20-06-2013

GE’s new TrueSense offers unparalleled corrosion control for crude unit overhead systems

GE today introduced an expansion to its family of advanced automation and control technologies with TrueSense for Process, an online Crude Overhead Monitoring System (COMS). The system continuously monitors, applies and optimizes the delivery of chemicals into the crude process stream to control corrosion.

Fouling and corrosion can threaten the reliability and safety of critical atmospheric fractionator overhead condensing systems. These problems often can impair production, raise maintenance costs and reduce profits. In addition, corrosion control is becoming more challenging as refiners around the world turn to lower-cost "opportunity" crude oil feedstocks and aim to maximize middle distillate production.

Episodic pH variations in the overhead of the crude unit that are measured in the condensate water are often missed. This is mainly because spot testing is performed manually due to the lack of online, reliable data-gathering devices that can make adjustments to corrosion control chemistry in real time. TrueSense for Process-COMS detects these pH variations quickly and rapidly minimizes their effects. Because undetected events can produce very high short-term corrosion, such a fast response helps to avoid unscheduled shutdowns, reduce maintenance expenses and improve profitability and operational flexibility.

“Not only can we help to achieve lower corrosion rates with this technology, from an operational perspective, it’s at a cost point that is a fraction of alternative approaches,” says Adnan Mansour, monitoring solutions global product management leader—water and process technologies for GE Power & Water.

The TrueSense for Process-COMS technology is a key element in an integrated solution and complemented by:
-Patented LoSALT neutralizer chemistries, which prevent fouling and corrosion caused by the salt deposition experienced with traditional amine neutralizers.
- pHilmPLUS state-of-the-art overhead filmer technologies that exhibit an extraordinary range of pH stability and complement the use of neutralizers.
- A LoSALT Ionic Equilibrium software model that uses advanced thermodynamic chemical relationships to determine system salt points, providing a mechanism for refineries to reliably optimize atmospheric distillation fractionator overhead conditions to increase middle distillate production.
- Steamate* Low Salt Amine (LSA) product chemistries that enhance utility steam-side corrosion protection and do not contribute unwanted amines where boiler steam is used in crude processing.
- InSight*cloud-based knowledge management platform that helps maximize reliability through visualization and diagnostics related to keeping system performance and the contributing parameters on track.

“This is a great example of aligning, converging and integrating innovations in chemistry, automation and control, as well as software and analytics to produce a better operating result for our customers,” added Mansour. “We are focused on the interrelationships between unit processes in the refinery. We consider the total situation and make all the connections we can, both water and process related, and look to improve the productivity of the overall system and profitability for our customers.”