BP Amoco No Corrosion Project - Technical Bulletin

Rev. 0, February 1999

CORROSION

OF

CUNIFER SEAWATER COOLING SYSTEM PIPEWORK

SUMMARY

Although copper-nickel (Cunifer) alloys have been utilised for many years in seawater handling systems with excellent service, BP Amoco and other operators continue to suffer costly failures of the material in seawater service. Most of these failures are avoidable by implementing simple practices in the design, commissioning and operational phases of an Assets life.

BACKGROUND
Failures arise from:

Cause
l

Examples
Pipework sizing, geometry and material selection, leading to erosion corrosion. Lack of, or inadequate provision of, continuous biociding capability. Use of polluted water leading to microbial corrosion. Inadequate biociding, leading to microbial corrosion and operating in flow regimes which lead to erosion corrosion.

Design Inadequacies: Commissioning Practices: Operational Issues:

l l

IMPACT
Corrosion of the cunifer seawater system pipework on BP Amoco Harding arising from commissioning with polluted harbour water combined with erosion has cost more than 0.6 million in repair and replacement (to date). BP Amoco Andrew suffered numerous perforations and serious pitting damage of their seawater system as a result of commissioning with untreated river water. Systems affected were pipework and coolers associated with the air compressors, nitrogen compressor, MOL pumps, re-injection compressor and power generation motor cooler inlet pipework. Estimated expenditure on repair and replacement to date is ~1M with associated production losses of ~600k. Costs (~350k) are being incurred retrofitting chlorination plant without which fouling would recur. Retrojetting to clear fouling between main skids and headers cost ~100k. Erosion corrosion of cunifer pipework has caused production shutdowns and has a major impact on maintenance requirements. For example, it was estimated that half to two-thirds of the repair and replacement work in a recent planned shutdown of a platform was on the cooling water system. This has obvious production implications.

Microbial corrosion of cunifer pipework

Microbial / erosion corrosion of a cunifer reducer

EXPERIENCE
Commissioning with contaminated river or estuarine water (even with low levels of bacteria) causes biofilm formation. These generate non-protective copper sulphide films instead of the naturally occurring copper oxide films which normally provide corrosion resistance. Inadequate biociding during operation also results in biofilm formation. Biofilm formation also has significant "non-corrosion" impact, i.e. biofouling of heat exchange surfaces with reduction in heat transfer. Biofouling leads to reduction in heat transfer, blockages of heat exchangers, increased maintenance and limits throughput. Erosion corrosion can occur when fluid velocity exceeds the erosion limit for the material, especially where impingement at bends or turbulence downstream of chokes increases shear forces at the pipewall. The two mechanisms can work together so that erosion occurs where the protective film has been weakened by bacterial action, i.e. erosion can occur at fluid velocities less than the erosion limit of the material.
This Bulletin has been sponsored by BP Amoco's "No Corrosion" Project to assist sharing of operations experience on corrosion and materials issues to New Projects, Partners and Business Units.

OPTIONS AND SOLUTIONS

Microbial Corrosion and Fouling
Cause
Commissioning using bacterially contaminated water

Solution
Use chlorinated water for commissioning. Use potable water for hydrotesting and commissioning. Sterilise after exposure to harbour, river or seawater. (Optional) - Treat system with ferrous sulphate or sodium dimethyl dithiocarbamate (SDD). Design for and use continuous chlorination as the major biofouling control in seawater systems. Electrocatalytic units on Miller and Magnus give adequate reliability. (An electrolytic copper-chlorine system has been suggested, but concerns exist on controllability and effectiveness - no long term track record). Cu-Al anodes are only effective against macrofouling, they are not effective against bacteria.

Inadequate biociding: Inadequate dose / frequency Electrochlorinator sizing Electrochlorinator operability Relying on copper - aluminium anodes without biocide

Erosion Corrosion
Cause
Poor design Operating outside design limitations

Solution
Design to BSMA 18. Use appropriate geometry and material. Monitor repeat failures and change configuration or material. Understand the actual velocities in the system, as the plant may be operating at velocities above the limit of the material. Monitor actual flows and throttle to non-erosional levels. Install more erosion corrosion resistant alloy downstream of control valves, e.g. 6Mo stainless steel.

Turbulence downstream of valves

SUMMARY
Cunifer will give good service in seawater systems provided it is kept clean. Commissioning with clean or treated water is critical. In operation, continuous chlorination is vital to avoid build-up of biomass and corrosion and fouling problems. Erosion corrosion can be avoided at the design stage or mitigated in operation by understanding and controlling flow velocities where possible. Monitoring repeat failures provides an opportunity to replace with more resistant material or to alter the piping configuration, or revise operating procedures.

For more information contact:

Paul Badelek (Corrosion Consultant) BP Amoco Exploration, Farburn Industrial Estate, Dyce, Aberdeen AB21 7PB
Tel: 01224 834071 E-mail: badelekp@bp.com

01131129, February 1999

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