Nalco Hac Report

Naphthenic Acid Corrosion in Refinery
Survey Report
IOCL Paradip Refinery

Sept-Oct 2012
Disclaimer
THE FOREGOING IS AN OPINION ON THE PROCESSING OF HIGH ACID CRUDE OILS, BASED ON
EXPERIENCE GAINED IN THE REFINING INDUSTRY; HOWEVER, THE READERS OF THIS OPINION
ARE EXPECTED TO MAKE THEIR OWN DETERMINATION AS TO THE SUITABILITY OF THE SUBJECT
FOR THEIR OWN INTENDED USES. THE REFINING OF CRUDE OIL IS SUBJECT TO MANY RISKS AND
UNCERTAINTIES AND NALCO ENERGY SERVICES ACCEPTS NO LIABILITY FOR ANY USE OR
RELIANCE ON SUCH OPINIONS. NALCO ENERGY SERVICES ASSUMES NO LIABILITY FOR ANY
DAMAGES, INCLUDING BUT NOT LIMITED TO LOSS OF PROFIT, AND SPECIAL, INCIDENTAL,
CONSEQUENTIAL, OR OTHER SIMILAR CLAIMS.
Confidential Information
This report is intended for IOCL Paradip Refinery only and for the purposes outlined in the
report and prepared in the context of Nalco Energy Services' High Temperature Corrosion
Abatement Program. IOCL Paradip Refinery shall keep and cause its employees and
subcontractors' employees to keep confidential any and all technical information, data,
drawing, specifications disclosed and discussed in this report except with written consent of
Nalco.
The assessment was conducted based on the data provided by the

Refinery.
REPORT NO. S-XXXX
PROJECT NO.
REPORT DATE 5 October 2012
SERVICE REPORT
Risk Assessment for Processing Naphthenic Acid Crudes
TITLE
At IOCL Paradip Refinery
AUTHOR(S) Arindam Roy, Glenn L Scattergood
CONTRIBUTOR(S) Walter Militello, Debjit Chandra, Pranab Kumar Datta,
DEPARTMENT RFM
LOCATION India
ABSTRACT
The IOCL Paradip Refinery is looking to assess the feasibility of processing naphthenic acid crudes
on their CD4 atmospheric and vacuum distillation trains. The aim of this survey is to look at the
feasibility of processing naphthenic acid crudes with minimal risk to the process units in order to take
advantage of “Opportunity” crudes at discounted prices.
When processing naphthenic acid crudes, the risk assessment has highlighted that sections of both the
CDU and VDU will be susceptible to elevated risks of naphthenic acid corrosion. As the plants do not
possess sufficient resistance to naphthenic acid corrosion from the metallurgy employed, an extensive
monitoring program will have to be put in place to ensure the corrosion rates are not excessive when
the TAN levels are increased.
If the refinery choses to adopt a chemical mitigation strategy, injection locations were identified
where chemical inhibitors could be used to improve the unit’s resistance to corrosion.
Considerations have to be made to the associated impacts of naphthenic acid crude processing and the
impacts on crude oil desalting and overhead corrosion control have to be considered. However, with
the correct processing strategies, many of these risks can be successfully mitigated.
Nalco Limited
Date: 5th Oct 2012 Page No: 1
Serial No: S-1001
Table of Contents
1) Introduction............................................ 3
2) Acknowledgements....................................... 3
3) Purpose of the Visit....................................... 3
4) Executive Summary and Recommendations....................... 4
5) Impact of Naphthenic Crude Processing ......................... 6

a) Naphthenic Acid Corrosion................................. 6
b) Impact on Desalting ..................................... 7
c) Impact on Overhead Corrosion Control ......................... 8
d) Downstream Impacts ..................................... 10
i) Hydrotreaters and FCC Units ........................... 10
ii) Thermal Conversion Units.............................. 10
iii) Sour Water Strippers ................................. 11
6) Overview of Nalco’s Risk Assessment Matrix ..................... 12
7. Mitigation of Naphthenic Acid Corrosion ........................ 13

a) Crude Blending Options................................... 13
b) Upgraded Metallurgy..................................... 14
c) Use of Chemical Corrosion Inhibitors .......................... 15
8. SCORPION Injection Requirements and Best Practices ............... 16
9. Corrosion Monitoring & Inspection ............................ 17

a) Overview ............................................ 17
b) Considerations for Determining Corrosion Monitoring Locations........ 18
c) Developments with FSM Technology .......................... 19
d) Permanent High Temperature UT Installations .................... 20
e) HydrosteelTM Hydrogen Flux Measurements ..................... 22
f) Cormon CEION Probes ................................... 23
The contents of this document are to the best of our knowledge accurate at the date of publication. We shall not be liable for
any loss or damage whatsoever resulting from reliance on its content. All warranties as to fitness for purpose or otherwise
(howsoever made or implied) in respect of this publication are excluded. Confidential Do not duplicate.
Nalco Limited
Serial No: S-1001
g) Stream Sampling and Laboratory Analysis....................... 23

h) Corrosion Coupons ...................................... 24
10) Observations & Discussion Paradip Refinery -IOCL ................. 25

a) Overall Review ........................................ 25
b) Crude Oil Blends to be Evaluated ............................ 26
c) Risk Matrix Evaluations of the Atmospheric and Vacuum Distillation unit . 32
i) Overview ......................................... 32
ii) Factors affecting the Naphthenic Acid Corrosion............... 33
iii) Summary & Discussion of the Calculated Risk Associated with High
Acid Crudes ....................................... 35
d) Monitoring Tools and Chemical Injection Locations............. 36
i) Atmospheric Distillation Unit ............................... 36
ii) Vacuum Distillation Unit .................................. 39
e) Monitoring of High Temperature Corrosion in AVU ................ 42
f) Impacts on Desalter Operation and on the CDU VDU Overhead corrosion issue 43
g) Impacts on Downstream Processes. ........................... 44
h) Generic Recommendations for Corrosion Monitoring ............... 46
12) Appendix ............................................. 51

Risk Matrix Output for TAN = 0.8 mg of KOH/g ...................... 52
Injection and Monitoring location ................................ 56
Slip Stream connection – LAGO slipstream P&ID 1020 ................. 67
Slip Stream connection – VGO slipstream P&ID 3013 .................. 68
Locations for FSMs and Permasence .............................. 69
Injection Quill Design detail .................................... 70
P&ID Chemical dosing system, Atmospheric Distillation Unit ............. 71
P&ID Chemical dosing system, Vacuum Distillation Unit ................ 72
Contact Details of Probe/FSM/Permasense .......................... 73
IOCL Paradip Crude Unit...................................... 74
IOCL Paradip Vacuum Unit .................................... 74
Overall Refinery -PFD........................................ 75
13) Organogram: ........................................... 77
Nalco Limited
Serial No: S-1001
1) Introduction
IOC Paradip Refinery is designed to process High Acid Crudes (HAC) in a blend with a crude blend
TAN up to 0.5 mg of KOH/gm. . The crude price tendency and the increased price gap between
“conventional” and “opportunity” crudes create an increased incentive to start processing HAC
crudes. IOC Paradip would like to process HAC as part of the crude feed to the CDU and VDU units
to profit from the price difference but are aware of the increased corrosion risks and possible side
effects on products and processing units. Nalco have over 28 years of experience with HAC corrosion
inhibition and with the risk management of opportunity crude processing.
The IOCL Paradip Refinery tasked Nalco with assessing the risks of processing naphthenic acid
crudes on the Crude Atmospheric and Vacuum distillation units. The aim of this study is to determine
the risk associated with processing naphthenic acid crudes on these units and whether the refinery can
take advantage of the availability of naphthenic acid crudes at discounted prices to realise a margin
improvement and increase profitability.
The refinery is under construction. As a result, a detailed survey was carried out at the refinery by a
Nalco Industry Technical Specialist and Global support and the findings and recommendations are
contained in this report. The whole survey was completed on the basis of supplied P&ID and other
plant detail supplied by Refiner.
2) Acknowledgements
Nalco would like to thank Process & Inspection personnel of PDRP-Core Group and RHQ process
group for sharing necessary information required for the Study.
3) Purpose of the Visit
The main purpose of the survey is to determine the level of risk to the refinery when processing
naphthenic acid crudes on the Paradip Refinery atmospheric and vacuum distillation units. This
determined by utilising Nalco’s SCORPION Risk Assessment methodology to determine the level of
risk to the units and from this, determine the appropriate monitoring & mitigation strategies.
By understanding the risks and what mitigation strategies can be employed, the aim is to provide the
refinery with the necessary detailed information so that naphthenic acid crudes can be processed
safely so that a significant increase in profitability can be achieved.
This report details the results of our enormous effort including visit and discussion at the refinery and
aims to detail all the concerns relating to the corrosivity and associated impacts of naphthenic acid
crude processing.
Nalco Limited
Serial No: S-1001
4) Executive Summary and Recommendations

♦ Nalco is the Market Leader on field of High Acid Crude processing with Scorpion II
technology. We have vast experience of corrosion controlling over 28 years. Nalco holds 70%
if the Global Market Share for HAC processing, here is a Market Share pie chart updated for
2012. We have experience of
treating Crude blend having TAN
level between 0.2 to 6.5 mg of
KOH/g in combination with raw
crude Sulphur level in the range of
0.2 to 5 %. So we have
confidence. We can provide a
corrosion control program to meet
the Key Performance Indicators.
For IOCL Paradip we also
followed our best practice to have
the Risk Assessment to find out
the most critical area of concern
during HAC period. Within the
provided Crude blend we are
confident to start HAC with
proper monitoring and chemical
application.
♦ Nalco conducted Risk Assessment for Crude Blend TAN level 0.8, 1.0, 1.2 and 1.5 mg of
KOH for IOCL Paradip.
♦ The IOC Paradip Refinery does not have the suited metallurgy for processing increased High
Acid Crude levels unaided. Some equipment metallurgy on the Paradip crude unit provides
little protection against naphthenic acid attack and will require either a metallurgical upgrade
or use of a chemical corrosion control program along with rigorous monitoring program.
♦ A high temperature corrosion control program will allow the refinery to safely process
naphthenic crudes with the existing plant.
♦ The inhibitors work by forming a passive layer on the internal surfaces of the process
equipment, and must be applied in advance of the introduction of naphthenic crudes. The Best
Practice Prepassivation plan will be submitted by Nalco before start-up of HAC.
♦ Due to the severe nature of the process streams, the addition of the inhibitors demands extra
care to ensure they work safely and efficiently. Slipstreams of cooled hydrocarbon liquid are
mandatory at injection sites where the process stream is above 150°C.
♦ Special injection quills MUST be used for these injection systems. Seamless tubing in a
heavy wall thickness of Hastelloy C-2000 is the most suitable material for the injection quills.
♦ Based on our Risk Assessment 23 monitoring locations are recommended for the atmospheric
and vacuum distillation units.
♦ Based on our Risk Assessment 12 inhibitor injection locations are recommended for the
atmospheric and vacuum distillation units.
♦ The inhibitors injected on the distillation units are expected to also provide protection to
downstream processes and plants. This needs verification with on-site corrosion
measurements.
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Serial No: S-1001
♦ The risk assessment matrix shows that acidity of some distillate fractions increases to a High
Risk level with certain elevated TAN level. Naphthenic acids will concentrate in certain
fractions depending on their molecular weight. The distillate acidity may be up to 2 times
greater than the crude blend acidity. So Crude blend should be planned accordingly to match
the system RISK.
♦ The location and the severity of the corrosion can depend on the specific crudes that are
processed since each crude distributes their naphthenic acids differently. Chemical
requirement to be decided on the basis of risk with planned crude blend to be processed.
♦ The F-101, F-201 and F-102 fired heaters will be susceptible to naphthenic acid corrosion at
relatively modest TAN levels.
♦ The existing plate material in CDU column and packing in Vacuum column are made of
SS410 which is not resistant to Naphthenic acid corrosion. Due to product distribution issues
and the fact that packing is very thin and has virtually no corrosion allowance, complete
protection of packing material with inhibitor cannot be guaranteed. It is recommended to
upgrade those section with SS316 or preferably SS317 material in near future..
♦ However Nalco has experience of successfully running HAC program with SS410 plate tray
with proper chemical inhibition. So it will good to run the HAC program with proper
monitoring with SS410 packing until the first opportunity for turnaround inspection.
♦ Enhanced corrosion monitoring facilities are required to ensure that the inhibitor protection is
adequately established and maintained.
♦ This monitoring should utilise techniques such as Corrosion Probes (Ceion or ER), FSM and
Permasense permanent ultrasonic thickness measurements. Locations for the placement of the
probes and FSMs have been identified and the number of probes for each location has been
outlined.
♦ Refiner will monitoring Probe/FSM/Coupon and metal analysis without HAC. Those data will
be considered as the base case data during our treatment program. As a normal practice during
HAC processing our KPI will be Base corrosion rate + 10 MPY corrosion rate for individual
Probe and FSM system.
♦ Three different locations are recommended for intensive FSM (“FSM or Permasense”)
corrosion monitoring. These are locations where the risk for corrosion can be significant.
♦ The desalter should be monitored closely during commencement of high acid crude
processing as there may be an impact on the electrical system caused by conductive
naphthenic acid crudes, which could impact desalting and dehydration efficiency.
♦ Light acid fragments are anticipated in overheads sections of the CDU and VDU due to the
degradation of naphthenic acids. The current overhead corrosion control programmes for
these units will need to be reviewed to ensure the risk posed to these sections are effectively
minimised.
Nalco Limited
Serial No: S-1001
5) Impact of Naphthenic Crude Processing
a) Naphthenic Acid Corrosion
Naphthenic acids are present in some crude oils as natural constituents, resulting from the precursor
molecules in the original biomass and biodegradation reactions over passing centuries. Figure 5.1
shows a generic structure for naphthenic acids. (The acidic functional group is in the upper right of
the molecule.)
The saturated ring part of the molecule

is either five or six carbon atoms in
length, and is responsible for the name
“Naphthene”.
The carboxylic acid groups are

responsible for the reactive behaviour
with metals, whilst the alkyl
substituents, especially the
hydrocarbon group chains, are
responsible for making the metal salts
oil-soluble. The two properties are both
important for the molecule’s corrosion
activity.
Figure 5.1 - Generic Structure of Naphthenic Acids
The quantity of acids present in a particular crude oil or distillate is usually measured as the Total
Acid Number, or TAN. This titration includes all acids such as phenols and H2S, and a refinement of
the method to separate out the naphthenic acids as a Naphthenic Acid Titration or NAT gives a more
accurate picture of the potential for corrosion. The naphthenic acids concentrate into the heavier
atmospheric gas oils and residue, as well as into the vacuum distillates and residue. Each naphthenic
crude oil has its own pattern of acid distribution throughout the distillation temperature profile, and in
some cases a particular distillate stream may contain more than twice the acid concentration found in
the raw crude.
Naphthenic acids have a wide range of structures in any given crude or distillate, and the strength of
the acids is partially dependent on the structure of the molecule. Acids with a sterically hindered
carboxylic group will be weaker than those with a more open structure. Additionally, the oil-solubility
of the metal naphthenate is responsible for the easy removal of the corrosion by-products from the
reaction sites, leaving a freshly exposed surface where further attack can occur. The rate at which
these soluble metal salts are removed from the substrates is accelerated by high liquid scouring rates
of the surfaces, so the corrosion is more severe with high velocity liquid streams and in impingement
zones. The hydrocarbon chain plays a strong part in the oil solubility of the metal naphthenates. In
very light acids, where the alkyl group is short, the metal naphthenate salts will dissolve in the
hydrocarbon fluids less readily than those formed with heavier acid molecules.
Therefore, the corrosivity of the molecules thus depends on the particular arrangement of the acid
group(s) present, as well as the quantity measured by a TAN or NAT titration.
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Serial No: S-1001
However, the use of NAT or even TAN data only shows the quantity of the acids present. It does not
indicate how corrosive those acids may be in a given environment nor does this data allow for the
natural inhibition effects that arise from the reactive sulphur components in a crude blend. Therefore,
when assessing the risk of naphthenic acid corrosion one needs to take into account the temperature,
phase behaviour, and localised velocity effects for a total environment evaluation. These parameters
are incorporated into the Nalco risk evaluation matrix and all these factors, together with plant
metallurgy and remaining thickness measurements, are taken into consideration before any estimation
of corrosion risk can be made for a given corrosion loop.
Areas particularly susceptible to corrosion are those that encounter mixed phase flow, hot
temperatures and high vapour velocities in the lines specifically, the radiant sections of furnaces,
furnace outlet headers and transfer lines. With partial vaporisation of the feed occurring in the final
furnace passes, the remaining heavy liquids will be richer in acidity. The residual liquid phase
droplets in the fast vapour stream provide a ready solvent of any metal naphthenates formed, and
where direct impingement occurs at elbows the shear forces will help to scour away any metal
naphthenate salts that are produced on the pipe walls.
The corrosion mechanism associated with naphthenic acid attack is quite distinctive and differs from
the general metal loss that accompanies high temperature sulphidic attack. Corrosion due to
naphthenic acid will be in the form of a localised pitting mechanism and the wall penetration rate
from this pitting attack can be up to ten times faster than the thickness loss from sulphidic corrosion.
b) Impact on Desalting
Due to higher densities and the tendency of naphthenic acids to stabilise emulsions at elevated pH’s,
high TAN crudes can be more difficult to process leading to reduced desalting and dehydration
efficiencies.
Naphthenic acids are capable of forming natural “soaps” when they are neutralised with inorganic
cations, such as sodium, calcium, and ammonium ions. The soaps formed in this way exhibit
surfactant behaviour at an oil-water interface, such that the interface region in the desalter may
become loaded with solids and emulsions. The expansion of these emulsion bands into the electrical
grids can increase amperage draws and decrease the voltage of the electrical field resulting in
decreased coalescence and dehydration performance. In extreme cases, the increase in amps can result
in the desalter tripping as the transformer safeguarding protocols turn off the power supply to the
grids.
Maintaining the pH of the desalter effluent water in the range 5.5 - 6.5 can control the naphthenate
soap formation. However, if stripped sour water is used as the source for desalter wash water, it may
be impossible to control the effluent pH in this band when the water contains high levels of ammonia.
Such waters are produced when hydrotreater and FCC overhead water streams are fed to the sour
water stripper plant. Another factor to consider is that FCC overhead water can contain appreciable
amounts of phenols and at elevated pH ranges these too can act as good emulsion stabilisers.
Therefore the condensate and wash water streams from hydrotreater and FCC units should not be used
in the desalters, when processing high percentages of naphthenic crude in the feed.
Additionally, naphthenic acid crudes themselves can be conductive and this is related to the levels of
calcium naphthenate (CaN) in the crude. A high level of CaN increases the crude conductivity and
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Serial No: S-1001
with the resulting increased amperage draw and

reduced voltage there is a loss of the electrical field
within the desalter that leads to lower dehydration and
desalting efficiencies.
When blended with other crudes the conductivity can

become even higher than the conductivity of the
individual crudes. Figure 5.2 shows the conductivity
of Doba, Arab Heavy and blends of 10% and 20%
Doba in Arab Heavy.
Figure 5.2 – Crude Conductivity of Doba
c) Impact on Overhead Corrosion Control
During processing, the naphthenic acids will thermally decompose due to the exposure to thermal
stresses in the crude and vacuum fired furnaces.
The most common effect from breakdown

fragments is to produce significant quantities of
formic, acetic, and propionic acids in the overhead
water condensates of both atmospheric and vacuum
columns. Even though these organics acids are
classed as weak acids, their presence in the
overhead condensate requires a disproportionate
amount of neutraliser to be dosed in order to
achieve a pH of >5.0.
The main problem with trying to mitigate the effect

of high concentrations of low molecular weight
organic acids with a neutraliser is the buffering
effect.
A buffer solution is an aqueous solution consisting of a mixture of a weak acid and its conjugate base,
or a weak base and its conjugate acid. It has the property that the pH of the solution changes very little
when a small amount of acid or base is added to it.
Figure 5.3 – Impact on Neutraliser Dosing
In the case of a CDU Overhead System, the neutraliser is consumed without significantly increasing
the pH of the overhead water (Figure 5.3). As more and more neutraliser is added, the pH will
eventually begin to rise but in doing so the excessive dose rates increase the risk of amine
hydrochloride salt formation.
Another factor to consider with overhead corrosion control is that naphthenic acids can also increase
the degree of hydrolysis of the calcium, magnesium and sodium chloride salts that remain in the
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crude after the desalting step and this can lead to a significant increase in OVHD chlorides and
[1,2, 3]
associated corrosion issues at CDU, VDU and VBU’s. Figure 5.4 shows the effect of naphthenic acids
on chloride salt hydrolysis simulated in the lab. (1) (2)
Figure 5.4 – Effect of Naphthenic Acids on Chloride Salt Hydrolysis
The key factor to consider from these observations is that either of these scenarios can impact greatly
on amine / ammonia hydrochloride salt formation in the overhead condensation sections, particularly
on crude units. The reaction between HCl and a base, either ammonia or a neutralising amine, to form
a salt is dependent on the concentration of the two reactants in the vapour phase and the temperature
of the system.
The potential for an amine or ammonia to form a hydrochloride salt with HCl is directly related to the
partial pressures of each constituent and the system temperature. The amount of neutralising amine
entering the crude tower has the most significant impact on its partial pressure while there are a
number of factors that contribute to increased chlorides such as poor desalting efficiency, poor caustic
injection practices and increased rates of salt hydrolysis.
Therefore, an increase in neutraliser dosing and a greater degree of salt hydrolysis will result in a
higher concentration of amines / ammonia and chlorides in the overhead system, thus increasing the
risk of salt formation.
In order to mitigate against this, the use of Nalco Pathfinder modelling software should be utilised in
order to determine the amount of neutraliser required to elevate the pH at the 5% condensation point
to ~5.0 while the remaining weak acids can be counteracted by the proper use for a filming amine.
Furthermore, Pathfinder can be utilised to track the water dew point temperature, salt formation
temperatures and the potential mass of salt that can be deposited in the overhead system.
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d) Downstream Impacts
i) Hydrotreaters and FCC Units
The naphthenic acids are readily destroyed in catalytic conversion units such as hydrotreaters and
catalytic crackers. In hydrotreaters the acids are converted to neutral alcohols, whilst in FCC reactors
they are converted into CO2 and low molecular weight organic acids mentioned previously. However,
there are risks of naphthenic acid corrosion in the pre-heating section of the aforementioned units.
The impact of opportunity crude processing on the Hydrotreaters and the FCC would be located in the
feed heating section, more specific in the parts that operate >250ºC.
On a hydrotreater, the rate of high temperature naphthenic corrosion would decrease after the addition
of hydrogen into the feed as the acidic species would begin to react and lose their corrosivity.
Common configurations on most Hydrotreaters are that the hydrogen is mixed into the feed below the
temperatures where naphthenic acid corrosion manifests itself.
Likewise on an FCC, the corrosion rates would decrease within the riser after the catalyst addition as
again the naphthenic acid species would breakdown.
However, it is a common characteristic of naphthenic acid crudes that they contain elevated levels of
nitrogen, particularly in the heavier distillates and residue streams, and these may present constraints
on the FCC and Hydrotreaters.
In the catalytic cracking process, higher levels nitrogen will result in greater amounts of ammonia
being generated. This is a risk to units processing low sulphur crudes since the higher amounts of
ammonia increases the sour water pH and may make the associated downstream fractionation trains
susceptible to carbonate stress corrosion cracking mechanisms. Additionally, higher nitrogen levels
can result in the generation of increased amounts of cyanide which, in combination with higher
ammonia contents and elevated pH levels, can increase the risk of bisulphide related hydrogen
permeation and blistering damage.
If a refinery processes the heavier distillates and residue on a hydrotreater or a resid finer /
hydrocracker, this can result in catalyst deactivation since nitrogen is a known catalyst poison.
Suitable catalyst types would have to be incorporated in the event that elevated nitrogen levels pose a
risk to unit operation.
ii) Thermal Conversion Units
With regard to thermal cracking units such as Visbreaker and Cokers, we do not typically see
naphthenic acid corrosion problems in units that are receiving residue feed from a CDU/VDU
processing high TAN crudes. The possible reason for this is that the large naphthenic acid molecules
have passed through two furnaces and the severe conditions there (mainly in the VDU furnace) causes
the larger and the more reactive naphthenic acids to crack into smaller components that distil into the
overhead sections or into the side cuts. Another possible reason can be due to the presence of high
temperature corrosion inhibitor that has already been injected at the CDU and VDU and residual
amounts in the feed streams will provide protection to the preheats of the thermal conversion units.
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However, when processing high TAN feeds on the thermal cracking process it is recommended that
corrosion in regularly monitored as part of a Risk Based Inspection schedule, especially around
furnace and transfer line sections.
Thermal conversion units such as Cokers and Visbreaker also degrade the naphthenic acids into
lighter organic acids, which are recovered in the overhead condensates of their fractionators and can
cause high rates of corrosion where the water condenses and low pH conditions are encountered. It is
a common consensus within the industry the produced gas oil distillates from these thermal
conversion units do not pose a threat of naphthenic acid attack due to the fact that decompose to the
lighter acids as discussed above.
However, recent experiences of processing naphthenic acids on Visbreaker has shown that under
certain process conditions high temperature corrosion has been seen in the gas oil cuts in the main
fractionator[5]. In this documented incident, high corrosion rates of up to 10.5mm were observed in the
Visbreaker fractionator. However, the process temperature ranged from 180 – 220°C, which is below
the typical temperature threshold of where high rates of naphthenic acid corrosion are observed.
The visual appearance of the corroded areas was consistent with corrosion by organic acids.
Specifically, the affected area had no adherent scale, had bright patches that appeared freshly
corroded, had a pattern of surface roughness that suggested it was flow related [5]. Corrosion due to
organic acids at this temperature range of been documented by Groysman et al [6] and the risk of
corrosion within the Visbreaker fractionator should be considered and monitored accordingly.
iii) Sour Water Strippers
The processing of opportunity crudes with naphthenic acids or with light organic acids increases the
sour water organic acid content that is fed to the unit. This can lead to low pH conditions throughout
the sour water system and corrosion. The effect can be easily monitored with pH checks in the
collected sour water, stripped sour water and stripper reflux water.
Acidic pH conditions < 5.5 can lead to excessive corrosion if the metallurgy is carbon steel. The
corrosion can be controlled by adjusting the pH (with caustic), the use of filming corrosion inhibitors
or a metallurgy upgrade.
If low pH conditions are observed, this will reduce the ammonia stripping efficiency and will result in
more ammonia being entrained in the stripper bottoms. If this water is the primary source of desalter
wash water, the increased ammonia levels can have a negative impact on desalting by promoting the
formation of naphthenic acid soaps and subsequent emulsion formation and stabilisation (as discussed
in section 5b)
If the water is run down to the effluent treatment plant, elevated levels of ammonia could cause
difficulties in meeting discharge limits.
Also, since naphthenic acid crudes can contain elevated levels of nitrogen, increased levels of
ammonia and cyanides can be generated during the catalytic cracking process. Since the overhead
sour water is then subsequently processed on a sour water stripper the increased pH level and cyanide
concentrations can increase the susceptibility of the unit to bisulphide related hydrogen charging
cracking mechanisms.
Nalco Limited
Serial No: S-1001
6) Overview of Nalco’s Risk Assessment Matrix
The risk assessment procedure uses a number of important factors that affect the corrosion rates when
processing naphthenic acid crudes to provide an indication of the level risk associated with processing
acidic crude blends and associated distillates. The main factors that contribute to the specific
corrosivity and aggressiveness of a particular stream are as follows:
• TAN of the hydrocarbon stream

• Sulphur level
• Solubility of metal naphthenate
• Temperature
• Velocity / turbulence
• Piping geometry (e.g. diameter changes, bend radius)
• Piping metallurgy
• Remaining corrosion allowance
The assessment tables for calculated risk levels depend on the weighting of the relevant factors
according to their impact on naphthenic acid corrosion. Output rankings showing the calculated risk
levels are intended to set the level of precautions for running high acid crude blends, as detailed in the
following table: -
Risk Rating Action

Low Maintain existing monitoring schedule to confirm corrosion rates are minimal
Low-Moderate Install some extra monitoring activity – Not necessarily permanent monitoring.
Moderate Install better monitoring equipment and attach access stubs for injectors
Moderate-High Install better monitoring equipment and chemical injectors. Have inhibitor ready
High Install full monitoring equipment and passivate with inhibitor before running crude
Install full monitoring equipment and passivate thoroughly with increased rate of
Very High
inhibitor before running crude
Figure 6.1 – Risk Phrases and Their Interpretation
Nalco are continuing to develop the risk assessment components, with enhancements that will offer
wider scope and capability of the tool. Additionally, Nalco are participating in a number of JIP
initiatives with leading oil companies and selected engineering companies looking at developing
models and tools to determine and understand the critical factors in predicting and mitigating
naphthenic acid corrosion.
Nalco Limited
Serial No: S-1001
7. Mitigation of Naphthenic Acid Corrosion
There are currently three options to manage corrosion effects from naphthenic acids in crude oils.
Two of these methodologies, blending and metallurgy selection, have been available for many years.
The third option, the use of a chemical passivation program, was first successfully applied 25 years
ago [4].
a) Crude Blending Options
The corrosion of refinery units from naphthenic acid attack has traditionally been managed by
processing only minor percentages of these crudes as components of the feed blend. Many refiners
have adopted a limit on the TAN of the feed and product streams as an effective strategy for keeping
the corrosion within acceptable rates.
Whilst this blending strategy has been widely practised, with generally good results, the percentage of
naphthenic crude that may be used in the feed blend has been low. The current marketing of new
naphthenic crudes brings a significant discount relative to non-acidic crudes, and so the pressure on
refineries to process higher percentages in their feed blends has increased.
Another strategy reported is the blending of naphthenic acid crudes with those containing reactive
sulphur species. In Figure 7.1 below, the benefits of small amounts of sulphur compounds in
establishing a renewable protective film on plain carbon steel can be clearly seen.
2.5
(mm/a)
Carbon Steel Corrosion Rate @ 300 °C vs Sulphur Content
2.0 TAN 5.00

TAN 3.05
TAN 1.55
TAN 0.65
TAN 0.15
1.5
1.0
0.5
0.0
0.0 0.5 1.0 1.5 2.0 Sulphur % 2.5 3.0 3.5 4.0 4.5
Figure 7.1 - Effects of Sulphur Protection Against Naphthenic Acid Attack
Some industry authorities prefer to quote only “reactive sulphur” levels, where thiophenic sulphur is
supposedly inactive for protection. However, as the sulphur content of the oil increases, the high-
temperature sulphur corrosion attack becomes dominant. The onset temperature and magnitude of this
effect will vary depending on the specific sulphur compounds present in the oil.
Nalco Limited
Serial No: S-1001
As the types of natural sulphur compounds in the processed blend are not controllable by the refiner,
this protection mechanism depends acutely on the blend components within the crude feed. It has
been suggested that Venezuelan crudes have been historically less corrosive than their TAN levels
would suggest, precisely because the sulphur compounds naturally present in their crudes have been
active inhibitors.
b) Upgraded Metallurgy
The obvious means to process higher acidity crudes in greater percentages is to employ materials in
construction of the refinery that are resistant to the mode of attack posed by naphthenic acids. This
strategy is successfully employed to resist high-temperature sulphidation attack, by incorporating
alloys with increased chromium content. Chromium containing stainless steels, such as 5Cr, 9Cr and
AISI SS410, are common materials of construction utilised on refineries where sulphidation is an
issue.
Whilst increasing the chromium content of steels does show improved performance against
naphthenic acid attack, the overall magnitude of the corrosion is still unacceptable unless AISI 316SS
is employed. Even then, the higher limit of the Molybdenum specification is preferred for satisfactory
results.
For metallurgical protection against naphthenic acid attack, it is necessary to incorporate higher
molybdenum into the alloy compositions. Of the materials commonly found in refinery and
petrochemical environments, only AISI 316SS and AISI 317SS in the austenitic stainless steel family
possess adequate resistance to naphthenic acid attack. The specification of these two alloys is for 2.0-
3.0% molybdenum and 3.0-4.0% molybdenum respectively in their compositions.
By requesting all new components in AISI 316SS to be above 2.5% molybdenum in any future
purchases, there will be significantly enhanced performance over the 2% Mo minimum grade of the
alloy.
For existing refineries, built without the enhanced alloy materials above, the option to fully upgrade
the metallurgy is expensive and requires an extended shutdown period to upgrade the plant. However,
there are minor upgrades possible where this will be by far the best solution. Such upgrades include
the packing material for any structured mesh packing in fractionating column beds, and any zones
where it may be impossible to use chemical passivation measures reliably. It may also be a preferred
choice where certain components that could in future operate under severe threat from naphthenic acid
attack, are already due for replacement.
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Serial No: S-1001
c) Use of Chemical Corrosion Inhibitors
The increased risk of naphthenic acid corrosion can be controlled by implementing a chemical
inhibitor program in advance of the naphthenic crude introduction. The inhibitors work by forming a
durable passive layer on the internal metal surfaces, and plant must build up this passive layer before
any increase in the crude feed TAN occurs.
The protection philosophy for application of naphthenic corrosion inhibitors is based on passivation of
susceptible metal surfaces. This is achieved by converting the ferrous alloy surfaces from a typical
sulphide film into a complex poly-phosphate / thiophosphate layer, which is far more resistant to
attack from naphthenic acids.
Other inhibitors based on polysulphide chemistry have also exhibited success in reducing naphthenic
acid corrosion and are used if refiners have specific concerns regarding the use of phosphorous.
When the two chemistries are combined in a blended polysulphide-phosphate ester inhibitor, there has
been an observed synergistic effect and the corrosion mitigation results have been even more
successful. The use of this chemistry is utilised when the sulphur levels of the stream are low and the
possible protective effect of sulphidation is minimal.
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8. SCORPION Injection Requirements and Best Practices
The protection philosophy for the naphthenic acid corrosion inhibitors is based on the passivation of
susceptible metal surfaces. This is achieved by converting the ferrous alloy surfaces from a typical
sulphide film into a complex poly-phosphate / thiophosphate layer that is far more resistant to
naphthenic acid attack
The typical inhibitor chemistry that is used to generate the phosphate complex layers is an organic
phosphate ester compound that becomes activated at elevated temperatures. The initiation of this
activation step occurs at around 170-200 °C, and above this temperature the concentrated chemicals
are aggressive to all common alloys and materials used in refinery construction.
Based on extensive experience Nalco have developed a set of Best Practices for the injection of its
SCORPION chemistry that utilises a proprietary designed Hastelloy C-2000 injections quill and the
use of a cooled hydrocarbon slipstreams. This is a mandatory requirement for transporting
SCORPION products into a hot process fluid.
Where this advice is not followed, there is

a severe risk of rapid corrosion of the quill
tube, and imminent failure in service. A
quill failure outside of the packing gland will
cause an uncontrollable process leak that may
not be isolatable requiring a unit shutdown. A
quill failure inside the process creates the
potential for the SCORPION product to leak
from the quill and concentrate at the pipe wall
leading to very high metal loss and possibly a
failure of the process equipment.
Figure 8.3 – Corroded Quill
Figure 8.3 shows a quill that failed in service as a result of a loss of slipstream flow and this particular
incident resulted in a loss of containment and a serious fire on the unit. This picture serves to
demonstrate the importance to adhering to Best Practices for the injection of SCORPION corrosion
inhibitors.
Heat transfer calculations have determined that a flow rate of 150 l/min of slipstream hydrocarbon at
a maximum temperature of 150 ºC will keep the injected chemical from reaching the activation
temperature whilst it is still inside the quill tube. This is for a worst case external temperature of 330
ºC in an injection site, and a quill insertion depth of 150 mm into the hot gas oil stream.
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9. Corrosion Monitoring & Inspection
a) Overview
The effective monitoring of corrosion is a crucial factor in successfully processing naphthenic crudes.
Far more inspections are required, and extra monitoring equipment must be installed. It is important
that this step is introduced before increasing naphthenic feeds, so that the underlying corrosion rates
from sulphidic attack can be established ahead of the increased corrosivity regime that accompanies
naphthenic crude processing.
The inspection routines that have become established in recent years for targeting the areas of
increased risk must be re-examined when naphthenic crudes are introduced. The historical modes of
corrosion in high temperature areas have mostly been sulphidic in nature, and the type of damage
caused with this mechanism is a general uniform metal loss. Naphthenic acid corrosion is a pitting
mechanism, or in extreme cases deep gouging of the metal and it can be very localised.
The change in mechanism to a pitting attack can also result in far quicker perforation of the metal than
previously expected from sulphidation, and this necessitates that corrosion measurement techniques
be used that have more sensitivity and quicker response times. They also have to work in a difficult
thermal environment, and normal corrosion probes are unsuitable in standard form.
The localised nature of naphthenic corrosion means that far more measurements are required from
techniques such as ultrasonic thickness or X -Ray surveys, but it also means that their chances of
successful detection of the attack are diminished. Other factors, such as the widespread use of thermal
insulation on the high temperature pipes, and often the remoteness of the pipes from easy reach from
normal platforms, make such inspections more costly and time-consuming.
The newer techniques that have been developed to help in the monitoring of naphthenic corrosion
include iiCorr’s Field Signature Method, (FSM) and Ion Science’s Hydrosteel 6000 Probe. Extensions
of existing methodologies have also been developed and GE Inspection Technologies and Permasense
have recently launched permanent, high temperature UT probes that can be clamped to a pipe and
inspected remotely at defined intervals. This technology eliminates many of the costly activities
associated with traditional UT inspections such as erect scaffolding to reach remote sections of lines
and employing personnel with rope access qualifications
Extensions of the traditional electrical resistance probe (ER) technology have been available for many
years in specialised high temperature versions, and a more recent development from Cormon with
their CEION probes has produced much faster response times and / or longer probe lifetimes. The
author recommends that all of these methods be considered, for refineries that significantly increase
the acidity of the feed..
It is accepted that experienced Corrosion Engineers and Inspectors will be aware of existing
monitoring technologies. However, Nalco will outline some of the considerations to be made when
identifying suitable monitoring locations and discuss some of the newer technologies that are being
seen within the industry.
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Serial No: S-1001
b) Considerations for Determining Corrosion Monitoring Locations
Corrosion monitoring focuses on streams and materials that are susceptible to attack. Appendix d
provides generic recommendations for monitoring locations and techniques. When choosing an
applicable monitoring technique, it is useful to gain an overall perspective by considering three
aspects of naphthenic acid corrosion: -
• High velocity (usually over 30 meters/second) two -phase flow. This is primarily found in places
such as the last few tubes of atmospheric and vacuum furnaces, the furnace transfer lines, and the
immediate flash zones of columns. This is a severe service—corrosion monitoring is difficult,
and, if not done carefully, monitoring probes can actually increase corrosion by inducing extra
turbulence.
• Condensing acid vapours - This is often found in columns, particularly in vacuum columns and
in packing down to temperatures of 177°C. Another susceptible area that requires monitoring are
the vapour return lines from side strippers. Corrosion often takes the form of “rivulets” as the acid
runs down and gouges out the material. Another susceptible area that requires monitoring are the
vapour return lines from side strippers.
• Moderate velocity erosion/corrosion - There is not a well -defined lower velocity for this
corrosion and it is very sensitive to turbulence at such locations as control valves, elbows, orifice
plates, and pumps.
At the same velocities smaller diameter piping will tend to show more erosion/corrosion than larger
piping due to wall shear stress effects. These
conditions are most often found in side cut piping and
pump-around loops, but can also be found in bottoms
piping. This zone is especially sensitive to
sulphidation effects.
Depending on the exact nature of sulphide scales

formed with the particular crude, the presence of
sulphur compounds can increase corrosion, but can
also significantly inhibit corrosion (as discussed in
section 7a). The corrosion monitoring locations given
in the report attempts to cover all three regimes.
Figure 9.1 – Recommended Inspection Locations
No single monitoring method for on-line detection should be used alone and a possible suite of
corrosion monitoring should consider using electrical resistance probes, corrosion coupons, field
signature method, hydrogen permeation, stream sampling for metals analysis, and conventional
equipment inspection techniques.
Baseline corrosion monitoring should be performed before the high acid crude is run. We recommend
accumulating a minimum of 30 -60 days of baseline data at each blending increment, until the final
blending target is achieved. Monitor and note any correlation of the corrosion rates with crude slate
changes, or other significant process changes.
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Serial No: S-1001
c) Developments with FSM Technology
Field Signature Method technology, FSM for short, is a non-intrusive corrosion monitoring method
that has some particular advantages for naphthenic acid corrosion monitoring. Corrosion
measurements are made on the actual process component, as opposed to using a probe that measures
the corrosivity of the process fluids.
Each FSM sensor consists of a matrix of up to 84 metallic pins, which are welded to the outer wall of
the pipe, in a rectangular pattern. An electrical current is passed from one side of the matrix to the
other, and the voltage developed between each pin and its neighbour is measured. This gives a unique
electric-field signature that depends on the geometry and thickness of the pipe and the electrical
conductivity of the metal. Any changes in the field (or signature) resulting from internal corrosion or
erosion are revealed by a change in voltage across the sensor pins.
While the FSM system has the advantage that it is

non-intrusive method that measures the corrosion of
the component directly, its major disadvantage is
that refinery FSM systems are not currently
configured to take readings continuously. A
technician (trained by ii-Corr) would take periodic
readings and then the data would have to be sent to
ii-Corr for interpretation and the issuing of a formal
report. This meant that there was a significant delay
from taking the reading to obtaining a meaningful
output while in the meantime a significant corrosion
even could have taken place.
Figure 9.2 – FSM Matrix in Refinery Service
A new version has the FSM technology has recently been brought to market. The FSM-Log uses the
same methodology to determine the wall loss due to corrosion but it differs from the original version
utilises a permanently installed data logger rather than the handheld portable logger. Additionally, the
FSM-Log has a greater degree of sensitivity with accuracy of 0.03% of pipe wall thickness versus
0.1% for the previous variant.
With this version, there is the ability to collect data more frequently, every hour if required. The data
logger also contains the software that has the capability to interpret each set of readings and provide
the operator with useable data, providing corrosion rate measurements without the need to send the
dataset to iiCorr for interpretation. The system can be set up to communicate with the refinery DCS
system so that data can easily be reviewed remotely.
With the increased frequency of measurements, the increased accuracy and resolution coupled with
the ability to obtain useable corrosion measurements remotely, the new FSM-Log offers the refinery a
flexible tool that can accurately measure corrosion rates on high temperature and remote sections of
the plant and provides the operator with the facility to optimise their corrosion control program and
responds quickly to events of increased corrosion.
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d) Permanent High Temperature UT Installations
One of the most interesting recent innovations in corrosion monitoring is the development of
permanent, high temperature ultrasonic thickness sensors that can provide online wall thickness
measurements. There are two systems currently available; Rightrax HT UT system developed by GE
Inspection Technologies and Permasense, a collaboration between Imperial College London and BP.
The most versatile system available in the market

is the Permasense system, which utilises
permanently installed sensors fixed to the pipe
surface. For this system, the probe is fixed to the
surface via two bolts that are stud welded to the
pipe surface. The system has been tried and tested
on pipework running at temperatures up to 600 °C
which provides an advantage over other systems
available in the market.
The probe has a measurement accuracy of 0.1mm

(0.0039”) and can take measurements in ranges
from every 5 minutes to several days. Continuous
wall thickness measurements from the same point
eliminates the uncertainty of manual
measurements made at extended time intervals and
enables corrosion rates to be determined with
much greater confidence, and trends to be flagged
and subsequently investigated Figure 9.3 – Permasense Probe in Service
Figure 9.4 – Data Manager Trend showing Corrosion Events
The above chart clearly illustrates the distinct trends in different time periods that can be identified
from the data, and this can then be associated with prevailing process conditions. This highlights the
value of the Permasense continuous monitoring system to not only provide real time wall thickness
data, but also to enable operations to be managed with clear knowledge of the respective corrosion
rates
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The devices are ATEX zone II rated and the Permasense system comprises of a number of sensors,
installed wherever corrosion is to be monitored. The sensors can be placed in multiple arrays to
monitor corrosion around critical areas such as elbows or pipe bends. The sensors then wirelessly
couple to each other and form a secure communication path to a gateway. This is in turn connected to
the customer’s server hosting the Permasense Data Manager which incorporates database and viewer
application.
Figure 9.5 – Representation of Permasense Network Array
The system is very low maintenance as the mesh is self-configuring, self-managing, and self-healing,
there are no sacrificial elements to replace and the batteries have exceptionally long life. These
systems have the potential to be a very valuable tool in monitoring high temperature corrosion and
there are over 3000 sensors deployed in ~30 refineries worldwide.
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Serial No: S-1001
e) HydrosteelTM Hydrogen Flux Measurements
The basis of this technique for corrosion monitoring is that certain modes of corrosion in a refinery
result in phenomena where atomic hydrogen diffuses into the steel pipe or vessel wall. When the
hydrogen atoms permeate to the outside surface of the pipe, they rapidly combine to form a hydrogen
gas molecule. By monitoring changes in the hydrogen diffusion rate, the variation of the internal
corrosion rate may be inferred. The instrument is used to detect hydrogen gas levels on the outside of
the process pipework, and can operate on equipment at temperatures up to 500 °C.
Ion Science, the manufacturers of the Hydrosteel™ commercial instruments claims that the high
temperature corrosion of steel alloys by naphthenic acids is one such corrosion mechanism. Several
technical papers have been published to show that the method can detect very low levels of hydrogen
gas, and that changes in naphthenic corrosion rate can be tracked fairly rapidly (within hours) for low
alloy steels. The response time is a function of temperature and wall thickness, as well as interference
arising from hard inclusions and deformities within the steel. The area of pipe surface from which the
hydrogen is gathered is defined by a thin circular aluminium plate that is held in close contact with the
steel pipe wall.
There has been a plethora of technical papers in which Ion Science have looked to correlate hydrogen
flux readings with readings from traditional corrosion monitoring methodology so that the flux
readings can be used to determine an instantaneous assessment of corrosion rates. While Nalco have
no direct experience of using this tool in this manner, two of the more recent papers published jointly
by Chevron Pembroke Refinery and Ion Science [5, 8] at a recent NACE conference claim that
corrosion rates derived from hydrogen flux measurements corresponded well with those determined
from UT measurements.
It is the author’s opinion that with the portable device, the measurement plate can become easily
deformed through prolonged normal use and this can result the swept surface area and side leakage to
vary between readings. This technique is only practical in routine field use when the detector plates
are firmly attached in specific locations, to eliminate variations in surface contact efficiency, and to
move the analyser head between these permanently fixed plates.
Another limitation is that the aluminium detector plates can only accommodate a small degree of
curvature in a single plane resulting in the fact that the device is not suitable for taking measurements
on pipes with a radius less than 4-5 inches and it is not suitable for a susceptible location such as a
pipe elbow.
However, bearing in mind the comments regarding fixed

measurement points, Ion Science have developed the Hydrosteel
7000 device which takes readings at fixed intervals and stores
them on a data logger. The data can then be downloaded and
variations in hydrogen flux can be correlated to corrosion events
and changes in stream composition.
Nalco is aware of a Super Major customer who is evaluating this

technology in naphthenic acid service. But it is not preferred
monitoring tool.
Figure 9.6 – Hydrosteel 7000 Online
Hydrogen Flux Monitor
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Serial No: S-1001
f) Cormon CEION Probes
In choosing traditional electrical resistance (ER) probes one must sacrifice sensitivity versus longevity
of the probe, which can be a problem if the probe cannot be readily retracted and replaced. Cormon
has a range of high temperature probes under their “CEION™” trademark, which are claimed to have
better sensitivity and longer lifetimes. For example, a traditional 1 mm flush mounted probe with a
“life” of 0.5mm (about 20 mils, or two years at 10 mpy) needs about a week to detect a 10 mpy
change in corrosion rate. The CEION probe with a 1.5 mm element has an expected “life” of 0.75 mm
(~ 3 yrs at 10 mpy) will respond almost instantaneously to a 10 mpy change. CEION™ probes report
the process stream temperature as well as the corrosion rate.
g) Stream Sampling and Laboratory Analysis
Laboratory tests for stream metal contents are not a sure -fire method of detecting naphthenic acid
attack, since the attack zone could be so localised that at very little metal needs to be lost before a pipe
or vessel becomes perforated. However, any significant increase in metal content above the base -case
readings can be taken as a sign that a more widespread or severe attack is occurring.
Base-case information should be gathered from non -naphthenic runs. There will be some evidence of
background corrosion from general sulphidic and low –TAN mechanisms for the base case runs. For
the crude and residue streams, there will be tramp corrosion debris from upstream oil field pipeline
and transportation vessel corrosion. These measurements will allow the engineers to assess the
variability of the contaminant levels between crude batches, and permit the average background levels
to be established.
Acidity of the crude and side cuts should be monitored with ASTM standard TAN measurements,
using the electrometric end-point determination (ASTM D-664). This is required for black oils, where
a colorimetric end-point is inappropriate. The same method should be used for the white oil distillates,
to maintain consistency throughout the data series.
Metals analysis should measure TOTAL iron and nickel, not just the hydrocarbon -soluble portions.
In most instances where naphthenic acid attack occurs, there is enough H2S present to decompose iron
naphthenates in solution, and to deposit solid FeS. This probably necessitates an ashing and acid
digestion method of sample preparation, to obtain all of the metals in a uniform solution for analysis.
Side cut streams should be sampled for TAN, Fe and Ni levels. Fe is the best indicator of corrosion
for carbon steel and low alloy equipment. Ni is the best indicator of corrosion of austenitic stainless
steel equipment. Prior to blending with the high acid crude, the background values for Ni and Fe
should be determined at the established stream sampling points.
On a weekly basis, monitor as a minimum, the diesel, and gas oil streams for the iron and nickel
content. Additional streams may be necessary as determined in the plant assessment. An increase in
Fe of 2 -4 ppm above background or an increase in Ni of 0.1 -0.2 ppm above background will indicate
an increase in corrosion rates.
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The following suggestions are offered to ensure that the stream sampling is accurate:
• Samples must represent the run on high acid crude, and should not be taken after the HAC
campaign has terminated.
• Analyses must include all metals in the stream (specifically both soluble & insoluble Fe & Ni
metals.)
• Analyse the TAN & metals in the crude and all the side cuts.
• Sample must represent the actual streams, not the sample piping. This means that the sample
piping must be adequately flushed before grabbing the actual sample.
• Samples also need to be periodically taken at heavy oil battery limits (FCC, MHC, VBU,
Coker, and HDS Units) to assure that the inhibitor is dispersed effectively to these limits.
h) Corrosion Coupons
Corrosion coupons are the classic measurement tools for refinery corrosion monitoring. Corrosion
coupons are very inexpensive and available from a variety of sources. We recommend that, in
addition to the corrosion rate and a verbal description of any pitting, a photographic record be
maintained before and after cleaning.
Coupons are not good where short-term effects dominate, because the coupon gives only an average
corrosion rate over the entire exposure interval. For most equipment, coupons are typically installed
and withdrawn at the scheduled unit shutdown. Coupons are a good compliment to ER Probes in
lower velocity flow regimes (side cuts), and within the atmospheric and vacuum towers.
Coupons have also been very effective in one UK refinery that installed a side stream flow loop in
their HVGO pump- around circuit. Here they gave a good comparison of before and after inhibitor
injection situations, and enabled evaluation of alternate metallurgies against pitting attack. The
coupons were used together with FSM, CEION, and E.R probes to evaluate the strengths and
weaknesses of each monitoring method under the same velocity, temperature, and process stream
property conditions.
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10) Observations & Discussion Paradip Refinery -IOCL
a) Overall Review
A block diagram of the complete refinery unit is in appendix. The refinery has one Crude unit (AVU)
unit. In downstream of Crude unit there are DCU, Indmax (FCCU), VGO HDT, DHDT, ATF Treater
and NHT units.
If HAC crudes are going to be processed they will be charged to AVU first and high TAN product
streams will normally end up in the feed to the downstream units.
IOC Paradip Refinery is east cost of India. Crudes will be imported by sea IOCL Paradip will have
dedicated jetty to receive Crude Cargo. Then crudes will be transferred through pipeline to tankage
and AVU to process in refinery. The temperature of crudes during this transportation from Cargo to
unit will be maintained close to normal environment temperature. So there is no risk of HAC
corrosion in this section.
The metallurgy of the individual components has been surveyed and in general, the plant is
constructed from carbon steel. For few selected location P5, P9 SS 410 and SS304 are also used. In
few locations higher metallurgy are also used.
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b) Crude Oil Blends to be Evaluated
IOCL Paradip provided a list of High TAN Crude through the tender document. During our visit to
Refinery we discussed on the provided list and came to know that IOCL Paradip has plan to process
any HAC available in market with economic benefit. The specific risk with that crude will be
discussed prior to processing. After discussion we came to a conclusion to run risk assessment (RA)
on four different crude blends having Max Crude TAN 0.8, 1.0, 1.2 and 1.5 mg of KOH/g.
We have prepared the following for crude blend with TAN distribution in different cut to have the RA
for those crude blends. This will give the flexibility of choosing your Crude Basket depending upon
availability and economics. You can process any HAC from market including all crudes mentioned in
the tender document at the required % to match your production requirements. You should mix those
crudes in right proportions to adjust the yield % of side cut and the TAN distributions.
Crude Blend 1 – Crude Blend 2 – Crude Blend 3 – Crude Blend 4 –

TAN 0.8 TAN 1 TAN 1.2 TAN 1.5
TAN TAN TAN TAN
Stream Mg of Sulfur % Mg of Sulfur % Mg of Sulfur % Mg of Sulfur %
KOH/g KOH/g KOH/g KOH/g
RAW
0.8 0.8 1 0.8 1.2 0.8 1.5 0.8
Crude
KERO 0.5 0.1 0.6 0.1 1 0.1 1.2 0.1
LAGO 0.8 0.15 0.8 0.15 1 0.15 1.5 0.15
HAGO 1 0.4 1.2 0.4 1.5 0.4 1.8 0.4
RCO / AR 1 0.9 1.5 0.9 1.8 0.9 2 0.9
Vac Dis 0.6 0.5 0.6 0.5 1 0.5 1 0.5
VGO 0.8 0.8 1 0.8 1.2 0.8 2 0.8
HVGO 1 0.9 1.2 0.9 1.8 0.9 2 0.9
Recycle
1 1 1.2 1 1.8 1 2 1
Oil
VR 1 1.2 1.2 1.2 1.8 1.2 2 1.2
The design Crude blend for IOCL Paradip is 20 % Kuito+48 % Kuwait+32% Maya of > 0.5 TAN in
the Crude Blend. Nalco has also studied the same blend and found high risk in HVGO section with
distributed highest TAN value close to 2.9 TAN unit. So we request IOCL to install corrosion
monitoring tool prior to processing of that crude blend.
Nalco has also suggested few possible crude blend compositions to have the targeted crude blend
TAN having Kuwait and Maya in 60:40 ratio in the blend. Please find the attached table.
Nalco Limited
Serial No: S-1001
Proposed crude blend compositions
TAN distribution of crude blends
Crude Oils of Interest

Some of the crudes in the list offered have processing problems other than the anticipated naphthenic
corrosion attack. Certain refineries have noticed these problems, whilst others have not encountered
them. This is due partially to the configuration of those refineries, and in some cases due to the other
blend components used in the feeds. A brief discussion of the crude follows, and where any problems
occurred these will be noted. Where the crudes have been processed extensively without problems,
this will also be stated. All these 23 no of crude should be processed with proper corrosion monitoring
program. Please find the brief of each individual crude as follows:
Doba
Doba is a heavy, low sulphur crude produced from the Doba basin in the southern region of the
Republic of Chad. It is a blend of three different fields. The three fields are Kome, Miandoum and
Bolobo. The Doba crude has low gravity, low asphaltenes, sulphur and nitrogen properties which
Nalco Limited
Serial No: S-1001
make it attractive, but it has a high acid number (TAN 4.1) and calcium levels. The Doba calcium
range is in the 200-250 ppm range.
Doba Export Blend contains significant amounts of organic calcium in the residuum. Calcium can
adversely impact the performance of residuum hydroprocessing or residuum FCC units and should be
removed before processing in these units.
Refiners have had success removing calcium in Desalter utilizing special chemical systems. Nalco can
provide information on successful practices. Calcium should not pose a problem for direct burning of
Doba Export Blend as a Utility Plant.
We don’t recommend to process DOBA from the very beginning. Once the plant performance is
established, then we can introduce DOBA in crude blend.
Dar Blend
Dar is low sulfur high TAN crude having API in the range of 25. Higher TAN is a concern with this
crude. But sometime the crude also contains higher BS&W upto 5 %. So it may require extra care in
tank settling to settle down the water. Higher Ni contain may affect the FCCU operation. The
conductivity of this crude is also higher. So the Desalter operation will get affected. We are
successfully processing this crude any many refinery.
Jubarte
This is a High TAN low sulfur crude from Brazil having very high iron content in the crude. Due to
presence of metal the conductivity of this crude will be higher. The conductivity will affect the
desalter electrical system. TAN is getting concentrated in the vacuum column. So the vacuum column
TAN will be very high, Vac gas oil TAN concentrate up to 6.7 TAN unit. Nalco has processed this
crude successfully. We recommend to start this crude @ 5% in blend to see the effect of this crude in
blend. It has 2 % asphaltene in it. So dilution of this crude with paraffinic or aliphatic crude can
destabilize the asphaltene and can cause emulsion problem inside desalter as well as fouling issue in
preheat exchangers.
Heidrun
Many refineries have processed this crude, even at up to 40% of the whole feed. The naphthenic acids
concentrate into the heavier fractions, and it is necessary to use inhibitors for these processing areas.
No other processing problems have been reported. One of our early customers processed this crude
without inhibitor protection in the top of the vacuum column, believing that naphthenic corrosion
would not occur below 200°C. The vacuum feed and heavy distillate areas were protected with
inhibitor. The 410SS tray at the top of the vacuum column was attacked in one quadrant, whilst the
rest of the tray was unaffected. The customer has seen no recurrence of this problem after installing
inhibitor on the vacuum top pump - around.
Roncardor Heavy
This is also a high TAN crude from Brazil having very heavy gravity. TAN is mostly getting
concentrated in Diesel and LVGO section. Few batches have issue with higher chloride in vacuum gas
oil. It has wax as well as asphaltene in it. The asphaltene destabilization issue may observed with this
Nalco Limited
Serial No: S-1001
crude. So we recommend to maintain the desalter wash water in pH close to 5.5 to 6 to have a better
emulsion breaking. We have experience of having higher chloride in vacuum overhead system due to
extended hydrolysis of CaCl2 in presence of Nap-acid. You may have some issue of coloration in
light KERO and ATF stream. Due to the low API there will be difficulties in desalter operation in
terms of oil under carry and emulsion breaking.
Ostra
This is also one Brazilian heavy crude having higher TAN and low sulfur. TAN gets concentrated in
in HVGO and LVGO section. There is no specific observation with this crude.
BCF-17
This is one very heavy crude from Venezuela. TAN and sulfur levels are high. The viscosity of this
crude is also high. This crude contains higher quantity of filterable solid. Due to all facts this crude is
having desalting issue. The conductivity of this crude is also higher which affects the desalter
electrical system. The higher Vanadium in FCCU feed can cause problem to FCCU operation.
Captain
This is one High TAN, heavy and low sulfur crude. The desalter operation will be handled with
proper desalting operation. The TAN will get concentrated in the Vac column. We have experienced
higher concentration of Chloride in vacuum overhead .Proper blending will minimize the issue.
Grane
This is one high TAN and heavy crude. Desalter operation needs to be taken care with proper Desalter
equipment. It contains 10.6% wax in it. So it will destabilize the asphaltene when mixed with
asphaltic crude. TAN will get concentrated in the HVGO section. Due to very high sulphur and TAN
in VR, this section needs to be monitored for naphthenic and sulphidic corrosion.
Albacora Laste
This is also one heavy high TAN and low sulfur crudes. It is having 2.3 % asphaltene in it. So the
chance of asphaltene destabilization is there to cause desalter upsets and fouling. The asphaltene will
get concentrate in VR and causes fouling in VDU and coker heater. Solid contain is also as high as 60
ptb. So very good desalting is required to minimize emulsion and fouling issue associated with solid
in crude. Nitrogen contain in HVGO is also very high.
Monagas 18
Monagas 18 is heavy crude from Venezuela. The sulfur is very high. Desalter will have some
difficulties to process this crude. Brine will contain higher quantity of H2S. The Neutralizing amine
consumption will be higher to maintain the pH of overhead system. We have limited observation with
this crude.
Nalco Limited
Serial No: S-1001
Kuito
Many refineries have used this crude, and in some cases it is not the acidity that limits the percentage
that can be processed. In one French refinery with a single distillation train, the diesel cetane index
dropped too far due to the large amount of naphthene ring hydrocarbons in the components for final
diesel blending. The naphthenic hydrocarbon rings do not crack sufficiently in the FCC unit and
straight distillation operations for the crude to be processed at high percentages whilst maintaining
diesel quality. Another refinery in Singapore reported that 20% was the highest rate they could
tolerate due to the high nitrogen contents that were in the HVGO streams used for feed to a mild
hydrocracker. The crude does have very high nitrogen contents in the HVGO and both residue
fractions (ATR 7,250 ppm and VR 12,700 ppm).
Vincent
This is also one heavy and high TAN crude. But, from desalting and corrosion control perspective, the
crude is running exceptionally well. But higher demulsifier dosing rate is required. Increase in NH3
and H2S level is observed in the overhead system.
Van gogh
Van gogh is a heavy and high viscous crude. So desalter operation is one of the challenges with this
crude. Special care need to be taken with proper Desalter equipment. Some batches reports very high
salt content (150 ptb). So blending needs to be done properly. The TAN level is also higher and it is
getting concentrated in the atm bottom and vacuum column.
Boscan
This is extra heavy and very high viscous crude. Very difficult for desalter operation. It should be
diluted in blend before processing. TAN and sulfur level are high. Nitrogen in VR is extremely high.
It contains 11.6% asphaltene. SO when it will be diluted with lighter crudes asphaltene will get
destabilized and will cause asphaltene precipitation. We recommend IOCL not to process this crude in
the unit.
Pazflor
Pazflor is high TAN crude from Angola. Corrosion monitoring for HAC program should be there to
control the Nap acid corrosion. We don’t have any specific issue reported with this crude.
Pyrenees
Pyrenees is high TAN low gravity crude from Australia. Metal contain is low But due to higher
gravity Desalter operation will have challenges. TAN will get concentrated in the atm bottom and in
the vac column. No specific issue has been observed in this crude.
Marlim
Marlim is high TAN crude from Brazil. It is also one heavy crude as well as high conductive crude.
So sometime it causes problem with desalter operation. We experience oil under carry. The
conductivity of this crude causes high amps in desalter transformer and creates huge emulsion rag
Nalco Limited
Serial No: S-1001
layer inside desalter. It leads to oil under carry. But we have taken care the issue with proper
demulsifier application. We have also observed increase in chloride as well as corrosion rate during
processing of this crude.
Duri
Duri is also high acidic crude. Maximum concentration of acid will be distributed in diesel and light
VAC gas oil. Bottom part of both the column need proper monitoring. Also, we have experienced
Naphthenic Acid activities in Kero section in one refinery. It is also heavier crude with API in the
range of 20. So there may be issues with Desalter operation. A very good demulsifier application
should be there to handle issues with Desalter operation.
Dalia
Dalia is heavy and high acidic crude. TAN level of raw crude varies from 1.2 to 1.6
mg of KOH/gm. (sometimes 1.75). Therefore, raw crude TAN should be monitored batch to batch.
With Dalia, Kero section should be monitored properly for acid corrosion. Being heavy Crude it will
have effect on Desalter operation which calls for a good demulsifier program. Some batches of Dalia
can have issues related to ETP due to presence of methanol in the crude.
Clair
This is one high acid crude with crude TAN 1.2 with sulfur value 0.44 %. The API is 23.3. So extra
care should be taken with desalter operation. The TAN will get concentrated in the vacuum column.
We should mix the crude in blend to maintain the TAN distribution within desire limit. No other
specific issue has been observed with this crude.
DCOM22
This is high TAN crude. So it should be processed with proper high tan chemical and monitoring
program. We don’t have any specific observation with this crude.
Frade
Different batches of Frade are having different properties. The TAN varies from 0.46 to 1.6 mg of
KOH/g. Asphaltene contain also varies from batch to batch. So every batches need to be monitored.
The asphaltene will get destabilized in presence of lighter crudes and will cause issue related to
asphaltene destabilization. The crude should be processed in presence of proper corrosion monitoring
program.
Nalco Limited
Serial No: S-1001
c) Risk Matrix Evaluations of the Atmospheric and Vacuum Distillation unit
i) Overview
It provides the details of potential impact of processing high TAN opportunity crude on equipment /
piping of units. It has been identified using our proprietary process simulation software and risk
assessment.
The risk assessment reviews result of product streams of interest, their operating conditions to identify
the possible impact of HAC.
The risk assessment matrices for AVU are presented in appendix, with stream characteristics describe
under crude blend detail. The assessment grades the severity of the environment on the metals
involved, and takes into account the (bulk flow) velocities, acid content, sulphur content, phase
change behavior and relative resistances of the employed metallurgies to naphthenic attack.
The properties of the crude stream are used for the feeds up to each furnace, but as the liquid begins to
flash the remaining liquid will resemble the heavier distillates and residue in character. For both
atmospheric and vacuum furnaces, the property of the “worst case fraction” has been assumed to
approximate the liquid phase in the radiant sections of furnaces and in the outlet headers and transfer
lines.
The impact of processing each crude blend is assessed and the risk to the identified corrosion loops is
presented in the following sections and implications to process units are discussed in detail in the Risk
Assessment Summary
The risk assessment procedure uses a number of important factors that affect the corrosion rates that
result from running naphthenic crudes. The main factors are the acid activity of the stream (acid
concentration and specific aggressiveness), temperature, velocity/turbulence, piping geometry (bend
radius), substrate metallurgy, solubility of metal naphthenate in surrounding process fluid, and the
presence of any corrosion-enhancing or inhibiting chemicals. The assessment tables for the resultant
compounded corrosion behavior depend on weighting of the relative factors according to their impact
on the final corrosion rate.
Acidity reported is the TAN of the stream, without separation of the naphthenic acids from other acid
contributions such as H2S or light organic acids. The enhancement of acidity in the distillates is due
to the weight fraction of each component in the stream, and the publicly reported acidities of the pure
crude fractions.
The output of the weighted calculations includes stream velocity and phase-change factors, base
metallurgy, and the compound effects of the sulphur and the TAN of the streams.
The tables 5-10 in appendix 2 and 3 show the risk severity in relative terms of expected naphthenic
acid attack for the equipment and plant components under consideration.
The pattern of the risk assessments shown in tables 5-10 is in line with the Nalco’s experience with
customers that have processed acid crude blends over several years and at elevated percentages. But
every operation is unique so proper monitoring is mandatory to check the corrosion activities.
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Serial No: S-1001
ii) Factors affecting the Naphthenic Acid Corrosion

•Naphthenic acids are aggressively corrosive
–Products of the chemical reaction between acid and metal are oil-soluble and are easily washed away
from the surface in the bulk oil fluids.
–This means that the corrosion is almost exclusively in a bulk liquid environment.
–Velocity of the fluids is also an important factor for the final corrosion rate
Main factors affecting high temperature naphthenic acid corrosion are as follows. But pressure drop
has no effect on Naphthenic acid corrosion.
–Temperature
–Acid number
–Velocity and locations
–Metallurgy
–Sulphur content
TEMPERATURE: Naphthenic acid corrosion does not take place when the temperature is below
177 Deg C. The favorable temperature range for the naphthenic acid corrosion to occur is between
177 to 425 deg. C. The max. effect of the naphthenic acid corrosion is observed in the range of 370
Deg C.
Thus the effect of naphthenic acid corrosion is most severe in the LVGO, HVGO and
HAGO streams. The naphthenic acid loses its corrosivity above 400 deg. C. due to the degradation of
its structure due to the thermal stress.
The corrosion is of more concern in the liquid phase then in the vapor phase. It is most severe when
both the liquid and the vapor phase are present.
HIGH VELOCITY: The oil-solubility of the metal naphthenates is responsible for the easy removal
of the corrosion by-products from the reaction sites, leaving a freshly exposed surface where further
attack can occur.
The rate at which these soluble metal salts are removed from the substrates is accelerated by high
liquid scouring rates of the surfaces, so the corrosion is more severe with high velocity liquid streams
and in impingement zones.
Prone locations: T joints, weld joints, angle bend, thermocouples, stubbing, bends and everywhere
where eddies can form.
TAN & NAT: It also depends on the total quantity of acids present mainly content of naphthenic acid
and its structure. However since NAT number is not easy to find out indications are made through
TAN number.
METALLURGY: This is an established worldwide practice: for resistance to high-temperature

sulphur attack, higher chromium alloys are employed. For resistance to naphthenic acids, alloys with
enriched molybdenum are required. The minimum specification for adequate resistance is >2.5%
molybdenum in the austenitic series of stainless steels, and that mandates at least 316SS (Mo range
>2.5%) or 317SS (Mo range 3% - 4%) grades to be used.
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Serial No: S-1001
SULPHUR EFFECT: Sulphur content up to certain extent provides protection against naphthenic
acid corrosion. But beyond certain levels it increases the corrosion rate.
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Serial No: S-1001
iii) Summary & Discussion of the Calculated Risk Associated with High Acid Crudes
This section outlines the calculated risk to AVU when processing the naphthenic acid crude blends.
summary of the calculated risks is shown in the table below:
Risk Assessment OUTPUT SCREEN

Unit / TAN 0.8 - Risk TAN 1.0 - Risk TAN 1.2 - Risk TAN 1.5 - Risk
System Description Assessment Assessment Assessment Assessment
Flashed Crude E122/222 D/S upto E124/224 Low-Moderate Moderate Moderate Moderate-High
Preheated crude D/S of E124/224 to common line Low-Moderate Low-Moderate Low-Moderate Moderate
Flashed Crude From E129 upto E127 Low-Moderate Moderate Moderate Moderate-High
Preheated crude Common line to heater after mixing Low-Moderate Low-Moderate Low-Moderate Moderate
Preheated crude Individual Passes to heater (8 passes) Moderate Moderate-High Moderate-High High
Heated Crude Heater Out Passes Low-Moderate Low-Moderate Moderate Moderate
Heated Crude Common transfer line from Heter ( 1 & 2 train) Low-Moderate Low-Moderate Moderate Moderate
KERO Product KERO Product Pump Sucn Low-Moderate Low-Moderate Low-Moderate Moderate
KERO PA KERO PA- Column to pump Low-Moderate Low-Moderate Moderate Moderate
KERO PA P005A/B Pump discharge Low-Moderate Low-Moderate Moderate Moderate
KERO Reflux P005A/B Pump discharge to column Low-Moderate Low-Moderate Moderate Moderate
LAGO Product Product to LAGO Stripper Low-Moderate Low-Moderate Moderate Moderate-High
LAGO Product Stripper bottom to pump P009A/B Low-Moderate Low-Moderate Moderate Moderate-High
LAGO Product pump discharge upto HAGO added Moderate Moderate Moderate-High Moderate-High
AGO Product Common line with HAGO Moderate Moderate Moderate-High High
LAGO PA Column to P006A/B Low-Moderate Low-Moderate Moderate Moderate-High
LAGO PA Pump disc up to DS E038 common line Moderate Moderate Moderate-High High
LAGO PA individual train up to common line to column Moderate Moderate Moderate Moderate-High
LAGO PA to E043/47 up to common line to column Low-Moderate Low-Moderate Moderate Moderate-High
LAGO PA common return to column Low-Moderate Low-Moderate Moderate Moderate-High
LAGO Reflux reflux to column Moderate Moderate Moderate-High High
HAGO Product product draw to striper Low-Moderate Low-Moderate Moderate Moderate-High
HAGO Product striper bottom to pump P029A/B Low-Moderate Low-Moderate Moderate Moderate-High
HAGO Product pump disc to AGO product line Low-Moderate Moderate Moderate-High Moderate-High
HAGO PA draw off to pump P030A/B Low-Moderate Low-Moderate Moderate Moderate-High
HAGO PA P030A/B disc up to distribution Moderate Moderate Moderate-High Moderate-High
HAGO Reflux reflux to column US control valve Moderate Moderate Moderate-High Moderate-High
HAGO Reflux reflux to column DS control valve Moderate Moderate Moderate-High Moderate-High
HAGO PA Individual train upto E123/223 Moderate Moderate Moderate-High Moderate-High
HAGO PA Individual train DS E123/223 upto mixing Low-Moderate Low-Moderate Moderate Moderate
HAGO PA common line to column Moderate Moderate-High Moderate-High High
Heated AR Vac heater out passes (12 nos) Low-Moderate Moderate Moderate-High Moderate-High
Heated AR Vac heater out passes (12 nos) Low-Moderate Moderate Moderate-High Moderate-High
VGO draw off to pump P022A/C Low-Moderate Low-Moderate Low-Moderate Moderate-High
VGO Common disc before distribution Low-Moderate Low-Moderate Low-Moderate Moderate-High
VGO To individual train (Pdt+PA) Low-Moderate Low-Moderate Moderate Moderate-High
VGO VGO Product each train Low-Moderate Low-Moderate Low-Moderate Moderate
VGO PA to strainer (each train) Low-Moderate Low-Moderate Moderate Moderate-High
VGO PA strainer common line Low-Moderate Low-Moderate Low-Moderate Moderate
VGO PA bypass Low-Moderate Low-Moderate Low-Moderate Moderate-High
HVGO individual Pump discharge Low-Moderate Low-Moderate Low-Moderate Moderate
HVGO common Pump discharge (wash oil+PA) Low-Moderate Low-Moderate Low-Moderate Moderate
HVGO HVGO PA to individual train to E124B/224B Low-Moderate Low-Moderate Moderate Moderate
HVGO individual train DS E124B/224B to strainer Low-Moderate Low-Moderate Moderate Moderate-High
HVGO HVGO to steam generator Low-Moderate Low-Moderate Moderate Moderate-High
HVGO Common line to PA strained Low-Moderate Low-Moderate Moderate Moderate
VR VR DS E126 to PDT DCU Storage Low-Moderate Low-Moderate Moderate Moderate-High
Figure 10.5 – Risk Output for Evaluated Naphthenic Acid Blends
The level of risk shown above table is based on the highest risk level for the specified corrosion
loop and the full risk breakdown is outlined in the appendix.
Nalco Limited
Serial No: S-1001
d) Monitoring Tools and Chemical Injection Locations
i) Atmospheric Distillation Unit
The section of the report contains following:
Provides the details locations / Areas to be affected by corrosion.

Provides the locations where dosing is recommended.
It also provides the details of Monitoring devices to be installed for the purpose of effective corrosion
control monitoring:
Nos. of monitoring devices to be installed.
Types of devices to be installed.
Locations of installation.
Stubbing facilities to be provided for installation of monitoring devices.
The CDU unit is made of carbon steel and low alloy P5 and P9 steel. The furnace coils and the crude
transfer line are made of P9. This means that injection facilities are required for protecting the
column internals, pump around loops, and product rundown equipment in these areas of the Crude
distillation unit. Corrosion monitoring provisions are also required for the same areas of the plant, to
confirm either that inhibitor protection is unnecessary, or that it is effective when it is applied. The
pump around return streams provide a good route for addition of inhibitor into the column, and
achieve effective distribution across the whole cross section of the tower.
The recommendations for the inhibitor injection sites as listed in table below will provide protection
on the atmospheric distillation unit:
Device Location Type Protected Zones

Suction of pumps 10P-003A/B/C.
Feed Preheat Train, Furnace 10F-101
Quill # Use Locally Cooled Slipstream. Flanged 2"
and 10F-102, Column C-001 Flash
1a/b Can be managed with 2 quills out RF
Zone & Bottoms
of 3 pumps.
In the KERO PA circuit U/S of KERO PA, Reflux and product circuits,
Quill # QV1004A. Inside the isolation Flanged 2" heat exchangers and lines. Trays 16
2 valves. Use Locally Cooled RF downwards, C-002 Stripper Trays and
Slipstream. downstream.
In the LAGO PA circuit U/S of LAGO PA, Reflux and product circuits,
Quill # QV1006A. Inside the isolation Flanged 2" heat exchangers and lines. Trays 27
3 valves. Use Locally Cooled RF downwards, C-003 Stripper Trays and
Slipstream. downstream.
In the HAGO PA circuit U/S of HAGO PA, Reflux and product
Quill # QV1008A. Inside the isolation Flanged 2" circuits, heat exchangers and lines.
4 valves. Use Locally Cooled RF Trays 32 downwards, C-008 Stripper
Slipstream. Trays and downstream. Overflash line.
Suction of AR pumps 10P-
Quill # 007A/B/C. Use Locally Cooled Flanged 2" AR line, VDU furnace, 10F-002, flash-
5a/b Slipstream. Can be managed with RF zone & bottom of VDU column
2 quills out of 3 pumps.
Table: Injection Locations on CDU
Nalco Limited
Serial No: S-1001
The table above is based on the assumption that fixed flanged quills will be used in all locations.
The inhibitor injection into the crude preheat train is intended to protect the feed heating equipment,
including the furnace passes and transfer line. The inhibitor will stay in the liquid phase and help to
protect the 10-C-001 flash zone, the column bottom parts and the residue line. The injection into the
AR pump is to refresh the protection for the residue line and to protect the vacuum feed section,
furnaces, transfer lines and flash zone of the vacuum column.
The temperature profile of the tower, together with the calculated blend properties, show that elevated
levels of naphthenic acids can be present in the all the sections when certain naphthenic crude blends
are processed at elevated percentages at elevated crude TAN level. The zone below the LAGO would
then require inhibitor protection. But the corrosion risk will be monitor with the help of monitoring
tool and variation in TAN and Sulfur level in streams. Accordingly corrosion inhibition will be
required.
The author recommends that the corrosion monitoring facilities should be used to determine the
requirement for injection of inhibitor into any circuits. Analyses for TAN for every stream including
lighter cut like KERO are also recommended during highly acidic crude runs. When any section of
the tower is treated, this will also carry residual inhibitor with the hydrocarbon to protect the feed
preheat system of the downstream units.
The injection into the HAGO circulation return is intended to protect the tower from tray 32 and
below, the overflash line, C-008 stripper drum and product handling lines for the AGO stream.
Residual inhibitor will be carried with the AGO to the downstream hydrotreater preheat train and
provide protection there.
The injected chemical in the AR pump will help to provide a better corrosion protection to the AR
lines at the VAC furnace inlet pass and Vac heater and in Vac column bottom part.
The existing plate material is SS410 which is not resistant to Naphthenic acid corrosion. Due to
product distribution issues and the fact that packing is very thin and has virtually no corrosion
allowance, complete protection of packing material with inhibitor cannot be guaranteed. The author
recommends replacing the beds 3, 4 and 5 with SS316 or preferably SS317 material.
However Nalco has experience of successfully running HAC program with SS410 plate tray with
proper chemical inhibition. So it will good to run the HAC program with proper monitoring with
SS410 packing until the first opportunity for turnaround inspection.
With partial vaporisation of the feed in the final furnace passes, the remaining heavy liquids may be
richer in acidity. The residual liquid phase droplets in the fast vapour stream provide a ready solvent
of any metal naphthenates formed, and where direct impingement occurs at elbows, the shear forces
will help to scour away any metal naphthenate salts that are produced on the pipe walls.
The risk model responds to phase change as these sections are exposed to high temperature, high
velocity turbulent flow. This is the region where high rates of naphthenic acid corrosion can be found
with unsuitable metallurgies especially carbon steel. As these sections are exposed to a high level of
risk increased monitoring will be required around the outlet headers of the F-101 and F-201 heater
and if elevated levels of corrosion are observed, the injection of SCOPRION inhibitor in Crude charge
pump will be required to control corrosion in these sections.
Nalco Limited
Serial No: S-1001
A rigorous monitoring program around the outlet passes of F-101/201 is essential and at these levels
of risk the facility to inject SCORPION naphthenic acid corrosion inhibitor is required should
monitoring confirm elevated corrosion rates.
The monitoring of high temperature corrosion on the atmospheric distillation unit requires the
installation of 2 FSM’s, 11 corrosion probes and an increase in the frequency of inspections
The monitoring tools and their locations are specified in the table below.
FSM # Field Signature Method (IIcor/CorrOcean) Matrix Location Description

FSM # 1 Outlet Pass Line from 10-F-101 Furnace pass – in one pass
FSM # 2 Outlet Pass Line from 10-F-201 Furnace pass – in one pass
Cormon CEIONTM High Temperature Flush Mount Probe Element
Probe #
Corrosion Probes Material
Probe # 1 Upstream of Atm Heater 10F101 –in liquid line (Heated Crude) 5 Cr
Probe # 2 Upstream of Atm Heater 10F201 –in liquid line (Heated Crude) 5 Cr
Probe # 3 Upstream of FV 1039 in 300 mm line. Inside Isolation Loop (Kero) CS
Probe # 4 Upstream of FV 1040 in 200 mm line. Inside Isolation Loop (LAGO) CS
Probe # 5 Upstream of FV 2019A in 400 mm line. Inside Isolation Loop (LAGO CS
Probe # 6 Upstream of FV 1042 in 250 mm line. Inside Isolation Loop (HAGO) SS410
Probe # 7 & Upstream of HV 1015A/B in 250 mm line. Inside Isolation Loop
5 Cr
8 (HAGO)
Probe # 9 &
In 10P007A/B suction line prior to chemical injection point (AR) 9 Cr
10
Probe # 11 At
In 10P007A/B
one inlet pass
suction
to Vacuum
line prior
Heater
to chemical
10F102 (AR)
injection point 9 Cr
Notes:
Utilize the furnace pass flow control valves on furnace inlets as existing "corrosion coupons" to check
the relative corrosion rates between furnace inlets and individual passes.
FCV and TCV valves may be used as "corrosion coupons" for visual inspection in emergency in pump
around return streams. These valves have high shear operation with mixed-phase fluids on exit side.
One spare valve may be used in rotation to remove valves sequentially for rating purposes.
We can also install few Permasense as additional corrosion monitoring tool.
Table: CDU monitoring techniques and locations
In most of refinery we face difficulty to access the recommended locations for probe, FSMs and other
monitoring tools. So it is recommended to finalize the locations for exact installation of corrosion
monitoring tools in field after a field survey. Actual field condition will be considered during
finalization of monitoring locations.
Nalco Limited
Serial No: S-1001
ii) Vacuum Distillation Unit
The vacuum unit is made of carbon steel, low alloy P5 and P9 steel. Few lines with very high
temperature are made of SS304 and SS316. The furnace and the Vacuum transfer line are made of P9.
Vacuum furnace coils are made of P9. The Common transfer line is of SS316.
Injection facilities are required for protecting the Furnace, column internals, pump around and reflux
loops, and product rundown equipment. Corrosion monitoring provisions are also required for the
same areas of the plant, to confirm either that inhibitor protection is unnecessary, or that it is effective
when it is applied.
The recommendations for the inhibitor injection sites as listed in table below will provide protection
on the vacuum distillation unit:
Device Location Type Protected Zones

In the Vac Diesel Reflux line,
Quill # Flanged 2" Bed 2 and downward inside column C-
upstream of STR 002 A/B. Inside
6 RF 007.
the isolation loop US of FV3029.
In the VGO PA, US of STR-
Bed 3 and downward inside column C-
Quill # 003A/B. Inside the isolation loop Flanged 2"
007.VGO Circulation exchangers &
7 US of QV3004 A. Use Locally RF
Lines and the downstream.
Cooled Slipstream.
In the HVGO PA, US of STR- Bed 4 and downward inside column C-
Quill # 004A/B. Inside the isolation loop Flanged 2" 007.HVGO Circulation exchangers &
8 US of QV3002 A. Use Locally RF Lines and the downstream in HVGO
Cooled Slipstream. PA, Product and wash oil circuits.
In the wash Oil line, upstream of
Quill # STR 005 A/B. Inside the isolation Flanged 2" Bed 5 and downward inside column C-
9 loop US of FV3016.. Use Locally RF 007.Recycle Oil Circulation Lines.
Cooled Slipstream.
In the VR Quench line. Inside the VR Circulation line and all exchangers
Quill # Flanged 2"
isolation loop US of FV3008. Use in this circuit. Downstream line to
10 RF
Locally Cooled Slipstream. Coker furnace and storage.
Table: VDU injection locations
The protection of the vacuum feed section, furnaces, transfer lines and flash zone of the vacuum
column is done with injection into the AR pump suction line.
An injection facility to Vac Diesel reflux line is also provided to take care any corrosion risk to Bed 2
in any situation.
Injection into the VGO PA return is intended to protect the 10-C-007 tower from bed 3 down, the
VGO circulation and product rundown lines. Residual inhibitor will be carried with the feed to the
downstream units to give protection to the feed lines and heaters.
The injection into the HVGO PA circulation return is intended to protect the tower from Bed 4 down,
the HVGO circulation and product rundown lines. The residual inhibitor will be carried with the feed
to the downstream unit and provide protection in the feed lines and heaters/reactor.
Nalco Limited
Serial No: S-1001
The injection into the HVGO Wash Oil circulation to column is intended to protect the tower from
Bed 5 down, the Recycle Oil circulation lines.
The existing packing material is SS410 which is not resistant to Naphthenic acid corrosion. Due to
product distribution issues and the fact that packing is very thin and has virtually no corrosion
allowance, complete protection of packing material with inhibitor cannot be guaranteed. The author
recommends replacing the beds 3, 4 and 5 with SS316 or preferably SS317 material.
However Nalco has experience of successfully running HAC program with SS410 packing bed with
proper chemical inhibition. So it will good to run the HAC program with proper monitoring with
SS410 packing until the first opportunity for turnaround inspection.
With partial vaporisation of the feed in the final furnace passes, the remaining heavy liquids may be
richer in acidity. The residual liquid phase droplets in the fast vapour stream provide a ready solvent
of any metal naphthenates formed, and where direct impingement occurs at elbows, the shear forces
will help to scour away any metal naphthenate salts that are produced on the pipe walls.
The risk model responds to phase change as these sections are exposed to high temperature, high
velocity turbulent flow. This is the region where high rates of naphthenic acid corrosion can be found
with unsuitable metallurgies especially carbon steel. As these sections are exposed to a high level of
risk increased monitoring will be required around the outlet headers of the F-101 and F-201 heater
and if elevated levels of corrosion are observed, the injection of SCOPRION inhibitor in Crude charge
pump will be required to control corrosion in these sections.
A rigorous monitoring program around the outlet passes of F-101/201 is essential and at these levels
of risk the facility to inject SCORPION naphthenic acid corrosion inhibitor is required should
monitoring confirm elevated corrosion rates.
The monitoring of high temperature corrosion on the VDU requires the installation of 2 FSM’s, 9
corrosion probes and an increase in the frequency of inspections. The monitoring tools and their
locations are specified in the table below.
Note: All the stub metallurgy, stub specification should be according to piping
specification for that mother piping and the MOC should match the main pipe metal.
For Stub / probe and quill design, please see the appendix. But we recommend to
discuss with probe vendor also.
Nalco Limited
Serial No: S-1001
FSM # Field Signature Method (IIcor/CorrOcean) Matrix Location Description
Outlet Pass line from 10-H-102 Furnace pass , (Location will be decided in
FSM # 3
field)
Cormon CEIONTM High Temperature Flush Mount Probe Element
Probe #
Corrosion Probes Material
Probe # 12 & Upstream of the HV1012A/B, in 250 “line. Inside Isolation
CS
13 Loop (VD)
Probe # 14 and Upstream of the HV3008A/B, in 400 “line. Inside Isolation
CS
#15 Loop (VGO)
Probe #16 and Upstream of the HV3007A/B, in 250 “line. Inside Isolation
5 Cr
#17 Loop (HVGO)
Upstream of the FV3013, in 150 “line. Inside Isolation Loop
Probe #18 9 Cr
(Wash Oil)
Probe #19 20 In 10P025 A/B Discharge line. Inside isolation loop. (VR) 9 Cr
Notes:
Utilize the furnace pass flow control valves on furnace inlets as existing "corrosion coupons" to
check the relative corrosion rates between furnace inlets and individual passes.
FCV and TCV valves may be used as "corrosion coupons" for visual inspection in emergency in
pump around return streams. These valves have high shear operation with mixed-phase fluids on
exit side.
One spare valve may be used in rotation to remove valves sequentially for rating purposes.
Slipstream Requirement
We do not require any slipstream for chemical injection in KERO and VD section. But slipstream will
be required for all other injection points.
LAGO slipstream will be used for injection chemical to Crude, LAGO and AGO section. A heat
exchanger will be used to cool down the LAGO to match the requirement of slip stream.
VGO slip stream will be used for injection chemical to RCO, VGO, HVGO, wash oil and VR quench.
Local cooling equipment will be used to match the slip stream requirements.
Additional Monitoring tools
We recommend installing 6 no. of Permasense online thickness monitoring tool in the Crude heater to
crude column transfer line. We also recommend installing two numbers of Permasense to each Heater
out let pass.
Note: As FSM and Permasense can be installed online, so we will find out the actual location in the
field. The Permasense is also easy move, so we can move the equipment as per our requirement
during running operation.
.
Nalco Limited
Serial No: S-1001
e) Monitoring of High Temperature Corrosion in AVU
Comprehensive corrosion monitoring is critical when processing naphthenic acid crudes as it can be
used to quantify the risk to specific corrosion loops and to also monitor how well the corrosion control
program is performing and ultimately how well the risk is being managed.
The techniques employed at each site should be specified by the refinery corrosion engineers and
maintenance inspectors, as the methods must satisfy the refinery engineers that they are suitable for
the intended purpose.
For the corrosion monitoring of transfer lines, the installation FSM matrices on bends and elbows of
transfer lines and furnace outlet headers should be considered. The coverage of matrix will provide
comprehensive monitoring of corrosion of the susceptible areas on the outer radius of the bend.
Permasense permanent UT probes could be utilised in these sections however, since the monitoring is
to provide adequate coverage.
Nalco also recommend that the refinery considers the use of corrosion probes for monitoring
corrosion in liquid full lines. The use of the correct corrosion probe can provide the sensitivity
required to quickly detect corrosion events and allow the refiner to modify chemical dose rates to
keep corrosion under control. Additionally, this sensitivity can be gained without sacrificing the life
span of the probe if Cormon’s CEION probes are utilized.
IOCL Paradip has Packing and plates of SS410 for both the CDU and VDU column. The column shell
is also cladded. So Nalco recommend to conduct Gamma scanning for those areas to monitor the
corrosion activities more closely.
Nalco has checked the existing plan for Lab analysis. That schedule is OK with Nalco. For better
monitoring during HAC program Nalco recommend the following analysis.
Stream Analysis Frequency Special comment

Raw Crude blend BS&W, Salt, 1 per day The analysis frequency
Viscosity, TAN, TS will be reviewed in
Desalted Crude blend BS&W , Salt 1 per day every three months
Brine water O&G, pH 1 per day interval.
Desalter Wash water NH3, pH 1 per day
Desalted Crude blend TAN, Fe, Ni, V, TS 3 times / week
For all side stream TAN, Fe, Ni, V, TS 3 times / week
Overhead boot water Cl, Fe, pH, NH3, H2S 1 per day
The generic recommendations for additional corrosion monitoring recommendations for naphthenic
acid crude service can be found in the report. .
Nalco Limited
Serial No: S-1001
f) Impacts on Desalter Operation and on the CDU VDU Overhead corrosion issue
We have already discussed the concern related to Desalter operation and CDU and VDU overhead
system during the HAC period. IOCL Paradip will have 4 Petreco Desalter vessels. As per Desalter
datasheet the guaranteed salt out in Desalted crude is around 0.7 PTB. But the desalter operation
depends on many factors. We recommend to have a KPI of less than 1 ptb salt in the ex-desalter crude
with design operating condition.
IOCL Paradip has facility for ex-desalter caustic injection to minimize the chloride in overhead
system. But there is no injection quill used for caustic injection. We suggest to provide one Hastelloy
injection quill for caustic injection. It will help to maximize the benefit of caustic injection as well as
reduce the risk of caustic corrosion. We recommend to use one 3 to 11 % caustic solution @ 2 to 11
ppm on crude flow to maintain the minimum corrosion risk due to chloride hydrolysis. This caustic
injection will go with hydrocarbon and will not have any effect on ETP operation.
IOCL Paradip has facility to dilute the all the chemicals. The pump capacities for maximum dosing
locations are very high. We recommend pumping neat chemical to get the better result. IOCL Paradip
needs to review all those existing pump capacity. Nalco Demulsified chemical should not be diluted.
We may require to increase the pump capacity for Antifoulant dosing system with 40 LPH capacities.
We recommend providing a steam connection as diluent / slipping stream to Neutralizer chemical line
to have the better neutralization effect. We also recommend to provide one naphtha connection to
corrosion inhibitor chemical as slip stream. Antifoulant and Demulsifier chemicals do not require any
slipstream. There is chance of corrosion inside column top section. We recommend to provide one
corrosion inhibitor chemical injection facility with dedicated pumps in the TOP PA line going back to
column. We recommend to install few ER type corrosion probe to monitor the corrosion activity in
overhead system.
We have already discussed that the normal practice is to have a 10 MPY corrosion rate for overhead
system. The corrosion risk will also increase during HAC period. So we recommend to have a 10
MPY corrosion rate as corrosion KPI for overhead system instead of 4 MPY.
We have also discussed that the chloride ppm in overhead system is not 100% in our control and we
have also discussed how the chloride level in overhead system gets affected by crude property and
Nap acids. With a better understanding of technical background we recommend to have a 30 ppm of
chloride limit for overhead boot water. Our KPI will be to maintain the corrosion profile under
acceptable corrosion rate. Even the chloride level is high, Nalco can take care the corrosion rate and
can keep it within the acceptable limit. Nalco will monitor the pH profile with the help of Nalco
Patented Pathfinder® technology and accordingly neutralizer dosing rate and pH will be monitored.
As per standard practice we recommend to have a KPI of 1 ppm of Iron in the Overhead system.
The following actions are recommended to ensure good, on-going overhead corrosion control:
• A good Amine bases corrosion control program is recommended to provide better pH

control of the water condensation profile and minimise the risk of salt formation. Amine
neutralisers are used extensively within the refining industry due to their improved properties over
ammonia. They are stronger bases, have lower salt formation propensity and partition into the
water phase at / close to the water dew point. The correct neutraliser for CDU can be determined
using Nalco’s PATHFINDER software.
Nalco Limited
Serial No: S-1001
• Incorporate Nalco’s proprietary Strong / Weak Acid analysis into the routine service
schedule. This is a very simple field test (about 10-15mins) to determine the amount of acidic
species in the overhead sour water. By determining the amount of strong acids present in the
system, the stoichiometric neutraliser demand can be calculated.
• Dose neutraliser based on Stoichiometric Strong Acid demand NOT to an accumulator sour
water pH spec. Dosing neutraliser to simply hit a pH specification can lead to significant
overdosing if weak acids are buffering the system, potentially increasing the risk of salt
deposition. Therefore, it is critical that during naphthenic acid crude processing, that the refinery
should not “go chasing the pH” by adding excessive neutraliser. Add sufficient neutraliser based
on the strong acid levels and then allow increased filmer rates to mitigate the corrosion due to the
weak acid species.
• Monitor the overhead condensing section with Nalco’s PATHFINDER overhead process
simulator. This software is capable of determining key parameters that cannot be directly
measured such as water dew point, salt formation temperatures, mass of salt generated, wash
water injection requirement to name but a few. Given the potential for elevated risks of salt
formation, it is critical that this modelling is carried out to ensure the risks are correctly managed.
Again, for the reasons, described above there is a very high probability that the higher molecular
weight naphthenic acids will thermally degrade under the action of vacuum distillation. This will
inevitably lead to a significant drop in the VDU overhead accumulator condensate pH.
The degree and severity of corrosion will have to be determined on site when the actual naphthenic
acid crudes are processed. Therefore, as discussed previously, samples of the VDU sour water should
be sent to the Nalco laboratory for detailed analysis to determine the identity of the strong and weak
acid species.
The routine water samples should also be analysed for the strong and weak acid content and this
should be incorporated into a service plan.
g) Impacts on Downstream Processes.
We have reviewed the detail Naphthenic Acid corrosion risk for the downstream unit according to the
data provided by IOCL Paradip. We don’t find any Naphthenic acid corrosion risk in these
downstream units (DCU/FCCU/ VGO-HDT/DHDT etc.).We have chemical injection point in and
monitoring in AVU for each and every feed stream for downstream. The residual chemical can also
take care of the downstream unit.
Naphthenic acid will start to destroy when it will pass through vacuum heater in AVU so very little
quantity of Naphthenic acid will remain active in downstream units.
Chevron research scientists and others have stated that “after admission of hydrogen to the gas oil
liquids in a hydrotreater, we have never seen an instance of naphthenic acid attack”. This also is in
line with the experience of many of our customers, some of whom have been refining naphthenic
feeds of up to 1.2 TAN continuously for more than ten years. None of them have reported naphthenic
attack in hydrotreater or hydrocracker units, including the feed pipework.
Nalco Limited
Serial No: S-1001
It is a logical chemical effect, since organic acids would be easy to reduce to aldehydes and then to
alcohols in the presence of the high temperatures and high hydrogen partial pressures found in
hydrotreaters/hydrocrackers. It also may be due to many hydrotreaters employing 316 stainless steels
to combat sulphidation, and the side effect is better immunity to naphthenic acid attack.
Nalco Limited
Serial No: S-1001
h) Generic Recommendations for Corrosion Monitoring
Nalco Limited
Serial No: S-1001
Nalco Limited
Serial No: S-1001
Notes for Tables (1) and (2):
In these regions, there is multi-phase flow at velocities greater than 30 m/sec, and naphthenic acid
corrosion of crudes down to a TAN of 0.3 has been observed. Specific locations of concern include
piping downstream of thermo wells, transfer line collection headers across from the furnace risers,
furnace tube return bends, the last few furnace tubes themselves (where two-phase flow initiates),
piping elbows and piping just downstream of the elbow weld.
Type 304, 321, and 347 for furnace tubes, headers and transfer lines give some benefit against
naphthenic acid or sulphidation/naphthenic acid attack, but higher levels of naphthenic acid can
readily attack such metallurgy. The exact levels that cause attack are not known. When naphthenic
acids are processed, use FSM for the transfer line and carefully UT/RT headers, elbows and other
turbulent areas as opportunities permit per the reliability plan.
Type 410 SS tower trays, packing and downcomers in the Atmospheric and Vacuum Towers are
highly vulnerable above 180oC. Type 304 provides somewhat more resistance, while Type 316 SS
provides marked improvement but still may not be enough for vacuum column packing where Type
317 SS is strongly recommended.
Type 405/410(S) SS cladding may not be adequate at temperatures above 180°C, especially in the
Vacuum Tower. Type 304 SS provides some improvement while Type 316SS should be adequate for
essentially all cladding in naphthenic acid service. The transition cone in the upper section of the
vacuum tower is of particular concern.
CS/5Cr/9Cr and even 304SS piping components taking side cuts and towers bottoms streams from the
atmospheric and vacuum towers are vulnerable when the temperature is greater than 180oC. Past
guidance has been that TANs below 1.5 will not cause significant harm, but that is not always the case
and must be verified by monitoring.
The highest TAN values are typically seen in the HVGO, vacuum residue, AGO, and atmospheric
residue lines. Specific areas of concern include control valves, piping downstream of control valves,
elbows and the associated piping just downstream of the elbow weld. Pump cases and impellers are
some of the most vulnerable components if not of highly resistant metallurgy (316 or 317SS), and in
fact this can be used as an early indicator of nap acid corrosiveness by careful monitoring and
inspection of pumps at these locations
Nalco Limited
Serial No: S-1001
11. Economic Study of Processing High TAN Crude in IOCL- Paradip Refinery
The estimated fixed cost for the required hardware is summarized in table 10.1 below.
Table 10.1
The estimated operating cost is summarized in table 10.2 and 10.3
Manpower Cost/yr
Type Number Rs/unit Rs
Manpower for
Chemical dosing 6 360,000 2,160,000
Manpower for
Monitoring/Lab
Analysis 6 1,200,000 7,200,000
Reporting 6 1,800,000 10,800,000
20,160,000
Table 10.2
Table 10.3
The above is calculated for 15 MMTPA Processing of High TAN Crude of 1.5 TAN.
Nalco Limited
Serial No: S-1001
Economic Benefit
Ø Assuming Price of 1.5 TAN Crude is USD 5/barrel lesser than normal crudes, hence total savings
on Crude Purchased per year
Rs. 15x5x53x1, 000,000x1000/159
= Rs. 25,000,000,000
Ø Total Cost ( Hardware+ Operating per year)
Rs. 868,475,000.
Ø ROI = 2879% in 1 year.
Ø Pay Back Period = 12.7 days.
Nalco Limited
Serial No: S-1001
12) Appendix
Nalco Limited
Serial No: S-1001
Risk Matrix Output for TAN = 0.8 mg of KOH/g
Risk Assessment OUTPUT SCREEN Unit ID - TAN 0.8

Unit / Temp. Flow Pipe Pipe Tan Sulfur Metal Run Risk
o
System Description C M3/Hr Size Sch. % Used Time Assessment
Crude Common line from Tank 40 2044.00 30 30 0.8 0.80 CS 5 Low
Crude Train 1 and to 2 upstream Flash Drum 175 1204.00 18 40 0.8 0.80 CS 5 Low
Flashed Crude Flash drum to flashed crude pump 176 2217.00 30 30 0.8 0.80 CS 5 Low
Flashed Crude Pump discharge upto common discharge 176 1109.00 16 40 0.8 0.80 CS 5 Low
Flashed Crude Common disc part 176 2217.00 20 40 0.8 0.80 CS 5 Low
Flashed Crude Individual HX train upto common line 176 1109.00 16 40 0.8 0.80 CS 5 Low
Flashed Crude 2nd part - upto E129/229 176 832.00 8 40 0.8 0.80 CS 5 Low
Flashed Crude E122/222 D/S upto E124/224 251 900.00 12 40 0.8 0.80 CS 5 Low-Moderate
Preheated crude D/S of E124/224 to common line 292 900.00 12 40 0.8 0.80 5CR 5 Low-Moderate
Flashed Crude From E129 upto E127 232 445.00 8 40 0.8 0.80 CS 5 Low-Moderate
Flashed Crude After 1st HX E127 317 445.00 12 80 0.8 0.80 5CR 5 Low
Preheated crude Common line to heater after mixing 299 1344.00 18 40 0.8 0.80 5CR 5 Low-Moderate
Preheated crude Individual Passes to heater (8 passes) 299 2 phase 6 40 0.8 0.80 5CR 5 Moderate
Heated Crude Heater Out Passes 356 2 phase 12 40 0.8 0.80 9CR 5 Low-Moderate
Heated Crude Common transfer line from Heter ( 1 & 2 train) 356 2 phase 36 40 0.8 0.80 9CR 5 Low-Moderate
TPA Draw off TPA draw from D1 to 10P04A/C 133 3306.00 42 XH 0.5 0.10 CS 5 Low
TPA Reflux TPA reflux from pump to column 133 718.00 12 40 0.5 0.10 CS 5 Low
TPA TPA BP of HE 133 1500.00 24 20 0.5 0.10 CS 5 Low
TPA TPA to individual train 133 1550.00 20 40 0.5 0.10 CS 5 Low
TPA TPA to column - common line 98 3121.00 24 20 0.5 0.10 CS 5 Low
KERO Product KERO Product Pump Sucn 193 201.00 8 40 0.5 0.10 CS 5 Low-Moderate
KERO Product KERO Product Pump Disc 178 201.00 8 40 0.5 0.10 CS 5 Low-Moderate
KERO PA KERO PA- Column to pump 193 1228.00 18 40 0.5 0.10 CS 5 Low-Moderate
KERO PA P005A/B Pump discharge 193 1228.00 16 40 0.5 0.10 CS 5 Low-Moderate
KERO PA to Individual train 193 251.00 10 40 0.5 0.10 CS 5 Low-Moderate
KERO PA common line to column 132 465.00 10 40 0.5 0.10 CS 5 Low
KERO Reflux P005A/B Pump discharge to column 193 726.00 12 40 0.5 0.10 CS 5 Low-Moderate
LAGO Product Product to LAGO Stripper 253 466.00 18 40 0.8 0.15 CS 5 Low-Moderate
LAGO Product Stripper bottom to pump P009A/B 242 466.00 16 40 0.8 0.15 CS 5 Low-Moderate
LAGO Product pump discharge upto HAGO added 242 466.00 10 40 0.8 0.15 CS 5 Moderate
AGO Product Common line with HAGO 251 543.00 10 40 0.8 0.15 CS 5 Moderate
LAGO PA Column to P006A/B 253 1445.00 30 30 0.8 0.15 CS 5 Low-Moderate
LAGO PA Pump disc up to DS E038 common line 253 1149.00 16 40 0.8 0.15 CS 5 Moderate
LAGO PA individual train up to common line to column 226 500.00 10 40 0.8 0.15 CS 5 Moderate
LAGO PA to E043/47 up to common line to column 226 110.00 6 40 0.8 0.15 CS 5 Low-Moderate
LAGO PA common return to column 193 1068.00 16 40 0.8 0.15 CS 5 Low-Moderate
LAGO Reflux reflux to column 253 296.00 8 40 0.8 0.15 CS 5 Moderate
HAGO Product product draw to striper 311 77.00 6 40 1 0.40 5CR 5 Low-Moderate
HAGO Product striper bottom to pump P029A/B 303 77.00 6 40 1 0.40 5CR 5 Low-Moderate
HAGO Product pump disc to AGO product line 303 77.00 4 40 1 0.40 5CR 5 Low-Moderate
HAGO PA draw off to pump P030A/B 311 1496.00 26 40 1 0.40 5CR 5 Low-Moderate
HAGO PA P030A/B disc up to distribution 311 1496.00 18 40 1 0.40 5CR 5 Moderate
HAGO Reflux reflux to column US control valve 311 472.00 10 40 1 0.40 5CR 5 Moderate
HAGO Reflux reflux to column DS control valve 311 472.00 10 40 1 0.40 5CR 5 Moderate
HAGO PA Individual train upto E123/223 311 512.00 10 40 1 0.40 5CR 5 Moderate
HAGO PA Individual train DS E123/223 upto mixing 256 512.00 10 80 1 0.40 CS 5 Low-Moderate
HAGO PA common line to column 249 949.00 14 40 1 0.40 CS 5 Moderate
AR Column bottom to P007A/C 357 1371.00 30 30 1 0.90 9CR 5 Low
AR individual Pump discharge 357 685.00 12 40 1 0.90 9CR 5 Low-Moderate
AR Pump discharge with RO to vac heater-Common360 1510.00 18 40 1 0.90 9CR 5 Low-Moderate
AR Individual Passes (12 nos) 360 2 phase 8 40 1 0.90 9CR 5 Low
Heated AR Vac heater out passes (12 nos) 401 2 phase 24 20 1 0.90 SS316 5 Low
Heated AR Vac heater out passes (12 nos) 401 2 phase 24 20 1 0.90 9CR 5 Low
Heated AR Vac heater out passes (12 nos) 401 2 phase 20 40 1 0.90 9CR 5 Low-Moderate
Recycle Oil Recycle Oil to AR line 373 139.00 6 40 1 1.00 SS316 5 Low
Vac Diesel VD draw to P021A/B 114 852.00 20 40 0.6 0.50 CS 5 Low
Vac Diesel P021A/B disc before distribution for Reflux 114 852.00 14 40 0.6 0.50 CS 5 Low
Vac Diesel P021A/B disc to E102/202 before distribution 114 712.00 12 40 0.6 0.50 CS 5 Low
Vac Diesel individual train E102/202 ( pdt + PA) to Air cooler
114 356.00 10 40 0.6 0.50 CS 5 Low
Vac Diesel After AC 016 to StrainerSTR 01A/B 42 612.00 14 40 0.6 0.50 CS 5 Low
Vac Diesel DS PA Strainer to column 42 612.00 14 40 0.6 0.50 SS304 5 Low
Vac Diesel Bypass line 114 200.00 14 40 0.6 0.50 CS 5 Low
Vac Diesel Reflux up to strainer STR 002A/B 114 140.00 6 40 0.6 0.50 CS 5 Low
Vac Diesel DS Reflux Strainer to column 114 140.00 6 40 0.6 0.50 SS304 5 Low
VGO draw off to pump P022A/C 250 1868.00 30 30 0.8 0.80 CS 5 Low-Moderate
VGO Common disc before distribution 250 1868.00 24 20 0.8 0.80 CS 5 Low-Moderate
VGO To individual train (Pdt+PA) 250 934.00 16 40 0.8 0.80 CS 5 Low-Moderate
VGO VGO Product each train 184 285.00 8 40 0.8 0.80 CS 5 Low-Moderate
VGO PA to strainer (each train) 250 605.00 12 40 0.8 0.80 CS 5 Low-Moderate
VGO PA strainer common line 183 1211.00 18 40 0.8 0.80 CS 5 Low-Moderate
VGO PA strainer DS to column 183 1211.00 18 40 0.8 0.80 SS304 5 Low
VGO PA bypass 250 400.00 16 40 1 0.90 CS 5 Low-Moderate
HVGO Draw off to P023 A/C 345 1327.00 24 20 1 0.90 5CR 5 Low-Moderate
HVGO individual Pump discharge 345 700.00 12 40 1 0.90 5CR 5 Low-Moderate
HVGO common Pump discharge (wash oil+PA) 345 1327.00 18 40 1 0.90 5CR 5 Low-Moderate
Wash Oil Wash oil to strainer STR 05A/B 345 327.00 10 80 1 0.90 5CR 5 Low-Moderate
Wash Oil Wash oil from strainer to column 345 327.00 10 40 1 0.90 SS304 5 Low
HVGO HVGO PA to individual train to E124B/224B 345 500.00 10 80 1 0.90 5CR 5 Low-Moderate
HVGO individual train DS E124B/224B to strainer 281 500.00 10 40 1 0.90 5CR 5 Low-Moderate
HVGO HVGO to steam generator 281 100.00 4 40 1 0.90 5CR 5 Low-Moderate
HVGO Common line to PA strained 281 890.00 16 40 1 0.90 5CR 5 Low-Moderate
HVGO PA strained to column 281 890.00 16 40 1 0.90 SS304 5 Low
HVGO PA Bypass 345 500.00 16 40 1 0.90 5CR 5 Low-Moderate
Recycle oil draw off to P24A/B 374 140.00 10 40 1 1.00 SS316 5 Low
Recycle oil Pump disc to AR 374 140.00 6 40 1 1.00 SS316 5 Low
Recycle oil to VR line 374 140.00 6 40 1 1.00 9CR 5 Low
VR From Column to P025A/B 354 756.00 18 40 1 1.20 9CR 5 Low
VR DS E127/227 common line 265 380.00 10 80 1 1.20 CS 5 Low-Moderate
VR VR Quench 265 156.00 6 80 1 1.20 CS 5 Low-Moderate
VR VR to E126 265 300.00 10 80 1 1.20 CS 5 Low-Moderate
VR VR DS E126 to PDT DCU Storage 254 290.00 10 40 1 1.20 CS 5 Low-Moderate
Nalco Limited
Serial No: S-1001

Risk Assessment OUTPUT SCREEN Unit ID- TAN 1.0
o
Crude Common line from Tank 40 2044 30 30 1 0.80 CS 5 Low
Crude Train 1 and to 2 upstream Flash Drum 175 1204 18 40 1 0.80 CS 5 Low
Flashed Crude Flash drum to flashed crude pump 176 2217 30 30 1 0.80 CS 5 Low
Flashed Crude Pump discharge upto common discharge 176 1109 16 40 1 0.80 CS 5 Low
Flashed Crude Common disc part 176 2217 20 40 1 0.80 CS 5 Low
Flashed Crude Individual HX train upto common line 176 1109 16 40 1 0.80 CS 5 Low
Flashed Crude 2nd part - upto E129/229 176 832 8 40 1 0.80 CS 5 Low
Flashed Crude 2nd part - upto E122/222 176 394 12 40 1 0.80 CS 5 Low
Flashed Crude E122/222 D/S upto E124/224 251 900 12 40 1 0.80 CS 5 Moderate
Preheated crude D/S of E124/224 to common line 292 900 12 40 1 0.80 5CR 5 Low-Moderate
Flashed Crude From E129 upto E127 232 445 8 40 1 0.80 CS 5 Moderate
Flashed Crude After 1st HX E127 317 445 12 80 1 0.80 5CR 5 Low-Moderate
Preheated crude Common line to heater after mixing 299 1344 18 40 1 0.80 5CR 5 Low-Moderate
Preheated crude Individual Passes to heater (8 passes) 299 2 phase 6 40 1 0.80 5CR 5 Moderate-High
Heated Crude Heater Out Passes 356 2 phase 12 40 1 0.80 9CR 5 Low-Moderate
Heated Crude Common transfer line from Heter ( 1 & 2 train) 356 2 phase 36 40 1 0.80 9CR 5 Low-Moderate
TPA Draw off TPA draw from D1 to 10P04A/C 133 3306 42 XH 0.6 0.10 CS 5 Low
TPA Reflux TPA reflux from pump to column 133 718 12 40 0.6 0.10 CS 5 Low
TPA TPA BP of HE 133 1500 24 20 0.6 0.10 CS 5 Low
TPA TPA to individual train 133 1550 20 40 0.6 0.10 CS 5 Low
TPA TPA to column - common line 98 3121 24 20 0.6 0.10 CS 5 Low
KERO Product KERO Product Pump Sucn 193 201 8 40 0.6 0.10 CS 5 Low-Moderate
KERO Product KERO Product Pump Disc 178 201 8 40 0.6 0.10 CS 5 Low-Moderate
KERO PA KERO PA- Column to pump 193 1228 18 40 0.6 0.10 CS 5 Low-Moderate
KERO PA P005A/B Pump discharge 193 1228 16 40 0.6 0.10 CS 5 Low-Moderate
KERO PA to Individual train 193 251 10 40 0.6 0.10 CS 5 Low-Moderate
KERO PA common line to column 132 465 10 40 0.6 0.10 CS 5 Low
KERO Reflux P005A/B Pump discharge to column 193 726 12 40 0.6 0.10 CS 5 Low-Moderate
LAGO Product Product to LAGO Stripper 253 466 18 40 0.8 0.15 CS 5 Low-Moderate
LAGO Product Stripper bottom to pump P009A/B 242 466 16 40 0.8 0.15 CS 5 Low-Moderate
LAGO Product pump discharge upto HAGO added 242 466 10 40 0.8 0.15 CS 5 Moderate
AGO Product Common line with HAGO 251 543 10 40 0.8 0.15 CS 5 Moderate
LAGO PA Column to P006A/B 253 1445 30 30 0.8 0.15 CS 5 Low-Moderate
LAGO PA Pump disc up to DS E038 common line 253 1149 16 40 0.8 0.15 CS 5 Moderate
LAGO PA individual train up to common line to column 226 500 10 40 0.8 0.15 CS 5 Moderate
LAGO PA to E043/47 up to common line to column 226 110 6 40 0.8 0.15 CS 5 Low-Moderate
LAGO PA common return to column 193 1068 16 40 0.8 0.15 CS 5 Low-Moderate
LAGO Reflux reflux to column 253 296 8 40 0.8 0.15 CS 5 Moderate
HAGO Product product draw to striper 311 77 6 40 1.2 0.40 5CR 5 Low-Moderate
HAGO Product striper bottom to pump P029A/B 303 77 6 40 1.2 0.40 5CR 5 Low-Moderate
HAGO Product pump disc to AGO product line 303 77 4 40 1.2 0.40 5CR 5 Moderate
HAGO PA draw off to pump P030A/B 311 1496 26 40 1.2 0.40 5CR 5 Low-Moderate
HAGO PA P030A/B disc up to distribution 311 1496 18 40 1.2 0.40 5CR 5 Moderate
HAGO Reflux reflux to column US control valve 311 472 10 40 1.2 0.40 5CR 5 Moderate
HAGO Reflux reflux to column DS control valve 311 472 10 40 1.2 0.40 5CR 5 Moderate
HAGO PA Individual train upto E123/223 311 512 10 40 1.2 0.40 5CR 5 Moderate
HAGO PA Individual train DS E123/223 upto mixing 256 512 10 80 1.2 0.40 CS 5 Low-Moderate
HAGO PA common line to column 249 949 14 40 1.2 0.40 CS 5 Moderate-High
AR Column bottom to P007A/C 357 1371 30 30 1.5 0.90 9CR 5 Low-Moderate
AR individual Pump discharge 357 685 12 40 1.5 0.90 9CR 5 Low-Moderate
AR Pump discharge with RO to vac heater-Common 360 1510 18 40 1.5 0.90 9CR 5 Low-Moderate
AR Individual Passes (12 nos) 360 2 phase 8 40 1.5 0.90 9CR 5 Low
Heated AR Vac heater out passes (12 nos) 401 2 phase 24 20 1.5 0.90 SS316 5 Low
Heated AR Vac heater out passes (12 nos) 401 2 phase 24 20 1.5 0.90 9CR 5 Low
Heated AR Vac heater out passes (12 nos) 401 2 phase 20 40 1.5 0.90 9CR 5 Moderate
Recycle Oil Recycle Oil to AR line 373 139 6 40 1.2 1.00 SS316 5 Low
Vac Diesel VD draw to P021A/B 114 852 20 40 0.6 0.60 CS 5 Low
Vac Diesel P021A/B disc before distribution for Reflux 114 852 14 40 0.6 0.60 CS 5 Low
Vac Diesel P021A/B disc to E102/202 before distribution 114 712 12 40 0.6 0.60 CS 5 Low
Vac Diesel individual train E102/202 ( pdt + PA) to Air cooler114 356 10 40 0.6 0.60 CS 5 Low
Vac Diesel After AC 016 to StrainerSTR 01A/B 42 612 14 40 0.6 0.60 CS 5 Low
Vac Diesel DS PA Strainer to column 42 612 14 40 0.6 0.60 SS304 5 Low
Vac Diesel Bypass line 114 200 14 40 0.6 0.60 CS 5 Low
Vac Diesel Reflux up to strainer STR 002A/B 114 140 6 40 0.6 0.60 CS 5 Low
Vac Diesel DS Reflux Strainer to column 114 140 6 40 0.6 0.60 SS304 5 Low
VGO draw off to pump P022A/C 250 1868 30 30 1 0.80 CS 5 Low-Moderate
VGO Common disc before distribution 250 1868 24 20 1 0.80 CS 5 Low-Moderate
VGO To individual train (Pdt+PA) 250 934 16 40 1 0.80 CS 5 Low-Moderate
VGO VGO Product each train 184 285 8 40 1 0.80 CS 5 Low-Moderate
VGO PA to strainer (each train) 250 605 12 40 1 0.80 CS 5 Low-Moderate
VGO PA strainer common line 183 1211 18 40 1 0.80 CS 5 Low-Moderate
VGO PA strainer DS to column 183 1211 18 40 1 0.80 SS304 5 Low
VGO PA bypass 250 400 16 40 1 0.90 CS 5 Low-Moderate
HVGO Draw off to P023 A/C 345 1327 24 20 1.2 0.90 5CR 5 Low-Moderate
HVGO individual Pump discharge 345 700 12 40 1.2 0.90 5CR 5 Low-Moderate
HVGO common Pump discharge (wash oil+PA) 345 1327 18 40 1.2 0.90 5CR 5 Low-Moderate
Wash Oil Wash oil to strainer STR 05A/B 345 327 10 80 1.2 0.90 5CR 5 Low-Moderate
Wash Oil Wash oil from strainer to column 345 327 10 40 1.2 0.90 SS304 5 Low
HVGO HVGO PA to individual train to E124B/224B 345 500 10 80 1.2 0.90 5CR 5 Low-Moderate
HVGO individual train DS E124B/224B to strainer 281 500 10 40 1.2 0.90 5CR 5 Low-Moderate
HVGO HVGO to steam generator 281 100 4 40 1.2 0.90 5CR 5 Low-Moderate
HVGO Common line to PA strained 281 890 16 40 1.2 0.90 5CR 5 Low-Moderate
HVGO PA strained to column 281 890 16 40 1.2 0.90 SS304 5 Low
HVGO PA Bypass 345 500 16 40 1.2 0.90 5CR 5 Low-Moderate
Recycle oil draw off to P24A/B 374 140 10 40 1.2 1.00 SS316 5 Low
Recycle oil Pump disc to AR 374 140 6 40 1.2 1.00 SS316 5 Low
Recycle oil to VR line 374 140 6 40 1.2 1.00 9CR 5 Low-Moderate
VR From Column to P025A/B 354 756 18 40 1.2 1.20 9CR 5 Low
VR DS E127/227 common line 265 380 10 80 1.2 1.20 CS 5 Low-Moderate
VR VR Quench 265 156 6 80 1.2 1.20 CS 5 Low-Moderate
VR VR to E126 265 300 10 80 1.2 1.20 CS 5 Low-Moderate
VR VR DS E126 to PDT DCU Storage 254 290 10 40 1.2 1.20 CS 5 Low-Moderate
Nalco Limited
Serial No: S-1001

Risk Assessment OUTPUT SCREEN Unit ID -TAN 1.2
o
Crude Common line from Tank 40 2044.00 30 30 1.2 0.80 CS 5 Low
Crude Train 1 and to 2 upstream Flash Drum 175 1204.00 18 40 1.2 0.80 CS 5 Low
Flashed Crude Flash drum to flashed crude pump 176 2217.00 30 30 1.2 0.80 CS 5 Low
Flashed Crude Pump discharge upto common discharge 176 1109.00 16 40 1.2 0.80 CS 5 Low
Flashed Crude Common disc part 176 2217.00 20 40 1.2 0.80 CS 5 Low
Flashed Crude Individual HX train upto common line 176 1109.00 16 40 1.2 0.80 CS 5 Low
Flashed Crude E122/222 D/S upto E124/224 251 900.00 12 40 1.2 0.80 CS 5 Moderate
Preheated crude D/S of E124/224 to common line 292 900.00 12 40 1.2 0.80 5CR 5 Low-Moderate
Flashed Crude From E129 upto E127 232 445.00 8 40 1.2 0.80 CS 5 Moderate
Flashed Crude After 1st HX E127 317 445.00 12 80 1.2 0.80 5CR 5 Low-Moderate
Preheated crude Common line to heater after mixing 299 1344.00 18 40 1.2 0.80 5CR 5 Low-Moderate
Preheated crude Individual Passes to heater (8 passes) 299 2 phase 6 40 1.2 0.80 5CR 5 Moderate-High
Heated Crude Heater Out Passes 356 2 phase 12 40 1.2 0.80 9CR 5 Moderate
Heated Crude Common transfer line from Heter ( 1 & 2 train) 356 2 phase 36 40 1.2 0.80 9CR 5 Moderate
TPA Draw off TPA draw from D1 to 10P04A/C 133 3306.00 42 XH 1 0.10 CS 5 Low
TPA Reflux TPA reflux from pump to column 133 718.00 12 40 1 0.10 CS 5 Low
TPA TPA BP of HE 133 1500.00 24 20 1 0.10 CS 5 Low
TPA TPA to individual train 133 1550.00 20 40 1 0.10 CS 5 Low
TPA TPA to column - common line 98 3121.00 24 20 1 0.10 CS 5 Low
KERO Product KERO Product Pump Sucn 193 201.00 8 40 1 0.10 CS 5 Low-Moderate
KERO Product KERO Product Pump Disc 178 201.00 8 40 1 0.10 CS 5 Low-Moderate
KERO PA KERO PA- Column to pump 193 1228.00 18 40 1 0.10 CS 5 Moderate
KERO PA P005A/B Pump discharge 193 1228.00 16 40 1 0.10 CS 5 Moderate
KERO PA to Individual train 193 251.00 10 40 1 0.10 CS 5 Low-Moderate
KERO PA common line to column 132 465.00 10 40 1 0.10 CS 5 Low
KERO Reflux P005A/B Pump discharge to column 193 726.00 12 40 1 0.10 CS 5 Moderate
LAGO Product Product to LAGO Stripper 253 466.00 18 40 1 0.15 CS 5 Moderate
LAGO Product Stripper bottom to pump P009A/B 242 466.00 16 40 1 0.15 CS 5 Moderate
LAGO Product pump discharge upto HAGO added 242 466.00 10 40 1 0.15 CS 5 Moderate-High
AGO Product Common line with HAGO 251 543.00 10 40 1 0.15 CS 5 Moderate-High
LAGO PA Column to P006A/B 253 1445.00 30 30 1 0.15 CS 5 Moderate
LAGO PA Pump disc up to DS E038 common line 253 1149.00 16 40 1 0.15 CS 5 Moderate-High
LAGO PA individual train up to common line to column 226 500.00 10 40 1 0.15 CS 5 Moderate
LAGO PA to E043/47 up to common line to column 226 110.00 6 40 1 0.15 CS 5 Moderate
LAGO PA common return to column 193 1068.00 16 40 1 0.15 CS 5 Moderate
LAGO Reflux reflux to column 253 296.00 8 40 1 0.15 CS 5 Moderate-High
HAGO Product product draw to striper 311 77.00 6 40 1.5 0.40 5CR 5 Moderate
HAGO Product striper bottom to pump P029A/B 303 77.00 6 40 1.5 0.40 5CR 5 Moderate
HAGO Product pump disc to AGO product line 303 77.00 4 40 1.5 0.40 5CR 5 Moderate-High
HAGO PA draw off to pump P030A/B 311 1496.00 26 40 1.5 0.40 5CR 5 Moderate
HAGO PA P030A/B disc up to distribution 311 1496.00 18 40 1.5 0.40 5CR 5 Moderate-High
HAGO Reflux reflux to column US control valve 311 472.00 10 40 1.5 0.40 5CR 5 Moderate-High
HAGO Reflux reflux to column DS control valve 311 472.00 10 40 1.5 0.40 5CR 5 Moderate-High
HAGO PA Individual train upto E123/223 311 512.00 10 40 1.5 0.40 5CR 5 Moderate-High
HAGO PA Individual train DS E123/223 upto mixing 256 512.00 10 80 1.5 0.40 CS 5 Moderate
HAGO PA common line to column 249 949.00 14 40 1.5 0.40 CS 5 Moderate-High
AR Column bottom to P007A/C 357 1371.00 30 30 1.8 0.90 9CR 5 Low-Moderate
AR individual Pump discharge 357 685.00 12 40 1.8 0.90 9CR 5 Low-Moderate
AR Pump discharge with RO to vac heater-Common 360 1510.00 18 40 1.8 0.90 9CR 5 Low-Moderate
AR Individual Passes (12 nos) 360 2 phase 8 40 1.8 0.90 9CR 5 Low
Heated AR Vac heater out passes (12 nos) 401 2 phase 24 20 1.8 0.90 SS316 5 Low
Heated AR Vac heater out passes (12 nos) 401 2 phase 24 20 1.8 0.90 9CR 5 Low
Heated AR Vac heater out passes (12 nos) 401 2 phase 20 40 1.8 0.90 9CR 5 Moderate-High
Recycle Oil Recycle Oil to AR line 373 139.00 6 40 1.8 1.00 SS316 5 Low
Vac Diesel VD draw to P021A/B 114 852.00 20 40 1 0.60 CS 5 Low
Vac Diesel P021A/B disc before distribution for Reflux 114 852.00 14 40 1 0.60 CS 5 Low
Vac Diesel P021A/B disc to E102/202 before distribution 114 712.00 12 40 1 0.60 CS 5 Low
Vac Diesel individual train E102/202 ( pdt + PA) to Air cooler114 356.00 10 40 1 0.60 CS 5 Low
Vac Diesel After AC 016 to StrainerSTR 01A/B 42 612.00 14 40 1 0.60 CS 5 Low
Vac Diesel DS PA Strainer to column 42 612.00 14 40 1 0.60 SS304 5 Low
Vac Diesel Bypass line 114 200.00 14 40 1 0.60 CS 5 Low
Vac Diesel Reflux up to strainer STR 002A/B 114 140.00 6 40 1 0.60 CS 5 Low
Vac Diesel DS Reflux Strainer to column 114 140.00 6 40 1 0.60 SS304 5 Low
VGO draw off to pump P022A/C 250 1868.00 30 30 1.2 0.80 CS 5 Low-Moderate
VGO Common disc before distribution 250 1868.00 24 20 1.2 0.80 CS 5 Low-Moderate
VGO To individual train (Pdt+PA) 250 934.00 16 40 1.2 0.80 CS 5 Moderate
VGO VGO Product each train 184 285.00 8 40 1.2 0.80 CS 5 Low-Moderate
VGO PA to strainer (each train) 250 605.00 12 40 1.2 0.80 CS 5 Moderate
VGO PA strainer common line 183 1211.00 18 40 1.2 0.80 CS 5 Low-Moderate
VGO PA strainer DS to column 183 1211.00 18 40 1.2 0.80 SS304 5 Low
VGO PA bypass 250 400.00 16 40 1.2 0.90 CS 5 Low-Moderate
HVGO Draw off to P023 A/C 345 1327.00 24 20 1.8 0.90 5CR 5 Low-Moderate
HVGO individual Pump discharge 345 700.00 12 40 1.8 0.90 5CR 5 Low-Moderate
HVGO common Pump discharge (wash oil+PA) 345 1327.00 18 40 1.8 0.90 5CR 5 Low-Moderate
Wash Oil Wash oil to strainer STR 05A/B 345 327.00 10 80 1.8 0.90 5CR 5 Low-Moderate
Wash Oil Wash oil from strainer to column 345 327.00 10 40 1.8 0.90 SS304 5 Low
HVGO HVGO PA to individual train to E124B/224B 345 500.00 10 80 1.8 0.90 5CR 5 Moderate
HVGO individual train DS E124B/224B to strainer 281 500.00 10 40 1.8 0.90 5CR 5 Moderate
HVGO HVGO to steam generator 281 100.00 4 40 1.8 0.90 5CR 5 Moderate
HVGO Common line to PA strained 281 890.00 16 40 1.8 0.90 5CR 5 Moderate
HVGO PA strained to column 281 890.00 16 40 1.8 0.90 SS304 5 Low
HVGO PA Bypass 345 500.00 16 40 1.8 0.90 5CR 5 Low-Moderate
Recycle oil draw off to P24A/B 374 140.00 10 40 1.8 1.00 SS316 5 Low
Recycle oil Pump disc to AR 374 140.00 6 40 1.8 1.00 SS316 5 Low
Recycle oil to VR line 374 140.00 6 40 1.8 1.00 9CR 5 Low-Moderate
VR From Column to P025A/B 354 756.00 18 40 1.8 1.20 9CR 5 Low-Moderate
VR DS E127/227 common line 265 380.00 10 80 1.8 1.20 CS 5 Low-Moderate
VR VR Quench 265 156.00 6 80 1.8 1.20 CS 5 Low-Moderate
VR VR to E126 265 300.00 10 80 1.8 1.20 CS 5 Low-Moderate
VR VR DS E126 to PDT DCU Storage 254 290.00 10 40 1.8 1.20 CS 5 Moderate
Nalco Limited
Serial No: S-1001

Risk Assessment OUTPUT SCREEN Unit ID -TAN 1.5
o
Crude Common line from Tank 40 2044 30 30 1.5 0.80 CS 5 Low
Crude Train 1 and to 2 upstream Flash Drum 175 1204 18 40 1.5 0.80 CS 5 Low
Flashed Crude Flash drum to flashed crude pump 176 2217 30 30 1.5 0.80 CS 5 Low
Flashed Crude Pump discharge upto common discharge 176 1109 16 40 1.5 0.80 CS 5 Low
Flashed Crude Common disc part 176 2217 20 40 1.5 0.80 CS 5 Low
Flashed Crude Individual HX train upto common line 176 1109 16 40 1.5 0.80 CS 5 Low
Flashed Crude 2nd part - upto E129/229 176 832 8 40 1.5 0.80 CS 5 Low
Flashed Crude 2nd part - upto E122/222 176 394 12 40 1.5 0.80 CS 5 Low
Flashed Crude E122/222 D/S upto E124/224 251 900 12 40 1.5 0.80 CS 5 Moderate-High
Preheated crude D/S of E124/224 to common line 292 900 12 40 1.5 0.80 5CR 5 Moderate
Flashed Crude From E129 upto E127 232 445 8 40 1.5 0.80 CS 5 Moderate-High
Flashed Crude After 1st HX E127 317 445 12 80 1.5 0.80 5CR 5 Low-Moderate
Preheated crude Common line to heater after mixing 299 1344 18 40 1.5 0.80 5CR 5 Moderate
Preheated crude Individual Passes to heater (8 passes) 299 2 phase 6 40 1.5 0.80 5CR 5 High
Heated Crude Heater Out Passes 356 2 phase 12 40 1.5 0.80 9CR 5 Moderate
Heated Crude Common transfer line from Heter ( 1 & 2 train) 356 2 phase 36 40 1.5 0.80 9CR 5 Moderate
TPA Draw off TPA draw from D1 to 10P04A/C 133 3306 42 XH 1.2 0.10 CS 5 Low
TPA Reflux TPA reflux from pump to column 133 718 12 40 1.2 0.10 CS 5 Low
TPA TPA BP of HE 133 1500 24 20 1.2 0.10 CS 5 Low
TPA TPA to individual train 133 1550 20 40 1.2 0.10 CS 5 Low
TPA TPA to column - common line 98 3121 24 20 1.2 0.10 CS 5 Low
KERO Product KERO Product Pump Sucn 193 201 8 40 1.2 0.10 CS 5 Moderate
KERO Product KERO Product Pump Disc 178 201 8 40 1.2 0.10 CS 5 Low-Moderate
KERO PA KERO PA- Column to pump 193 1228 18 40 1.2 0.10 CS 5 Moderate
KERO PA P005A/B Pump discharge 193 1228 16 40 1.2 0.10 CS 5 Moderate
KERO PA to Individual train 193 251 10 40 1.2 0.10 CS 5 Low-Moderate
KERO PA common line to column 132 465 10 40 1.2 0.10 CS 5 Low
KERO Reflux P005A/B Pump discharge to column 193 726 12 40 1.2 0.10 CS 5 Moderate
LAGO Product Product to LAGO Stripper 253 466 18 40 1.5 0.15 CS 5 Moderate-High
LAGO Product Stripper bottom to pump P009A/B 242 466 16 40 1.5 0.15 CS 5 Moderate-High
LAGO Product pump discharge upto HAGO added 242 466 10 40 1.5 0.15 CS 5 Moderate-High
AGO Product Common line with HAGO 251 543 10 40 1.5 0.15 CS 5 High
LAGO PA Column to P006A/B 253 1445 30 30 1.5 0.15 CS 5 Moderate-High
LAGO PA Pump disc up to DS E038 common line 253 1149 16 40 1.5 0.15 CS 5 High
LAGO PA individual train up to common line to column 226 500 10 40 1.5 0.15 CS 5 Moderate-High
LAGO PA to E043/47 up to common line to column 226 110 6 40 1.5 0.15 CS 5 Moderate-High
LAGO PA common return to column 193 1068 16 40 1.5 0.15 CS 5 Moderate-High
LAGO Reflux reflux to column 253 296 8 40 1.5 0.15 CS 5 High
HAGO Product product draw to striper 311 77 6 40 1.8 0.40 5CR 5 Moderate-High
HAGO Product striper bottom to pump P029A/B 303 77 6 40 1.8 0.40 5CR 5 Moderate-High
HAGO Product pump disc to AGO product line 303 77 4 40 1.8 0.40 5CR 5 Moderate-High
HAGO PA draw off to pump P030A/B 311 1496 26 40 1.8 0.40 5CR 5 Moderate-High
HAGO PA P030A/B disc up to distribution 311 1496 18 40 1.8 0.40 5CR 5 Moderate-High
HAGO Reflux reflux to column US control valve 311 472 10 40 1.8 0.40 5CR 5 Moderate-High
HAGO Reflux reflux to column DS control valve 311 472 10 40 1.8 0.40 5CR 5 Moderate-High
HAGO PA Individual train upto E123/223 311 512 10 40 1.8 0.40 5CR 5 Moderate-High
HAGO PA Individual train DS E123/223 upto mixing 256 512 10 80 1.8 0.40 CS 5 Moderate
HAGO PA common line to column 249 949 14 40 1.8 0.40 CS 5 High
AR Column bottom to P007A/C 357 1371 30 30 2 0.90 9CR 5 Low-Moderate
AR individual Pump discharge 357 685 12 40 2 0.90 9CR 5 Low-Moderate
AR Pump discharge with RO to vac heater-Common 360 1510 18 40 2 0.90 9CR 5 Low-Moderate
AR Individual Passes (12 nos) 360 2 phase 8 40 2 0.90 9CR 5 Low
Heated AR Vac heater out passes (12 nos) 401 2 phase 24 20 2 0.90 SS316 5 Low
Heated AR Vac heater out passes (12 nos) 401 2 phase 24 20 2 0.90 9CR 5 Low
Heated AR Vac heater out passes (12 nos) 401 2 phase 20 40 2 0.90 9CR 5 Moderate-High
Recycle Oil Recycle Oil to AR line 373 139 6 40 2 1.00 SS316 5 Low
Vac Diesel VD draw to P021A/B 114 852 20 40 1 0.60 CS 5 Low
Vac Diesel P021A/B disc before distribution for Reflux 114 852 14 40 1 0.60 CS 5 Low
Vac Diesel P021A/B disc to E102/202 before distribution 114 712 12 40 1 0.60 CS 5 Low
Vac Diesel individual train E102/202 ( pdt + PA) to Air cooler 114 356 10 40 1 0.60 CS 5 Low
Vac Diesel After AC 016 to StrainerSTR 01A/B 42 612 14 40 1 0.60 CS 5 Low
Vac Diesel DS PA Strainer to column 42 612 14 40 1 0.60 SS304 5 Low
Vac Diesel Bypass line 114 200 14 40 1 0.60 CS 5 Low
Vac Diesel Reflux up to strainer STR 002A/B 114 140 6 40 1 0.60 CS 5 Low
Vac Diesel DS Reflux Strainer to column 114 140 6 40 1 0.60 SS304 5 Low
VGO draw off to pump P022A/C 250 1868 30 30 2 0.80 CS 5 Moderate-High
VGO Common disc before distribution 250 1868 24 20 2 0.80 CS 5 Moderate-High
VGO To individual train (Pdt+PA) 250 934 16 40 2 0.80 CS 5 Moderate-High
VGO VGO Product each train 184 285 8 40 2 0.80 CS 5 Moderate
VGO PA to strainer (each train) 250 605 12 40 2 0.80 CS 5 Moderate-High
VGO PA strainer common line 183 1211 18 40 2 0.80 CS 5 Moderate
VGO PA strainer DS to column 183 1211 18 40 2 0.80 SS304 5 Low
VGO PA bypass 250 400 16 40 2 0.90 CS 5 Moderate-High
HVGO Draw off to P023 A/C 345 1327 24 20 2 0.90 5CR 5 Low-Moderate
HVGO individual Pump discharge 345 700 12 40 2 0.90 5CR 5 Moderate
HVGO common Pump discharge (wash oil+PA) 345 1327 18 40 2 0.90 5CR 5 Moderate
Wash Oil Wash oil to strainer STR 05A/B 345 327 10 80 2 0.90 5CR 5 Low-Moderate
Wash Oil Wash oil from strainer to column 345 327 10 40 2 0.90 SS304 5 Low
HVGO HVGO PA to individual train to E124B/224B 345 500 10 80 2 0.90 5CR 5 Moderate
HVGO individual train DS E124B/224B to strainer 281 500 10 40 2 0.90 5CR 5 Moderate-High
HVGO HVGO to steam generator 281 100 4 40 2 0.90 5CR 5 Moderate-High
HVGO Common line to PA strained 281 890 16 40 2 0.90 5CR 5 Moderate
HVGO PA strained to column 281 890 16 40 2 0.90 SS304 5 Low
HVGO PA Bypass 345 500 16 40 2 0.90 5CR 5 Low-Moderate
Recycle oil draw off to P24A/B 374 140 10 40 2 1.00 SS316 5 Low
Recycle oil Pump disc to AR 374 140 6 40 2 1.00 SS316 5 Low
Recycle oil to VR line 374 140 6 40 2 1.00 9CR 5 Low-Moderate
VR From Column to P025A/B 354 756 18 40 2 1.20 9CR 5 Low-Moderate
VR DS E127/227 common line 265 380 10 80 2 1.20 CS 5 Low-Moderate
VR VR Quench 265 156 6 80 2 1.20 CS 5 Low-Moderate
VR VR to E126 265 300 10 80 2 1.20 CS 5 Low-Moderate
VR VR DS E126 to PDT DCU Storage 254 290 10 40 2 1.20 CS 5 Moderate-High
Nalco Limited
Serial No: S-1001
Injection and Monitoring location
Quill # 1a/b - Suction of pumps 10P-003A/B/C. – P&ID -1010
Nalco Limited
Serial No: S-1001
Quill # 2 In the KERO PA circuit U/S of QV1004A – P&ID -1019
Quill # 3 In the LAGO PA circuit U/S of QV1006A– P&ID -1020
Nalco Limited
Serial No: S-1001
Quill # 4In the HAGO PA circuit U/S of QV1008A – P&ID -1021
Quill # 5a/b Suction of AR pumps 10P-007A/B/C – P&ID -1037

Probe # 9 & 10 In 10P007A/B suction line prior to chemical injection point (AR) – P&ID -1037
Nalco Limited
Serial No: S-1001
Quill # 6 In the Vac Diesel Reflux line, upstream of STR 002 A/B., US of FV3029. P&ID -3012
Nalco Limited
Serial No: S-1001
Quill # 7 In the VGO PA, US of STR-003A/B. US of QV3004 A. P&ID -3013
Quill # 8 In the HVGO PA, US of STR-004A/B, US of QV3002 A. P&ID -3006

Quill # 9 In the wash Oil line, upstream of STR 005 A/B. US of FV3016 P&ID -3006
Probe #16 and #17 Upstream of the HV3007A/B, in 250 “ line. (HVGO) P&ID -3006
Nalco Limited
Serial No: S-1001
Quill # 10 In the VR Quench line. Inside the isolation loop US of FV3008. - P&ID 3003
Probe # 3 Upstream of FV 1039 in 300 mm line. (Kero) - P&ID 1019
Nalco Limited
Serial No: S-1001
Probe # 4 Upstream of FV 1040 in 200 mm line. (LAGO) - P&ID 1019
Probe # 5 Upstream of FV 2019A in 400 mm line. (LAGO) - P&ID 2004
Nalco Limited
Serial No: S-1001
Probe # 6 Upstream of FV 1042 in 250 mm line. (HAGO) – P&ID –1021
Probe # 7 & 8 Upstream of HV 1015A/B in 250 mm line. (HAGO) – P&ID –1021
Nalco Limited
Serial No: S-1001
Probe # 12 & 13 Upstream of the HV1012A/B, in 250 “ line. (VD) – P&ID –1001
Probe # 14 and #15 Upstream of the HV3008A/B, in 400 “ line. (VGO) – P&ID –3013
Nalco Limited
Serial No: S-1001
Probe #18 Upstream of the FV3013, in 150 “ line. (Recycle Oil) – P&ID 3005
Nalco Limited
Serial No: S-1001
Probe #19 20 In 10P025 A/B Discharge line. (VR) – P&ID -3004
Nalco Limited
Serial No: S-1001
Slip Stream connection – LAGO slipstream P&ID 1020
LAGO slipstream will be used for injection chemical to Crude, LAGO and AGO section. A heat
exchanger will be used to cool down the LAGO to match the requirement of slip stream.
Nalco Limited
Serial No: S-1001
Slip Stream connection – VGO slipstream P&ID 3013

VGO slip stream will be used for injection chemical to RCO, VGO, HVGO, wash oil and VR quench.
Local cooling equipment will be used to match the slip stream requirements.
Nalco Limited
Serial No: S-1001
Locations for FSMs and Permasence
The piping arrangements are not very clear to select the location for FSM and Permasence. FSM and
Permasence also can be installed online, so we will find out the actual location in the field. The
Permasence is also easy move, so we can move the equipment as per our requirement during running
operation.
We jointly will find out the location in the field, once the piping job is completed.
Nalco Limited
Serial No: S-1001
Injection Quill Design detail
Nalco Limited
Serial No: S-1001
P&ID Chemical dosing system, Atmospheric Distillation Unit
Nalco Limited
Serial No: S-1001
P&ID Chemical dosing system, Vacuum Distillation Unit
Nalco Limited
Serial No: S-1001
Contact Details of Probe/FSM/Permasense
Because some of the material is protected by copyright we cannot include it in this report and we refer to
the different vendors for detailed product information.
CEION Probes
Detailed information regarding the CEION probes can be found at:
http://www.cormon.com/products/datasheets/CMEP023ogOct03.pdf
Cormon Asia can be contacted at:
Teledyne Oil & Gas

No. J-03-2, Dataran Glomac, Jalan SS6/18, Kelana Jaya 47301,
Petaling Jaya, Selangor, MALAYSIA
Tel: +60 (3) 7805 7712
Email: LNG.SALES@TELEDYNE.COM
Tindakan Bestari Servis Sdn Bhd
Suite 2A-2-1, Wisma Menjalara,
Jalan 7A/62A, Bandar Menjalara,
52200 Kuala Lumpur, Malaysia.
Mr. Eric Lay - General Manager
Tel: 603-62758121 / 7723
Fax: 603-62767121
E-mail: sales@tbestari.com
FSM
IIcor Asia can be contacted at:
Address:
No 33 Jalan PJS 11/16
Bandar Sunway
46150 Petaling Jaya
Selangor Darul Ehsan
Malaysia.
Telephone: +60 (03) 5635 5002
Fax: +60 (03) 5635 5004
Email: kl@iicorr.com
Permasense
Permasense info can be found at:
http://www.permasense.com/
Nalco Limited
Serial No: S-1001
IOCL Paradip Crude Unit

(the drawing is only guidance for those locations, the shape of those equipment s and the dimensions
may not match with the actual equipment)
Nalco Limited
Serial No: S-1001
IOCL Paradip Vacuum Unit

(the drawing is only guidance for those locations, the shape of those equipment s and the dimensions
may not match with the actual equipment)
Nalco Limited
Serial No: S-1001
Overall Refinery -PFD
Nalco Limited
Serial No: S-1001
13) Organogram:
After the award of the project in Phase-II, the organogram will be as follows:
Site
Manager
Application Application
Engineer Engineer
Technical Technical Technical Technical

Service Rep Service Rep Service Rep Service Rep
Nalco Limited
Serial No: S-1001
Author(s): Arindam Roy
Typed and Assembled:
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Naphthenic Acid Corrosion in Refinery

IOCL Paradip Refinery

The assessment was conducted based on the data provided by the

Date: 5th Oct 2012 Page No: 1

Serial No: S-1001

3) Purpose of the Visit....................................... 3

4) Executive Summary and Recommendations....................... 4

5) Impact of Naphthenic Crude Processing ......................... 6

6) Overview of Nalco’s Risk Assessment Matrix ..................... 12

7. Mitigation of Naphthenic Acid Corrosion ........................ 13

8. SCORPION Injection Requirements and Best Practices ............... 16

9. Corrosion Monitoring & Inspection ............................ 17

Date: 5th Oct 2012 Page No: 2

Serial No: S-1001

g) Stream Sampling and Laboratory Analysis....................... 23

10) Observations & Discussion Paradip Refinery -IOCL ................. 25

12) Appendix ............................................. 51

13) Organogram: ........................................... 77

Date: 5th Oct 2012 Page No: 3

Serial No: S-1001

3) Purpose of the Visit

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Serial No: S-1001

4) Executive Summary and Recommendations

Date: 5th Oct 2012 Page No: 5

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Serial No: S-1001

5) Impact of Naphthenic Crude Processing

a) Naphthenic Acid Corrosion

The saturated ring part of the molecule

The carboxylic acid groups are

Date: 5th Oct 2012 Page No: 7

Serial No: S-1001

Date: 5th Oct 2012 Page No: 8

Serial No: S-1001

with the resulting increased amperage draw and

When blended with other crudes the conductivity can

Figure 5.2 – Crude Conductivity of Doba

c) Impact on Overhead Corrosion Control

The most common effect from breakdown

The main problem with trying to mitigate the effect

Figure 5.3 – Impact on Neutraliser Dosing

Date: 5th Oct 2012 Page No: 9

Serial No: S-1001

Figure 5.4 – Effect of Naphthenic Acids on Chloride Salt Hydrolysis

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Serial No: S-1001

i) Hydrotreaters and FCC Units

ii) Thermal Conversion Units

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Serial No: S-1001

iii) Sour Water Strippers

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Serial No: S-1001

6) Overview of Nalco’s Risk Assessment Matrix

• TAN of the hydrocarbon stream

Risk Rating Action

Figure 6.1 – Risk Phrases and Their Interpretation

Date: 5th Oct 2012 Page No: 13