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PETRO CASE STUDY ASSESSMENT OF PIPELINE CORROSION

BACKGROUND
Internal corrosion monitoring & assessment of subsea production and export carbon steel pipelines during operation is a crucial part of overall subsea pipeline corrosion management strategy. Internal corrosion of the pipelines is generally assessed by continuous monitoring of operational parameters and periodic inspection of pipeline’s internal condition by inspection tools such as NDT (non- destructive testing) techniques. However, corrosion assessment is highly challenging for the pipelines not equipped with facilities (un-piggable pipelines) to run the inspection tools. One prominent alternative for the corrosion assessment of un-piggable pipelines is to use a combination of different corrosion models.
CORROSION ASSESSMENT MODELS
Carbon steel pipelines are widely used in subsea for transport of multiphase production fluids due to their significant economic impact on offshore projects. However, carbon steel is highly susceptible to internal corrosion caused by presence of carbon dioxide (CO2) and hydrogen sulphide (H2S) in free water, an environment commonly present in multiphase (oil, gas and water) production systems and pipelines. During design stage of the carbon steel pipelines, a corrosion allowance is usually added to pipe wall thickness in order to accommodate metal loss due to corrosion during the operational life. Corrosion allowance is an effective barrier for mitigating the loss of pressure containment of a carbon steel pipeline due to internal corrosion. The corrosion allowance during the design phase is determined based on the predicted corrosion rates by corrosion modelling and anticipated corrosion management strategy will be in place during the operational phase.
Pipelines are not always equipped with permanent pigging facilities. Pigging of such lines requires temporary installation of subsea pig launchers and receivers. Such arrangements are very costly and not always economically feasible for aged assets. For such systems, periodic corrosion assessment by different corrosion models can be a prominent alternative.
A case study needs to be done of corrosion assessment of different pipelines by semi-empirical and mechanistic corrosion models. The assessment is carried out by NORSOK M-506 CO2 corrosion model, Multicorp (Multiphase Flow Modelling Program), ECE (Electronic Corrosion Engineer) and Cassandra. These models are selected to represent both empirical and mechanistic approach and build confidence in the modelling results comparable to realistic conditions.
The methodology and input data used and the results of the models are provided. The results of the different models are compared in order to assess the internal condition of the pipelines. The study also provides the minimum allowable wall thickness and the effective corrosion allowances for each pipeline, calculated from DNV-OS-F101 standard. Cumulative metal loss of each pipeline due to CO2 corrosion since the start of the operation is calculated by the corrosion models. Based on the effective corrosion allowances and the cumulative metal loss to date calculated, the pipelines future life is assessed.

FLOWLINE DATA
The subsea pipelines presented in this study, transport multiphase production fluids from subsea production template to top side platform facilities. The production fluid is processed and separated. After separation, the oil and gas are exported. Some of the produced gas is used for gas lift purposes. The gas is mixed with production fluid and transported through the pipelines.
A selection of multiphase data from six different flowlines was collected by a major operator in North Sea and was made available for use in the evaluation of three corrosion models. An overview of the field data cases is shown in given table.
Minimum allowable wall thickness (MAWT) and maximum allowable operating pressure (MAOP) data in accordance with DNV-RP-F101 are used to calculate effective corrosion allowance, the result is presented in the following table.

Four metallic weight loss coupons in coupon holders and two ER probes installed on the topsides and are pulled out for analysis every 12 months. The off-line corrosion monitoring results and metallic weight loss coupon for different flowlines for the last 12 months is given in the following table.

RESULTS OF CORROSION ASSESSMENT
Below table shows the predicted un-inhibited and inhibited results from three different models during the last year. The inhibited result is calculated from un-inhibited corrosion rate with considering the actual inhibitor availability from filed data. According to the results Norsok and ECE models predict high corrosion rates whereas Multicorp model gives relatively low corrosion rate.

Next table shows the allowable corrosion rates with and without the manufacturing tolerance versus the highest average corrosion rates from three models.

The remaining life is calculated as follow: Effective corrosion allowance – metal loss to date = remaining wall thickness available for loss; Remaining Wall Thickness available divided by the predicted future corrosion rate gives the remaining life.
Based on the effective corrosion allowances and the metal loss to date calculated, the production lines are deemed to have a future life (based on the DNV-RP-F101 code, including design safety factor), based on the present conditions, as presented in table below.

DISCUSSION QUESTIONS 1. Do a SWOT analysis on the petroleum pipeline transportation. (Include economic, social, ecological aspects and the corrosion problems).

2. Give your views on current scenario of pipeline corrosion problems in India.

3. Analyze the different corrosion assessment models used in the study, compare them and suggest which is more effective in assessing internal conditions of pipelines.

4. Analyze on economic implications for DNV-RP-F101 corroded pipeline. [Max.250 words]

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