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TAKREER DESIGN GENERAL SPECIFICATION (DGS)

DGS-FF-106

CORROSION MONITORING SYSTEM


FOR PIPELINES

REVIEWED
REV DATE DESCRIPTION BY ENDORSED APPROVED

0 MAR 2006 Base Reference – Project 6089

ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER:


DGS-FF-106

CORROSION MONITORING SYSTEM


Rev: 0 Date: March 2006
FOR PIPELINES
Page 1 of 7
TABLE OF CONTENTS

1.0 GENERAL .................................................................................................................................................................. 3


2.0 REFERENCE DOCUMENTS.................................................................................................................................... 3
3.0 DESIGN CRITERIA................................................................................................................................................... 3
3.1 GENERAL.....................................................................................................................................3
3.2 CORROSION MONITORING PHILOSOPHY............................................................................3
3.3 CORROSION COUPONS AND CORRSION PROBES LOCATION .........................................3
3.4 TECHNICAL REQUIREMENTS.................................................................................................3
3.5 PIPELINE DATA...........................................................................................................................3
4.0 MATERIALS .............................................................................................................................................................. 3
4.1 CORROSION COUPONS ............................................................................................................3
4.2 ELECTRICAL RESISTANCE CORROSION PROBES ( HIGH SENSITIVE E.R. PROBES): .3
4.3 ACCESS FITTINGS FOR CORROSION COUPONS AND ER PROBES: ............................3
4.4 RETRIEVER AND SERVICE VALVE KITS: ..............................................................................3
4.5 PORTABLE ER CORROSION MONITORING INSTRUMENTS (CORROSION METER)
WITH THE FOLLOWING CHARACTERISTICS: .....................................................................3
5.0 INSPECTION AND TESTING .................................................................................................................................. 3
6.0 PAINTING AND MARKING .................................................................................................................................... 3
7.0 SPARE AND ACCESSORIES ................................................................................................................................... 3
8.0 VENDOR DOCUMENTATION TO BE SUBMITTED ........................................................................................... 3

ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER:


DGS-FF-106

CORROSION MONITORING SYSTEM


Rev: 0 Date: March 2006
FOR PIPELINES
Page 2 of 7
1.0 GENERAL

This specification covers the minimum requirements for design, fabrication, procurement, installation
and testing of high resolution/high sensitive Electrical Resistance Corrosion Probes, Mild Steel
Corrosion coupons, Standard Corrosion coupon holders and retrievable solid plug assemblies, Access
fittings, Retriever & Service valve kits and Portable ER corrosion monitoring instruments to be
installed at receiving terminal of Pipelines carrying SRR( Straight Run Residue), Naptha/Reformate,
Multi-products & Jet A-1 fuel.

2.0 REFERENCE DOCUMENTS

The supply shall be in accordance with but not limited to the following applicable documents;

a) Process Design Basis DB-PU-001


b) Other applicable documents - This Specification
- Manufacturer’s Standard
c) Pipeline Engineering Design Basis DB-PU-401
d) Material Selection & Corrosion TEC-PU-101
Control Philosophy

3.0 DESIGN CRITERIA

3.1 GENERAL

All the corrosion Monitoring ER probes, Mild steel corrosion coupons, standard corrosion coupon
holders and retrievable solid plug assemblies Access fittings and portable ER corrosion monitoring
instruments (Corrosion meters) shall be identified as per the design and operating pressure, temperature
and corrosivity of SRR (Straight Run Residue), Naptha, Reformate, Multi-products & Jet A-1 fuel
being transported. The pipe line details like material, thickness, operating and design conditions,
location and quantity of corrosion probes, corrosion coupons and access fittings to be installed shall be
decided based on the process design basis and engineering documents.

3.2 CORROSION MONITORING PHILOSOPHY

The corrosion monitoring system will be used to establish the internal corrosion profile using corrosion
probes consisting of high sensitive Electrical Resistance(ER) probes and Corrosion coupons in
conjunction with inspection techniques like UT at selective points, pipe to soil potential measurement,
Residue analysis for iron pickup, intelligent pigging and chemical analysis. The intelligent pigging is a
technique which ca

n locate and detect the metal loss defects from pig launcher to receiver. The need for IP & frequency
will be determined based on corrosion monitoring.

The corrosion rate data will be utilized to optimize corrosion Inhibitor Injection rate. Considering the
non-corrosive nature of the products being transported and some of the lines are being internally coated,
the Corrosion rate measurement shall be more accurate and frequent, which can be obtained by high
resolution/ high sensitive ER probes. The corrosion coupons provide only an indicative rate over a very
long period of exposure the non corrosive petroleum products.

ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER:


DGS-FF-106

CORROSION MONITORING SYSTEM


Rev: 0 Date: March 2006
FOR PIPELINES
Page 3 of 7
3.3 CORROSION COUPONS AND CORRSION PROBES LOCATION

The Mild steel corrosion coupons and high resolution/high sensitive ER Corrosion Probes shall be
positioned at 6 ‘o’ clock position on terminal piping near flow Tee. The accessibility of locations for
installation and retrieval of corrosion coupons and probes during operation of pipelines shall be made
by providing a suitable size of underground pit . The corrosion coupons shall be of flush and retrievable
type mild steel circular disc coupons and the high sensitive ER probes shall be of flush type, which do
not get damaged while carrying out the Intelligent pigging during the service of pipeline. The corrosion
coupon and corrosion probe locations are given as below:

Corrosion Coupons, Electrical Resistance ER Probes and Access fittings :

a) 12 “ SRR pipeline: Receiving side at MUSSAFAH 1 point


b) 12” SRR pipeline: Receiving side at RUWAIS 1 point
b) 10” Naptha Reformate pipeline: Receiving side at RUWAIS 1 point
c) 10” Naptha Reformate pipeline Receiving side at MUSAFAH 1 point
d) 16” Multiproducts pipeline: Receiving side at MUSAFAH 1 point
e) 10” Jet A-1 pipeline: Receiving side at ADIA 1 point
f) 10” Multiproducts pipeline: Receiving side on above ground portion of 1 point
pipeline at MAQTA

Total number of locations 7 points

3.4 TECHNICAL REQUIREMENTS

3.4.1 CORROSION COUPONS

The Corrosion coupons shall be flush and retrievable type mild steel ASTM 1010 grade circular disc
coupons of 1.25” dia. x 1/8” thickness with one mounting hole of ID 0.312” with an exposed surface
area of 2.4 sq.inch with at least one year shelf life.

3.4.2 CORROSION PROBES

The high sensitive ER probe length, Retriever stroke length, pressure rating and designing at service
temperature shall be decided by the corrosion monitoring system manufacturer. The Process Design
Basis No. DB-PU-001 and Pipeline Engineering Design Basis DB-PU-401 shall be consulted for
deciding the requirements.The high resolution/high sensitive ER probes shall be of mild steel, high
pressure, flush type, retractable and retrievable from a high pressure petroleum products like SRR,
Naptha Reformate, multi-products(ULG 98, ULG 95, Gas oil, Jet A-1 fuel) and jet A-1 fuel. Pipeline
inlet pressure will vary according to pipeline pressure drop due to different flow rate and molecular
weight.

The corrosion monitoring system shall be suitable for operation under this fluctuating pressure
conditions. The ER Probes shall be of high resolution/ high sensitivity type to comply the
measurement of low corrosion rate in the above product pipelines. The corrosion rate data shall be
transferred to SCADA system.The manufacturer shall provide operating manual wherever required.

ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER:


DGS-FF-106

CORROSION MONITORING SYSTEM


Rev: 0 Date: March 2006
FOR PIPELINES
Page 4 of 7
3.5 PIPELINE DATA

The details of the pipelines, based upon pipeline design basis, Document No. DB-PU-401 and process
design basis, Document No. DB-PU-001, are mentioned below:

Design Data Details

FROM UAN Ruwais Mussafah Mussafah


TO Ruwais Ruwais Mussafah ADIA Maqta
Product Naphtha /
SRR Multiproduct Jet A1 Multiproduct
Reformate
Pipeline Diameter, inches 12 10 16 10 10
Pipeline length, Km 230 230 203 30 20
Design Pressure, Kg/cm2 g 94 96 102 47 142
2
Operating Pressure, Kg/cm g 6.0 – 74 6.0 – 81 6.0 – 91 6.0 – 19 6.0 – 122
Design Temperature , oC above 87 87 87 87
105
ground
Design Temperature , oC 95 45 45 45 45
buried
Inlet Temperature, oC 55 – 85 30 – 45 30 – 45 30 – 45 30 – 45
Velocity , m/s 0.7 – 0.74 0.81-1.26 0.5-1.39 1.07 0.64-1.07
Normal Operating Flow, m3/hr 184 148-242 220-597 200 120-200
CS + CS + CS + CS + CS +
Pipeline Material
1mm CA 1mm CA 1mm CA 1mm CA 1mm CA
Pipeline External Coating 3LPP 3LPE 3LPE 3LPE 3LPE
Pipeline Cathodic Protection Yes Yes Yes Yes Yes
Pipeline Insulation PUF No No No No
Pipeline Internal Coating No Yes Yes Yes No
Corrosion Inhibition No * No * No * No * Yes

* Inhibitor injection point provision only.

4.0 MATERIALS

The scope of supply consist as minimum requirement of the following components:

4.1 CORROSION COUPONS

The corrosion coupons shall be of flush and retrievable type mild steel ASTM 1010 grade circular disc
coupons of 1.25” dia x 1/8” thickness with one mounting hole of ID 0.312” with an exposed surface
area of 2.4 sq. inch with at least one year shelf life.

ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER:


DGS-FF-106

CORROSION MONITORING SYSTEM


Rev: 0 Date: March 2006
FOR PIPELINES
Page 5 of 7
Quantity required for each location: 1 + 4 (for replacement after every 90 days)=5

The corrosion coupon holders shall be of 2”standard adjustable and retrievable solid plug assemblies
for disc flush type circular disc coupons, suitable for 2”NB, 5.25 “ height flare weld standard Access
fittings.

Corrosion coupon holders for each location : 1

4.2 ELECTRICAL RESISTANCE CORROSION PROBES ( HIGH SENSITIVE E.R. PROBES):

The E.R Probes shall be of high resolution/ high sensitive, high pressure, suitable to the maximum
design pressure of 142 bar and maximum design temperature of 105 deg.C in IRP pipelines given in
3.5 above retrievable, flush mounted body in 316SS with hollow plug and designed for installation on
standard 2” access fittings. The proposed Corrosion coupons and high sensitive ER probes shall be
approved by the Company before installation. The probe shall be suitable for measurement of corrosion
rate in range of 0-5 mpy; probe life shall be at least 2 years at 1 to 1.5 mpy corrosion rate.

The probe element shall be AISI 1018CS. The probe length shall be decided by the vendor as per the
locations and pipe details given in the Design basis document. The supply shall include essential
consumable spares.

Quantity required for each location = 1(installation)+ 1(standby) = 2 Nos.

4.3 ACCESS FITTINGS FOR CORROSION COUPONS AND ER PROBES:

The Access fittings shall be Tee Type of heavy duty CS protective covers with hole; 2” NB 5.25”
height, flare weld suitable for welding to pipeline as per pipeline data given in 3.5 , body materials
AISI-1020 carbon steel threaded inside and outside to accommodate 316SS hollow plug assembly and
heavy duty protective carbon steel cover.

Quantity required for each location.: 1 No.

4.4 RETRIEVER AND SERVICE VALVE KITS:

a) Retriever kit complete with repairs spares and seal kit. The stroke length shall be decided by the
vendor suitable for Corrosion coupons and high sensitive ER Probes with all essential spares for
2 years.
Quantity required for two locations : 1 No.

b) Service valve kits: Complete with Blanking plug, extension lever, brass hammer, spare face to
access fitting O-ring, heavy duty field service box essential repair and seal kit and other essential
spares for 2 years.
Quantity required for every two locations : 1 No.

4.5 Portable ER Corrosion Monitoring Instruments (Corrosion Meter) with the following characteristics:

• Quantity required for each terminal : 1 No.

• Digital data display

ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER:


DGS-FF-106

CORROSION MONITORING SYSTEM


Rev: 0 Date: March 2006
FOR PIPELINES
Page 6 of 7
• Intrinsically safe

• Rechargeable battery and AC Battery charger

• Probe extension adapter

• Probe extension cable of length as required based on locations

• 24V portable & battery operated

• Corrosion Resolution: 1 division(0.1% of Probe span)

• Measurement Repeatability: +1 dia division

• Measurement Range:0-10 mpy

• Operating temperature: -18 to 45 deg. C

• Complete with carrying case, 4 batteries, operation and maintenance manual.

5.0 INSPECTION AND TESTING

The manufacturer shall carryout inspection and testing as per the service requirements of this
specification, for all items of his works prior to shipment. Manufacturer'’ test certificates in printed
format must be sent with the dispatch paper of all supply items.

6.0 PAINTING AND MARKING

All Access fittings shall be painted and marked as per manufacturer’s standard before shipment. All
items shall be properly packed and protected to avoid damage during shipment. Insurance during
shipment shall be ensured by the manufacturer

7.0 SPARE AND ACCESSORIES

The manufacturer shall supply required spare and accessories as specified in the specification of the
materials.

8.0 VENDOR DOCUMENTATION TO BE SUBMITTED FOR REVIEW & APPROVAL AT


APPROPRIATE STAGES OF MANUFACTURE, SUPPLY, INSTALLATION AND
CONSTRUCTION.

• All component data sheets.

• Engineering, purchasing and construction schedule

• Spare part list of commissioning & Start up.

• Spare part list for 2 years of operation

• Installation, Operating and Maintenance manual

• Quality Assurance Plan for manufacture and construction.

ABU DHABI OIL REFINING COMPANY DOCUMENT NUMBER:


DGS-FF-106

CORROSION MONITORING SYSTEM


Rev: 0 Date: March 2006
FOR PIPELINES
Page 7 of 7