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Corrosion Roche Hadhramout Part 3
Corrosion Roche Hadhramout Part 3
Managing Corrosion
in the Oil & Gas Industry
Theory and practice of corrosion and
corrosion prevention
Marcel ROCHE
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Managing Corrosion in the Oil & Gas
Industry
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Monitoring the treatment efficiency and
residual corrosivity
Major tools and methods:
Water samplings for:
Iron counts
Residual corrosion inhibitor content
pH
Planctonic bacteria numeration
LPR (Linear Polarisation Resistance probe)
Coupons
ERP (Electrical Resistance Probe)
Bioprobes (Sessile bacteria numeration)
Flexible UT mats
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Iron counts
Irion counts vs time
160,0
140,0
120,0
100,0
mg/L
80,0
60,0
Averave ppm iron vs S1 temperature
140
120
40,0
100
20,0 2004
80
2006
60
0,0
40 9/11/04 29/12/04 17/2/05 8/4/05 28/5/05 17/7/05 5/9/05 25/10/05 14/12/05 2/2/06 24/3/06 13/5/06
20 Time
0
40 50 60 70 80 90 100
Temperature (°C)
Corrosion Monitoring: coupons and probes
Bioprobes
Flush
(Cormon data
sheet)
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Corrosion Monitoring: Access fittings
Corrocean type (from Corrocean data sheet) Standard R/C type (from Cormon data sheet)
Corrosion Monitoring: HP extractors for
probes
COUPONS
ERP
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1
MPY
100
150
200
250
300
350
400
450
500
0
50
20-09-04
21-09-04
22-09-04
23-09-04
24-09-04
25-09-04
26-09-04
27-09-04
28-09-04
04-10-04
05-10-04
Vcorr 2-ECP-0124
06-10-04
07-10-04
08-10-04
09-10-04
10-10-04
11-10-04
12-10-04
13-10-04
Fecha
14-10-04
15-10-04
16-10-04
17-10-04
18-10-04
19-10-04
Vcorr 2-ECP-0124(acumulada)
20-10-04
21-10-04
Velocidades de Corrosión Medidas en S1
22-10-04
23-10-04
24-10-04
25-10-04
Measurement of corrosivity (LPR)
26-10-04
27-10-04
28-10-04
Vcorr 2-CC-0124
29-10-04
30-10-04
Product anomaly
31-10-04
01-11-04
02-11-04
03-11-04
04-11-04
05-11-04
Follow-up of corrosion rate with ERP
V c o r r G a s o d u c t o 1 0 " S 1 -C P F
En S1
E n e r o -J u lio : 7 ,7 3 m p y C a m b io d e P r o b e ta
9,5
( m ils )
9,0
8,5
M e t a l L o s s
8,0
7,5
7,0
6,5
6,0
5,5
E v
J an 2005 Feb M ar A pr M ay J un J ul
D ate/Tim e
D ate R ange G raphed: 21/09/2004 to 21/03/2006
Corrosion monitoring: UT measurements
at specific locations
Managing Corrosion in the Oil & Gas
Industry
Corrosion-related Inspection
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The challenge of inspection
negligible
Only INSPECTION
allows direct I
information N
S
on physical status of faible
P
Risk assessment
equipement E
C
T
I
O
N
important
The evolution of approach
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RBI (Risk Based Inspection)
A definition
The establishment of optimised inspection programmes,
adapted to the risks facing the facilities
A methodology
A structured approach involving:
Assessment of consequences of failures
(explosivity, flammability, toxicity, pollution,…)
Assessment of degradation modes (corrosion, fatigue, etc.)
Physical status of equipment (previous results of inspections)
and delivering quantified and auditable results
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RBI (Risk Based Inspection): Calculation
of consequences
Q
ESDV
EVALUATION OF
CONSEQUENCES
EXPLOSION, FIRE
P, T POLLUTION,
TOXICITY
ESDV
DCS
COMPENSATION
PROTECTION
DETERMINATION OF
CONSEQUENCE
FACTOR
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RBI (Risk Based Inspection) : Calculation
of probability of damage
Conditions of operation Materials
(fluid, P, T, environment…) and design
TEMPERATURE
Specific data for each mode PRESSURE
FLOW RATE
VIBRATIONS
ETC.
Determination of identified
damage probabilities
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RBI (Risk Based Inspection) : Calculation
of criticity
Calculation criticity
Degradation Mode 2
Degradation Mode 1
Probabilities 2
of failure
Consequences
in case of failure Consequences
Impact on
production Level of Criticity
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Inspection methods for corrosion:
pressure vessels, piping
•Internal and external visual
examinations
•Ultrasonic measurements (Internal
corrosion, cracks)
•Magnetoscopy, Dye penetrant,
Eddy currents (superficial cracks)
•Radiographies (X or γ sources,
Internal corrosion, welds, deposits)
•Hydrotest (Construction,
verification of repairs, regulatory
aspects)
•Verification of materials (Hardness,
Composition,…)
UT measurements
Main applications:
Detection of cracks in pressure
vessels
Surface structures
•Visual inspection
•Detection of cracks
through NDT
Underwater structures
•Visual inspection (ROV,
Divers)
•Detection of cracks
through NDT
•Cathodic Protection
Methods for inspection of corrosion: well
tubings, pipelines
Calipers for tubings (geometrical
fingers or magnetic systems)
Intelligent(smart) pigs for internal
inspection of pipelines ("In-Line
Inspection", ILI)
Self propelled pigs, autonomous
fluid
Tethered pigs propelled by
crawlers
Magnetic tools ("MFL", Magnetic
Flux Leakage)
Ultrasonic tools ("UT")
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In-Line Inspection (ILI) of pipelines:
MFL Intelligent pigs
Advantages:
•Applicable
whatever the Drawbacks:
fluid •Imperfect
•High level of sizing of
detection defects (not a
(continuous direct
measurement) measurement
of thickness)
•Evaluation to
Clean surface
be checked by
and
direct
verification of
measurements
absence of
obstacles
mandatory
In-Line Inspection (ILI) of pipelines:
MFL Intelligent pigs
Magnets
Primary detector
Secondary detector
Data storage
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Example of report
Example of corrosion reconstituted image
(MFL)
Sizing of defects
Corrosions vs. distance to girth welds
An example of external corrosion under
disbonded coatings on the hottest end
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In-Line Inspection (ILI) of pipelines:
UT intelligent pigs
Advantages: Drawbacks:
•High •Not applicable
accuracy of in gas or
sizing of heterogeneous
defects (direct fluids
measurement) •May miss small
defects
(discontinuous
Clean surface
measurements)
and
verification of
absence of
obstacles
mandatory
In-Line Inspection (ILI) of pipelines:
UT intelligent pigs
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Managing Corrosion in the Oil & Gas
Industry
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Examples of atmospheric corrosion
Electrolyte
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The challenges of paint systems in Oil & Gas
Environment:
Most often, marine C5M atmosphere as per ISO 12944-2 (offshore,
coastal areas)
IM2: for submarine facilities (with cathodic protection)
Thermal insulation, fire protection, test of deluge systems,
important thermal cycles, mechanical impacts…
Offshore, desert areas, …
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External paints for atmospheric protection
A "paint system" is defined including the surface
preparation method, which is a highly critical issue: at a
minimum Sa2 ½ as per ISO 8501-1
The system is generally made of several layers:
A primer (mainly zinc rich: zinc ethylsilicate for the best durability, zinc
epoxy), about 70 μm
A sealer, about 20 μm
One or several tightness layer(s) (mainly epoxy), generally 2 x 150 μm
A finition for UV resistance (PU or acrylic), about 50 μm.
Alternative
systems are proposed for better applicability
and/or durability, generally with less layers
End users to keep in mind that the final objective is proven durability
Use accelerated testing for qualification (ISO, NORSOK, NACE)
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An example of major structure to protect:
The case of a FPSO (deep offshore)
For hull:
56 000 tons of steel, 5,5 x the weight of Eiffel Tower
140 tons of paints
1800 inspections of « blocks » before assembling, 3 per day
Cost of paints: 10% of total cost
For topsides:
27 000 tons of steel, 2,5 x the weight of Eiffel Tower
6900 tons of equipement
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Examples of coating failures on offshore
structure
Good support
Bad support
Examples of coating failures on offshore
structures
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Problems with riser coatings (offshore)
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Corrosion underneath offshore riser
coatings in the transition zone
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Metallic coatings
•Zinc coatings (galvanizing or
electrolytic coating) the most
used for atmospheric protection:
, stairs, handrails, ladders,
gratings, bolts and nuts, etc.
•Good general behaviour,
including on offshore structures,
except in the most exposed
areas to chlorides where lifetime
may be reduced down to a few
years (lower level of platforms,
areas with leaks of seawater or
heavy condensations)
•Short life in seawater especially
when flowing
Metallic coatings
TSA (Thermal Spray Aluminium) used in atmospheric
zone of offshore structures in areas with difficult access
to reduce maintenance works with paint systems
Used also in seawater when cathodic protection is
difficult to apply
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TPA Training Course
Managing Corrosion
in the Oil & Gas Industry
End of Part 3
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