Prediction Of Flow Induced Corrosion And Development Of Monitoring And Management Platform For For Hydrogenation Hot High Pressure Air Cooler System

Energy is the foundation of social and economic development, as petroleum and chemicalindustry is an important pillar of energy industry. However, with the exhausted of oil resourcesand the increase of high sulfur, acid and chlorine crude oil imports from the Middle East, non-scheduled shutdown accidents in petrochemical refining system, for example pipe bursting andeven fire explosion, have appeared generally caused by flow induced corrosion. This seriouslythreats the device and personal safety. Therefore, in face of complex petrochemical process, howto realize scientific management for the prediction and monitor of flow induced corrosion hasalways been the focus of academia and engineering.Aimed at flow induced corrosion of hydrogenation hot high air cooler system, this paperstudies on the prediction and monitoring technology of flow induced corrosion. The mainresearch results included:1) Corrosion loop was determined based on process analysis. Usingtypical working conditions by ASPEN to build process model and obtain phase behavior anddistribution of corrosive medium, it was affirmed that main failure mechanism of hydrogenationair cooler was multiphase flow erosion.2) Combined with heat transfer calculation for the fluidtemperature distribution trends inside air cooler and CFD numerical simulation to obtain wallshear stress for charactering the danger zone for bundle erosion failure, the prediction wasverified based on the test results of Remote Field Eddy Current.3) On the basis of predictionresults of multiphase flow erosion, corrosion prevention and control system was constructed,confirming soft-sensing model for corrosion control parameter sets including flow velocity,concentration of NH4HS, partial pressure of H2S, pH and content of Cl-, establishing criticalindex control parameters as well as prevention and control measures after exceeds.5) On thebasis of prevention and control system for flow induced corrosion, a monitoring andmanagement platform of flow induced corrosion for hydrogenation air cooler system wasdeveloped based on C/S pattern. Through the platform server interactions with, real-time basicconditions data was collected from the DCS and LIMS system. Through the automatic control server, the applications interacted with ASPEN to obtain the real-time values of the corrosioncontrol parameters, and judged the state of the corrosion by the critical index of these parameters.Sound-light alarm and treatment measures are given for excessive parameters. Field applicationresults show that, monitoring and management platform developed, realizing online real-timeregulation for the state of flow induced corrosion could effectively reduce the corrosion risk ofhydrogenation air cooler system, raise the level of optimal operation for equipment system andguarantee device safety, stable operation for a long period of time.In this paper, the innovations include:1) Based on process simulation, heat transfer calculation and flow numerical simulation,prediction model of flow induced corrosion was constructed and failure mechanism, danger zonewas achieved.2) The corrosion control parameter sets for hydrogenation air cooler were acquired by theprediction of flow induced corrosion, at the same time soft-sensing model for the corrosioncontrol parameters was built by mathematics.3) Develop prevention and control system platform of flow induced corrosion based on C/Spattern with the technology of.NET Remoting, and realize online real-time monitoring andmanagement for the state of flow induced corrosion.