Project N° Unit Document Code Serial N° Rev.

Page
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SCOP – IRAQ (Contract n° 2171)
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for

Study Report

On-Line Corrosion Monitoring Study

which it is specifically furnished or outside the extent of the agreed upon right of use.

0 15/09/2010 ISSUE FOR FEED M.E. RENELLA F. CIFA’ C. PASCALI / O. LOIACONO

REV. DATE STATUS WRITTEN BY CHECKED BY APPROV./AUTHOR. BY

(name & visa) (name & visa) (name & visa)
DOCUMENT REVISIONS

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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KARBALA REFINERY FEED PROJECT

SCOP – IRAQ (Contract n° 2171)
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for

1 SCOPE 3

2 ONLINE CORROSION MONITORING PHILOSOPHY 4

2.1 Corrosion coupons monitoring 4

2.2 Electrical resistance probes 5

2.3 Probes selection 5

3 MONITORING SUMMARY TABLE AND LOCATIONS 6

4 COUPON PREPARATION 10

5 PROCEDURE FOR FIELD HANDLING OF COUPONS BEFORE AND AFTER

EXPOSURE 11

5.1 Laboratory analysis 11

5.2 Typical Corrosion Coupon Report 12

6 REFENCE DOCUMENTS AND LIST OF ATTACHMENTS: 13

6.1 Reference Documents 13

6.2 List of attachments 13

which it is specifically furnished or outside the extent of the agreed upon right of use.

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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KARBALA REFINERY FEED PROJECT

SCOP – IRAQ (Contract n° 2171)
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for

1 SCOPE

The Corrosion monitoring study presents the recommendations for the online corrosion monitoring
for KARBALA REFINERY FEED PROJECT.
It includes description of the applied techniques and corrosion monitoring locations.
Results of this study to be implemented in the design in the EPC phase.
which it is specifically furnished or outside the extent of the agreed upon right of use.

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

 Project N° Unit Document Code Serial N° Rev. Page
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KARBALA REFINERY FEED PROJECT

SCOP – IRAQ (Contract n° 2171)
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for

2 ONLINE CORROSION MONITORING PHILOSOPHY

On-line monitoring refers to a special group of measurement techniques which are suitable for use
while the facility is in operation.
Contractor shall developed a comprehensive corrosion control program which includes several
techniques since no single technique is capable of providing all the information necessary to
assess completely all the ongoing degradation mechanisms.
Below is presented an overview of the online corrosion measurement techniques selected for the
KARBALA REFINERY FEED PROJECT.

2.1 Corrosion coupons monitoring

Coupons are the oldest and simplest device used in the monitoring of corrosion. Coupons are
small pieces of metal, usually of a rectangular or circular shape, which are inserted in the process
stream and removed after a period of time for study.
The most common and basic use of coupons is to determine average corrosion rate over the
period of exposure. This is accomplished by weighing the coupon before and after exposure
(coupons must first be cleaned following exposure to remove corrosion products and any other
deposits) and determining the weight loss. The average corrosion rate can easily be calculated
from the weight loss, the initial surface area of the coupon and the time exposed. It is advisable to
leave a coupon exposed for at least 30 days to obtain valid corrosion rate information.
There are two reasons for this recommended practice. First, a clean coupon generally corrodes
much faster than one which has reached equilibrium with its environment. This will cause a higher
corrosion rate to be reported in a short test than is actually being experienced on the pipe or
vessel.
Second, there is an unavoidable potential for error as a result of the cleaning operation. Coupon
cleaning procedures are designed to remove all of the deposits without disturbing the remaining
uncorroded metal of the coupon. A small amount of the underlying metal is often removed with the
deposits, however, and if the actual metal loss from corrosion is small (as would be the case in a
short test) the effect of metal removed during cleaning would create a significant error. Care must
be taken to correct for this effect. It should be recognized that a coupon can only provide corrosion
rate data based on the total weight loss divided by the total time of exposure.
One of the most important roles of coupons is to provide information about the type of corrosion.
Unlike electrical resistance probes, which only detect the amount of metal removed, coupons can
be examined for evidence of pitting and other localized forms of attack that may arise in the
which it is specifically furnished or outside the extent of the agreed upon right of use.

monitoring location.
Coupons indicate the attack of the environment only at the point of exposure; for this reason the
coupon (as the electrical resistance probe) are installed at representative locations as close as
possible to critical points where corrosion measurements is considered relevant for the plant
service life (e.g. such as vessel or pipe walls, tube sheets, trays, etc.).
Anyway, conditions of flow, temperature, concentration, etc., may change considerably only a few
inches away from any given location, with resulting differences in corrosion rates. Coupons
suspended in the center of a pipeline or vessel may corrode at different rates than coupons
suspended near the wall of the vessel or pipe, for example. Since corrosive conditions can change
significantly from one location to another, coupon data is best used for relative comparisons
(changes in the rate or characteristics of corrosion over time at a single point) and to obtain an
approximate corrosion rate at a particular point in the system rather than to precisely calculate the
corrosion rate.

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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KARBALA REFINERY FEED PROJECT

SCOP – IRAQ (Contract n° 2171)
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for

2.2 Electrical resistance probes

Electrical Resistance probes and instruments are basically "automatic coupons" and share many
characteristics with coupons, as discussed above, when it comes to advantages and limitations.
Electrical resistance systems work by measuring the electrical resistance of a thin metal probe. As
corrosion causes metal to be removed from the probe, its resistance increases. The major
advantage of the electrical resistance method compared to coupons is that measurements can be
obtained on a far more frequent basis and require much less effort to make. With automated
systems, continuous readings are in fact made and sophisticated data analysis techniques are
now available which permit the detection of significant changes in corrosion rate in just a few
hours.

2.3 Probes selection

In the electric resistance probe wire loop and tube loop elements do have a tendency to be
electrically shorted by a bridge of iron sulphide corrosion product. This is especially prevalent in
low-velocity streams over an extended period. The effect of such bridging is to reduce the
measured metal loss of the probe, creating a misleadingly low corrosion rate. Cylindrical probes
demonstrate more resistance to iron-sulphide bridging due to their construction and lower inherent
which it is specifically furnished or outside the extent of the agreed upon right of use.

resistance per unit length, thus minimizing the effect of the shunt resistance.
In KARBALA REFINERY FEED PROJECT substantial FexSy deposition are expected to be
problems in main of the prevented probes and therefore particular attention should be paid on
probe design and selection.
Cylindrical probes are recommended over other types because they are less sensitive to sulphide
scale bridging; in particular, for electric resistance probe, Rohorback Cosasco Microcorr ® type or
equivalent is recommended.

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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KARBALA REFINERY FEED PROJECT

SCOP – IRAQ (Contract n° 2171)
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for

3 MONITORING SUMMARY TABLE AND LOCATIONS

A corrosion monitoring system is developed to measure the general corrosion development and
the efficacy and efficiency of the corrosion inhibitors and water washing (if any).

The summary table presents the recommended monitoring locations and the corrosion monitoring
type (coupons and/or probes).

- CC : Corrosion Coupon
- CM: Corrosion Probe (Electric Resistance)

Corrosion Monitoring type, number and locations shall be finalized during Detailed Engineering
Phase.

Unit Location* Type and

Progressive Number
01-T-001 downstream after
CC1
chemical injection
01-E-003 downstream CM1
01-E-003 downstream CC2
01-EA-004 downstream CM2
01-EA-004 downstream CC3
01 Crude and Vacuum
01-V-005 downstream CM3
Distillation Unit
01-V-005 downstream CC4
01-T-051 downstream after
CC5
chemical injection
01-PK-051 downstream CC6
01-V-051 downstream CC7
01-V-051 downstream CM4
*Reference to 2342-AA01-MSD-0011-001_0 pages from 1 to 7

Unit Location* Type and

Progressive Number
02-EA-002 downstream CC1
which it is specifically furnished or outside the extent of the agreed upon right of use.

02-EA-002 downstream CM1

02-V-003 downstream CC2
02-T-001 downstream after
02 Naphtha Hydrotreating Unit CC3
injection
02-EA-003 downstream CM2
02-EA-003 downstream CC4
02-V-005 downstream CC5
*Reference to 954085-115-msd-rev-01 marked up pages from 1 to 3 (see attachments)

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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KARBALA REFINERY FEED PROJECT

SCOP – IRAQ (Contract n° 2171)
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for

Unit Location* Type and

Progressive Number
05-EA-001 downstream CC1
05-EA-001 downstream CM1
05-V-003 downstream CC2
05-V-004 downstream CM2
05 Kerosene 05-T-001 downstream after
CC3
Hydrodesulfurization Unit injection
05-EA-002 downstream CC4
05-EA-002 downstream CM3
05-V-005 downstream CC5
05-V-005 downstream CM4
*Reference to 03317-05-MMD_Rev_B marked up pages from 1 to 4 (see attachments)

Unit Location* Type and

Progressive Number
06-EA-001 downstream CC1
06-EA-001 downstream CM1
06-V-004 downstream CC2
06-T-002 downstream after
CC3
06 Diesel injection
Hydrodesulfurization Unit 06-EA-002 downstream CC4
06-EA-002 downstream CM2
06-V-007downstream CC5
06-V-007downstream CM3
06-E-007 downstream CM4
*Reference to 03317-06-MMD_Rev_B marked up pages from 1 to 5 (see attachments)

Unit Location* Type and

Progressive Number
07-E-008 downstream CC1
07-EA-003 downstream CC2
which it is specifically furnished or outside the extent of the agreed upon right of use.

07-EA-003 downstream CM1

07-V-005 downstream CC3
07-V-006 downstream CC4
07 VGO Hydrotreating Unit 07-V-006 downstream CM2
07-EA-005 downstream CC5
07-EA-005 downstream CM3
07-V-010 downstream CC6
07-V-010 downstream CM4
07-P-008 A/B downstream CM5
*Reference to 954088-115-msd-rev-00 marked up from pages 1 to 12 (see attachments)

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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KARBALA REFINERY FEED PROJECT

SCOP – IRAQ (Contract n° 2171)
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for

Unit Location* Type and

08 Fluid Catalytic Cracking
Unit
*Reference to 954213-115-msd-rev-00 marked up pages from 1 to 4 (see attachments)
*Reference to 954214-115-msd-rev-00 marked up pages from 1 to 5 (see attachments)
Progressive Number
main column reflux feed line CC1
main column reflux feed line CM1
08-T-201 downstream after
CC2
water injection
08-EA-201 downstream CC3
08-EA-201 downstream CM2
08-V-202 downstream CM3
08-K-301 downstream after
CM4
water injection
08-K-301 downstream after
CC4
water injection
08-E-302 downstream CC5
08-E-302 downstream CM5
08-V-303 downstream CM6
08-E-303 downstream CM7
08-E-304 downstream CM8
08-E-307 downstream CM9
08-E-316 A/B downstream CC6
08-E-316 A/B downstream CM10
08-V-306 downstream CM11

Unit Location* Type and

Progressive Number
16 Gas Sweetening and
Rich Amine inlet line CC1
Amine Regeneration Unit
*Reference to 2342-AA16-MSD-0011-001_0 from 1 to 5 pages
which it is specifically furnished or outside the extent of the agreed upon right of use.

Unit Location* Type and

Progressive Number
17-E-101 downstream CC1
17-T-101 downstream CC2
17-P-102 A/B downstream CC3
17-V-101 upstream CC4
17 Sour Water Stripper Unit
17-E-201 downstream CC5
17-T-201 downstream CC6
17-P-202 A/B downstream CC7
17-V-201 upstream CC8
*Reference to 2342-AA17-MSD-0011-001_0 pages from 1 to 4

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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KARBALA REFINERY FEED PROJECT

SCOP – IRAQ (Contract n° 2171)
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for

Unit Location* Type and

Progressive Number
30 Raw Water Treatment Unit 30-TK-009 A/B downstream CC1
*Reference to 2342-AA30-MSD-0011-001-01_1 marked up (see attachments)

Unit Location* Type and

Progressive Number
CC1 (coupon rack)
33 Cooling Water Unit Cooling Water Return
CM1 (LPR)
*Reference to 2342-AA33-MSD-0011-001-02-01_0

Unit Location* Type and

Progressive Number
60 River Water Intake Unit 60-TK-001 A/B downstream CC1
*Reference to 2342-AA60-MSD-0011-001-02-01_0 marked up (see attachments)

Unit Location* Type and

Progressive Number
18 Sulphur Recovery Unit - CC1-CC3
Number and location: HOLD
1st train CM1

Unit Location* Type and

Progressive Number
19 Sulphur Recovery Unit - CC1-CC3
Number and location: HOLD
2nd train CM1

Unit Location* Type and

Progressive Number
which it is specifically furnished or outside the extent of the agreed upon right of use.

20 Sulphur Recovery Unit CC1-CC4

Number and location: HOLD
common parts and TGT CM1-CM2

Nevertheless it should be pointed out that corrosion monitors measure corrosion events taking
place on their probes only.
The measurements should not be considered precise or exact replica of all corrosion of the plant.
Corrosion is not a property of a material that could be measured with precision; it is a process that
can vary between one location and another on the same surface.
Is extremely important, to perform ultrasonic thickness program to supplement the monitors.

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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KARBALA REFINERY FEED PROJECT

SCOP – IRAQ (Contract n° 2171)
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for

4 COUPON PREPARATION

A serial number shall be stamped or etched on each coupon.

Coupons may be prepared by grinding smooth with 120 grit paper, by tumbling with loose grit, or
blasting with abrasive blasting material. All abrasives should be free of metallic particles.

After the coupons have to be cleaned and handled by suitable means to prevent contamination of
the surface with oils, body salts, and other foreign materials. Clean, lint-free cotton gloves or
cloths, disposable plastic gloves, coated tongs, or coated tweezers should normally be used.

Under a ventilated hood, remove any residual oils with a hydrocarbon solvent such as xylene,
toluene, or 1,1,1 trichloroethane and rinse with anhydrous isopropyl alcohol. If oils are not present,
cleaning with alcohol or acetone should be sufficient.

Dry, measure, and weigh the coupons to within ±0.1 mg. Record the mass, serial number, and
exposed dimensions. Calculate the surface area (including the edges) and record. The areas
covered by the coupon holder and shielded areas of flush-mounted coupons must be excluded.

Prior to shipment, store the individually packaged coupons in a closed container with indicating
silica gel.
which it is specifically furnished or outside the extent of the agreed upon right of use.

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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KARBALA REFINERY FEED PROJECT

SCOP – IRAQ (Contract n° 2171)
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for

5 PROCEDURE FOR FIELD HANDLING OF COUPONS BEFORE AND AFTER EXPOSURE

Prior to coupon installation, record the following information: coupon serial number, installation
date, name of system, location of the coupon in the system (including fluid or vapour phase), and
orientation of the coupon and holder. (see a Typical Corrosion Coupon Report hereinafter
reported)

During installation, handle the coupon carefully to prevent contamination of the coupon surface.

When the coupon is removed, record the coupon serial number, removal date, observations of any
erosion or mechanical damage, and appearance of scale or corrosion product.
The coupon should be photographed immediately after removal, particularly if appearance of the
corrosion product or scale is important. Protect the coupon from contamination by oxidation and
handling. Place the coupon in a moisture-proof or special envelope impregnated with volatile
corrosion inhibitor and ship immediately to a laboratory for analysis. Do not coat the coupon with
grease or otherwise alter it. Gentle blotting with tissue paper or a clean soft cloth may be desirable
to remove moisture prior to shipment. Corrosion products or scale deposits should not be removed
in the field.

5.1 Laboratory analysis

Laboratory procedure for cleaning and weighing coupons after exposure should be realized in
accordance with the recommended practice NACE RP0775. The average corrosion rate, mass
loss, the deepest measured pit, the maximum pitting rate, the description of deposit before and
after cleaning(e.g., etch, pitting, erosion, etc.) and analysis of deposit should be reported in the
attached form
which it is specifically furnished or outside the extent of the agreed upon right of use.

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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SCOP – IRAQ (Contract n° 2171)
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for

5.2 Typical Corrosion Coupon Report

Coupon location in system
3 3
Flowrate Oil, m /d Water m /d
3
Gas m /d
2
Temperature °C Pressure kg/cm
Fluid analysis (attach if lengthy)

Gas analysis (attach if lengthy)

Sketch of system with coupon position shown:

Coupon number Material
Exposed area
Dimensions
Installation date Installation mass
Removal date Removal mass
Days in system Mass after cleaning
Average corrosion rate: mm/y Mass loss
Deepest measured pit mm Maximum pitting rate mm/y
Description of deposit before cleaning

Analysis of deposit
which it is specifically furnished or outside the extent of the agreed upon right of use.

Description of coupon after cleaning (e.g., etch, pitting, erosion, etc.)

Chemical treatment during exposure

Other remarks

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68

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KARBALA REFINERY FEED PROJECT

SCOP – IRAQ (Contract n° 2171)
The present document or drawing is property of TECHNIP ITALY S.p.A. and shall not, under any circumstances, be totally or partially, directly or indirectly, transferred, reproduced, copied, disclosed or used, without its prior written consent, for any purpose and in any way other than that for

6 REFENCE DOCUMENTS AND LIST OF ATTACHMENTS:

6.1 Reference Documents

- Material Selection Diagrams: 2342-AA01-MSD-0011-001_0

- Material Selection Diagrams: 2342-AA16-MSD-0011-001_0
- Material Selection Diagrams: 2342-AA17-MSD-0011-001_0
- Material Selection Diagrams: 2342-AA33-MSD-0011-001-02-01_0
6.2 List of attachments
- Material Selection Diagrams: 954085-115-msd-rev-01 marked up
- Material Selection Diagrams: 03317-05-MMD_Rev_B marked up
- Material Selection Diagrams: 03317-06-MMD_Rev_B marked up
- Material Selection Diagrams: 954088-115-msd-rev-00 marked up
- Material Selection Diagrams: 954213-115-msd-rev-00 marked up
- Material Selection Diagrams: 954214-115-msd-rev-00 marked up
- Material Selection Diagrams: 2342-AA30-MSD-0011-001-01_1 marked up
- Material Selection Diagrams: 2342-AA60-MSD-0011-001-02-01_0 marked up
which it is specifically furnished or outside the extent of the agreed upon right of use.

TECHNIP ITALY S.p.A. - 00148 ROMA - Viale Castello della Magliana, 68