Corrosion — another process parameter

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Corrosion — another process parameter. Do you know what another process parameter is, besides temperature, pressure, flow rate, and liquid level? It’s corrosion. Below, this issue is explained from the perspectives of the hazards of corrosion, the reasons and significance for corrosion monitoring, and the groundbreaking nature of Honeywell’s corrosion solutions. The hazards of corrosion: Statistics from surveys conducted both domestically and internationally show that in some countries around the world, the losses caused by corrosion each year account for 2.5% to 4% of that country’s GDP. Last year, the corrosion-related losses in our country were estimated to be as high as 500 billion yuan, far exceeding the total losses caused by natural disasters and various accidents. In addition, corrosion and scaling result in an additional consumption of 17.5 million tons of standard coal per year. Corrosion has drawn significant attention across the entire industrial sector. It is a phenomenon of degradation and damage that all objects in nature must face; it not only consumes resources and pollutes the environment but also endangers human safety and health. Humans cannot eradicate corrosion, but they can control it; by adopting existing effective anti-corrosion measures, the service life of equipment and apparatus can be extended. By actively promoting the use of new anti-corrosion equipment, technologies, processes, and materials that help save electricity, energy, protect the environment, and enable recycling, China can reduce corrosion-related losses by at least 30%, amounting to around 150 billion yuan, which represents 1%–1.5% of GDP. Corrosion is characterized by its ubiquity, concealment, gradual progression, and sudden onset; it can be controlled but not completely eradicated. Coupled with the delayed and indirect nature of the benefits associated with corrosion control, most people turn a blind eye to it. Therefore, the whole society should pay attention to corrosion just as it does to the environment, natural disasters, and epidemics ； Just as importance is attached to water conservation, energy conservation, power conservation, material conservation, environmental protection, and safety, the same importance should be given to corrosion control. Reasons and significance of corrosion monitoring: Why is it necessary to conduct corrosion monitoring? } First of all, in the major industries where corrosion is recognized as a problem (such as oil and gas, refining and chemicals, pulp and paper, power plants, water treatment, steel, non-ferrous metals, biopharmaceuticals, and other industries), it is only natural to use corrosion monitoring techniques. In these industries, corrosion experts or material specialists are well aware that monitoring techniques constitute an important part of their toolkit for combating corrosion. More appropriately, however, other business units, including senior management, also recognize that corrosion monitoring is a reliable and effective means of controlling corrosion. Furthermore, corrosion monitoring can address those corrosion problems that are difficult or even impossible to solve using other methods. More commonly, corrosion monitoring techniques can simplify the resolution of corrosion issues or serve as an important factor in implementing solutions. Furthermore, when economic figures are available, the tangible benefits are often quite significant. In most cases where technical success is achieved, although the economic benefits cannot be quantified, tangible economic effects can still be observed. Finally, although it is sometimes not possible to expect purely technical organizations to fully believe that corrosion monitoring is a technologically valuable approach, experts from both scientific and industrial fields consider it a technology with great potential for development and significant profit generation. Such potential development includes making more extensive use of existing technologies, creating new or improved technologies, enhancing data quality, and making rational use of the data obtained. }Ù†Ç=¼XXnÜbbs.petroren.comאõ7 Â_N.o Taking the petroleum refining and chemical industries as an example, the main advantages and benefits of carrying out corrosion monitoring include 1) it provides a basis for scientific management and decision-making, such as optimizing the selection of corrosion inhibitors; for instance, in petroleum refining processes, a large amount of corrosion inhibitors are used to reduce internal corrosion in the processing equipment. However, whether the type and ratio of the added corrosion inhibitor are suitable for this system can only be determined through certain measurements and evaluations. By using corrosion monitoring, it is possible to keep an eye on the effectiveness of the corrosion inhibitors at any time; based on the monitoring results, adjustments and optimizations can be made promptly regarding the type or ratio of the inhibitors, as well as the timing of their addition. (2) It helps to prevent accidents and reduce risks: harmful leaks or changes in process parameters can sometimes lead to severe corrosion. By using corrosion monitoring, it is possible to keep an eye on the corrosion status of the medium at any time. If a sudden change in the corrosion rate is detected, the system is inspected immediately to identify the problem and prevent serious accidents from occurring. (3) Predicting equipment lifespan: Corrosion monitoring allows for an accurate assessment of the corrosion rate under normal operating conditions, enabling the prediction of the equipment’s lifespan and thus ensuring both safety and cost-effectiveness. } (4) Reducing corrosion costs: By carrying out online corrosion monitoring, it is possible to keep track of the corrosion status of equipment in real time. Selective repairs and maintenance can be carried out on those pieces of equipment that are severely corroded, rather than relying on passive, periodic major overhauls; this can help companies save more than 20% on their corrosion-related costs. 5) Improving the operational condition of equipment, enhancing efficiency and energy utilization, and reducing pollution: In addition to bringing significant economic benefits by improving the operational condition of equipment, increasing its reliability, prolonging its service life, and reducing downtime for maintenance, corrosion monitoring technology also enables equipment to operate under conditions as close as possible to those specified in the design. It also plays a positive role in ensuring the safety of the equipment, protecting operators, and reducing environmental pollution. 6) Analyzing the causes of corrosion and assessing changes in fluids, the environment, and process parameters: Corrosion monitoring also facilitates the analysis of the causes of corrosion, helps to understand the relationship between the corrosion process and various process parameters, and allows for an assessment of the effectiveness of different anti-corrosion methods. } The groundbreaking significance of Honeywell’s corrosion solutions } Following Honeywell’s acquisition of InterCorr International Corrosion Company, the company introduced the groundbreaking concept of including corrosion within the framework of process control, making it another element of process control alongside temperature, pressure, flow rate, and liquid level. } Honeywell’s corrosion solutions form a comprehensive, top-to-bottom integrated system that includes three main components: services, instrumentation, and software products. Honeywell’s corrosion protection services include material consulting, laboratory testing, measurement and testing equipment services, analysis services, as well as corrosion diagnosis and control services. In addition, the company also offers a range of software for corrosion prediction, risk assessment, material selection, and asset management. Meanwhile, InterCorr has developed its latest patented product, the SmartCET5000 series, based on uniform corrosion and pitting corrosion, as well as process control and monitoring systems. This series takes advantage of InterCorr’s SmartCET patent technology, along with Honeywell’s extensive experience and advanced technologies in process control, to enable real-time online monitoring of corrosion rates and pitting corrosion. SmartCET corrosion monitoring technology provides continuous, real-time corrosion measurement in the laboratory or in the field, and is an automated solution. The global process control industry spends $50 billion per year on corrosion issues, **which affects the optimal operation of enterprises. By integrating InterCorr technology with Experion PKS, it is possible to help customers save costs on corrosion monitoring and prevention. The SmartCET technology enables equipment operators to obtain information on process variables that are relevant at the moment, such as corrosion rates and detection of pitting (localized) corrosion. Other parameters obtained using SmartCET technology are output as 4-20mA standard signals; when combined with process and other process parameters, they can be used for online corrosion diagnosis and to improve the accuracy of corrosion rate data, something that cannot be achieved through a standalone process control system. Integrated with Experion, SmartCET technology enables operators to convert raw corrosion monitoring data into high-value process knowledge. Operators can use this information to make quick key business decisions and take proactive actions to optimize equipment performance. Therefore, the equipment offers several advantages, including: } 　　△ Increased uptime of the equipment due to improved reliability of the assets} 　　△ Reduced maintenance costs by shifting from routine maintenance to reliability-focused maintenance} △ Maximization of output} △ Enhanced safety and minimization of the negative impacts of process disruptions} Corrosion has ceased to be merely a concept as a parameter for process control; it is now a reality that is being applied in many fields with good results. This breakthrough is truly epoch-making; it enables countless process operators to realize their dream of effectively controlling corrosion. From now on, corrosion is no longer something elusive – it will be just as familiar, understandable, and controllable as temperature and pressure