Use of Corrosion Inhibitors in Oil and Gas Production

112 Pages·2004·4.354 MB·English

by  Palmer, J.W., Hedges, W., Dawson, J.L. (Eds.)

European Federation of Corrosion
Publications
NUMBER 39
A Working Party Report on
The Use of Corrosion Inhibitors
in Oil and Gas Production
Edited by .J W. Palmer, W. Hedges and .J .L Dawson
MANEY
Published for the European Federation of
Corrosion
behalf of the Institute of Materials, Minerals and Mining
on
B0804
First published in 2004 by
Maney Publishing
1 Carlton House Terrace
London SW1Y 5DB
UK
on behalf of
the Institute of Materials, Minerals and Mining
© 2004 Institute of Materials, Minerals and Mining
All rights reserved
ISBN 1-904350-33-X
Typeset, printed and bound in the UK
by The Charlesworth Group, Wakefield
stnemegdelwonkcA
This document has been put together by members of the EFC Working Party
13 -- 'Corrosion in the Oil and Gas Industry', chaired by Stein Olsen (Statoil).
Guideline documents produced by BP and Shell provided the basis for several
sections of the document and permission to use this information is greatly
appreciated. Significant contributions were also received from the following:
Chris Bowman Baker Petrolite
John Dawson CAPCIS Ltd.
Drew McMahon Helix RDS
Rolf Nyborg IFE
Liane Smith Intetech
Jim Stott CAPCIS Ltd
Mark Gough Ondeo Nalco
Stein Olsen Statoil
In addition, the sections on inhibition of preferential corrosion of weldments
have included new information from a recent Joint Industry Project. The project
was entitled 'Risk of Preferential Weldment Corrosion of Ferritic Steels in CO2 -
Containing Environments' and was conducted jointly by CAPCIS, TWI and IFE.
The permission of the sponsoring companies to include this information is greatly
appreciated. The sponsors were: BP, Clariant, ENI SpA, HSE, Petrobras, Saudi
Aramco, Shell and Tfe.
The Co-Chairmen of the Work Group would like to thank all who have
contributed their time and effort to ensure the successful completion of the
document.
Jim Palmer Bill Hedges
CAPCIS Ltd. BP
Co-Chairmen
European Federation of Corrosion Publications
Series Introduction
The EFC, incorporated in Belgium, was founded in 1955 with the purpose of
promoting European co-operation in the fields of research into corrosion and
corrosion prevention.
Membership of the EFC is based upon participation by corrosion societies and
committees in technical Working Parties. Member societies appoint delegates to
Working Parties, whose membership is expanded by personal corresponding
membership.
The activities of the Working Parties cover corrosion topics associated with
inhibition, education, reinforcement in concrete, microbial effects, hot gases and
combustion products, environment sensitive fracture, marine environments, refin-
eries, surface science, physico-chemical methods of measurement, the nuclear
industry, the automotive industry, computer based information systems, coatings,
tribo-corrosion and the oil and gas industry. Working Parties and Task Forces on
other topics are established as required.
The Working Parties function in various ways, e.g. by preparing reports,
organising symposia, conducting intensive courses and producing instructional
material, including films. The activities of the Working Parties are co-ordinated,
through a Science and Technology Advisory Committee, by the Scientific Secre-
tary. The administration of the EFC is handled by three Secretariats: DECHEMA
e.V. in Germany, the Soci6t6 de Chimie Industrielle in France, and The Institute of
Materials, Minerals and Mining in the United Kingdom. These three Secretariats
meet at the Board of Administrators of the EFC. There is an annual General
Assembly at which delegates from all member societies meet to determine and
approve EFC policy. News of EFC activities, forthcoming conferences, courses,
etc.. is published in a range of accredited corrosion and certain other journals
throughout Europe. More detailed descriptions of activities are given in a
Newsletter prepared by the Scientific Secretary.
The output of the EFC takes various forms. Papers on particular topics, for
example, reviews or results of experimental work, may be published in scientific
and technical journals in one or more countries in Europe. Conference proceedings
are often published by the organisation responsible for the conference.
In 1987 the, then, Institute of Metals was appointed as the official EFC
publisher. Although the arrangement is non-exclusive and other routes for publi-
cation are still available, it is expected that the Working Parties of the EFC will
use The Institute of Materials, Minerals and Mining for publication of reports,
proceedings, etc.. wherever possible.
The name of The Institute of Metals was changed to The Institute of Materials
on 1 January 1992 and to The Institute of Materials, Minerals and Mining with
effect from 26 June 2002. The series is now published by Maney Publishing on
behalf of The Institute of Materials, Minerals and Mining.
P. McIntyre
EFC Series Editor, The Institute of Materials, Minerals and Mining, London, UK
xii Series Introduction
EFC Secretariats are located at:
Dr B A Rickinson
European Federation of Corrosion, The Institute of Materials, Minerals and
Mining, 1 Carlton House Terrace, London SWIY 5DB, UK
Dr J P Berge
F6ddration Europ6ene de la Corrosion, Soci6t6 de Chimie Industrielle, 28 rue
Saint-Dominique, F-75007 Paris, FRANCE
Professor Dr G Kreysa
Europaische F6deration Korrosion, DECHEMA e.V., Theodor-Heuss-Allee 25,
D-60486 Frankfurt, GERMANY
OTHER VOLUMES IN THE EFC SERIES
1 Corrosion in the Nuclear Industry 31 Predicting 2OC Corrosion in the Oil and
deraperP by the Working Party on Nuclear Gas Industry
noisorroC deraperP by the Working Party on noisorroC
in Oil and saG Production (Out of print)
2 Practical Corrosion Principles
deraperP by the Working Party on noisorroC 41 Guidelines for Methods of Testing and
Education (Out of print) Research in High Temperature
Corrosion
3 GeneralGuidelines for Corrosion deraperP by eht Working Party on noisorroC
Testing of Materials for Marine by Hot sesaG and Combustion Products
Applications
51 Microbial Corrosion (Proc. 3rd Int. EFC
deraperP by the Working Party on Marine
Workshop)
noisorroC
deraperP by the Working Party on Microbial
4 Guidelines on Electrochemical noisorroC
Corrosion Measurements
61 Guidelines on Materials Requirements
deraperP by the Working Party on
for Carbon and Low Alloy Steels for
lacimehC-ocisyhP Methods of noisorroC
H2S-Containing Environments in Oil
Testing
and Gas Production
deraperP by the Working Party on noisorroC
5 Illustrated Case Histories of Marine
in Oil and saG Production
Corrosion
deraperP by eht Working Party on Marine 71 Corrosion Resistant Alloys for Oil and
noisorroC Gas Production: Guidance on General
Requirements and Test Methods for H,S
6 Corrosion Education Manual
Service
deraperP by eht Working Party on noisorroC
deraperP by the Working Party on noisorroC
noitacudE
in Oil and saG Production
7 Corrosion Problems Related to Nuclear 81 Stainless Steel in Concrete: State of the
Waste Disposal Art Report
deraperP by the Working Party on Nuclear deraperP by eht Working Party on noisorroC
noisorroC of Reinforcement in etercnoC
8 Microbial Corrosion 91 Sea Water Corrosion of Stainless Steels
deraperP by the Working Party on Microbial -- Mechanisms and Experiences
noisorroC deraperP by eht Working Parties on Marine
noisorroC and Microbial noisorroC
0 Microbiological Degradation of
Materials -- and Methods of Protection 20 Organic and Inorganic Coatings for
deraperP by eht Working Party on Microbial Corrosion Prevention -- Research and
noisorroC Experiences
srepaP from E UROCORR 69'
10 Marine Corrosion of Stainless Steels:
12 Corrosion-Deformation Interactions
Chlorination and Microbial Effects
CDI 69' in conjunction with EUROCORR
deraperP by the Working Party on Marine
'96
noisorroC
22 Aspects of Microbially Induced
11 Corrosion Inhibitors
Corrosion
deraperP by the Working Party on Inhibitors
srepaP from EUROCORR'96 and eht EFC
(Out of print)
Working Party on Microbial noisorroC
21 Modifications of Passive Films 32 2OC Corrosion Control in Oil and Gas
deraperP by the Working Party on ecafruS Production-- Design Considerations
ecneicS and Mechanisms of noisorroC and deraperP by eht Working Party on noisorroC
noitcetorP in Oil and saG Production
lHX
xiv The Use of Corrosion Inhibitors in Oil and Gas Production
42 Electrochemical Rehabilitation 23 Guidelines for the Compilation of
Methods for Reinforced Concrete Corrosion Cost Data and for the
Structures -- A State of the Art Report Calculation of the Life Cycle Cost of
deraperP by eht Working Party on noisorroC Corrosion-- A Working Party Report
of Reinforcement in etercnoC deraperP by eht Working Party on noisorroC
in Oil and saG Production
52 Corrosion of Reinforcement in Concrete
-- Monitoring, Prevention and 33 Marine Corrosion of Stainless Steels:
Rehabilitation
Testing, Selection, Experience,
srepaP from EUROCORR 79"
Protection and Monitoring
62 Advances in Corrosion Control and Edited by D. F&on
Materials in Oil and Gas Production
34 Lifetime Modelling of High
srepaP from EUROCORR '97 and
Temperature Corrosion Processes
E UROCORR '98
sgnideecorP of an EFC Workshop 2001.
72 Cyclic Oxidation of High Temperature Edited by M. ,eztdihcS W. .J srekkadauQ and
Materials .J R. Nicholls
sgnideecorP of an CFE ,pohskroW
,niaM~trufknarF 1999 53 Corrosion Inhibitors for Steel in
Concrete
82 Electrochemical Approach to Selected
deraperP by .B Elsener with support from a
Corrosion and Corrosion Control
Task Group of Working Party 11 on
Studies
noisorroC of Reinforcement in etercnoC
srepaP from 50th ISE Meeting, Pavia, 1999
63 Prediction of Long Term Corrosion
92 Microbial Corrosion (Proceedings of the
Behaviour in Nuclear Waste Systems
4th International EFC Workshop)
Edited by D. nor~F of Working Party 4 on
deraperP by eht Working Party on Microbial
noisorroC Nuclear noisorroC
03 Survey of Literature on Crevice 73 Test Methods for Assessing the
Corrosion (1979-1998): Mechanisms, Susceptibility of Prestressing Steels to
Test Methods and Results, Practical Hydrogen Induced Stress Corrosion
Experience, Protective Measures and Cracking
Monitoring by .B ekcesI ofEFC WP11 on noisorroC of
deraperP by .F .P IJsseling and the Working Reinforcement in etercnoC
Party on Marine noisorroC
03 The Use of Corrosion Inhibitors in Oil
13 Corrosion of Reinforcement in and Gas Production
Concrete: Corrosion Mechanisms Edited by .J W. Palmer, W. Hedges and
and Corrosion Protection .J .L Dawson
srepaP from EUROCORR 99" and eht
Working Party on noisorroC of 04 Control of Corrosion in Cooling Waters
Reinforcement in etercnoC Edited by .J .D Harston and .F Ropital
Available from
MANEY
MANEY PUBLISHING, HUDSON ROAD, LEEDS LS9 7DL, UK
Tel: [phone] Fax: [phone]
Email: [email protected]
Preface
This practical industry-oriented guide has been compiled to meet the needs of
personnel employed by operators, design engineers, contractors and chemical
suppliers working in the oil and gas industry. The document draws on the expe-
rience of specialists employed in various organisations and incorporates appropri-
ate industry and in-company guidelines. Both technical and management issues
are addressed and key points are provided at the end of each chapter to aid in the
assimilation of the many and varied aspects that contribute to successful corrosion
inhibition.
The background to the document compilation has been the increased drive in
the oil and gas industry towards reducing costs but at the same time decreasing
risks to the operation, the environment and safety by the adoption of appropriate
and auditable systems. Expenditure can be controlled by drilling fewer wells and
producing them at higher rates but this imposes increasing demands on inhibitor
technology. Similarly, the development of high pressure/high temperature reser-
voirs and transportation of multi-phase fluids, often with high 2OC and S2H
contents means that the performance of inhibitor packages must continuously
improve while meeting increasingly restrictive environmental legislation.
The use of carbon steel plus inhibition in ever more stringent conditions also
demands increasingly rigorous approaches to product selection, deployment and
performance monitoring. There are requirements to have management systems
that not only address risks posed by corrosion to facilities but also to have in place
performance indicators that have both proactive and reactive control measures.
The document addresses fundamental concepts to selection criteria, field
deployment, monitoring, data acquisition and management of inhibition pro-
grammes. The early chapters provide basic information for industry personnel not
familiar with corrosion and inhibition but the bulk of the text is concerned with
selection strategies, performance testing, injection issues and typical treatment
scenarios such as downhole, pipelines, and hydrotest fluids. An important feature
is the listing and use of typical key performance indicators as the means by which
inhibition management systems can be benchmarked and audited.
Contents
stnemegdelwonkcA
ix
seireS Introduction xi
ecaferP
xv
1. Introduction 1
1.1. Aims of the Document 1
1.2. Corrosion in Oil and Gas Equipment 2
1.2.1. Background 2
1.2.2. Causes of Oil Field Corrosion 2
1.2.3. Corrosion and Inhibition Issues 4
1.3. Key Points 7
2. Inhibition Concepts and Issues 9
2.1. General Background and Basics of Inhibition 9
2.2. Inhibitor Efficiency 11
2.3. Inhibitor Availability 21
2.4. Inhibition Terminology 31
2.5. Continuous/Batch Dosage 51
2.6. Condensation, Water Cuts and Oil/Water Emulsions 51
2.7. Downstream Processing Issues 61
2.8. Environmental Issues 71
2.9. Key Points 91
3. Inhibitor Selection Strategies 21
3.1. Planning for the Use of Inhibitors 32
3.2. Corrosivity Assessments 32
3.2.1. Fluid Chemistries 32
3.2.2. Hydrodynamic Considerations 42
3.2.3. Predictive Models 52
3.3. Inhibition Risks 62
3.4. Inhibitor Selection Process 27
3.4.1. Performance Evaluation 28
3.4.2. Inhibitor Compatibility 13
vi Contents
3.5. Design Implications with Inhibition Systems 33
3.5.1. General Design Considerations 33
3.5.2. Inhibition System Components 34
3.5.3. Inhibitor Availability Requirements 34
3.6. Key Points on Selection 35
4. Inhibitor Performance Testing 37
4.1. Test Protocols 37
4.2. Preliminary Screening 39
4.3. Dynamic Tests 40
4.4. Specialised Corrosion Tests 41
4.5. Physical Property Tests 44
4.6. Compatibility Tests 47
4.7. Field Trials 48
4.8. Key Points in Testing 48
5. Deployment of Corrosion Inhibitors in the Field 51
5.1. Deployment Considerations 51
5.1.1. Injection System Requirements 51
5.1.2. Storage and Injection System 51
5.1.3. Monitoring and Data Acquisition 55
5.1.4. Data Storage, Analysis and Information System 61
5.1.5. Management of Inhibition Programmes 62
5.2. Deployment Issues 64
5.2.1. Quality Control of Corrosion Inhibitor Supplies 64
5.2.2. Storage and Dilution Issues 65
5.2.3. Corrosion Inhibitor Pumping Problems 66
5.2.4. Data Analyses and Management 67
5.3. Keypoints -- Deployment 68
6. Inhibitor Treatment of Various Systems 71
6.1. Hydrostatic Testing and Commissioning 71
6.1.1. General 71
6.1.2. Water Treatment for Hydrotest and Wet Lay Up 72
6.1.3. Implementation of Dewatering and Lay Up after 74
Dewatering
6.2. Downhole Applications 75
6.2.1. General 75
6.2.2. Continuous Injection 76
6.2.3. Batch Treatment 77
6.2.4. Squeeze Treatment 78
6.2.5. Inhibitor Selection 79
6.2.6. Performance Monitoring 79
6.3. Pipelines and Flowlines 81
6.3.1. General 81
6.3.2. Continuous Injection 83
6.3.3. Batch Treatment 84