be a minimum run of 5D of straight
Page 47 of 58
pipe downstream of the fitting before a bend, reducer, etc. When more than one
access fitting is installed in one location, the fittings must be separated by a
minimum three (3) feet. In order to operate the retriever, a minimum of twelve
(12) inches clearance is required around the access fitting body and a minimum
of eight (8) feet is required above or to the side of the pipe for top and side
mounted fittings, respectively.
Check valves are required immediately upstream of the shut-off valve at the
fitting. The shut-off valve should be 316L stainless steel and after installation
onto the nipple must be seal welded in accordance to Saudi Aramco welding
procedures. Positive shut-off valve required such as gate, needle or ball.
Short nipples and shutoff valves must be rated for sour service and they should
be identifiable (grade and rating) as per SAES-L-105, Section 5. All valves
installation and seal welding should be as per SAES-L-110, Section 8.
If a chemical injection fitting is not in service, the solid plug, injection nut and
quill shall be extracted, the quill must be removed from the injection nut and a
solid stainless steel pipe plug installed in its place. This prevents service fluid
from migrating up the quill through the hollow injection nut and contacting and
possible corroding the threaded nipple installed in the access fitting body tee.
Prior to re-installing the plugged injection assembly into the access fitting the
upper and lower O rings shall be replaced.
13.2 Injection Locations
The following is a list of some of the chemical types and their typical injection
locations in upstream facilities and Gas Plants:
♦ Corrosion Inhibitor
• GOSP production/test header
• Trunk lines/flow lines with high water cut
• GOSP Wasia wash water line
• GOSP LPPT/IPPT/HPPT gas compressor discharge lines
• GOSP dry gas line to NGL
• GOSP disposal water header
• GOSP wash water supply
• GOSP fire water supply
• Disposal water line in the 3-Phase Separators
(Plant 429 of Abqaiq Plants)
• Gas out line from De-Ethanizer to Gas Plant
(Plant R-57 of Abqaiq Plants)
Page 48 of 58
• Suction line of the inter-stage/after coolers in NGL Plant

(All NGL Plants in Abqaiq Plants)
• Off-gas from the De-Ethanizer reflux drum to Gas Plant
• Off-gas from the De-Ethanizer surge drum to condenser
• Off-gas from stripper feed drum to De-Ethanizer or Gas Plant
• NGL line (QA-10) to Ras Tanurah Refinery (Plant 462 of Abqaiq Plants)
• Total off-gas line to De-Ethanizer feed chiller
• Suction line of stripper overhead cooler (Plant 499 of Abqaiq Plants)
• Overhead gas line (Plant 334 of Abqaiq Plants)
• Discharge of condensate shipper pump (Gas Plants)
• Downstream of the gas wellhead christmas tree (Gas Plants)
• Ethane “C2” injection well
(only during the reproduction in some of the Gas Plants)
• Sour/Sweet wet gas flowlines
♦ Scale Inhibitor
• GOSP production/test header
• GOSP disposal water header
• IPPT/HPPT crude oil out stream in some GOSPs
• Discharge of Condensate Shipper Pump (Gas Plants)
♦ Oxygen Scavenger
♦ Biocide Injection
♦ Demulsifier Injection
• Production Manifold
Page 49 of 58
• GOSP test header

• Dehydrator/Desalter inlet
• Upstream of 3-Phase Separators (Plant 429 of Abqaiq Plants)
13.3 Requirements for Chemical Injection System in Upstream Facilities and

Gas Plants
The typical design of the chemical injection point is shown in the library
drawing DA-950035 “2-Inch high Pressure Access System Chemical Injection
and Corrosion Monitoring”. The following table summarizes the chemical
injection requirements in upstream facilities and Gas Plants.
Table 9 - Chemical Injection Requirements

Variable/Location Target or Limit Comments
Injection rate As communicated by the Area Corrosion Engineer
install in straight run pipe
The fitting must not be
installed closer than a
minimum of two pipe
diameters downstream of a
bend, valve or reducer
there must be a minimum run
of 5D of straight pipe
downstream of the fitting
before a bend, reducer, etc.
Access fitting design
the fittings must be separated This is required when more than one access fitting is
by a minimum three (3) feet installed in one location
A minimum of twelve (12)
inches radial clearance is
required around the access
fitting body and a minimum of
This is required in order to operate the retriever
eight (8) feet is required above
or to the side of the pipe for
top and side mounted fittings,
respectively.
The style of the injection quill
should have a scarf cut instead
of a plain open end
The recommended injection location is the center of
Inject in center 1/3 of the the pipe to ensure even distribution away from pipe
stream walls and for more homogeneous mix to take place in
Quill design the pipe.
12 o’clock position
Page 50 of 58
Variable/Location Target or Limit Comments

For liquid-phase stream, the
quill should be installed in the
To insure proper positioning of the quill cut in the pipe,
pipe so that the angled face of
the solid plug should be permanently marked to show
the quill faces the fluid
orientation. One of the recommended field practices is
Quill orientation downstream. While for mixed
to permanently mark the long side of the quill with a
and vapor phase stream, the
straight line using a file, small hacksaw cut or
angled face of the quill should
waterproof paint marker.
face the fluid upstream as
shown in Figure 6 & 7.
The injection quill should be
made out of 316L stainless The quill material should be suitable for sour service
Quill metallurgy material. Pipe and not tubing and meet the requirement of SAES-A-301, if injection
shall be used to fabricate the is required into a sour service process.
quill.
14 Steam Generator Chemical Injection
Chemical treatment of water inside the steam generators is necessary to prevent scaling
and corrosion in the steam generator and its associated condensate system.
Scaling in steam generators is caused by impurities being precipitated out of the water
directly on heat transfer surfaces or by suspended matter in water settling out on the
metal and becoming hard and adherent. Scaling in steam generators will result in
excessive fuel consumption due to loss of heat transfer and may also cause localized
overheating. This can lead to tube failure. The first preventative measure for scaling is
to supply good quality water as make–up feed water.
Feed water also contains dissolved gases such as oxygen or carbon dioxide. These
gases in the presence of water and metal can cause corrosion. Oxygen attack is one of
the most common causes of corrosion inside steam generators. Oxygen attack can
cause damage to economizers, steam drums, mud drums, boiler headers and condensate
piping. A deaerator removes most of the oxygen in feed water; however, trace amounts
are still present and can cause corrosion-related problems. Oxygen scavengers are
added to the feed water, preferably in the deaerator storage section, to react with the
trace amounts of oxygen not removed by the deaerator.
Corrosion can also occur from excessive alkalinity of excessive pH of the boiler water.
This caustic attack is most likely to occur under scale or deposits, where very high local
concentrations of hydroxide can build or in zones where insufficient cooling.
Neutralizing Amines are high pH chemicals that intended to react with trace levels of
carbon dioxide in the condensate system. Being alkaline, neutralizing amines also raise
the pH in the condensate system, which aids in reducing corrosion rates.
Page 51 of 58
14.1 Design Basis
Refer to section 13.1 and table 9 for complete design requirements of the steam
generator chemical injection point. Chemicals used in steam generator systems
are best injected neat, to avoid batch preparation errors and to minimize the size
of the dosing pumps. Most water treatment vendors supply chemicals in semi-
bulk tanks of 1000 liter capacity. The use of semi-bulk tanks avoids the need for
day tanks. For more information on boiler water treatment refer to COE-202.02
in the engineering encyclopedia under corrosion/industrial water treatment.
There will be separate best practices for utility cooling towers and desalination
units.
14.2 Injection Locations
The optimum injection locations are indicated in Figure 11.
Figure 11 - Optimum Injection Points for Steam Generator Chemicals
15 Chemical Dosage Control
Chemical injection system requires continual operator attention to make sure that the
correct dosage rate is being injected in the system. Adjustments to the volume of
chemical injected should be made to maintain the dosage rate set point. The operator
should visually check the condition of the chemical pumps, tanks and piping in a daily
basis. Maintaining the optimum chemical dosage to process streams and monitoring the
effect on corrosion rates are extremely important in corrosion control. Failure to do so
Page 52 of 58
would result in surprises and unplanned equipment failures. Plant operators should
check the chemical injection rates twice per shift.
Frequent field visits and spot-checks should be conducted by the Area Corrosion
Engineer to ensure strict adherence to the chemical injection procedures. The intent of
the spot checks is to bring to the attention of the operations organizations the
deficiencies in the chemical dosage rates, chemical injection pumps, type of chemicals
used and similar issues.
Monthly status reports should be issued by the area Corrosion Engineer and sent to the
Operations Foreman, highlighting the monthly spot check deficiencies noted and the
required course of action. Tracking of chemical consumption and adherence to
established injection targets is an Operations responsibility. Operations staff should
highlight the deficiencies up through their organization on a daily basis. Follow-up
visits by the Corrosion Engineer should be made to observe the implementation of
recommendations. In addition to the periodic reports, more formal chemical injection
system review meetings and audits are recommended to be conducted regularly. The
frequency of review meetings and audits depends on the corrosivity and history of the
plant piping and equipment system, and has to be determined for each specific case and
chemical.
The success of the effective chemical injection program ultimately revolves around the
ability of operations personnel, process and corrosion engineers to interact and
effectively communicating targets, objectives, and problems.
Strict adherence to this procedure allows the plant operations staff to reliably and
accurately optimize the chemical injection rate. This level of chemical dosage control
can significantly reduce the need for maintenance, lower the risk of unexpected failure
and further reduce operation and maintenance costs by assuring adequate dosage of the
chemical is injected in the plant piping and equipment.
16 Chemical Injection Effectiveness
The most important aspect of the chemical obviously is its performance and effectiveness.
Therefore, regular corrosion monitoring to obtain trended data are the only means to
ensure that chemical injection is effective. Inspection is also used periodically to ensure
the integrity of plant piping and equipment. The monitoring and recording of all available
parameters, including flow rates, and chemical consumption, is required to ensure that the
chemical treatment program is operated and managed correctly.
Corrosion monitoring is used to confirm that inhibition is actually controlling the

corrosion to an acceptable rate. Monitoring can:
• Detect of compliance conditions
Page 53 of 58
• Provide plant operators with sufficient reaction time to implement remedial actions
such as:
Repair of injection equipment
Change of operating procedures
Change of chemical dosage rate
The following data should be collected to assist in system performance evaluation:

• Corrosion monitoring data such as:
Iron counts (regular chemical analysis to provide trends)
Corrosion coupons
On-line monitoring probes
• Chemical injection data
• Inhibitor residuals
• Process Parameters (in-direct measure of corrosion) such as:
Flow rate
Fluid chemistry
Water cut
Temperature
Pressure
pH
Gas composition
• System upsets
• Chemical cost
• Maintenance record
• Inspection data including but not limited to:
Periodic ultrasonic surveys
RT
MPI
LPI
Instrument scraping runs for pipelines
Reliance on data from a single corrosion monitoring method is not recommended. The
aim should be to use data from at least two types of technique to obtain consistent
information; for example, on-line corrosion monitoring, weight loss coupons, and iron
Page 54 of 58
counts. Appropriate sampling equipment location is also crucial for the determination
of the system corosivity.
Data from the monitoring activities outlined above should be gathered together and
correlated with relevant process data and other information. The trended data should
enable out-of-compliance conditions to be detected and for the appropriate corrective
actions to be taken or for repairs to be completed before the operation or integrity is
compromised. The main goal of overall process system condition monitoring, should
be to detect out of compliance conditions very early after their occurrence and to correct
the condition and return the system to compliance before there would be enough
damage to the system to warrant repair.
17 Strategies for Chemical Optimization
Regular monitoring and adjustments are typically needed to optimize the performance
of the costly chemicals due to operational conditions changes. The chemical
optimization activity concentrates on injecting the correct amount of treatment chemical
into a system or specific piece of equipment under the current process conditions, to
achieve the result anticipated from the application of the chemical. The chemical
requirement is driven by factors such as water cut, water volume, flow regime, and
condition of the equipment. However, the ultimate measure of whether or not enough
chemical is used can only be determined by consideration of other factors such as
corrosion monitoring data and/or the amount of active corrosion detected by the OSI
program, results of inspections during T&Is and process variables changes. The
correlation between the inspection data and the corrosion monitoring data allows the
corrosion monitoring data to be interpreted with better confidence to manage the
chemical injection program in an efficient manner.
Information from corrosion monitoring and inspection activities should be collated and
gathered together to help in the chemical optimization. This information should also
include relevant process conditions and chemical inhibition data. Typically the data
gathered should include:
• Process conditions, highlighting any changes.
• Visual observations.
• Corrosion monitoring data.
Weight loss coupons.
Electrical Resistance (ER) probes.
Linear polarization resistance (LPR) probes
• Inspection data covering
Ultrasonic inspection data (OSI data)
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Radiographic (X-ray) inspection data

T&Is inspection reports
Leak History
Instrument scraping results for pipelines
• Corrosion and failure analysis reports
Not all inspection and monitoring systems are required/applicable for any particular
facility and their use will be dependent on the type of corrosion process/material
damage that is anticipated. It is not intended that this Best Practice document provides
a detailed description of the different techniques which can be found elsewhere.
The usual monitoring tools for chemical optimization are corrosion coupons, Linear
Polarization Resistance (LPR), electrical resistance (ER) probes and iron counts.
Weight loss coupons provide a check on LPR and ER results and identify the onset of
pitting but do not usually give specific information about weld corrosion. The probes
are often installed on a side or top stream of the main production line, for measuring
corrosion rates. LPR measurement can provide a relatively faster response than ER
probes where both of them are used to detect general corrosion. The main difficulty
with this approach is that flow and corrosive conditions in the side or top stream can be
different from those in the main lines. This is particularly true in the case of localized
corrosion. The localized corrosion can be as crevice or pitting caused by water
accumulation at the bottom of the line. In addition, the duration of the chemical
injection optimization study is often not long enough to ensure that stable corrosion
conditions have been established.
Chemical optimization requires faster methods so on-line corrosion monitoring should

be utilized to aid the plant engineers and operators in optimizing the corrosion inhibitor
required. On-line corrosion monitoring will allow the operators to vary the injection
rates of chemicals as flow conditions fluctuate. The corrosion rate can be monitored
hourly as the chemical inhibition levels varied and a maximum allowable corrosion rate
can be set and acted upon by the operators. Moreover, On-line corrosion monitoring
permits the operators to have a closer look at the corrosion characteristics of the plant
piping, and to determine the extent of temporary corrosion protection afforded by the
residual corrosion inhibitor after the chemical inhibition pumps are switched off.
Lab analysis for the process should be taken periodically to lead for good monitoring
and chemical optimization as well as protection the system.
Chemical optimization study should be run over an extended period of weeks/months.

The optimization study results should be promptly evaluated. This should be a joint
activity with the lead taken by the Corrosion Engineer assisted by the Process Engineer,
inspection personnel and vendor's experts.
Page 56 of 58
Records of injection dosage compared to site deliveries, storage and purchase

information can often reveal discrepancies and identify causes of poor performance.
18 Quality Control of Chemicals
Chemical injection inhibitors are typically not pure chemicals. Many of the ingredients
that are used for the formulation of these chemicals are side stream products having
some degree of variation from batch to batch. These chemicals undergo a multitude of
laboratory and field tests before they can be injected in the operating units.
SAES-A-205 “Oilfield Chemicals” and SAES-A-208 “Water Treatment Chemicals”

establish requirements for selection, quality assurance, quality control, and first-fill
purchase of oilfield and water treatment chemicals. The purpose of these standards is to
implement a program that results in the cost-effective purchase and performance of
oilfield and water treatment chemicals.
19 Contributing Authors
Name Department
Ahmed M. Al-Zahrani Consulting Services Department
Ahmad S. Al-Omari Consulting Services Department
The authors of this document would like to thank all of those who contributed to
produce this Best Practice and special thanks go to:
Name Department
Robin D. Tems Consulting Services Department
Brian W. Burgess N. A. Producing Engineering Department
Graham R. Lobley Consulting Services Department
Revision Summary
1 July 2007 New Saudi Aramco Best Practice.
Page 57 of 58
Appendix A
INSPECTION UNIT
Chemical Injection Point Datasheet
(Injection Point Number: Title)
1. Receiving Stream Description

Unit Description
Line Number P & ID No.
Receiving Stream Phase G L G/L Line Size (inch)/Schedule
Line Metallurgy Operating Temperature (°F)
Operating Pressure (psi) Corrosion Rate (mpy)
Upstream Equipment Downstream Equipment
Flow Rate (BPD or MMSCF/D) Normal:______________ Min:________________ Max: ____________ Optimum:___________
2. Injection Stream Description
Injection Phase G L G/L Line Size (inch)/Schedule
Line Metallurgy Operating Temperature (°F)
Operating Pressure (psi) Corrosion Rate (mpy)
Injection Rate (GPD) Normal:______________ Min:________________ Max: ____________ Optimum:___________
Type of Injection Continuous Intermittent (Frequency:_____________________ )
Back Flow Prevention Check valve Other (Specify:____________________________ )
3. Injection Hardware
Injection Point Type 45o Bevel Quill Spray Nozzle Normal elbow Small Circular Hole
Injection Origin (From) Top Bottom Side of Horizontal Pipe Side of Vertical Pipe
Direction of Injection Injection Face the Fluid Upstream Injection Face the Fluid Downstream
Injection Tube Metallurgy
Flow Measurement System Flow Control System
Name of Vender (if any)
Nearest Pipe Change is Bend Tee Reducer Orifice Other (Specify:_______________ )
Distance
4. Chemical Data
Generic Description
Injection Purpose
Supplier
Product Name
Injection Start Date
(m/d//yr)
5. Injection Point Inspection
Isometric Sketch No.
Inspection Interval
Inspection Technique
Last Inspection Date
Next Inspection Date
6. Note: Attach any available information/sketch/P&ID related to this injection point.
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Best Practice

SABP-A-015 1 July 2007

Saudi Aramco DeskTop Standards

Previous Issue: New Next Planned Update: TBD

Corrosion Technology Unit of Consulting Services Department has developed

1.3 Conflicts with Mandatory Standards

Saudi Aramco assumes no responsibility or liability whatsoever for any reliance

2.1 Saudi Aramco References

Saudi Aramco Engineering Procedure

Saudi Aramco Engineering Standards

Saudi Aramco Materials System Specifications

Saudi Aramco Library Drawings

Saudi Aramco Best Practice

Saudi Aramco Engineering Reports

Saudi Aramco Inspection Procedures

2.2 Industry Codes and Standards

American Petroleum Institute

American Society of Mechanical Engineers

Manufacturers Standardization Society of the Valve and Fittings Industry, Inc.

2.3 Other References

Nalco Best Practices

Chevron Best Practices

3 Definitions and Abbreviations

Be°: Baumé is a scale used to measure the density of various liquids.

Catalyst: A material that aids or promotes a chemical reaction between other

CCR: Continuous Catalyst Regeneration

CHB: Chemical Hazard Bulletin. CHB is an internal company document (available in

CRA: Corrosion Resistant Alloy

ER: Electrical Resistance

Fouling: Accumulation of deposits in condensers, exchangers, etc.

GOSP: Gas Oil Separation Plant

HPPT: High Pressure Production Trap

IPPT: Intermediate Pressure Production Trap

LPPT: Low Pressure Production Trap

LPR: Linear Polarization Resistance

LPI: Liquid Penetrant Inspection

MSDS: Material Safety Datasheet. MSDS is a document containing information on

MPI: Magnetic Particle Inspection

NGL: Natural Gas Liquids

OSI: On-Stream Inspection

PMI: Positive Material Identification

PWHT: Post-Weld Heat Treatment

QA/QC: Quality Assurance/Quality Control

RSS Report: Refinery Shift Superintendent Report

RT: Radiography Test

SARCOP: Saudi Aramco Refining Chemical Optimization Program

T&I: Test & Inspection

TDS: Total Dissolved Solids

RVL: Restricted Vendor List, generated by Saudi Aramco

“Typical” or “Target”: indicate desirable but not mandatory items

“Limit,” “Required,” “Shall,” and “Must”: indicate mandatory items

4 Chemical Injection Overview

Chemical injection philosophy depends primarily on the fluid composition, fluid

Chemical injection systems are an invaluable component of corrosion control systems

Figure 1 - Retrievable Type Injection System

Figure 2 - Retractable Type Injection System

Figure 3 - Fixed Type Injection System

Table-1 summarizes the configurations of chemical injection and their applications.

Table 1 - Injection System Styles

Configuration Pressure Range Facility

5 Chemical Injection System Design

A typical chemical injection system (Figure 4) should consist of a chemical supply

Figure 4 illustrates a diagrammatic view of the main components of the chemical