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Collaborating Authors
Pipeline Corrosion
ABSTRACT Corrosion of reinforcing steel bars is considered the major cause of premature deterioration of reinforced concrete structures, costing owners and operators high repair bills and asset`s downtime. The Arabian Gulf's coast is known for elevated temperatures, high humidity levels and exceptionally high chlorides in sea and land. This severe exposure dramatically reduces the corrosion initiation time and increases rebar corrosion rate. Rebar corrosion is understood to be the limiting factor for the service life of reinforced concrete structures. Therefore, Concrete Society Guide 163 [1] and other technical guidelines have recommended including an additional durability enhancement technique to help reinforced concrete assets achieve their desired service life, in excess of 30 years. Amine carboxylate corrosion inhibiting admixture has been widely accepted globally and regionally as an effective yet economical additional durability enhancement technique. This paper will present a literature review of the latest industry standards, test methods and acceptance criteria of corrosion inhibiting admixture. The paper will also explain how lab and field result outputs were used as inputs to a service life prediction model. A simulation of service life will be presented highlighting the inputs in a typical project located near the coast in a marine exposure condition, with a specific triple blend concrete mix with various concrete covers, explaining the impact of amine carboxylate-based inhibitor on service life when added to the same mix, in each cover scenario. INTRODUCTION Corrosion inhibiting admixtures has been initially used as concrete additives to inhibit chloride induced corrosion of rebars in the late 1970's. The first chemistry introduced to the market was based on Calcium Nitrite chemical composition, which in performance is classified as anodic inhibitor, protecting the anode site of the corrosion cell. Calcium Nitrite inhibitor's mechanism of protection depends on the interference with the chloride complexing process by oxidizing the more easily attacked Fe2+ form of iron to the more stable Fe3+ form. The above mechanism of corrosion protection requires variable dosage, depending on surface chloride, buildup time, concrete permeability, and concrete cover depth. According to ACI 212.3R[2], the exact dosage that ranges from 10-30 liters per meter cube of concrete shall be calculated based on the maximum chlorides that will reach out onto the rebar surface during the whole service life cycle.
- North America > United States (0.48)
- Asia > Middle East > UAE (0.46)
- Materials > Construction Materials (1.00)
- Energy > Oil & Gas > Upstream (0.49)
- Well Completion > Well Integrity > Subsurface corrosion (tubing, casing, completion equipment, conductor) (1.00)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Materials and corrosion (1.00)
Comprehensive Liner Inspection Using Smart Integration of Acoustic and Caliper Logs
Tanveer, Muhammad Sohaib (SLB) | Bari, Abdul (SLB) | Zubair, Talha (SLB) | Khan, Mohammad Rasheed (SLB) | Asif, Aleeza Tahoor (SLB) | Inam, Sahir (Mari Petroleum Company Limited) | Hussnain, Muhammad Sana ul (Mari Petroleum Company Limited) | Ullah, Rafi (Mari Petroleum Company Limited)
Abstract A well integrity system is comprised of a complete evaluation of both cement placement and tubular condition. In this regard, casing degradation evaluation is of primary importance to ensure that the well is capable of producing for its complete lifecycle. Evaluation techniques include mechanical calipers which have been the traditional and conventional technology in the past half century or so are capable of assessing the internal pipe condition. More recently, high resolution ultrasonic imaging has been introduced that determines casing thickness by transmitting pulse-echo waveforms to excite the casing in its thickness mode through the principles of resonance. In the work this paper presents, a holistic interpretation approach is used by integrating two technologies of acoustic and mechanical measurements for identifying the liner tortuosity in a deep exploratory well in Pakistan. This work pertains to the production liner section (7-inch) across which the operator was facing problems while running the string down. The well was a newly drilled exploratory well and the operator wanted to ensure the integrity of the well and identify possible bottlenecks restricting the tool movement within the wellbore. Therefore, it was decided to acquire extended data and not rely on a mono-source evaluation. A six-arm mechanical caliper log was acquired subsequently followed by an ultrasonic acoustic pulse-echo measurement; data from both the sources was integrated to obtain the borehole profile for detailed evaluation and analysis. Comprehensive corrosion evaluation was performed using ultrasonic and caliper data. Ultrasonic data was processed and oriented by using industry-standard software to azimuthally identify the damaged zone across the 7-in liner section. In addition, caliper data was also analyzed in detail through borehole section plots at individual depths of the damaged zone. Resultantly, both datasets were integrated into a single log display to diagnose and identify the liner buckling with the observed metal loss. Dynamic and integrated corrosion evaluation helped to holistically identify the well's tubular integrity concerns. As a result, with this unique integration, accurate borehole geometrical profiling was assessed that would allow for more robust planning of future well intervention and completion activities.
Corrosion Inhibition of Benzyl Quinoline Chloride Derivative-Based Formulation for Acidizing Process
Yang, Zhen (Key Laboratory of Unconventional Oil & Gas Development, China University of Petroleum (East China)) | Wang, Yefei (Shandong Key Laboratory of Oilfield Chemistry, School of Petroleum Engineering, China University of Petroleum (East China)) | Yang, Jiang (Key Laboratory of Unconventional Oil & Gas Development, China University of Petroleum (East China)) | Wang, Jing (Shandong Key Laboratory of Oilfield Chemistry, School of Petroleum Engineering, China University of Petroleum (East China) (Corresponding author)) | Finšgar, Matjaž (Key Laboratory of Unconventional Oil & Gas Development, China University of Petroleum (East China))
Summary Due to the severe and rapid corrosion of metallic equipment by strong acids at high temperatures, a high concentration of acidizing corrosion inhibitors (ACIs) is required during acidizing processes. There is always a need to develop more effective and environmentally friendly ACIs than current products. In this work, a highly effective ACI obtained from a novel main component and its synergistic effect with paraformaldehyde (PFA) and potassium iodide (KI) is presented. The ACI was prepared from the crude product of benzyl quinolinium chloride derivative (BQD) synthesized from benzyl chloride and quinoline in a simple way. The new ACI formulation, named “synergistic indolizine derivative mixture” (SIDM), which consists of BQD, PFA, and KI, showed superior corrosion inhibition effectiveness (IE) and temperature stability compared with commercially available ACI. More importantly, the SIDM formulation eliminates the need for commonly used highly toxic synergists (e.g., propargyl alcohol and As2O3). In a 20 wt% hydrochloric acid (HCl) solution, the addition of 0.5 wt% SIDM mitigates the corrosion rate of N80 steel down to less than 0.00564 lbm·ft at 194°F, while the corrosion rate at 320 °F is 0.0546 lbm·ft·when 4.0 wt% SIDM is added.
- Europe (0.68)
- North America > United States > Texas (0.47)
- Energy > Oil & Gas > Upstream (1.00)
- Materials > Chemicals > Commodity Chemicals > Petrochemicals (0.69)
- Well Completion > Well Integrity > Subsurface corrosion (tubing, casing, completion equipment, conductor) (1.00)
- Well Completion > Acidizing (1.00)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Materials and corrosion (1.00)
Corrosion Under Insulation (CUI) – Risk Based Inspection, Non-Destructive Inspection and Fitness for Service API-579
Largura, Luiz C. (MSc., Mechanical Engineer, Professional Engineer in Arizona, and Texas) | Araujo, Mauro D. (Araujo Engenharia, Vinhedo, SP, Brazil) | Silva, Arilson R. (Araujo Engenharia, Vinhedo, SP, Brazil)
Abstract This paper presents a Risk-Based Inspection (RBI) analysis of a pressure vessel (distillation column type) with a "Fitness-for-Service" (FFS) assessment of the equipment according to API-579 level 3. The evaluation of the resistance and stability of equipment corroded by Corrosion Under Insulation (CUI) is considered when subjected to design loads. The Risk Based Inspection evaluation was performed according to API 581 3 edition, using the latest version of the GIEnd-RBI specialized software. The analysis showed a high probability level for Corrosion Under Insulation, which represents a Medium-High risk for the equipment, as the calculated Consequence of Failure is Medium. The highly effective "A" Inspection required by RBI Analysis, was done after thermal insulation removal, surface preparation and visual inspection, which revealed an advanced local metal loss of the equipment component areas as predicted by the RBI analysis. With the inspection results and 3D scan of the corroded areas, an FFS assessment was performed according to API-579. The conclusion is that the equipment has a remaining strength factor of 1.0, more than the RSF of 0.9 required by the standard. Risk-Based Inspection (RBI) is an approach used in various industries, including oil and gas, petrochemicals, and chemical processing, to optimize inspection and maintenance activities. It prioritizes inspection efforts based on the risk associated with equipment or assets, focusing on areas most susceptible to damage and degradation. Corrosion under insulation (CUI) is a significant concern in industries where insulated equipment or piping is exposed to corrosive environments. RBI can be effectively employed to manage CUI-related risks. Benefits of Risk-Based Inspection for Corrosion Under Insulation: Cost Optimization: RBI allows organizations to allocate inspection resources more effectively, focusing efforts on areas with the highest risk, which can lead to cost savings in the long run. Safety Improvement: By identifying and addressing high-risk areas prone to CUI, the likelihood of unexpected failures and potential safety incidents is reduced. Enhanced Reliability: RBI ensures that assets vulnerable to CUI are appropriately maintained, which can extend their operational life and increase overall system reliability. Compliance and Integrity Assurance: Employing RBI can help organizations comply with regulatory requirements and demonstrate a commitment to maintaining asset integrity. It's essential to note that RBI is a risk management tool and should be used as part of a comprehensive asset integrity management program, incorporating other elements such as corrosion monitoring, material selection, and proactive maintenance practices to effectively mitigate the risks associated with corrosion under insulation. In summary, the main advantage of the methodology presented in this paper is the use of RBI to define the areas to be inspected in a more accurate way, as well as the use of a 3D scan technique to map the corroded regions with more refinement than other techniques like C-Scan, providing a more precise data for the FFS evaluation level 3 using finite element analysis.
- South America > Brazil (0.47)
- North America > United States (0.28)
Making Available High Resolution UT Technology for Subsea Wall Thickness Scans
Oliveira, Nathan (Shell, London, United Kingdom) | Rincon, Pedro (Shell, London, United Kingdom) | Chittenden, Paul (TSC Subsea, Milton Keyes, United Kingdom) | Kenny, Stuart (TSC Subsea, Milton Keyes, United Kingdom) | Monnerat, Marcio (TSC Subsea, Milton Keyes, United Kingdom)
Abstract High resolution thickness mapping is a widely accepted method for fitness for service inspection and provides a permanent and quantitative record for remaining life assessment and through periodic campaigns can be used for comparative analysis. Subsea infrastructure introduces many challenges for inspection delivery and although robotic systems have been readily accepted, traditional methods of ultrasonic thickness reading is not possible through a large range of subsea coatings. In 2017, a major Oil Company started a collaboration with a subsea inspection service specialist to investigate the plausibility of Acoustic Resonance Technology (ART) on its insulated pipeline inventory. Having recognized the potential impact this technology could have in the subsea integrity process, the company supported the commercialization of this technology with the subsea service provider in 2020 and since then the method has continued to evolve. Nowadays in 2023, acoustic resonance technology is becoming rapidly recognized for the first-choice method for insulated and coated piping for subsea infrastructure. It provides fully quantitative information, is radiation free and can collect large areas of data points extremely quickly. The paper will explain the timeline of technology evolution from initial concept, lab tests and successful field trials. It will describe the method that was applied, how the signal processing and software algorithms determine resonance as a wall thickness and provide practical examples of the benefits of this method. It will talk about the different coatings that are typical for subsea applications and describe how the new acoustic resonance technology can eliminate the requirement to remove this coating or deploy a less productive and sometimes challenging radiographic method.
- South America > Brazil (0.48)
- Europe (0.29)
- South America > Brazil > Espírito Santo > South Atlantic Ocean > Campos Basin > Block BC-10 > Parque das Conchas Field (0.98)
- South America > Brazil > Brazil > South Atlantic Ocean (0.89)
- North America > Cuba > Gulf of Mexico (0.89)
- Facilities Design, Construction and Operation > Offshore Facilities and Subsea Systems (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Risers (0.71)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Materials and corrosion (0.47)
Offshore Pipeline Case-Study: State-Of-The-Art Comparison Between Different ILI Technologies for Challenging Metal Loss Diagnosis and Remaining Lifetime Assessment
Lopes, M. (Perenco, Rio de Janeiro, Brazil) | Souza, M. (Perenco, Rio de Janeiro, Brazil) | Zanelli, R. (Perenco, Rio de Janeiro, Brazil) | Barraud, B. (Perenco, Rio de Janeiro, Brazil) | Ayala, M. (Perenco, Rio de Janeiro, Brazil)
Abstract This paper describes the history of an offshore pipeline that failed from an internal corrosion defect that was not detected by the MFL-A technology. After the failure, the pipeline was inspected with different technologies such as MFL-A, MFL-C, IEC, and Ultrasonic Wall Thickness Measurement. The authors discuss different detection capabilities, inspection variables, data analysis process, inspection results, and integrity management. Internal corrosion is one of the main failure mechanisms of rigid pipelines. Accordantly to the U.S. Department of Transportation [3], between 1998 and 2017 approximately 12% of pipeline incidents were caused by internal corrosion. To detect, measure and evaluate the corrosion anomalies, the ILI technologies are the most accurate approach to define the maximum operating pressure and manage their integrity [13]. The industry offers different types of technologies, such as Ultrasonic Wall Thickness Measurement, Axial and Circumferential Magnetic Flux Leakage, and Internal Eddy Current. Corrosion defects offer different levels of complexity for detection and sizing depending on the nature of the corrosion phenomenon and its morphology. All technologies have advantages and limitations; therefore, it is important for operators to identify the priorities to select the most appropriate technology based on needs. The decision of which technology or combination of technologies should be used is the main task and responsibility of the Integrity Manager, and involves technical, commercial, and operational factors. The paper proves that some ILI technologies are not able to correctly identify and measure specific nature and geometry of corrosion anomalies. It intends to create a guideline for operators to correctly choose the ILI technology and be able to properly manage the integrity of rigid pipelines, defining its maximum operating pressure and evaluating the necessity for repair. The authors intend to share with the industry the technical particularities in the data comparison from the last two inspections carried out to pipeline with Ultrasonic Wall Thickness Measurement, with special focus on challenging anomalies due to its location, geometry, and size. This Offshore pipeline case is turned public to share the knowledge gathered through many inspections and engineering analysis conducted during life extension assessment of the pipeline.
- South America > Brazil (0.69)
- North America > United States (0.54)
- Research Report (0.82)
- Summary/Review (0.54)
- Energy > Oil & Gas > Upstream (1.00)
- Energy > Oil & Gas > Midstream (1.00)
- Government > Regional Government > North America Government > United States Government (0.54)
Abstract Caissons are typical large diameter and long length piping installed on FPSO (Floating, Production, Storage and Offloading) and oil platforms. Basically, the components of a Caisson system are a centralized pump inside a cylinder (shell) and generally operates with sea water. These Caissons are susceptible to wall thickness thinning caused by abrasion and corrosion [3] on the internal surfaces. This corrosion occurs due to internal coating damages caused by internal shell impacts of the decentralized pump parts, during the operating condition. Detecting Caisson internal thinning is not a simple task once the thinned areas are localized, which can occur at any place on the internal surface, and it is a huge area to inspect since a Caisson can have tens of meters and a large diameter. For this reason, punctual/spot ultrasonic thickness (UT) measurements are not effective, as it requires a complete surface scan using an NDT technique sensitive enough, such as an UT C-Scan. Another benefit of this application is the unnecessity of scaffolding or rope access, reducing human exposition risks and costs. The mapping and sizing accuracy was achieved using a robotic remote-controlled magnetic wheel automated robotic scanner. The scanner adhered to the pipe's external surface following X, Y coordinates defined by the NDT instruction and adjusted during the field inspection. The robotic system is a high-resolution equipment, achieving up to 1x1 mm resolution. Another important system characteristic is the maneuverability that allows reaching even the most difficult access areas. The objective of this paper is to present the results of an external inspections on Caissons using Robotic Automated Ultrasonic (C-Scan) corrosion mapping for detecting and sizing internal thinning. This NDT was done without scaffolding and coating removal. Many localized thinned areas were found, mapped, and sized. These localized thinned areas would not have been detected using punctual thickness measurement. The results of 20 Caisson walls inspection showed outstanding results locating all corroded areas and high precision defect sizing. All robotic inspections were faster and provided lower costs and less human exposition risks, when compared to the traditional thickness measurement method used before.
- Well Completion > Well Integrity > Subsurface corrosion (tubing, casing, completion equipment, conductor) (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Materials and corrosion (1.00)
- Facilities Design, Construction and Operation > Offshore Facilities and Subsea Systems > Floating production systems (1.00)
Maintaining the Integrity of Wellhead Components Using a Polymeric Compound
Alramadan, F. B. (Saudi Aramco PE&D, Dhahran, Saudi Arabia) | Aljuryyed, N. W. (Saudi Aramco PE&D, Dhahran, Saudi Arabia) | Alissa, F. M. (Saudi Aramco PE&D, Dhahran, Saudi Arabia) | AlJuaydi, H. S. (Saudi Aramco SAOO, Dhahran, Saudi Arabia)
Abstract This study presents an innovative approach to prevent wellhead equipment corrosion in the cellar by employing a composite gel of polyacrylamide (PAM) with sand to enhance mechanical strength. Experiments were conducted to investigate the effect of varying PAM-to-sand ratios on the composite gel's mechanical and corrosion inhibition capabilities. The mechanical properties, including stress and strain, were examined using a rheometer. The corrosion inhibition capability was evaluated using corrosion test coupons. The results showed a notable improvement in mechanical strength and corrosion resistance with the inclusion of PAM and sand. Among the tested ratios, a composite gel consisting of 10% PAM offered the optimal balance of mechanical strength and corrosion inhibition. This finding suggests that filling the cellar with a 10% PAM composite gel can significantly enhance the lifespan of wellhead equipment by effectively protecting it from corrosive agents. Further research will focus on optimizing the composite gel for improved performance and assessing long-term durability under real field conditions.
- North America (1.00)
- Asia > Middle East > Saudi Arabia (0.47)
Microbiologically Influenced Corrosion (MIC) is responsible for a large number of annual failures and integrity issues in conventional oil and gas facilities. Sessile microbes survive and thrive in biofilms bound to metallic surfaces of asset infrastructure. Dang et al. states that'almost every abiotic surface of a material is readily colonised by bacteria, algae, and fungi, contributing to the degradation processes of materials'. Both biocorrosion and MIC refer to the interaction of microbial cells and their metabolic products, such as extracellular polysaccharides (EPS), with an abiotic surface. MIC is an electrochemical process as shown in Fig.1. By extracting nutrients for metabolism and then providing by-products, they trigger cathodic reactions, which cause a severe threat to metallic material integrity. Fig 1: MIC Overview and Electrochemical Processes (Adapted from Enning etal, 2014) The diagnostic methods we select from our MIC diagnostics toolbox must therefore focus on surface interaction with a managed approach essential for understanding surface corrosion damage in any corrosion mode forensics where MIC is suspected as a facilitator or influencer. This paper provides insight into the use of TIMA-X technologies and SGS MIRAS diagnostics for this essential demand. 1 Fig 2: Typical field sample from an injection well tubing showing the intensity of typical MIC derived failures.
- North America > United States > Kentucky > Illinois Basin (0.99)
- North America > United States > Indiana > Illinois Basin (0.99)
- North America > United States > Illinois > Illinois Basin (0.99)
- Well Completion > Well Integrity > Subsurface corrosion (tubing, casing, completion equipment, conductor) (1.00)
- Reservoir Description and Dynamics > Improved and Enhanced Recovery (1.00)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Materials and corrosion (1.00)
Debottlenecking of a Deepwater Production Network by Converting an Uninsulated Service Line Into a Production Line: Engineering Analyses and Successful Application
Montini, Marco (Eni SpA) | Brioschi, Samuele (Eni SpA) | Bianco, Amalia (Eni SpA) | Di Lullo, Alberto (Eni SpA) | Torri, Lucia (Eni SpA) | Piseri, Chiara (Eni SpA) | Magi, Stefano (Eni SpA) | Locci, Andrea (Eni SpA) | Lamberti, Andrea (Eni SpA) | Castelnuovo, Luca (Eni SpA)
Abstract This paper presents the repurposing of a non-insulated, carbon steel service line into a production line for a deep-water oil field, successfully carried out without any plant shutdowns and continued for several months and under several operating conditions. The main differences between the repurposed service line and the subsea production lines of the field were the lack of insulation, to prevent hydrates during shutdowns and wax deposition during production, and the lack of internal cladding, to protect the line from generalized CO2 corrosion. Therefore, the conversion required deep multidisciplinary analyses, including flow assurance, production chemistry and materials technology, along with the definition of a proper continuous monitoring workflow. The analyses started from a reservoir study to quantify the potential production increase and recovery factor due to the availability of the repurposed line, from some wells to the FPSO. After a positive outcome, a detailed flow assurance study was performed to select the wells to be routed to the service line and to define its operating conditions. The laboratory identification of the most effective wax inhibitor and hydrates anti-agglomerant was conducted, together with a corrosion study to estimate the life span of the carbon steel line to be repurposed. The lack of subsea chemical injection umbilical lines was addressed by identifying a combo product with both hydrate and corrosion inhibitor functionalities. All the above studies were associated to the definition of a strict monitoring workflow of the line corrosion and performance, in terms of potential restriction due to deposits. The overall techno-economic analysis demonstrated the feasibility and benefits of the production mode achievable with the repurposed line, even at higher operating costs. Consequently, the conversion was successfully carried out and is now effectively in place since more than one year. The whole study also strongly benefitted by the critical re-evaluation of all the engineering and operating margins made possible by the data acquired and recorded by Eni’s digital oilfield e-DOF system.
- Research Report > New Finding (0.48)
- Research Report > Experimental Study (0.46)
- Well Completion > Well Integrity > Subsurface corrosion (tubing, casing, completion equipment, conductor) (1.00)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Inhibition and remediation of hydrates, scale, paraffin / wax and asphaltene (1.00)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (1.00)
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