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Corrosion of carbon steel materials in brine solutions. Model results will be compared with literature data and lab experiments. Conditions will be limited to near neutral pH (5-9), temperature from 22oC to 55oC, and O2 atmospheres up to 101.325 kPa.
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Kuwait is among the ten top oil producing countries in the world. The state run Kuwait Oil Company produces crude oil through more than 5000 wells spread across the company’s South-East, North and West Kuwait asset areas. The crude oil produced along with saline water and gases (carbon dioxide, hydrogen sulfide & hydrocarbon gas) is received at manifold headers at Gathering Centers (GC).
In Oil & Gas industries, Cr-Ni-Mo stainless steels and Ni-Cr-Mo alloys with Pitting Resistance Equivalent Number (PREN) lower than 40 could be selected for Rigid Production subsea risers, pipeline, and associated structure’s piping, according to a CO2/H2S corrosion assessment that considers all steady and transient conditions foreseen to operate the reservoir.
However, there are frequently some localized corrosion concerns for these materials during the installation and pre-commissioning of the line, when the internal surface of the line could be in contact temporarily with untreated seawater. These concerns systematically lead to discard the selection of these materials and to select, for conservative purpose, UNS N06625 that is admitted immune to localized corrosion in ambient seawater in international standard and operator’s specification, whatever the outcomes of the CO2/H2 corrosion assessment.
In seawater handling systems, better dissolved oxygen controls would permit the use of more cost effective materials such as duplex stainless steel UNS S82551. Corrosion testing of tubes joined together with a proprietary premium threaded connection was performed in controlled seawater loops simulating service conditions at 30°C.
Austenitic stainless steels (SS), such as 304L and 316L alloys, are largely used for structural components in nuclear power plants due to their good corrosion resistance, especially under high temperatures and aqueous environments. However, operational experience on the primary circuit of pressurized water reactors (PWRs) has shown an increasing number of cases of stress corrosion cracking (SCC) on austenitic stainless steels components after long-term exposure.
It has become somewhat common in the oil and gas industry to convert producing wells containing 13Cr stainless steels to water injection wells. This practice has led to numerous tubing failures due to pitting of the 13Cr from oxygen dissolved in the injection water. The water source for these wells is often from produced water and seawater but other waters may also be injected.
Stainless steels have been used for a wide range of applications in seawater. They are known to be susceptible to localized corrosion under given conditions. This is often the limiting factor for the use of stainless steels for seawater applications.
In Upstream, CRAs (Corrosion Resistant Alloys) are widely selected to handle seawater and brines in piping, valves, pumps, heat exchangers, vessels, and seawater injection1-4. Also, disposal of produced water is commonly performed through injection into spent fields. Water from a variety of sources including produced water, seawater and surface/fresh water may also be injected to create pressure drive for existing fields. Usually dissolved oxygen (DO) is not fully controlled when there are multiple sources of injection water and sometimes even possibility of injection of fully oxygenated water exists. For oxygenated seawater, the PREN (Pitting Resistance Equivalent Number = %Cr + 3.3 *(%Mo + 0.5 %W) + 16 %N) shall be >40 and limits are applied to the temperature4. Other applications involve Solid CRA or cladded production pipelines which may get flooded with seawater during installation and precommissioning.
Ammonium Chloride (NH4Cl) corrosion is prevalent in the refinery and petrochemical industries and its prediction, monitoring and control has been well documented. In Chemical plants, when NH3 and HCl are present in a gas-mixture and the temperature drops, NH4Cl can desublime. In the presence of water-vapor, NH4Cl desublime within components like heat-exchanger tubes, creating saturated wet salt deposits, causing general and localized corrosion.