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Development of Corrosion Control Document (CCD) In Crude Distillation Unit Process

Junghwan Kim1, Wonsub Lim2, Sang-Rok Park3, and Il Moon2. (1) Chemical and Biomolecular Engineering, Yonsie University, A446, 134 Shinchondong, Seodaemunku, Seoul, South Korea, (2) Chemical and Biomolecular Engineering, Yonsei University, A446, 134 Shinchondong, Seodaemunku, Seoul, South Korea, (3) Reliability Team, GS Caltex Corporation, 1056, Wollae-dong, Yeosu-si, Jeollanam-do, South Korea

This paper deals with techniques to improve refinery reliability, availability and profitability. Our team developed a CCD for processing of Crude Distillation Unit (CDU). According to recent study the Loss due to corrosion in US is around 276 billion $. It's a big concern for both managers and engineers of refinery industry.

The CCD consist of numerous parts namely damage mechanism (DM), design data, critical reliability variable (CRV), guidelines, etc. The first step in development of CCD is Material Selection Diagram (MSD). We need to choose damage mechanisms affecting equipments and process. These processes are based on API 571. The selected nine DM from API 571 are (1) creep/stress rupture, (2) Fuel Ash Corrosion, (3) Oxidation, (4) High Temperature Sulfidation, (5) Naphthenic Acid Corrosion, (6) Hydrochloric Acid (HCL) Corrosion, (7) Ammonium Chloride (Salt) Corrosion, (8) Wet H2S Corrosion and (9) Ammonia Stress Corrosion Cracking. Each DM related to corrosion of CDU process was selected by design data, P&ID, PFD, corrosion loop, flow of process, equipment's history and experience. Operating variables affecting severity of DM were selected in initial stage of CRV. After the CRV were set, we proposed the guidelines for reliability of equipments. The CCD has been developed on the basis of the corrosion control in refinery industry. It also improves the safety of refinery process and reduces the cost of corrosion by a big factor.