ormen lange – corrosion management of import pipelines 2011... · corrosion management systems...
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Ormen Lange – Corrosion Management of Import Pipelines Grethe Selboe, MainTech AS
Introduction • MainTech was awarded a contract
with A/S Norske Shell within “Inspection &Corrosion Monitoring for Draugen and Ormen Lange”
• Member of Shell’s start-up team for Ormen Lange from 2005
• Localised together with the project in Oslo to prepare for start-up in 2007
This lecture will present the work done from 2005 and how the corrosion management systems for the import pipelines are managed today
Ormen Lange - Facts • Reservoir is located 120 km north
west of Kristiansund • Discovered: 1997 • Production start: September 2007 • When Ormen Lange produces at
its top, this will cover about 20 % of Great Britain’s gas needs.
• Norsk Hydro was operator during design and construction.
• Operator today: Norske Shell
Ormen Lange - Challenges
• Deepwater project • Reservoir in landslide area,
steep rise towards land • Rough seabed • 120 km to the control
centre • Multiphase • Minus 1.7 degree C,
hydrates can form
Ormen Lange – Subsea CORROSION CHALLENGES: • No corrosion monitoring
subsea • Rely on sampling and
online monitoring onshore • Pigging is difficult and non-
conclusive in early stage of operation
Template A
Template B
Template D
Template C (future)
2x30” multiphase pipelines
2x6” MEG pipelines and umbilicals
42” Langeled
ESTABLISHMENT OF A RELIABLE CORROSION MANAGEMENT SYSTEM TO CONTROL THE PIPELINES BECAME VERY IMPORTANT
Corrosion Protection Philosophy Import pipelines contains: – 0.3mol% CO2 – 0.5ppmv H2S – Acetate is present in the produced gas – Formate is present in drilling fluids Protection Philosophy by Injection of Chemicals: – MEG is injected @ wellhead to prevent hydrates – pH-stabilizer (added to MEG) – scale and corrosion inhibitor (added to MEG)
Based on extensive testing by Hydro before start-up
Import Pipelines – Design Details • Made of X65 carbon steel • Design life is 50 years
• Robust Corrosion Allowance
• Nominal wall thickness is 26.8-35.5mm
• Thick film coating externally • Sacrificial anodes subsea • Impressed Current in buried
landfall area
Main Internal Threats
1. Bottom of line – pH stabiliser + corrosion inhibitor – Control CO2 concentration
2. Top of line – Inspection of external coating (avoid
condensation) – Control CO2 concentration – Control formate and acetate
concentration – Alkalinity in MEG
Sampling & Monitoring •Concentration of:
pH stabiliser Corrosion Inhib
•pH + Fe •Acetate + Formate •Water/MEG content
•Fe
•Concentration of: pH stabiliser Corrosion Inhib
•pH + Fe •Acetate + Formate •Water/MEG content •Oxygen
Kp 0
ER probes + WLC
•Erosion probes •Sand detectors •Temp •Pressure
CO2 + H2S sampling in gas from SC (+ in export gas)
Wells
Inspection
Kp 0
Inspected internally by NDT externally
Inspected externally for coating damage
+ Internal pigging if found necessary
Wells
Intergrity Operating Window (IOW) What is IOW? A selection of sample data, process data, corrosion data to control that we
are operating within defined limits. For example:
0
50
100
150
200
250
300
10-m
ar
17-m
ar
24-m
ar
31-m
ar7-a
pr
14-ap
r
21-ap
r
28-ap
r5-m
ai
12-m
ai
19-m
ai
26-m
ai2-j
un9-j
un
Con
cent
ratio
n
0
2
4
6
8
10
12
pH
Lean - pHStab (mg/l)Rich - pHStab (mg/l)Lean - Alk (mg/l)Rich - Alk (mg/l)Lean - pHRich - pH
pH in MEG Formate concentration
Example of IOW Parameters
Corrosion loop
Monitoring point
System
Priority (X = Rem
oved)
Frequency (R= O
n Request)
Tag # Type Parameter
Threat
Unit Limit
Physical Location
Comm
ents
Data Location
Time interval: 01.06.09-31.08.09Sign: GSReviewed
Time interval: 01.09.09-30.11.09Sign: GSReviewed
Time interval: 01.12.09-28.02.10Sign: GSReviewed
Time interval: 01.03.10-31.05.10Sign: GSReviewed
Time interval: 01.06.10-31.08.10Sign: GS/KB
Time interval: 31.08.10-30.11.10Sign: KBReviewed
01
CE-16-1025ER probe / Corrosion rateLOCATION: Import pipeline
16 1 3m CE-16-1025 ER probeCorrosion
rateCO2
corrosionmm/yr
max 0,33 mm/yr (CA 10 mm)
Import pipeline A before pig receiver/slug catcher
PCAD/Livelink
0,000 mm/y (Q3 2009) (not reviewed in corrosion
0,001 mm/y (Q4 2009) (not reviewed in corrosion
0,000 mm/y (Q1 2010) (not reviewed in corrosion
0,000 mm/y (Q2 2010) (not reviewed in corrosion
0,000 mm/y (Q3 2010) (not reviewed in corrosion
0,0012 mm/y (Q4 2010) (not reviewed in corrosion
01
CE-16-1024WLC / Corrosion rateLOCATION: Import pipeline
16 1 1yr CE-16-1024 WLCCorrosion
rateCO2
corrosionmm/yr
max 0,33 mm/yr (CA 10 mm)
Import pipeline A before pig receiver/slug catcher
Not online, manual measurements yearly
Livelink
0,001 mm/y (Q4 2009) (not reviewed in corrosion
0,001 /mm/y (Q4 2010) (not reviewed in corrosion
01
EC-89-0050ICCP / Potential on pipelines PL-A/B, Kp 0 to HATLOCATION:
89 1 1w EC-89-0050 ICCP
Potential on pipelines PL-A/B, Kp 0 to
HAT
External corrosion
-0.85 to -1.20 V vs. Cu/CuSO4-
Landfall, L56
Send report to Gassco monthly
Livelink ICCP area
Potentials outside acceptable levels from 10th of
Problem fixed, system is working satisfactory
OK OK
OK - still current leakage for Pl-B
OK - still current leakage for Pl-B
01
QN-16-1084Sampling / Iron content (total iron)LOCATION: After
16 1 3m QN-16-1084 SamplingIron content (total iron)
CO2
corrosionmg/l
No limit defined
After slug catcher
Sample Manager
Incrasing trend, (6, 6 and 32 mg/l)
~ max 10 mg/l
Max 14.8 mg/l (3 samples)
Max 6.3 mg/l (3 samples)
Max 17 mg/l (2 samples)
Max 26 mg/l (2 samples)
01
QN-16-1084Sampling / Iron content (dissolved iron)LOCATION: After
16 2 3m QN-16-1084 SamplingIron content (dissolved
iron)
CO2
corrosionmg/l
No limit defined
After slug catcher
Sample Manager
Incrasing trend, (12, 7 and 36 mg/l)
~ 5 mg/l (only 1 sampling)
No sampling performed
No sampling performed
No sampling performed
No sampling performed
01
QT-18-0638Erosion probe / ErosionLOCATION: Template A, well
18 2 3m QT-18-0638Erosion probe
Erosion Erosion micronNo limit defined.
Template A, well 6
PI Max. 47 Max. 46 Max. 46 Max. 39 Max. 38 Max. 37
Expert Group Meeting Typical members of the group: • Material & Corrosion Engineer (head of the group) • Area Inspection Engineer • Operations Representative • Process Engineer • Production Chemist • Pipeline Engineer • Maintenance Engineer • Technical Safety Engineer
Meeting frequency: Every 2nd month
Modifications to CorrMngt System • Tests performed before start-
up showed that the CI was effective after regeneration.
• Concentration of CI was included as an IOW paramter to follow
• Corrosion tests of field MEG show that the CI partly looses its effect after regeneration
• IOW was then revised to include corrosion tests, in addition to CI concentration sampling
Rich MEG
Lean MEG
Modifications to CorrMngt System Original CI limits: Lean MEG: 200 ppm Rich MEG: 100 ppm
Monthly/Bi-monthly Evaluation
QN-38-0686
LabA - rotating1
LabA - rotating2
LabA - stationary1
LabA - stationary2
LabB rich lean rich lean rich lean rich lean rich lean
End March 2008 MG exp group 0 300 390 60 70 100 110 80 92August 2008 MG exp group 5 0.11 0.14 0.06 0.1 230 290 80 100 90 100 80 92January 2009 MG exp group 9 0.12 0.16 0.06 130 170 110 130 200 240 77 92April 2009 MG exp group 12 0.08 110 150 80 95 180 210 6 6 6.9 75 92June 2009 MG exp group 1 0.04 0.02 0.03 200 250 95 110 190 210 6.1 6.4 6.9 76 92July 2009 MG exp group 2 0.03 230 330 95 120 210 210 6.2 6.4 6.4 76 91August 2009 MG exp group 3 0.04 230 330 120 140 200 230 6.3 6.7 6.3 70 90November 2009 MG exp group 2 0.06 270 330 no analysisno analysisno analysisno analysis 6 6.2 6.2 76 92December 2009 MG exp group 3 0.06 220 330 220 250 350 400 6.3 6.4 6.3 77 92March 2010 MG exp group 1 0.05 280 370 220 240 320 350 6.1 6.4 6.0 77 92April 2010 MG exp group 2 0.07 270 370 200 250 280 330 6 6.5 6.0 77 92July 2010 MG exp group 1 0.03 400 500 200 250 280 330 6.3 6.4 6.0 80 92September 2010 MG exp group 3 0.06 330 430 200 290 330 400 6.1 6.5 6.1 77 92October 2010 MG exp group 1 0.06 350 530 200 310 320 450 6.1 6.4 6.0 75 92November 2010 MG exp group 1 0.05 350 460 200 270 320 440 6 6.4 6.1 73 92December 2010 MG exp group 2 0.06 310 430 200 300 320 460 6.1 6.3 6.1 75 92April 2011 MG exp group 3 0.07 410 560 250 340 350 450 6.2 6.4 6.0 75 92April 2011 MG exp group 0 0.02 410 760 250 340 350 450 6.2 6.4 6.0 75 92
Date Sign Review by
No of months w ithout
CI
Rate (mm/year)
QN-20-0121/QN-38-0686 QN-20-0121/QN-38-0686 QN-20-0121/QN-38-0686 QN-20-0121/QN-38-0686
CI concentration (mg/l)Acetate
concentration(mg/l)Formate concentration
(mg/l)pH @1bar CO2 rich
(lean) MEG
pH @1bar CO2 rich
MEGMEG concentration (%)
QN-20-0121/QN-38-0686
Yearly Review • Review of all parametres collected last year • Review of all inspection results • HydroCor calculations
– Result is compared to corrosion tests of sampled MEG and rates found during qualification of chemicals
• PipeRBA assessment gives pipeline remaining life and inspection due date
Follow-up of IOW
1. Monthly to 3-Monthly review of most important parameters in IOW
2. Yearly review of entire IOW + inspection results + experience from operation + HydroCor calculations + PipeRBA
MIGHT LEAD TO A CHANGE IN PROTECTION PHILOSOPHY, PIGGING INTERVAL, CHANGES IN SAMPLING/MONITORING PROGRAM
Summary
• By establishing a Corrosion Management system from day 1, this will be the tool to document any life extension in the future, if necessary
• Early involvement in project phase (approx. 2 years before start-up) allowed us to have: – Good understanding of challenges – Good transfer from project (NH) to operation (Shell/MainTech) – Good communication between disciplines, when in operation
• Systemising useful information allows you to optimise your risk based decision, away from conservatism