CARBON DIOXIDE (C02) CORROSION

Condensate wells produce water with pH as low as 4 at the bottom and pH less than 7 at
the wellhead. This is caused by:
1. High C02 content of gas usually 1-3%
2. High total pressure, 1000-8000 psi at the wellhead
3. The presence of organic acids such as acetic acid (CH3 C00H)
4. Also high velocity condensate flow accelerate erosion due to C02/erosion
phenomenon.
Corrosion rates high = low pH thus acidic environments.
Water production is about 40 gal per MMCF. Most corrosive condensate wells are found at
depths greater than 50000ft. Bottom-hole temperatures are pressure above 1600F and
1500psi respectively, and C02 partial pressures are above 15psi.
Corrosion pits are formed. The top portion of the tubing and surface flowlines are most
susceptible to this type of corrosion. The higher the wellhead pressures the higher the
corrosion rates because more C02 will dissolve in the water vapour at higher pressures
forming a stronger carbonic acid.
Evaluation of corrosiveness of Gas wells. This depends on
the partial pressure of C02, Pv.
Pv = (%mole fraction C02) (total wellhead pressure).
The higher the C02 content and wellhead pressure the
higher the partial pressure and the more corrosive the gas
well. Tubing parting is often experienced e.g. in an SPDC
field in the West. Partial Pressure, Pv (psi)
Corrosiveness

0–7 3 Non Corrosive

7 – 30 or 3 -30 Possibly Corrosive
30+ Corrosive
A two-stage separation requires one separator & a
&

storage tank. A three-stage separation requires two

separators and a storage tank etc. The optimum
number of stages is governed by the gathering line
pressure and the characteristics of the wells.
According to Campbell` , the operating pressure
can be determined from an equation based on
equal pressure ratio between the stages. The
pressure ratio, R is defined as
 From the above,
1
 P1  n

R   
 Ps 

P1 P2 Pm -1
R   .... 
P2 P3 Pm

P1 n 1
P2   Ps R
R
For m-stage separation,

n  m 1
Pm  Ps R
Where n= no. of stages, n’ = n -1, P1, P2, P3 are pressures (in psia) of the first,
second & third stages, respectively; Ps is the stock tank pressure (psia).
The point of diminishing returns in stage separation is reached when cost of
additional stages of separation is not justified by increased profit.
Example: Determine the intermediate separator pressure for a three system
where the first stage pressure is 1000 psia and storage tank pressure is at 16
psia.
SOLUTION
Given, P1 = 1000 psia,
Ps = 16 psia,
n = 3,
n’ = 3 –1 = 2
P2 = ?
1
 1000  2
R   7.906
 16 
P2 = P1/R = 1000/7.906 = 126.5 psia