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Introduction
Black powder, a mix of iron sulfides, oxides, and other material can represent a serious threat to the
integrity of pipelines by plugging pipelines, eroding compressor components, plugging
instrumentation and pipeline drips, preventing valid in-line inspection by In-Line Inspection (ILI) pigs,
and causing damage to customer equipment.
However, black powder may not be a problem until it starts to move due to fluid velocity. The
velocity to cause movement of dry black powder in pipelines is presented for black powder in gas
pipelines. Once black powder starts to move, it will continue to move until the flow rate is reduced
or the gas is compressed. Examples of black powder problems in the field are presented. Movement
of dry black powder can be partially controlled by using corrosion inhibitors, while powder wet with
compressor oil requires higher velocities
Black powder is the least understood but most prominent contamination problem in gas pipelines,
but it is a problem that is increasingly being recognized. Black powder is the name given to the
mixture of iron oxides, carbonates and sulfides found in gas pipelines, and can also include salt,
sand, clay, mineral scales such as calcium carbonates and gypsum, strontium and barium sulfates,
metal powder, welding flux and weld rod stubs.
The sources of black powder include mill scale, corrosion products from inside and upstream
sources, salts and scales from gas wells and wet gas gathering systems, and atmospheric rusting. The
variability of black powder is illustrated by reports of the powder being completely iron sulfide to
completely iron oxide. Red rust (rouge) can be present both from atmospheric oxidation of pipe not
properly stored nor cleaned. Magnetite and elemental sulfur result from air oxidation of pyrophoric
iron sulfide. Dry iron sulfide powder will spontaneously ignite if exposed to air, and represents a
safety, storage and disposal problem. This paper will illustrate that the problem of black powder is as
much one of powder movement as one of the presence of black powder.
A technique to calculate the velocity required to sweep solids through horizontal pipelines by fluid
drag has been developed by Wicks. A similar analysis also has been presented by Wicks and Fraser to
predict the entrainment velocity for water in flowing oil, one of the most important and
fundamental analysis techniques for analysis of internal pipeline corrosion. The following analysis
was developed to predict at what fluid velocity particulates can be dislodged from a bed of particles
in the bottom of a pipe, and then carried through the pipeline.
References:
1.0 Bid should be complete covering all the scope of job / supply and should conform to the
technical specifications indicated in the bid documents, duly supported with technical
catalogues/ literatures wherever required. Incomplete and non-conforming bids will be
rejected outright.
Should have carried out at least 50 risk assessment / Fit-For Purpose / Residual Life Assessments
and at least 50 major anomaly assessments / Corrosion Growth Assessment (CGA) for onshore or
offshore pipelines and/or Subsea Umbilical, Riser and Flowline (SURF) equipment during the last 5
(five) years reckoned from the date of opening of the techno- commercial bid.
To this effect, Bidder should submit copies of respective contracts, along with documentary
evidence in respect of satisfactory execution of each of those contracts, in the form of copies of any
of the documents (indicating respective contract number and type of services any other documentary
evidence that can substantiate the satisfactory execution of each of the contracts cited above.
In cases where scope of work involves rendering services and supply of material also, the offer from
a bidder who meets the experience criteria either on its own or based on the experience of
the supporting company shall be accepted.
In case bidder is not able to execute supply of material portion of the scope of work on its
own, then it shall be allowed to supply material through other company provided that the
bidder and the company supplying material belongs to same group of companies
3.0 Bidder should have on his payroll at least one specialist each for following disciplines with
qualification and experience as mentioned against each:
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