0 Emission CORM CORM CORM March 98

REV. DESCRIPTION COMP. VERIF. APPR. DATE

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DESIGN CRITERIA
CORROSION SURVEYS GUIDELINES
14039.VAR.COR.PRG
Rev. 0
March 1998
14039.VAR.COR.PRG
Rev. 0 March 1998
Sheet 2

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FOREWORD
Rev. 0 Emission
No. sheets 30
March 1998
14039.VAR.COR.PRG
Rev. 0 March 1998
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CONTENT
1 GENERAL
1.1 Scope
1.2 Normative references
1.2.1 European normative references
1.2.2 Normative references of ISO , IEC and national organizations
1.2.3 Normative references of other organizations
1.2.4 Internal normative references
2 CORROSION SURVEYS
2.1 Types and objectives of corrosion surveys
2.1.1 Survey in case of failure
2.1.2 Survey for the assessment of corrosion control systems
2.1.3 Survey for residual life evaluation
2.2 Guidelines on corrosion survey execution and organization
2.2.1 Work Plan editing
2.2.2 Data acquisition at office
2.2.3 On field data acquisition
2.2.4 On field surveys and specialized inspections
2.2.5 Results analysis
2.2.6 Laboratory tests
2.2.7 Survey Report Issue
2.3 Data to obtain
2.4 Typical corrosion surveys
2.5 Security
3 PIPELINE - INTERNAL WALL
3.1 Survey particular aims
3.2 On field operations
3.3 Data to obtain
3.4 Measurements and inspections
3.4.1 Fluids analysis
3.4.2 Compliance assessments
3.4.3 Integrity assessments
4 UNDERGROUND PIPELINE - EXTERNAL WALL
4.1 Survey aims
4.2 On field operations
4.3 Data to obtain
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Rev. 0 March 1998
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4.4 Measurements and inspections
4.4.1 Soil corrosivity class assessment
4.4.2 Cathodic protection assessment measurements
4.4.3 Inspection techniques
4.4.4 Coating assessment methods
4.4.5 Integrity assessments
5 OFFSHORE PIPELINE - EXTERNAL WALL
5.1 Survey particular aims
5.2 On field operations
5.3 Data to obtain
5.4 Measurements and inspection
5.4.1 Environmental corrosivity conditions assessment
5.4.2 Cathodic protection assessment measurements
5.4.3 Coating assessment survey techniques
5.4.4 Pipeline integrity assessment inspections
6 CORROSION SURVEY - HEAT EXCHANGER
6.1 Guidelines on corrosion survey execution
6.2 Data to obtain
6.3 Assessments, measurements and inspections
6.3.1 Compliance assessments
6.3.2 Fluids chemical-physical analysis
6.3.3 Corrosion deposits and chemical-physical products analysis
6.3.4 Integrity assessment inspections
7 CORROSION SURVEY - PRESSURE VESSEL
7.1 Data to obtain
7.2 Assessments, measurements and inspections
8 CORROSION SURVEY - TANK, INTERNAL WALL
8.1 Data to obtain
8.2 Measurements and inspections
8.2.1 Cathodic protection measurements
8.2.2 Paint measurements and inspections
8.2.3 Integrity assessment inspections
9 CORROSION SURVEY - TANK, EXTERNAL WALL
9.1 Survey aims
9.2 Data to obtain
9.3 Measurements and inspections
9.3.1 Environmental corrosivity characteristics assessment
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Rev. 0 March 1998
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9.3.2 Cathodic protection assessment measurements
9.3.3 Paint measurements and inspections
9.3.4 Integrity assessment inspections
10 JACKET STRUCTURE
10.1 Survey aims
10.2 Guidelines on corrosion survey execution
10.3 Data to obtain
10.4 Measurements and inspections
10.4.1 Environmental corrosivity conditions assessment
10.4.2 Cathodic protection assessment measurements
10.4.3 Integrity assessment inspections
14039.VAR.COR.PRG
Rev. 0 March 1998
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Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
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1 GENERAL
1.1 Scope
This document provisions apply to oil and gas production plants and lines, either
operating or inactive.
The purpose of the present document is the correct execution of corrosion surveys,
with special reference to data acquisition and on field operations.
The document intends:
to give guidelines on corrosion surveys execution;
to identify the applicable corrosion normative references;
to identify the most important data to obtain, in connection with the type of
survey considered;
to identify the applicable inspection techniques and instruments.
The survey shall be carried out by personnel experienced in corrosion, suitably
trained; in specific occasions special qualifications can be required.
The aims of this document do not comprise:
the criteria leading to the decision to carry out the corrosion survey;
special methods of carrying out the survey;
survey results analysis.
The document does not deal with periodical inspections to the plants, as: non
destructive controls, cathodic protection assessment measurements. The document
does not intend to replace the existing normative references on periodical
inspections.
This document is specifically directed to:
technical personnel in charge of corrosion surveys operation;
personnel in charge of the corrosion survey management;
Contractors that carry out corrosion surveys.
Generally, this document is directed to technical personnel in charge of plants
control and management.
14039.VAR.COR.PRG
Rev. 0 March 1998
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1.2 Normative references
1.2.1 European normative references
UNI 68.00.002.0 Interferenze elettriche tra strutture metalliche
interrate
UNI 68.00.003.0 Corrosione di strutture metalliche interrate -
Valutazione della corrosivit dei terreni per materiali
ferrosi non legati e basso legati
UNI CEI 5 Protezione catodica di strutture metalliche interrate:
misure di corrente
UNI CEI 6 Protezione catodica di strutture metalliche interrate:
misure di potenziale
UNI CEI 7 Protezione catodica di strutture metalliche interrate:
misure di resistenza elettrica
1.2.2 Normative references of ISO , IEC and national organizations
ISO 9223 Corrosion of Metals and Alloys - Corrosivity of
atmospheres - Classification
ISO 9224 Corrosion of Metals and Alloys - Corrosivity of
atmospheres - Guiding Values for the Corrosivity
Categories
1.2.3 Normative references of other organizations
API RP14E Design and Installation of Offshore Production
Platform Piping System
API Method RP-38 Recommended Practice for Biological Analysis of
Water Flood Injections Waters
API RP651 Cathodic Protection of Aboveground Petroleum
Storage Tanks
API Std 653 Tank Inspection, Repair, Alteration and
Reconstruction
NACE RP 0193 External Cathodic Protection of On-Grade Metallic
Storage Tank Bottoms
NACE RP0188 Discontinuity (Holiday) Testing of Protective Coating
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Rev. 0 March 1998
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NACE MR0175 Sulphide Stress Cracking Metallic Material for Oil
Field Equipment
NACE RP0675 Control of External Corrosion On Offshore Steel
Pipelines
ASTM G 51 Test Method for pH of Soil for Use in Corrosion
Testing
1.2.4 Internal normative references
02555.VAR.COR.PRG Internal corrosion. Corrosion parameters and
classification of the fluids
03580.MAT.COR.PRG Internal corrosion. Metallic materials in contact with
sea water
08038.VAR.COR.SPC Inspections of cathodic protection systems for
submarine pipelines
08041.VAR.COR.PRG Cathodic protection for the internal surface of steel
storage tanks and equipment using sacrificial anodes
08047.PLI.COR.SPC External coating survey of buried pipelines
08053.MAT.COR.PRG Internal corrosion. Materials and corrosion control
methods in gathering and treatment oil and gas plants
14059.PLI.COR.PRG Inspections with intelligent pig
MOD.COR.MON.001 Data sheet - Corrosion survey - Pipeline internal
corrosion
MOD.COR.MON.002 Data sheet - Corrosion survey - Pipeline external
corrosion
MOD.COR.MON.003 Data sheet - Corrosion survey - Sealine external
corrosion
MOD.COR.MON.004 Data sheet - Corrosion survey - Heat exchanger
MOD.COR.MON.005 Data sheet - Corrosion survey - Pressure vessel
MOD.COR.MON.006 Data sheet - Corrosion survey - Tank internal
corrosion
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Rev. 0 March 1998
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MOD.COR.MON.007 Data sheet - Corrosion survey - Tank external
corrosion
MOD.COR.MON.008 Data sheet - Corrosion survey - Jacket structure
14039.VAR.COR.PRG
Rev. 0 March 1998
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Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
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2 CORROSION SURVEYS
Oil and gas production structures, during their operating life, are subject to
corrosion, due either to the environment where they operate and to the transported
fluids. These two situations are referred to as, respectively, external corrosion and
internal corrosion.
Corrosion control and monitoring systems are designed in order to prevent the
external and internal corrosion of structures throughout their operating life. But
corrosion failures often happen during operations. We use failure in a wide
meaning; the typical case of failure is the perforation of a wall, a tubular element or a
vessel, but it can be a valve blockage or pipeline obstruction by corrosion products,
a early coating deterioration, cracks appearance in a structure.
When a corrosion failure occurs, it is necessary to carry out a survey to identify its
causes and the appropriate remedies. The opportunity to carry out a corrosion
survey may be extended to the case in which the scope is only to assess the actual
condition of the structure.
Field surveys may be carried out by the Customer or by Contractors under the
Customer supervision.
2.1 Types and objectives of corrosion surveys
2.1.1 Survey in case of failure
It is carried out after a corrosion failure. The aims of the survey are the following:
to identify the event causes;
to suggest measures suitable to avoid the event repetition.
2.1.2 Survey for the assessment of corrosion control systems
It is the case of surveys carried out in order to prevent corrosion failures. Its aims
are the following:
to evaluate the environment corrosivity characteristics;
to verify corrosion control systems adequacy and correct functioning;
to suggest interventions.
2.1.3 Survey for residual life evaluation
This is the case of surveys, usually included in activities not only concerning
corrosion, carried out on structures close to the end of their design life and requiring
interventions to extend their operating life. The survey aims are the following:
14039.VAR.COR.PRG
Rev. 0 March 1998
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Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
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to calculate the structure residual life relevant to corrosion;
to design corrosion control systems, new or additional, relevant to the possible
operating life extension.
2.2 Guidelines on corrosion survey execution and organization
2.2.1 Work Plan editing
It is the document for survey start-up. It identifies:
the survey aims;
the accomplishment steps;
costs and times foreseen;
required personnel resources;
required instruments;
required specialized services;
the prevision of the critical decisional terms for the survey execution.
The Contractors intervention may be already necessary in this phase.
2.2.2 Data acquisition at office
It is the first work accomplishment step. It includes both the acquisition of data
available at the offices and the identification of the ones to obtain on field; the
acquisition of existing documentation and applicable normative references.
2.2.3 On field data acquisition
It completes the previous step, on the basis of data and information available only
on field.
2.2.4 On field surveys and specialized inspections
It includes the execution of all the planned operations necessary to gain the survey
objective. Some of these can be carried out directly by the corrosion expert (for
example: visual examinations; photographic surveys; potential measurements for
cathodic protection assessment); others, more specialized, require the Contractors
intervention.
This phase includes meeting with plant workers for the possible acquisition of
marginal information helpful in the survey execution.
After operations on field, the suitability of implemented operations shall be verified,
or the opportunity to resort to additional surveys, either to be carried out on field or
elsewhere (for example specialized laboratories). This assessment shall be carried
out also considering times and costs expected in the Work Plan.
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Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
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The preliminary report of shall be issued as a conclusion of the present phase.
2.2.5 Results analysis
At this point, usually carried out at the offices, the results of field surveys, additional
surveys and laboratory tests are analysed, processed and interpreted.
2.2.6 Laboratory tests
They include specialized surveys, supporting the general survey, like:
chemical analysis of fluids samples;
corrosion deposits or product analysis;
metallographic analysis;
mechanical tests.
Usually they are carried out by specialized laboratories.
2.2.7 Survey Report Issue
After the completion of the above mentioned operations, a Survey Report shall be
issued, organized in the following sections, if possible:
survey aim;
conclusions;
reference documents;
normative references;
data;
survey activities results;
results analysis and discussion;
recommended interventions and advises.
Enclosures:
on field measurements and inspections results;
laboratory tests results;
2.3 Data to obtain
The acquisition of an essential data series is a corrosion survey integral part. The
data are organized in the following classes:
structure design data;
materials (inclusive of possible coatings or paints) data;
historical data;
fluids or environment data;
operational data;
monitoring data.
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Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
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The most important data to obtain for the different types of surveys dealt with in this
document, organized in the above-defined classes, are reported in the enclosed data
sheets.
Economic and context data must be added to the previous ones.
Economic data include:
corrosion control systems costs, both investment and operation;
possible failure costs;
production loss costs.
Context data characterize the environment surrounding the component or the plant
subject of the survey and are used to evaluate the social consequences of a corrosion
failure that implies a fluid leakage in the surrounding environment. The social impact
is assessed in terms of:
security;
environmental impact
2.4 Typical corrosion surveys
Here follow the corrosion surveys dealt with in this document:
pipeline - internal wall;
underground pipeline - external wall;
offshore pipeline - external wall;
heat exchanger;
pressure vessel;
tank - internal wall;
tank - external wall;
jacket structure.
Units or equipment not typical of oil production, like boilers or compressors, have
been excluded.
The following chapters, for each corrosion survey, include:
the structures to be surveyed and the units they belong to;
the survey particular aims;
applicable corrosion normative references;
the data to obtain;
applicable measurements and inspections types.
2.5 Security
All field operations shall be carried out in accordance with applicable security
requirements.
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3 PIPELINE - INTERNAL WALL
Reference structure is a carbon or low alloy steel pipeline. It includes the following
plant functional units:
flowline unit 150
oil pipeline / sealine unit 160
gas pipeline / sealine unit 170
product pipeline / sealine unit 180
The most important element is the pipeline.
3.1 Survey particular aims
The pipeline - internal wall survey includes the following particular objectives:
fluid corrosivity evaluation;
corrosion control systems suitability assessment;
pipeline assessment.
3.2 On field operations
The most important steps in the survey execution are:
data acquisition;
measurements execution to assess the fluid corrosivity;
corroded metal samples drawing and their documentation;
pipeline integrity assessment measurements and inspections execution.
3.3 Data to obtain
They can be found in the enclosed MOD.COR.MON.001 data sheet.
14039.VAR.COR.PRG
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3.4 Measurements and inspections
3.4.1 Fluids analysis
Some of them can be carried out with the support of portable systems, others need a
chemical laboratory. Expected measurements are:
pH;
dissolved iron concentration;
residual inhibitor concentration;
O
2
dissolved in the water concentration;
H
2
S presence;
bacterial counts (in accordance with API RP 38).
Fluids analysis, together with operating conditions and chemical composition data,
allows the fluid corrosivity class definition (Internal Normative document 02555.
VAR.COR.PRG).
3.4.2 Compliance assessments
The compliance of all the components with the design specifications shall be verified.
For the selection of materials in contact with oil and gas see the Internal Normative
document 08053.MAT.COR.PRG.
In case of H
2
S presence the compliance of materials with NACE MR0175
specifications shall be verified.
In the pipelines, for all fluid corrosivity classes, corrosion-erosion resistance criteria,
in compliance with API RP14E, and abrasion resistance criteria, if the fluid holds
sand, shall be verified.
3.4.3 Integrity assessments
The following techniques can be used:
hydraulic test;
inspection with intelligent pig (Internal Normative document
14059.PLI.COR.PRG);
non destructive controls with ultrasounds and welding inspection with
radiography.
14039.VAR.COR.PRG
Rev. 0 March 1998
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Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
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4 UNDERGROUND PIPELINE - EXTERNAL WALL
Reference structure is a pipeline for fluid transportation, usually gas or oil, and
exposed to the aggressive action of soil and supplied with coating and cathodic
protection system; the reference material is carbon or low alloy steel. It includes the
following plant functional units:
flowline unit 150
oil pipeline unit 160
gas pipeline unit 170
product pipeline unit 180
The most important element, for the considered units, is the pipeline. Usually it is
supplied with insulating joints or flanges for electric sectioning. Other possible
relevant elements for corrosion are valves and pumps; connected electrical
grounding systems; anchorage blocks.
External corrosion is possible if the following conditions take place simultaneously:
soil is corrosive;
coating is not integral;
cathodic protection level is not adequate, even locally.
The corrosion survey shall consider the three mentioned aspects, relevant to the soil
corrosivity in association with the structure design life, coating and cathodic
protection, both separately and jointly, in order to assess the underground pipeline
corrosion and protection level.
4.1 Survey aims
The underground pipelines - external wall corrosion survey includes the following
operations:
soil corrosivity evaluation;
cathodic protection assessment;
coating integrity assessment;
pipeline condition analysis.
4.2 On field operations
The most important steps in the survey are the following:
data acquisition;
measurements to assess the soil corrosivity category;
measurements to assess cathodic protection;
measurements to assess coating integrity;
drawing of corroded metal samples and their documentation;
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pipeline integrity assessment inspections.
4.3 Data to obtain
They can be found in the enclosed data sheet MOD.COR.MON.002.
4.4 Measurements and inspections
4.4.1 Soil corrosivity class assessment
The soil corrosivity class can be determined following UNI 68.00.003.0 indications.
The most important measurements to assess soil corrosivity are:
aqueous chemical analysis;
pH (as indicated in the document ASTM G51);
current measurements (as indicated in the document UNI CEI 5);
potential gradient measurements (as indicated in the document UNI CEI 6);
resistivity measurements (as indicated in the document UNI CEI 7).

4.4.2 Cathodic protection assessment measurements
These surveys may be carried out by the corrosion expert, supplied with portable
instruments, inclusive of:
material provided for security provisions;
high impedance voltmeter;
reference electrode;
electrical connections material.
4.4.2.1 Cathodic protection system operation measurements
They are carried out at the Transformer-Rectifier and include: power supply current
and voltage, potential for constant potential difference systems.
4.4.2.2 Potential measurements
They can be carried out near measurement points, if present, or with a portable
reference electrode.
The potential measurements procedures are described in the document UNI CEI 6.
4.4.2.3 Interference measurements
The preliminary survey shall be carried out in structure parts important for the
electric situation, like crossovers or parallelisms with other structures, in proximity
of groundbeds and electrical railway lines, following UNI 68.00.002.0 indications.
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If the detected parameters show interference presence, it is necessary to carry out a
series of measurements, in accordance with the Institution that owns the interfering
structure.
4.4.3 Inspection techniques
These surveys require an external Services Society intervention.
4.4.3.1 Cathodic protection assessments
The following methods can be used:
close interval potential profile;
transverse gradients method.
4.4.3.2 Current and resistance measurements
Current and resistance measurements are carried out to assess the correct operation
of cathodic protection system. They include:
measurement of longitudinal current flowing throughout the pipeline;
measurement of transverse current, exchanged with the environment;
insulation resistance measurement;
groundbed resistance measurement;
insulating joints measurements;
anodes measurements;
drainage points measurements.
4.4.4 Coating assessment methods
4.4.4.1 Methods for holiday coating localization
The techniques used for coating defects localization require pipeline localization and
precise knowledge of burial depth (see Internal Normative document
08047.PLI.COR.SPC).
The following inspection techniques can be used:
magnetic field variation method;
Pearson method;
transverse gradients method;
transverse tension drops detection method;
longitudinal tension drops detection method;
potential profile detection method.
4.4.5 Integrity assessments
The techniques described in par. 3.4.3. can be used.
14039.VAR.COR.PRG
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Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
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5 OFFSHORE PIPELINE - EXTERNAL WALL
Reference structure is a carbon or low alloy steel pipeline, exposed to seawater
aggressive action and supplied with coating and a cathodic protection system. It
includes the following plant functional units:
flowline unit 150
oil sealine unit 160
gas sealine unit 170
product sealine unit 180
The most important element, for all considered units, is the pipeline. Usually it is
supplied with insulating joints or flanges for electric sectioning. Other possible
significant elements from corrosion viewpoint are valves and pumps; anchorage
blocks.
On the basis of the pipeline extent, it is possible to identify the following pipeline
sections, each one exposed to specific aggressive conditions, from a corrosivity
point of view:
riser;
tube laid on the seabed;
tube suspended in seawater;
tube buried under the seabed.
The corrosion survey shall consider the aspects regarding coating and cathodic
protection, both separately and jointly, in order to assess pipeline corrosion and
protection level (see NACE RP0675).
5.1 Survey particular aims
The offshore pipelines - external wall survey includes the following particular aims:
corrosivity evaluation of the environments which the pipeline is exposed to;
corrosion control systems suitability assessment;
pipeline condition assessment.
5.2 On field operations
The most important survey execution steps are:
data acquisition;
measurements and tests to assess the environment corrosivity;
measurements and tests to assess cathodic protection;
measurements and tests to assess the coating integrity;
on field drawing of corroded metal samples and relevant documentation;
laboratory tests.
14039.VAR.COR.PRG
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Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
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5.3 Data to obtain
They are reported in the enclosed data sheet MOD.COR.MON.003.
5.4 Measurements and inspection
The inspection type depends on the pipeline depth and accessibility; the general
survey execution procedures shall be oriented and adapted to geographical area,
seabed configuration, meteo-marine conditions (see Internal Normative document
08038.SLI.COR.SPC).
The offshore pipeline - external wall corrosion survey requires Contractors
intervention; the survey is carried out through:
surface inspections carried out by boat;
underwater inspections carried out by scuba divers;
underwater inspections carried out with a remote operating vehicle (ROV).
In order to carry out the inspection the precise knowledge of pipeline route location
is necessary.
5.4.1 Environmental corrosivity conditions assessment
The marine environment (seawater; mud; marine atmosphere in the splash zone)
shall be always considered very severe. Nevertheless it is recommended to acquire
the characteristic environmental data.
5.4.2 Cathodic protection assessment measurements
5.4.2.1 Potential measurements
They include:
structure potential measurement in correspondence significant positions, with a
mobile reference electrode;
close interval potential profile measurement along the pipeline;
electric field gradient measurements near the pipeline with remote potential
correction; this measurement technique is a pipeline potential evaluation, which is
obtained as algebraic sum of measured potential gradient plus measured remote
potential.
5.4.2.2 Measurement at sacrificial anodes
They include:
potential and current density measurements;
anode assessment and consumption visual inspections.
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Rev. 0 March 1998
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Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
5.4.3 Coating assessment survey techniques
They include:
visual inspections carried out by scuba divers, with video recording and/or
photographic documentation;
visual inspections carried out with ROV, supplied with video camera and/or
photo camera.
5.4.4 Pipeline integrity assessment inspections
The following techniques may be used:
hydraulic test;
inspections with intelligent pig (see Internal Normative document
14059.PLI.COR.PRG);
thickness measurements with ultrasounds;
magnetic particles inspections to detect fatigue cracks presence.
14039.VAR.COR.PRG
Rev. 0 March 1998
Sheet 22

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
6 CORROSION SURVEY - HEAT EXCHANGER
Reference structure is a pipes bundle or plates heat exchanger. It is a component of
the following plant functional units:
oil separation unit 200
crude oil treatment unit 210
liquid hydrocarbons recovery unit 320
gas sweetening unit 330
gas hydrocarbons dew point control unit 340
natural gas liquefaction (LNG) unit 370
glycol system unit 390
The corrosion survey may become necessary:
as a consequence of corrosion event with bundle pipes perforation;
as a consequence of corrosion event with damage of the tube plate;
as a consequence of corrosion event with shell perforation;
in order to assess the corrosion conditions of various heat exchanger elements, in
connection to the environment corrosivity characteristics or to corrosion
monitoring systems results.
6.1 Guidelines on corrosion survey execution
The most important survey execution steps are:
data acquisition;
plant possible inspections execution;
pipes bundle and shell on field examination;
on field drawing of corroded metal samples and their documentation;
on field drawing of possible encrusting deposits samples;
laboratory tests possible execution on drawn samples;
corrosion laboratory tests possible execution;
report issue.
6.2 Data to obtain
They are reported in the enclosed data sheet MOD.COR.MON.004.
6.3 Assessments, measurements and inspections
6.3.1 Compliance assessments
The compliance of all components materials with design specifications shall be
verified. For materials choice in seawater presence see Internal Normative document
03580.MAT.COR.PRG.
14039.VAR.COR.PRG
Rev. 0 March 1998
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Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
In the case of H
2
S containing fluids, the materials compliance with operations in
sour environment and particularly with NACE MR0175 prescriptions shall be
verified.
If the heat exchanger, particularly the distribution boxes in case of water, is provided
with a cathodic protection system, the latter compliance with Internal Normative
document 08041.VAR.COR.PRG shall be verified.
6.3.2 Fluids chemical-physical analysis
The environment corrosivity evaluation, both shell and tubes sides, is a related to the
chemical-physical characteristics of process fluids and thermovector, particularly
aqueous phases. If they are not available, or not up-to-date, the suitable analysis
shall be carried out. Particularly necessary are:
ionic analysis;
O
2
concentration analysis;
pH measurements;
dissolved iron count;
bacterial counts (carried out on field, using suitable kits to detect the presence of
SRB, or in laboratory).
The measurements shall be carried out on fluid samples drawn both from inlet and
outlet sides of the component. The fluid corrosivity class assessment, in function of
detected parameters value, shall be carried out in accordance with Internal
Normative document 02555.VAR.COR.PRG.
6.3.3 Corrosion deposits and chemical-physical products analysis
They may become necessary with diagnostic purposes on deposits accumulated on
the heater bottom, on possibly existing scaling and corrosion products deposits.
6.3.4 Integrity assessment inspections
The following inspection techniques can be used:
visual inspection;
thickness measurements with ultrasounds;
welding radiography;
endoscopy;
hydraulic tests.
In heat exchangers provided with cathodic protection system, anodes integrity (for
impressed current systems) or consumption (for sacrificial anodes systems) control
shall be carried out.
14039.VAR.COR.PRG
Rev. 0 March 1998
Sheet 24

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
7 CORROSION SURVEY - PRESSURE VESSEL
Reference structure is a pressure vessel, containing gas or oil.
The structure in question is a component of the following plant functional units:
oil separation unit 200
crude oil treatment unit 210
gas separation unit 300
gas dehydration unit 310
liquid hydrocarbons recovery unit 320
gas sweetening unit 330
dew point control unit 340
gas dehydratation glycol syst. unit 380
glycol system unit 390
waste water system unit 560
7.1 Data to obtain
They are reported in the enclosed data sheet MOD.COR.MON.005.
7.2 Assessments, measurements and inspections
It is possible to apply par. 6.3 provisions.
14039.VAR.COR.PRG
Rev. 0 March 1998
Sheet 25

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
8 CORROSION SURVEY - TANK, INTERNAL WALL
Reference structure is an atmospheric storage tank, in carbon steel, usually
cylindrical and with 90% minimum of its volume above the ground, containing
stabilized oil, gasoline, water, glycol; the tank roof may be fixed or floating. It is a
component of the following plant functional units:
crude oil treatment unit 210
crude oil transportation and storage unit 220
gas sweetening unit 330
gas dehydratation glycol system unit 380
glycol system unit 390
The tank internal corrosion depends on the fluid corrosivity, on adopted corrosion
control systems (coating, cathodic protection) and on operating conditions.
For oil storage tanks, in relation to survey corrosion three areas are distinguished:
bottom and side wall corresponding, generally, with the first ferrule: they are the
areas where the metal surface is in direct contact with the aqueous phase
decanting under the oil phase; it is the most critical tank zone. The tank bottom
and the first ferrule, usually, are protected from corrosion with coating and,
sometimes, with a sacrificial anodes cathodic protection system;
upper side wall: the surface is in contact with the oil phase, therefore it is not a
critical zone because oil does not act as an electrolyte;
roof: fixed roof and floating roof are distinguished; in the first case the surface
can be subjected to corrosive attacks as water and acid gas drops can condense;
on the contrary, in the latter case the floating roof is always in contact with the oil
phase and therefore is not subject, usually, to severe corrosive aggressions.
The tank upper internal side wall can be supplied with coating, as the fixed roof, in
function of the stored fluid corrosivity characteristics.
The tank - internal wall corrosion survey shall consider the aspects related to the
cathodic protection system effectiveness and the coating state, if they are present, in
order to assess the structure integrity conditions.
In case of water containing tanks, the structure is usually supplied with an impressed
current cathodic protection system and with coating on the whole internal surface.
8.1 Data to obtain
They are reported in the enclosed data sheet MOD.COR.MON.006.
14039.VAR.COR.PRG
Rev. 0 March 1998
Sheet 26

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
8.2 Measurements and inspections
8.2.1 Cathodic protection measurements
They regard tanks with an internal cathodic protection system (internal Normative
document 08041.VAR.COR.PRG).
8.2.1.1 Potential measurements
They can be carried out only on operating tanks, with fixed reference electrodes, if
installed, or with a mobile reference electrode, appropriately inserted inside the tank.
8.2.1.2 Sacrificial anodes measurements
Sacrificial anodes consumption is controlled with visual inspection and dimensions
acquisition.
8.2.2 Paint measurements and inspections
In internally painted tanks, the paint assessment is carried out by:
visual inspection;
paint thickness measurements;
adherence measurements.
8.2.3 Integrity assessment inspections
Tanks inspection methods and procedures are exposed in the document API Std
653.
The most important inspection techniques are:
visual surveys;
hardness measurements, particularly for welding;
shell and bottom ultrasounds controls, preferably with computerized scanning.
14039.VAR.COR.PRG
Rev. 0 March 1998
Sheet 27

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
9 CORROSION SURVEY - TANK, EXTERNAL WALL
Reference structure is an above ground storage tank, built in carbon steel, usually
cylindrical and with 90% minimum of its volume above ground, containing stabilized
oil, gasoline, water, glycol; the tank roof may be fixed or floating. It is a component
of the following plant functional units:
crude oil treatment unit 210
crude oil transportation and storage unit 220
gas sweetening unit 330
gas dehydratation glycol system unit 380
glycol system unit 390
In relation to corrosion surveys, two areas of the tank are distinguished:
bottom: in direct contact with the soil, usually supplied with coating or paint and
with cathodic protection;
side wall and roof: exposed to atmospheric corrosion, and protected with paints.
The corrosion survey shall consider the following aspects, both separately and
jointly:
soil corrosivity and cathodic protection system, for the underground tank part;
atmospheric corrosivity and coating condition, for the above ground tank surface.
9.1 Survey aims
The tank - external wall corrosion survey includes the following operations:
corrosivity evaluation of the environment in contact with the bottom;
cathodic protection assessment;
coating integrity assessment of the atmospheric part;
tank integrity analysis.
9.2 Data to obtain
They are reported in the enclosed data sheet MOD.COR.MON.007.
9.3 Measurements and inspections
9.3.1 Environmental corrosivity characteristics assessment
9.3.1.1 Soil
See par. 4.4.1 of this document.
14039.VAR.COR.PRG
Rev. 0 March 1998
Sheet 28

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
9.3.1.2 Atmosphere
It is possible to apply the criteria reported in the documents ISO 9223 and ISO
9224.

9.3.2 Cathodic protection assessment measurements
They shall be carried out on tanks supplied with a cathodic protection system for the
bottom - external wall (see documents API RP 651 and NACE RP 0193).
For measurements execution see the provisions of par. 4.4.2 in this document.
9.3.3 Paint measurements and inspections
Paint assessment is carried out through:
visual inspection;
thickness measurements;
adherence tests.
9.3.4 Integrity assessment inspections
See par. 8.2.3 in this document.
14039.VAR.COR.PRG
Rev. 0 March 1998
Sheet 29

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
10 JACKET STRUCTURE
Reference structure is a carbon or low alloy steel tubular structure, installed on the
seabed, supporting the deck (unit 800).
In relation to the corrosion survey it is possible to distinguish the following jacket
structure areas:
the splash zone;
the part in contact with seawater;
the part in contact with mud.
10.1 Survey aims
The jacket structure survey has the following aims:
corrosivity evaluation of the environments the jacket is exposed to;
coating assessment in the splash zone;
cathodic protection assessment in the plunged part;
integrity assessment.
10.2 Guidelines on corrosion survey execution
The most important steps of the survey are the following:
data acquisition;
measurements and tests to assess the environment corrosivity;
measurements and tests for cathodic protection assessment;
measurements and tests for coating integrity assessment;
laboratory tests.
10.3 Data to obtain
They are reported in the enclosed data sheet MOD.COR.MON.008.
10.4 Measurements and inspections
The survey general procedures shall be directed and adjusted in accordance with
geographic area, seabed configuration, meteo-marine conditions.
The corrosion survey requires the intervention of qualified Service Companies.
Underwater inspections shall be carried out by scuba divers.
14039.VAR.COR.PRG
Rev. 0 March 1998
Sheet 30

Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
10.4.1 Environmental corrosivity conditions assessment
The marine environment (seawater; mud; marine atmosphere in the splash zone)
shall be always considered very severe. Nevertheless it is recommended to obtain the
environmental data distinctive of the environment where the jacket is situated.
10.4.2 Cathodic protection assessment measurements
10.4.2.1 Potential measurements
They can be carried out with a fixed reference electrodes monitoring system and by a
scuba diver supplied with a measurement portable device.
10.4.2.2 Sacrificial anodes measurements
They include:
potential and current density measurements;
visual inspections for anodes condition assessment.
10.4.3 Integrity assessment inspections
They include:
surfaces visual inspection, with photographic and video documentation, for
possible corrosive aggressions detection (pitting, corrosion-fatigue cracks).
thickness measurements with ultrasounds;
nodes inspections with magnetic particles to detect corrosion-fatigue cracks.