You are on page 1of 42
EFFECT OF VELOCITY ON CORROSION IN KHUFF GAS; BAHRAIN a 20 BS 40 50 __60 ary 7 = 50 Tene no manor _// / ut 907 swat abe mnbeg Fue 4 E pomeie oye it eave a 60 [anes | 5 oj cme | Anat Q f — |niB TE 2 / STRAIGH SECTIONS & 20 ° ° _ From Bpncanff Ine. 10 20 30 40 50 60 VELOCITY, FT./SEC. FIGURE 18a wee aaa *quaduno passeuduy 2uso3%x@ ue 40 vol 28>} de au. fq poujesuyea pus panajuae s| 9post29 [9 ayesins s9déo>-addo> & 0} Basaebau auou 0 3[0h S9°G~ 8 40 [2s vaa0d BEA [os399|8 04 [ey—Ue LOI “Z qugauno pessouduy reusoyxe ve Jo wor ear {doe 243 ‘hq pauyeguyeu pue apru’s, te} uaz0d 83f[04339|9 02. [220 psn2820sdun ao’ oumaeu uy UL 3104 0f°0 48eaL ae JO (134uS) s6uEyD aaraeGou ¥ ua “T :pado|anap u9q anny ey sartu9 ony ‘asodund s1uy 404 uaujadxa fq paujusaaap useq sey [er udyod ayy *[2v0U90 ul “ang *poye |n9[2> 2q ed Leyqueyed s4uy s9se0 naj © UT “Seoue 21poue 9sou ayy 30 [23us200 14n2459 ado as no1oq"padono{. 99 plnous 3 12U3 S1_JaNSUB 21u9pe7" OU, ZPoJONO| ‘De tosauaged au) plnoYe YANN Moy “Uo 01409 00 Feauy "pu seas8~ >: poLe fou aq Lym aaaua.*s1Us0d |e 38 1259S 22 PUeNOL MOLL LAM quos3n9 own €43u—49 yun posano| sj (99a5 40 Le1quayod aun JT “UoyToa704g 3] powseD Jos €1193159 TECCEM TASTES Jo wojso140> [wUsBIUL waned youUes woryaeyosd 31pOueS poy Jey azyubo0es 0} WUeVsOGN, S| AT “434 [rai sssozeut Jo asmeaaq Suda 40 BATE ay2 y304048 04 yauorie oy [e>1y3eudul 05 |e St aT “sdoyaNpuoD.(29}.99]9 'tood aie squewuo.t.ua asauy aenedeq $88. Jo [jo Gulusequea sfassen ul a0 2.3ud “Souye’aya uy 945399459 9q OWNED 4nq “s9}0K Used) puR 7[es ujUseqUOD s9559K ue syueh 98teud At eusaquy ula 31” -s{Umy. 26420 pur dys. pur *sasnonays auoysijo ‘a5uise9. {lat "40u) {9d\@ paiead pu site Uo voLsoue> [eus03x0 [011409 ‘tanj33auge uea ay. svoj 3e4od0 Uojaonpoad u|_"aye[oay39|2 ue UyLM 3923u09 fa apejuns. 393s AUP ALenaajA YoaroLd OF pasn aq ued uOLyD93010 91 pour) aoequ0a go squyod Liv ae autionyze19 ayy wouy pexou ays. su93u9 (Leo! quoAVOD). uadin> 7eUy 05 (aAtjebau°auou apes) KL leo}4a99|9 powawo| sp a9esuns. [esau 943 42u9 51 S4N200 You, "uo}3a4g01d 24 poyse pal eas} 94¢\OsI99|@ 949 ous [Paw 34> Bul s—3Ue Juavan passalduy [eUsayx0 ue Jo asn aia Aq spouie> & 07. [esau a4y JO UOLS sono au Mavttosioa|o aio ofoovies spew st (eee 2 go a0esans Gasndee ‘31102 242.44 Da] jo4veD aq Ue9_uoj $1309 3642 $9) (du TESTE 21 POUTED WLR Tarsus yo aaShapuE SPaAe SEPOUR WaIHUO}SGUGGD go doy yejaoste BML RIOR] TOSI PTT “0 ‘asodund sues 241 0g J992M 395 J9[L0@ 32813 02 peppe UBIJ0 St ‘ujze.phy “va6svo ponlossyp §} uel suo} 3e4qua9u0> MOL 3e 9M1Sos40D SSO a2) ale ‘Spix0} anjlns 0 a4eg Ns enypos syanpoud Uola>e=s 2y2 t9sodund ayy 10) S2u110 pools Jeeh 0}. pappe aq ued S€6 apivoip anjins 40 a3}s(NS Un POs” “UOys01409 Sonpos smyy pur UaBCxo poalossip 24 4 tK 32804 s4a6UDNe2s asou] 94) 50.109 quBtg aq ue2 HOU, 2M UdLUM UaBKvO pon[ots)p 9A0U9) 0} SUREIIS Joq0N 04. pappe 2 Seer auns ue9 SvebUeKeSS VaBAYH "Uo|souu07 40 sod) 439 vol yes3u20U00, bujanpad sng “auea[> ujeuas sovesuns (eaau pur s03%e9 [4395 [LLM aos7e aoyuied papuadsns yeu os “samejuaauy aseyd uasnoq uo|su23 992J4ns 243 30NfO4 THUPGSEGIMG "uayerold usoq ancy 254093eq as9\p Uo}so1u09 a9npoa pue URISKS Pn uea1> A e0}seueyp ou) yauns ueD squaée aay) “ejv930"q Duy Aq. [942009 ‘uy 0} A{unuuy 0 29u24 [03 ¢ dn SuLplLNg ploAe 2 u9p40 Uy A\sMonuy Iu09 ueuy woujen AL ivaaa;uA99u poq2|13 Bujaq waysks 943 ou) posnposqUy AL LeNSN ave ‘These values have been established in AACE Standard RP-01-69 (revised January 1972}, Recommended Practice for Control of External Corrosion on Underground or Submerged Metallic Piping Systens.” They have been adopted by the Departnent of Transportation Office of Pipel ine Safety Operations in requirenents for corrosion contret of pipelines. subject to regulation under the Federal Kininum Safety Standards for Gas Pipel ines. (See Aopendix A, Py. 38)- ‘The metal to electrolyte potential {s measured by the use of a high resistance volt meter or a potent ioneter voltmeter, the positive sige of the meter con acting the electrolyte through a ngn-polarizing reference electrode. A CU ~ Cu $0q reference electrode is used for contacting the soil (Figure is Important. to determine the metal-clectrolyte potential as accurately as 1s practical because over-protect ion atthe metal surface (cathode) ean be very harmful to protective coatings, and thus as undesirable as under-pratect fon Current Requirements. The anount of current required to cathodically protect 2 metallic structure Tike a buried pipel ine is directly proportional to the area Of bare metal exposed to the soil (electrolyte). The more netal exposed, the snore the surface area there ts for current drainage, And, the more current required, the greater the cost for cathodic protect ion As a general rule of thumb, #t will require 1 to 2 milliamperes protect ive current per square foot of bare pipe in most cases to secure sufficient potential Shift inthe cathgdie direction to achleve protect ion. Old, corroded Vines may Fequire 3-4'ma/fte, Marine structures may require § or wore ma/fte, BUSE be stressed that these values apply to bare pipes good external coatings Grastically reduce the anount of bare pipe exposed and thus the current require: ment. For exanple, 10 milgs of 36° 0.0. steel pipe has an external res of 373,000 sq. ft; at'2 ma/fte sone 750 anperes of protective current would be requires. "Again as @ rule of thumb, @ good external coating can be regarded to have a coating factor of 0.95; that is, it. fs 954 effective in eliminating bare Steel, — (Host. good new coatings are considerably more effective than this). In this Case, the current requivenent would be reduced to only 37 anperes A point to be made in this respect Ss that in designing new Vines or tanks for example, provision should be made for an effective costing as the irst defense against ‘corrosion, Cathodic protection can then be appl fei as a secondary imeans to protect gaps or holidays in the coat ings. This combination of pro- ection methods usually provides the best overall protection for the least overall cost’ In the absence of better information the above current density crits used to estimate cathodic protection requirements for an installati practice, current requirenents can be determined by actual Tield test: je'direct current welding generator (bare metal) or a car battery (coated metal), an ameter, a variable resistance and a temporary ground bed are used for applying the current and varying the current output. Pipe-to-soll potential readings. aleng the pipel ine on each side of the generator will show the current Spread of ‘cathodic protection being obtained for a set atperage output of the Generator. The current output can be changed and held constant for another Bipe-to-sofl potential survey. a oz SundIa u pouy wnseubew: Ly aya mesa et aunols QOHASW TVILNALOd 3LATOUL37a OL TWLaN Galvanic Anode Method. The galvanic anode method uses an active metal as an ‘expendable anode to Turnish the inpressed current (Figure 20). In order for a ‘metal to be active when couples with fron (steel), it tust have a potent {al Grive sufficient’ to force current through the electrolyte to the fron and Sufficient currant output to make all the exposed turface of the ‘ron cathodic to the electrolyte Table § shows the theoretical potentials of three metals which can do this: mmagnesiun, aluninun, and zinc, and their relationship to steel. All three have very favorable voltages to steel. In Table 6 tne actual driving potentials for the three metals are shown. It can be seen that magnesium hae three times the voltage drive that, zinc or alusinum has when connected to a metal under cathodic protect ion of 0,88 volts TABLE 5 REVERSIBLE POTENTIALS Difference to Metal volts Steel agnesivn 24 “1.96 Auninun “1.86 1.2 tine 0.76 0.32 steel “0.48 ° HALE 6 DRIVING POTENTIAL solution Against 0.85 etal Potential Volts Volts Magnesium 16 0.75, unin 1a 0.25 zine La 0.25 ‘The current output of metals 1s also an important factor in their performance a8 galvanic anodes. The theoret ical and actual current output in anpere-hours per pound of metal expended 1s included in Table 7, which summarizes the ‘inpartent properties of comon anode materials. The current output of galvanic anode metals fe also given In Table 72s rate of consumption fn pounds per ‘anpere autput per year. 235° 3-10 tee a oy2eg apouy 2LALa1IM =H soyoe} audeus 2 2z)$ ap0uy = J suayauyv9aig Uy Aa}A}25)38u [hO8 = oy enbe ays @ pase -nayea 99 ue> spoue unyssubew @ 30 3ndgno qusvana ayy “su0I9%) 95047 usULquOD (g pue g s9\geL) [2ttesed uy sogenu pue buj2eds t2zys ‘eoueasysas [10s 242 sepove'2tuen|e6 J0 doveuojied yndyno.yuavano 917) a2uan{U1 Y>1Wm 3103985 400 evete-e a TABLE 7 APPROXINATE CHARACTERISTICS OF SACRIFICTAL ANODES zine AGNES ALUATNUM-GALVALUN E11 Specific Gravity 7 19 29 Density (1b/ft) as 120 14 current dutput (anp-hrs/1b) Theoret ical 32 1000 1350 petual 335 350 1150) Current Efficiency (2) %0 55 85 Consumption (1b/amp-year) ‘Theoretical 23.5 8.7 6.5 Actual 26 6 Ts Potent ial (Volts Cu/CuSO) La 1.6 1.08 cost ($/1b) 0.50 0.65 1.20 cost ($/anp-year) 13.00 10.40 gute cov sree ora seuadues L1W Uy 3Aé3N0 aUEaIND = 1 ‘Spunoa th 3U6\94 = satay UL 98) = 7 2400 Vn p2'90 = 9 ou 1 90"1S = 7 un, s2u6eH, smo| Los Se page [MDLe0 S| sepoue Jo faveroadxe 9417 Wao = 1 ST SpE SOE FS HHT BL oy oe ose $ we ore we + sez we wre € oot at wT 2 = TERT seas apy amiag BapaeaE sau BE WDA Sow Ta 7H zt (pe6er0%) oF ot (pbexsea) 20 oot (pster2e9) ot wo 6 a0 $ oo e TG sane ats spay WDE WOTTTRRAOT STS SOON Tar 1 a4 09 papuesou Sy 349 quasead HOE 40 €31A1351s04 SEA3S1500 [105 punou6 poob yrim L408 A344 5 $58| 40 $u930uyUa9-ay0 QOOT 30 fayayasised ‘unqsyou 40. junoue.‘an-ayeu 14941 Uo 6u4pUBdap 5 ‘au ““umsjez0{pue Uys9p paq. punosB ut 404384 que 3.0 For protection of marine structures, 2 new aluninun alloy, Galvalun, is preferred This anode 1s available in the alloys, Galvalun 1, IL and’IIT, each’ for specific environments, decause of its outstanding current ‘efficiency, Galvalun gives tore current per dollar than any other anode material. The characteristics of Galvalun {Il are Visted in Table 7 Applications for Galvanic Anodes. Because of their low driving potential to Steet, gavvanic smote: are Tinted In the anount. of steel surface they can protect: they cannot. therefore be used for cont inuous. protect ion of bare. steeT Tines or Targe uncoates tanks. As secondary protection for all costed lines i tanks they are quite satisfactory, and they can be used for occastonal or ‘hot spot" protection of bare lines.” They are Weel for such applications as the water channels of heat exchangers. The advantages of galvanic anodes are thet'no external power is required: lnstallation and maintenance costs are lows and there are few interference probless. The chief disadvantages are the low Griving voltage and low current output of the anodes. On offshore structures, Feplaccnant may be a problen.” New offshore structures are now being built with Sufficient galvanic anode material fabricated into the structure to provide 20° years of protection Rectifier Method. A second means of achieving cathodic protection is to ‘press on the structure being protected a negative 0.C. potential with respect to the electrolyte. This could’ be achieved in several ways ~ a battery or D.C. generator could be used, for example. The means most generally used 1 @ Fectifier, which transforms. and converts A.C. power from 2 power Tine (110-440¥) to low Del, voltage, The negative Teal of the rectifier 1s connected to the Structure belng protected; the positive Tead ‘connects to a ground Ded composed Of one or nore anodes inserted in the electrolyte or soft. node mater ts graphite or silicon tron. In some cases no Such es platinun are Used, particularly when using rectifiers for protect ing internal surfaces of vessels and tanks. Rectifiers are sized for the job they are expected to do and then purchased faccordingly., They can be obtained with various 0.C. voltage and anperage Capacities; hence one advantage is read fly apparent sufficient driving pe [ort vottage output) can be designed into the unit to secure. the Gesired current output no matter what the overall circuit resistance (sun of the Internal resistance of the rectifier and anode bet, the soil or electrolyte Pesistance, the setal-electrolyte film resistance and the metal resistance of tthe protected structure) is expected to be. Ground beds must be designed to satisfy the current drainage required for corrosion contral for a fixed period of time. Materials used with consunpt ion Fetes and recommended current drainage rates (current density) are show in able 10, “39. 2-815 oe 22 aunold nypeg snosoeuogas ‘uo4} wo2tlts 40 anyderg, G38 GNTOWS WOULIA bz aunois Ta aT Taste 10 GROUND BED MATERIALS Consunpt fon Current Density Hetals Pounds/amp./Year fAnp./Sq. Ft. Carbon, Graphite 2 1 Sfl4eon Cast Iron 0.2 1t05 Although there are many possible ground bed configurat fons, the most connon is the vert eal. type. shown in Figure 22. When anodes are burfed in ground. bed Special backfill (usually coke breeze or graphite) 1s used in order to inc the size of the anode and lower the resistance of the anode to earth. Increasing lise iz being made of Seep ground beds, where a hole is drilled as deep as 200 feet and a'string of anodes. suspended’ vert icaTly around which the beckfiT1 is placed. this has e multiple advantage of decreasing ground bed resistance, perticularly sf a low resistivity strata 4s penetrated, and increasing the effect ive range or "throw" of protective current. ‘The performance of rectifier type cathode protect ion instal Tat fons con be Checked by period ically checking the metal to sofl potent fal, the external resistance of the rectifier (ground bed), and the monthly power biTls ‘The advantages of a rectifier installation for cathodic protection are a Targe tnd Flexidve current output, and a high voltage drive (applicable in high resistivity soils). The digacvantages are the high installation and operating Costs and the possibilty of Interference problens. Interference occurs when protective current fran 4 foreign cetnodic protection systen or outside electri al. influence util izes some port on of the base systen as a partial return path.” The point on the dase system where this current leaves to reenter the Soll will suffer accelerated corrosion. Figure 231s an illustration of how this frequently gecurs. In this example, the foreign rectit interference on the Exxon Tine; with Exxon creating the proble. Other than for an excavation and eran’ Of the line at the crossing the most obvious indict ion of interference is 2 hot iceable depression of pipe-tovso') potent ial on the Tine suffering inter ference, at the crossing point and dipinishing in either direction avay fron the crossing, There are tho practical methods of handling interference problems. The foreign Tine operator may be asked to move His vectifier sone distance aways often this 2 impractizal for him, The other method. involves. instal ing a'resistance bord between the lines at the crossing, adjusted to carry the Soount of interference current which Would otherwise skip through the’ soil Other solutfons, such as trying to coat the interfered Tine at the crossing, are less practical. Soil Resistivity. Some understanding 4s needed of the effect of soil resistivity ‘an galvante anode and rectifier performance. Soils have greatly differing Specific resistivities (defines in ohncent ineters, the resistance across a cube oF sof] one centineter on a side} ‘Clayey or Toany soils with igh moisture le 3-817 82 Bald JNIT NOIYOd OL ALIWIXOYNd AG GASNVD JONAYSANSLNI (goNvLsia 3NOS AB qalvuvd3s. S3NI1) ANIOd ONISSOUD ann Noxxa NO vauy SONSUSSUSLNI 3 ro “San NOTaHOr ©. -42- content usually have low resistivities (1,000 ohn-cent ineters or Tower) while Sendy'soits, particularly in arid regions, may have resistivities of 10,000 to 100,000 ohn-centincters. Low resistivity soils are conducive to high current. ‘output from protective systems; this tz Usuelly offaet by higher current demand to maintain proper protective potentials. Mich resistivity sofls restrict the Current qutput of galvanic anodes, sonet ines requiring the use of rectifiers for sufficient driving potentials: soil resistivities can easily be determined with an instrunent ‘called 2 Vibroground or similar device 3-819 zee a sea 2d s|yu 91 0} § poaax9 sexeu siayn sounseau vo} 226} 310 2381 3}UL oy aoiy2eud [eaguab si 2] “s0ueD)jpuBtS pur quaq%e UL u30q “AL apLM AJeA UED so}e4 U9] S009 *$u0) 89} [dod asa4_ 40 ashed0g “aun|te) 3ua[otA songoud UD ess2n aunssa4d-e uj ab@95"[2o)2] 49 ® 60, ygead uo;so1409 wiogiun 3[Lym *3an|Le) ‘nso [ax woplas yng syea| sonpoad feu 6UL334d po2e[0s] “VOL yea] AeD.pue Sujaaast tq *0u1 99049 *6ul74,0 pore|Os| 02 LeAoUeA Wog}UN HOAs A\9pIM LEA OSE uo}so1s09 Jo sade] “20042 4120|24 pue aauaynqung Aq_pequeus dns. ‘ounes0d9) ue "aunsssud *ayex 212 v0|So.u0> oy Jo 9404 pur qusyx2 oY 4304J8 DIUM s4oy2t} Bu} 329} [abo SqUeUjueIUOD pur saURpo.u09 Jo S9uesaad a4} 0, UOLILPPe UT -ueasys ssanoud e 30 suoy2eay aveye ur ut 9q213U92000 03 pued LLM snuyq pue aueyra 03 3sas0[2 ue Aoua suoqueI0Aphy JO 3501 O1 paseduo> 910 3ptsins us6ospry pue 2pixo1p uoqse> JO so.nssoad aodeA pue siulod ‘Busis0q au3 ual sno} aqo sy. Siul.“loysAs S96 passauduose4 ays uy. pue si03e ~uoraeas pu2 SLLL4s yr 30 suoysAs peayidno ayy us paqe.quaoueD auo2aq ssa204d ug us. paujesau s9AjS01d09 942.40 ISO “SUDISAS [[F¥8 97 UL yUaseud Kpeoue eu 02 9171p Uoque> [eUO]a}ppe seIng|.quo> uBUY uoLyeu9do.BuLddes3S.S1uL aayneay ayy nous SuoqseaoapKy w2qyBl au Gis9s oF S{ [145 2u} OWUL.pozD2fUL st ‘ua{soq. aU8|d 942 Uy Vola} Soduodap ayeuDqueosg wo4y PLxOLP uoqieD BusuLequOD ‘uroig. "S00. lang pur sales. que[d yyim aaquosge au meal 40 yuauIzeAt04d ‘hq panouea aie Jopuyeua. ay} 15899040 uy ul S5e0 S9n| 501409 Bu) 93U9 94 49 uopri0d © Kup *usbsxo. pu *spj3e.2yuebdo *2pi.i0{yo un|saubew ‘Any s 9945 apisine tRuogiea “ung ns Gesdeaiau “api ns uabouptl 9q Ae ss9430 [este fur puajso ledioulad a4 st 9p1x01p vogue) vwrazs Aa) [Lan pazeoUe6—qUeld pue sayesuapue> stb "seb 42[ut 9u) yyiM $5920.10 que{d ay2 10109 squsUOdUND 2n4501309 oyso1s0 40 3243 vey} Bus31uL| pue 2A} suBdx 240W 328 joud ay 94 3494) “98U89p 9008 u UOLSOJUOD leUIeyUL 02 429CqNS Suossaidan> fue "syues “sdund "5|9sS8n aunssoud “suobue4x0 1204 ae7ey Kage pur asuadx9 Gui 721900 208|d $e a[qe|39.0de uP auo2=q ew quawdynba 40 volsoaio> yeuseyu, *Suol 3evedo esau. 30 499 UT “UOL Ieuph\ep fq fp pue “suogae20s6ey pinbi | posano2ad 40 uoLaduosge fq ves ‘unl ez} cangynsap ka aoons 9pru aq Fm SeB oul “ual yonpoad plnby uorqeatst300s pub seb ‘ap ‘uea{ "330HS B40 UOLIONpOWd aut saajnbas A 2s0U98 Sujss020ad se [eAneH RT “suo, esado Sut puey seB 1994J0 y>qya squauDs;nbo4 Kove nau qua4ana 04 a2u940494 434M &{Je(N2) 1486 papn{duy uBeq aney.SUOL i ppe DUE suousuayxa uye3129 "011eu 209fans oa Jo a6e49N09 9yeUOge [9 9J0W e405 304N05 feu 02 porsadip 918 not pur. (enuey uot soso Mueduog aut. Jo UOL3795 S3U [g ep ul uoys0is09, 943 ous pasuopuod A {3eaJ0 <5 sho{ [04 Yosup UO, IeMAD;EL ‘ayy 40 Urq "Guy puey SEB 0} anbyun yeupauds aur y>iyR 5 [01qu0> pur s9sse20ud ioySoado> 24340, 200s 341 1uBLy) 0} pspnjout ueaq sey Aseuuns Bu}wo4 10} 242 ‘uoseo. sti. 10g *3(q21[dde A{peo.q se. jou aie possnos}p seunseou (044409 241 uou3e01Ldde [eusu96 stey uo1s0.40> 40 s2{d)2uLad o1Seq 2u2 9[4uMm pue ‘Uo} 29NpO.d 520 pue 10 02 AL{RO}2u) ud $9} {dde vO}S0.400 Uo uOyssnasyp Oyj08040). 34, RT SLwv1é S¥@ NI NoISowOD “AL Control measures usually inc’ operating conditions, additional metal thickness as corrosion allowance, protective coatings, ‘corrosion resistant materials of construction, and Economies should gictate waich control method or combination should prev Mnatever the appl {ed method, to be effective the control measures must. be ssaintained and monitored regularly and adjusted as called for. Process areas most subject to corrosion are strippers, still, fract ionators and aasociatel equament. Parts ofthe bubble trays, por iculaty caps and risers {nthe strippers, stills and fractionators are very suscepe ible. Vapor piping fron these vessels and the condensors. and. accunulatars handling’ the condensed Fluids frequently becase seriously corroded. Special process units such a6 glycol dehydrators and monoethanolanine (NEA) units for removal of carbon Gioxide and/or hydrogen sulfide present special. problens Because of the concentration of corradants present and the possible thermal deterioration of the process Muid. The water cooling systens of gas processing plants present corros of a'different nature. Such systens are either the open type ative cool ing toxers or the closed recirculating system, usually to provide Jacket-water cooling for compressors. Here oxygen corrosion and/or scaling as airule are the predominant. problens although corrosion is usually minor in Closed systems.” Corrosion and. zeale control may be Desed on the use of pole Bhosphates, chromate, or a combination of the two. The use of the various Ehronates has consistently provided the best corrosion protection. Hovever, in the open recirculation systens. continuous Blowdown of water. is required to avold concentration of dissolved salts. Discharge of hexavalent. chromium fon to natural drainage 1s prohibited by the Environmental Protection Agency at concentrations above about 0.25 ppm, based on total quantity discharge.” Since Subsurface disposal of fresh water wastes presents other difficult probslens, Subsurface disposal is used omy infrequently. To perait surface disposal of water effluent, a nusher of plants have been provided large serpent ine retention ponds for the discharge water, with treatment by ferrous sulfate (copperas) aivich precipitates out the chromium in the non-toric bivatent form. It. 1s. also Feasibte to enploy comercial electrochemical units which reduce the soluble hexavalent chroaiun to insoluble chromium hyéroxiées havever, these are somewhat expensive particularly were large volumes of effluent are handled. In plants requiring stean generation, corrosion and scaling can also be problens im the boilers and. stean systen. Corrosion may occur from the presence of oxygen oF carbon dioxide or both, and seal ing mist be scruputously avoided. Treatnents may cons ist of deaeration or treatment with ammonia, scavenging with sodium sulfite, and other agents, and must be carefully tailored for the particular requirenents of each systen. This discussion has thus far been concerned with internal corrosion of gas Plant facilities. The protection of external surfaces of this equipment is equally important. Vessels, piping, tanks, etc. which are exposed to the air Should be well coated to avdid atnostpherie corrosion. Conditions are often Aggravated by condensation of moisture on cool vessels and coating deteriorat ion fon hot vessels. This problem fs particularly noticeable in the cryagenic process a5. 3-821 zeae aa 5942414284 Bus [puey $26 ano uj pauequreW ag su2sBoud uot S040 9n}209458 IRN ‘bujnbaa sase9 Augw uj Suoy3@(néou jour aziub0294 4shu oR "586 anos Sup [puey '53}2} (384, 40 wosyesaeo pue UB}S9p Jodoud s9ajnba. 9e ainy Quy sexSL (TL beg) Aysn0| dad pouoy quau sy "se431 L2es pue soul | SuLipueunseD (1e AL.engsya os, age2| (ede 90°04 Se peoag A1qu942{)JNS 5) 95N0]9 seul” “spunbLL 21qLsnquo> fio atgeaue |) 60s {puew Buydye |e Jo uor49930s0. UDLS01I09 40} [eohs toads ‘arenpuy. (e12ua6 40} Spuepueds YHsO *S9U}| UO}ssiusuesy se6 pue seo. paye nbas 1 Suoygeas. lot 1eapryap pus. sosso.cuo> pue Sout | SUL.0U86 se6. s9K00 s90p nq sued bussss901d £88 63 uyeqaad Jou s90p toy ShUL_(¥¥! puaddy 9s) 3 ‘AyaseS Aut od}d SUD LeaNdeH 949 Uh Bsou B4e SuoLze{NB=s Les—pE) UL papN|ouL faze youn siuaupajnbas [ouqued UOysouse9 34s}3ads £40 99 ‘909. 09Sesa SY 's1ue|é $26 uno ut queudindo ay 03 on6 a4 yeu losquOD puE 20Ue | LsanINs uoysosso> so yujodpueas ayy Wo.y Uoj u99¥8 ues au} 8144 [120s 952423415 OM yeu} gueqiodiy 450m 5).2) "sean yey [eUo]appe prone OL "S8ULL 3524 Uy stOds Trot. ut 64j329{ [00 s0484 Jo-a[nsaa'® se A{[ensn “uo! Soss0> [eUsazUt_pDALOAY) ‘sney se9uadin900 sno} 195. 750u 94) 4Nq*padoLeK—p BAey SB.NL|2p IAL S040 [pusoaya pu eussquy 40g, “seuy1 2anp04d puE $06" [50 polesado-tueduoy uy Ayguaaad poaunaoe aeey Soun|ses £13500 pue aiudosaseyea (esonas “ue (n24 qed “surehs gue s0U4 | pue £34un UOj2eupKyap pub 8Usss8>046 plats “suol yeas aossoaduoa apn{auj-aan[jes uojsoado> 0} 3>9PQrs Sue YtUM $9.21 [192) se6 40430 aunydns aut wos eunieey 21YG0s28eI09 fq Sod plore 03 pansesqo 29 Susehd jue[d yo seaue Om 9s942 0 Uo\ oodsur SUL ynou Dipoy ied yeu3 papuswuore. Mv6Ly 31 21 “OgTT-¥9 dPsN-02992014 5}, 2944405 aaky stu ut 4 OOE 03 941229440 99 02. suoas.Yojum 9[qe [ene mou Bus 3202 y uo, s0.u0o pazedo 99" Buy aa}usad “an pueys 03 paltes ALsusnbess 9124 soul 1209 ‘unge36ub1-UB14) pa| 29 05 *s9s0495)p Jossaicuo> uo.y saul | a.nseveduD3 YyBiy_potaing sepn|2u, eoue >| gedouyna X(YBiy pu0des y “3zeud4.az9p sbuL 7200 se Uotsotuos auanse senea U2 legused usin Busiup pue Bujstan syeusor [y "puns aug sane, 410 519300 4} 5° 1949] punode no[aq 2snP pue ye BuLdld polung yo 110d ua sapniouh ease su” “vol soaios (euisyxs 07 9[qessULMA AL 210080 ae Sujdid urd Jo seaue on *5,9n9{ U0] 1993030 9} poyres syenbape Aipasoddns Jo 24105 UT posgnbaa se paysnfpe worsAs ayy pup sleasagul seinBoa ye pauoy1uow aq sup peas Ljoscog-auid yeu aueasoduy st 31 uosead Sti 40J "s{9n@| UO} 2—}040 43918 ued sa6uey> 6uj 3esedo pu uoi3ei0) 939p Gulrec> pus *uoLy2o40ud [nj ye ule Oi any g4se uosso sh Sy asia eu Gain BUjo\@ pol ang Jo seu ay Jo ssneseg *{bsgue0 voyso4409 [eUeRxe 40s Yoau Wain £{gesaseud *U0L4203008 >upounes piAoad 07 Auessa90u AL ensn si 3] “paieso}Jazap aq few 3) g93e09 sem Busgyd avay uot. pu vaueq ple] sem Sulsia [le 40 auOS “sqUe|d Seb Japlo UT Sbiso [2vusaxe ausnas Jos Uj qe20, e s9u9s0ld Se0de UELS Uy Hud) pong 4398 { 09 wea vor yesuspu0> 20 uyes 2voyp uo}22\nsuy ayy yaeousspun azejuns. [2838 aif. Jo. UO,s0409 furyaid s1enas 1 2U0152000 pone 0} poujequiea pur paje9s [12h 20 pinous Uuoja@ insu Gujdsa puF lassen “pal .easur useq 4248204 1S0u oneY Y>quR S3Ue|d \. CORROSION CONTROL OF OFFSHORE PRODUCTION EQUIPHENT Production of of1 and gas from offshore areas constitutes a major part of our total production. ‘Currently, approxinatley 13 percent of our total product ion iS from offshore sources, prinarly fron the Loulsiana and Texas Gulf Coast areas.” Corrosion ef product ion facilities in this marine environment incl Structures, production platforns, offshore pipelines, and floating drilling faqugnant sa iajor cost item and e concentrated effort aust be Girected to its contra! ‘ne contro} of corrosion on this equipment falls into specific areas referred to as: 1) the atmospheric zone, 2) the tidal or splash zone, and 3) the submerged zone. The stnospheric zone 1s that area in witch the equipment ts exposed to the marine atmosphere, out is essentially free of spray except in the most. severe weather conditions. The splash zone 1< that area from about minus 3 feet to plus 10 feet, mean water level, which is alternately wet with Salt water and contacted by air. This eres hai presented very critical corrosion Drablems. The Submerged zone 1S that area which is under constant Iners‘on A. Atmospheric Zone Corrosion {n the atmospheric zone is nomally controlled by the application of protective coating Systems. The printing of floating ané dest ing product fon equipment. is a costly and fot wholly satisfactory operat fon due primarily to the Himitations of weather which affect the quality of the painting Job Steel surface areas requiring coat ing can be minimized and problens associated with the costing can be greatly reduced by substituting tubular wanbers Tor Dther structural shapes, seaT welding ané boxing in of structural units, the elimination of skip welding and other closely Fitting aress. The effect iveness, fof the protective costing system used is greatly dependent upon the degree of Surface preparation to receive the coating systen. Generally, al1 surface preparation should be completed during daylight hours, early enough to permit Priming prior to the development of any surface rusting. If blasting 1 done Et nights the surfaces should be reblasted the following day prior to priming. No Surface preparation or priming should be undertaken unless the surface. and anbient temperatures are 5'F or more above the dew point. Although wet blast Cleaning enses the dust problem, ft fe not recomended for offshore platTores if this type cleaning ts used, the coating Systens must be compat ible with the inhibitor and chesicals in thé water systen. Under no conditions should a steel surface be costed while it is damp ormte Exxon specifications for coating most areas of offshore structures, including decks, platforn menbers, and praduct fon equipment. and. piping catl for white hnetal send Slasting using a dry blast system. Coating systens will vary considerably but 2 typical system for steel decking 1 a5 follows: ory EAIm coat Material Thickness, hi Tse (rrise] RISE Bar Polyanide-Cured Epoxy Er Tete 2nd Rust an Polyanide-Cured Epoxy EH-S665 alo = 610 3rd Rust Gan Polyamide-Cured Epoxy EN-6654 9 = 6.0 “47. 3-623 vere oo ove woag f9pIN Kuen squauosynbad quaJang “uo}39—3044 244 [-Buo{ 0p (P)J23eH Spoue.3iuene(b posh Alapim. as0u ou St un[eale9 "UOLy2o104d 25 pouyED 2na1oe ‘ot pasn sue sunyske.quatin> passaiduy pie [eeu 9jUALeS [2121 }1A98s 4208 s6u1 3200 tu uoj3aag0ud 4 poyae> q 40 uo} 3283044 4poygeD 30 uO} 29) anajuse st Bu02 pabuougns oyy Jo seexe [Russaxa 249 40) ym uo} asunFuo> ide oun énoaya 309 Uo} $0130) aye pur aayen vas 0} gunsodva Bus pone snya pue squownueduo> yons Jo Gus [228 40) $1182 ‘bo 13ead uBysep piepueys asne9%q 9[4)54[69U £1 [eueues S| 2Uu0z_pab.0uqNS ay uy uojso1s09 eusaauy Ps 943 mOleg 24n330438 24 Jo VOL yiod 704g. smd qoots poraaneuajen sapniou}.pue suo? Yse[ds 943 UOJ) PUBMUAOP SpuB}x9 BLOT 544) 2 ay IBIAS TT aouene| [2 01501409 941 p999%9 you se0p $501 04) 3843 aujusozep 03 apeu 2q_p[noys sqUBURInseoe ss—Uqu% Lien 35p0,.10d_*pobeuep K(eajueyseu useq 3ney 10 pay2i0] 1019p aney suysKs ‘huyyeon anjdoatosd pur pasn ove saqeid wean J] “Alo1e| pou ayes popoeu se uos}oe aa1290au00. pie. possasse aq p[Moys Su0qune [Punyan4s 6uLéLsepun OF ‘abeuep jo wa4xa ay1 *pansoeqo sadn iies sf 344299459 8). [019u0D worsos409 Sr euvwlonep of A lenuue.posaodsuy £1 Lensyn oq. pLrous [eassqut auoz yseLés dul "eave syus Us. [aaas. [eantonsys 349 Jo woL429y0u4. pony 00D 94nsse 03 ueraoduy £1Y6y4 St Sounseau [049009 uo, 501409 suor use [ds 40 90ueUDqULeu 34 “suaguou [eanionsns [Le 403 64) ppeL> Axoda paLiss pues pue Guydyd soranpuos uo Buyyeays [2u0q bulsn 94@ aN & qUaLanD suayshs.[euo}uenuo> pur tsa4e[é sean [2035 “Bul ppe[2 ULsod a4usutyod pea0j=s0 Tooaosujad sse18400)5 ‘Busppel> Ussed Avods pol [Ls pues “3uaId02U pozyuea{nA “bujuaeous OP 1aUoH ane gT Jo UO}3eD} [doe ayy sprLut sUoz yse\ds oy uy sunquau {3036 Jo Uaj eso} 1949p 94) 9ZsMIUIU 0} Pash UBEq SAey 1242 SONSEoH “eo 32109 41a sia uh pokgsqo uoag arty stour aseuy ut Abu O57 Jo ssoar8 uae yenosg s3b.eq pur s4%0q 30 UoLsesge uO) jou fq $Bu}3809 9A} 2003040 40 un yes aanyeadad fq poreAedbOe saypany 3ue e908 sjua Ul s9384 UO{s0u409 294S990"9 "ea |goud UOLSO1409 129) ‘hugh & paquasasa sey ate 0} pasodxs pue soieM [es q payin feieU, Si yojun “taep OT amid 0} 3835 € snuju Woap eaue 1eU *2U0Z yse [ds vO [EPI OYL wer a au Buj9q 218 suo} ye2ss1 304s 3ey3 9ansud 02 pauseay £1 2i2ads2 axe oWm suoyoadsuy wayeduo> a past asadns jaso.2 90 ptnoys pub #14809 3). smiosae|d yans Jo 20ueUazuleu pue BUl1209 UL aoueeadde 403 you pue u013293044 vo|sou09 104 2209 oy Aussmpuy aya Jo 92ya2esd sun S148“ [euau26 uf" [ovu0ss9d Jo Ayajes" 24 puE “suas yevado Bu} 3809 243 Gujanp 243 UNOP jusudenbs Aue pue uo| yonpo.d passsj=P Jo 3809 ayy. *siaqseu wio4ye[a panaeaye 942 40 OuLpeo| Jo ssa.7s 249 “abel uuo{sosuo> Aue 40 vol 200, pue quayxo ayn Aq paouan gus AluBLy sy ay “UseDUeD ejo0es 30 wa[qoud e $1 ‘2de[d uy 30U0 “sbo4shs Buj3e0> yons 30 asueuaqULeU ou, to area, dependent upon relative areas of submerged steel, the area below the fnud Vine, the water resistivity, the water teaperature, and the extent of wave action and turbulence. The galvanic anode systens are relatively simple and when property designed and {instal led_are quite Yel ‘able. The anodes may be cast on pipe. cores. and welded ‘into the structure most convéniently at the tine of platform fabrication or may be hung by support ing cable following platform instal at fon. A Fixed inpressed current system requires availability of electrié pover and installation of an AGLOC rectifier-enode systen. The anodes most frequently Used include a lead-silver alloy, platinun over var fous substrates, lead Platinum, graphite, silfeons iron, sna scrap stee?- Of the two types of systems, galvanic anode systens have been most widely accepted Secause of their relib!Tity. Although the initial cost fs greater ‘than with inpressed current maintenance costs ere significantly Tess. Because of this factor, most tnpressed current. systems on aur offshore facilities are being replaced’with galvanic anades.” A'negative (cathodic) voltage of at Teast 0.80 volts as measured between the platfor surface and a silver-silver chloride reference electrose contact ing the water fs the commonly used standard for effective protection level. Potential measurements are conmonly mage. by Suspending the reference electrode in the water as close es practicable to the Platform to mininize errors. In sone cases a number of reference electrodes fre persanently ButTt in on a platform at the tine of Fabrication, thus Provising specific point reference potentials. Visual inspection, including physical measurements such as pit depth or wall thickness, using sppropriate instruments, are of uch value’ in evaluating the effectiveness of the cathadic protection systen and in sone cases, underwater Photography may be used to provide persanent records of condition’. Coupons may be placed on the platform for later renoval to determine actual weight loss. Such coupons are frequently installed. in areas suspected of being Comparatively inaccessible to the cathodic protection current. The only known serious cause of interference to a platform is from welding operations during the time that welding machines are mounted on a barge oF vessel with the machines negative lead grounded to the vessel with electrodes positive. Sone serous. danage has occurred to pletforms as a result of welding Current interference. the interference can be el minated by isolating the Welding machine negai ve from the barge, thereby forcing ali current to return Through the negative cable. The negative cable should be connected to the platform at a point as close to the barge as possible. As evidence of the effectiveness of cathodic protection in the submerged zone many platforms have een salvaged after 20 or more years service and with ‘minimum repair re-used in'new locations of comparable water depths. 3-825 see oo spaysou asay 40 uo} yeujquaa e Aq 10 6us6544 Kq dnueo|> o1po1sod pue “ssoaiq}uuE ojsosso2 so ssn avy “uosgezy yesaneu sq) 40 $86 138 aug JO [Peowad 9ua *3Ut [ogL 94 Gujssqua wo4y squeujunyuoD pyn|s Jo voL3ueseud "SEB aur Jo voyteapiyap Ag poiedyayu A ewsou s; uoysosi0> a "sauys.[e1 01989 Jo/pie *apj sins vetoupty ‘Rig4Ss0d "apixo1p uoquea 40 2ouaseud O49 Y4m Uo} zeus quOD Uh u ‘suoyen3,2 MOL ut s932K pasuspuOD pue 2125 jo vol elnunose 343 :5at ‘8 S039) Sues 94 S9nLOnul SapySKS 9Uj [odd sJoyss 40 40 Uoy sous09 swogae id ‘ayy 40 seaue paB.owgns ayy Jepun pogisosep asouy 01 vests suayshs. quo4ano passoidiy 40 sapoue jUPAteD.[ey3|ssages Suysn *paLleysuy uauy sy uoSrs toy 3283016 24pouseo paubssep A \sadoud y “sa6uel) Bus re nsuy 40 uo}r2{ 89504 Aq ‘Seunqanags. 911 [24u 619105 10420 wo4} pare L054. A{[22}.4399|8 sp “suO} j22ps9da ons Aue. 40 J}edau pub sep} (oy 40s Uoyyaedsus (ny9se> asaye “aut| paze6> 24L “ast usgess pe Kouabuougns poutsep useaqo 03 613209 quaWa> © Ya|M pareosuan0 &[iUenbo4s ‘ue s6uy3¢0> asou “S59U921\3 Pappe apiAoud 02 pue Geum p Yoo. ysujeb8 juouaas0yu121 40) 42am Jog.) pue Sse [b.0q1) Y2iM padeam A onsn gue su) 1209 ons. "su0) 1eaad0 adh [aa4-s6ueG 405 po. SP 5} 45 [}GLxoL4 a19uM IUBI%2 possuy B03. pasn UR0q aney $9) [0U94a pal 4} pow Kvodo pue $9] xods posoptod uy s6uy 3909 wigs ui «| quEDe4 949y | *Sadey 9UB LEUR—K od od au 3 yans sis} pazediugesa4d ple s,aueuD 2[eudse pu ede 30) Bpnjus Al nsssanans. pos ua9q 2Aey yD1UH suBySKs GUL 720) uo 203008 fe 243 pue sueysAs aut ladid ayn jo voryelos) 12313199)9 i13a[9_ 40. U0} 18>) lade aedoJd ayy uo <{yseuy 18 pusdap ‘bu, {281d auoysuo’ ayy. Jo Xbojouysey. tngssoa9ns 212 40 uoy2e944ypou Jo 71nsa1 342 Se pado[snep sAey Sounpa2o.d [043U09 Uo1s0Js09 [eusa3x3 “sua gout yeus9y19 pue eusou} 4209 s19p}su0> Saut{ asaup_uo uoysousoo Jo youquoy “Suoyaevadg 44226 3u}[2dyd 40 994540 ‘uz Aq Uo} 32\n694 02 y2—Fans 248 [40 pue Seb y10q SUL pueY Soul (adhd 94045150 SONG 3 suey} 95au3 40 volsouso9 93ruyuy 19 o apew st 130449 91261 *rvaudynbs paziuen| yo 9sn aun UB sanyyo pe 9{qopladro.palapi suo) ase. sAewy[en 40 424 puey. se Yons “juamdjnbs 30 spay urelis> “seaue 3seu UT 19S [2U013089%9 UALé Bary suagsis 2)38eu vode pur (Cuya sup sue Seze01 1s 2417 d1uebaou, oy “suDyshs "ured 343 40 “UoLr3ex0ud 2|ge=aiA19s 9p}4040 suBIsAs.quLed adh} eods Bue 289} [15 DU4z_ 3) uebA “au gurus se], (P09 [FUO} USntOD ‘poz iuen|es paddy 104 1504309 945399459 404. ‘aver a,pudsOuRe aaj passnasy pismo dad se {12} 109589 po[puey s} “busdyd pur “Sassen Sanssoud!*squey 30035 Guipniouy “Wsosye d auy pue0g UO yuatd.nbe Uo, y2NpO.g TORRE We TaMTS “0 VE. MONITORING AND SURVETLLANCE There is no aspect of corrosion engineering more inportant than the job of determining where corrosion is occurring in our facilities, what its economic effect 1s and the mechantem by which itis occurring. Snfornation 1s absolutely essential if we ever expect to initiate control measures which can be at all effective, mich less economical ‘There are several ways the corrosion engineer can recognize that corrosion is Gccurring and. at what rate itis occurring. These can be Broadly classified Snto three categories, inspection, corrosion rate tests, and chemical tests A. Inspect ion Visuat_Inspection. Obviously, the most definitive indication of corrosion is The physical appearance of the equipment involved. Physical {nspect ion, Sneluding measuring pit depth with a pit gauee, and decrease in vessel or pipe wall thickness using a caliper gauge ean give very specific. information about the extent of corrosion. (A handy pit depth gauge can be obtained from Ranck Engineering Co., Richardson, Texas 79080 for $18.00.) If inspect ions are repeated perf ‘the progress of corrosion, if any, can be noted. One probien with visual inspection is that eqvipnent in service {s usually inacces- Bible for the type of inspect ion needed. This is particularly true where ‘internal corrosion 1s suapectad. ‘To ingernally inspect a vessel ft must. be ranoved fron service and possibly steaned out. Therefore, other means of fngpect ion must. frequently be used. Ultrasonic Thickness Testing, A very handy means of determining wal) thickness ‘Gf pipe and vescels Ts by We of a portable ultrasonic thickness tester. These Gevices measure wall thickness by tining the travel of an ultrasonic bean fron 42 transducer pressed against one wall, through the metal and reflected from the ‘Opposite walle. Readings can be teken'with the equipment in service. These esters can now be obtained in digital readout form fron Krautkraner~Branson (Figure 24) and Nortec for about $2300 and are very easy to use. and reasonably accurate. One dranback 1s that if isolated pitting ts present on the inner wall itimay be missed by the operator; therefore, as many readings as possible Should be made ina systenat ic: scanning manner. Radiographic (X-Ray) Surveys. Another non-destruct ve survey fnvolves_ taking Toray surveys of suspected piping, valves, and related equipment. Snel vessels con be x-rayed, but larger diaseter vessels separate the film from the Souree too far to be effective. Figure 25 shows an Xeray of a Xmas tree wing Valve where sone internal corrasion was noted. X-ray surveys are conducted by Contract concerns, and can usually be sade while equipnent is in service. Electromagnetic Surveys. Qevices such as the AMF Tuboscope Linglog are now Gvatlsble Tor determining the overall condition of pipelines. These devices are instrumental pigs rich are forces through the Vine at 2 constant rate by g2s or fluid pressure and by neans of a number of contact shoes the pipe Eondstion throughout. its entire periphery and length 1s determined electromag heticslly.. Defects such as corrosion pits, inclusion, ete. change the magnetic se 3-827 NILLId G3M3YOS NI NOISOHOO ONIMOHS BATVAONIM 33¥1 SYWXNY JO AVH-X 9z auNDI4 YBLS31 SSANNOIML SINOSYHLIN WAIDIG 318VLNOd HIWVENINVEN 2 BYNDIS flux of the pipe wall; this can be detected by the device as it passes. Figure 26 shows a view of a Linalog pig being inserted in an 1G-inch Tine; Figure 27 Shows 2 section of the Tog made on this run. Corrosion pitting and other Gefects can be found with reasonable accuracy and further defined if necessary by other means of test ing. Other electromagnet surveys include the on-the-rack surveys conducted to jon of new and used casing and tubing. A nunber of companies Tuboscope, Pipe Inspectors and Vetco offer these services. They are iy effective in finding mill defects, etc. in nen pipe out may be Tess accurate in correctly classifying corroded used pipe for re-uses such pipe Should only be reused in Tow pressure non-critfcal wells Failure Data, Sone of the soundest data on which to base corrosion control ‘prograng Te that involving faflure frequencies. For exanple, leak data on Flow ines ina field accumulated over a period of time will indicate the econonte impact, the degree of increase with tine of corrosi eventual ly the relative success of the control progran. the cooperat ion of operat ng personnel be secured in obta effective means of doing this’ is through use of EQUIPT Fi Shese forms. Include corrosion failure data which can be sinply and easily Fillee iny furthertore, this data can be computer processed as may be desired failures. ana necessary that ng this data, One Walfunct ian Reports. 8. Corrosion Tests Test Spools. In order to visually observe the internal condition of @ Tine fn FervTee, short flanged test spools one or two feet long can be installed in the ine, At appropriate tines the Tine can be’ shut down or the spool bypassed: it Cam then be removed for visual inspection. Although this 4s a very effective ‘heck on Tine performance, the logistics of using test spools usually rules then out except for very critical lines. Coupons. & corrosion coupon is a small piece of metal, usually a rectangular Strip, that fe. installed. in a systen for a period of time to test the corrosivity Of the environment, (Figure 28). Coupons are usually made of 1020 mild steel which is similar to most steels from wich vessels or piping {s made. However, their. composition cannot ‘ractly dupl jeate the Composition of the vessel in all respects, and their ate of corrosion may not be identical with that of the vessel or pipeline. Coupons are prepared in the laboratory by cleaning and accurately weighing: they are installed, usually in pairs, in an insulated holder in the test Vocation for a period of a few weeks, then removed, cleaned and reveighed. The Corrosion rate 's calculated and usually reported as a penetration rate in mils per year (NPY) Under most condition, corrosion rates can be interpreted as follows: Less than 1HPY Minor corrosion 5-10 WY Moderate corrosion 15 WY Severe corrosion 53 3-29 FIGURE 26 LINALOG PIG BEING INSERTED IN 18- INCH LINE | FIGURE 27 SECTION OF LINALOG OBTAINED ON 18- INCH LINE FIGURE 28 CORROSION COUPONS REMOVED FROM WATERFLOOD LINE, 55 - ev-ae oem anyso1i0o f\gea2430u 9q ou [JM 3U950J4 St wLLy Jaz0H pyNd| OU a1aUN seeaLas S00 pogeuptyap A(anj109j43, vol soo Bura%ia syousd 62 jam 9q 33he uealas yy yey) $1 Suead3s seb Jo A]4j501309 902 Bujalonuy Uo} e49p|su09 ue} .0euN, uy aiqeusinbusysip £1yse2 30u st uojsouso9 6us324¢ uo 3994)9 syays “quaseud ‘Atyenqnu &{tensn 942 s2se6 avy asus’ sous. 3nq_*uoysosaea uy 33}d ujetsns 02 Pousrbas Sie sey J0 Suoy zestusaveD saUBty +299 40 a2uasqe 8uy UL “BUN SeAS 552435 apesins 02 aj (a adaasns prove os ueyey aq plnols suo) 3neDeAd U>qiy Bnoge *S/-T0-ah 03 uo4s124 Buyuod4 a0) ayy UL Sd G09 Jo aunssaud [243000 plousaayie 195 01 po4200x> St S9WN Ud OT 03 p SE mal Ge Jo. s]uNOUD Sea uf vane 5904s ypbuau3s uBsy Uy su>Lgo4d SUL yaEAD asne> ueD 3p15 {ns Us6O.PIH sounssoad (eq qed s2u6iy 3¢ (4ah 405) su2nas anjnd 9q ue> vojsoui0> seye2jpuy pu siti sil su0> TT ul Prep ayy £150 § 3Moge spaanxs' 29g 40 aunssaud (ey 3sed 94 a3NoUayR S249) (528) Buy ipuey Seb uy pe4nedre 94 uP> sun[qo1d Yojs0.J09 “ou (opin yonOL SY “sysfyeur pue Sus dues veamyaq $354x0 Ae ap ‘aus3 Buo e 44 aiger20x0p aq you Few pur $490} e3U09 a{dues (2015 4aim $1980 lado opi sins ua6oupfy 3eus peyou aq pinoys 44 ‘sanbyuyoaa [20] Yeue [2UoL3 ~uaAu0> &q peyseiep A1jse9 248 Aayy YBnouy ly “slats peanpo.d 30 siuany{1sU09 ‘9myS0uu00 yeu ays Je SpIxXO1D Uogse> pue PL {Ms UabOIpKy “STSKTEUY Ses Tremp 3 Fo 10 S86 Kuo 54 aseud aajsosso> ayy assy pasn 2q gouue> anbyuyoor siya *-a'L *saueiauazala ut fluo anygaejs9 ae 530010 aul “anb;uy3e3 eatuausos359[0 ue hq Sayed Uoys04J09 gsnooUe eISuL,. Buy snseol oj 8049p wou AoAi2e|a4 B10 989ul “SQOIF ylNOg, aTv LOIS IO T9TOIIOD (Sanoy nj e ‘5900 auos us) £ypjde4 asou yonw apew ag leo sauaueunseou ‘aqoad 40 32409 ado1d jim 3nq “suodno> 40) seus se SUR aif St pouieago vol iewioju 341 "s[assen Jo aus mo Ls OQuy. perUssul s2Qoad 813805 430 8421 uoys01409 a4 Bul anseau 105 39449p P55 JayauDsouse) au “W9IIUOSOAIOD x puaddy “5¢-fo-dy puepuers 3DyN ut_pousA0> ae se2,n19s uoj onpoud {Jo uw, suadnoa' so 95m pie Unsae tensa) uj 19H09 suOLy2nz9Sut Ssnopsezey pur suosequn> 219% Soo) aLgeLyene AYsno}s94g *5H025K3_peunssoud UL suedno> Buynouas pur Buri teasuy 40 anbjuysay 943 SoAosau K(qeap}su09 u>tun (35 puadde uy ouny2oJg 85) 00} vol zs@suL vodno © SeA(OnN) (1538) S00] 994445 pur quaudjnby unig fue vox] Jo. iuaudolanap 3ujof 109983 Y 40 aLyze4 24e>} pus few sausy asaya uy uoja}sod jew1ou ayy uy pay yeasuy. suodnoD {404501409 yans J03\uoW A 3201209 03°5° 4Em e Yons uy suodno3 | eISut oF aunaigs4p 443K sp 4 196 f50U1 | 98aun Jo wo}430g aus Ul 28s0H 99 (IM VOL SoaA09 5eR5 J0 sods wo| us sou inuiove 10 Sut ayy 40 ao3%0q a3 Buo{e soAow Y21¥hH siayen pinbj Jo weaugs e saey A{lensn [LIM aug 8B 39M 40 SOUL | uoLS [nue Fe yons suaasés a8eud-ony *psye30| 918 Au} u>ryn Uy uBDdas pynls au J0 UO} 2400 yeu) Atuo Joayuow (lum fouy yey si ash asaya on uosIeqeh| Y "eeaats & Uy uo}s04d09 Jo aunseau ose Ku0a2ejsi3es «| (e4au—® pue any uadeads ove suodno) even with high fractions of acid gases; an effective way of minimizing corrosion in gas handling facilities is to provide effective dehydration so that the gas tenperature is well above its dew points Mater Analysis. Convent ional analytical techniques can be used for predicting The scat ing teidency cr corrosiveness of injected or produces water.” Oxygen determination ts especially important in water injection systens, since oxygen Concentration as low as 0.05 ppm can cause serious problens. Evidence of this may be noted. in Figures 6 and 7. The first indicates how ovygen content. and Suspended solids can effectively be Towered by maintaining a good gee blanket fon SHO tanks. The second iTTustrates how, in turn, corrosion rates in SHO ‘nection Vises are reduced as a result of eliminating axygen content. The NobiT Model 100 oxygen meter has proven very satisfactory as a field detection mneter for oxygen in both water and gases One of the least expensive techniques for detecting changes in corrosion rate is determination of the iron content of produced water or water recovered fron "traps and bleeders. Tron which i dissolved or suspended in this water will most 11kely have cone trom corrosion in upstrean facilities. Single fron count readings at a given location have Tittle significance, but 2 Series of such readings over a period of tine can sonet ines be very indicat ive OF corrosion rate, particularly in response to changes in inhibitor treatment. serubber dump Mater sasples can also be analyzed for presence of aerobic and anaerobic (SRB) bacteria.” AS previously mentioned, anaerobic bacterie can cause severe corrosion under certain conditions, and suc fe should be conducted if they are suspected. API RP30 for Biological Analysis of Subsurface Inject on Water details the test procedure, which Exxon chemical Field representatives are usually equipped to carry out. 3b-Ad -poRseTUOS 3y SORT UTD s0,eu4 94009 oso Uo}S4AI sas suo} {NBSA ROG Jo UOLIEZ24dJ0IUL ue uo43e94 [408 Sujvsoou0> suolyanuqsut 21j120ds Joy "suoysiAOJd Eoua.aapun uos nba sao 23, 32974ns 918 929uu0D 932454901 UL sou tanpead 40°47 pub Sais odh@ (10. ~spinby, snopsezeu Oyj |puey sou | 0} A[dde oy Jayjoue Jo su0Ls} A016 we} uo 20vepine. pu oyreauosuy_(euaua6 Joy papuatul sj pur pabp1ae2 #LUB1y | SuyoGax0) Sul “2461 “TE Aine s2nye 4d9y 9g spuo2es loxque> uo}s01s09 24432945 peson,uow un payesnsuowsp 2q sma uoysoui0> [euv93uL Jo soUssqe 40 10s3U0) sysp3 30U sop quauuo.t ue 2501409 @ yeu pSyesySuCLAP 2g ueD 2) $5a[UN ‘wo, 3ona3suo> aaije aan 900 UjuaIM pal e%su U0} 42eq0%d 21 pouse> fue payeas A leusoaxe 8g Senw TZ6T “Le Ming 9348 polLessus SOUL | MON punoy s{_uoyso.soo anj32e usu us sease uy ovey ST asnény ka porsoa0ud f eaupouge> ueaq aney 25mw Sous aseq BUL9Six9 A(eLI MIS sr asnBny &q poyoazoud f4.z21poune> usaq eney smu p22209 Due payang ase y>tua saus{ payenbos (261 “1 2snby 240494) 64) 35533 sqeuy “TOUT TUT BUR “sauunbos wor 321 fauedn990 ueuny 0} papuarut 59124suap 6u1 pian paq22foud 40 6uj3s1x9 uleqaaa 9Aey YDtyN snq *(2) 40° as012 apisin0 seoay Beth 40 wor “4349 paxeuoduogujun 40 poyesoduoous fue Jo Sait] a4} uyunym eave AUy offslh “Ion @ @) ) @ ) i634 3uL @ we) apniouj seave peaeinbay “soup uoussiusuesy seg “s,yehL weld ssenoud Jo apiszne suo. yeas uoyyeuptyap pue uossesdi09 sus $06 any due> pur plays 3441-526 ‘uorz22rul seg “peayiam aya 28 524038 aust 343 “ued Butssoo0ud ‘uy pur peayiyan oy2.Uaemieq soveedss ou SL oJayy 940UM S| [aK seb og, (E}soteaeeas uoyyon90.d 243 wou) UeoAAsimOP soup | BulusYseE SEQ seaue pean ina, Uy (5964) soyyo ujoria> se 12m se) suorzeuad Sujuyequad sauy Jo $9043, 959un s9K0 VOL pSLANE SQ 242 SBKIO L9¥ =u “1osnu09 voysoue> Jo} suorsyAoud O) 0 (@) ) sno 03 “eUusti8 uyequso uyeruos ‘suos3eun6ad sao 40 ‘10g “4aBH paLLe> Alsnowwen *Suo! e694 asouL 328 yeanieu BusAaue> seus 19444 40° UO) eA9d0 pue uo! zan44su0 243) Buyuaed woo Aa,uoyane 2441 98ds uo} edsodsued] 40 quaunedag 2Ua u} svoj reAado faxes aut {adi 40 891340 94 s34}6 B96T JO 454 AUS [9dbg seo [euMIeN [edepes 2UL Wako ORO OL ST SHOTDRERIO ALa¥S a0ITaela 40 301450 30 SNOLLVTORN WIVES Tne saaastneeeee eee eel BASIC CORROSION MITIGATION STRATEGY FOR FACILITIES DESIGN ¢ karan Us - Proectn Department |. Maintenance of each divisions corrosion control effort is handled by a division corrosion engineer in the division Production Engineering Group, as follows: East Texas Division Dan 5, Atteberry 680-5182 ‘Micontinent Division Orville W, Davenport S6831375 Southeastern Division Troy Ws Michie S36 1-u0 South Texas Division Carl C. Ernest §:387-2257 Western Division Martin Capages £552.7950 11, Each district's corrosion program is handled by engineers and/or engineerin technicians assigned to that responsiblity ins facilities (production engineering) C roup. |. Corrosion mitigation requirements shall be considered an integral part of the design procedure for all major facilities installations or replacements. Designs in corrosion engineer before . This is required when designing facilities handling produced fluids Ege nanny Anson 5 9804 Me or iling on ever-increasing rumber of high pressure and high temperoture wells and e+ Mr. C.D, Roxburgh ty [CHARACTERISTICS OF PRODUCING ENVIRONMENTS, REQUIRING DIVISION CORROSION ENGINEERING ENDORSEMENT OF A NEW WELL, FLOWLINE AND ASSOCIATED. FACILITIES DESIGN, AND MATERIAL SPECIFICATIONS Parameter crite siWHe > 5000 ps pp Hs 0.05 ps PP CO, 27s Reservoir Temperature >20F FoHP (> HC Dew! Flow Velocity >15 0p Minimum Ambient Temperature a0F Related Operating Experience Limited Tertlary or Enhanced Recovery Project Yes Water Production >sooum Notes 1, The Division Corrosion Engineer should be consulted if the expected value of any single parameter exceede the criteria, 2 The Division Corrosion Engineer should be consulted if the expected value of any single parameter cannot be established with reasonable ‘certainty. 3. Routine batch treatment will, in most cases, provide sufficient protec ton for dovinole tubulars if none of the above criteria are exceeded, PROBLEM MAGNESIUM ANODE BED DESIGN ‘A coated 12.00" 0.0. Tand line 5 miles Tong is to be Tatd and protected with 32-Tb. magnesium anodes in individual beds, § anodes per bed on 10-Ft. spacings. If the coating factor 1s 95& (SH bare), 3 milTianperes per sq. ft. of bare steel are required for protection, and soil resistivity {¢ 750 ohn- cent ineters: 2) How many beds will be required? b) Wat 1¥e may we expect from these beds? aik:s9 PROBLEM CORROSION INHIBITION ith @ gatoil ratio of 2,500 95"), Con the flowline be | producing 600 8/0 of oll ond saltwater, through @ 2" nominal flowline (LD. effectively inhi ‘AverogeFlowline Pressure = —=—«*150 psig Average Liquid Specific Grovity = 085 Temperature . 10°F Gos Specific Gravity - 0s a veo PROBLEM MAGNESIUM ANODE BED DESIGN A coated 12.00" 0.0. land Tine 5 miles Tong is to be 12id and protected wi = magnesium anodes in individual beds, 5 anodes per bed on 10-f the coating factor 1s 95% (5H bare), 3 peres per sq. f are required for protection, and so: sty 45, 250 oh centineters: 2) How many beds wit! be required? b) What Tife may we expect from these beds? Cvi‘ent @EQ0: 72°00 Veer 62,938 « O05 = WIYd W bave Wy 4 3 mag he WY me. LT smi pgrtos C2 PE Bees Keb: poy (480,002) (L440) 7s0 a Ma yilmatyl 72.7% = 13 beds G22 9 fe = Gam bo Luce Libicteo: a LZ = (5208) (32) 992 Je = OSG ye f PROBLEM CORROSION INHIBITION AverogeFlowlinePremure = (S09 Average Liquid Specific Gravity = 095 : Temperot = 100% Gos Specie Gravity . oss io ee ve ~ Le 400% el Pn * Cirvos) (0.95) 65) + 229 (2509) (06 1 Wrksjern - (an. 1DCes) + (2500)(56 1 a su ero . = Ae Ve» wo/¥ite * 93 Sys. A: Ang = (an = 313 iat toes

You might also like