Corrosion & Corrosion Control in

OIL & GAS PRODUCTION & PROCESSING

SOME COMMON EXAMPLES OF CORROSION DAMAGE

•Oil and Gas Production Is Highly CapitalOil and Gas Production Is Highly Capital Intensive Industry

•This is Specially Important in Case of Off Shore Production Where Operational & Maintenance Costs are Many Times Higher

* Return-On-Investments Requires Increased Return On Investments Requires Increased Productivity By

* Increasing Availability Of Equipment Without Break Downs And

* Achieving low maintenance cost.

WHY FAILURES OCCUREWHY FAILURES OCCURE• ALL MATERIALS ARE

SUBJECTED TO STRESSSTRESSES BEYOND CERTAIN LIMIT RESULTS INSTRESSES BEYOND CERTAIN LIMIT RESULTS IN FAILURE

• ARE EXPOSED TO ENVIRONMENT WHICH• ARE EXPOSED TO ENVIRONMENT WHICH ATTCKS THEMTHIS RESULTS IN LOSS IN THICKNESS OR• THIS RESULTS IN LOSS IN THICKNESS OR CRACKINGTOGETHER THEY LIMIT LIFE• TOGETHER THEY LIMIT LIFE

• CONTROLLING FACTORS IN MAXIMISING CO O G C O S S GEQUIPMENT LIFE ARE

• STRESSES, (INTERNAL OR EXTERNAL), TO BESTRESSES, (INTERNAL OR EXTERNAL), TO BE WTHIN LIMITS

• PREVENTION OF ENVIRONMETAL DAMAGE DUE TO CORROSION

• PRESENT SERIES OF LECTURESPRESENT SERIES OF LECTURES SHALL DEAL WITH SECOND ASPECT, THAT IS CORROSION & CORROSIONTHAT IS, CORROSION & CORROSION PROTECTION

CORROSION & ITS EFFECT• CORROSION INVOLVES REACTION WITH ENVIRONMENT

RESULTING IN LOSS IN WEIGHT & CROSS SETIONAL AREA• WHAT IS THE EFFECT?

• LET US TAKE AN ARBITRARY SITUATIONCASE A: A ROD OF AREA 1 IS LOADED WITH 1TON ROD HOLDSCASE A: A ROD OF AREA 1 IS LOADED WITH 1TON. ROD HOLDS

THE WEIGHT AREA

1AREA0.5.

AREA 0.3

CASE B: CORROSION REDUCES AREA TO 0 5 OF ORIGINAL BUTAREA TO 0.5 OF ORIGINAL BUT LOAD WEIGHT REMAINS 1TON

CASE C: CORROSION REDUCES

CASE A CASE B CASE C

1T 1T1T

CASE C: CORROSION REDUCES AREA TO 0.3 OF ORIGINAL BUT LOAD WEIGHT REMAINS 1TON

CASE A CASE B CASE C

CORROSION & ITS EFFECT (CONTD.)

• WHAT ARE THE RESULTS IN 3-CASES• EFFECT OF APPLIED STRESS• CASE A: ROD HOLDS THE WEIGHT• CASE B: ROD UNABLE TO HOLD WELGHT FULLY & DEFORMS BUT

DOES NOT BREAKCASE C: ROD UNABLE TO HOLD WEIGHT AND BREAKS• CASE C: ROD UNABLE TO HOLD WEIGHT AND BREAKS

• EFFECT OF CHANGE IN DIMENSION• LOSS OF METAL• COMPONENT DAMAGED NEEDS REPAIR OR REPLACEMENT• COMPONENT DAMAGED NEEDS REPAIR OR REPLACEMENT• INCREASE IN CONSUMPTION OF METAL• LOSS OF NATURAL RESOURCES• LOSS OF PRODUCTION IF SHUT DOWN NEEDEDOSS O O UC O S U O• INCREASE IN COST OF PRODUCTION• THUS CORROSION HAS A COST COMPONENT

WHICH IS CALLED COST OF CORROSIONWHICH IS CALLED COST OF CORROSION

COST OF CORROSION

• FIRST ATTEMPTED BY PROF HOAR COMMITTEE IN UK WHICH WAS LATER FOLLOWED IN USA, GERMANY AND OTHER COUNTRIESOTHER COUNTRIES.

• COST OF CORROSION WAS ARRIVED AT BROADLY BY TAKING COST OF STEEL AS BASE.

• ANY ADDITIONAL COST FOR PROTECTION OF STEEL AGAINST CORROSION LIKE PAINTING, COATING INHIBITOR, ETC WAS TAKEN AS COST OF CORROSION.

• USE OF CORROSION RESISTANT ALLOYS (CRA) FERROUS ALLOYS AND• USE OF CORROSION RESISTANT ALLOYS (CRA) - - FERROUS ALLOYS AND NON FERROUS METALS AND ALLOYS, IS ALSO CONSIDERED AS ADDITIONAL COST

• VARIOUS STUDIES MADE SHOWED COST OF CORROSION TO BE APOUT 3% %OF GDP.

• STUDIES FURTHER SHOWED THAT AT LEAST 1/3RD OF COST CAN BE REDUCED BY TAKING PROPER STEPS.

COMPARISON OF % COST OF VARIOUS TYPES OF DAMAGES INCLUDINGTYPES OF DAMAGES INCLUDING

CORROSION IN OIL & GAS INDUSTRY

SOME EXAMPLES OF COST OF CORROSION – IN USA

$8.3$7.0

$0.3$7.0

$

Highway BridgesGas and Liquid Transm. PipelinesWaterways and PortsHazardous Materials StorageAi t

ESTIMATED COST OF

GAS & LIQUID PIPELINE 7 BILLION

$-$-

$5.0$36.0

$6.9$

AirportsRailroadsGas DistributionDrinking Water and Sewer SystemsElectrical Utilities

CORROSION IN USA

$-$23.4

$2.7$2.2

$0.51.00

TelecommunicationMotor VehiclesShipsAircraftRailroad Cars

$0.9$1.4

$0.1$3.7

$1.7

Hazardous Materials TransportOil and Gas Expl.and ProductionMiningPetroleum RefiningChem., Petrochem., Pharm.

PETROLEUM REFINING: 3.7 BILLION

CHEM, PETROCHEM,PHARM: 1.7 BI

OIL & GAS: 1.4 billion

$6.0$1.1

$2.1$-

$1.5

, ,Pulp and PaperAgriculturalFood ProcessingElectronicsHome Appliances

$:

$20.0$0.1

$- $10 $20 $30 $40Cost Of Corrosion Per Analyzed Economic Sector, ($ x billion)

Home AppliancesDefenseNuclear Waste Storage

CORROSION DAMAGE IS ALSO

RELATED TO SAFETYRELATED TO SAFETY ANDAND

ENVIRONMENTAL HAZARDS

CORROSION & SAFETYSOME ILLUSTRATIONS

1. Acccident related to pipe line corrosion• After the incidence of oil spill in the 1200 mm dia 1280 km long crude line from Prudhoe Bay, an intelligent pig inspection indicated that at 12 locations the steel had corroded up to 70-81% of original thickness. • The field had to be shut resulting in the reduction in supply of roughly 20 percent of US oil annual production or 2,6% US national supply or b t 400 000 b l dabout 400,000 barrels per day.

* Other recent incidences being the line that served 265 kilometersOther recent incidences being the line that served 265 kilometers Tempino-Sungai Gerong of Trans-Sumatran Pipeline and

* Pipeline explosion at Ghislenghien Industrial Park Belgium in 2004

CORROSION NOT ONLY LEADS TO EQUIPMENT DAMAGE BUT CAN CAUSE CATASTROPHIC ACCIDENTS.BUT CAN CAUSE CATASTROPHIC ACCIDENTS.

• Flixborough (UK) AccidentCompany produced highly explosive caprolactum from cyclohexane,

- Reactor 5 out of six developed leak.- It was isolated by joining 4th to 6thIt was isolated by joining 4 to 6

reactor

SOON AFTER RE CONNECTING PIPE CRACKED RESULTING IN RELEASE OF CYCLOHEXANERESULTING IN RELEASE OF CYCLOHEXANERESULTED IN FORMATION OF VAPOUR CLOUD FOLLOWED BY EXPLOSION EQUIVALENT TO 15 TONS OF TNTBY EXPLOSION EQUIVALENT TO 15 TONS OF TNT

ROOT CAUSE – CORROSION & STRESS

• PRIOR TO LEAKAGE, REACTOR 5, WAS BEING SPRAYED WITH RIVER WATERBEING SPRAYED WITH RIVER WATER BECAUSE OF A LEAKY FLANGE. RIVER WATER CONTAINED HIGH NITRITE WHICHWATER CONTAINED HIGH NITRITE WHICH CAUSED SCC.NO STRESS ANALYSIS WAS DONE OF• NO STRESS ANALYSIS WAS DONE OF PIPING CONNECTEING 4TH AND 5TH

REACTORREACTOR • PIPE GAVE AWAY BECAUSE OF

EXCESSIVE STRESS.

UNION OIL REFINERY, LEMONT , USA

RUPTURE OF H2S ABSORBER COLUMN

• AMINE ABSORBER COLUMN FOR SOUR GAS SWEETENING SUFFERED FROM HEAVYSWEETENING SUFFERED FROM HEAVY BLISTERING IN BOTTOM SECTION

• TWO COURSE OF AFFECTED SECTIONTWO COURSE OF AFFECTED SECTION REPLACED BY NEW PLATES USING WINDOW TECHNIQUE.

• AFTER A YEAR OF OPERATION BOTTOM SECTION RUPTURED AND TOP SECTON THROWN FAR AWAYTHROWN FAR AWAY

• RESULTANT FIRE CAUSED LARGE SCALE DAMAGE

• ROOT CAUSE: HIC ALONG WITH HYDROGEN EMBRITTLEMENTHYDROGEN EMBRITTLEMENT

ADVANCES IN CORROSION PREVENTION

• OVER YEARS CONSIDERABLE PROGRESS HAS BEEN MADE IN CORROSION CONTROLHAS BEEN MADE IN CORROSION CONTROL IN AREAS OF

• PAINTS & COATINGS• INHIBITIORS • TEMPORARY PROTECTION• ALLOYS• ALLOYS• CONVERSION COATINGS• CHEMICALS• DIFFUSION COATINGS• CORROSION MONITORING TECHNIQUES

OTHERS• OTHERS

CORROSION MANAGEMENT

• DEVOLOPMENTS HAVE OPENED UP NUMBER OF OPTIONS TO ENGINEERS & MANAGEMENTMANAGEMENT

• COSTS HAVE ALSO SIMULTANEOUSLY INCREASEDINCREASED

• IT HAS THUS BECOME NECESSARY TO HAVE A BALANCE BETWEEN COST AND GAIN

• CAUTION IS REQUIRED NOT TO GET OVERLY INFLUNCED BY AGGRESSSIVEOVERLY INFLUNCED BY AGGRESSSIVE SALES TALK AND TAKE A BALANCED APPROACH