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RBI Corrosion Calculation Training

RBI Corrosion Calculation Training

T. Illson, S. Abdollah & A. Hilmi 16 th December 2008

Copyright © 2007 Advantica Inc. (USA Only) and Advantica Ltd. (Outside USA). All rights reserved by the respective owner.

 

Overview

Overview
Natural Gas & Glycol Amine Condensate Yes Algorithm 3 See Algorithm 2 See Algorithm 1 See
Natural Gas
&
Glycol
Amine
Condensate
Yes
Algorithm 3
See
Algorithm 2
See
Algorithm 1
See
Dryness factor Final Theoretical Inspection Corrosion Rate Corrosion Rate Calculation FINAL CORROSION RATE (Refer Table 1)
Dryness factor
Final Theoretical
Inspection Corrosion Rate
Corrosion Rate
Calculation
FINAL CORROSION RATE (Refer Table 1)
No Material = Other?
No
Material = Other?
Material = Stainless Steel?
Material = Stainless
Steel?
Yes Material = Carbon Steel? Start Representative Fluid?
Yes
Material = Carbon
Steel?
Start
Representative Fluid?
Yes Amine?
Yes
Amine?

Yes

Yes
 

CONTACT

CORROSION

SPECIALIST

No

No

CORROSION RATE = 0.01 mm/yr
CORROSION RATE =
0.01 mm/yr

Natural Gas & Condensate Corrosion Measurement

Natural Gas & Condensate Corrosion Measurement
If the product temperature is less than T(scale) then no correction to the corrosion rate should
If the product temperature is less than T(scale) then
no correction to the corrosion rate should be made.
log F ( pH ) = 0.13( pH (act ) − pH ( sat ))
log F ( pH ) = 0.32( pH ( sat ) − pH ( act ))
No
Yes
Apply pH
correction
factor
Theoretical Corrosion Rate Calculation
− ⎛ ⎜ 1710 ⎟ ⎞ + 0.671 log(
Natural Gas or
Condensate
Calculate base corrosion rate
(de Waard & Milliam)
Apply scale
factor
Start
If pH(sat) > pH(act),
If pH(sat) < pH(act),
Is water pH
known?
0.6 log fCO
F scale =
T scale
T scale
2400
fCO
6.7 +
2400
⎛ 1 ⎞
V =
log
log
5.8
⎟ − ⎜
) =
⎞ ⎞
⎠ ⎠
2 )
1.6
2 )
T
T
(
)
(
)
1
(
(
Glycol Corrosion Calculation Start • Based on de Waard & Milliams equation Glycol • Glycol correction
Glycol Corrosion Calculation
Start
Based on de Waard & Milliams
equation
Glycol
Glycol correction factor for TEG
(1.2 log
W −
2.4 )
F t =
( )
10
Calculate base corrosion rate
(de Waard & Milliam)
Apply glycol
where
F(t) = reduction factor for TEG
factor
W
= wt% brine in glycol/brine solution
Apply scale
factor
NOTE:
Applicable for glycol above pH6.
Theoretical Corrosion Rate Calculation
Below pH6, detailed calculation required
carried out by subject expert.
 

Glycol Corrosion

Glycol Corrosion
 

Corrosion occurs in glycol units for two reasons:

 

Breakout of acid gas dissolved in the glycol, this leads to conventional CO 2 /H 2 S attack which can be predicted using a modified DeWaard approach

Degradation of the glycol by oxygen contamination or overheating. This forms organic acids which then cause acid attack. This can be detected by monitoring glycol pH.

 

The following slide shows the theoretical prediction for the first mechanism, if acid attack is suspected then specialist advice should be sought and process changes undertaken.

Amine Corrosion Calculation Start Materials - Carbon Steel? No Material = Stainless Steel? No Material =
Amine Corrosion Calculation
Start
Materials - Carbon
Steel?
No
Material = Stainless
Steel?
No
Material = Other?
Yes
Yes
MDEA concentration
Determine corrosion
Determine corrosion
Heat Stable Amine
Salts (HSAS)
Yes
rate using
rate using
Table 3
Table 4
Acid loading gas
CONTACT
Estimated corrosion rate
ADVANTICA
 

Amine Corrosion

Amine Corrosion
 

Carbon steel can corrode in gas treatment amines

 

Amines in themselves are not very corrosive but corrosion rates are increased by:

• Amines in themselves are not very corrosive but corrosion rates are increased by:
 

Contaminants such as heat stable salts, bicines and organic acids

Increases in temperature

Increases in velocity that remove protective films

Increased amine concentration

Acid gas loading

 

Amine Calculation – Table 3

 
Amine Calculation – Table 3
 
 

Corrosion Rate (mm/yr)

 
 

Acid

Temperature (ºC)

 

Gas

Loading

HSAS

< 87.78

87.78 - 98.89

99.44 - 110.00

110.56 - 121.11

Velocity (m/s)

251.67 - 132.22

 

> 132.22

(mol/mol)

(wt %)

6.096

> 6.096

6.096

> 6.096

6.096

> 6.096

6.096

> 6.096

6.096

> 6.096

6.096

> 6.096

 

< 0.1

0.5

0.025

0.076

0.025

0.076

0.076

0.254

0.127

0.381

0.254

0.635

0.381

1.016

 

0.051

0.152

0.051

0.152

0.152

0.508

0.381

1.016

0.508

1.143

0.762

2.032

0.51 - 4.0 > 4.0

0.127

0.254

0.127

0.381

0.381

1.016

0.762

1.524

1.016

2.286

1.524

3.048

 

Velocity (m/s)

 
 

1.524 > 1.5024 1.524 > 1.5024 1.524 > 1.5024 1.524 > 1.5024 1.524 > 1.5024 1.524 > 1.5024

 

0.1 - 0.2

0.5

0.025

0.076

0.051

0.152

0.127

0.381

0.254

0.762

0.381

1.143

0.508

1.524

 

0.051

0.152

0.102

0.305

0.254

0.762

0.508

1.524

0.762

2.286

1.016

2.032

0.51 - 4.0 > 4.0

0.127

0.381

0.203

0.635

0.508

1.524

1.016

2.032

1.524

3.048

3.048

3.809

 

0.21 - 0.3

0.5

0.051

0.152

0.076

0.229

0.178

0.508

0.254

0.762

0.508

1.524

0.635

1.905

 

0.102

0.254

0.152

0.508

0.381

1.016

0.508

1.269

1.016

2.032

1.269

2.539

0.51 - 4.0 > 4.0

0.203

0.635

0.381

1.143

0.762

1.524

1.016

2.032

2.032

3.048

2.539

3.809

 

0.31 - 0.4

0.5

0.051

0.152

0.102

0.254

0.178

0.508

0.381

1.016

0.635

1.778

0.762

2.032

 

0.102

0.254

0.203

0.635

0.381

1.143

0.762

1.524

1.269

2.539

2.539

3.809

0.51 - 4.0 > 4.0

0.203

0.635

0.381

1.016

0.889

1.778

1.524

2.539

2.539

3.556

3.809

4.572

 

0.41 - 0.5

0.5

0.076

0.229

0.127

0.381

0.254

0.762

0.381

1.143

0.889

1.778

1.143

0.254

 

0.152

0.381

0.254

0.762

0.508

1.524

1.143

2.286

1.778

3.302

2.286

3.809

0.51 - 4.0 > 4.0

0.254

0.762

0.508

1.016

1.016

2.032

2.286

3.048

3.048

3.809

3.809

4.572

 

0.51 - 0.6

0.5

0.076

0.229

0.178

0.508

0.254

0.762

0.635

1.905

1.016

2.539

1.269

3.048

 

0.152

0.508

0.381

1.143

0.508

1.524

1.269

2.539

2.032

3.556

2.539

3.809

0.51 - 4.0 > 4.0

0.254

0.762

0.762

1.524

1.143

2.286

2.539

3.809

3.556

4.572

4.063

5.078

 

0.61 - 0.7

0.5

0.102

0.254

0.229

0.762

0.381

1.016

0.762

2.539

1.269

3.048

1.524

3.809

 

0.203

0.381

0.508

1.016

0.762

1.524

1.524

2.539

2.286

3.556

2.539

3.809

0.51 - 4.0 > 4.0

0.381

0.889

1.016

2.032

1.524

2.539

2.539

3.809

3.556

4.572

4.063

5.078

 

> 0.7

0.5

0.127

0.381

0.254

0.762

0.508

1.524

1.016

2.539

1.524

3.048

1.778

3.809

 

0.254

0.762

0.508

1.524

1.016

2.032

1.778

3.048

2.539

3.809

3.048

3.809

0.51 - 4.0 > 4.0

0.508

1.143

1.016

2.032

1.524

2.539

2.539

3.809

3.809

4.572

4.317

5.588

 

Amine – Table 4

 
Amine – Table 4
 
 

Acid Gas Loading

Temperature ºC

(mol/mol)

148.89

<0.1

0.00254

0.1 - 0.2

0.00254

0.21

- 0.3

0.00254

0.31

- 0.4

0.00508

0.41

- 0.5

0.00508

0.51

- 0.6

0.00762

0.61

- 0.7

0.01016

> 0.7

0.01270

 

Estimated Corrosion Rates (mm/yr) for Stainless Steel for all Amines

 

Deadlegs

Deadlegs
 

Corrosion in deadlegs can be different from active pipe

systems Require active monitoring (thickness monitoring locations

– TML) Prime location for corrosion in oil or condensate systems

 

Location

Factor

Condensate system

0.33

Amine system

1.00

Dry hydrocarbon gas systems

0.10

Wet hydrocarbon gas systems

1.33

Glycol service

1.00

 

Stress Corrosion Cracking

Stress Corrosion Cracking
 

Three factors needed for stress corrosion cracking

 
 

Susceptible material

Tensile stress (may be residual)

Corrosive environment

 

Remove any of the factors and cracking will not occur

Three types

 

Active path dissolution where corrosion follows a line of susceptibility typically a grain boundary

Film induced cleavage (amine cracking) where cracks occur in a passive film, corrosion occurs at the crack tip – directed corrosion

Hydrogen embrittlement (SSC) – hydrogen atoms dissolve in the metal reducing its tensile strength and fracture toughness – cracks then initiate at defects

Stress corrosion cracking

Stress corrosion cracking
Stress corrosion cracking
Stress corrosion cracking
 

Wet Hydrogen Cracking

Wet Hydrogen Cracking
 
Natural Gas / Condensate / Amine H 2 S ?
Natural Gas /
Condensate / Amine
H 2 S ?
Material = Yes No NACE? Yes MEDIUM HIGH
Material =
Yes
No
NACE?
Yes
MEDIUM
HIGH

No

LOW

 

Different types – hydrogen blistering, hydrogen induced cracking, stress oriented hydrogen induced cracking, SSC

Based on ISO 15616-2

 
 

Amine Cracking

 
Amine Cracking
 
Carbon Steel / Amine > 60 degC
Carbon Steel / Amine
> 60 degC
 

Cracking of steels under combined tensile stress + aqueous alkanolamine

 

systems

 

Factors include

Yes PWHT?
Yes
PWHT?
 

temperature & PWHT

   

No

Based on API RP 945

   
 

Yes

 
 
 
LOW
LOW
 
HIGH
HIGH