7/28/2015

A Severe Top of the Line Corrosion Case Study

Top of the Line Corrosion Conference 2015 Presented by Ussama K.

Top of the Corrosion Field Case

PTTEP Presentation

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 7/28/2015

Top of the Corrosion Field Case

PTTEP Presentation

Top of the Corrosion Field Case

Objectives of the Presentation
• To share our field experience on top of the line corrosion
– Subsea repair experience
– Root cause analysis
• To evaluate the performance of top of the line mitigation
technique

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Top of the Corrosion Field Case

Sealine Leakage Chronology
Start up
TLC mitigation 
by
2‐BIDI
TLC mitigation 
by
splash pig

1st Leak at
cold spot Leakages

1997 2000 2004 2005 2008 2009 2010 2011 2012 2013 2014
MFL  47%                         73%                                                   85%       86% 

Replacement and
Leakage investigation

Top of the Corrosion Field Case

General Information about the Sealine
Operating Condition: Characteristics
CO2 up to 40 %mol
H2S <20 ppm Wall thickness:
Inlet Temperature 80‐90 oC • Riser: 17.5 mm
Inlet Pressure 30‐40 barg • Sealine/dogleg: 15.9 mm
• Corrosion allowance: 10 mm
Production Rates:
Gas ~40‐100 MMscfd Coating:
Condensate ~200‐900 bbl/d • Riser: EPDM 12 mm
Water ~1400‐1800 bbl/d • Sealine/dogleg: 3LPP 2 mm

The sealine has been operated in 
stratified flow.  

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Top of the Corrosion Field Case

Subsea Leak Survey and Repair
Typical scenario of Emergency Pipeline Repair (EPR)
• Detection
• Confirmation and evaluation of repair method(s)
• Mobilization of marine spread and material/equipment
• Repair

Top of the Corrosion Field Case

Subsea Leak Survey and Repair (1st leak)

• ROV pre-survey found the leak

location at 0.046 km. on the
sealine between two split
sleeves which were installed in
2008.
• The leak location located at 3
o’clock position (look toward
RP)

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Top of the Corrosion Field Case

Subsea Leak Survey and Repair (1st leak)
• Workshop in Songkhla had been conducted..
• To re-check all 14” split sleeve potentially to be
used is 100% functioning
• To decide the most effective procedure of
deploy and install the split sleeve
• To find the minimum tensioning pressure which
the sealing system can withstand against the
test pressure at 38 bar
• Trial to collapse the pipe
• Preliminary prepare the materials and
equipment to be ready to mobilize offshore

Top of the Corrosion Field Case

Subsea Leak Survey and Repair (1st leak)
• Then, the repair vessel had been mobilized
to conduct a repair.
• The wall thickness measurement had been
conducted by UT probe at the area of leak
location to decide which length of 14” split The clamp after completed 
installing and testing
sleeve to be used
• The FURMANITE 14” x 14” length split
sleeve was selected to clamp on the pipe
based on the UT result covered by the
insulation mattress
• Finally, the production restored.
The clamp after covered by 
insulation mattress

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Top of the Corrosion Field Case

Subsea Leak Survey and Repair (2nd leak)

Sealine replacement was required. 

Top of the Corrosion Field Case

Sealine Replacement for Root Cause Analysis
MFL inspection in 2012 showed 
metal loss in the first 2 km

WH RP

Flow Direction

Sealine Sealine
Flange Flange

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Top of the Corrosion Field Case

Sealine Replacement for Root Cause Analysis
Leak hole

Measurement thickness 
at leak hole area

Top of the Corrosion Field Case

Sealine Replacement for Root Cause Analysis
12 o’clock

3 o’clock

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Top of the Corrosion Field Case

Sealine Replacement for Root Cause Analysis
Corrosion Mapping

Manual Technique Semi‐auto Technique

Top of the Corrosion Field Case

Sealine Replacement for Root Cause Analysis

Leak at 3 o’clock

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Top of the Corrosion Field Case

Sealine Replacement for Root Cause Analysis

Top of the line 
The most severe trace of TLC located at the side of the pipe???
corrosion

Multiphase stratified flow and wet 
gas transportation

Top of the Line Corrosion Mitigation

TLC  Join  TLC‐JIP,  Corrosion Likelihood  Pipeline Integrity Management 
Assessment Ohio University Study Program Development

Sealine Latest 
Leaks leaks

2008 2009 2010 2011 2012 2013 2014 2015

1. Batch Treatment (BT) Program

TLC 
Mitigation

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Top of the Line Corrosion Mitigation

Batch Treatment Injection

Film Persistency/
Efficiency 
Recommended Frequency 
(%)
(month)
70 1.5
BT has always been delayed due to operational limitation

Pipeline is not fully protected against TLC!!! 

BT frequency optimization and strictly complied with the 
recommendation 

Top of the Line Corrosion Mitigation

TLC  Join  TLC‐JIP,  Corrosion Likelihood  Pipeline Integrity Management 
Assessment Ohio University Study Program Development

Sealine Latest 
Leaks leaks

2008 2009 2010 2011 2012 2013 2014 2015

BT complied with 
recommendation due 
to higher gas potential
BT frequency was hardly been followed 
1. Batch Treatment (BT) Program
due to production constraint 

TLC 
Mitigation VCI 
2. VCI selection, efficiency test and field trial
evaluation

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Top of the Line Corrosion Mitigation

Development of Volatile Corrosion Inhibitor

VCI Field Trail for 2 years

Top of the Line Corrosion Mitigation

TLC  Join  TLC‐JIP,  Corrosion Likelihood  Pipeline Integrity Management 
Assessment Ohio University Study Program Development

Sealine Latest 
Leaks leaks

2008 2009 2010 2011 2012 2013 2014 2015

BT complied with 
recommendation due 
to GBN higher gas 
BT frequency was hardly been followed 
1. Batch Treatment (BT) Program potential
due to production constraint 

TLC 
Mitigation VCI 
2. VCI selection, efficiency test and field trial
evaluation

3. TLC mattress installation

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Top of the Line Corrosion Mitigation

Condensation Prevention by TLC Mattress
Tsea  25oC
Tmattress/pipe >>25oC
Warming  Up!

Slow down the 
condensation 
rate and TLC
Tpipe > 50oC

Top of the Line Corrosion Mitigation

Cost Comparison

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Conclusion
• One of the most sever TLC was recovered for investigation. The
results showed high density of defects at the side of the line.
• The BT was firstly performed in 2003, which is approximately 7
years after start up. TLC for this pipeline was far progressed
before mitigation by splash pig. Pipeline failure due to TLC
cannot be avoided (can only be delayed).
• TLC mitigation methods have been developed; however, all TLC
mitigations shall be implemented since the production started up,
to obtain the most beneficial for TLC prevention.

Acknowledgement
• PTTEP Inspection and Corrosion Team
• PTTEP Subsea Inspection Team
• PTTEP Support Team in Songkla
• PTTEP and NACE ICT Support Team

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Thank you
Q&A

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Back up

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Sealine Leakage Investigation

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Actual CR (mm/y) 0.85 Design life
Predicted CR (mm/y) 0.97 (weighted average)

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Nominal wall thickness 15.9 mm
Wall thickenss (mm)

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Retired wall thickness 11.6 mm

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0
Nov‐03

Nov‐14
Jan‐97
Jun‐98
Oct‐99
Feb‐01
Jul‐02

Apr‐05
Aug‐06
Jan‐08
May‐09
Sep‐10
Feb‐12
Jun‐13

Mar‐16
Aug‐17
Dec‐18
Apr‐20
Sep‐21
Jan‐23
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Operating year

Top of the Line Corrosion Mitigation

Condensation Prevention by TLC Mattress

Single Mattress

Continuous 
Mattress

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