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flowline corrosion
The paper presentation shows the application of a holistic approach to corrosion prediction that overcomes classical pitfalls in corrosion testing and modelling at high pressure, high temperature, and high CO2 conditions. Thermodynamic modelling of field and lab conditions allows for more accurate predictions by a novel CO2/H2S general corrosion model validated by laboratory tests. The results from the model and tests extend the application of selected stainless steel grade beyond the threshold conditions calculated by simplistic models and guidelines. In the case study used to showcase the workflow, conventional stainless steel is validated for most of the tubing. Harsh environments pose a challenge to the application of conventional steel materials.
- 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)
The recent significant influx of large amounts of government incentives for a variety of green initiatives including CCS and CCUS has created a rush to drill and complete CO2 injection wells. However, the necessary corrosion data to make informed choices for corrosion resistance in these wells is minimal at best. Some oil and gas professionals have argued that there is no difference between the more than 40 years of petroleum experience with CO2 EOR and planned CCS wells. This comparison is not a valid one and can be risky considering the need for very long-term containment of CO2 required by regulators. This article presents a comparison between CO2 EOR and CCS for injection well metallurgy and explains why this comparison is invalid.
- Energy > Oil & Gas > Upstream (1.00)
- Government > Regional Government > North America Government > United States Government (0.33)
- North America > Canada > Saskatchewan > Williston Basin > Weyburn Field > Mission Canyon Formation (0.99)
- North America > Canada > Saskatchewan > Williston Basin > Weyburn Field > Madison Formation (0.99)
- North America > Canada > Saskatchewan > Williston Basin > Weyburn Field > Forbisher Formation (0.99)
- North America > Canada > Saskatchewan > Williston Basin > Weyburn Field > Charles Formation:Middale Formation (0.99)
- Well Completion > Well Integrity > Subsurface corrosion (tubing, casing, completion equipment, conductor) (1.00)
- Reservoir Description and Dynamics > Storage Reservoir Engineering > CO2 capture and sequestration (1.00)
- Reservoir Description and Dynamics > Improved and Enhanced Recovery > Chemical flooding methods (1.00)
- (3 more...)
Many operators in the Arabian Gulf operate assets that are worth several billions of dollars. The bulk stocks of wells are intended to have a production well life as long as possible with a minimum design age of 25 to 30 years. Field observations indicated the actual life span to be between 7 and 25 years, mainly due to degraded well integrity. This is of great concern for operators. Besides the importance of safety and environmental aspects of the production operations, without adequate well integrity, wells are unlikely to reach their full production volume potential as intended in the field development plan.
- Well Completion > Well Integrity > Subsurface corrosion (tubing, casing, completion equipment, conductor) (1.00)
- Production and Well Operations (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Materials and corrosion (1.00)
- Reservoir Description and Dynamics > Formation Evaluation & Management > Open hole/cased hole log analysis (0.84)
Abstract Non-metallic pipe systems are the perfect option for transporting highly corrosive fluids from oil and gas production which are potentially environmentally hazardous, since they contain volatile organic hydrocarbons. The operation of oil and gas production in agricultural lands is common in Europe and requires permeation tight solutions in order to prevent any kind of environmental contamination. In the past, leakages caused by corrosion damages on carbon steel pipes or by permeation of hydrocarbons through pipes made of high-density polyethylene (HDPE) have resulted in environmental damages. In order to prove the suitability of plastic pipes with an integrated aluminum barrier layer tests over a 4-year time period were done in the context of field- and laboratory trials. For the pilot tests performed in a crude oil production system, the oil and water composition was given by the real case. For the systematic laboratory tests, clearly specified test liquids which came as close to providing a representative sample as possible were used. In order to simulate the most severe conditions conceivable, the test liquids were a saturated solution consisting of various volatile hydrocarbons, some of them also chlorinated, and a mixture of pure volatile hydrocarbons with a 10-per-cent share of aromatic toluene. In contrast to single-layer plastic pipes, the pipes featuring a barrier layer were shown to be resistant to permeation of all of the dissolved volatile organic ingredients examined by the tests. These results could be confirmed by the performed pilot test in Romania. Thus, plastic pipes equipped with a metallic barrier layer can be recommended for loss-free transport of aqueous liquids containing hydrocarbons, such as production water in crude oil. Combined with permanent monitoring for the purpose of damage detection, this non-metallic pipe solution complies with even the strictest environmental requirements, thus enabling oil production in environmental sensitive areas and guarantees reliable protection of the environment.
- Materials > Chemicals > Commodity Chemicals > Petrochemicals (1.00)
- Energy > Oil & Gas > Upstream (1.00)
- Health, Safety, Environment & Sustainability > Environment > Waste management (0.94)
- Production and Well Operations > Production Chemistry, Metallurgy and Biology > Corrosion inhibition and management (including H2S and CO2) (0.68)
- Health, Safety, Environment & Sustainability > Environment > Water use, produced water discharge and disposal (0.68)
Abstract With increasing interest in non-metallic products for downhole applications, such as the fiberglass tubing, it is essential to ensure the well integrity in similar way as standard carbon steel completions. One important aspect of well integrity is the ability to routinely access the downhole condition of the tubing and perform basic intervention. This paper demonstrates the testing and validation of different mechanical evaluations of the integrity of fiberglass tubing using logging and intervention tools. In this work, two joints of Fiberglass were connected together in order to study the effect of logging and intervention tools on the integrity of these joints from inner and outer surfaces as well as the structural integrity. For inner wall evaluation, a multifinger caliper tool was run inside the two joints several times in order to investigate potential damage caused by the fingers. In addition, a tubing puncher was used to punch a hole and characterize the surface damage and any effects on the structural integrity of the fiberglass. Furthermore, a tubing cut was performed in order to confirm the performance of the cutting tool in such environment. All the tests were conducted safely and successfully at surface using two different sizes of fiberglass tubing. The tested tubulars were split cut to further investigate internal condition. The effect of applied fingertips on the inner wall surface of the fiberglass from several passes indicated minor scratches that can be further investigated using an accelerated wear test. The integrity of this non-metallic tubular can be evaluated using standard mechanical tools in order to identify defects and scale buildup. Other intervention tools such as the mechanical puncher and cutter indicated successful deployment under surface conditions. Investigation of existing downhole evaluation and intervention technologies can provide an immediate assessment of the benefits and limitations with respect to unconventional completions such as the fiberglass tubing and other non-metallic pipes. Future research and development programs can rely on such solid basis to tailor advanced solutions for any specific application or products.
Development of a Model to Predict Corrosion Rate and Flow Pattern in Oil and Gas Production
Frapiccini, Ana (YPF Tecnologรญa S.A. / CONICET, Consejo Nacional de Investigaciones Cientรญficas y Tรฉcnicas) | Perez, Teresa (TEP Consultora S.R.L.) | Goldschmit, Marcela (Independent Consultant) | Cirimello, Pablo (YPF Tecnologรญa S.A.) | Santilli, Fernanda (YPF Tecnologรญa S.A.) | Morris, Walter (YPF Tecnologรญa S.A.)
Abstract A numerical compositional one-dimensional model to predict the flow pattern and the CO2 corrosion rate of carbon and low alloyed steel tubing/casing in oil and gas production is presented. The model estimates the chemical composition of the present phases (oil/gas/water), the pH and the corrosion rate as function of depth. The effects of acid gases (CO2 and H2S) and water chemistry (Na, K, Ca, Mg, Cl, SO4, among others) are considered. Different flow patterns are also taken into account: bubble, slug, dispersed bubble, annular and segregated, which are determined from fluid properties and production rates of oil, gas and water. The present tool is based on the semi empirical de Waard 95 model and a 2003 modification. For oil and vapor phases, equilibrium is considered with the Soave-Redlich-Kwong equation of state. For the water phase, the Pitzer's model is used to calculate the activity of water, and activity coefficients of cations, anions, and neutral species in the solution. To analyze flow pattern the Drift-Flux Model is used. Different modules calculate equilibrium composition, flow pattern and flow velocities. All the modules previously mentioned are coupled and require an iterative resolution at each position in the production string. The obtained outputs are temperature, pressure, flow pattern, flow velocities, gas and liquid holdup, pH, and corrosion rate. Each of the different modules of the program were validated, however only validations of the water/gas phase equilibrium are presented in this paper. The comparison of predicted CO2 solubility in pure water, NaCl solutions and synthetic formation brine (NaCl/CaCl2 solutions) and pH show a very good fitting with experimental data. The model results for vertical/horizontal gas-oil-water well are also shown. The Y- TubCor (YPF Tecnologรญa Tube Corrosion) program is part of the Y-WIMS (YPF Tecnologรญa Well Integration Management System) platform. Introduction Corrosion has a key impact on the integrity of tube materials used in oil and gas production and transportation. The CO2 corrosion (sweet corrosion) is the most prevalent forms of attack encountered in this industry. The implication of corrosion includes its effect on capital and operational expenditures and health, safety, and the environment. This impact was the driven force for the development of Corrosion Prediction Models. The models are mainly focused on the evaluation of carbon and low alloyed steel performance. As these steels are the lower cost material alternative to be used, the models are part of the set of tools used for the material selection. Other application is to estimate the possible corrosion damage in service due to changes in environmental and/or production conditions.
- Well Completion > Well Integrity > Subsurface corrosion (tubing, casing, completion equipment, conductor) (1.00)
- Reservoir Description and Dynamics (1.00)
- Production and Well Operations (1.00)
- Facilities Design, Construction and Operation > Pipelines, Flowlines and Risers > Materials and corrosion (1.00)
It seems that it has been a very productive period for production and facilities. I reviewed a significant number of abstracts on such an interesting variety of topicsโnew technology developments down- and midstream, improvements in corrosion detection and prediction, new systems for emulsion monitoring, and even downhole drones, as well as several optimization works using artificial intelligence and machine learning, for quality and control. In the materials-science aspect, composite and nonmetallic materials continue to be significantly researched, as well as additive manufacturing for fast replacement of parts. I also reviewed abstracts on new materials development for downstream applications, such as dielectric sealants and dissolvable rubbers. Some fundamental research on emulsion stability was also present, as well as new emulsion monitoring systems based on microwave, acoustic, and capacitance measurements. In the area of equipment reliability, a common trend is using digital methods on historical data for prediction of equipment failure or corrosion vulnerability. There were also inspection developments such as the use of chemical tracers to identify the location of equipment failure downstream. A couple of works in this area are suggested in paper SPE 205687, which provides an example of deep learning used for intelligent identification of equipment status, and paper SPE 205056, which is a more-fundamental work on corrosion-prediction models. My attention was particularly drawn to environmentally oriented submissions this year. Energy integration continues to be a topic of interest, with geothermal and even green hydrogen being considered for energy generation in production facilities, especially in remote locations. An example of an interesting energy integration viability study can be found in paper SPE 204551. Another relevant aspect addressed was waste management, with submissions regarding abandoned wells management and waste disposal. A very thorough review on how to deal with produced solids can be found in paper SPE 210003, which clearly explains all stages of handling, from separation to disposal, with case studies as examples. An interesting work, paper SPE 213000, combines two issues: the disposal of wind-turbine waste and the use of abandoned wells. Because of the toxicity of wind-turbine blades, abandoned wells and cement coprocessing are considered as disposal options. It is quite interesting how costs and emissions were carefully analyzed in this study. Paper SPE 211932 caught my attention for its social and economic impact. This work presents the use of modular refineries as an alternative, cheaper solution to increase refining capabilities. Many developing nations produce more oil than their internal market consumes but still need to import large quantities of refined products. This work points this out as an anomaly. While some refining companies may profit from this, deep social impacts are caused by the increased gas prices in nations that are petroleum-rich. It is nice to see developments in our field that can contribute to less social inequality in the world. Recommended additional reading at OnePetro: www.onepetro.org. SPE 205056 Possible Missing Link in CO2 Corrosion Prediction by Yves Gunaltun, Retired SPE 205687 A Deep-Learning Model To Intelligently Identify the Working Status of Screw Pumps for Oil Well Lifting by Zhen Wang, Luming Oil and Gas Exploration and Development, et al. SPE 204551 Challenges and Opportunities for Green Hydrogen Power Supply in Oil and Gas Remote Facilities by Salvador Alejandro Ruvalcaba Velarde, Heriot-Watt University
Abstract Large-scale CO2 and energy storage is a mandatory part of the green shift to reduce CO2 emissions and limit consequences of climate change. Large-scale storage will require the use of shut-down depleted hydrocarbon fields to take advantage of well-characterized reservoirs and cap rocks. Thanks to extensive data from historical hydrocarbon production, the uncertainties related to storage capacity, injectivity, and containment are limited. However, legacy exploration and production infrastructure, and especially legacy wells, are the main threat for possible fluid leakage toward the surface. Such legacy wells are numerous and penetrate the full rock column. In this paper, we describe a workflow to screen and monitor legacy wells in the shut-down Frigg Field in the North Sea. By using numerical modeling of electromagnetic (EM) field propagation in one of the Frigg Field wells, we explore the complex interactions of fields, currents, and well structure in the presence of corrosion. The corrosion is implemented as a change in the electrical conductivity of the innermost steel casing at different depths along the structure. To enhance probing depth, we plug the dipole source (1 km long) into the casing at the seafloor and excite the casing as an antenna. We find that at moderate levels of corrosion, the current distribution is significantly modified with respect to the uncorroded case. This generates a signal that propagates and can be observed at the seafloor in the numerical results. Other elements of the well geometry (e.g., concentric overlapping cement casings) have their own effect on the signal. This leads the possibility of estimating the location of the corroded area within the well geometry. These results suggest that by relaxing some of the model's approximations and implementing realistic transmitters, it will be possible to evaluate and optimize controlled-source EM survey strategies for detecting and monitoring corrosion levels.
- Europe > Norway > North Sea (0.92)
- Europe > United Kingdom > North Sea (0.92)
- Africa > South Africa > Western Cape Province > Indian Ocean (0.24)
- North America > United States > Texas > Dawson County (0.24)
- Oceania > Australia > Victoria > Otway Basin > Naylor Field (0.99)
- Europe > United Kingdom > North Sea > Northern North Sea > South Viking Graben > Block 10/1 > NOAKA Project > Frigg Field > Frigg Formation (0.99)
- Europe > United Kingdom > North Sea > Northern North Sea > Viking Graben > PL 030 > Frigg Formation (0.97)
- (3 more...)
Precise Wellbore Geometry Preparation and Determination Led to a Successful Installation of Permanent 456-Series ESPs in 5.5-in. Casing
Hammad, Mustafa (Sirte Oil Company, Marsa al Brega, Libya) | Musa, Abdulnaser. Alfadel (Sirte Oil Company, Marsa al Brega, Libya) | Musbah, Ahmed. M. (Sirte Oil Company, Marsa al Brega, Libya) | Abdellatief, Walied. A. (Sirte Oil Company, Marsa al Brega, Libya) | Dakheel, Abdulrahem. S. (Sirte Oil Company, Marsa al Brega, Libya) | Sherik, Ayoub (SLB, Libya) | Awedan, Hassan (SLB, Libya) | Abdulgader, Omar (SLB, Libya) | Elhamali, Bubaker (SLB, Libya) | Elhajjaji, Rami (SLB, Libya) | Bosnina, Seraj (SLB, Libya) | Bunkheila, Kais (SLB, Libya) | Belhaj, Walid (SLB, Libya)
Abstract Installing permanent 456-series electrical submersible pumps (ESPs) in old and potentially corroded wells completed in 5.5-in. X17ppf casing involves many challenges and risks such as small clearance of 0.009 to 0.13 in., which could lead to string damage or sticking; uncertainty in casing weight due to limited tally information; a corrosive environment that leads to various types of casing deformation; rugosity; and deposits. In a field in North Africa, slim ESP equipment does not meet the production target per well due to limited flow capacity. In addition, in this field, the number of wells with 5.5-in. completions being converted from gas lift to ESP is growing rapidly to meet the field production target. For these reasons, the operator planned an integrated workover operation that included preparing the wellbore with advanced scraper and magnets, investigating the casing condition and cement status, and determining the feasibility of installing a 456-series string and the desired setting depth with minimal risks. The candidate wells underwent a cleanout operation using heavy-duty scraping tools to restore the nominal casing inside diameter from any deposits. This heavy-duty scraping tool can leave ferrous metallic debris, which might affect corrosion and cement logs; therefore, multiple runs of a high-capacity magnet were performed to remove all the ferrous debris left in the well. The wells were then logged with corrosion and cement tools to evaluate the casing geometry and cement status to identify any restrictions, oval or deformed spots, or bad cement intervals to assess any potential risks involved in running in hole/pulling out of hole the 456-series ESP string and to determine the best setting depth for production. Finally, a special equipment configuration and running-in-hole procedures were followed to land the 456-series ESP string safely through 0.009 to 0.13-in. clearance at the desired depth. Six wells underwent a workover operation and were evaluated in terms of wellbore geometry and cement. Some of these wells exhibited excellent geometry condition, and 456-series ESPs were installed at the desired depth without any issues. Other wells exhibited wellbore geometry issues such as different casing weights, oval joints, and casing corrosion or deformation. These wells were evaluated intensively in terms of ESP configuration, design, setting depth, and pump performance, and necessary steps were followed to successfully set the pump at the maximum possible depth. The 456-series ESPs installed in the six wells resulted in production gain of approximately 28,000 BLPD at an average 71% water cut (approximately 8200 BOPD). The novel integrated approach led to first successful 456-series installation in 5.5-in. casing in North Africa in a challenging condition. This integrated approach helped the operator to save 20% of replacement cost of downhole equipment and eliminate the cost of stuck and fishing operations while maintaining the workover schedule. In addition, the solution enabled the operator to meet the company production target of 100,000 BOPD.
- Africa > Middle East > Libya (0.68)
- Africa > North Africa (0.44)
- Africa > Middle East > Libya > Al Wahat District > Sirte Basin > Concession 6 > Zelten (Nasser) Field > Zaltan Formation (0.99)
- Africa > Middle East > Libya > Sirte Basin > Al Jebel Field (0.93)
Abstract This work describes how microbiology surveillance can be used to drive improvements in unconventional assets. Various microbiology enumeration tools are compared in different case histories for well workovers, surface facilities and production sites. When correctly deployed, new tools and strategies for microbiology management can be powerful resources to further risk assess operations and improve understanding of operating envelopes for safe and reliable production.
- Oceania > Australia (0.29)
- North America > United States (0.29)
- Health & Medicine > Pharmaceuticals & Biotechnology (1.00)
- Energy > Oil & Gas > Upstream (1.00)