CORROSION CONTROL

IN THE REFINING INDUSTRY

Improve Your Working Knowledge of Corrossion Control with Expert Specialist
25th - 29th August 2014, Kuala Lumpur, Malaysia

Case Studies,
Discussion, Simulation
Learning and many
Practical exercises!

Petrosync Lecturer
Yousuf Memon B.E.
Plant Inspection & Corrosion Control Consultant

Major Corrosion Projects

Over 35 years of experience in upstream & downstream
oil & gas industry
CEO of Reliance Swift Veritas (Pvt) Ltd.
Director of Petrosult & Unimart
Specializing in corrosion & integrity management systems
execution and training

Prepared Policies for Corrosion Monitoring Systems & Corrosion

Inhibitor Injection System for Total ABK.
Prepared Corrosion Management System for Jeddah Oil Refinery
Presented technical paper on Failures in Refinery Overhead of
Atmospheric Distillation Column.

Masterclass Overview

Petroleum Refineries are perusing sustained approach from identification of corrosion and material
failure issues to long-term corrosion control approaches. However, the risks to corrosion failures
are still evident in the refineries. The course covers key topics pertaining to refinery processes,
corrosion issues, corrosion monitoring and corrosion control methods.
Supported by

Specially Designed For

This course is geared toward those with a minimum of 1-2 years experience in refineries including:

design engineers
process engineers
procurement agents
maintenance planners
service company representatives who support refineries
corrosion and equipment engineers
metallurgists
inspectors
inspection supervisors.

Masterclass Objectives

To provide understanding various petroleum refinery processes including CDU, FCC, Platformer,
Hydrocracker, Amine Units, etc.

To provide understanding of common material construction and metallurgy used in petroleum

refinery equipment.

To provide understanding of common corrosive environment encountered in petroleum refinery processes.

To provide understanding of refinery-specific corrosion problems, material degradation and

various damage mechanisms involved in the refinery.

To provide understanding of corrosion monitoring techniques used in different units of the

petroleum refinery.

To provide understanding of corrosion prevention methods mainly corrosion control chemicals

injection at different stages of refinery processes.

WHY YOU SHOULD ATTEND PETROSYNCS EVENTS

To ensure that all objectives of the course matches yours, all PetroSync programs are developed after intensive and extensive research
within the industry
PetroSync programs focus on your immediate working issues to ensure that you are able to apply and deliver immediate results in real work
situations
Application and implementation of industry knowledge and experience are the drivers for our course design, not theoretical academic lectures
PetroSync training focuses on practical interactive learning tools and techniques including case studies, group discussions, scenarios,
simulations, practical exercises and knowledge assessments during the course. Invest a small amount of your time to prepare before attending
the course to ensure maximum learning
PetroSync follows a rigorous selection process to ensure that all expert trainers have first-hand, up-to-date and practical knowledge and are
leaders of their respective industrial discipline

CORROSION CONTROL IN THE REFINING INDUSTRY

25th - 29th August 2014, Kuala Lumpur, Malaysia
1

DAY 1
1

SECTION 1

Refinery Operations & Overview

Refinery Operating Objectives
Refinery Process Overview

Fundamentals Metallurgy & Corrosion

Other Damage Mechanism
SECTION 2

Common Metals & Alloys Used in Refinery

Killed Steel
Steels
Carbon Steel
C-Mo Steels
Low-Alloy Steels
Cr-Mo Steels
Nickel Steels
Stainless Steels
Other Metals and Alloys

SECTION 3
1
Crude Distillation
Unit

Sources of Crude Oil

1
Composition of Crude Oil
Remaining Constraints
3 Crude Oil Pre-treatment
Desalting

Corrosion in Crude Distillation Units

Columns
Exchangers and Piping
Fired Heaters

Corrosion Monitoring in Crude Units

Water Analysis (Overhead Corrosion Control)
Hydrocarbon Analysis
Corrosion Rate Measurement
On-Stream, Non-destructive Examination

Materials of Construction of CDU

DAY 2
1 1

SECTION 4

Corrosion Control in Crude Distillation Units

Desalting
Caustic Addition

Overhead pH Control
Corrosion Inhibitor
Control Washing

Vacuum Distillation Unit (VDU)

SECTION 5

Fluid Catalytic Unit (FCCU)

Process Description
Riser/Reactor
Regenerator
Flue Gas System
Fractionator

Thermal & Mechanical Aspects

Type selection
Fouling behavior/mitigation
Tube Insert Technologies
Header types
High Fin tube types

Materials of Construction of FCCU

Corrosion in FCCU
Regenerator Reaction Mix Line
Main Fractionator
Bottoms Piping
Flue Gas Systems
High-Temperature Oxidation
High-Temperature Sulfidation (H2S Attack)
High-Temperature Carburization
Polythionic Acid Stress Corrosion Cracking
Catalyst Erosion
Feed Nozzle Erosion
Refractory Damage
High-Temperature Graphitization
Sigma-Phase Embrittlement
885 F (475 C) Embrittlement
Creep Embrittlement
High-Temperature Creep
Thermal Fatigue

Corrosion Control in FCC Units

Damage Mechanisms and Suitable Materials
Reactors

 Regenerators
Catalyst Transfer Piping System
SECTION 6

Catalytic Light Ends Recovery Unit (CLERU) Units

CLER Process Description

Materials of Construction
Columns
Exchangers

Corrosion in CLERU
Hydrogen Induced Damage
Inspection Techniques for Hydrogen Induced Damage
Prevention and Repair Techniques
Ammonia Stress Corrosion Cracking
Carbonate Stress Corrosion Cracking
Fouling/Corrosion of Reboiler Circuits

Corrosion Control Measures

Water Washing
Polysulfide Injection
Corrosion Inhibitors
Corrosion Monitoring
Hydrogen-Activity Probes
Chemical Tests
Corrosion Probes

DAY 3
1 1

SECTION
1 7

Sulfuric Acid Alkylation Unit (SAAU)

1
Process Description
Reaction Section
Treating Section
Fractionation Section
Refrigerator Section

Materials of Construction

Corrosion in SAAU
Sulfuric Acid Corrosion
Acid Concentration
Acid Temperature and Velocity
Acid Dilution
Hydrogen Grooving
Feed Contaminants
Acid and Neutral Esters
Acid Carryover
Corrosion Under Insulation

Fouling Problems
Corrosion Control Measures
Reactor Section Corrosion
Tower Overhead Corrosion
Reboiler Corrosion and Fouling Control
Acid Tanks
Corrosion Under Insulation

Corrosion Monitoring
Reaction Section
Treating Section
Fractionation Section
Refrigeration Equipment
Acid Tank

SECTION 8

Hydroprocessing Units (HPU)

Hydroprocessing
Hydrotreating
Hydrocracking
Variations on Hydroprocessing

Corrosion in HPU
Hight-Temperature Hydrogen Attack
High-Temperature H2S CorrosionWith Hydrogen Present
High-Temperature H2S CorrosionWith Little or No Hydrogen Present
Naphthenic Acid Corrosion
Ammonium Bisulfide Corrosion
Chloride Stress Corrosion Cracking
Failures Often Happen After Startup
Failures Happen at Predictable Points
Reactions with Stainless Steel
Polythionic Acid (PTA) Stress Corrosion Cracking
Other Methods Used to Prevent PTA SCC
Wet H2S Cracking
Sulfide Stress Cracking
Temper Embrittlement
Hydrogen Embrittlement

Materials of Construction of HPU

Reactor Loop-General
Reactor Feed System
Reactor Feed Furnaces
Reactors
Reactor Effluent System
Fouling/Corrosion of Reboiler Circuits

Reactor Effluent-Distillation Feed Exchangers

Effluent Air Coolers
Effluent Air Cooler Inlet and Outlet Piping
Separator Vessels
Recycle Hydrogen System
Distillation Section

SECTION 9

Catalytic Reforming Unit (CRU)

Octane Number (RON)

Catalyst
Catalytic Reforming Process
Platformer (UOP)
Catalytic Reformer, Semi-Regenerative
Reactor Design

Corrosion I CRU
HTHA
Stress Corrosion Cracking

Materials of Construction
Reactors
Exchangers and Piping
Fired Heaters and Other Equipment

Corrosion Control
Corrosion Monitoring
DAY 4
1

SECTION 10

Delayed Coking Units (DCU)

Equipment and Operation of the Delayed Coking Unit

High-Temperature Sulfur Corrosion
Naphthenic Acid Corrosion
High-Temperature Oxidation/Carburization/Sulfidation
Erosion-Corrosion
Aqueous Corrosion
Corrosion Under Insulation
Thermal Fatigue
Temper Embrittlement of Cr-Mo Steels

SECTION
1 11

Amine Treating Unit (ATU)

Process Description
Tail Gas Units
Corrosion Phenomena
Corrosive Species
Amine Degradation
Cracking Phenomena
Corrosion Inhibitors
Materials of Construction
Corrosion Monitoring
Corrosion Control Measures

SECTION 12

Sulfur Recovery Units (SRU)

Sulfur Recovery Units

Sulfur Chemical Processes
Sulfur Recovery Process
Tail Gas Treating Unit
Incinerator
Cold Bed Adsorption (CBA) Unit

Corrosion Mechanisms
Sulfidation of Carbon Steels
Sour Environment Corrosion
Weak Acid Corrosion

Corrosion of CBA Units

Burner and Mixing Chamber
Tail Gas Reactor and Waste Heat Exchanger
Water Quench and Re-Circulation Blower System
H2S Adsorption System

DAY 5
1

SECTION 13

Refinery Corrosion Prevention Methods

Process Additives and Corrosion Control

Factors Affecting Corrosion

Acids
Temperature
Pressure

IN-HOUSE SOLUTIONS
SAVE COST IMPROVE PERFORMANCE REDUCE RISK
PetroSync understands that in current economic climate, getting an excellent return on your training investment is critical for all our clients. This
excellent training can be conducted exclusively for your organization. The training can be tailored to meet your specific needs at your preferred
location and time. We will meet you anywhere around the globe.
If you like to know more about this excellent program, please contact on +65 6415 4500 or email general@petrosync.com

 Flow
Turbulence
Material Selection

Methods to Mitigate Corrosion

Desalting and Caustic Injection
Water Washing
Acid Neutralization
Barrier Between Metal and Environment
Chemicals Used to Combat Corrosion
Filming Amines
Filming Formulation
Filmer Application
Treat Rates
Monitoring Filmer Performance
Neutralizing Amines
Polysulfides
Napthhenic Acid Corrosion Inhibitors

Application of Corrosion Inhibitors

SECTION 14

Corrosion Monitoring Methods in Refineries

Uses of Corrosion Monitoring

Corrosion Monitoring Techniques
Corrosion Coupons
1
1
Electrical
Resistance
Monitoring

Electrochemical Corrosion Monitoring

Linear Polarization Resistance
Potential Monitoring
1 Zero Resistance Ammetry (ZRA)
Electrical Impedence Spectroscopy (EIS)
Electrochemical Noise (EN)
Hydrogen Flux Monitoring

Atmospheric Distillation Unit

Vacuum Distillation Unit
Fluid Catalytic Cracking Unit
Amine Treating Unit
Sour Water Stripper Units
Sulfuric Acid Alkylation Unit
Automated On-Line Monitoring

SECTION 15

Refinery Injection Systems

Materials Selection Considerations

Location of Injection Point
Injection System Hardware
Chemical Storage Tanks
Chemical Injection Pumps
Additive Control Systems
Piping Systems
Injector

Petrosync Quality
Limited Attendees
The course has limited seats to ensure maximum learning and experience for all delegates.
Certificate of Attendance
You will receive a Certificate of Attendance bearing the signatures of the Trainer upon successful completion of the course. This certificate is proof of
your continuing professional development.
Interactive Training
You will be attending a training designed to share both the latest knowledge and practical experience through interactive sessions. This will provide
you with a deeper and more long-term understanding of your current issues.
High Quality Course Materials
Printed course manual will provide you with working materials throughout the course and will be an invaluable source of reference for you and your
colleagues afterward. You can follow course progress on your laptop with soft copies provided.

Program Schedule
08:00 09:00
09:00 11:00
11:00 11:15
11:15 13:00
13:00 14:00
14:00 15:30
15:30 15:45
15:45 17:00
17:00

Registration (Day1)
Session I
Refreshment & Networking Session I
Session II
Lunch
Session III
Refreshment & Networking Session II
Session IV
End of Day

Petrosync Lecturer

Mr. Yousuf Memon B.E.

Plant Inspection & Corrosion Control Consultant

more than 38 years, Mr. Joshi worked in the areas of Plant Design,
fabrica on, Inspec on, including in-service inspec on of Plant equipments, Pressure vessel, Heat
exchangers,
Piping
systems
andReliance
Tank-farms
Refineries,
Petrochemical
plants,
Client
ListOil terminals, Fer lizer
Yousuf Memon
is the
CEO of
Swift for
Veritas
(Pvt) Ltd.
with
plants,
Gas
sweetening
plants,inOshore
produc
on facili es,
Power plants. His is well known expert in
over 35
years
of experience
upstream
& downstream
oiland
& gas
BP
DEWA
the
following
codes. in corrosion & integrity management systems
industry,
specialized
UEP
DPL
execution and training. Yousuf Memon has been working for
ADCO
& ASME
Sec. VIIIoil
Div.
1 and
Div 2.
API 620,
API 650
HUBCO
national
international
& gas
exploration,
petroleum refineries,

API
510,
API
570
and
API
653

ASME
B
31.1,
B
31.3
petrochemical plants, chemical plants, fertilizer plants, power GASCO
FODCO
codes plants for several years. Different areas
ASME
IX
plants andTEMA
desalination
of Sec.
ZADCO
Fauji Power
AD-MERKBLATTER
API
Bri sh Standard BS 5500
Mechanical
Integrity remained his areas of expertise such as;
QP
Engro Powergen
Plant, Risk-Based Inspection, Failure Analysis, Fitness-For-Services,

PSO
FFC
NonJoshi
Destructive
Testing
Corrosion
Mr.
has worked
with(Conventional
several mul &naAdvanced),
onal companies
worldwide and was, involved
/

PAPCO
Monitoring,
Corrosion
Inhibitor
Injection,
Material
Selection,
Protective

OMIFCO
interacted with leading mul na onal giants, such as:
Coatings, Material Performance Evaluation, Cathodic Protection System. PARCO
Engro Fertilizer
He alsodelivers
public training courses,and distant learning
Toyoin-house,
Engineering
Mitsubishi
Heavy
Industries
Asia Petroleum Engro Polymers
courses
on Corrosion
Control,Renery
Plant Inspection & Mechanical Integrity tolocal
Umm-Al-Nar
PT. PUSPETINDO, Indonesia.
TUV
NORD
DUBAL
Balcke upstream,
Durr GMBH
and
Thermax
limitedetc,
etc
and international
midstream, and downstream oil
gas industries.
Professional Affiliations
National Association of Corrosion Engineers (NACE)
The American Society of Mechanical Engineers (ASME)
American Society of Quality (ASQ)
American Educational Society of Surface Finishing (AESF)
American Institute of Chemical Engineers (A.I.Ch. E.)
Pakistan Engineering Council (PEC)
Skill & Expertise

Piping
Inspection
Oil & Gas
Refinery
NDT
Metal Fabrication
Power Plants
Plant Inspection

Risk Based Inspection

API 510
API 570
Desalination Plants
Boilers
Petroleum Refinery
Natural Gas
Petrochemicals

Material Selection
Metallurgy
Corrosion Control
Protective Coatings
Damage Mechanisms
Fertilizers
Petrochemical
Petroleum

CORROSION CONTROL IN THE REFINING INDUSTRY

PROGRAMME CONSULTANT

25th 29th August 2014, Kuala Lumpur, Malaysia

Contact
Email
Phone
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Deadline

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TERMS AND CONDITIONS

22nd Aug 2014

SGD $ 2,995

DISCLAIMER

25th Jul 2014

SGD $ 2,795

22nd Aug 2014

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