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FACILITIES UPGRADING &
DEBOTTLENECKING CONCEPTUAL &

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DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 1 OF 32
STAROIL OPERATING COMPANY LIMITED
FACILITIES UPGRADING & DEBOTTLENECKING

CONCEPTUAL & FEED
CORROSION & MATERIAL SELECTION REPORT
CONTRACT NO.: STAROIL/100/2014
CS-EPPM/JV PROJECT NO.: AR 17/14-WO1
0 Final issue 04/08/15 AMG MGD AZ

B Issued For Approval 30/07/15 AMG MGD AZ
A Issued For Review 11/07/15 AMG MGD AZ
REV. DESCRIPTION DATE BY CHECKED APPROV. CLIENT
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TABLE OF CONTENTS
1.0 INTRODUCTION.................................................................................................................... 4
1.1 PROJECT DESCRIPTION............................................................................................................4
1.2 DOCUMENT SCOPE..................................................................................................................5
2.0 REFERENCES DOCUMENTS...............................................................................................5
2.1 PROJECT DOCUMENTS............................................................................................................. 5
2.2 CODES & STANDARDS.............................................................................................................5
2.3 REFERENCE PUBLICATIONS......................................................................................................6
3.0 DEFINITION & ABBREVIATION LIST....................................................................................6
3.1 DEFINITIONS............................................................................................................................ 6
3.2 ABBREVIATIONS....................................................................................................................... 7
4.0 GENERAL PRINCIPLES FOR MATERIAL SELECTION AND INTERNAL CORROSION
OVERVIEW...................................................................................................................................... 8
4.1 MATERIALS SELECTION........................................................................................................... 8
4.2 GENERAL PRINCIPLES FOR MATERIAL SELECTION...................................................................8
4.3 INTERNAL CORROSION OVERVIEW...........................................................................................8
4.4 CORROSION AND MATERIAL DEGRADATION THREATS................................................................9
4.4.1 CARBON DIOXIDE CORROSION ..............................................................................................10
4.4.2 CHLORINATION EFFECT......................................................................................................... 11
4.4.3 PITTING CORROSION............................................................................................................. 11
4.4.4 EROSION CORROSION.......................................................................................................... 11
4.4.5 FLOW ENHANCED CORROSION..............................................................................................12
4.4.6 MICROBIAL INFLUENCED CORROSION....................................................................................12
4.4.7 GALVANIC CORROSION.......................................................................................................... 12
4.4.8 EXTERNAL CORROSION.........................................................................................................13
5.0 INPUT DATA......................................................................................................................... 13
5.1 DESIGN LIFE.......................................................................................................................... 13
5.2 RESERVOIR FLUID COMPOSITION............................................................................................13
5.3 PRODUCTION FLOWRATE........................................................................................................14
5.4 PRODUCED WATER ANALYSIS.................................................................................................15
5.5 NEW EQUIPMENT DATA........................................................................................................... 16
6.0 CORROSION ASSESSMENT METHOD..............................................................................20
6.1 CORROSION TENDENCIES......................................................................................................20
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6.1.1 BASIC CORROSION RATE .....................................................................................................20

6.1.2 HIGH TEMPERATURE PROTECTIVE FILMS..............................................................................21
6.1.3 ADJUSTMENT FOR PH........................................................................................................... 21
6.1.4 CORROSION UNDER DEWING (CONDENSING ) CONDITIONS.....................................................22
6.1.5 EFFECT OF GLYCOL AND METHANOL ....................................................................................22
6.1.6 EFFECT OF LIQUID FLOW VELOCITY......................................................................................23
6.1.7 WATER IN OIL...................................................................................................................... 23
6.2 CORROSION TENDENCIES IN WATER.....................................................................................23
6.2.1 INTRODUCTION.................................................................................................................. 23
6.2.2 LANGELIER SATURATION INDEX (LSI)..................................................................................24
6.2.3 RYZNAR STABILITY INDEX...................................................................................................25
6.2.4 WATER CORROSION CHARACTERIZATION ...........................................................................27
6.2.5 CONCLUSION.................................................................................................................... 27
7.0 MATERIAL SELECTION......................................................................................................28
7.1 PROCESS EQUIPMENTS MATERIAL SELECTION SUMMARY........................................................28
7.2 PROCESS PIPING MATERIAL SELECTION SUMMARY.................................................................30
8.0 CONCLUSIONS AND RECOMMENDATIONS.....................................................................32
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1.0 INTRODUCTION
1.1 PROJECT DESCRIPTION
In 2006, STAR OIL COMPANY a Consortium of Ansan (66%) and Sudapet (34%) signed the
EPSA for Block 17 which covers an area of 22,185 sq. km. This Block has three (3) oil discoveries
namely:
 AbuGabra field which covers an area of 20 sq. km.
 Sharif field which covers an area of 10 Sq. km
 The recent discoveries in South ANNAJMA the main contracted area
In Dec 2012 STAROIL produced its first oil from South ANNAJMA Field by implementing Early
Production Project which includes:
 Early Processing Facilities (EPF) with a capacity of 15 kBOPD Oil and 7.5 kBWPD Water.
 6 x 1000KVA Power Plant.
 33 Kv Transmission Overhead Lines.
 6 Wells Oil Producers.
 43 Km Pipeline.
Crude oil from producing wells is gathered and processed at EPF plant. EPF plant has single
process train, one storage tank, export pump system and utilities.
As for case of single process train, it is very difficult to carryout maintenance activity during
normal operation of the plant as some major equipment must be taken out for scheduled
maintenance. Due to current situation, hence for major maintenance work the plant has to be
shut down since no redundant of process train is available which resulted into significant
production losses.
In order to have a robust plant, reliability of the plant has to be verified in terms of redundancy,
facilities improvements and identification of debottlenecks which aims at eliminating operation
troubles and minimizing the plant down time
Based on the above facilities upgrading and debottlenecking has been initiated with the following
scope of work:
 Conceptual design which shall address a full review of the entire EPF plant system
summarizing major findings and recommendations (debottlenecking/upgrade, operation
troubles/malfunction…etc).
 Feed elaboration of the conceptual study output scheme based on STAROIL’s decision and
approval, taking into consideration the addition of a second process train and a produced
water facilities.
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1.2 DOCUMENT SCOPE

The main objective of this report is to provide a corrosion study and materials selection for new
process train within South Annajma EPF upgrading project.
The scope of this document is to assess the expect corrosion rates and then to recommend the
most suitable material for each service. Also, some suggested solutions for corrosion mitigation
and / or prevention are to be provided.
The material selection of each component of the facilities in this report shall be defined to ensure
safe operation during its design life time.
2.0 REFERENCES DOCUMENTS
2.1 PROJECT DOCUMENTS

Design Philosophy SA-DBM-GEN-1501-9002
PFD R1714-DWG-PR-01-002
Equipments list SA-SCH-PRO-1501-2010
2.2 CODES & STANDARDS
API RP 14E Recommended Practice for Design and Installation of Offshore
Production Platform Piping Systems
ASTM A153 Standard Specification for Zinc Coating (Hot-Dip) on Iron and
Steel Hardware
ASTM A193 Standard Specification for Alloy-Steel and Stainless Steel Bolting
for High Temperature or High Pressure Service and Other
Special Purpose Applications
ASTM A194 Standard Specification for Carbon and Alloy Steel Nuts for Bolts
for High Pressure or High Temperature Service, or Both
ASTM A320 Standard Specification for Alloy-Steel and Stainless Steel Bolting
for Low-Temperature
ASTM A106 Standard Specification for Seamless Carbon Steel Pipe for High-
Temperature Service
ASTM A105 Standard Specification for Carbon Steel Forgings for Piping
Applications
ASTM A216 Standard Specification for Steel Castings, Carbon, Suitable for
Fusion Welding, for High-Temperature Service
ASTM A182 Standard Specification for Forged or Rolled Alloy-Steel Pipe
Flanges, Forged Fittings, and Valves and Parts for High-
Temperature Service
BS 7371 Coatings on metal fasteners
BS EN ISO 10684 Fasteners - Hot dip galvanized coatings
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ISO 15156 Petroleum and natural gas industries - Materials for use in H2S-
containing environments in oil and gas production
ISO 21457 Petroleum, petrochemical and natural gas industries - Materials
selection and corrosion control for oil and gas production
systems
API 5L Specification for Line Pipe
ASME B 31.4 Liquid Petroleum Transporting Piping System
ASME sect II Part A Materials specification
NACE MR-01-75-94 Material recommendation, NACE international 1994
NACE 1985 Influence of environmental factors on corrosion in CO2 wells
NACE1989 Computer model of a gas condensate well containing carbon
dioxide.
2.3 REFERENCE PUBLICATIONS
[1] C. De Waard, U. Lotz, D.E. Milliams, “Predictive Model for CO2 Corrosion
Engineering in Wet Natural Gas Pipelines”, Corrosion 91, Paper 577, NACE Houston,
1991
[2] Costerton, J.W. et al., "Bacterial Biofilms in Relation to Internal Corrosion Monitoring
and Biocide Strategies", CORROSION/87, Paper No.54, NACE, San Francisco, CA,
1987
[3] Kowaka, M., Metal Corrosion Damage and Protection Technology, Allerton Press Inc.,
1989
[4] Shell International Oil Products B.V., Manual for HYDROCOR 1999 spreadsheet for
the prediction of CO2 corrosion in multi-phase pipelines transporting wet
hydrocarbons OP.99.draft
3.0 DEFINITION & ABBREVIATION LIST

3.1 DEFINITIONS
For the purpose of this document the following definitions shall apply:
PROJECT : Facilities Upgrading and debottlenecking conceptual & FEED

ENGINEERING COMPANY : CSC / EPPM JV
OWNER / CLIENT : STAROIL OPERATING COMPANY LIMITED
MANUFACTURER/ : The party manufacturing and/or supplying the materials,
SUPPLIER/VENDOR equipments and services required to perform the duties as
specified by the Contractor/Engineering Company
SUBCONTRACTOR/ : The party(s) which carries out all or part of the design,
SUBVENDOR
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procurement, installation and testing of the system(s) as

specified by the Contractor/Engineering Company
Shall : Indicates a mandatory requirement
Should : Indicates a strong recommendation to comply with the
requirements of this document
3.2 ABBREVIATIONS
The abbreviations that will adopt on this document are defined as follow:
CPF : Central processing facility

GRP : Glass Reiforced Plastic
LSI : Langelier Saturation Index
RSI : Ryanar stability index
TDS : Total Dissolved Solid
TSS : Total Suspended Solid
CA : Corrosion Allowance
CI : Corrosion Inhibitor
CRA : Corrosion Resistant Alloy
Cri : Corrosion Rate Inhibited
Cru : Corrosion Rate Uninhibited
CS : Carbon Steel
CUI : Corrosion Under Insulation
CW : Condensed Water
DSS : Duplex Stainless Steel
FEED : Front End Engineering Design
H&MB : Heat and Mass Balance
HIC : Hydrogen Induced Cracking
NR : No Restriction
PFD : Process Flow Diagram
PREN : Pitting Resistance Equivalent Number
SLC : Service Life Corrosion
SS : Stainless Steel
SSC : Sulphide Stress Cracking
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4.0 GENERAL PRINCIPLES FOR MATERIAL SELECTION AND INTERNAL CORROSION

OVERVIEW
4.1 MATERIALS SELECTION
Material selection shall be optimized, considering investment and operational/maintenance costs,
such that overall costs are minimized while providing acceptable safety and reliability. As
minimum, the following shall be considered:
• Corrosivity, taking into account specified design & operating conditions;
• Design life and system availability requirements;
• Failure probabilities, failure modes and failure consequences for human health, environment,
safety and material assets;
• Inspection and corrosion monitoring possibilities.
For the final materials selection the following additional factors shall be included in the evaluation:
• Priority shall be given to inherently safe materials for the approved design conditions.
• The material with good market availability and documented fabrication and service performance.
• The number of materials types shall be minimized considering stock, costs, inter-changeability
and availability of relevant spare parts.
4.2 GENERAL PRINCIPLES FOR MATERIAL SELECTION
Material selections generally follow the principles and recommendations defined in ISO 21457
and ISO 15156.
When feasible, carbon steel with corrosion allowance is selected as the preferred material of
construction considering cost, availability and constructability. Internal corrosion loss is
accommodated by increasing wall thickness over that required for mechanical design. This
additional wall thickness or corrosion allowance (CA) shall match or exceed the predicted
cumulative service life loss in wall thickness, known as service life corrosion (SLC).
The SLC is calculated by multiplying the predicted corrosion rate for carbon steel in mm/yr by the
duration when the internal surface of the stream is expected to be at risk of water wetting.
Materials and corrosion allowance are selected on the basis of expected corrosion concerns,
predicted corrosion loss of carbon steel and material degradation associated with composition
and pH, operating and design temperatures and pressures, and the external environment. For
age-related corrosion mechanisms where there is a risk of long-term corrosion attack, the
operating conditions dictate the materials selection.
4.3 INTERNAL CORROSION OVERVIEW
To predict the corrosion phenomena, we have to evaluate a large number of environmental
parameters to assess the corrosive severity of the environment and to determine a corrosion rate
in steels.
We will use a widely accepted CO2-based corrosion prediction model to obtain an initial
assessment of corrosion severity in carbon steels. This base corrosion rate is modified to take
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into account for the effects of additional factors such as temperature, H2S, chlorides, velocity and
chemical injection.
Relevant parameters in steel evaluation include:
CO2 Partial pressure of carbon-dioxide in the operating environment
pH Hydrogen ion concentration of the operating environment
H2S Partial pressure of hydrogen sulfide in the operating environment
Chlorides Dissolved chlorides in the operating environment
Temperature Operating temperature for the environment
Gas/Oil Ratio (GOR) Volumetric ratio of produced gas to oil
Water/Gas Ratio Ratio of water to gas in gas dominated systems (gas wells)
Dew Point Dew point of operating environment
Water Cut Amount of water as a volumetric ratio of total fluid produced
Oil Type Type of persistence of oil films in an oil dominated condition
Fluid Velocity Flowing Velocity of in the operating environment
Corrosion Allowance Allowable general corrosion in mils (or mm) over the life time of the
project
Service Life Life of project in years
Flow Type Type of fluid flow
Type of Inhibition Inhibition method and type.
4.4 CORROSION AND MATERIAL DEGRADATION THREATS
The materials selection considers the following potential causes of corrosion and damage threats
based on the stream compositions, operating and design conditions, and external environment:
 General Carbon Dioxide Corrosion;
 Chloride Corrosion
 Pitting Corrosion
 Erosion Corrosion
 Flow Enhanced Corrosion
 Microbial induced Corrosion, MIC;
 Galvanic Corrosion.
 External Corrosion;
These corrosion threats are considered individually in the following paragraphs, which
summarizes the philosophy adopted to deal with them.
4.4.1 CARBON DIOXIDE CORROSION
General CO2 corrosion is the uniform deterioration of the exposed surface of pipelines, piping
and equipment with time and is the basis for many models used for predicting corrosion rates of
carbon steels in such environments.
When carbon dioxide is dissolved in water, carbonic acid is formed which reacts with the iron in
carbon steel to form iron carbonate as a corrosion product.
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This is shown by the following chemical reactions:

CO2 + H2O = H2CO3
(Carbon dioxide) + (Water) = (Carbonic Acid)
Fe + H2CO3 = FeCO3
(Iron) + (Carbonic Acid) = (Iron Carbonate)
The amount of dissolved CO2 in any free water and consequently the concentration of carbonic
acid are related to the partial pressure of CO2 gas in equilibrium with the free water.
Typically a higher equilibrium partial pressure of CO2 will give a lower water pH and a more
corrosive acid solution.
The water may originate as formation water from the reservoir itself and contain impurities such
as chloride, bicarbonate and organic acids. Water may also arise from water vapor condensing
out of the gas streams, in which case it is considered to be free of such impurities but not organic
acids if present.
The effect of pH is an important factor in CO2 corrosion of carbon steel as it influences
both the electrochemical reactions and the propensity for the deposition of corrosion products
and protective scales. Where the associated water phase contains salts, these may buffer the
solution by raising the pH and promoting the deposition of protective scales on the surface of the
metal, reducing the corrosion rate. Any organic acids present will tend to cause the opposite
effect and increase the corrosion rates.
The presence of bicarbonate buffers the pH and therefore a conservative corrosion rate has been
determined based on bicarbonate of 70 mg/l.
The degree of corrosion caused by carbonic acid becomes more severe with increases in both
partial pressure of carbon dioxide in equilibrium with any free water and the process temperature.
Crude oil flows can reduce the CO2 corrosion rate by entraining the water up to typical levels of
20% by volume under normal flowing conditions. A minimum fluid velocity of 1 m/s is generally
required to keep the water entrained in crude oil. The presence of a small quantity of water in
crude oil is inevitable and water dropout and accumulation can occur at low velocities and under
stagnant conditions, even at very low water cut levels. All un-stabilized oil containing any free
water is considered to have the potential for water dropout and accumulation.
However, no benefit for water entrainment/oil wetting has been considered in the corrosion
assessment for the process lines.
The dominant internal corrosion mechanism in South Annajma EPF and facilities will be carbonic
acid corrosion.
4.4.2 CHLORINATION EFFECT

Produced water from hydrocarbon formations typically contains varying amounts of chloride salts
dissolved in solution. The chloride concentration in this water can vary considerably, from zero to
few ppms for condensed water to saturation in formation waters having high total dissolved
salts/solids (TDS). In naturally de-aerated production environments, corrosion rate increases with
increasing chloride ion content over the range 10,000 ppm to 100,000 ppm . The magnitude of
this effect increases with increasing temperature over 60°C (150 F). The Chloride species in the
aqueous phase can work to penetrate and destabilize protective surface films (uniform corrosion
films) and lead to increased corrosion. This phenomenon of penetration of surface corrosion films
increases in occurrence with both chloride ion concentration and temperature.
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4.4.3 PITTING CORROSION

Pitting corrosion occurs in areas with a low flow rate or stagnant conditions and in oil producing
environments it is caused by environments containing chlorides, carbon dioxide and/or hydrogen
sulphide, and in particular when oxygen is present. This form of corrosion can be avoided by
designing out areas of stagnant fluids or by selecting alternative materials which have a good
pitting resistance number (PREN). The PREN is given by the following equation:
PREN = Cr% + 3.3Mo% + 16N%
Crevice corrosion occurs in small crevices or gaps in components such as under a gasket or a
seal ring. The crevice results in a lowering of the pH in the gap, which in turn increases
susceptibility to localized corrosion. This is particularly important when considering materials in
the presence of critical seal areas. It is therefore common practice to overlay the carbon steel
seal areas with materials such as Alloy 625, that are resistant to crevice corrosion.
4.4.4 EROSION CORROSION
Erosion corrosion is another phenomenon which can exist in carbon steels and CRA materials as
a result of the presence of sand and/or corrosion products. The constant removal of any
protective film which forms on the surface of the metal increases the corrosion rates markedly.
The rate of removal is directly related to the velocity of the flow through piping. CRA materials
have a much more tenacious surface oxide film, and are, therefore, less susceptible to erosion
effects.
Erosion-corrosion risk is considered low on the assumption that piping and equipment are sized
appropriately (e.g. limiting flow velocities for piping to comply with the recommendations of API
RP 14E). Solid erosion is generally not considered a concern within process piping and facilities,
provided the well completion design contains measures to prevent solids being produced at the
well surface. Erosion from sand is considered negligible at levels of 1lb/1000bbl for liquid
systems. The production of sand and other solids is not reported in the documents reviewed to
date. Erosion is rarely an issue in oil piping because the density difference between the particles
is small and the flow velocities of the crude oil will be modest. Erosion corrosion is not anticipated
to be of significance.
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4.4.5 FLOW ENHANCED CORROSION

The inlet pressure to the piping and equipment is modest. Liquid velocities in the piping and
equipment will have to be restricted to values that will not introduce an excessive pressure drop. It
is expected that the flow velocities will not exceed the conservative flow velocities required to
conform to requirements of API RP-14E. Flow enhanced corrosion is not anticipated to be a
significant corrosion issue.
4.4.6 MICROBIAL INFLUENCED CORROSION
Corrosion may also be caused or facilitated by the activity of micro-organisms living on the pipe
wall.
Referred to as Microbiologically Influenced Corrosion (MIC), this type of corrosion can occur when
microbes and nutrients are available and where water, corrosion products and deposits present
on the pipe wall provide sites which are favorable for colonisation of microbes.
Microbial activity, in turn, may create concentration cells or produce organic acids or acid-
producing gases, making the environment aggressive for carbon steel. The microbes can also
metabolise sulphur or sulphur compounds to produce products that are corrosive to steel or that
otherwise accelerate the attack on steel.
MIC is of particular concern in low flowrate or stagnant liquid flows that contain produced water,
treated seawater and comingled water.
This kind of corrosion will be treated for water lines.
Seawater will not be used for this project.
Microbiological corrosion requires the introduction of sulphate-reducing bacteria (SRB) and an
adequate concentration of organic material to support the bacteria and at least 50 ppm sulphate.
In the event that microbiological growth does initiates periodic treatment with biocides will be
necessary to manage the bacterial growth. Microbiological analysis and treatment shall accord
with NACE RP-0194.
4.4.7 GALVANIC CORROSION
When two different metals are in contact in an oxygenated electrolyte, current flows through the
solution from the more anodic metal to the cathodic metal. As a consequence the cathodic metal
tends to be protected and the more anodic metal may suffer enhanced or galvanic corrosion. The
magnitude of the enhanced corrosion effect is dependent on the relative surface areas of the two
metals in contact, and the potential developed between the two metals when coupled in the
electrolyte.
There is sufficient operating experience available to substantiate that internal galvanic corrosion
is not a problem within carbon steel systems in deaerated hydrocarbon production systems where
corrosion resistant alloys are used for weld overlays and flange sealing rings. The risk of external
galvanic corrosion shall be controlled using paints and coatings. The risk of galvanic corrosion in
this project is unlikely due to dry environment.
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4.4.8 EXTERNAL CORROSION

External corrosion occurs due to contaminants in the atmosphere in the presence of an
electrolyte. The main modes of attack are pitting corrosion, crevice corrosion and corrosion under
insulation (CUI), which can occur at ambient temperature.
No external corrosion allowance is added to equipments or piping to accommodate atmospheric
corrosion, therefore painting or coating is necessary where carbon steel is used. The painting
should be maintained during the design life to afford adequate external corrosion protection.
For the pipes laid above ground in this project, the risk of external corrosion is unlikely due to the
following reasons:
Piping and equipments are located in dry environment conditions, with very high soil resistivity at
soil surface.
Contrary to underground installation, for piping and equipments laid above sol surface, the risk of
corrosion by an environment electrolyte is reduced.
For the piping laid underground (case of underground firefighting piping) these should be made
with GRE material.
5.0 INPUT DATA
This section collects the available data, as taken from the reference project documents, provided
for the purpose of corrosion assessment and material selection.
5.1 DESIGN LIFE
The new facilities shall have a design life of 25 years.
A 25 year design life is preferred where there will be no cost saving associated with a design life
reduction. Second hand, modularized, fit for purpose equipment may be acceptable subject to
Company approval.
5.2 RESERVOIR FLUID COMPOSITION
Two reservoir fluid compositions are available for use in South ANNAJMA EPF; Abugabra and
Bentiu
Abugabra has a higher GOR and contains a higher concentration of CO2 compared to Bentiu.
Table 1: CO2 and H2S Content [% mole]

Abugabra formation Bentiu formation Abugabra field
Flashed Stock Well Flashed Stock Well Flashed Stock Well
Component
gas tank oil stream gas tank oil stream gas tank oil stream
H2S 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000 0.0000
CO2 1.7270 0.0000 0.7406 0.3295 0.0000 0.0805 2.5310 0.0000 0.7140
Table 2: Properties of Crude Fluid

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Bentiu Abugabra Abugabra

Fluid
formation formation Field
Pour point, °C 39 48 42
API Gravity @ 15.6 °C 37.34 38.09 36.48
Relative Density g/cm³ @ 15.6 °C 0.8355 0.8336 0.8273
GOR (SCF/STB) 208.4 287.189 61.79
Gas gravity (Air) 1.069 0.6983 0.9206
Asphaltene content (wt %) 0.1 NA 0.03
Wax content (wt %) 20.8 NA NA
Sulfur content (% m) 0.0463 NA 0.0777
Salt Content (mg/NaCl/L) 8 NA 170
No H2S is reported in the reservoir fluids.

There is currently no mercury reported.
Any sand produced by reservoirs shall be effectively managed to prevent damage to the piping
and equipment downstream. Sand production should be managed by the use of down hole
control and sand screens or de-sanders, as well as choice of adequate piping diameter for
adequate speed of fluid.
5.3 PRODUCTION FLOWRATE
A range of production flowrate shall be considered for process piping and equipment. These
include maximum oil and maximum water flowrate and gas to oil ratio GOR.
Table 3: Production Flowrate & GOR
Average Daily Average Daily

GOR
Oil Rate Water Rate
std barrel/day std barrel/day SCF/SBD
Flowrate 25000 17000 500
In oil and gas production, where the environment has a GOR < 890 m3/m3, the tendency for
corrosion and environmental cracking is substantially reduced.
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This is caused by the inhibiting effect of the oil film on the metal surface, which effectively
reduces the corrosivity of the environment. However, the inhibiting effect is dependent on the oil
phase being persistent and acting as a barrier between the metal and the corrosive environment.
5.4 PRODUCED WATER ANALYSIS
Water analysis representing south Annagma field is not yet available.
However to carry out requested corrosion study in this phase we have used PW analysis
representing Bentiu formation.
The following formation water chemical analysis has been adopted for design of the oil/water
separators and the produced water clean – up unit.
Cations Sodium 1611 mg/l Anions Chloride 2836 mg/l

Potassium 640 mg/l Sulphate 8 mg/l
Calcium 48 mg/l Bicarbonat 580 mg/l
e
Magnesium 7 mg/l Carbonate Nil
Barium 9 mg/l Hydroxide Nil
Iron 2 mg/l
pH 7,05
SG (60/60F) 0,9998
Total Dissolved Solids (mg/litre) (Calculated) (TDS) 5742
According to “Produced Water Sample Analysis Report”, the main results obtained from the
analyses conducted on the water samples related to cations, anions and physical parameters
allow making the following observations:
 Sodium is the predominant element of cations and represents an average proportion of 69%
followed by Potassium with an average proportion of 28%.
 The obtained results indicate a relatively low content in sulfate (lower than 40 mg/L) and high
content in Bicarbonate and chloride is the predominant element of anions.
 According to SULIN classification, the genetic type of water is "Bicarbonate - Sodium".
CONCEPTUAL & FEED
5.5 NEW EQUIPMENT DATA

The New South Annajma EPF equipments characteristics are as described by the following table.
Table 4: New equipments characteristics
Design
Operating Operating /
Capacity / Suction/
Equipment Name / Design Design
ITEMS Tag Number Number Type Dimensions Discharge
/ Service Pressure Temperature
Pressure
(barg) (°C)
(DxL)
Exchanged
Shell & tube heat
E-1301 B 1st train Production Heater 1 Area 1-3 / 8 50-90 / 120 -
exchanger
251.3 m2
Shell & tube heat
E-1301 C 2end train Production Heater 1 - 1-3 / 8 50-90 / 120 -
Main Process exchanger
V-1301B 2end train Three phase separator 1 Horizontal Vessel - 3-3.5 / 8 50-90 / 120
2end train Electrostatic Heater

EHT-1301C 1 Horizontal Vessel - 1.5-2 / 8 90 / 120
Treater
Horizontal Vessel
D =1,524 m
V-1307 B 1st train Test Separator 1 Three Phase 3-3,5/8 50-90/120 -
X L=5,834 m
Separator
V-1303 B Fuel Gas Scrubber 1 Vertical Vessel D=0,6 m X 3/8 50-75 /100 -
H=2,5 m
CONCEPTUAL & FEED
Design Operating Operating /

Capacity / Suction/
ITEMS Tag Number Number Type Dimensions Pressure Discharge
/ Service Temperature
Pressure
(barg) (°C)
(DxL)
Crude Oil Storage 5000 m3 atm / 20-(- 60-75 / 10-
T-1301 B 1 Fixed Roof Tank D=20 m X -
Tank H=17 m 6)mbarg 100
Storage
System D=0.27 m X 60-75 / 10-
V-1305 Degassing Boot 2 Vertical Vessel atm -
H=18 m 100
E-1303 Electrical Heater 1 Immersed Heater HOLD HOLD 60-120 -

Centrifugal
P-1501 C/D Electrical Export Pump 2 132,5 m3/h - 50-75 / 85 atm / 23
Horizontal Pump
Centrifugal
P-1502 B Diesel Export Pump 1 132,5 m3/h - 50-75 / 85 atm / 23
Horizontal Pump
500 m3 atm / 20-(- 60-75 / 10-
T-1302 B Off spec Tank 1 Fixed Roof Tank D=9 m X -
H=9 m 6)mbarg 100
Off Spec
System 60-75 / 10-
P-1302 C Off spec Pumps 1 Screw Pumps 35 m3/h - atm / 9
100
E-1304 Electrical Heater 1 Immersed Heater HOLD HOLD 60-120 -
B-1401 Basket Filter 1 Filter 500 µm 45 m3/h atm / 3,5 50-75 /100 -
Off Loading
P-1310 Offloading Pumps 1 Volumetric Pumps 45 m3/h - 50-75 / 100 atm / 3
System
C - 1601 Desander 1 Solid / Liquid 45 m3/h 3/8 50-75 / 100 -
CONCEPTUAL & FEED

Capacity / Suction/
Pressure
(barg) (°C)
(DxL)
Common B-1402 Basket Filter 1 Filter 500 µm 45 m3/h atm / 3,5 AMB -
Utilities
Diesel Supply
P-1311 1 Volumetric Pumps 45 m3/h - AMB atm / 3
Pump
Diesel System 37 m3
Diesel supply atm / 20-(-
V-1314 1 Vertical vessel D=2,6 m X AMB -
vessel 6)mbarg
H=9,3 m
Diesel Transfer
P-1320 1 Volumetric Pumps 5 m3/h - AMB atm / 3
Pump
1.5
F -1301 C Cold vent 1 - atm / 3.5 50-75 / 120 -
MMSCFD
Flare System
D=2,8 m X
V-1310 Knock Out Drum 1 Horizontal Vessel atm / 3,5 50 - 65 / 100 -
L=7 m
Water Produced Water 1800 m3
Treatment Unit T-1308 A/B 2 Fixed Roof Tank D=14,8 m X atm / 3,5 50 - 65 / 85 -
Tank H=12 m
Recovered Oil
P-1313 A/B 2 (1+1) Submersible pumps 10 m3/h - 50 - 65 / 85 atm / 3
Pump
Produced Water
P-1314 A/B 2 (1+1) Centrifugal Pumps 200 m3/h - 50 - 65 / 85 atm / 2
Tranfer pump
S-1301 B CPI separator 1 Atmospheric HOLD atm 50-65/85 -
CONCEPTUAL & FEED

Capacity / Suction/
Pressure
(barg) (°C)
(DxL)
CPI Recovered Oil 2
P-1304 C/D Centrifugal pumps 3 m3/h - 50-65/85 atm / 3
Pump (1+1)
P-1319 A/B DGF Inlet Pumps 2 (1+1) Centrifugal Pumps 200 m3/h - 50 - 65 / 85 atm / 2
Dissolved Gas
V-1313 1 Horizontal Vessel 2,3 m X 9 m atm / 3,5 50 - 65 / 85 -
Flottation
F -1302 Floculation Tube 1 - 200 m3/h 50 - 65 / 85 -
DGF recirculation
P-1315 A/B 2(1+1) Centrifugal Pumps 40 m3/h - 50 - 65 / 85 atm / 1,5
Pump
DGF Recovered Oil
P-1316 A/B 2(1+1) Centrifugal Pump 3 m3/h - 50 - 65 / 85 atm / 3
pump
FEED
6.0 CORROSION ASSESSMENT METHOD

6.1 CORROSION TENDENCIES
For process equipments and interconnection piping we select to the most common corrosion
prediction method based on the work of DeWaard and Milliams.
The determination of potential corrosion is based upon process data for temperature, pressure,
molar percentage of CO2, flowrates, presence of produced and/or condensing waters, presence
of hydrate suppressant and related chemicals. The methodology of deriving a final potential
corrosion, using the base corrosion and its modification, is discussed in the following sections. .
6.1.1 BASIC CORROSION RATE
The internal corrosion rates due to the presence of CO 2 on carbon steel can be assessed by the
method of DeWaard and Milliams, using the modified formulae recommended in their 1991 paper
(Ref.1). In this paper the corrosion rate V, in mm/year, is given by:
1710
log(VCO 2 )  5.8   0.67 x log( Pco2 ) (1)
t  273,15
Where t= temperature in °C and P CO2 is partial pressure of CO 2 (in bara), which is the product of
the mole fraction of CO2 in the gas phase and the operating pressure (absolute) of the system.
The following points should be considered:
 In multiphase systems where the CO 2 content may be expressed as a fraction of total fluids,
or of the water phase, this content must be converted into an equivalent, gas phase CO 2
partial pressure.
 Equation (1) assumes the presence of condensing (i.e. pure) water. Where produced or other
waters are present, account must be taken of the mineral content and its effect on pH.
 Liquid water must be present for corrosion to take place. Thus corrosion will only take place
below the water dew point of the system and, in mutiphase systems, where the water can wet
the surfaces.
At higher pressures the non-ideality of natural gas will have a significant effect. The fugacity of
the CO2 rather than the partial pressure should be used in the above equation (1), which is given
by fCO2 =ax PCO2, where “a” is the activity coefficient. DeWaard gives an approximate correction
factor, F(system) for V, given by the equation:
1.41
log F ( system)  0.67(0.0031  )P (2)
T
As the effect of higher pressure is not greatly altered by other factors, the basic corrosion rate for
any system is that rate corrected for fugacity, i.e.
Basic corrosion rate (mm/year) = F(system) x V (3)
This basic corrosion rate, together with V and F (system), can then be reported for each system
under consideration. This may be modified by other factors, as described in the following
sections.
FEED
6.1.2 HIGH TEMPERATURE PROTECTIVE FILMS

Equation (1) predicts that the corrosion rate due to CO 2 will increase indefinitely with increasing
temperature. At higher temperatures and CO 2 partial pressures, however, the iron carbonate
corrosion products become harder and less prone to damage and removal, producing a
protective film. For a given CO 2 partial pressure, therefore, a temperature is reached at which the
corrosion rate will reach a maximum, and will actually decline at higher temperatures. DeWaard
(Ref. 1 and 2) names this temperature the scaling temperature, given by the equation:
2400
T ( scale)  (4)
(6.7  0.6( fCO2 ))
Where T(scale) is in K and f(CO 2) may be estimated by back calculating from F(system), equation
2, although substituting PCO2 gives sufficient accuracy
In the above references DeWaard gives a factor which decreases the corrosion rate with
increasing temperature. However, this is not fully proven and thus it is prudent to assume that the
corrosion rate will increase, as calculated by equations 1-3, up to the rate corresponding to
T(scale) and then remain constant at that value at higher temperatures. Caution needs to be
exercised in applying this correction, as low pH, high flow velocities, turbulence and the presence
of sand can lead to damage to the films and localised pitting.
For this development the temperature is above T(scale) (56°C), an adherent scales will form.
6.1.3 ADJUSTMENT FOR PH
DeWaard (Ref 1 and 2) discusses the adjustment of the corrosion rates for the actual pH of the
water in the system. For systems containing produced (formation) water, however, the effect of
the mineral content on the actual pH may be taken into account by the following method:
The initial pH (pH (measured)) may be taken from direct measurement of the produced waters or
may be calculated using the method given by Rogers et al.:
pH(measured)=log(Alk/PCO2)+8.68+(4.05x10 -3xT)+(4.58x10-7xT2)-(3.07x10 -5xP)-
(0.477xIS0.5)+0.193xIS (5).
Where: T = Operating Temperature (Degrees F for Equation 5)
P = Operating Pressure (P.S.I. for Equation 5)
Alk = conc HCO3 (ppm)/61,000
IS = Total Dissolved Solids (ppm)/58,500
(The above formula does not take into account acetate (acetic acid), which may be present in
some formation waters and may reduce the pH)
Where actual, measured, pH values are used it must be ascertained that these are proper
measurements of the pH at pressure and not readings taken after sampling at atmospheric
pressure which will give a false picture.
The pH for pure water may be calculated according to DeWaard (Ref.2)
pH(calc) = 3.71 - 0.5log(PCO2) + 0.0042t (6)
FEED
Where t = temperature in degrees C
A modifying factor, F, may then be calculated (Ref1):
Log F(pH) = -0.13(pH(measured) - pH(calc))1.6 (7)

Where pH(measured) > pH(calc),
The corrected corrosion rate is then= F(pH) x Basic Corrosion Rate
For this development adjustment in pH is not considered.
6.1.4 CORROSION UNDER DEWING (CONDENSING) CONDITIONS
Where water is condensing slowly on steel surfaces, the volume of water in contact with the
steel is often so low that it rapidly saturates with corrosion product and increases in pH.
Corrosion rates under these conditions are therefore less than where larger volumes of water
are present.
DeWaard (Ref.1) proposes a modifying factor F(cond) when the condensation rate <2.5g/m 2.s,
defined as:
F(cond) = 0.4 x (condensation rate g/m 2.s) (8)
2
For condensation rates > 2.5 g/m .s, F(cond) = 1
The corrected corrosion rate is then = F(cond) x Basic Corrosion Rate.
The condensation rate is often far below 2.5 g/m 2.s and an F(cond) value of 0.1 could be
considered applicable for many systems.
The following points should be noted in the application of F(cond):
 It does not apply to bulk volumes of water, even where they have been produced by
condensation (e.g. along the bottom of a pipeline under stratified flow).
 Condensation rates at “cold spots” can be higher than 2.5 g/m2.s and the corrosion rates
in these areas can even be higher than the base corrosion rate due to the constant supply
of pure water.
 At higher temperatures protective films will be formed and, under these conditions, the
corrosion rate would be the lower of that indicated.
It should be noted that, if the condensation rate is extremely low, corrosion, even at the bottom
of the pipe, may be considerably lower than the basic corrosion rate, due to their being
insufficient water to ensure continuous wetting of the pipe surface.
For this development this phenomenon may occur in upset conditions.
6.1.5 EFFECT OF GLYCOL AND METHANOL
Glycol, injected into wet gas systems to control hydrate, has two effects upon CO 2 corrosion:
(1) It reduces the corrosivity of the water phase it mixes with.
(2) It absorbs water from the gas phase.
A reduction factor F(glyc) has been defined as (Ref.2):
F(glyc) = 1.6 (log (W%) -2) (9)
FEED
Where W%= the weight percentage of water in glycol.

A more conservative approach is to put:
F(glyc) = W%/100. (10)
Glycol will prevent free water condensing (particularly at lower values of W%) and hence
F(glyc) will be applicable to all parts of the system.
The corrected corrosion rate will be, as before, = F(glyc) x Base corrosion rate.
Once Inhibitor corrosion injected in the system, a correction factor F(glyc) = 0.1 will be used.
Methanol will absorb water and reduce the base corrosion rate. This may be taken into
account in assessing total corrosion but the scatter is too large to define F(methanol). It could
however, be taken into account as a non-empirical “comfort factor” in assessing corrosion
inhibitor efficiency.
6.1.6 EFFECT OF LIQUID FLOW VELOCITY
Work has been published (Ref.4) on the effect of liquid velocity on the mass transfer of
corrosive species across the pipe wall concentration boundary and hence on the corrosion
rate. The estimated corrosion rate V(cor) is given by:
1/V(cor) = (1/Vr) + (1/Vm) (11)
Where Vr is the highest possible reaction rate (i.e. where the mass transfer rate is infinitely
fast) and Vm is the rate corresponding to the highest mass transfer rate of the corrosive
species (as given in Ref.4)
The assessment of this effect depends on the accurate description of the fluid flow conditions.
6.1.7 W ATER IN OIL
Where oil or condensate contains small amounts of water, corrosion is prevented provided the
water is held in emulsion, i.e. away from the pipe surfaces. Whether or not this happens
depends on the following factors:
 Water content.
 Viscosity of Oil/Condensate.
 Flow effects (e.g. centrifugal separation of water at the outside of bends).
The water content, flow conditions and oil/condensate viscosity at which water drop out will
occur is a subject of some discussion and the risks of drop out should be carefully assessed.
It is prudent to assume that, for condensate, drop out will occur at very low water contents (1-
2%). For heavier oils higher water contents can probably be tolerated, but the figure of 30%,
quoted in some guides is considered non-conservative.
6.2 CORROSION TENDENCIES IN WATER
6.2.1 INTRODUCTION
This study is relevant to systems where only Produced water is present.
Corrosion indices are important in monitoring water supply distribution and management. This
may be assessed by analyzing the water tendency to scaling.
In order to study the water scaling potential, it is indispensable to study the water saturation
and stability indices:
 Langelier Saturation Index (LSI)
FEED
 Ryznar Stability Index

Here below, we will define and use the Langelier Index and Ryznar Stability Index
6.2.2 LANGELIER SATURATION INDEX (LSI)
The Langelier Saturation Index (LI), a measure of a solution’s ability to dissolve or deposit calcium
carbonate, is often used as an indicator of the corrosivity of water. The index is not related directly
to corrosion, but is related to the deposition of a calcium carbonate film or scale; this film can
insulate pipe internals and other components of a system from contact with water. When no
protective scale is formed, water is considered to be aggressive and corrosion can occur. Highly
corrosive water can cause system failures because of dissolved lead and other heavy metals. An
excess of scale can also damage water systems, necessitating repair or replacement.
The pH at which the water containing bicarbonate and calcium is just saturated with calcium
carbonate (CaCO3) is known as the pH of saturation, or pHs. The Langelier saturation index (SI) is
defined as the actual pH minus pHs.
LSI is defined as:
LSI = pH - pHs
Where:
pH is the measured water pH
pHs is the pH at saturation in calcite or calcium carbonate.

The Langelier Saturation index (LSI) is an equilibrium model derived from the theoretical concept
of saturation and provides an indicator of the degree of saturation of water with respect to calcium
carbonate. It can be shown that the Langelier saturation index (LSI) approximates the base 10
logarithm of the calcite saturation level. The Langelier saturation level approaches the concept of
saturation using pH as a main variable. The LSI can be interpreted as the pH change required
bringing water to equilibrium.
  
 K a *  Ca 2 * Ca 2 *  HCO  HCO3  
LSI  pH  log 3 
  H  * K sp 
 
  
 K a *  Ca 2 * Ca 2 *  HCO  HCO3 
pH s   log 3 
  H  * K sp 
 
As the equilibriums describing the dissociation of carbonic acid are given below:
H 2CO3  HCO3  H 
HCO3  CO32  H 
It is concluded that :
FEED
 
 H  * H  *  CO 2 * CO32  
Ka 
 
3
 HCO * HCO3
3
 
K sp   Ca 2 * Ca 2 *  CO2 * CO32
3
 
Where:
Ka = Equilibrium Constant
K sp = Solubility Constant
H  = Activity Coefficients of the Hydrogen-Ion
 CO 2
3
= Activity Coefficient Carbonate
 HCO 
3
= Activity Coefficient Bicarbonate
H  
= Concentration of Hydrogen Ions
CO  = Concentration of Carbonate
2
3
 HCO  
= Concentration of Bicarbonate.
3
The indications for the LSI are based on the following values:
1. For LSI > 0, water is super saturated and tends to precipitate a scale layer of CaCO 3.
2. For LSI = 0, water is saturated (in equilibrium) with CaCO 3. A scale layer of CaCO 3 is
neither precipitated nor dissolved.
3. For LSI < 0, water is under saturated and tends to dissolve solid CaCO 3.
The following table summarizes the LSI indications according to Carrier (1965).
Table 5 : Interpretation of the Langelier Saturation Index (LSI)
LSI Index Value Indication

2.0 Scale forming but non corrosive
Slightly scale forming and
0.5
corrosive
Balanced but pitting corrosion
0.0
possible
Slightly corrosive but non-scale
-0.5
forming
-2.0 Serious corrosion
6.2.3 RYZNAR STABILITY INDEX

Ryznar stability index (RSI) attempts to correlate an empirical database of scale thickness
observed in municipal water systems to the water chemistry. Like the LSI, the RSI has its basis in
the concept of saturation level.
Ryznar attempted to quantify the relationship between calcium carbonate saturation state and
scale formation.
The Ryznar index takes the form:
FEED
RSI = 2 * (pHs) – pH
Where
pH = measured pH
pHs = the pH at saturation in calcite or calcium carbonate
The empirical correlation of the Ryznar stability index can be summarized as follows:
   
 K a *  Ca2 * Ca 2 *  HCO HCO3 
RSI  2 * log 3   pH
  H  * K sp 
 
  
 K a *  Ca 2 * Ca 2 *  HCO HCO3 
pH s   log 3 
  H  * K sp 
 
The following table summarizes the RSI indications according to Ryznar 1942.
1. For 6.5 < RSI < 7 water is considered to be approximately at saturation equilibrium with
calcium carbonate
2. For RSI > 8 water is under saturated and, therefore, would tend to dissolve any existing
solid CaCO3
3. For RSI <6.5 water tends to be scale forming
Table 6: Interpretation of RI based on Ryznar (1942)

RI Index Value Indication (Ryznar 1942)
RI<5,5 Heavy scale will form
5,5 < RI < 6,2 Scale will form
6,2 < RI < 6,8 No difficulties
6,8 < RI < 8,5 Water is aggressive
RI > 8,5 Water is very aggressive
FEED
The following table summarizes the RSI indications according to Carrier (1965).
Table 7 : Interpretation of RI based on improved Ryznar index by Carrier (1965)
RI Index Value Indication (Carrier 1965)
4.0 - 5.0 Heavy scale
5.0 - 6.0 Light scale
6.0 - 7.0 Little scale or corrosion
7.0 - 7.5 Corrosion significant
7.5 - 9.0 Heavy corrosion
> 9.0 Corrosion intolerable
6.2.4 W ATER CORROSION CHARACTERIZATION
According to the water analysis, see paragraph 5.4, the calculation results of the Langelier
saturation and Ryznar stability indices are as follows:
Table 8: Calculation results of the Langelier saturaton and Ryznar stability
Langelier Indication based on Langelier Water is undersaturated with respect to
saturation (1936) calcium carbonate.
Index
Undersaturated water has a tendency to
LSI = -0.67 remove existing calcium carbonate protective
coatings in pipelines and equipment.
Indication based on improved Serious corrosion.
Langelier by Carrier (1965)
Ryznar Indication based on Ryznar (1942) Water is aggressive
stability
Index Indication based on improved
Heavy corrosion
Ryznar index by Carrier (1965)
RI = 8.4
6.2.5 CONCLUSION
As the actual pH of the water is below the calculated saturation (pHs= 7.7), the LSI is negative
and the water has a very limited scaling potential.
It is also worth noting that the LSI is temperature sensitive. The LSI becomes more positive as the
water temperature increases. This increase in temperature can cause scaling. Conversely,
systems that reduce water temperature will have less scaling. In our case temperature variation is
significant and this issue can be considered. (T > T (scale))
The RI value indicates that the water is aggressive and has a heavy tendency to corrosion.
FACILITIES UPGRADING & DEBOTTLENECKING CONCEPTUAL & FEED
7.0 MATERIAL SELECTION

7.1 PROCESS EQUIPMENTS MATERIAL SELECTION SUMMARY
Table 9 : Equipments corrosion rate
Corrosion Phase Corrosion rate
Top Pop CO2 V PCO2 corrosion Corrosion
No. Name Phase log V log F(p) F(p) F(cond) rate: V * Material
bara T(scale) All.
°C barg mol % mm/year f(CO2) F(p) * cloride mm/1year mm/ 25 year
°C
F(cond)
V-1307 B 1st train Test separator 90 3,5 0,09% M -0,511 0,308 -0,002 0,995 0,004 1 55,767 0,33 0,101 0 0,101 2,530 SA-516 3,2
1st train Production Heater shell
90 3 0,05% M -0,716 0,192 -0,002 0,995 0,002 1 55,767 0,33 0,063 0 0,063 1,578 SA-516 3,2 (5)
E-1301 B side
1st train Production Heater tube
90 3 0,05% M -0,716 0,192 -0,002 0,995 0,002 1 55,767 0,33 0,063 0 0,063 1,578 SA-516 3,2 (5)
E-1301 B side
2nd train Production Heater shell
E-1301 C 90 3 0,05% M -0,716 0,192 -0,002 0,995 0,002 1 55,767 0,33 0,063 0 0,063 1,578 SA-516 3,2 (5)
side
2nd train Production Heater tube
E-1301 C 90 3 0,05% M -0,716 0,192 -0,002 0,995 0,002 1 55,767 0,33 0,063 0 0,063 1,578 SA-516 3,2 (5)
side
V-1301 B 2nd train Three Phase Separator 90 3,5 0,09% M -0,511 0,308 -0,002 0,995 0,004 1 55,767 0,33 0,101 0 0,101 2,530 SA-516 3,2
2nd train Electrostatic Heater
90 2 0,05% M -0,800 0,159 -0,002 0,996 0,002 1 55,767 0,33 0,052 0 0,052 1,304 SA-516 3,2 (5)
EHT-1301 C Treater
V-1303 B Fuel Gas Scrubber 75 3 0,84% G -0,098 0,798 -0,003 0,994 0,034 1 55,768 0,1 0,079 0 0,079 1,983 SA-516 3,2
T-1301 B Crude Oil Storage Tank 75 0 0,05% M -1,320 0,048 -0,001 0,999 0,001 1 55,767 0,33 0,016 0 0,016 0,395 A36 1.6 (1)
V-1305 Degassing boot 75 0 0,05% M -1,320 0,048 -0,001 0,999 0,001 1 55,767 0,33 0,016 0 0,016 0,395 SA-516 3,2
P-1501 C/D Electrical Export Pump 75 0 0,05% M -1,320 0,048 -0,001 0,999 0,001 1 55,767 0,33 0,016 0 0,016 0,395 S1 3
P-1502 B Diesel Export Pump 75 0 0,05% M -1,320 0,048 -0,001 0,999 0,001 1 55,767 0,33 0,016 0 0,016 0,395 S1 3
T-1302 B Off spec Tank 75 0 0,05% M -1,320 0,048 -0,001 0,999 0,001 1 55,767 0,33 0,016 0 0,016 0,395 A36 1.6 (1)
P-1302 C Off spec Pumps 75 0 0,05% M -1,320 0,048 -0,001 0,999 0,001 1 55,767 0,33 0,016 0 0,016 0,395 CS 3
B-1401 Basket Filter 75 0 0,09% M -1,149 0,071 -0,001 0,999 0,001 1 55,767 0,33 0,023 0 0,023 0,585 SA-516 3,2
P-1310 Offloading Pumps 75 3 0,09% M -0,748 0,179 -0,003 0,994 0,004 1 55,767 0,33 0,059 0 0,059 1,465 CS 3
C - 1601 Desander 75 3 0,09% M -0,748 0,179 -0,003 0,994 0,004 1 55,767 0,33 0,059 0 0,059 1,465 SA-516 3,2
B-1402 Basket Filter 50 0 0,09% M -1,529 0,030 -0,001 0,998 0,001 1 55,767 0,33 0,010 0 0,010 0,244 SA-516 3,2
P-1311 Diesel supply Pump 50 0 0,09% M -1,529 0,030 -0,001 0,998 0,001 1 55,767 0,33 0,010 0 0,010 0,244 CS 3
V-1314 Diesel supply vessel 50 0 0,05% M -1,700 0,020 -0,001 0,998 0,001 1 55,767 0,33 0,007 0 0,007 0,164 SA-516 3,2
P-1320 Diesel transfer Pump 50 0 0,05% M -1,700 0,020 -0,001 0,998 0,001 1 55,767 0,33 0,007 0 0,007 0,164 CS 3
V-1310 Knock Out Drum 65 0 0,84% M -0,644 0,227 -0,001 0,998 0,009 1 55,768 0,1 0,023 0 0,023 0,567 SA-516 3,2 (5)
T-1308 A/B Produced Water Tank 65 0 0,05% M -1,465 0,034 -0,001 0,998 0,001 1 55,767 1 0,034 0 0,034 0,856 A36 3 (1) (2) (3)
Recovered Oil
65 0 0,05% M -1,465 0,034 -0,001 0,998 0,001 1 55,767 0,33 0,011 0 0,011 0,282 S6 3
P-1313 A/B Pump
P-1314 A/B Produced Water Tranfer pump 65 0 0,05% M -1,465 0,034 -0,001 0,998 0,001 1 55,767 1 0,034 0 0,034 0,856 D-1 or D-2 0 (3)
S-1301 B CPI separator 65 0 0,05% M -1,465 0,034 -0,001 0,998 0,001 1 55,767 1 0,034 0 0,034 0,856 A36 3 (5)
P-1304 C/D CPI Recovered Oil Pump 65 3 0,05% M -1,064 0,086 -0,003 0,993 0,002 1 55,767 0,33 0,028 0 0,028 0,707 S6 3
P-1319 A/B DGF Inlet Pumps 65 2 0,05% M -1,148 0,071 -0,002 0,995 0,002 1 55,767 1 0,071 0 0,071 1,770 D-1 or D-2 0 (3)
V-1313 Dissolved Gas Flottation 65 0 0,05% M -1,465 0,034 -0,001 0,998 0,001 1 55,767 1 0,034 0 0,034 0,856 Duplex / SS316 L 0 (3) (4)
F -1302 Floculation Tube 65 0 0,05% M -1,465 0,034 -0,001 0,998 0,001 1 55,767 1 0,034 0 0,034 0,856 Duplex / SS316 L 0 (3)
P-1315 A/B DGF recirculation Pump 65 0 0,05% M -1,465 0,034 -0,001 0,998 0,001 1 55,767 1 0,034 0 0,034 0,856 D-1 or D-2 0 (3)
P-1316 A/B DGF Recovered Oil pump 65 0 0,05% M -1,465 0,034 -0,001 0,998 0,001 1 55,767 0,33 0,011 0 0,011 0,282 S6 3
Note : 1- Tank shell and bottom To be internally coated.

2- Tank material could be FBE with 1.6 mm CA
3- The CA adjustment was done further to water corrosion study
4- Material to be Duplex / SS316 L or CS with 3 mm CA and internal coating
5- With internal protective coating
7.2 PROCESS PIPING MATERIAL SELECTION SUMMARY

The table 11 given below resumes the results of calculation of the corrosion rate of the piping of the EPF station. The suitable materials are given in the same table.
Table 10 : Piping corrosion rate
No. Stream Corrosion Phase Corrosion rate
Top Pop CO2 Pco2 Phase log V V log F(p) F(p) F(cond) corrosion Material Corrosion
rate: V *
°C barg mol % bara mm/year F(p) * cloride mm/year mm/ 25 year All.
F(cond)
V-1301 B Inlet Three Phase Separator V-1301 B 90 3,5 0,09% 0,004 M -0,511 0,308 -0,002 0,995 0,330 0,101 0,000 0,101 2,530 A 106 GrB 3,2
V-1301 B Outlet Three Phase Separator gas V-1301B 75 3 0,84% 0,034 G -0,098 0,798 -0,003 0,994 0,100 0,079 0,000 0,079 1,983 A 106 GrB 3,2
V-1301 B Outlet Three Phase Separator water V-1301B 90 3 0,05% 0,002 W -0,716 0,192 -0,002 0,995 1,000 0,191 0,000 0,191 4,783 A 106 GrB 6 (1)
V-1301 B Outlet Three Phase Separator oil V-1301B 90 3 0,05% 0,002 M -0,716 0,192 -0,002 0,995 0,330 0,063 0,000 0,063 1,578 A 106 GrB 3,2
Outlet of Production Heater E-1301 C Oil to Electrostatic Heater
E-1301 B 90 3 0,05% 0,002 M -0,716 0,192 -0,002 0,995 0,330 0,063 0,000 0,063 1,578 A 106 GrB 3,2
Treater EHT-1301 C (tube side)
E-1301 B Outlet of Production Heater E-1301 B Oil (shell side) 90 3 0,05% 0,002 M -0,716 0,192 -0,002 0,995 0,330 0,063 0,000 0,063 1,578 A 106 GrB 3,2
Outlet of Electrostatic Heater Treater EHT-1301 C Oil to
EHT-1301 C 90 2 0,05% 0,002 M -0,800 0,159 -0,002 0,996 0,330 0,052 0,000 0,052 1,304 A 106 GrB 3,2
Production Heater E-1301 B
Outlet of Electrostatic Heater Treater EHT-1301 C gas to Flare
EHT-1301 C 90 2 0,76% 0,023 G -0,008 0,982 -0,002 0,996 0,100 0,098 0,000 0,098 2,447 A 106 GrB 3,2
Header.
EHT-1301 C Outlet of Electrostatic Heater Treater EHT-1301 C Water 90 2 0,05% 0,002 W -0,800 0,159 -0,002 0,996 1,000 0,158 0,000 0,158 3,952 A 106 GrB 6 (1)
Outlet of FG Scrubber V-1303 B Gas to New Flare Stack F-1301
V-1303 B 75 3 0,84% 0,034 G -0,098 0,798 -0,003 0,994 0,100 0,079 0,000 0,079 1,983 A 106 GrB 3,2
B
V-1305A Intlet and outlet oil degassing boot V-1305A 75 0 0,05% 0,001 M -1,320 0,048 -0,001 0,999 0,330 0,016 0,000 0,016 0,395 A 106 GrB 3,2
T-1301 B Outlet of New Oil storage Tank T-1301 B to Export pumps. 75 0 0,05% 0,001 M -1,320 0,048 -0,001 0,999 0,100 0,005 0,000 0,005 0,120 A 106 GrB 3,2
P-1501 A/B P-
1502 A P-1502 Outlet Export pumps to Petroenergy CPF 75 23 0,05% 0,012 M -0,398 0,400 -0,015 0,965 0,100 0,039 0,000 0,039 0,964 A 106 GrB 3,2
C/D P-1502 B
T-1302 B Inlet of New Oil Off Spec Tank T-1302 B 65 3 0,05% 0,002 M -1,064 0,086 -0,003 0,993 0,330 0,028 0,000 0,028 0,707 A 106 GrB 3,2
T-1302 B Outlet of New Oil Off Spec Tank T-1302 B to Off Spec pumps. 75 0 0,05% 0,001 M -1,320 0,048 -0,001 0,999 0,100 0,005 0,000 0,005 0,120 A 106 GrB 3,2
P-1302 C Outlet Off spec Pumps P-1302 C P-1302 A/B to Inlet Production
75 9 0,05% 0,005 M -0,653 0,222 -0,006 0,985 0,100 0,022 0,000 0,022 0,548 A 106 GrB 3,2
P-1302 A/B line
F-1301C Inlet of Cold vent F-1301C 75 0 0,05% 0,001 M -1,320 0,048 -0,001 0,999 0,100 0,005 0,000 0,005 0,120 A 106 GrB 3,2
B-1401
Inlet and Outlet Basket Filters 75 0 0,09% 0,001 M -1,149 0,071 -0,001 0,999 0,330 0,023 0,000 0,023 0,585 A 106 GrB 3,2
B-1402
Outlet Offloading Pump P-1310 to Dessander C-1601 /
P-1310 75 3 0,09% 0,004 M -0,748 0,179 -0,003 0,994 0,330 0,059 0,000 0,059 1,465 A 106 GrB 3,2
Production Manifold
Outlet Hydrocyclone C-1601 to inlet Crude Oil Off loading Tank
C-1601 75 3 0,09% 0,004 M -0,748 0,179 -0,003 0,994 0,330 0,059 0,000 0,059 1,465 A 106 GrB 3,2
T-1302
No. Stream Corrosion Phase Corrosion rate

Top Pop CO2 Pco2 Phase log V V log F(p) F(p) F(cond) corrosion Material Corrosion
rate: V *
°C barg mol % bara mm/year F(p) * cloride mm/year mm/ 25 year All.
F(cond)
T-1302 Outlet Crude Oil Offloading Tank T-1302 to Pump P-1310 75 0 0,09% 0,001 M -1,149 0,071 -0,001 0,999 0,100 0,007 0,000 0,007 0,177 A 106 GrB 3,2
Outlet Diesel Supply Pump P-1311 to Diesel Supply Vessel V-
P-1311 50 3 0,09% 0,004 M -1,128 0,074 -0,003 0,992 0,330 0,024 0,000 0,024 0,610 A 106 GrB 3,2
1314
P-1320 Inlet and Outlet Diesel Supply Pump P-1320 50 3 0,05% 0,002 M -1,299 0,050 -0,003 0,992 0,330 0,016 0,000 0,016 0,411 A 106 GrB 3,2
V-1310 Outlet Knock Out Drum V-1310 Gas to Flare Stack F-1301 65 0 0,76% 0,008 G -0,673 0,212 -0,001 0,998 0,100 0,021 0,000 0,021 0,530 A 106 GrB 3,2
Outlet Knock Out Drum V-1310 condensate to Close drain V-
V-1310 65 0 0,76% 0,008 M -0,673 0,212 -0,001 0,998 0,100 0,021 0,000 0,021 0,530 A 106 GrB 3,2
1302
T-1308 A/B inlet Produced Water Tank T-1308 A/B 65 0 0,05% 0,001 M -1,465 0,034 -0,001 0,998 1,000 0,034 0,000 0,034 0,856 A 106 GrB 6 (1)
Outlet Produced Water Tank T-1308 A/B to Inlet Produced Water
T-1308 A/B 65 0 0,05% 0,001 M -1,465 0,034 -0,001 0,998 1,000 0,034 0,000 0,034 0,856 A 106 GrB 6 (1)
Transfer Pumps P-1314 A/B
Outlet Produced Water Tank T-1308 A/B to Inlet Recovery Oil
T-1308 A/B 65 0 0,05% 0,001 M -1,465 0,034 -0,001 0,998 0,330 0,011 0,000 0,011 0,282 A 106 GrB 3,2
Pumps P-1313 A/B
S-1301 Inlet CPI Separator 65 2 0,05% 0,002 M -1,148 0,071 -0,002 0,995 1,000 0,071 0,000 0,071 1,770 A 106 GrB 6 (1)
S-1301 Outlet CPI Separator - PW to P-1319 A/B 65 0 0,05% 0,001 M -1,465 0,034 -0,001 0,998 1,000 0,034 0,000 0,034 0,856 A 106 GrB 6 (1)
S-1301 Outlet CPI Separator - Recovered oil 65 0 0,05% 0,001 M -1,465 0,034 -0,001 0,998 0,330 0,011 0,000 0,011 0,282 A 106 GrB 3,2
V-1313 Inlet V-1313 New DGF 65 2 0,05% 0,002 M -1,148 0,071 -0,002 0,995 1,000 0,071 0,000 0,071 1,770 A 106 GrB 6 (1)
Phases:
G Gas phase
M mixed phase
oil oil wetted
W Water
Note: 1- The CA adjustment was done further to water corrosion study

FEED
8.0 CONCLUSIONS AND RECOMMENDATIONS

Carbon steel is suitable for the piping and process equipments with the exception of some
sensitive equipment which are handling aggressive water.
Carbon steel is suitable for Gas piping with 6 mm for water service and 3.2 mm for remaining
services.
Almost the most of equipments should be CS material with 3 / 3.2 mm CA except some ones
which are handling PW which should be internally coated.

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FACILITIES UPGRADING &

DEBOTTLENECKING CONCEPTUAL &

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 1 OF 32

STAROIL OPERATING COMPANY LIMITED

FACILITIES UPGRADING & DEBOTTLENECKING

CORROSION & MATERIAL SELECTION REPORT

CONTRACT NO.: STAROIL/100/2014

CS-EPPM/JV PROJECT NO.: AR 17/14-WO1

0 Final issue 04/08/15 AMG MGD AZ

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 2 OF 32

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 3 OF 32

6.1.1 BASIC CORROSION RATE .....................................................................................................20

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 4 OF 32

1.1 PROJECT DESCRIPTION

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 5 OF 32

1.2 DOCUMENT SCOPE

2.0 REFERENCES DOCUMENTS

2.1 PROJECT DOCUMENTS

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 6 OF 32

2.3 REFERENCE PUBLICATIONS

3.0 DEFINITION & ABBREVIATION LIST

PROJECT : Facilities Upgrading and debottlenecking conceptual & FEED

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 7 OF 32

procurement, installation and testing of the system(s) as

CPF : Central processing facility

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 8 OF 32

4.0 GENERAL PRINCIPLES FOR MATERIAL SELECTION AND INTERNAL CORROSION

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 9 OF 32

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 10 OF 32

This is shown by the following chemical reactions:

4.4.2 CHLORINATION EFFECT

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 11 OF 32

4.4.3 PITTING CORROSION

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 12 OF 32

4.4.5 FLOW ENHANCED CORROSION

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 13 OF 32

4.4.8 EXTERNAL CORROSION

Table 1: CO2 and H2S Content [% mole]

Table 2: Properties of Crude Fluid

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 14 OF 32

Bentiu Abugabra Abugabra

No H2S is reported in the reservoir fluids.

Average Daily Average Daily

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 15 OF 32

Cations Sodium 1611 mg/l Anions Chloride 2836 mg/l

Total Dissolved Solids (mg/litre) (Calculated) (TDS) 5742

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 16 OF 32

5.5 NEW EQUIPMENT DATA

2end train Electrostatic Heater

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 17 OF 32

Design Operating Operating /

E-1303 Electrical Heater 1 Immersed Heater HOLD HOLD 60-120 -

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 18 OF 32

Design Operating Operating /

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 19 OF 32

Design Operating Operating /

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 20 OF 32

6.0 CORROSION ASSESSMENT METHOD

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 21 OF 32

6.1.2 HIGH TEMPERATURE PROTECTIVE FILMS

DOC NO. SA-RPT-MEC-1501-3005 Rev. 0 DATE: 04/08/15 PAGE 22 OF 32

Where t = temperature in degrees C

A modifying factor, F, may then be calculated (Ref1):