Corrosion monitoring in hydrogen bromide

08/15/2005


For years, a major processor of hydrogen bromide has had a corrosion problem. The compressor that pushes hydrogen bromide gas through their plant required regular repairs and replacement, and each compressor was only able to provide five years of operation.

Hydrogen bromide is a highly corrosive gas, especially with water present. In this application compressors are used to push the gas throughout the plant for processing. The carbon steel lines are assumed to be dry, however thousands of dollars were being spent to repair/replace corroded parts on the compressor. When the compressor broke down, the ability to process also stopped, costing money in down time.

It was determined that water must be present in the line. How was the water getting in? When? What could be done to monitor this in the process? Moisture detection equipment was used for a time. This solution did not prove fruitful, and the devices often failed. Additionally, the equipment did not assist in any planned maintenance or repair. When they did work it only confirmed that water must be in the “dry gas line,” as corrosion would not be occurring otherwise. They were unable to link the information to other process control variables being monitored.

The solution to this problem was an online corrosion-monitoring device called CorrTran from Pepperl+Fuchs, Inc. The device detects and measures corrosion rates and provides that information in an industry standard 4-20mA signal to the DCS system. The device uses algorithms and data analysis techniques that measure corrosion rate and localized corrosion, or pitting. Harmonic distortion analysis is applied to improve the performance of the industry accepted linear polarization resistance technique used to measure corrosion rate.

The plant monitored the corrosion rate over a 60-day period. Carbon filters are used in the compressor lines to assist with removing/reducing moisture content in the line. Results showed that when corrosion rates started to rise and stay high, it was an indication that the carbon filters needed to be changed.

There is a direct correlation between the corrosion spikes and the fact that filters needed to be replaced. After replacing the filters, corrosion decreased. By making this part of planned maintenance, over time repair and parts replacement costs on the compressor will be significantly reduced, and the life of the compressor will be extended.

Source: Pepperl+Fuchs , Twinsburg, OH, www.am.pepperl-fuchs.com





Top Plant
The Top Plant program honors outstanding manufacturing facilities in North America.
Product of the Year
The Product of the Year program recognizes products newly released in the manufacturing industries.
System Integrator of the Year
Each year, a panel of Control Engineering and Plant Engineering editors and industry expert judges select the System Integrator of the Year Award winners in three categories.
September 2018
2018 Engineering Leaders under 40, Women in Engineering, Six ways to reduce waste in manufacturing, and Four robot implementation challenges.
July/Aug
GAMS preview, 2018 Mid-Year Report, EAM and Safety
June 2018
2018 Lubrication Guide, Motor and maintenance management, Control system migration
August 2018
SCADA standardization, capital expenditures, data-driven drilling and execution
June 2018
Machine learning, produced water benefits, programming cavity pumps
April 2018
ROVs, rigs, and the real time; wellsite valve manifolds; AI on a chip; analytics use for pipelines
Spring 2018
Burners for heat-treating furnaces, CHP, dryers, gas humidification, and more
August 2018
Choosing an automation controller, Lean manufacturing
September 2018
Effective process analytics; Four reasons why LTE networks are not IIoT ready

Annual Salary Survey

After two years of economic concerns, manufacturing leaders once again have homed in on the single biggest issue facing their operations:

It's the workers—or more specifically, the lack of workers.

The 2017 Plant Engineering Salary Survey looks at not just what plant managers make, but what they think. As they look across their plants today, plant managers say they don’t have the operational depth to take on the new technologies and new challenges of global manufacturing.

Read more: 2017 Salary Survey

The Maintenance and Reliability Coach's blog
Maintenance and reliability tips and best practices from the maintenance and reliability coaches at Allied Reliability Group.
One Voice for Manufacturing
The One Voice for Manufacturing blog reports on federal public policy issues impacting the manufacturing sector. One Voice is a joint effort by the National Tooling and Machining...
The Maintenance and Reliability Professionals Blog
The Society for Maintenance and Reliability Professionals an organization devoted...
Machine Safety
Join this ongoing discussion of machine guarding topics, including solutions assessments, regulatory compliance, gap analysis...
Research Analyst Blog
IMS Research, recently acquired by IHS Inc., is a leading independent supplier of market research and consultancy to the global electronics industry.
Marshall on Maintenance
Maintenance is not optional in manufacturing. It’s a profit center, driving productivity and uptime while reducing overall repair costs.
Lachance on CMMS
The Lachance on CMMS blog is about current maintenance topics. Blogger Paul Lachance is president and chief technology officer for Smartware Group.
Material Handling
This digital report explains how everything from conveyors and robots to automatic picking systems and digital orders have evolved to keep pace with the speed of change in the supply chain.
Electrical Safety Update
This digital report explains how plant engineers need to take greater care when it comes to electrical safety incidents on the plant floor.
IIoT: Machines, Equipment, & Asset Management
Articles in this digital report highlight technologies that enable Industrial Internet of Things, IIoT-related products and strategies.
Randy Steele
Maintenance Manager; California Oils Corp.
Matthew J. Woo, PE, RCDD, LEED AP BD+C
Associate, Electrical Engineering; Wood Harbinger
Randy Oliver
Control Systems Engineer; Robert Bosch Corp.
Data Centers: Impacts of Climate and Cooling Technology
This course focuses on climate analysis, appropriateness of cooling system selection, and combining cooling systems.
Safety First: Arc Flash 101
This course will help identify and reveal electrical hazards and identify the solutions to implementing and maintaining a safe work environment.
Critical Power: Hospital Electrical Systems
This course explains how maintaining power and communication systems through emergency power-generation systems is critical.
Design of Safe and Reliable Hydraulic Systems for Subsea Applications
This eGuide explains how the operation of hydraulic systems for subsea applications requires the user to consider additional aspects because of the unique conditions that apply to the setting
click me