Predict-SA 2.0

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Corrosion Prediction

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Training & Support

Predict®-SA 2.0 helps industrial users predict and quantify corrosion in sulfuric acid alkylation units as a function of sulfuric acid and Acid Soluble Oil (ASO) concentrations, temperature and various additional parametric variables. It helps users make fact-based financial and engineering decisions to optimize production and minimize the risk of corrosion.

What Is It?

Predict-SA 2.0 is a high-value corrosion modeling software offering the following features:

Data for up to five materials ranging from carbon steel to Alloy B-3

Data for active and passive corrosion for two alloys – 316L and Alloy 20

A multi-phase flow modeling module correlating key flow parameters and corrosion rates to quantify contribution of typical flow-induced corrosion parameters

Ability to estimate the density, viscosity and solubility of sulfuric acid mixtures

Ability to evaluate the effect of iron content and hydrocarbon

Graphically view service life of pipe using predicted time-to-failure plot

Study parametric effects with sensitivity analysis tool

On-the-fly and secure electronic access to actual laboratory test data and program reports

Support for generation of extensive data reports, multiple case analyses and data-sharing across platforms.

How Does It Work?

Predict-SA 2.0 encapsulates inferences, experimental results, and research data from a comprehensive Joint-Industry research program (JIP) conducted by Honeywell and sponsored by industry leading refining and engineering companies. The program was aimed at developing a quantitative engineering database and decision-support model to predict corrosion of carbon steel and corrosion resistant alloys (CRAs) in sulfuric acid alkylation units. It specifically studied the relationship between corrosion and critical environmental parameters, such as temperature, sulfuric acid, acid soluble oil (ASO) and hydrocarbon concentrations.

In addition, it integrated this data characterization of flow regimes and wall shear stress for several commonly used alloys in the following three zones:

Zone A—Concentrated sulfuric acid piping service (fresh, recirculating, and spent sulfuric acid with concentrations from 99.5 wt% down to 87.4 wt%)

Zone B—Concentrated sulfuric acid reactor/contactor section (emulsion service—approximately 50 vol% hydrocarbon, 50 vol% sulfuric acid)

Zone C—Entrained acid service to the caustic/water wash system (low-level acid carryover in raw alkylate).

What Problems Does It Solve?

Predict-SA 2.0 enables the selection of appropriate materials and facilitates safe operational practices of sulfuric alkylation units, leading to enhanced safety and cost savings by preventing unplanned downtime that may stem from corrosion failures.

With the help of Predict-SA 2.0 users can:

Effectively characterize and predict corrosion and identify appropriate, resistant material (when carbon steel is not applicable)

Develop and implement Integrity Operating Windows (IOW)

Understand the significance of different corrosion evaluation parameters and their effects

Easily perform full pipeline analysis with corrosion prediction and flow modeling for horizontal/ vertical pipe sections.

Documentation

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Predict-SA 2.0 is the only system of its kind, which provides plants an ability to predict/ quantify corrosion in sulfuric acid alkylation units and select optimum metallurgy for them.

Product Information Note

25 Feb 2016

Case Studies

Training & Support

Training, maintenance and support are critical aspects to consider when choosing a technology partner. Honeywell offers world-class training through our Automation College as well as comprehensive maintenance and support services designed to leverage your physical and intellectual assets and help you sustain and increase their value and performance over time.

View support information and downloads related to Predict-SA 2.0