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This paper was presented at the 24th Annual OTC in Houston, Texas, May 4-7, 1992.
This paper was selected for presentation by the OTC Program Committee following review of information contained in an abstract submitted by the author(s), Contents of the paper,
as presented, have not been reviewed by the Offshore Technology Conference and ere subject to correction by the author(s). The material, as presentad, does not naceaaarily reflect
any position of the Offshore Technology Conference or its offlcars. Permission to mpy is restrlctad to an abstract of not more than 3GQ words. Illustrations may not ba coplad, The abstract
should sontain conspicuous acknowledgment of whera and by whom the peper Is presentad.
ABSTRACT
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described as “characteristic of individual corrosion allowance, thus virtually no corrosion at all is
pitting, general corrosion containing pitting, selective permitted over the entire life of a pipeline, ofien more
corrosion attack of girth welds, and areas of relatively than 50 years. Offshore lines typically are designed on
uniform metal loss, which resembles general wall a 50% SMYS, effectively resulting in some corrosion
thinning but with a rough internal surface texture. ” allowance. A poll taken by the author indicates that
many pipelines accept a corrosion rate of about 0.3
Most oil and gas pipelines are well designed for mpy ( 0.01 mndyr) for pipeline internal corrosion as
corrosion control in their Mltial operation, but changing something they think they can live with.
conditions frequently result in offdesign operation afier
some period of time. System add-ens and partial
abandonments change the type and volume of fluids in INTERNAL CORROSION IN PIPELINES
the line and create dead spaces. Maturing of oil and gas
fields results in greater amounts of water and smaller Crude 011 Pipelines
amounts of oil and/or gas. This results in lower line
velocity and allows water to stratify in the bottom of or Crude oil pipelines can be characterized by low water
at low spots in the line where it can cause corrosion. content and low acid gas partial pressure compared to
Rlcca has also reported that internal corrosion has crude oil production pipelines. Crude oil pipelines
occurred in “dead legs” in the Trans Alaska Pipeline usually have some beneficial carry-over of corrosion
(Ref 3). inhibitor from crude oil production units. Pipeline
crudes, however, are subject to oxygen and bacteria
Full Well Fluids Transmission (FWFT), has resulted in contamination from truck hauling and from storage in
substantial volumes of water being transmitted through lease and pipeline terminal tanks, which can negate the
offshore pipelines which did not previously transport beneficial effect of inhibitor carryover from production
water, and for which the pipelines were not designed. facilities, and make crude oil pipelines significantly
The development of environmental regulations in the corrosive.
1970’s limited the discharge of oil into the sea. This led
to transmission of the entire liquids production from In oil pipelines, water is usually specified to be at a
offshore platforms, including free water, to shore when low level, typically 0.5 to 2% BS&W. Usually, once
the fluids could not be adequately treated offshore. At oil enters a pipeline, no further effort is made to
the same time, cost reduction pressures in the gas remove water until the oil is refined. Indeed, active
industry has resulted in some ofihore gas dehydration efforts are made to keep any water in the oil in
units being shut down, with all well fluids again being suspension such as by the use of mixers in storage
transmitted to shore for dehydration and further tanks.
treatment.
Water can stratify in pipelines, however, if the
Declining oil and increasing water production from velocity in the line is less than that required to sweep
maturing fields, acceptance of off-spec gas to fidfill the oil through the line or if the line is operated in a
contracts when shortages have occurred, increased stop-start mode. The oil velocity at which water is
construction activity during the past 20 years and the entrained in flowing oil can be ~timated by the
aging nature of the pipeline system are also important technique of Wicks and Fraser (4), and depends upon
reasons for internal corrosion failures. Internal the relative densities of the oil and water, the
corrosion can also result from process upsets which interracial tension between the oil and water, and the
introduce liquids into normally dry pipelines. pipe diameter. Entrainment velocity is typically in the
range of 0.8 to 3 feet per second, and is greater in
The allowable corrosion rate for pipelines is usually larger pipe sizes. Once water accumulates in low
very small. Many land based pipelines are designed points, the pipe wall can become water wet and
based upon a 72% Specified Minimum Yield Strength corrode at a rate determined by the properties of the
criterion for wall thickness. This results in no corrosion water, the condition of the pipe wall, and whether or
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not bacteria are in the line. Monitoring corrosion in low Transmission service.
spots can be very difllcult, however, as they are
frequently under a river or offshore.
FEDERAL REGULATIONS ON MONITORING
Gas Pipelines INTERNAL CORROSION IN PIPELINES
Wet gas pipelines present a more complex internal Currently, the US DOT Pipeline Safety Regulations
corrosion problem, as they typically are in multi-phase (Ref. 11) require internal corrosion control and
flow and have higher partial pressures of corrosive monitoring of gas and hazardous liquid pipelines.
gasses such as carbon dioxide and hydrogen sulfide. These include corrosion control measures, monitoring,
Gas pipelines experience many different regimes in and inspection and repair, replacement or derating of
multi-phase flow, including stratified flow (liquids in corrosion damaged pipe.
gas and watty in hydrocarbon), slug flow, and annular
mist flow. The corrosion parameters of these different
flow regimes can be different, and include condensing MONITORING INTERNAL CORROSION
water conditions leading to possibly large volumes of IN PIPELINES
water and a high water/oil ratio, diftlculty in estimating
the velocity required to sweep water through the In review, on-line, accurate and representative
pipeline, and difllculties in applying corrosion inhibitors monitoring of corrosion in pipelines can be a difllcult
under changing flow regime conditions. task for several reasons, including:
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develop stagnant conditions which do not reflect actual 2. have a water zone in which to make
pipeline corrosion rates. continuous corrosion measurements;
3. have non-stagnant conditions representative of
Often the fwst sign a pipeline operator has of internal fresh pipeline fluids, and be capable
corrosion problems is when he finds rouge or black of determining changes in the
deposits on his pump filters. Rouge is a fine iron oxide corrosivity of pipeline fluids in a short
corrosion product, and is considered to be a nuisance time;
due to plugging up the filters. The meaning of finding 4. preferably, the pipeline should remain
significant amounts of rouge in the filters is open to piggable.
interpretation. Superilcially, the uniform corrosion rate
in a ~ipeline represented by finding rouge is minuscule. To meet these requirements, a new pipeline corrosion
For instance, if 1 pound of rouge per day is recovered monitoring system has been developed, shown
in the filters from 50 miles of 8 inch line, the uniform schematically in Figure 2, which is capable of mtilng
corrosion rate in the pipeline would be only 0.011 roils accurate and continuous on-line corrosion rate
per year (.0005 rnm/yr). Corrosion in pipelines is measurements on fresh pipeline fluids under worst
seldom uniform, however, and occurs over an unknown case conditions. The system developed consists of a
but usually very small fraction of the internal pipe wall. by-pass arrangement connected to the pipeline through
If the corrosion is assumed to occur in a band 0.5 access fittings, including a test chamber through which
inches wide along the bottom of the pipe and to occur pipeline fluids are circulated and tested, and then
along only 1% of the length of the pipe, then the returned to the pipeline. Measurements are made at
equivalent corrosion rate would be 50 mpy, capable of pipeline operating pressure and temperature.
penetrating most pipelines within a few years or causing
the line to leak or burst. The corrosion test chamber features 3 sections:
Once corrosion is suspected in a system, intelligent pigs Pipeline fluids are metered into the test chamber by a
are the best way to inspect for existing corrosion positive displacement circulating pump. The flow rate
damage. Intelligent pigs describe actual damage which is designed to give effective mixing of the pipeline
has occurred to the pipeline, but must be run frequently fluids with the test chamber water phase without
to determine corrosion rates. emulsifying the two phases, clean separation of
pipeline hydrocarbons from the water phase, provide
conditions suitable for bacteria to colonize the test
instruments, and to provide rapid response to changing
DEVELOPMENT OF AN ON-LINE INTERNAL conditions in the pipeline.
PIPELINE CORROSION AND BACTERIA
MONITORING SYSTEM Corrosion and bacteria coupons and probes are located
in the water section of the test chamber, and additional
Design coupons can also be located in the vapor space and in
the hydrocarbon layer. Any number of access points
For an internal pipeline corrosion monitor to be able to can be built into the test chamber. Liquid sampling
function in an on-line, representative and reliable valves are also included to allow water and
manner, it must: hydrocarbon sampling for analysis.
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Construction Operation
The pipeline monitor system is built to all applicable The monitoring system is attached to the pipeline, and
pipeline codes, with the standard unit equipped with the test chamber containing the coupons and probes is
ANSI 600 fittings with a nominal 1440 psi working filled with water. Water from the pipeline system is
pressure. Higher or lower pressure capacities are preferred, if possible, to minimize initial differences
available. The monitor is fully weld inspected, between pipeline conditions and those in the test
hydrotested, and internally coated. Electric power is chamber. The isolation valves are opened, and fittings
required to operate the circulating pump, and is and probes tested for leaks. Closing the isolation
preferred for operation of the data gathering system. All valvw allows work on the unit, such as changing of
electrical equipment is NEMA Class I so that the unit coupons and probes and cleaning of the system to be
can be installed in Class I areas such as inside tank farm done under ambient pressure conditions. This greatly
walls, on offshore platforms, or even on refinery piping simplifies operation and eliminates the need for
runs. pressure retrieval equipment.
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To test and demonstrate the operation of the monitor, a MONITORING EQUIPMENT
full scale clear plastic model was constructed for use in
the laboratory. The laboratory system model differed Four monitoring devices are suggested for use in the
from the field model design in only two ways: standard unit, although there is no limit on the number
of coupons and probes which can be installed in the
1. the hydrocarbon and water phases were taken device. These are:
from a reservoir, circulated through the
monitoring system, and recirculated to the 1. coupons,
reservoir; and 2. galvanic probe,
3. linear polarization probe,
2. a centrifugal circulating pump and a flow 4. bacteria probe.
control valve were used rather then a positive
displacement metering pump. This was done to In addition, oil and water fluid sampling points are
be able to conveniently change the circulation provided to permit the measurement of fluid properties
rate to establish the operating range of the such as water pH and analysis, iron counts, cmrosion
device. inhibitor residuals, other bacteria testing, and oil
properties of interest. Other monitoring probes also
Stable operation with good liquid-liquid contact was can be included, such as hydrogen probes for use in
established between the hydrocarbon and water phases, sour systems, and there is no limit on the number of
and rapid and complete separation achieved over a probes and coupons which the unit can be designed to
range of operating conditions, including flow rate, include. Automatic data logging equipment is
water/oil ratio, and oil density and viscosity. Response recommended for continuous monitoring of the
time to changes in the fluids ranged from about two Galvanic Probe and the Linear Polarization Probe.
minutes to about ten minutes, with the most rapid
response occurring when mostly fkee water entered the Coupons are included as they fulfill US DOT
monitoring system. A vapor space was seen to develop monitoring requirements, and can monitor corrosion in
at the top of the unit when gases were introduced into all three phases, including the vapor space at the top
the monitor. This vapor space remained in the unit until of the monitor. They also give long term cumulative
the top-side fluid sampling valve was opened. corrosion results, and are usefid for comparison to
past monitoring results. Coupons also would determine
One objective in the development of this monitoring if scale or parafiln problems are occurring in the
system was to maintain clean water in the test chamber pipeline.
for the long term accurate performance of the
polarization probes. If the electrodes of polarization Bacteria monitoring is performed by a sessile bacteria
probes become contaminated with oiI, they can give probe installed in the water layer which provides a
erratic results. Clean water was observed during the large surface area for bacteria to colonize. The
initiaI operation of the plastic monitoring system model. bacteria probe provides convenient samples to culture
The plastic model test chamber water eventually became upon removal from the unit, or examine using
cloudy, however, due to using a high shear centrifugal microscopy or other rapid assay tests.
pump, a high shear flow control valve, and recirculation
of the fluids during laboratory testing. This is not On-Line Monitoring
expected to be a problem in field operation as a low
shear positive displacement metering pump is used, the Both the linear polarization probe and the Galvanic
flow control valve is not used, and fluids are not Probe give continuous readings of system conditions,
recirculated except possibly when the pipeline is not and thus on-line capability.
flowing.
Computer driven polarization probes can be used to
enhance the capacity of this type of probe, including
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the tendency towards pitting. Electrochemical techniques contamination are quickly detected, permitting
have also been shown to detect the presence of bacterial treatment at the source or use of oxygen scavengers as
corrosion. (Refs. 13,14). Linear polarization probes are appropriate.
also very useful in evaluating the actual performance of
corrosion inhibitors in-situ, and can thus evaluate the One potential use involves the proposed evaluation of
need for and performance of corrosion inhibitors in a the treatment of crude oil entering a long sub-sea
pipeline. pipeline from an offshore producing field. The
The Galvanic Probe also provides continuous output, monitor would be installed at the beginning of the line
and thus, on-line capability. The Galvanic Probe has the to evaluate inhibition of fluids entering the line, and
advantage of being a rugged device suitable for field possibly again at landfall. Due to the properties of the
operation, but the disadvantage of not giving crude, the operating conditions in the line, and the
information from which a corrosion rate can be directly vital nature of the pipe line, the operator was
calculated. It consists of a brass rod and a steel rod concerned that the inhibition program must be
connected through an external resistor and ammeter. effective.
Two different metals in an electrolyte create an
intentional galvanic cell similar to a battery. The A second application would install the monitor at the
controlling resistance in the electrical circuit, and thus inlet manifold to a pipeline terminal receiving crude
the determination of the amount of current flowing in oil from several different fields. Corrosive crude oil
the probe, is the strength of the cathode (brass) was being received intermittently at the terminal but
electrochemical polarization film. the source was unknown. This required the terminal
operator to treat the crude at his own expense. By
Parameters which affect the strength of the cathode manifolding the inlet lines into the monitor, the source
electrochemical polarization film cause the output of the could be quickly switched to the different sources,
galvanic probe to vary. Principle among these are allowing the operator to determine when and from
oxygen, chlorine, hydrogen sulfide, and sulfate reducing whom he was receiving inadequately treated and
bacteria, and corrosion inhibitors (Ref 15). This makes corrosive fluids.
the galvanic probe a very useful device in monitoring
the most important causes of pipeline corrosion: oxygen Another application involved a products pipeline which
and bacteria. Both oxygen and SRB’S cause cathode carried several different products in batches ranging
depolarization, decreasing its electrical resistance, and from liquid mixed ethane/propane to distillates. Rouge
thus causing the amount of current passing through the was being picked up on the pipeline pump filters even
ammeter to increase. On the other hand, corrosion though all products were being inhibited. The operator
inhibitor films cause the polarization film to be was treating everything in the line uniformly and at a
enhanced, and lower the current produced. standard rate, but management questioned:
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monitor system with its on-line capability, and provide 8. Private Communication, M. A. Clarke,
the answers needed in this evaluation. Monitor Ltd
2. This system can be used for the determination 11. US Dept of Transportation
of corrosion rates in a pipeline, and evaluation Research and Special Programs Administration
of corrosion control programs. Pioeline Safety Remdation$
Natural Gas, Parts 191-192
Hazardous Liquids, Part 195
6. Private Communication.
642
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