02 - Siva Subramanian (Chevron) - Designing For TOLC

7/28/2015
Designing for Top of Line Corrosion

Management in Deepwater Subsea
Gas Condensate Flowlines
Siva Subramanian
PT Chevron Pacific Indonesia
I Made Adi Wardana, Yesudas Manimala, Robert Foster

Chevron Indonesia Company
Ferhat Erdal
Chevron Energy Technology Company
Dr.Ir. Bambang Widyanto

Institut Teknologi Bandung
© 2015 Chevron Indonesia. All Rights Reserved.
Corrosion Risk Assessment in Gas Dominated Flow
 Stratified flow regime

 Cooling & condensation with distance
 Mixing of fluid streams at different temperature
 CO2 in reservoir fluid
 Acetate in the formation water, produced gas
 Acetate in lean MEG injected (from regeneration)
 Bottom of line strategy
– Film forming corrosion inhibitor cocktailed with MEG
– Corrosion Allowance
 Top of Line
– Risk level  ?? Determined by multiple factors
– Mitigation  ?? Should be driven by risk level 2
© 2015 Chevron Indonesia. All Rights Reserved.
1
7/28/2015
Flowline Case # 1
 Subsea:
 Commingling
 1 x10” line with 3 mm external corrosion coating (3LPP), 2 mm CA
 Total ~32 km long, TAmbient = 4 oC
 Fluids
 0.9 mol% CO2
 Only Condensed water predicted
 HAc in formation water = 3360 mg/Kg, Total alkalinity = 4500 mg/kg
 Lean MEG composition = 85 wt% MEG, Free HAc = 4400 mg/Kg
 Partitioning into Gas:
 WGR = 0.5 bbl/MMscf
 Free acetic acid predicted = 0.06 ppm (mol)
© 2015 Chevron Indonesia. All Rights Reserved. 3
Comparison with Other Cases
HAc in Flowline 3LPP Flowline

Pressure Temp CO2 Lean MEG Corrosion
Formation Size Coating Lengths
(bar) (°C) (mol%) Composition Allowance
Water (mg/kg) (inch) Thickness (km)
4 km 
Case 1 200 68 0.9 10 3 mm 2 mm Commingling
 28 km
85 wt% MEG
2 km 
Case 2 137 41 1 3360 10 3 mm 3mm Commingling
Free HAc =
 6 km
4400 mg/kg
> 50 mm 2 km 
Case 3 191 97 2 10 Wet 6 mm Commingling
Insulation  7 km
Case # 2 Case # 3
Higher Temperature
Lower Temperature
Higher CO2
Shorter Length
Shorter Length
Formation Brine
Fully Insulated
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7/28/2015
Objective
 Can we use Carbon Steel flowlines?
– Perform quantitative risk assessment
Evolution of TOLC Risk Assessment
2011 2012-13
(Internal (External SMEs)
SMEs)
Detailed desktop study (simulation)

with & without regenerated MEG
Preliminary assessment using 2” wet gas flow loop experiments to measure
Critical Condensation Rate Limits Corrosion rates at flowline conditions
for sweet systems
0.025 g/m2s with organic acids
0.25 g/m2s without organic acids TOLC model
Multiscale
OLGA
QUANTITATIVE
@ F/L Inlet
QUALITATIVE
Case # 1  1.2 mm/yr
Case # 1  Medium/High Risk
Case # 2  0.42 mm/yr
Case # 2  Medium Risk
Case # 3 0.07 mm/yr
Case # 3 Low/Medium Risk
Effect of FeCO3 film not considered
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7/28/2015
TOLC Model (Nyborg and Dugstad, 2007) - NACE 07555

Top of Line Corrosion and Water Condensation Rates in Wet
Gas Pipelines Applicable for Sweet CO2 Systems
CR = 0.004 * Rcond * CFe * (12.5 - 0.09 * T)
Temperature
Top of Line Corrosion in °C
Rate in mm/yr
Water Condensation Rate
in g/m2.sec
Supersaturation
Solubility of Iron in of FeCO3
10x ppm weight
For Pitting f (T, P, pCO2, MEG concn.,
HAc concn.)
1.79x - 3.14x
For MEG co-condensation
Scenarios
Results A – Injection of Regenerated MEG  Both Co-condensation of MEG + Acetate from lean MEG
B – No MEG injection  No Co-condensation of MEG + No Acetate supply from lean MEG
TOL Corrosion Rate = Pitting Factor 10 x TOLC Model Predicted Rate
Years to
Predicted Pitting
Corrosion Consume
Pressure Temp CO2 Corrosion Corrosion
Scenario Allowance Corrosion
(bar) (°C) (mol%) Rate Rate
(mm) Allowance
(mm/yr) (mm/yr)
(yrs)
A 1.2 2 12 0.2
Case 1 200 68 0.9
B 0.37 2 3.7 0.5
A 0.42 3 4.2 0.7
Case 2 137 41 1
B 0.19 3 1.9 1.6
A 0.066 6 0.66 9.1
Case 3 191 97 2
B 0.062 6 0.62 9.7
 Case 1: Highest corrosion rate of 1.2 mm/yr @ the flowline inlet location
 Case 3: > 2 inch thick wet insulation yields lowest TOL corrosion rate
 Acetate in regenerated MEG is a significant source for acetic acid in the pipeline
 Application of a Pitting Factor = 10 would eliminate a Carbon Steel solution
4
7/28/2015
2013 Focus Activity - Clarifications
 Can model be considered benchmarked?

– Limited benchmarking with field. NACE 07555 discusses one case.
– Predicted rates in the same range as measured for one field pipeline (Ref:
Paper No. 09283, CORROSION/2009)
– Predicted TOLC rates reasonably agree with measured rates in flow loop
experiments
– YES
 Is Pitting factor = 10 justified on top of model calculated rates?

– NO
– Model is already based on the maximum corrosion that can take place and is
based on the fact that top of line corrosion can be localized.
Multiflash CPA-Infochem Model is Appropriate to Study Co-

condensation Issue
Reference - Research Report RR-211, GPA, 2011,

Chapoy et al., Heriot-Watt Univ.
Equilibrium Water Content in Natural Gas With Hydrates or
MEG Solutions
Data range: 25-200 bara, -20 to +10 C
MEG VLE of Binary Water-MEG system

Co-condensation Data Source: From Perry's ChE Handbook
With Water
5
7/28/2015
Comparison of Condensation Rates – Case 1

MEG
Co-condensation
Without MEG With Water
0.22 g/m2.sec from OLGA
vs.
0.19 g/m2.sec from
Multiflash-CPA
With MEG
0.53 g/m2.sec
(with scaling up factor of 2.4 for
MEG Co-condensation)
vs.
0.125 g/m2.sec from
Multiflash-CPA
76% Lower
Conclusion: Scaling up Factor of 1.79 - 3.14 Not Justified

Modeling Approach Revisited

Still Based on Nyborg and Dugstad (2007) - NACE 07555
CR = 0.004 * Rcond * CFe * (12.5 - 0.09 * T)
Temperature
Top of Line Corrosion in °C
Rate in mm/yr
Water Condensation Rate
in g/m2.sec
Supersaturation
Multifash CPA- Infochem Solubility of Iron in of FeCO3
10x for water content & ppm weight
hence, condensation rate
For Pitting along Flowline
f (T, P, pCO2, P, MEG
concn., HAc concn.)
1.79x - 3.14x
For MEG co-condensation
6
7/28/2015
2014 Internal Study Activities
 EVALUATE BENEFIT OF INCREASED EXTERNAL PIPE COATING

THICKNESS AS A TOLC MITIGATION SOLUTION
 ESTIMATE CORROSION ALLOWANCES NECESSARY FOR EACH

FLOWLINE SECTION
1) Pressure, Temperature profile along flowlines  New OLGA 7.3 simulations

2) Water content of gas (with MEG & No MEG)  Multiflash 4.1 CPA-Infochem
3) Condensation rates  Combination of (1) & (2), Both cases - with MEG & No MEG
4) Solubility of Iron (with MEG & No MEG)  Based on curve fits to Multiscale predictions
and adding a multiplier of 1.2
Temperature Profiles
(0 – 12 mm Coating Thickness)
Flow
Flowline Case # 1 – Early Life Snapshot
Transition in
coating thickness
Commingling
7
7/28/2015
Condensation Rates – With MEG

Order of Magnitude Reduction

in Condensation Rate With a
Few mm of Coating
Calculated Using Water Contents From

Multiflash CPA-Infochem Model
Transition from 8 mm
to 3 mm coating Transition from 10 mm/12 mm
to 3 mm coating
Commingling
Top of Line Corrosion Rates – With MEG (1)


Order of magnitude reduction in
Corrosion Rate with a
few mm of coating
Sudden change in temperature due to commingling of warm

flowstream with cooler production at the manifold results in
a spike in condensation rate (& hence, corrosion rate)
immediately downstream of the commingling point.
8
7/28/2015
Top of Line Corrosion Rates – With MEG (2)

Flowline Case #1 – Early Life Snapshot
Order of magnitude reduction in Corrosion

Rate with a few mm of coating
Spikes in TOLC rates can also occur due to

sudden change in external coating thickness
Commingling
Sensitivity to
Coating Thickness
 Polypropylene (PP) coating

thickness has significant impact
 4 mm of PP coating on bare pipe

can reduce Condensation rate and
Top of Line Corrosion rate by an
order of magnitude.
 Two orders of magnitude reduction

possible with 55 mm thick PP
coating (similar to Wet Insulated
Case # 3)
3 mm
9
7/28/2015
Proposed Mitigation Solution

 Hybrid Solution = Thicker Coating + Increased Corrosion Allowance
– Possibly more robust compared to just corrosion allowance (or) coating
– Non unique solution sets possible
– Methodology described can help optimize Design vs. Cost
 Flowline Case # 1
4.5 mm thick 3LPP coating 4.5 mm thick 3LPP

+ Minimum 4 mm coating + Minimum 8 mm
Corrosion Allowance Corrosion Allowance
Due to higher TOLC risk for Case # 1 and uncertainties around modeling, recommended
design for Case # 1 is slightly more conservative than purely model generated numbers.
Conclusions (1)
 Collaborative work between different disciplines allowed an in-depth systematic

modeling study of the TOLC risk.
 Engineering workflow was implemented for quantitative risk assessment -

 Model based on Nyborg and Dugstad (2007) which has been benchmarked against
experimental data under realistic field conditions
 Multiflash for water content with MEG / No MEG (hence, defined condensation rates)
 Eliminated multiplier for MEG co-condensation
 Eliminated application of pitting factor
 Sensitivity studies with varying 3LPP coating thickness
 Considered coating only, metal only, and hybrid solutions as part of picking final solution
 Life of Field (LOF) approach to account for production profile/decline
10
7/28/2015
Conclusions (2)
 Flowline Cases #1 & #2: Carbon steel flowlines can be used instead of
CRA based solutions, with some modifications.
 Combination of Thicker External 3LPP Coating + Increased Corrosion

Allowance can be effective in mitigating TOL corrosion.
 Flowline Case # 3: Wet insulation thicknesses > 50 mm can be sufficient

to mitigate TOL corrosion risk in flowline.
Terima Kasih Banyak
 Chevron and my colleagues
 Institut Teknologi Bandung
 IFE for technical collaboration
11
7/28/2015
Back-up Slides
Factors Affecting TOLC – Sweet Systems
 Temperature profile
– f (Gas rate, Thickness of coating, Properties of coating, External heat transfer)
 Condensation Rate
– f (Gas rate, Incoming water saturation, Temperature change, Surface area)
 Presence of CO2
– f (Gas composition)
 Presence of Organic Acids in the Condensing Water
– f (Water composition, lean MEG composition, Partitioning to the vapor phase)
 Solubility of Iron Carbonate
– f (Temperature, Pressure, CO2 partial pressure, MEG concentration, Presence of
Organic Acid)
 Presence of MEG
– Impacts water content of the vapor and hence, condensation rate, FeCO3 solubility
12
7/28/2015
Flowline Case #1 – Early Life Snapshot

Previous External SME Calculation vs. Revised Internal Calculation
External SME
Spike from Assuming -

commingling 1) Early life corrosion rate applies for all of field life, and
2) Field life = 20 yrs
Cumulative metal loss = 24 mm (first estimate)

@ F/L inlet vs.
7 mm (revised estimate)
 Can reproduce 1.2 mm/yr calculated previously by external SMEs

 Revised rate of 0.34 mm/yr @ F/L inlet predicted for both Scenarios A & B
 Carbon steel based flowlines solution mayy be feasible
TOL Corrosion Rates for Flowline Case # 2 are

Predicted to be Lower than Flowline Case # 1

With MEG
Spikes in TOLC rates predicted at points of

commingling flowstreams and locations associated
with change in external coating thickness
13
7/28/2015
Model Results For Flowline Cases

Coating Only
Metal Only Solution
Solution
Original Original Minimum 3LPP Maximum Predicted Minimum

Planned Planned 3LPP Coating Thickness Corrosion Rate Along Required CA for
CO2 Flowline
Case Corrosion Coating Required to Stay Flowline with Planned TOLC with 3mm
(mol%) Section
# Allowance Thickness with Planned CA 3mm 3LPP Coating 3LPP Coating
(mm) (mm) (mm) (mm/yr) (mm)
Upstream of
14 mm 0.49 10
commingling
1 0.9 2 3
Downstream of 14 mm / 10 km
0.24 5
commingling 3 mm / Rest
Upstream of
10 mm 0.27 5.5
commingling
2 1 3 3
Downstream of 10 mm / 3 km
0.11 2.5
commingling 3 mm / Rest
Upstream of
0.1 2
commingling Already heavily
3 2 6 > 50 insulated
(wet insulated) Downstream of
> 50 mm PP
0.1 2
commingling
Case # 3  Planned CA and Wet Insulation Levels are Sufficient

Industry Example of Proposed Strategy
 OTC 16557 (2004) - Pipelines in Harsh Environment - Henriksson et al.
 Design of 2 x 30” Ormen Lange pipelines in upto 875 meters water depth
 BOL Corrosion strategy  pH Stabilization followed by FFCI injection
 TOL Corrosion mitigation strategy deployed –
 Hybrid Solution
8 mm of FBE + 3LPP coating
+
10 mm CA for 50 yr. Design life for pipeline inlet
(=4 mm CA equivalent for 20 yr. life)
+
7.5 mm CA for 50 yr/. Design life for downstream sections
(=3 mm CA equivalent for 20 yr. life)
14
7/28/2015
Subsea Equipment – Hybrid Strategy
COATING
 Coated PLETs
 Coated Flowline jumpers
 Same thickness as that required for flowline coating
CORROSION ALLOWANCE
 Same Corrosion Allowance as that required for associated flowline
MATERIAL
 Cladding for Manifold headers & Branch piping
15

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7/28/2015

Designing for Top of Line Corrosion

I Made Adi Wardana, Yesudas Manimala, Robert Foster

Dr.Ir. Bambang Widyanto

© 2015 Chevron Indonesia. All Rights Reserved.

Corrosion Risk Assessment in Gas Dominated Flow

 Stratified flow regime

© 2015 Chevron Indonesia. All Rights Reserved.

© 2015 Chevron Indonesia. All Rights Reserved. 3

Comparison with Other Cases

HAc in Flowline 3LPP Flowline

 Can we use Carbon Steel flowlines?

– Perform quantitative risk assessment

© 2015 Chevron Indonesia. All Rights Reserved. 5

Evolution of TOLC Risk Assessment

Detailed desktop study (simulation)

TOLC Model (Nyborg and Dugstad, 2007) - NACE 07555

CR = 0.004 * Rcond * CFe * (12.5 - 0.09 * T)

TOL Corrosion Rate = Pitting Factor 10 x TOLC Model Predicted Rate

2013 Focus Activity - Clarifications

 Can model be considered benchmarked?

 Is Pitting factor = 10 justified on top of model calculated rates?

© 2015 Chevron Indonesia. All Rights Reserved. 9

Multiflash CPA-Infochem Model is Appropriate to Study Co-

Reference - Research Report RR-211, GPA, 2011,

MEG VLE of Binary Water-MEG system

Comparison of Condensation Rates – Case 1

Conclusion: Scaling up Factor of 1.79 - 3.14 Not Justified

Modeling Approach Revisited

CR = 0.004 * Rcond * CFe * (12.5 - 0.09 * T)

2014 Internal Study Activities

 EVALUATE BENEFIT OF INCREASED EXTERNAL PIPE COATING

 ESTIMATE CORROSION ALLOWANCES NECESSARY FOR EACH

1) Pressure, Temperature profile along flowlines  New OLGA 7.3 simulations

© 2015 Chevron Indonesia. All Rights Reserved. 14

Flowline Case # 1 – Early Life Snapshot

© 2015 Chevron Indonesia. All Rights Reserved. 15

Condensation Rates – With MEG

Flowline Case # 1 – Early Life Snapshot

Order of Magnitude Reduction

Calculated Using Water Contents From

© 2015 Chevron Indonesia. All Rights Reserved. 16

Top of Line Corrosion Rates – With MEG (1)

Flowline Case # 1 – Early Life Snapshot

Sudden change in temperature due to commingling of warm

© 2015 Chevron Indonesia. All Rights Reserved. 17

Top of Line Corrosion Rates – With MEG (2)

Flowline Case #1 – Early Life Snapshot

Order of magnitude reduction in Corrosion

Spikes in TOLC rates can also occur due to

© 2015 Chevron Indonesia. All Rights Reserved. 18

 Polypropylene (PP) coating

 4 mm of PP coating on bare pipe

 Two orders of magnitude reduction

Proposed Mitigation Solution

4.5 mm thick 3LPP coating 4.5 mm thick 3LPP

 Collaborative work between different disciplines allowed an in-depth systematic

 Engineering workflow was implemented for quantitative risk assessment -

© 2015 Chevron Indonesia. All Rights Reserved. 21

 Combination of Thicker External 3LPP Coating + Increased Corrosion

 Flowline Case # 3: Wet insulation thicknesses > 50 mm can be sufficient

© 2015 Chevron Indonesia. All Rights Reserved. 22

Terima Kasih Banyak