Escolar Documentos
Profissional Documentos
Cultura Documentos
2009-0013
The Canadian Association of Petroleum Producers (CAPP) represents 130
companies that explore for, develop and produce more than 90 per cent of
Canada’s natural gas and crude oil. CAPP also has 150 associate member
companies that provide a wide range of services that support the upstream oil and
natural gas industry. Together, these members and associate members are an
important part of a $120-billion-a-year national industry that affects the
livelihoods of more than half a million Canadians.
Disclaimer
Figures
Figure 1.1 Total Sour Gas Pipeline Incidents and Sour Gas Pipeline Incidents/1000 km...............1
Figure 1.2 Sour Gas Pipeline Incidents by Cause...............................................................................1
Figure 2.1 An Example of Internal Corrosion in a Sour Gas Pipeline ..............................................3
Tables
Table 2.1 - Contributing Factors – Mechanisms.................................................................................4
Table 2.2 - Contributing Factors – Operating Practices.....................................................................7
Table 3.1 - Recommended Practices – Design and Construction....................................................10
Table 3.2 - Recommended Practices – Operations...........................................................................13
Table 4.1 – Recommended Practices - Corrosion Mitigation..........................................................17
Table 5.1 – Corrosion Monitoring .....................................................................................................20
Table 6.1 – Corrosion Inspection Techniques ..................................................................................23
Tabel 7.1 - Leak Detection Techniques.............................................................................................25
Table 8.1 - Repair and Rehabilitation Techniques ...........................................................................26
i
Overview
This document is intended for use by corrosion specialists involved with the
development and execution of corrosion mitigation programs, engineering teams
involved in the design of gathering systems, and operations personnel involved
with the implementation of corrosion mitigation programs and operation of wells
and pipelines in a safe and efficient manner. It contains a consolidation of key
industry experience and knowledge used to reduce oil effluent pipeline corrosion;
however it is not intended to be a comprehensive overview of all practices.
38 39
15 40
33
30 30 31
28 29 28
25 25 25 30
10 23 23 24
20 19
18
8.6 15 20
7.4 13 13 12
10
5 6.0 10
3.8 4.9 3.8 1.5 1.8 2.0 1.5 1.6 1.3 1.5
3.6 2.5
2.8 2.1 1.7 2.5 2.7 2.5 2.5 3.0 3.0
0 0
1985198619871988198919901991 19921993199419951996199719981999200020012002200320042005200620072008
# SG Incidents / 1000km 8.6 7.4 3.8 4.9 6.0 3.6 2.5 2.8 2.1 1.7 3.8 2.5 2.7 2.5 2.5 3.0 3.0 1.5 1.8 2.0 1.5 1.6 1.3 1.5
To tal SG Incidents 25 23 13 20 28 18 13 15 12 10 25 19 23 25 29 38 44 24 30 39 30 33 28 31
SG Length (1000's km) 2.9 3.1 3.4 4.1 4.7 5.0 5.2 5.4 5.8 6.0 6.6 7.5 8.5 9.9 11.4 12.8 14.5 15.8 16.7 19.3 20.2 21.1 21.7 21.3
Figure 1.1 Total Sour Gas Pipeline Incidents and Sour Gas Pipeline Incidents/1000 km
30
25
20
15
10
0
1985 1990 1995 2000 2005 2010
All Other Causes includes: Earth Movement (2), Girth Weld Failure (3), Mechanical Joint Failure (1),
Miscellaneous (3), Operator Error (3), Overpressure Failure (3), Unknown (1).
Pitting corrosion along the bottom of the pipeline is the primary corrosion
mechanism leading to failures in sour gas pipelines. The common features of this
mechanism are:
• the presence of water containing H2S in combination with any of the
following: CO2, chlorides, elemental sulphur or solids.
• pipelines carrying higher levels of free-water production with no means of
water removal (i.e. no well site separation or dehydration).
• the presence of fluid traps (i.e. low spots) where water and solids can
accumulate due to low gas velocity.
In wet gas gathering systems containing H2S & CO2 the initiation and growth of
pitting corrosion can be influenced by the following variables:
• In sour systems semi-protective iron sulphide(s) scales will form.
• The scales are only protective in the absence of scale disrupters such as
solids, chlorides, methanol, sulphur, high velocities, etc.
• Localized breakdown of iron sulphide(s) scales usually results in
accelerated pitting attack.
2.2 Vapor Phase Corrosion
Vapor phase corrosion is a less common mechanism that has also led to failures.
High rates of methanol injection have been a known contributor to vapor phase
corrosion in sour systems.
Evidence of bacteria has been reported in some sour gas failure investigations
however there is no industry consensus with regard to the overall contribution to
the corrosion mechanism.
• Localized breakdown
of FeS scales results
in accelerated pitting
• Corrosion rates
increase with
increasing CO2 and
H2S partial pressures
and temperatures
Water Holdup • Low gas velocity or • Water acts as the • Install pigging
poor pigging electrolyte for the facilities and
practices allow water corrosion reaction maintain an
to stagnate in the effective pigging
pipelines • Turbulence caused program
by slug flow regime
can accelerate the • Remove water at
corrosion rate the wellsite by
separation or
dehydration
• Control corrosion
through effective
inhibition
• Increased chloride
levels can reduce
inhibitor
effectiveness
• Insufficient gas
velocities or poor
pigging practices
Note:
The inhibitor added to the methanol is designed to form a passive layer to mitigate O2
corrosion. This inhibitor is not intended to act as film forming inhibitor and should not
be expected to protect against other types of corrosion.
The effect of chemistry of residual stimulation fluids such as chlorides should also be
considered. The existing inhibitor program may not be effective for these conditions.
Note:
There are CSA and regulatory restrictions on the use of HDPE, Nylon and composite
materials in sour gas service. The application of these materials is changing with
industry experience and technological improvements.
• Develop shut-in
guidelines for the
timing of required
steps to isolate and
lay up pipelines in
each system
• Technique utilized
depends on access
and ground
conditions
Table 4.1 describes common techniques that should be considered for the
mitigation of internal corrosion in sour gas pipelines.
Large diameter lines may require special design and/or procedures to ensure batch
slug remains intact.
Note:
Table 5.1 describes the most common techniques for monitoring corrosion and
operating conditions associated with internal corrosion in sour gas pipelines.
Gas and Oil • Ongoing monitoring of gas • Acid gas content must be
Analysis composition for H2S and CO2 understood and should be
content. If present, the analysis of periodically re-assessed
liquid hydrocarbon properties
including viscosity is useful
Water Analysis • Ongoing monitoring of water for • Changes in water chemistry will
chlorides, dissolved metals, influence the corrosion potential
suspended solids and chemical
residuals • Trends in dissolved metals (e.g.
Fe, Mn) concentration can
indicate changes in corrosion
activity
• Electrochemical monitoring
should be used in conjunction
with other monitoring and
inspection techniques
Table 6.1 describes common techniques that should be considered for the
detection of internal corrosion in sour gas pipelines.
Note: Due to localized corrosion being the prevalent failure mechanism in Sour
Gas Pipelines, hydrotesting alone may not be adequate to prove pipeline
integrity.
Table 7.1 describes common techniques that should be considered for detection
of pipeline leaks caused by internal corrosion in sour gas pipelines. Proactive
leak detection can be an effective method of finding small leaks and mitigating
the consequences of a major product release or spill.
H2S detection • H2S detection can be portable or • Permanent monitors are used at
permanent tools surface facilities
Table 8.1 describes the common techniques used for repair and rehabilitation of
pipelines damaged by internal sour gas corrosion.
• The steel pipe must provide the • Polymer liners may eliminate the
pressure containment capability need for internal corrosion
mitigation, corrosion monitoring
and inspection
Pipeline • Using internally coated steel • Must be pig and inspection tool
Replacement pipeline systems with an compatible
engineered joining system should
also be considered • Refer to Section 4
“Recommended Practices ” in this
• The alteration or replacement of document for details
the pipeline allows for proper
mitigation and operating practices • Ensure that when replacements in
to be implemented kind occur, the alteration or
replacement of the pipeline allows
for proper mitigation and
operating practices to be
implemented
For more background on corrosion in sour systems the reader should refer to the
following technical societies:
http://www.nacestore.com/NACE/knowledgebase/KnowledgeBaseIndex.asp
http://www.efcweb.org/
http://www.asme.org/catalog/