Hadhramout University of Science & Technology

Mukalla, Republic of Yemen

Managing Corrosion
in the Oil & Gas Industry
Theory and practice of corrosion and
corrosion prevention

Marcel ROCHE

Part 3 March 27 – 31, 2010

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Managing Corrosion in the Oil & Gas
Industry

Monitoring of internal corrosion

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Monitoring the treatment efficiency and
residual corrosivity
Major tools and methods:
 Water samplings for:
 Iron counts
 Residual corrosion inhibitor content
 pH
 Planctonic bacteria numeration
 LPR (Linear Polarisation Resistance probe)
 Coupons
 ERP (Electrical Resistance Probe)
 Bioprobes (Sessile bacteria numeration)
 Flexible UT mats
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 Iron counts
Irion counts vs time

160,0

140,0

120,0

100,0
mg/L

80,0

60,0
Averave ppm iron vs S1 temperature

140

120
40,0

100

20,0 2004
80
2006
60
0,0
40 9/11/04 29/12/04 17/2/05 8/4/05 28/5/05 17/7/05 5/9/05 25/10/05 14/12/05 2/2/06 24/3/06 13/5/06
20 Time
0
40 50 60 70 80 90 100
Temperature (°C)
Corrosion Monitoring: coupons and probes

Electrical Resistance LPR probes Coupons

Bioprobes

Flush
(Cormon data
sheet)

Cylindrical Flush Intrusive Flush

(Cormon data (Corrocean data
intrusive sheet) sheet)
(RCS data sheet)
Internal corrosion monitoring: recovered
probes and coupons

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Corrosion Monitoring: Access fittings

Corrocean type (from Corrocean data sheet) Standard R/C type (from Cormon data sheet)
Corrosion Monitoring: HP extractors for
probes

Mechanical system (Rohrback-Cosasco) Hydraulic system (Corrocean)

Location of corrosion monitoring probes

COUPONS

ERP

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 1
MPY

100
150
200
250
300
350
400
450
500

0
50
20-09-04
21-09-04
22-09-04
23-09-04
24-09-04
25-09-04
26-09-04
27-09-04

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28-09-04

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29-09-04
30-09-04
01-10-04
02-10-04
03-10-04
Field testing new inhibitor

04-10-04
05-10-04
Vcorr 2-ECP-0124

06-10-04
07-10-04
08-10-04
09-10-04
10-10-04
11-10-04
12-10-04
13-10-04

Fecha
14-10-04
15-10-04
16-10-04
17-10-04
18-10-04
19-10-04
Vcorr 2-ECP-0124(acumulada)

20-10-04
21-10-04
Velocidades de Corrosión Medidas en S1

22-10-04
23-10-04
24-10-04
25-10-04
Measurement of corrosivity (LPR)

26-10-04
27-10-04
28-10-04
Vcorr 2-CC-0124

29-10-04
30-10-04
Product anomaly

31-10-04
01-11-04
02-11-04
03-11-04
04-11-04
05-11-04
Follow-up of corrosion rate with ERP

V c o r r G a s o d u c t o 1 0 " S 1 -C P F
En S1

E n e r o -J u lio : 7 ,7 3 m p y C a m b io d e P r o b e ta
9,5
( m ils )

9,0

8,5
M e t a l L o s s

8,0

7,5

7,0

6,5

6,0

5,5

E v
J an 2005 Feb M ar A pr M ay J un J ul
D ate/Tim e
D ate R ange G raphed: 21/09/2004 to 21/03/2006
Corrosion monitoring: UT measurements
at specific locations
Managing Corrosion in the Oil & Gas
Industry

Corrosion-related Inspection

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The challenge of inspection

Monitoring is not sufficient !

negligible

Only INSPECTION
allows direct I
information N
S
on physical status of faible
P
Risk assessment
equipement E
C
T
I
O
N

important
The evolution of approach

PREVIOUSLY: Prescriptive, regulated and not

selective ("Time-based Inspection")
•Mandatory systematic inspections, without taking into
account operating conditions
•High Maintenance and Operation costs (need of
shutdowns)
TODAY: Risk Based Inspection (RBI) approach
•A selective verification, based on probable risks
•Potential savings associated to a better
availability of facilities

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RBI (Risk Based Inspection)

A definition
The establishment of optimised inspection programmes,
adapted to the risks facing the facilities

A methodology
A structured approach involving:
Assessment of consequences of failures
(explosivity, flammability, toxicity, pollution,…)
Assessment of degradation modes (corrosion, fatigue, etc.)
Physical status of equipment (previous results of inspections)
and delivering quantified and auditable results

A tool: For Total, FAME+

A software allowing quick compilation and management of a
great number of parameters

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RBI (Risk Based Inspection): Calculation
of consequences

Q
ESDV
EVALUATION OF
CONSEQUENCES

EXPLOSION, FIRE
P, T POLLUTION,
TOXICITY
ESDV

DCS

COMPENSATION

PROTECTION

DETERMINATION OF
CONSEQUENCE
FACTOR

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RBI (Risk Based Inspection) : Calculation
of probability of damage
Conditions of operation Materials
(fluid, P, T, environment…) and design

Identification of potential degradation modes

TEMPERATURE
Specific data for each mode PRESSURE
FLOW RATE
VIBRATIONS
ETC.

Calculation of corrosion rates and/or sensibilities

Determination of identified
damage probabilities

Thickness thining Cracking Localised Corrosion Embrittlment

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RBI (Risk Based Inspection) : Calculation
of criticity
Calculation criticity

Degradation Mode 2
Degradation Mode 1
Probabilities 2
of failure

Consequences
in case of failure Consequences

Impact on
production Level of Criticity

Strategy of inspection for each

mode of degradation

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Inspection methods for corrosion:
pressure vessels, piping
•Internal and external visual
examinations
•Ultrasonic measurements (Internal
corrosion, cracks)
•Magnetoscopy, Dye penetrant,
Eddy currents (superficial cracks)
•Radiographies (X or γ sources,
Internal corrosion, welds, deposits)
•Hydrotest (Construction,
verification of repairs, regulatory
aspects)
•Verification of materials (Hardness,
Composition,…)
 UT measurements

Previously: measurements on specific locations at periodical intervals

Better : performing scanning on critical areas
(recording of minimum value of thickness)
Advanced inspection techniques: Acoustic
emission

Main applications:
Detection of cracks in pressure
vessels

Evaluation of internal corrosion

of tank bottoms
Other advanced inspection techniques

Corrosion under insulation

Thermography
Numerical Gammagraphy

Long range Ultrasonic testing

Inspection techniques of offshore structures

Surface structures
•Visual inspection
•Detection of cracks
through NDT

Underwater structures
•Visual inspection (ROV,
Divers)
•Detection of cracks
through NDT
•Cathodic Protection
Methods for inspection of corrosion: well
tubings, pipelines
Calipers for tubings (geometrical
fingers or magnetic systems)
Intelligent(smart) pigs for internal
inspection of pipelines ("In-Line
Inspection", ILI)
 Self propelled pigs, autonomous

 Tethered pigs propelled by the

fluid
 Tethered pigs propelled by

crawlers
 Magnetic tools ("MFL", Magnetic

Flux Leakage)
 Ultrasonic tools ("UT")

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In-Line Inspection (ILI) of pipelines:
MFL Intelligent pigs
Advantages:
•Applicable
whatever the Drawbacks:
fluid •Imperfect
•High level of sizing of
detection defects (not a
(continuous direct
measurement) measurement
of thickness)
•Evaluation to
Clean surface
be checked by
and
direct
verification of
measurements
absence of
obstacles
mandatory
In-Line Inspection (ILI) of pipelines:
MFL Intelligent pigs

Magnets

Primary detector

Secondary detector

Data storage

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Example of report
Example of corrosion reconstituted image
(MFL)
Sizing of defects
Corrosions vs. distance to girth welds
An example of external corrosion under
disbonded coatings on the hottest end

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 In-Line Inspection (ILI) of pipelines:
UT intelligent pigs

Advantages: Drawbacks:
•High •Not applicable
accuracy of in gas or
sizing of heterogeneous
defects (direct fluids
measurement) •May miss small
defects
(discontinuous
Clean surface
measurements)
and
verification of
absence of
obstacles
mandatory
In-Line Inspection (ILI) of pipelines:
UT intelligent pigs

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Managing Corrosion in the Oil & Gas
Industry

Atmospheric corrosion and its

prevention by coatings

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Examples of atmospheric corrosion

The only solution:

Good coatings
Passive protection by coatings

Electrolyte

METAL Oxidation of metallic

Ia phase
Anode
Fe → Fe²+ + 2e-
(corrosion)
Perfect coating = no
COATED
2e more current exchange
MATERIAL
Cathode Reduction of oxidising
Ic species in water phase
(protection)
2 H2O + O2 + 4 e- → 4 OH-
H2O + e - → H + OH-
General policy for paint systems in Oil & Gas
 Use of high durability systems, if possible certified (ACQPA)
 Qualified suppliers with worldwide production and logistics
 Use of ISO referential and coating contractors and inspectors
certified (ACQPA, FROSIO, NACE, …)
 Objective of minimum maintenance on facilities in operation,
especially for offshore and geographically remote areas:
 New offshore structures:
 15 years without major maintenance
 5 years of contractual guaranty co-ensured by supplier and
contractor
 Mean periodicity of major maintenance for existing structures for
atmospheric offshore exposure: 10 years

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The challenges of paint systems in Oil & Gas

Expected lifetime of structures to be protected:

 Design: 20 to 30 years
 In practice: sometimes > 40 years

Environment:
 Most often, marine C5M atmosphere as per ISO 12944-2 (offshore,
coastal areas)
 IM2: for submarine facilities (with cathodic protection)
 Thermal insulation, fire protection, test of deluge systems,
important thermal cycles, mechanical impacts…
 Offshore, desert areas, …

Safety and Health:

 Painting works may be dangerous and require a lot of precautions

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External paints for atmospheric protection
A "paint system" is defined including the surface
preparation method, which is a highly critical issue: at a
minimum Sa2 ½ as per ISO 8501-1
 The system is generally made of several layers:
 A primer (mainly zinc rich: zinc ethylsilicate for the best durability, zinc
epoxy), about 70 μm
 A sealer, about 20 μm
 One or several tightness layer(s) (mainly epoxy), generally 2 x 150 μm
 A finition for UV resistance (PU or acrylic), about 50 μm.

 Alternative
systems are proposed for better applicability
and/or durability, generally with less layers
 End users to keep in mind that the final objective is proven durability
 Use accelerated testing for qualification (ISO, NORSOK, NACE)
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An example of major structure to protect:
The case of a FPSO (deep offshore)
For hull:
 56 000 tons of steel, 5,5 x the weight of Eiffel Tower
 140 tons of paints
 1800 inspections of « blocks » before assembling, 3 per day
 Cost of paints: 10% of total cost
For topsides:
 27 000 tons of steel, 2,5 x the weight of Eiffel Tower
 6900 tons of equipement

 5000 tons of pipings

 13 500 tons of structures

Duration for construction: 24 months, the same as for

Eiffel Tower
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6 Eiffel Towers…..but more compact!

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Examples of coating failures on offshore
structure

Major issue for

protection of bolts
Examples of coating failures on offshore
structure

Good support

Bad support
Examples of coating failures on offshore
structures

Passive Fire Protection

Deck near the flare

Corrosion under insulation (CUI)
 The major cause of external corrosion in process plants
 Ingress of aerated water under thermal insulation when
tightness not achieved or damaged
 Corrosion possible up to 140°C when no coating or a non
efficient or damaged coating, increasing with temperature
 Very difficult and expensive to detect and size during
inspection campaigns
 USE THERMAL INSULATION ONLY WHEN CLEARLY
NECESSARY FOR PROCESS REASONS
 Use other systems (mechanical protection) for personnel
protection

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Problems with riser coatings (offshore)

 Coatings to be especially mechanically resistant for

tidal and splash zone offshore conditions
 8mm thick Fiberglass Reinforced Epoxy coating has
been used with success mainly in Gulf of Guinea and
North Sea
 Elastomeric coatings (mainly polychloroprene,
sometimes EPDM for higher temperatures) constitute
the conventional solution used world wide.
 Several cases of disbondments with corrosion at the
transition zone with thin atmospheric paint system have
been noticed after 20 yr for both coatings: penetration
of water and corrosion by undercutting

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Corrosion underneath offshore riser
coatings in the transition zone

Fiberglass reinforced epoxy,

Gabon Polychloroprene, Argentina
Metallic coatings
 Only anodic materials in
aggressive environments.
Risk of localised corrosions
if cathodic coating
damaged
 Zn, Cd and Al are the most
Anodic coating
frequently used anodic
metals for protecting C
steels
 Possibilityof cathodic
protection for cathodic
coatings when immersed
Cathodic coating

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Metallic coatings
•Zinc coatings (galvanizing or
electrolytic coating) the most
used for atmospheric protection:
, stairs, handrails, ladders,
gratings, bolts and nuts, etc.
•Good general behaviour,
including on offshore structures,
except in the most exposed
areas to chlorides where lifetime
may be reduced down to a few
years (lower level of platforms,
areas with leaks of seawater or
heavy condensations)
•Short life in seawater especially
when flowing
Metallic coatings
 TSA (Thermal Spray Aluminium) used in atmospheric
zone of offshore structures in areas with difficult access
to reduce maintenance works with paint systems
 Used also in seawater when cathodic protection is
difficult to apply

Cadmium (bichromated) coatings

currently used for temporary
protection of bolts and nuts
(a few months in marine atmosphere)

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TPA Training Course

Managing Corrosion
in the Oil & Gas Industry

End of Part 3

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