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This paper shares experiences and challenges of corrosion risk assessment in the down-stream petroleum industries and simplify ways of managing corrosion through effective corrosion assessment regime.
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Corrosion inhibitors (CI) are typically evaluated using either short-term electrochemical methods or long-term weight loss methods in laboratory set up. Although electrochemical methods provide fast and real-time corrosion information, corrosion subject matter experts, in general, rely on long term weight loss methods to determine localized corrosion information. These long-term methods include exposure of the metal coupon in a corrosive media under specific field conditions/parameters such as temperature, pressure, wall shear stress, corrosive gas species and test length in the presence of corrosion inhibitor active(s).
This production asset located in the deep-water offshore Brazil, producing heavy oil in the range of 16 to 24 oAPI. Mudline caisson separators with electrical submersible pumps (ESPs) are used to process fluids from multiple wells and boost them to the receiving floating production, storage, and offloading (FPSO) vessel(1). There are significant flow-assurance and corrosion challenges in operating the asset. One of the challenges is the production fields have limited subsea umbilical, necessitate the use ofmultifunctional products to maintain the field’s integrity and mitigate any flow assurance and scale issues.
Top-of-the-line corrosion (TLC) of carbon steel (CS) pipelines can be encountered during the transportation of wet gas under stratified flow conditions where temperature differences between the internal and external environments results in condensation of saturated vapors and water-wetted surface on the upper portion of the inside pipeline surface causing corrosion issues.1 Initially at least, the condensed water phase can be particularly corrosive with a low pH caused by dissolved acid gases (such as carbon dioxide and hydrogen sulfide) as well as organic acids in an unbuffered thin water film. Like bottom-of-the-line corrosion, TLC can be dominated by either carbon dioxide or hydrogen sulfide corrosion mechanisms.
An operating company was concerned that its biocide and corrosion mitigation strategy was not sufficient to control corrosion in their pigging operations across the Gulf Coast of Texas. They provided water samples from several pigging access points that were heavily contaminated with SRBs, APBs, black deposits and oil. H2S was present in most of the samples suggesting a heavy presence of SRBs. They suspected that the black deposits were most likely FeS caused by the presence of microorganisms interacting with their pipelines. Indeed, culture vial tests (sometimes referred to as “bug bottles”) proved that the samples were heavily contaminated with microorganisms.
Offshore metallic structures have an average life-time of 20-25 years. They consist of four different zones, the buried, the submerged, the tidal/splash and the atmospheric one. According to NACE 2013 the global corrosion cost is estimated to be US$2.5 trillion, consisting a major economic problem. Hence, protection from corrosion is essential. Each zone is protected either with cathodic methods, or with a combination of cathodic methods and coatings. More specifically, the protection of the atmospheric zone, which is the aim of this research, due to the lack of continuous electrolyte (seawater) does not allow the application of cathodic protection.
TOL corrosion is reported to occur in large diameter wet gas pipeline in stratified flow conditionsdue to low fluid velocities1. With increasing distance from the inlet, the wet gas pipeline becomescooler as it loses heat to the environment. Such cooling causes water, hydrocarbon, and otherhigh vapor pressure species to condense on the pipe wall. The upper part of the pipe willconstantly be supplied with freshly condensed water while the less corrosive water saturatedwith corrosion products will be drained along the pipe wall to the bottom of the line.
Corrosion inhibitors are used to prevent pipeline corrosion in oil and gas industry. The evaluation of corrosion inhibitors is one of the most important tasks for the corrosion engineers. Corrosion of the metal is suppressed by the inhibitor adsorption on the metal surface. Active ingredients of corrosion inhibitors are, in general, surfactants. A surfactant can adsorb on the internal metal surface of piping and makes a hydrophobic film preventing the contact of water with the metal surface.
In hydrocarbon production systems, mild steel is overwhelmingly used for the construction of pipelines and tanks for the transmission and storage of crude oil, natural gas, and derived petroleum products. Although mild steel has excellent mechanical properties and low cost, it is susceptible to corrosion attack in typical service environments. Inhibition of internal corrosion is essential for assuring asset integrity of oil and gas transportation pipelines.
Corrosion of the internal surfaces of pipelines is one of the serious issues facing the oil and gas industry. Produced oil and gas always contain some water mixed with brines and contain varying amounts of carbon dioxide (sweet gas), hydrogen sulfide (sour gas) and organic acids1. All of these can affect the integrity of the low-carbon steel pipes used in the construction of downhole gas wells. CO2 gas, along with the high salt content of production water, causes serious corrosion on the internal walls of corrosion resistance alloys (CRAs) and steel pipelines used in downhole gas wells.