PETRONAS TECHNICAL STANDARDS

DESIGN AND ENGINEERING PRACTICE

MANUAL

CORROSION INHIBITION OF
DOWNHOLE PRODUCTION TUBING,
PROCESS PIPING AND PIPELINES

PTS 20.210
OCTOBER 1995

PREFACE

PETRONAS Technical Standards (PTS) publications reflect the views, at the time of publication,
of PETRONAS OPUs/Divisions.
They are based on the experience acquired during the involvement with the design, construction,
operation and maintenance of processing units and facilities. Where appropriate they are based
on, or reference is made to, national and international standards and codes of practice.
The objective is to set the recommended standard for good technical practice to be applied by
PETRONAS' OPUs in oil and gas production facilities, refineries, gas processing plants, chemical
plants, marketing facilities or any other such facility, and thereby to achieve maximum technical
and economic benefit from standardisation.
The information set forth in these publications is provided to users for their consideration and
decision to implement. This is of particular importance where PTS may not cover every
requirement or diversity of condition at each locality. The system of PTS is expected to be
sufficiently flexible to allow individual operating units to adapt the information set forth in PTS to
their own environment and requirements.
When Contractors or Manufacturers/Suppliers use PTS they shall be solely responsible for the
quality of work and the attainment of the required design and engineering standards. In
particular, for those requirements not specifically covered, the Principal will expect them to follow
those design and engineering practices which will achieve the same level of integrity as reflected
in the PTS. If in doubt, the Contractor or Manufacturer/Supplier shall, without detracting from his
own responsibility, consult the Principal or its technical advisor.
The right to use PTS rests with three categories of users :
1)
2)
3)

PETRONAS and its affiliates.

Other parties who are authorised to use PTS subject to appropriate contractual
arrangements.
Contractors/subcontractors and Manufacturers/Suppliers under a contract with
users referred to under 1) and 2) which requires that tenders for projects,
materials supplied or - generally - work performed on behalf of the said users
comply with the relevant standards.

Subject to any particular terms and conditions as may be set forth in specific agreements with
users, PETRONAS disclaims any liability of whatsoever nature for any damage (including injury
or death) suffered by any company or person whomsoever as a result of or in connection with the
use, application or implementation of any PTS, combination of PTS or any part thereof. The
benefit of this disclaimer shall inure in all respects to PETRONAS and/or any company affiliated
to PETRONAS that may issue PTS or require the use of PTS.
Without prejudice to any specific terms in respect of confidentiality under relevant contractual
arrangements, PTS shall not, without the prior written consent of PETRONAS, be disclosed by
users to any company or person whomsoever and the PTS shall be used exclusively for the
purpose they have been provided to the user. They shall be returned after use, including any
copies which shall only be made by users with the express prior written consent of PETRONAS.
The copyright of PTS vests in PETRONAS. Users shall arrange for PTS to be held in safe
custody and PETRONAS may at any time require information satisfactory to PETRONAS in order
to ascertain how users implement this requirement.

REVISION REGISTER

REVISION NO.

DATE

DETAIL OF REVISION

5/93

Draft document. No registered distribution

7/95

General Revision to Draft. No registered distribution

Initial Issue

CONTROLLED DISTRIBUTION LIST

Copy No.

Registered Holder

01

ETS/4

02

ETS/6

03

PET/3

04

PET/33

05

OPM/41

06

EPD/63, SIPM

07

ME/122, KSLA

08

ETS/43

09

ETS/431

10

ETS/433

11

ETS/434

12
1314
15
16
17
18
19
20

Date Distributed

TABLE OF CONTENTS

1.

INTRODUCTION

1.1

PURPOSE AND SCOPE

1.2

ABBREVIATION .

1.3

CROSS REFERENCES

DESCRIPTION OF PRODUCTION AND TRANSPORT SYSTEMS

2.1

SINGLE-PHASE GAS SYSTEMS

2.2

SINGLE-PHASE LIQUID SYSTEMS

2.3

TWO-PHASE GAS-LIQUID SYSTEMS

2.3.1

Annular Dispersed Gas-liquid Flow

2.3.2

Stratified Gas-Liquid Flow

2.3.3

Slug Gas-Liquid Flow

2.4

TWO-PHASE LIQUID-LIQUID SYSTEMS

2.4.1

Dispersed Liquid-Liquid Flow

2.4.2

Separated Liquid-Liquid Flow

2.5

THREE-PHASE GAS LIQUID-LIQUID SYSTEMS

2.5.1

Annular Dispersed Flow With a Very High GLR

2.5.2

Stratified Flow With a Very High GLR

2.5.3

Stratified Flow With a Very Low GLR

3.

CORROSION INHIBITOR INJECTION DOSAGES

4.

REFERENCES

5.

TABLE

6.

ATTACHMENTS

1.

INTRODUCTION

1.1

PURPOSE AND SCOPE

The purpose of this philosophy is to ensure that a structured approach is made and followed
during the design stage and/or the production stage, in selecting an effective inhibitor for
various production systems and transport systems.
Due consideration is given to the possible occurences of corrosion under varying production
scenarios particularly the liquid velocities, watercut factors and flow regimes. Corrosion
control by inhibition in this case is applicable to carbon steel systems only. Selection of
corrosion inhibitors is covered elsewhere (ref. 1,4).
This philosophy should be used where it has been determined that a corrosion inhibitor is
required, usually by corrosion modelling, field experience or field monitoring data. Other
methods of corrosion control that reduce the corrosion rates to acceptable levels (e.g.
deoxygenation of seawater injection systems} are not considered here.
For any chemical selected, how the chemical portions between oil and water phases and the
point of ultimate discharge of the water phase (including some chemical) must be considered.
This philosophy gives recommendations for the type of inhibitor to be selected for specific
flow environments. There will be cases where the alternative type of inhibitor is selected, even
though in theory it is not be the most (cost) effective inhibitor. Typical reason for selection
would be desire to minimise the number of different inhibitors used, proven track record,
environmental considerations etc.

1.2

1.3

ABBREVIATION
CO2

Carbon Dioxide

SRB

Sulphate Reducing Bacteria

CGR

Condensate Gas Ratio

GLR

Gas Liquid Ratio

HHP

High High Pressure

HP

High Pressure

H2S

Hydrogen Sulphide

CROSS-REFERENCES
Where cross-references to other parts of the main text in this procedure are made, the
referenced section number is shown in brackets. Documents referenced by this procedure are
listed under references (4).

2.

DESCRIPTION OF PRODUCTION AND TRANSPORT SYSTEMS

The production and transport systems in PETRONAS can be distinctly divided into three
major systems, (Ref. 2), namely Single-Phase system, Two-Phase system and Three-Phase
system. These three systems consists of production, transport and re-injection systems.
A critical part of this analysis is to first determine the flow regime present. This can be done
by using the hydraulic model TWOPHASE or the Shell corrosion models Wetgas7,
for wetgas pipelines or Flowline7 for all other conditions.

2.1

SINGLE-PHASE GAS SYSTEMS

The principal examples of single phase gas systems are:

2.1 .1

downhole tubulars below the level of liquid condensation

dry gas export pipelines.

Corrosion
In single-phase gas systems no aqueous phase is present and aqueous corrosion thus
cannot occur.
For downhole tubulars generally liquid condensation will occur at some point in the tubulars.
The depth where condensation occurs will vary through the life of the well, as pressures and
temperatures change. Above the point of condensation the tubulars needs corrosion control
measures. This portion of the well that is corrosive drives the corrosion control measures. The
portion of the well that is technically non-corrosive, because it is only single phase gas,
usually has to be protected to be able to protect the rest of the well, so no account can be
made of the fact that this portion is non-corrosive.
For "dry" gas export pipelines, where the gas is dried before transport to prevent formation of
gas hydrates and corrosion, however an aqueous phase may still be present unintentionally
under certain circumstances:
-

insufficient drying of a line after hydrotesting,

temporarily bypassing or misoperation of the drying units,

due to glycol carry over.

inadequate drying of condensate reinjected into the line.

This condition will change the single-phase gas system to a two-phase gas-liquid system
(2.3).

2.1 .2

Corrosion Control
In true single phase gas systems corrosion control by inhibition is normally not required.
However, in the event that the presence of a water phase is possible for extended duration,
corrosion control measures may be required.
In downhole tubulars the single phase portion of the tubulars has inhibitor injected in order to
be able to protect the portion of the tubulars that is in two-phase flow. For dry" gas pipelines,
when the gas drying system goes out of specification some pipelines have systems installed
to inject inhibitors as a protection system in this system which is now two-phase.

2.2

SINGLE-PHASE LIQUID SYSTEMS

2.2. 1

Corrosion
Single-phase liquid systems in production and transport systems are systems where crude oil
or gas condensate (usually containing dissolved water and gas) is produced, or where all the
liquids are fully emulsified (i.e. no free water phase).
The principal examples are:

oil wells above the bubble point pressure and where the fluids are fully emusified. Note
the depth that the well reaches the bubble point will depend on the pressures in the well
and the reservoir. The bubble point pressure could be reached at or downstream of the
wellhead, at some point in the tubulars or in the formation itself. For most mature oil wells
(i.e. PETRONAS wells) the water cut is high and the pressures are relatively low, so that
the tubulars contain 3 separate phase, oil, water and gas.

export oil lines ("trunklines"), where the gas has been separated from the oil and the
water remaining in the oil is at a low enough concentration and high enough velocity to be
fully emulsified or disposed (i.e. no free water phase). The minimum velocity to ensure no
water dropout in these situation is above a critical value of at least 1 m/s (ref. 5).

water injection systems.

In single-phase liquid systems whenever the water content is higher than the amount which
can dissolve molecularly the water will be present as a separate phase. From a corrosion
stand point this starts to be a concern in a crude system at water cuts of > 40 % and/or at
water cuts < 40 % with liquid velocities < 1 m/s Under this condition the system should be
regarded as a two-phase liquid-liquid system (2.4). Note that the 40 % limit is believed to be
conservative and there is ongoing research to redefine this limit. Further data on the critical
water/oil ratio can be obtained by running the Wetgas7 or Flowline7 corrosion modelling
programs. The effects of emusification of the crude/water also need to be considered.
In the water injection systems, where produced water is re-injected and dissolved corrosive
gases (CO2 and/or H2S) are not completely removed, corrosion may occur. In cases where
seawater is injected to enhance oil recovery, the injected water is usually de-aerated to
remove dissolved oxygen and chemically treated with biocides to suppress SRB-induced
corrosion. If oxygen is present in the injected water (through leaks or poor de-aeration), the
corrosion rates will be extremely high and unlikely to be economically treatable with inhibition;
effort needs to be placed on first reducing the oxygen level in the water.

2.2.2

Corrosion Control
In true single-phase condensate or oil systems, there is no free water phase, hence, corrosion
control normally will not be needed. However there are few systems that are truely singlephase and these must be treated as two-phase or multi-phase systems. The conditions which
would allow water to settle out must be clearly understood, before a system can be called
"single-phase".
Injection of corrosion inhibitor into water injection systems is generally not favoured because
film forming corrosion inhibitors may block the reservoir pores. If this needs to be considered,
specific tests with reservoir cores should be carried out.

2.3

TWO-PHASE GAS-LIQUID SYSTEMS

An aqueous phase in contact with the steel wall is a pre-requisite for aqueous corrosion. In
two-phase gas-liquid systems the systems of concern are where the liquid phase is water or a
(single phase) aqueous mixture (e.g. glycol and water mixtures).
Two phase systems with no free water phase are non-corrosive, so are not considered
further.
In these two-phase systems the corrosivity will depend upon the flow regime present.

2.3.1

Annular Dispersed Gas-Liquid Flow

At relatively high superficial gas velocities and relatively low superficial water velocities the
flow pattern in the two-phase gas-water flow will be annular-dispersed, (ref. 3).
This situation occurs in production tubings, flowlines, gathering lines of gas wells with low
CGRs and in gaslift lines when water (but no gas condensate) has condensed from the gas or
is produced from the formation.

2.3.1.1 Corrosion
With respect to corrosion, the two-phase gas-liquid systems being considered with annulardispersed flow have an aqueous phase in contact with the steel pipe wall over the whole
circumference of the pipe, and are consequently corrosive.

2.3.1.2 Corrosion Control

Continuous injection of corrosion inhibitors soluble in water or water/glycol mixtures is
recommended, Ref. 2 and Attachment 2. Corrosion control by continuous injection of an
inhibitor soluble in a hydrocarbon phase into the system is not recommended. If a
hydrocarbon soluble inhibitor was used, since there is no continuous hydrocarbon phase in
this situation, the inhibitor would not be transported to all the locations where it is required.

2.3.2

Stratified Gas-Liquid Flow

In horizontal and inclined pipes the annular-dispersed flow pattern can change to a stratified
flow pattern upon a decrease of the superficial gas velocity. For vertical flow such a transition
does not occur.
The stratified gas-water flow pattern is usually found:
- in trunklines where an aqueous phase (but not gas condensate) has condensed from the gas
which has been insufficiently dried, or dried with glycol such as in gaslift lines from
compression platforms, or
- when natural gas separated from co-produced liquids, but not dried, is transported such as in
gaslift lines from HHP and HP separators.

2.3.2.1 Corrosion
In a non-vertical pipeline operating in stratified two-phase gas-liquid flow the bottom of the line
will be in contact with the aqueous phase. The top of the line will be in contact with the flowing
vapour phase of the system. In practical situations this means that the top of the line will be
wet due to water condensation. The latter may occur due to temperature gradient across the
pipe wall or due to capillary condensation of water vapour in the pores of the corrosion
products present on the pipe wall.

2.3.2.2 Corrosion Control

With respect to the control of corrosion in the bottom of the line in pipelines operating in
stratified two-phase gas-water flow, addition of corrosion inhibitors soluble in water or
water/glycol mixtures is recommended, (Ref. 2).
Corrosion control by continuous injection of an inhibitor soluble in a hydrocarbon phase into
the system is not recommended, (2.3.1.2)
Control of corrosion in the top of the line is only possible by:
-

addition of a vapour phase corrosion inhibitor to the gas phase, or

mechanical transport of water soluble or water/glycol soluble corrosion inhibitors to the

top of the line. Transport of corrosion inhibitor to the full bore of the pipeline is possible by
batching a volume of corrosion inhibitor between two batching pigs through the line.

2.3.3

Slug Gas-Liquid Flow

2.3.3.1 Corrosion
With respect to the occurrence of corrosion, systems operating in slug flow of gas and liquid
have to be regarded as being in single-phase liquid flow for a time fraction, t, and in stratified
flow for a time fraction, 1-t. The fraction t is determined by Eq(1) as follows:

t = f (L / v )

Eq(1)

where:
L

= length of pipeline ft

= mixed gas/liquid velocity ft/s

= frequency of the slugs

2.3.3.2 Corrosion Control

With respect to corrosion control methods a two-phase gas-liquid system operating in slug
flow has to be treated either as a:
-

two-phase gas-liquid system operating in annular-dispersed flow or

two-phase gas-liquid system operating in stratified gas-liquid flow.

The choice will depend on the value of t in Eq(1) above. For both cases, continuous addition
of the corrosion inhibitors soluble in water or water/glycol mixtures is recommended, (Ref. 2).
Corrosion control by continuous injection of an inhibitor soluble in a hydrocarbon phase into
the system is not recommended.

2.4

TWO-PHASE LIQUID-LIQUID SYSTEMS

In practical situations the liquid phases are an aqueous phase and a hydrocarbon phase. The
local flow condition of this system will affect the place and rate of corrosion. The extremes of
the possible flow conditions are separated flow and dispersed flow of both liquids.

2.4.1

Dispersed Liquid-Liquid Flow

Dispersed flow of two-immersible liquids, such as oil and water for horizontal/inclined flow and
vertical flow regime are described in detail in ref. 3.
Either the aqueous phase or the non-aqueous phase can be regarded to be the continuous
phase. In crude systems with a high water to oil ratio i.e. a water cut > 40% and/or a water cut
< 40% with liquid velocities < 1 m/s, the aqueous phase (water) will generally form the
continuum (see comment on the 40% limit in 2.2.1).

2.4.1.1 Corrosion
For aqueous corrosion to occur the aqueous phase must be in continuous contact with the
steel wall.

2.4.1.2 Corrosion Control

The choice of inhibitors is between either water soluble/oil dispesible inhibitors or oil
soluble/water dispesible inhibitors. In deciding on which type of inhibitor to use, consideration
should be made for:
-

which is the continuous phase, i.e. will the inhibitor reach all areas where it is required?

what are the economics for the two types of inhibitor.

No definite guidelines can be given - each case must be reviewed separately. Generally for
high water cuts a water-soluble/oil dispesible corrosion inhibitor is used and for low water cuts
an oil-soluble/water dispesible corrosion inhibitor is used. There is a middle range of water
cuts where either type of inhibitor can be used.

2.4.2

Separated Liquid-Liquid Flow

In horizontal and inclined pipeline at moderate flow velocities, separation of the dispersed flow
will occur. The resulting separated flow condition can be described as a dispersed two-phase
liquid-liquid system, (2.4.1).

2.4.2.1 Corrosion
For aqueous corrosion to occur the aqueous phase must be in continuous contact with the
steel wall.

2.4.2.2 Corrosion Control

Corrosion control in for flow regime is the same as for dispersed liquid-liquid flow (2.4.1.2).

2.5

THREE-PHASE GAS-LIQUID-LIQUID SYSTEMS

In the majority of practical situations the prevailing systems have three phases in equilibrium:
-

saline water,

liquid hydrocarbon phase and

gas phase

In systems producing crude oil, the crude oil may act as a natural inhibitors; note however
that it is very unlikely that condensate will act as a natural inhibitor in gas production systems.

2.5.1

Annular Dispersed Flow With a Very High GLR

Fluid flows with a high to very high gas-liquid-ratio (GLR) can be described as two-phase gasliquid systems. In annular dispersed flow, droplets of water and gas condensate or oil will be
entrained in the gas core. On the wall of the pipe a liquid film will be present.

2.5.1.1 Corrosion
If there is separate flow of water and gas condensate or oil and the water phase is in contact
with the pipe wall the corrosion characteristics of the system can be described as for the case
of an annular dispersed two-phase gas liquid system (2.3.1).

2.5.1.2 Corrosion Control

Corrosion control for this flow regime is generally the same as for two-phase gas liquid
systems (2.3.1.2).
However, for this flow regimes if the water in the film is dispersed i.e. water is dispersed in the
gas condensate or oil phase then an oil-soluble/water-dispersable corrosion inhibitor is
recommended because the continuous phase in the liquid film is hydrocarbon.

2.5.2

Stratified Flow With a Very High GLR

In stratified flow in horizontal and inclined pipes the corrosion and inhibition aspects can be
described by a two-phase gas-liquid model with respect to the corrosion mechanism and
control (2.3.2).

2.5.3

Stratified Flow With a Very Low GLR

Three-phase gas-liquid-liquid systems with a very low GLR can be in most cases be
described as two-phase liquid-liquid systems with respect to the corrosion mechanism and
corrosion control (2.4).

3.

CORROSION INHIBITOR INJECTION DOSAGES

The initial injection rates of the corrosion inhibitors shall be governed by the minimum
recommended level of residual concentrations required in the hydrocarbon phase and the
water phase for optimum protection. This criteria shall be provided by the individual corrosion
inhibitor Suppliers specific for their respective products and verified by Company laboratories.
These rates need to be later optimised by the use of field tests and review of corrosion rates.

4.

5.

REFERENCES/RELATED GUIDELINES
1.

Engineering Guideline No DIN:ECG.XXX.4001

Selection of Corrosion Inhibitor Systems for Downhole Production Tubing, Process
Piping and Pipelines.

2.

Flow effects on corrosion of carbon steel by L. Van Bodegom and U. Lotz, KSLA,
Corros. Prev. Process Ind., Proc NACE Int. Symp., 1 st Meeting date 1988, page
123-138, Editor Parkins and N. Redvers, Publisher, NACE Houston Texas USA.

3.

Production Handbook, Vol. 8

4.

Selection and set-up of laboratory test methods for corrosion inhibitors for sweet oil
and gas production and transport, S.F. Keij, KSLA report AMGR.95.236.

5.

Fluid flow aspects of corrosion - Field measurements of water distribution in eight

PDO pipelines, J.F. Hollenberg and B.F.M. Pots, AMGR.95.014.

TABLE
1.

6.

Summary of Systems, Corrosion and Corrosion Control.

ATTACHMENTS
1.

Single Phase Systems

2.

Two Phase Gas-Liquid (water) Systems

3.

Two Phase Liquid (oil) - Liquid (water) Systems

4.

Three Phase Gas-Liquid (oil) - Liquid (water) Systems

TABLE 1 SUMMARY OF SYSTEMS, CORROSION AND CORROSION CONTROL

ATTACHMENT 1 SINGLE PHASE SYSTEM

ATTACHMENT 2 TWO PHASE GAS-LIQUID (WATER) SYSTEMS

ATTACHMENT 3 TWO PHASE LIQUID (OIL) LIQUID (WATER) SYSTEMS

ATTACHMENT 4 THREE PHASE GAS-LIQUID (OIL) LIQUID (WATER) SYSTEMS