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The use of access fitting for intrusive corrosion monitoring tools is a common practice in the Oil & Gas industry; however, the Company (Petroleum Development Oman) has faced several difficulties including a recent incident during retrieval operations which has led to suspend, or significantly reduced the use of corrosion coupons and probes, decrease the frequency of retrieval, and eliminate its use in new projects.
The use of access fitting for intrusive corrosion monitoring tools is a common practice in the Oil & Gas industry; however, the Company has faced several difficulties including a recent incident during retrieval operations which has led to suspend, or significantly reduced the use of corrosion coupons and probes, decreasing the frequency of retrieval, and eliminating its use in new projects. In order to reduce the risk, it was decided to decrease 91% the use of corrosion coupons, hence suspending the retrieval activities in those locations. Therefore, more than 300 access fittings / locations were no longer required. These locations, un-attended, might result in dead legs (corrosion threat) which could create a possible leak path in the pipeline systems. In that sense, there was an urgent need to define a safe, efficient and permanent solution for the abandonment of the existing access fittings. Several options were reviewed, considering technical aspects as well as costs.
In the petroleum industry, much greater attention has been focused on more highly sour and acidic oil resources due to the gradual depletion of conventional sweet oil resources. In addition, reducing crude oil costs have forced to look for opportunity (alternate) crudes, usually low-quality corrosive crude oils with high concentrations of naphthenic acids and sulfur compounds.1 The main constituents in the crude that cause corrosion are sulfur compounds, organic and inorganic chlorides, salt water, organic and inorganic acids. Processing of these highly acidic and sulfur-containing crudes at high temperatures in refineries has promoted significant corrosion problem in hot oil distillation units and associated piping systems.
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Electrochemical corrosion rate probes have been constructed and tested along with mass loss coupons in an air plus water vapor and a N2/O2/CO2 plus water vapor environment. Temperatures ranged from 200º to 700ºC. Results show that electrochemical corrosion rates for ash-covered mild steel are a function of time, temperature and process environment.