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    API RP 939-C-2009 Guidelines for Avoiding Sulfidation (Sulfidic) Corrosion Failures in Oil Refineries (FIRST EDITION)《炼油厂中避免硫化作用(Sulfidic)腐蚀失效用指南.第1版》.pdf

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    API RP 939-C-2009 Guidelines for Avoiding Sulfidation (Sulfidic) Corrosion Failures in Oil Refineries (FIRST EDITION)《炼油厂中避免硫化作用(Sulfidic)腐蚀失效用指南.第1版》.pdf

    1、Guidelines for Avoiding Sulfidation (Sulfidic) Corrosion Failures in Oil RefineriesAPI RECOMMENDED PRACTICE 939-C FIRST EDITION, MAY 2009Guidelines for Avoiding Sulfidation (Sulfidic) Corrosion Failures in Oil RefineriesDownstream SegmentAPI RECOMMENDED PRACTICE 939-C FIRST EDITION, MAY 2009Special

    2、NotesAPI publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.Neither API nor any of APIs employees, subcontractors, consultants, committees, or other assignees make any warranty or

    3、representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any use, or the results of such use, of any information or process disclosed in this publication. Neither API nor an

    4、y of APIs employees, subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights.Classified areas may vary depending on the location, conditions, equipment, and substances involved in any given situation. Users of this recomme

    5、nded practice should consult with the appropriate authorities having jurisdiction.Users of this recommended practice should not rely exclusively on the information contained in this document. Sound business, scientific, engineering, and safety judgment should be used in employing the information con

    6、tained herein. API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and he

    7、reby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any authorities having jurisdiction with which this publication may conflict.API publications are published to facilitate the broad availability of proven, sound engineering and

    8、 operating practices. These publications are not intended to obviate the need for applying sound engineering judgment regarding when and where these publications should be utilized. The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other

    9、practices.Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to

    10、the applicable API standard.All rights reserved. No part of this work may be reproduced, translated, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, A

    11、PI Publishing Services, 1220 L Street, N.W., Washington, D.C. 20005.Copyright 2009 American Petroleum InstituteForewordNothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or produc

    12、t covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent.This document was produced under API standardization procedures that ensure appropriate notification and participation in the develop

    13、mental process and is designated as an API standard. Questions concerning the interpretation of the content of this publication or comments and questions concerning the procedures under which this publication was developed should be directed in writing to the Director of Standards, American Petroleu

    14、m Institute, 1220 L Street, N.W., Washington, D.C. 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the director.Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years.

    15、 A one-time extension of up to two years may be added to this review cycle. Status of the publication can be ascertained from the API Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is published annually by API, 1220 L Street, N.W., Washington, D.C. 20005.

    16、Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, D.C. 20005, standardsapi.org.iiiContentsPageIntroduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    17、 . . . . . . . . . . . . . . . . . . . vii1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Normative References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    18、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Definitions and Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.1 Definitions . . . . . . . . . . . . . . . . . . . . . . . . .

    19、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13.2 Acronyms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Basics of Sulfidati

    20、on Corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Location of Sulfidation Corrosion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 Effects

    21、of Process and Material Variables on Corrosion Rates . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.2

    22、H2-free Sulfidation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56.3 H2/H2S Corrosion. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    23、 . . . . . . . . . . . . . . . 97 Practical Guidelines for Avoiding Sulfidation Corrosion Failures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107.1 For Existing Units and Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    24、 . . . . . . 107.2 New and Replacement Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138 Limitations of Current Knowledge Base. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    25、. . . . 159Incidents. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Annex A (informative) Failure Experience Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    26、. . . . . . . . . . . . 17Annex B (informative) Sulfidation Corrosion Prediction Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19Annex C (informative) Corrosion Data for Carbon Steel Piping with Higher and Lower Si Contents . . . . . . . . 31Bibliography . . . .

    27、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Figures1 NPS 8 Carbon Steel Piping Failed Due to Sulfidation Corrosion (H2Free) . . . . . . . . . . . . . . . . . . . . . . . . . 42 Corroded Car

    28、bon Steel Sight Glass Nipple . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 FCC Fractionator Bottoms Carbon Steel Piping Operating at 150 psig (1 MPa) and 650 F to 700 F (340 C to 370 C). . . . . . . . . . . . . . . . . . . . . . . . . . . .

    29、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 FCC Fractionator Bottoms Carbon Steel Piping Shown in Figure 3 Operating at 150 psig (1 MPa) and 650 F to 700 F (340 C to 370 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65 Summary of Reported Fai

    30、lures by Type, Number of Reported Instances, and Percentage of the Total . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16B.1 Modified McConomy Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

    31、. . . . . . . . . . . . . . . . . . . . . . . . . . . 21B.2 Modified McConomy Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21B.3 Couper-Gorman H2/H2S Curves for Carbon Steel for Both Gas Oil and Naphtha. . . . . .

    32、. . . . . . . . . . . . . 22B.4 Couper-Gorman H2/H2S Curves for 1.25Cr Steel for Both Gas Oil and Naphtha. . . . . . . . . . . . . . . . . . . . 23B.5 Couper-Gorman H2/H2S Curves for 2.25Cr Steel for both Gas Oil and Naphtha . . . . . . . . . . . . . . . . . . . . 24B.6 Couper-Gorman H2/H2S Curves f

    33、or 5Cr Steel for Both Gas Oil and Naphtha . . . . . . . . . . . . . . . . . . . . . . 25B.7 Couper-Gorman H2/H2S Curves for 7Cr Steel for Both Gas Oil and Naphtha . . . . . . . . . . . . . . . . . . . . . . 26B.8 Couper-Gorman H2/H2S Curves for 9Cr Steel for Both Gas Oil and Naphtha . . . . . . . .

    34、. . . . . . . . . . . . . . 27B.9 Couper-Gorman H2/H2S Curves for 12Cr Steel (Same for Both Gas Oil and Naphtha). . . . . . . . . . . . . . . 28B.10 Couper-Gorman H2/HH2S Curves for 18Cr Steel (Same for Both Gas Oil and Naphtha) . . . . . . . . . . . . . 28B.11 Corrosion Rate in H2S/High H2Partial P

    35、ressureAll Vapor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29vContentsPageB.12 Corrosion Rate in H2S/High H2Partial PressureLiquid Shifted by a Factor of 6 Lower vs Vapor . . . . 29B.13Corrosion Rate in H2S/H2VaporLow H2Partial Pressure (High H2Partial PressureAll Vapor

    36、 Curves Adjusted by Experience) . . . . . . . . . . . . . . . . . . . . . . . . . . . 30C.1Corrosion Rate vs Si Content for FCC Slurry Carbon Steel Piping Failure (Operating Conditions: 150 psig and 650 F to 700 F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32C

    37、.2Corrosion Rate vs Si Content for FCC Slurry Piping Failure (Operating Conditions: 1 MPa and 340 C to 370 C) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33C.3Corrosion Rate vs Si Content for Various H2-free Services. . . . . . . . . . . . . . . . . . . . . .

    38、. . . . . . . . . . . . . . . 34C.4Corrosion Rate vs Si Content for Various H2-free Services. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34viIntroductionSulfidation corrosion, also often referred to as sulfidic corrosion, of piping and equipment within the refining indus

    39、try continues to be a significant cause of leaks leading to equipment replacements, unplanned outages, and incidents associated with large property losses and injuries. The objective of this recommended practice (RP) is to provide practical guidance to inspectors, maintenance, reliability, project,

    40、operations and corrosion personnel on how to address sulfidation corrosion in petroleum refining operations. This document is intended to provide a better understanding of sulfidation corrosion characteristics. Examples of failures are discussed to highlight the common causes. An overview of the two

    41、 mechanisms of sulfidation corrosion (with and without H2present) and the methods used to control and inspect for sulfidation corrosion are summarized. The data herein is a compilation of information extracted from published technical papers, industry information exchanges (NACE and API) and contrib

    42、utions from several owner/operators. Some refining companies have developed proprietary methods to predict sulfidation corrosion and these were not made available as part of this effort. Common refinery units in which essentially H2-free sulfidation corrosion occurs are the crude/vacuum, fluid catal

    43、ytic cracker, coker, and visbreaker units. Hydroprocessing and hydrocracking units experience H2-free sulfidation corrosion in their feed and distillation sections. They experience sulfidation in the presence of hydrogen in their reaction sections. This sulfidation in the presence of H2is typically

    44、referred to as H2/H2S corrosion. Included in this RP are: background to the degradation mechanism, the most common types of incidents and damage observed, root causes of sulfidation corrosion, methods to predict and monitor the corrosivity of systems, materials selection for new and revamped process

    45、es, inspection and nondestructive examination (NDE) methods used for detecting sulfidation corrosion. Materials and corrosion specialists should be consulted for additional unit-specific interpretation and application of this RP.vii1Guidelines for Avoiding Sulfidation (Sulfidic) Corrosion Failures i

    46、n Oil Refineries1 ScopeThis recommended practice (RP) is applicable to hydrocarbon process streams containing sulfur compounds, with and without the presence of hydrogen, which operate at temperatures above approximately 450 F (230 C) up to about 1000 F (540 C). A threshold limit for sulfur content

    47、is not provided because within the past decade significant corrosion has occurred in the reboiler/fractionator sections of some hydroprocessing units at sulfur or H2S levels as low as 1 ppm. Nickel base alloy corrosion is excluded from the scope of this document.While sulfidation can be a problem in

    48、 some sulfur recovery units, sulfur plant combustion sections and external corrosion of heater tubes due to firing sulfur containing fuels in heaters are specifically excluded from the scope of this document. 2 Normative ReferencesThe following referenced documents are indispensable for the applicat

    49、ion of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced doucment (inlcuding any amendments) applies.API 510, Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair, and Alteration API 570, Piping Inspection Code: Inspection, Repair, Alteration, and Rerating of In-service Piping Systems API Recommended Practice 571, Damage Mechanisms Affecting Fixed Equipment in the Refining IndustryAPI Recommended Practice 578, Material Verification Program for New and Existin


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