www.mejournal.

orgJournalofMetallurgicalEngineering(ME)Volume4,2015
doi:10.14355/me.2015.04.008

CorrosionFailureof4PipelineofaGas
ProductionWellinEgyptWesternDesert
Z.AbdelHamid,IbrahimMGhayad,N.Gomaa
CentralMetallurgicalResearch&DevelopmentInstitute(CMRDI),P.O.Box:87Helwan,Cairo,Egypt
ighayad@yahoo.com

Abstract
Acorrodedpartofa4pipeofAGwhichisagasproducingwellcametoproductionsinceJuly2011.ItwassenttoCMRDIto
investigate the failure analysis of the failed pipe. Severe corrosion was observed in the 6 Oclock position inside the pipe.
Combinederosionandpittingcorrosionoccurredonthebottom(6Oclock)ofthefailedpipe.TheCorrosionattackisthought
to occur due to associated condensate waterwhich is relatively high (as this case).Water is mostly acidic due to the high
concentrationofCO2whichdissolvesinwaterformingcarbonicacidH2CO3.Highcorrosivenatureofwaterisalsoevidentfrom
thegreatamountsofchloridepresentinthecondensatewater.Itissuggestedthatpropertreatmentoftheproblemcanrelyon
the use ofsuitable corrosioninhibitor and also increase the efficiency ofdewatering process to decrease the amountof water
associatedwiththeflowinggas.
Keywords
GasWellPipline;Corrosion;FailureAnalysis

Introduction
Majorpipelinesacrosstheworldtransportlargequantitiesofcrudeoil,naturalgas,andpetroleumproducts.These
pipelinesplayanimportantroleinmodernsocietiesandarecrucialinprovidingneededfuelsforvitalfunctions
suchaspowergeneration,heatingsupply,andtransportation.
Inlightofthehazardouspropertiesoftheproductsbeingtransmittedthroughthesepipelines,afailedpipelinehas
thepotentialtocauseseriousenvironmentaldamage.Theriskassociatedwithpipelineintermsofsafetyofpeople,
damage to the environment and loss of income has been a major concern. Sources of failure include structural
problems,corrosionproblems,operatorerror,outsideforcedamageandcontrolproblems.
Therehavebeenanumberofstudiesconductedbyresearchersoncausesofoilpipelinefailuresintheoilandgas
industry[1].Infailuresresultinginproductloss,leaksconstituted86.8%offailuresandruptures13.2%.Corrosion
isthepredominantcauseofleaks.Accordingtothefindings,thethirdpartydamageistheleadingcauseofline
ruptures. Ndifon[2]reviewed the number ofinternalcorrosionfailuresfor multiphase pipelinesand discovered
that internal corrosion failures increased steadily while the number of external corrosion failures held steady.
MoffatandLinden[3]statedthatforsourgaspipelines,internalcorrosionisthemajorcauseoffailure.External
corrosionfailureshavedeclined,possiblyastheresultofimprovedcoatingsandincreasedinspection.Ofthesour
linefailures,about86%wereleaksand14%wereruptures.
Naturalgaspipelinesectionslocatedneartotheextractionwellsaremoresusceptibletofail.Thisfactisduetothe
high concentration of corrosive agents carried in the gas stream, such as CO2, H2S, calcium and chlorine
compoundswhichpromotethedeteriorationofthesteelpipe,mainlyduetoerosioncorrosion[47].Inadditionto
thecontaminants,thepresenceofsaltwaterwhichusuallyencountersinsidethepipelineaggravatesthecorrosion
process.Processvariables,suchasflowrate,pressureandpipelinedesigninteracttocreateasynergisticeffectof
corrosionanderosivewearofthepipe.Corrosionproductsarefirstdepositedontheinternalgaspipelinesurface
intheformofscales.Theseproducts,whicharemainlyCaCO3andFeCO3,initially,actasaprotectivebarrierto
preventthecorrosionofthesteelsurface[89].Oncethescaleshavegrowntoacertainthickness,theywillbecome
highlybrittleandeasilyremovedbythemechanicalforcesofthegasstreaminlocalizedzones.Thus,thenewly

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exposedareasbecomehighlysusceptibletoagalvaniccorrosionprocessaggravatedbytheattractionofchlorine
ions into these areas. This develops localized pits due to pitting corrosion until the final failure of the pipe is
produced.
Service History
Acorrodedpartofa4pipeofAGwhichisagasproducingwellcametoproductionsinceJuly2011.Thecurrent
productionrateofthewellis9.8MMSCFD/Water:31BBL/Condensate:103BBL.Thepipedataandgasanalysis
areshownbelow:

MaterialAPI5LX52gradeBPSL2

Pipesize4sch.40

Nominalthickness:6.019mm

Manufacturedby:BAOsteel

PONO:19804/AS

HeatNo.:3276913

Totallength2Km
TABLE 1 ANALYSIS OF CONDENSATE WATER CONDUCTED BY EGYPTIAN PETROLEUM RESEARCH INSTITUTE

Element

N2

Cl

CO2

C2

C3

I-C4

Wt.%

0.402

84.63

3.678

6.774

2.393

0.51

Element

C6+

I-C5

N-C4

N-C5

C6+

Total

Wt.%

0.48

0.653

0.28

0.202

0.48

100

TABLE 2 ANALYSIS OF MINOR ELEMENTS CONDUCTED BY EGYPTIAN PETROLEUM RESEARCH

Element

SG

H2S

C4

C5+

ppm

0.685

1.163

0.962

Performed Investigations
Thefollowinginvestigationsareperformedontheheatexchangertubes:

Visualexamination

Chemicalanalysis

MechanicalTesting

Metallographicexamination

Corrosiontesting

Results and Discussion

Visual Examination
No indications of localized corrosion attack were observed at the external surface. In other words, the localized
corrosionattackwasconfinedonlytotheinternalsurfaceofpipe.Thepipewasfoundtobeseverelycorrodedat6
Oclockposition.Theinternalsurfaceofthepipewascoveredwithcorrosionproducts.Alongitudinalcorrosion
groovingwasobservedatthe6Oclockposition(Fig.1).

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FIG.1CLOSEUPOPTICALMICROGRAPH(50X)OFTHEINTERNALSURFACEOFTHEPIPE,SHOWINGSSEVERLOCALIZED
CORROSIONAT6OCLOCKPOSITION

Theinternalsurfaceofthepipebetween3and9Oclockpositionswasaffectedbygeneralandlocalizedcorrosion
(Fig.2).

FIG.2GENERALCORROSIONOBSERVEDATTHE3ANDTHE9OCLOCKPOSITIONSUSINGOPTICALMICROSCOPE(50X)

Thepittingwas1.1mmindepth,whichcorrespondingto18%reductionoftheoriginalwallthickness(Fig.3).

FIG.3OPTICALMICROGRAPHS(50X)OFCROSSSECTIONSTAKENFROM6OCLOCKPOSITIONOFPIPE.

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Chemical Analysis
The chemical analysis of the pipe samples was performed using the Spectrolab (optical emission spectrometer)
device to determine the main elements of manufactured material. Table 3 shows the results of chemical analysis
conductedbyCMRDIandcomparedwiththerequiredspecifications.Table3showsthatthechemicalcomposition
isconfirmedwithAPI5LgradeX60PSL2asmentionedbytheclient.Thechemicalcompositionconfirmedwith
API5LgradeX52PSL2
TABLE3CHEMICALCOMPOSITIONOFPIPEONCOMPARISONWITHSTANDARD

Element,wt%

Mn

CMRDI

0.133

1.29

0.017

0.003

Standard(max.)

0.24

1.4

0.025

0.015

CMRDI

Si

Nb

Fe

Standard(max.)

0.27

0.063

0.035

Bal.

MechanicalTesting
Thereceivedpipewascutandprocessedfortensileandhardnesstests.Thetensilestrengthtestwascarriedout
usingaUniversalTestingMachine(UTM).HardnesstestwascarriedoutusingaVickersHardnessMachine(Hv).
TheresultsoftensileandhardnesstestsareshowninTable4incomparisonwiththestandardspecifications.The
datarevealsthatthemeasuredvaluesareconfirmedwithAPIgrade5LX52PSL2.Themechanicaltestresultsare
confirmedwithAPIgrade5LX50PSL2.
TABLE4MECHANICALTESTOFTUBEMATERIAL

Sample

Yieldstrength(N/mm2) Ultimatestrength(N/mm2)

Elongation(%)

Hardness(Hv)

CMRDI

377

552

27.2

198

Standard(min)

360530

490760

196

MetallographicExamination
1)MicrostructureInvestigation
Themicrostructureinvestigationwascarriedoutforthepipewithinthecorrodedarea,andrevealedastructure
which consists of ferriticpearlitic structure, as shown in Fig.4 {ferritic matrix (white area) and some pearlite
(blackarea)}.Therewerenometallurgicaldefectswhichcouldresultincorrodedarea.

FIG.4MICROSTRUCTUREOFTHEPIPEWITHINTHECORRODEDAREA

2)ScanningElectronMicroscopy/EnergyDispersiveSpectroscopyExamination
Aspecimenfromthereceivedpipewascut,processedandthelocalizedcorrosionattackontheinnersurface
was examined usingscanningelectron microscope(SEM)(Fig.5).Corrosion products weredistinguished from

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themetalsurfaceinsidethepit.TheEDSspectraareshowninFig.6.Nocorrosionproductswereobtainedon
themetalsurface(Fig.6a).EDSspectrainsidethepit(Fig.6b)showsthepresenceofoxygenandchlorinepeaks
insidethepitsindicatetheformationofironoxideandironchlorideascorrosionproducts.

FIG.5SCANNINGELECTRONMICROSCOPE(SEM)PHOTOGRAPHSHOWINGTHELOCALIZEDCORROSIONATTACKONTHE
INNERSURFACEOFTHEFAILEDPIPE

FIG.6AEDSANALYSISONTHESUBSTRATESURFACEFIG.6BEDSSPECTRUMOFTHEDEPOSITINSIDEPIT

Corrosion Testing and Mechanism

Aspecimenfromthepipelinewassubjectedtoelectrochemicalcorrosiontestingin0.8%sodiumchloridesolution
(simulatingwaterassociatesthegasflowinginthepipe)usingcomputerizedpotentiostat(seeFig.7).Thetestgives
important information about the susceptibility of material towards pitting corrosion attack. Current increases
rapidly with increasing potential until it reaches a steady value of 13 mA/cm2. The high currents (0.13 A cm2)
shown by the curve indicates high susceptibility of the pipe material towards corrosion in general and pitting
corrosioninparticular.

FIG. 7 POTENTIODYNAMIC POLARIZATION CURVE OF THE PIPE MATERIAL IN 0.8% NACL. CURRENT MEASURED IN AMPERE (A) WHILE
POTENTIAL MEASURED IN VOLT (V)

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Combined erosion and pitting corrosion occurred at the bottom (6 Oclock) of the failed pipe. Erosion corrosion
reaults from the disruption of protective passive films by erosive or abrasive processes. Once the protective or
passivefilmisremovedinanaqueouselectrolyte,theelectrochemicalprocessesforpittingcorrosionwilltakeplace.
The initiation of a pit occurs when electrochemical or chemical breakdown exposes a small local site on a metal
surface to damaging species such as chloride ions. The sites where pits initiate include; scratches, surface
compositionalheterogeneities(inclusions),orplaceswhereenvironmentalvariationsexist.Inthepresentcase,the
sitesofpitinitiationarelikelyduetoscratchesformedbysolidparticles(sand)containedinthewaterassociates
thegasflowinthepipe.Inaddition,theveryhighconcentrationofchlorideionsenablesthemtopenetratethe
metalsurfacelayerandinitiatepittingcorrosionbythemselves.Anotherfactorintensifiespittingcorrosionattack
is the high CO2 content. CO2 increases the acidity of the water inside the pipe and thus facilitates and increases
pitting attack. The pit grows if the high current density (the area of breakdown initiation is exceedingly small)
involved in the repassivation process does not prevent the formation ofa large local concentration of metalions
producedbydissolutionatthepointofinitiation.Iftherateofrepassivationisnotsufficienttochokeoffthepit
growth, two new conditions will be developed. First, the metal ions produced by the breakdown process are
precipitated as solid corrosion products (such as the Fe(OH)2 which usually cover the mouth of the pit. This
covering traps the solution in the pit and allows the buildup of positive hydrogen ions through a hydrolysis
reaction. Then, chloride or other damaging negative ions diffuse into the pit to maintain charge neutrality.
Consequently, the repassivation becomes considerably difficult because the solution in the pit is highly acidic,
containingalargeconcentrationofdamagingionsandmetallicions,andalowoxygenconcentration.Therebythe
rateofpitgrowthaccelerates[6].
Thepitistheanodeofanelectrochemicalcorrosioncell,andthecathodeofthecellisthenonpittedsurface.Since
thesurfaceareaofthepitisaverysmallfractionofthecathodicsurfacearea,alloftheanodiccorrosioncurrent
flows to the extremely small surface area of the breakdown initiation site. Thus, the anodic current density
becomesveryhigh,andpenetrationofametalstructurebearingonlyafewpitscanberapid.
Expected Causes of Corrosion Attack
AssociatedCondensateWater
Corrosionnaturallyoccursinpipelineswhereverwaterwetsthepipelinewall.Iftheamountofwaterisrelatively
high(asthiscase),thepipecancorrodeatalmostanylocationsubjectedtowaterreplenishment.
CorrosiveNatureofWater
WaterismostlyacidicduetothehighconcentrationofCO2whichdissolvesinwaterformingcarbonicacidH2CO3.
Highcorrosivenatureofwaterisalsoevidentfromthegreatamountsofchloridepresentinthecondensatewater.
FlowPattern
Theflowpatterninthepipelineistransitionalinnatureandgivesachancetostratificationoftheliquidphases.
Since the water cut is about 30% (may be more or less), water will wet the pipeline even in the transition flow
conditions. At low lying areas (Pipeline Crossings) where the chances of condensate water accumulations are
greater,aggressivelocalizecorrosionisexpectedinthesestagnantareas.
Conclusion and Recommendation

Mechanicalandchemicalanalysisisinconformitywiththespecifications.

The pipeline failed as a result of localized pitting corrosion initiated from the internal surface in the 6
Oclockposition.

The most significant parameters contributing to the failure by localized corrosion are the associated
condensatewater.

The localized corrosionisinfluenced by some variablessuch asacidity, operation, water wetting, scheme
depthsandbacterialeffect.Theinfluencesoftheseparametersarecloselylinkedwitheachother;andthe

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mechanismofseparateactionofeachisshownindetailsinitemNo.6ofthisreport.

Dewateringtreatmentunitshouldbetransferredtothewellsiteoratleastanewtreatmentunitshouldbe
installedinapointbeforegasflowinthepipeline.

Biocides:Additioncanbehelpfulforfightingbacterialcorrosion.Referencetoaspecialistinthisrespectis
helpful,providedthattheaboverecommendedactionswereimplemented.

Corrosioninhibitormustbeinjectedonthegasflowlinewithrapidfilmforming.

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