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Integrated Corrosion
Management

Dr Kirsten Oliver
Upstream Manager Production & Integrity
Mr Ruurd Abma
Chief Operating Officer Rakgas
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About Intertek

• Intertek is one of the world’s largest independent testing

and inspection organisations, supporting our customers
in their global trade.
• Extensive network of offices and advanced laboratories
in The Gulf area and the entire Middle East for
independent product testing & inspection services for
the petroleum, chemical, food safety
• Dedicated Upstream Division to service Upstream Oil
and Gas clients
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Company Structure
DIVISION Consumer Goods Food, Textiles, Toys, Hardlines, CSR, Advisory
Risk Management,
INDUSTRIES
Commercial & Electrical, Automotive, HVAC, Building Products,
Electrical Medial

Minerals Minerals

Oil, Chemical & Oil, Chemical, Agri

Agri Cargo

Analytical Pharma and Specialty Chemicals, Oil, Chemical

Services and Materials
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Industrial Technical Inspection, System Certification,
Services Health & Environment

Government Fiscal Support, Standards, Cargo Scanning

Services

TESTING │ CERTIFICATION │ AUDITING │ SAFETY │ INSPECTION

SERVICES
QUALITY ASSURANCE │ ADVISORY │ TRAINING │ OUTSOURCING
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Production and Integrity Services

Reservoir Fluid Microbiological

Analysis Analysis

Geochemistry Asset Integrity

Management

Production Chemistry Materials Consultancy

and Testing

Fluid Sampling & Corrosion Consultancy and

Analysis Testing

Meter Calibration Risk based inspection

(RBI)

Flow Assurance Allocation Analysis

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Local Team

• Production & Integrity Team supported by international

group companies
• Modelling and complex analysis carried out
internationally
• Routine interpretation and analysis, coordination, data
collection, ongoing support supplied via local team
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Case Study – Corrosion Management for New Subsea
Pipeline
• The processes and procedures that have been put in
place for the subsea pipeline connecting the newly
installed Atlantis platform to the new onshore facilities
at the RakGas onshore process facility
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Field overview

14” diameter
75km
Design life 25yrs

Atlantis offshore
platform Rak Gas onshore
process plant
Fluid
Saturated gas, no formation water
6.57 mol% CO2 and 0.05 mole% H2S
Inlet T and P of 100ºC and 89.5 Bara
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Pipeline properties

• Mechanical
– API 5L X60,
– NACE TM0175 compliant
– 6.5 mm corrosion allowance (CA)
• External Protection
– Coated (concrete asphalt enamel and 3 layer PP)
– Impressed current and Sacrificial Anodes
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Pipeline Corrosion Management Strategy

Health &
Safety,
Integrity &
Corrosion Getting it
• Development of a strategy to Issues Right

meet Corporate objectives Clear Policies

& Objectives
• The CMS is a live document
and as such must be
Reports
Organisational used to achieve
Structure & improvements

reviewed and updated Responsibilities

regularly Planning,
Procedures &
Reviews
used to provide
Implementation correction

Measure
System
Performance Yes No

Review Meeting
System the control
Performance criteria?

Independent
Audit
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Rak Gas Corrosion Management Policy

• Pipeline will be operated to:

– To minimise safety risks.
– No hydrocarbon leaks or emissions.
– The prevention of unscheduled facility shutdown as a
result of corrosion.
– To minimise the lifecycle costs of the RAKGAS facilities.
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Rak Gas Corrosion Management Strategy

• In order to achieve the policy objectives the Corrosion

Management Strategy has been developed that compresses:
– Corrosion will be controlled by design to ensure the minimum
design wall thickness is maintained over the design life of the
facility (25 years).
– Where corrosion rate calculations predict a 25 year metal loss
greater than the specified corrosion allowance, additional
measures will be used to reduce carbon steel corrosion rate
– Chemical management will be optimised to minimise chemical
cost whilst achieving adequate corrosion protection.
– A Risk Based approach will be used for inspection planning.
– Key Performance Indicators (KPIs) will be used to assess and
monitor adherence to these plans.
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Organisational Structure
• Rak Gas are responsible for Pipeline & Delivering CI to platform
• Atlantis are responsible for Platform & Injection of chemical

• Monthly operational meetings between RAK and Atlantis

• Monthly corrosion management meetings
Clearly defined roles for Rak Gas Clearly defined roles for Atlantis
 Operations Manager  VP Operations
 Production / Inspection Manager  Production Manager
 Production Engineer  QHSE
 QHSE  Production Function

 Corrosion Function
 Corrosion Engineer  Inspection Function
 Inspection Engineer  Production Chemistry
 Production Chemistry

Outsourced
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Planning Procedures and Implementation

1. Review Design, Process and Commissioning Details

2. Assess Threats and Corrosion Control System
3. Define Planned Control Systems
4. Carry out Risk Assessment
5. Define Inspection & Monitoring Plans
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CORAM

• Corrosion And Risk Assessment Methodology

• Assess the probability and consequence of a corrosion
related failure for pipelines, piping and vessels.
• Developed based on in-house industry experience and
industry recognised standards (eg API 570, API 580,
Institute of Petroleum IP12 and IP13 and ISO 15156-1 /
NACE MR0175)
• Embedded into a Microsoft Access database as a
enable transparent auditable tool.
 CORAM
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External Corrosion

• Threat
– Atmospheric exposure on platform
– Seawater splash zone (on the platforms riser section),
– Submerged sections exposed to Seawater
• Risk of pipeline and other crossings that could lead to spans
• interaction between 3rd party cathodic protection systems.
– Onshore – Buried soil conditions -
• risk of stray current corrosion from plant cathodic protection
systems
• high voltage electrical transmission systems.
• Mitigation
– Coatings
– Cathodic protection.
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Internal Corrosion
• Threat
– CO2 corrosion
• condensing water expected,
• corrosion rate depend on water hold up rates & protection due to
FeS scale
• 8-20 mm/yr calculated,
• TOL and BOL corrosion
– MIC
• Review of hydrotest procedures shows unlikely
– HIC / SCSS due to high H2S
• Unlikely as pipeline meets NACE MR0175
• Mitigation
– Corrosion inhibition
– Monitoring and pipeline cleaning
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Corrosion Inhibition

• Chemical forms film on pipe internal surface that

prevents corrosive media (acidic water phase) coming
into contact with steel
– Function of Chemical Efficiency and Availability
• Efficiency
– how well it can perform
• Availability
– % of time at the surface to be protected
» chemical supply,
» maintenance of injection pumps,
» power supplies, etc
» Persistency of chemical
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Management Strategy

• Mitigation
– Very efficient Corrosion inhibition programme
– Running cleaning pigs to remove stagnant water
• Monitoring
– Corrosion Coupons on platform
– Corrosion Coupons at inlet to plant
– Corrosion Inhibitor Dosing
– Corrosion Inhibitor Residuals
• Inspection
– Periodic In Line Inspection (Intelligent Pigging)
– NDT of offshore and onshore facilities
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Corrosion Inhibition

• Continuous Dosing
– Injected into pipeline at pre-defined rate (L/min) to meet
target dose in water or total fluids (ppm)
• Batch Dosing
– Slug of chemical between / after cleaning pig
• Ensures film on pipe surface is re-applied
• Ensures film on pipe surface is around entire internal
circumference
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Risk Assessment Output

Likelihood of

10 Very High
occurrence

5 High 3b
2 Medium 3a
1 Low 1, 2, 4
Low Medium High Very High
1 2 5 10
Consequence of Hazard

1 External corrosion subsea

2 External corrosion onshore
3a Internal corrosion with inhibitor batch treatment control of TLC
3b Internal corrosion without batch treatment
4 Internal corrosion – environmental assisted cracking
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Corrosion inhibitor Selection Programme

• Laboratory screening of candidate chemicals in

simulated environment
• Evaluation of specified target dose rate for continuous
dose rates
• Specification of batch dose rates

• Continuous injection dose rate as specified by

Chemical vendor 2500ppm in water phase shown to be
sufficient to protect pipeline.
• Potential for field optimisation
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Implementation (1)

• Fluid Sampling (Reported and trended monthly)

– Fe Count – indication of degradation offshore or in
pipelines
– CI residual – indication of CI performance
– H2S in condensate – confirmation of H2S levels for
integrity operating window

• CC analysis (Reported and trended quarterly)

– Retrieval and analysis in accordance with NACE
– Offshore and Onshore
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Implementation (2)

• Pipe Cleaning
– Removal of any water collected in the pipelines
– Analysis of debris to understand deposits and
composition of fluid.

• Communication
– Included in daily operational data
– Regular meetings with Atlantis and Rak Gas
– Monthly Corrosion Management Meetings
– Produce Quarterly and Annual reports
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Summary

• A fit-for-purpose Pipeline Corrosion management

system has been developed and implemented.
• There is good communication between offshore and
onshore operating companies
• Successful out sourcing of Corrosion Management
function
• Local Integrity Engineer working alongside Operations
Team
• International expert support relating to corrosion
inhibition, monitoring, inspection planning, risk
assessment etc also available when (if) required.