NACE Paper No.

MECCOCT18-12629

Managing Corrosion in NGL Plant Through Establishment of IOW

Lay Seong Teh, Faisal M. Al-Mutahhar, Mohammed Y. Al-Salloum, Qasim J. Al-Hassan

Consulting Services Department
Saudi Aramco
Dhahran, 31311
Saudi Arabia

Ahmad Fadzil B. Mohammad

Process & Control Systems Department
Saudi Aramco
Dhahran, 31311
Saudi Arabia

Salman A. Al-Dossary, Soelistiono K. Prasetiyo, Mohammad I. Al-Dazaz

Abqaiq Plants Operations Department
Saudi Aramco
Abqaiq, 31311
Saudi Arabia

ABSTRACT

Proactive corrosion management is crucial for an ageing natural gas liquids (NGL) processing facility to
safeguard asset integrity, personnel safety and environment while operating to meet increasingly
challenging demands in wet sour service. To ensure continuous improvement and sustainability of the
corrosion management program (CMP), integrity operating windows (IOWs) have been developed from
the key variables that were re-defined on the basis of better performance due to (i) the recent change of
a more cost effective and efficient corrosion inhibitor and (ii) the optimization study of operating
parameters for enhancing the Tri Ethylene Glycol (TEG) dehydration performance. Integrated with real-
time data historian, the IOWs are developed together with corrosion key performance indicators (KPIs)
into an online dashboard. Monitoring the IOWs through an online dashboard allows early detection of any
deviation and ensures timely implementation of corrective actions. This paper describes the proactive
approach of re-defining the operating envelope for the development of IOWs and its integration into an
online dashboard to more effectively manage corrosion for an ageing NGL facility processing wet sour
gas.

Key words: Integrity operating window, IOW, corrosion management, proactive, NGL, TEG

1
 INTRODUCTION

Operations with ageing assets constructed of non-hydrogen induce cracking (HIC) resistant carbon steel
in wet sour service pose real challenges in managing corrosion in this ageing NGL facility. With increasing
demand for higher productivity in a more efficient manner, it is important to maximize plant availability
with minimum unplanned outages by proactively ensuring asset integrity. A structured corrosion
management program (CMP) to monitor, control corrosion in relation to degradations and the associated
risks becomes key to improving asset integrity. The success of a sustainable CMP lies in its ability to
evolve with changes in environment, i.e. the proactiveness to identify and mitigate emerging corrosion
threats, to adopt new concepts and to integrate changes into the CMP framework.

Upstream of TEG – Compression and Fractionation

Wet sour gas is compressed and cooled in two stages via fin-fan inter-stage and after coolers in several
compression trains. Condensed liquid hydrocarbon is sent to NGL strippers, of which C3+ NGL is
produced at the bottom and off-gas at the overhead. The most critical locations with high likelihood of
leaks are the fin-fan tubes. This system consists of NGL and wet sour gas streams. These non-HIC
resistant carbon steel fin-fan tubes, are susceptible to wet H2S damage and acidic sour water corrosion
since the internal surfaces are exposed to high hydrogen sulfide (H2S) partial pressure, significant
presence of carbon dioxide (CO2) with low pH and the water condensation, particularly in winter months.
As a result, corrosion inhibitor has been injected at the inlet of these coolers to primarily protect the fin
fan tubes.

Statistic of major failure history showed that about 25% of corrosion failures were caused by fin-fan tube
leaks despite having protected by the corrosion inhibitor system. It is also reported that the current
corrosion inhibitor experienced problems with plugging of flow meters.

Downstream of TEG – De-ethanizing and Refrigeration

The stripped overhead off-gas then joins the stripper feed drum off-gas as wet gas to TEG unit for
dehydration before flowing to de-ethanizing section as a dry gas for further NGL recovery and
hydrocarbon dew point control. Without free water in the process stream, none of the commonly
encountered damage mechanisms, i.e. sour water corrosion and wet H2S damage, can take place and
hence, reducing the likelihood of loss of primary containment in de-ethanizing section, in which the high
H2S concentration is expected at de-ethanizer overhead.

However, recent historical data showed that the average feed gas rate to TEG contactor was in many
occasions higher than the design flowrate. In addition, the contacting temperature was often higher than
design; especially during day time in summer season. Higher feed gas rate and higher inlet temperature
would increase water load to TEG system, both at contactor and regenerator; hence causing higher
moisture content in the dry gas leaving TEG unit. As a result, the off-specs dehydrated gas flowing to the
de-ethanizing section would contain higher moisture content than what the system was originally
designed for. Saturated with lean TEG and contained entrained lean TEG, the excessive moisture would
co-condense with TEG at de-ethanizer feed chillers and de-ethanizer overhead condensers, hereafter
referred as chillers and condensers, respectively.

A combination of excessive moisture content, TEG carryover (in both vaporized and entrained forms)
and high H2S concentration at de-ethanizer overhead creates an undesirable wet sour environment,
which it was not designed for. Over the years, this has led to several unanticipated tube leaks in chillers
and condensers, which potentially contaminated the propane in an otherwise clean refrigeration system.

2
 APPROACH

To effectively and efficiently mitigate corrosion threats, corrosion engineering by itself is considered
insufficient and corrosion management is a prerequisite. Corrosion management could be defined as the
process of reviewing the required integrity management measures, regular monitoring of their
performance and the assessment of their effectiveness during asset operation. 1 A corrosion
management program is typically developed encompassing corrosion loops, damage mechanisms,
corrosion risk assessment, corrosion mitigation strategy, inspection plan, corrosion monitoring plan and
IOWs. Success and sustainability of CMP depends on the effectiveness and optimization of these
elements, the integration among these elements and the continuous efforts striving for improvement.

This paper focuses on the integration into the development of IOWs the latest optimization of corrosion
control measures in the most critical areas. The proactive nature of these IOWs should provide early
signs of relevant degradations that may lead to partial loss of function of the asset over time. Accordingly,
corrosion prevention via IOWs is of paramount importance to preventing critical failures.

Acknowledging the deficiencies in the corrosion inhibitor system in the compression section and TEG
dehydration performance as well as significantly higher risks of failure associated with fin-fan tubes and
the de-ethanizer column, optimizations were conducted.

Enhancement of Corrosion Inhibition Performance

Laboratory evaluations of five chemicals were conducted using autoclave methodologies under simulated
field operating conditions (temperature, H2S, CO2, purged and pressurized with N2 to achieve required
pressure) of the inter-stage and after coolers in a synthetic brine prepared per field sample properties.
Weight loss coupon was mounted in the autoclave to measure the corrosion rates in the uninhibited and
chemically inhibited brines. Efficiencies of individual chemicals were calculated by comparing the
corrosion rates in the inhibited brine and the uninhibited brine. Two chemicals that provided superior
corrosion inhibition efficiency (78%-88.5%) were subject to a field trial for six months.

During the field trial, injection rates were optimized without exceeding a target corrosion rate of 0.076
mm/yr (3 MPY). The field trial concluded that Chemical D offers for the same corrosion protection (or
inhibition efficiency) with about 20% less consumption than the incumbent corrosion inhibitor
consumption and a cost saving of more than 30%.

Table 1: Summary of the laboratory evaluation and field trial of corrosion inhibitors

Efficiency through Laboratory

Field Trial
Chemical Evaluation
Inter-stage Cooler After Cooler Cost Factor Cost Saving
Chemical A 88.51% 77.96% 0.92 -45%
Chemical E 88.24% < 60%
Chemical C 72.37% 72.75%
Chemical D 82.6% 86.77% 0.82 30%
Incumbent 90.7% 73.95% 1 0%
Note: Cost factor is a measure representing an equivalent concentration of a chemical providing the same
protection as provided by the incumbent chemical.

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Optimization Study of TEG Dehydration Performance

Various simulation runs were performed by varying (i) lean TEG circulation rate to TEG contactor and (ii)
stripping gas rate to stripping column. Operating conditions were applied based on the worst-case
scenarios.

Figure 1: Water dew points with presence of TEG at various moisture contents

Presented in Figure 1 are:

i. The heavy liquid phase dew points with the presence of TEG in the dehydrated gas at various
moisture contents. It should be noted that presence of TEG in the dry gas will significantly increase
heavy liquid phase dew point.
ii. The recommended operating temperatures for the chillers and condensers are 27°C - 33°C (80°F-
92°F) and 21°C (70°F), respectively to minimize the likelihood of condensation and hence the
impact of corrosion.

Based on simulation runs, the maximum allowable water content with presence of TEG in the dry gas is
approximately 25% higher than design at the specific operating parameters with nearly 25% higher wet
feed gas. Beyond this value, co-condensation of water and TEG will occur and the presence of free water
will potentially lead to corrosion issues downstream, with particular concern of wet H2S damage at de-
ethanizer overhead section due to high H2S concentration.

1) Optimize the reflux ratio at still column by adjusting rich TEG bypass flowrate around still reflux
condenser.
2) Maintain steam temperature to the reboiler operating at design temperature.
3) Maintain lean TEG circulation at optimum flowrate and use stripping gas to increase lean TEG
purity with gradual introduction of stripping gas.
4) Use feed gas inlet temperature as reference temperature for controlling lean TEG temperature to
TEG contactor i.e. maintaining lean TEG temperature 10°F higher than inlet feed gas
temperature.

4
Development of IOWs

Per API Recommended Practice 584 2, IOWs are the “Established limits for process variables
(parameters) that can affect the integrity of the equipment if the process operation deviates from the
established limits for a predetermined length of time”. The document explains the importance of IOWs
(also known as the “operating envelope”) for corrosion and process safety management. This
recommended practice also guides users in establishing and implementing an IOW for the express
purpose of avoiding unexpected equipment degradation that could lead to loss of containment.

The operating envelope is a collection of constraints, boundaries, and operating limits in a process unit.
When the envelope is exceeded, the integrity of the asset is at risk. These boundaries are typically based
on a combination of factors, such as degradation mechanism thresholds, integrity safety limits, process
unit capacity, equipment constraints, and safety concerns. It should be noted that to maximize the life of
an asset in an industrial facility, assets must be operated according to safe integrity parameters, and not
simply within process safety limits. That means extending operating strategies beyond process
engineers’ understanding, to all those interacting with the CMP.

Variables based on Damage Mechanisms 3

As discussed earlier, the equipment and piping in this NGL facility are predominantly susceptible to wet
H2S damage and acidic sour water corrosion. The most important variables that affect wet H2S damage
are environmental conditions (pH, H2S level, temperature), material properties (hardness, microstructure)
and tensile stress level (applied or residual). On the other hand, H2S content, CO2, pH, temperature and
oxygen concentration are all critical factors for sour water corrosion.

Among these variables, H2S content depends on the stabilization depth of the crude stabilization column
upstream and is beyond the control of NGL facility. Hardness and residual stress are controlled during
welding process whereas microstructure was limited during design/construction phase. Operating
temperatures and pressures fall within susceptible range of both damage mechanisms. The variable that
should be monitored is pH in the water sample for the following reasons:

• Above a pH of about 4.5, a protective, thin iron sulfide layer limits the corrosion rate.
• At a pH above 4.5, a thicker, porous sulfide film layer can form promoting pitting under sulfide
deposits.
• pH below 4.5 indicates the presence of a strong acid which would be the main corrosion concern.

Variables for Corrosion Inhibition System

Since the corrosion inhibitor dosage was optimized with a corrosion rate less than 0.076 mm/yr (3 MPY)
during the field trial, this variable should be controlled and monitored for the amount of chemical injected
per feed gas flowrate as per optimized target. In order to gauge the efficiency and effectiveness of the
corrosion inhibition system, it is important to monitor the residuals and total iron counts (5-10 ppm) in
aqueous phase as well as the corrosion rates (< 0.127 mm/yr / 5 MPY) of the weight loss coupons
installed/retrieved in the chemically treated lines.

Variables based on Optimization of TEG Performance

The following variables need to be monitored based on the optimization study of TEG:

• Moisture content of the dehydrated TEG gas

• Operating temperatures for the chillers and condensers to be controlled above the associated
dew points, respectively

5
 • Lean TEG temperature: 10°F higher than inlet feed gas temperature
• Limiting operating conditions applied in the simulations

The following IOWs, as listed in Table 2, were developed through an interactive workshop involving a
team of process/corrosion/operations engineers knowledgeable in corrosion and deterioration
mechanisms as well as in the processes being evaluated. Once all the potential and likely types of
degradation and modes of failure are identified, limits were set on those process variables that can have
an impact on the type and rate of deterioration. The limits may require revision based on experience.

Table 2: IOWs defined for the development of online dashboard

# Description & Location
1 Corrosion Inhibitor Dosage Rate
at Interstage Cooler inlet
2 Corrosion Inhibitor Dosage Rate
at After Cooler inlet
3 Corrosion Inhibitor Dosage Rate
at HP Stripper Feed
Accumulator Drum Off Gas
4 Inhibitor Residual at Interstage
Separator water boot
5 Inhibitor Residual at Stripper
Feed Accumulator Drum water
boot
6 Iron Counts at Interstage
Separator water boot
7 Iron Counts at Stripper Feed
Accumulator Drum water boot
6 pH at Interstage Separator water
boot
7 pH at Stripper Feed Accumulator
Drum water boot
8 Corrosion rates of Corrosion
Coupons at CI lines
9 TEG Inlet Feed Gas Throughput
(for information only)
10 Feed Gas Temperature to TEG
Contactor (for information only)
11 Lean TEG Circulation Rate
12 Differential Temperature
between Lean TEG (higher) and
Feed Gas (lower)
13 Dry Gas Moisture Content
Min Max Unit Timescale Consequences Action Required
GPD/MM Continuous min. - accelerated internal Adjust injection rate to
SCFD corrosion at fin fan tubes meet target range
max. - cost impact
GPD/MM Continuous min. - accelerated internal Adjust injection rate to
SCFD corrosion at fin fan tubes meet target range
max. - cost impact
GPD/MM Continuous Adjust injection rate to
SCFD meet target range
ppm Monthly min. - accelerated internal Adjust injection rate to
corrosion at fin fan tubes meet target range
max. - cost impact
ppm Monthly min. - accelerated internal Adjust injection rate to
corrosion at fin fan tubes meet target range
max. - cost impact
ppm Monthly min. - accelerated internal Adjust injection rate to
corrosion at fin fan tubes meet target range
max. - cost impact
ppm Monthly min. - accelerated internal Adjust injection rate to
corrosion at fin fan tubes meet target range
max. - cost impact
Monthly min. - accelerated internal Inject neutralizer until pH is
corrosion within target range
Monthly min. - accelerated internal Inject neutralizer until pH is
corrosion within target range
MPY per max. – high internal Increase CI injection rate
retrieval corrosion activities
interval
MMSCF Continuous Corrosion downstream of Document and report the
D TEG unit due to exceedances to concerned
excessive water carryover parties
deg. F Continuous Corrosion downstream of No action - this cannot be
TEG unit due to controlled
excessive water carryover
GPM Continuous Corrosion downstream of Adjust Lean TEG
TEG unit due to circulation rate to meet
excessive water carryover target range
deg. F Continuous Corrosion downstream of Adjust Lean TEG
TEG unit due to temperature to meet
excessive water carryover differential temperature
target range
ppm Continuous Corrosion downstream of Investigate and adjust
TEG unit due to parameters impacting TEG
excessive water carryover performance

6
 # Description & Location
14 TEG Still Column Reflux
Temperature
15 TEG Reboiler Temperature
16 Lean TEG Concentration
17 Stripping Gas Flowrate
18 pH of Lean TEG
19 pH of Rich TEG
20 H2S content in Propane
Min Max Unit Timescale Consequences Action Required
deg. F Continuous Corrosion downstream of Adjust the reflux bypass
TEG unit due to
excessive water carryover
deg. F Continuous Corrosion downstream of Adjust the steam flowrate
TEG unit due to
excessive water carryover
% wt Bi-Weekly Corrosion downstream of 1.) Adjust the stripping gas
TEG unit due to flowrate to meet Lean TEG
excessive water carryover concentration target range
2.) Refill Lean TEG
MMSCF Continuous Corrosion downstream of Adjust fuel gas flowrate to
D TEG unit due to meet target range
excessive water carryover
Continuous Corrosion in TEG unit Min: Inject neutralizer
(Amine) until pH is within
target range
Daily Corrosion in TEG Min: Inject neutralizer
Regeneration system (Amine) until pH is within
target range
0 % mol Weekly HIC Refill with fresh propane

Online Dashboard 4

With the company in-house software, the IOWs are then integrated with real-time process variable
measurements, laboratory analysis results, and inspection history records, in a simple to read web-based
dashboard. This dashboard provides a holistic view of the defined operating envelope, ensuring its
compliance is tracked continuously against its limits

Driven by the necessity of reporting all relevant process excursions impacting asset integrity to concerned
parties in the facility and at central engineering, the system was developed to send notifications to users,
according to the corrosion risk of a given variable excursion (or sets of excursions) constitutes to asset
integrity. The notification relates the corrosion risks associated with each or a combination of excursions.
For example, a pH drop below 4.5 causes more severe damage than a 20% under-dosage of corrosion
inhibitor for a couple of days. Such pH drop requires immediate corrective action to avoid potential
corrosion failures.

CONCLUSIONS

Integrity operating window (IOW) is an essential CMP element to proactively manage corrosion in this
ageing NGL facility. Capturing the recent improvement in corrosion inhibitor system and optimization
study of TEG dehydration performance, key process and corrosion related parameters were re-defined
to mitigate emerging corrosion threats and developed into IOWs. Such proactiveness is key to a
sustainable CMP. Monitoring the IOW through an online dashboard allows early detection of any
deviation and ensures timely implementation of corrective actions through a notification tool.

ACKNOWLEDGEMENTS

The authors would like to thank all professionals who contributed to the development of the IOWs and
online dashboard. We would like to also thank our management for allowing us to submit and present
this work.

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 REFERENCES

1. H.J. Debruyn, S.M. Al-Ghamdi, “Corrosion Management Implementation in Large Oil and Gas
Projects,” NACE CORROSION/2016, paper no. NACE International, Houston, Texas, 2016.
2. API Recommended Practice 584 (first edition), “Integrity Operating Windows,” American Petroleum
Institute, May 2014.
3. API Recommended Practice 571 (second edition), “Damage Mechanisms Affecting Fixed Equipment
in the Refining Industry,” American Petroleum Institute, April 2011.
4. R.S. Costa, H.J. Debruyn, “Monitoring Performance of Corrosion Management Program through
Online Dashboards,” Materials Performance and Welding Technologies Conference, Dammam, Kingdom
of Saudi Arabia, 2017