Characterization and evaluation of corrosion damage in refineries is of critical importance due to the need for safety, reliability, throughput and operational integrity for plant facilities. Appropriate corrosion assessment, prediction, ionic modeling/analyses and monitoring have the potential to eliminate expensive failures, minimize damage to the environment, and eliminate abnormal situations that can restrict asset availability.

The most significant issues when evaluating corrosion damage to refinery equipment and installations are the dominant mechanisms of deterioration and failure related to corrosion damage. Corrosion damage, in turn, requires a clear understanding of the role of equipment metallurgy and dominant corrosion mechanisms such as naphthenic acid corrosion, sour water corrosion, ammonium chloride effects, corrosion due to cyanides, amine corrosion, etc., as well as relevant cracking concerns such as carbonate cracking, hydrogen induced cracking (HIC), stress oriented hydrogen induced cracking (SOHIC), and sulfide stress cracking (SSC).

The ability to characterize the potential for corrosion and cracking damage and to use such knowledge to monitor and control corrosion will allow the refiner to "Enhance the Reliability" by proactively managing corrosion versus conventional methods whereby plant personnel act reactively to corrosion issues.

An integrated corrosion management solution that incorporates thermodynamic, process and corrosion modeling tools (collectively referred to as Modeling) can be used effectively to manage refining corrosion problems. Such a solution is designed to allow the plant to identify critical spots in the operations from a corrosion standpoint and have the ability to run refinery processes within appropriate system boundaries to ensure safe unit operations. Once corrosion is effectively being managed the resulting data and information can be easily integrated to Asset and Boundary Management applications to link process and corrosion management to operations allowing to:

  • Understand when operating conditions cause an adverse impact on corrosion
  • Enable Operators' awareness about critical limits (for process and corrosion)
  • Set appropriate alarms according to identified limits for corrosion and other relevant, critical parameters
  • Alert plant management about the impact of deviations on equipment reliability, as well as plausible remediation paths to address the deviations
  • Align with the site's management of change process to approve any changes to operations when deviation from limits occurs

Monitor critical boundaries (Integrity Operating Windows), enabling operator comments on causes and corrective actions for deviation
Validate material performance, chemical/neutralizer injection, water wash, inspection frequencies and locations, monitoring locations, etc
Achieve the benefits of enhanced asset integrity, i.e., reduced cost of maintenance, inspection, turn-around, failure-risk, improved reliability, safety and efficiency

This corrosion and asset integrity methodology represents a life-cycle based approach to corrosion control, and integrates multiple, comprehensive components of corrosion control in a complementary closed-loop control framework.

Reader Tip Provided by: Juan P. Hernandez, Advanced Solutions Leader - Honeywell Corrosion Solutions

For more information on Honeywell corrosion solutions please visit:

Thanks for the tip Juan - per your request we have sent a $10 donation on your behalf to the Harry Chapin Food Bank.

Want us to donate $10 to the Harry Chapin Food Bank on your behalf? Please send us your Maintenance-tip here

Upcoming Events

August 9 - August 11 2022

MaximoWorld 2022

View all Events
80% of newsletter subscribers report finding something used to improve their jobs on a regular basis.
Subscribers get exclusive content. Just released...MRO Best Practices Special Report - a $399 value!
Three Things You Need to Know About Criticality Analysis

When it comes to criticality analysis, there are three key factors must be emphasized.

Turning the Oil Tanker

This article highlights the hidden trap of performance management systems.

Optimizing Value From Physical Assets

There are ever-increasing opportunities to create new and sustainable value in asset-intensive organizations through enhanced use of technology.

Conducting Asset Criticality Assessment for Better Maintenance Strategy and Techniques

Conducting an asset criticality assessment (ACA) is the first step in maintaining the assets properly. This article addresses the best maintenance strategy for assets by using ACA techniques.

Harmonizing PMs

Maintenance reliability is, of course, an essential part of any successful business that wants to remain successful. It includes the three PMs: predictive, preventive and proactive maintenance.

How an Edge IoT Platform Increases Efficiency, Availability and Productivity

Within four years, more than 30 per cent of businesses and organizations will include edge computing in their cloud deployments to address bandwidth bottlenecks, reduce latency, and process data for decision support in real-time.

MaximoWorld 2022

The world's largest conference for IBM Maximo users, IBM Executives, IBM Maximo Partners and Services with Uptime Elements Reliability Framework and Asset Management System is being held Aug 8-11, 2022

6 Signs Your Maintenance Team Needs to Improve Its Safety Culture

When it comes to people and safety in industrial plants, maintenance teams are the ones who are most often in the line of fire and at risk for injury or death.

Making Asset Management Decisions: Caught Between the Push and the Pull

Most senior executives spend years climbing through the operational ranks. In the operational ranks, many transactional decisions are required each day.

Assume the Decision Maker Is Not Stupid to Make Your Communication More Powerful

Many make allowances for decision makers, saying some are “faking it until they make it.” However, this is the wrong default position to take when communicating with decision makers.