As refineries navigate an increasingly complex operating environment, the challenge of managing corrosion risks while maintaining operational flexibility has become paramount. Emerson’s Rosemount™ Wireless Corrosion and Erosion Transmitters, with over a decade of proven field performance, are transforming how facilities approach this critical balance between asset integrity and processing capabilities.
Corrosion in crude unit overhead systems presents a persistent challenge for refiners. The chemistry involved is complex – hydrochloric acid formation, amine-based compounds, and various corrosive species can create conditions that threaten equipment integrity. Traditional monitoring and inspection approaches, such as manual ultrasonic testing or intrusive probes, have significant limitations in providing the comprehensive, real-time insights needed for modern operations.
Manual ultrasonic thickness measurements do not offer the repeatability or frequency of data required for informed decision making, as opposed to permanently installed monitoring solutions.
Emerson’s patented ultrasonic sensor technology offers unique advantages that address these longstanding challenges. The system’s couplant-free design eliminates a common point of failure in traditional ultrasonic monitoring, while the waveguide technology enables reliable operation at surface temperatures up to 600°C (1100°F). Most importantly, proprietary Adaptive Cross Correlation (AXC) signal processing provides unprecedented measurement stability, even when monitoring aggressive internal surface corrosion and erosion.
Emerson’s Adaptive Cross Correlation (AXC) Signal Processing is a patented signal processing designed to handle extreme conditions, delivering industry- leading measurement repeatability and resolution.
The technology’s effectiveness is proven through more than 100 million automated measurements delivered to over 250 refineries worldwide. One North American refinery used Rosemount Corrosion and Erosion Transmitters to identify corrosion linked to organic chlorides in specific crude batches, leading to enhanced pre-processing protocols. Another facility optimized its chemical treatment program by tracking corrosion rates in real-time, achieving significant cost savings while improving equipment protection.
Beyond the core technology advantages, Rosemount Corrosion and Erosion Transmitters offer practical benefits that make them ideal for refinery environments. The wireless communication and extended battery life enable monitoring in remote locations without complex infrastructure. The transmitters can be installed during normal operations without shutdowns using clever magnetic and strap mounting, and the non-intrusive design eliminates safety concerns associated with traditional corrosion probes.
The business case is compelling. While exact figures vary by facility, the cost of an unplanned shutdown in a crude unit can quickly escalate into millions of dollars per day. This solution’s ability to detect developing issues early – with resolution down to 1 micrometre – helps prevent surprises. The automated data collection also reduces the need for manual inspections in difficult-to-access locations, improving both safety and efficiency.
Online corrosion monitoring solutions allow both root cause analysis and predictive maintenance, promoting informed decision making on critical topics.
Looking ahead, the role of advanced corrosion monitoring will likely expand as refineries face continued pressure to maintain operational flexibility while ensuring asset integrity. Emerson’s decade-plus experience in this field, combined with ongoing innovation in sensor technology and signal processing, positions their solutions as market-leading for these challenges.
For facility managers and technical professionals, the value proposition is clear: while corrosion challenges in crude processing units remain complex, Emerson’s proven technology offers a reliable path forward. The combination of continuous monitoring, precise measurement, and comprehensive coverage, backed by years of field experience and ongoing technical support, enables more confident decision-making about processing parameters, maintenance scheduling, and chemical treatment programs.
This technology-driven approach to corrosion management represents more than just an incremental improvement – it fundamentally changes how refineries can approach the balance between operational flexibility and equipment integrity. As the industry continues to evolve, you can trust Emerson’s Corrosion & Erosion Monitoring Solutions to provide the insights needed to maintain competitive, reliable operations.
