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Risk Analysis of Oil and Gas Pipelines Subjected To CO2 Corrosion - ESREL2007
Risk Analysis of Oil and Gas Pipelines Subjected To CO2 Corrosion - ESREL2007
Maneesh Singh
University of Stavanger, Stavanger, Norway
AGR EmiTeam, Sandnes, Norway
Tore Markeset
University of Stavanger, Stavanger, Norway
ABSTRACT: The corrosion of pipelines for transporting oil and gas, significantly increases the possibility
of their accidental release. Hence, it is important to be able to accurately predict the degree of corrosion and
corresponding risk of leakage through the corroded pipeline. However, the degree of corrosion and corresponding
probability of failure (leakage) are difficult to model, because, firstly, the mechanism of corrosion and subsequent
failure are complex processes that have not been completely understood; and secondly, there is a lack of data,
due to the fact that most of the time the plant operators are unable maintain an accurate record of the operating
conditions and inspection data. This paper discusses various types of corrosion models; the uncertainties involved
in calculating the rate of corrosion; and the capability of three different approaches – deterministic, probabilistic
and fuzzy logic – in handling those uncertainties.
1991
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1992
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Various models have been proposed for the calcula- Center, Ohio University (Nesic et al., 2005; Nesic
tion of pH. This step is required because on exposure et al., 1995; Nesic et al., 2004a; Nesic et al., 2004b;
to air the fluid changes its pH value, hence the labora- Vitse et al., 2003; Wang, 1997; Zhang et al., 1997) in
tory analytical value does not reflect the true pH of the developing these models.
fluid inside the pipe. The most common ones are by: Since these models are based more on fundamen-
tal understanding of the complete corrosion process,
• de Waald,
hence, they have the potential to accurately predict the
• Oddo & Tomson (1982) – used by Gunaltun and
corrosion rate. The drawbacks of these models include
NORSOK M-506,
complex modeling work, need for complete funda-
• Bonis & Crolet (1987) – used by Predict™ (Srini-
mental understanding of the individual steps of the
vasan & Kane, 1996).
process, need for extensive data and difficulty in incor-
The calculation has been generalized by showing porating the effect of morphology of the deposited
that the combined effects of CO2 partial pressure, ionic film on the protectiveness. While these models are
strength, temperature and initial bicarbonate ion con- able to predict laboratory results with high accuracy,
centration may be described by a single variable pH they face problems during implementation in actual
(Herce et al., 1995). This pH can then be related to field condition where the operating conditions vary
the corrosion rate under a variety of conditions. A considerably.
more elaborate method of calculating pH has been
propounded by Zhang et al. (1997).
Using the values of the pH, CO2 partial pressure,
3 DIFFICULTIES IN MODELING CORROSION
shear stress and temperature, the initial corrosion rate
PROCESS
is calculated. Depending upon the requirements the
effect of other parameters like H2 S, inhibitors, chloride
While a number of mathematical models have been
and sulfate may be included in the calculation of the
developed, unfortunately none of them is able to reli-
final corrosion rate (Srinivasan & Kane, 1996).
ably predict the rate of corrosion over a wide range
These models are quite simple and flexible in use,
of conditions. A number of reasons are responsible
and hence are models of choice for the plant operators.
for the inaccuracies in the prediction, these include
However, since these models are not based on funda-
.(Edwards et al., 1996; Gunaltun, 1996; Srinivasan &
mental theories, they do not shed light on the actual
Kane, 1996):
corrosion mechanism.
• Poor understanding of the corrosion mechanism.
• Difficulty in modeling multiphase fluid flow.
2.2 Mechanistic models • Lack of reliable fundamental data for kinetic, ther-
modynamic, fluid flow, heat and mass transfer
Mechanistic models describe the corrosion process
calculations.
based mostly on the fundamental principles, hence
• Large number of inter-related variables affecting the
they have a strong theoretical background. They take
corrosion process.
into account details of the multi-phase fluid flow, trans-
• Effect of secondary processes like formation of
port of reactants and products, anodic dissolution of
scales, deposition of wax, inhibitor efficiency, etc.
metals and of cathodic reduction of oxidants. Accord-
• Frequent variations in the operating parameters of
ing to these models, the overall corrosion process takes
plant.
place in four steps (Dayalan et al., 1995):
• Low accuracy of field data.
• Dissolution of carbon dioxide in water to form • Poor record of operating conditions.
different reactive species which take part in the • Metallurgical variations in material of construction.
chemical reaction. • Incomplete understanding of the behavior of corro-
• The transport of the reactive species from the bulk sion inhibitors.
flow to the metal surface.
• The electrochemical reaction (anodic and cathodic)
that takes place at the surface of the metal.
4 UNCERTAINITIES IN MODELING CO2
• The diffusion of the products from the metal surface
CORROSION
to the bulk liquid.
The corrosion rate is governed by the rate- Due to the problems associated with the modeling
determining step – kinetics or the transport. Different of CO2 corrosion, a number of uncertainties are
models differ in their approach in the treatment of introduced in the calculations. Most often these uncer-
the different steps. Extensive work has been done at tainties make a precise model useless or difficult to
the Institute for Energy Technology, Oslo (Nyborg implement. Thus, a good model should be robust
et al., 2000) and the Corrosion in Multiphase Systems enough to handle the uncertainties, yet be flexible
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enough to implement easily. Luckily, for developing approaches that are applied to assist in the handing
a risk-based maintenance program, it is not important of the uncertainties are:
to accurately model the whole corrosion process which
• Probabilistic approach: This approach is useful
would be able to predict the rate of corrosion over a
when the fluctuations in the data are quantified.
wide range of conditions. Instead the requirement is
Hence, it is useful for treating uncertainties of Type
of a practical model which is simple to use, flexible
A (Edwards et al., 1996; Melchers, 2001).
enough to be modified according to the requirements
• Fuzzy logic approach: This approach is preferred
of different sections of the plant, and able to incor-
when the quantification of the uncertainty is not
porate field data. According to Gunaltun (1996): The
available but is described in imprecise, subjective
corrosion rate cannot be predicted with high accuracy.
or linguistic terms. Hence, it is useful for treating
Such a prediction is neither required nor possible. Only
uncertainties of Type B and C (Ross, 2004).
the “order of magnitude” of the corrosion rate has a
practical meaning. Since, the way the uncertainties have been handled
and the interpretations drawn will have an impact on
4.1 Causes of uncertainties in the CO2 the final decisions taken, the source and extent of
corrosion models uncertainty should be made explicit and the impli-
cations should be transparent. It is often helpful to
While using a corrosion rate model, the uncertainties discuss alternative scenarios and interpretation of the
may be introduced due to: calculations.
1. The structure of the model. The highly complicated
nature of the corrosion process makes even the most
advanced mechanistic models inaccurate. Hence, 5 PROBABILISTIC APPROACH FOR CO2
based on certain assumptions every model simpli- CORROSION MODELING
fies the effect of individual steps or ignores some
steps altogether, resulting invariably in a number of The probabilistic approach combines a CO2 corrosion
uncertainties. model with the probability density distribution of the
2. The data used for input and/or model parameters. available data regarding the structural and operation
Since it is difficult (if not impossible) to collect data parameters to predict the probability of failure. Hence,
from an actual plant due to the difficulties in mon- while it cannot handle the uncertainties arising due to
itoring and recording, most often the data used by the CO2 corrosion model (Cause 1) itself, it can take
various models is obtained from the limited num- into account the variations in the operating conditions,
ber of experiments carried out in laboratory under like gas-liquid flow rates, density, viscosity, tempera-
simplified conditions. This lack of plant data is one ture, CO2 content, pressure (Cause 2). Hence, unlike
of the major sources of uncertainties. deterministic modeling which gives crisp values, this
3. The numerical approximation. Once the concep- method gives the probability of reaching the limit
tual model has been prepared, it is often difficult state (degree of corrosion leading to leakage) at any
to mathematically solve the equations. Thus the stage during the lifetime of the pipeline (Ahammed,
uncertainties are introduced depending upon the 1997; Ahammed, 1998; Ahammed & Melchers, 1995;
simplifications, boundary conditions and accuracy Ahammed & Melchers, 1996; Ahammed & Melch-
of the numerical methods used in calculation. ers, 1997; Edwards et al., 1996; Hellevik et al., 1999;
Lawson, 2005).
As an example, based on the NORSOK M-506, a
4.2 Types of uncertainties in the CO2 corrosion
probabilistic calculation for a pipeline was carried out.
models
Table 1 shows the data used for the calculation. This
Depending upon the causes of uncertainties, three data includes the type of distribution, mean value and
different types of uncertainties can take place: coefficient of variation (COV – ratio of standard devi-
ation and mean). The purpose of the example was to
A. Uncertainties when the variations are quantified
study the methodology. The data was chosen arbitrar-
and available for proper statistical analysis.
ily and the effect of corrosion inhibitor was not taken
B. Uncertainties when the variations are random, not
into account.
quantified or unavailable.
In order to define the failure event (Fi ) and its prob-
C. Uncertainties due to unknown process or mecha-
ability it was necessary to define the failure or limit
nism arising mostly due to lack of knowledge.
state function. In this example the failure function was
Hence, while selecting an appropriate methodology, defined as the mean corrosion depth of 16.5 mm with
it is essential to consider the uncertainty that can be COV 0.1. The calculations were carried out using the
tolerated or dealt with using an appropriate uncertainty First Order Reliability Method (FORM) by PROBAN
approach. Currently, the two most commonly used (DNV) (Tvedt, 2006).
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Mean
Var. Description Distribution Value COV
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1996
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1997
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process which is not amenable to simple modeling planning of piping subjected to CO2 corrosion. Inter-
and the field data required for modeling is normally national Journal of Pressure Vessels and Piping, 76,
not available, it is difficult to accurately predict the 527–538.
rate of corrosion. While a number of models have Herce, J.A., Wright, E.J., Efird, K.D., Boros, J.A. &
Hailey, T.G. (1995). Effects of solution chemistry and flow
been proposed to model CO2 corrosion, they all suffer on the corrosion of carbon steel in sweet production. In
from a number of weaknesses. This paper discusses CORROSION ’95, Paper No. 111. NACE International.
the problems of modeling CO2 corrosion and some Heuer, J.K. & Stubbins, J.F. (1999). An XPS characterization
possible approaches for handling the uncertainties. of FeCO3 films from CO2 corrosion. Corrosion Science,
41, 1231–1243.
Lawson, K. (2005). Pipeline corrosion risk analysis – an
assessment of deterministic and probabilistic methods.
Anti-corrosion Methods and Materials, 52, 3–10.
ACKNOWLEDGEMENT Melchers, R.E. (2001). Structural reliability analysis and
prediction. John Wiley & Sons.
The authors are grateful to Ole Jørgen Melleby and Nesic, S., Cai, J. & Lee, K.-L.J. (2005). A multiphase flow
Ole Tom Vårdal, AGR EmiTeam (www.agr.no), for and internal corrosion prediction model for mild steel
their guidance and support. pipelines. In CORROSION 2005, Paper No. 05556. NACE
International.
Nesic, S., Pots, B.F.M., Postlethwaite, J. & Thevenot, N.
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