Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
Page 2 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
This Best Practice covers primarily transmission pipelines in gas, crude oil, condensate,
NGL, sales gas, and refined product service. Its main intent is to serve as a resource for
field personnel to provide the optimum corrosion management approach for
transmission pipelines. It covers applicable damage mechanisms and lists viable
mitigation and validation options based on established industry guidelines and field
experience.
Effective corrosion control can extend the useful life of all pipelines. The increased risk
of pipeline failure far outweighs the costs associated with installing, monitoring, and
maintaining corrosion control systems. Preventing pipelines from deteriorating and
failing will save money, preserve the environment, and protect public safety.
This Best Practice was written to be consistent with Saudi Aramco and applicable
international standards. If there is a conflict between this Best Practice and other
standards or specifications, please contact the Coordinator of ME&CCD/CSD for
resolution.
3 References
API RP 570 "Piping Inspection Code: Inspection, Repair, Alteration and Re-rating
of In-Service Piping Systems" - Addresses inspection, repair, alteration, and re-
rating procedures for metallic piping systems that have been in service.
Page 3 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
ISO 15156 (NACE MR0175) "Petroleum and Natural Gas Industries - Materials for
Use in H2S-containing Environments in Oil and Gas Production"
This standard defines the minimum mandatory requirements for positive material
identification (PMI) of pressure-retaining alloy material components, flange bolting,
welds, weld overlays and cladding. It is intended to ensure that the nominal
composition of the alloy components and associated welds have been correctly
supplied and installed as specified. Where applicable, this entire standard shall be
attached to and made a part of purchase orders. Although this document addresses
PMI requirements for alloy materials, provisions are also given for carbon steels
under certain conditions.
This standard presents metallic material requirements for resistance to sulfide stress
cracking (SSC) for petroleum production, drilling, gathering and flowline
equipment, field processing facilities, and refining facilities to be used in hydrogen
sulfide (H2S)-bearing hydrocarbon service (liquid, gas, and/or multiphase). This
standard does not include and is not intended to include design specifications. Other
forms of corrosion and other modes of failure, although outside the scope of this
Page 4 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
SAES-H-002: Internal and External Coatings for Steel Pipelines and Piping
This Standard defines the minimum mandatory internal and external coating
selection requirements for steel pipelines and piping (including associated fittings
and appurtenances) and the mandatory performance requirements of these coatings.
Excluded from this Standard are temporary coatings. This Standard does not
preclude the use of galvanized, alloy, or nonmetallic pipe where allowed by other
Saudi Aramco standards.
This standard covers the minimum mandatory requirements for the material
specifications for piping, valves, and fittings for new piping for use in general,
refining, and utility services, whose design is in accordance with either ASME
B31.1, B31.3, B31.4, or B31.8 Codes.
This standard covers the basic materials of construction for various piping systems
as governed by the fluid to be transported, and supplements the requirements of
piping codes ASME B31. The materials are also subject to the further requirements
and limitations regarding chemical, mechanical and dimensional properties per
specifications stated in this standard.
This Standard supplements the ASME B31 Piping Codes, provides requirements for
the selection of metallic pipe, and sets certain restrictions on the use of metallic
pipe.
Page 5 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
This Standard covers requirements and limitations for the design, installation and
testing of nonmetallic piping in all areas and in all applications.
This procedure covers requirements for inspection and testing of static equipment
and external inspection of general equipment as described in the procedure. This
procedure does not cover requirements for preventive maintenance programs of
rotating, electrical, instrumentation, and digital equipment.
This procedure provides guidelines for assessing carbon steel pipelines containing
corrosion metal-loss defects. Application of the guidance will establish the
remaining strength of corroded pipelines and provide the technical basis for
determining the acceptability of anomalies. The assessment methods described in
this procedure are intended to be used on corrosion metal-loss anomalies in
pipelines that have been designed to a recognized pipeline design code, including
but not limited to ASME B31.4, ASME B31.8. The procedure can be used for in-
plant piping designed and constructed.
This SAEP describes the procedures to be followed for the repair and maintenance
of onshore pipelines, as covered by ASME B31.4 and ASME B31.8. The methods
and procedures set forth herein are minimum requirements and are not a release
from the responsibility for prudent action that circumstances make advisable.
Monitoring of the cathodic protection (CP) systems is required to ensure that the CP
systems perform satisfactorily and the structures receive adequate protection. This
procedure provides the instructions and establishes the responsibilities to monitor
(CP) systems for onshore and offshore facilities.
Page 6 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
This procedure describes the steps necessary to plan and operate a program for the
on-stream inspection (OSI) monitoring of fixed equipment. OSI Monitoring in this
SAEP means the systematic monitoring of piping, pipelines, vessels and tanks for
general loss of wall thickness and localized metal loss.
Page 7 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
This Engineering Procedure provides the general instructions for manual ultrasonic
thickness testing (UTT) of base materials in plates, tubing, pipes, tanks, vessels,
castings and forgings having a nominal wall thickness of 0.050 inch (1.2 mm) to
6.0 inches (150 mm) in accordance with the referenced Codes and Standards. This
procedure is limited to contact testing using longitudinal wave techniques only.
This Saudi Aramco Inspection Procedure provides guidelines for the external visual
inspection of all existing equipment within Saudi Aramco facilities including
associated structures to identify deficiencies and maintain its integrity.
This manual provides basic guidelines and recommendations for the preparation of
detailed procedures for mothballing buildings, oilfield production, processing, and
refining equipment. Due to long range forecasts for crude production In-Kingdom,
some buildings, operating plants and pipeline systems are being considered for
mothballing for a period of 3 - 10 years. Various plants and facilities have already
been mothballed for 2 years and may remain mothballed for an additional 5 to 10
years.
Page 8 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
This section of the Pipeline Corrosion Best Practice Manual describes and categorizes the
pipeline network based on its service fluid type: gas, crude, condensate, NGL, and refined
products. Furthermore, each service type is sub-categorized to sour, non-sour, and sweet
services. The data provided in the attached tables include the name of the pipeline,
service type, service condition, coating type, diameter, length, chemical treatment, and
onstream scraping frequency (onstream scraping frequency is subject to change). Also,
some of the pipelines listed in subsequent tables may be mothballed. Detailed SIS data,
Page 9 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
The gas service can be categorized under three service types: sour, non-sour, and
sweet (CO2 containing gas). Sour gas service pipelines flow from the GOSP to
the gas plants. Some GOSPs reheat the sour gas stream up to 165F to prevent
liquid from dropping out as the gas cools down the pipeline. Enough corrosion
inhibitor solution (Champion KR-2237X or ATROS Dodigen 1641X) is injected
into the sour gas stream to turn it into a two phase regime to properly disperse
the corrosion inhibitor. The specified amount of corrosion inhibitor injected in
sour gas pipelines is based on the maximum operating temperature: 0.5 gallon
inhibitor/MMSCFD at <50C and 1.0 gallon inhibitor/MMSCFD at 50C. The
amount of water moisture in the sour gas stream varies from GOSP to GOSP.
Sweet service gas pipelines flow from the well head to the gas plants at
Hawiyah. Champion KRN-264 corrosion inhibitor is injected into sweet service
pipelines at 3.0 pints/MMSCFD of gas. The amount of water moisture in sweet
service pipelines varies from non-detected to 1700 PPMV @ 120 psig
depending on which wells are produced.
Non-sour gas service pipelines flow from gas plants to Saudi Aramco customers.
The sour gas flowing into the gas plants goes through sweetening and
dehydration processes to produce non-sour gas. The maximum water moisture
in sales gas pipelines is 7.0 lbs. of water per MMSCFD of non-sour gas as
specified in A120 Dry Gas Specifications. No corrosion inhibitor is injected in
non-sour gas pipelines because it is considered as non-corrosive.
Tables 5.1.1, 5.1.2 and 5.1.3 in the Appendix list the sour, non-sour, and sweet
gas service pipelines, respectively.
The crude service can be categorized under two service types: sour and non-
sour. The sour crude service pipelines flow from the GOSPs to either Abqaiq
Plant in the southern area or from Abu Ali to Ras Tanura Refinery in the
northern operating area. Champion AR-505 corrosion inhibitor is injected into
all sour crude pipelines at a rate of 20 ppm in the maximum water volume. The
maximum BS&W allowed in sour crude service is 0.2 vol% but typically is
about 0.1 vol% in actual operating situation.
Non-sour stabilized crude flows from Abqaiq Plant to either Ras Tanura Refinery
or Yanbu Refinery and dehydrated and desalted crude flows from Safaniyah to
Ras Tanura Refinery. Biocide will have to be injected into all non-sour crude
Page 10 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
service pipelines due to the presence of Sulfate Reducing Bacteria (SRB). The
recommended treatment program consists of 30 to 120 minutes of biocide slug at
250 ppm dosage every month depending on the non-sour crude pipeline. The
maximum BS&W allowed in non-sour crude pipelines is 0.2 vol%.
Tables 5.2.1 and 5.2.2 in the Appendix list the sour and non-sour crude service
pipelines, respectively.
Condensate flows from Tanajib Onshore Plant condensate to Berri Gas Plant.
Corrosion inhibitor (Champion 2237D or ATROS 1641D) is injected in all sour
condensate pipelines inside the GOSP between the gas compressors and the fin
fan coolers or Champion AR-505 at Tanajib Onshore Plant for the SBCL-1
pipeline. The amount of water in sour condensate service varies from 1.0 vol%
from Tanajib Onshore Plant and varies from GOSP to GOSP.
The NGL service is normally non-sour and comes from either Abqaiq Plant or
gas plants to Ras Tanura Refinery or Yanbu NGL Plant. Champion KR-2237D
or ATROS Dodigen 1641D corrosion inhibitor is injected into QA-10/QRT-10
pipeline at a dosage of 20 ppm at total NGL volume because the service in this
line is considered sour. The amount of water in NGL service varies from
pipeline to another.
All refined products come from the crude refinery and flows to either the bulk
plant or airport fueling terminal. No corrosion inhibitor is injected in refined
product pipelines because they are considered non-corrosive. Although, all
diesel is allowed to have a maximum 0.05 vol% BS&W except bunker diesel
which can have as much as 0.10 vol% BS&W.
Page 11 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
6 Damage Mechanisms
Corrosion is the dominant contributing factor to failures and leaks in Saudi Aramco
pipelines. Pipelines are susceptible to both internal as well as external corrosion. Internal
corrosion in pipelines is influenced mainly by temperature, pH, carbon dioxide (CO2) and
hydrogen sulfide (H2S) content, water chemistry, flow velocity, microbial contamination,
oil or water wetting, and composition and surface conditions of the metal. For corrosion
to occur in a pipeline there must be liquid water or other electrolyte and the water must be
in a form that can wet the wall of the pipe. Once water wet, the pipe will corrode at a rate
determined by the properties of the water. Pipelines, however, can act as long thin
separators and collect free water in low spots in the line if the velocity of the oil is less
than the entrainment velocity for water in oil. Most of the failures in pipelines are caused
by localized corrosion in the form of isolated pitting.
Internal corrosion in dry gas pipelines normally occurs when upstream gas processing/
dehydrating units deliver gas that does not meet quality specifications with regards to
the water content of the gas or dew point. Presence of a liquid electrolyte (water)
although necessary, is not sufficient for internal corrosion. Gas transmission pipelines
transmit gas with a varied composition with respect to CO2, H2S and also significantly
different operating parameters. Presence of liquid water, although provides a medium
for corrosion, the actual parametric conditions and composition define the extent of
corrosion if any.
Pipelines are subject to external damage due to corrosion and sleeve collapse.
Page 12 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
HIC and SOHIC failures occur in low strength steels and the failure
mode is ductile. HIC occurs in the base metal along the plate rolling
direction in the absence of any stress. SOHIC is a special form of HIC
that mostly occurs adjacent to the heat affected zone (HAZ) of a weld
seam due to the presence of high stress (applied and/or residual) and can
develop in HIC susceptible or resistant steel. The through thickness
cracks in SOHIC are aligned approximately perpendicular to the applied
stress. These forms of corrosion again are usually controlled by proper
material selection at the design phase of a project. 01-SAMSS-016
Page 13 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
Material deterioration of carbon and low alloy steels in contact with CO2
dissolved in water is called "sweet corrosion" that has been one of the
important problems in oil and gas industry since 1940 because of both
high corrosion rate and severe localized corrosion. Sweet corrosion
affects the materials used in production, gathering transportation and
processing facilities, resulting in typically pitting (mesa-type) or uniform
metal loss. Mesa can be formed when carbon or low alloy steels are
exposed to flowing wet carbon dioxide conditions at slightly elevated
temperatures. An iron carbonate surface scale will often form in this
type of environment which can be protective rendering a very low
corrosion. However, under the surface shear forces produced by flowing
media, this scale can become damaged or removed and exposure fresh
metal to corrosion. This localized attack produces mesa-like features by
corroding away the active regions and leaving the passive regions
relatively free of corrosion resulting in the surface profile reminiscent of
the mesas produced in rock by wind and water erosion. There are many
parameters controlling sweet corrosion: temperature, CO2 partial
pressure, pH flow rate, flow character, water chemistry, hydrocarbon
Page 14 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
Sour corrosion occurs when metals are in contact with hydrogen sulfide
dissolved in water. Signs of sour corrosion include the presence of black
corrosion products of iron sulfide and shallow round pits with etched
bottoms. Sour systems generally have lower corrosion rates than do CO2
system in many cases at temperatures below 100C due to the formation
of a protective film of iron sulfide especially at lower temperatures and
low H2S partial pressures. But still sour corrosion can shorten the life
span of carbon steel production tubing in flowing conditions. Sour
corrosion occurs in several forms of hydrogen embrittlement that cause
materials to fail at stress levels below their normal yield strength: sulfide
stress cracking (SSC), hydrogen-induced-cracking (HIC) and stress-
oriented-hydrogen-induced-cracking (SOHIC). Hydrogen sulfide is a
weak acid when dissolved in water, and can act as a catalyst in the
absorption of atomic hydrogen in steel, promoting SSC and HIC in high
and low strength steels, respectively. SOHIC can also occur if the metal
is subjected to cyclic stresses or tensile stress. Selection of materials
resistant to sour corrosion is primarily means of controlling the
embrittlement mechanisms. Inhibitor treatments are oftentimes effective
when general or pitting corrosion occurs in carbon or low alloy systems.
The most harmful and notorious bacteria known to enhance corrosion are
the sulfate-reducing bacteria (SRB). SRB reduce the sulfate to the
corrosive H2S, which again reacts with the steel surface to form iron
sulfides. Both SRB colony populations and sulfide corrosion
mechanisms are more pronounced in stagnant or near stagnant
conditions.
Page 15 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
SRB are ubiquitous, meaning that they are everywhere. They remain in
soils, surface water streams and waterside deposits in general. Their
mere presence, however, does not mean they are causing corrosion. The
key symptom that usually indicates their involvement in the corrosion
process of ferrous alloys is localized corrosion pits filled with black
sulfide corrosion products.
Page 16 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
7 Mitigation Options
7.1 Inhibition
Corrosion inhibition is utilized to protect pipelines from wet and/or sour service
fluids that is considered as a corrosive medium by decreasing the rate of attack
to retard or slow down the chemical reaction. The mechanisms of inhibition
covers many type such as adsorption to form a thin film, bulk precipitates that
coats the metal, metal passivation, etc. Typically, corrosion inhibitors used in
pipelines are filming amine type.
There are many parameters that affects the effectiveness of a corrosion inhibitor
type. Thus, it is advisable to perform a lab qualification tests to determine the
adequate and most effective corrosion inhibitor available in the market.
Research & Development Center has the protocol to perform the screening tests
for the best corrosion inhibitor (refer to SAES-A-205, Oilfield Chemicals, for
guidelines on chemical selection and testing, quality assurance, quality control
and first-fill purchase of oilfield chemicals).
7.2 Biocide
Page 17 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
a bio-stat treatment where the existing low level of bacteria count is being
maintained.
The onstream scraping frequency may change with time depending on changes
in the variables listed above.
7.4 Coatings
Coating on buried pipelines are used to minimize pipe metal surface area
exposed to potentially corrosive soil environment. It is the first line of defense
against external corrosion. However, coating applied on pipelines is never
perfect. Thus, CP must also be applied on pipelines to protect metal surfaces
exposed by coating damage such as holidays and cracks, which could otherwise
result in potential external corrosion.
The coating type used historically for newly constructed pipelines have been;
coal tar mastic, tape wrap, or fusion bonded epoxy (FBE) with the coating
actually applied depending on the pipeline construction date. For example, coal
tar mastic was typically applied before 1961, tape wrap from 1961 to 1981, and
FBE after 1981. Currently, only FBE is applied on new pipelines and can only
be applied in pipe coating plants.
Coal tar mastic and tape wrap coatings have a distinction of disbonding in wet
soil (subkha) environment. Cathodic protection is ineffective in protecting
pipelines with these type coating that disbonds because CP shielding occurs. On
the other hand, a disbonded FBE coating does not have the same problem that a
Page 18 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
disbonded coal tar mastic or tape wrap poses because FBE coating has enough
porosity to allow cathodic protection.
The type of coating used during pipeline rehabilitation is either the two-
component epoxy coating with <85% solids, two components epoxy coating
with >85% solids, or STOPAQ with rubber like mastic. Coating rehabilitation is
done for coating repair or replacement on existing operating pipelines. The two-
component epoxy coating with <85% solids is only allowed to be used on
pipelines in dry soil condition. The two-component epoxy coating with >85%
solids is allowed to be used on pipelines in dry or wet soil condition. The
STOPAQ coating is also allowed to be used on pipelines in dry or wet soil
condition. Coal tar or tape wrap are generally not used in coating rehabilitation.
There are two types of cathodic protection, the sacrificial (galvanic) anode and
the impressed-current method. The sacrificial anode method is the simpler
method, and utilizes galvanic corrosion. Sacrificial anodes are castings of a
suitable alloy electrically connected by a wire or steel strap to the structure to be
protected. The alloys used must be less noble than steel (the common oilfield
material), such as magnesium, zinc, or aluminum. The sacrificial anodes
corrode, releasing electrons to the steel. As cathodic electrochemical reactions
consume electrons, the steel surface becomes a preferential cathode and is thus
protected from corrosion. Magnesium and zinc are usually used in soils, and
zinc can also be used in brine environments. Sacrificial anodes are most often
used when current requirements are relatively low, electric power is not readily
available, and when system life is short, which calls for a low capital
investment.
Page 19 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
graphite, high silicon cast iron, lead-silver alloy, platinum, or even scrap steel
rails. Impressed-current cathodic protection is used when current requirements
are high, electrolyte resistivity is high, fluctuations in current requirements will
occur, and when electrical power is readily available.
Buried pipelines (and plant piping) are protected with impressed current remote
and distributed anodes, while short isolated piping and buried sections of
normally above grade pipelines are protected with galvanic anodes. In plant
areas, a combination of remote and distributed anode systems could be more
feasible, viable, practical and cost-optimum than the distributed anode system
alone.
As stated in Section 6.2.6, black powder is formed due to high moisture in sales
gas service primarily coming from Uthmaniyah Gas Plants and Safaniyah
Onshore Plant. Thus, water dew point control in these two plants is necessary to
mitigate further black powder formation in sales gas pipelines. Water dew point
control may be reached by having an effective dehydration process and liquid
knockout drum in these plants to make sure that the sales gas service is delivered
dry into the pipelines. Monitoring of the sales gas services water dew point is
then essential in mitigating black powder formation.
8 Corrosion Monitoring
Pipeline systems need monitoring systems that will provide early warnings to allow for
mitigation measures to be adjusted and/or initiated to control the degradation. The
primary goal of monitoring is to have a leading indicator of the potential for degradation
to the pipeline systems before significant damage occurs and allow intervention to stop
or reduce the rate of degradation to an acceptable level.
Page 20 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
There are many corrosion monitoring techniques available to investigate the corrosion
performance and reliability of operating pipelines, each technique has its strengths and
weaknesses. Selection of the most appropriate techniques is dependent upon the service
environment as well as the type of information required. No single technique stands out
to meet all the needs. The factors that influence decisions for selecting the appropriate
monitoring technique are: the reliability of the technique, its adaptability to operating
conditions, cost benefit, and user-friendly operation. It should also be emphasized that
many operating factors will affect the performance of corrosion measuring and
monitoring techniques. The factors, which are of equal importance, include:
temperature fluctuation, pressure fluctuation, environmental variation, and deterioration
of ruggedness after installation and during operation. Usually more than one technique
is used so that the weaknesses of one are compensated for by the strengths of another.
So, it is highly recommended to combine multiple complementary monitoring
techniques in order to provide an added level of reliability of data and serve as back up
in the event of pipelines failures. One technique should always be metal loss coupon.
Corrosion monitoring tools are generally used for the monitoring and optimization of
the chemical treatment efficiency. The intent is not the measurement of the precise
value of the corrosion rate but of its variation in time as a function of changes in the
environment. Monitoring methods are given in Table 8.1 for pipeline systems. Other
methods that can be used to assess corrosivity are water and other fluid analyses,
nondestructive testing (NDT) and solid or scraping debris analysis.
Method Comments
Coupon should be of the same/similar material as the
Corrosion Coupons
wall. May include weld.
Linear Polarization Requires normally minimum 30 % aqueous phase with
Resistance (LPR) minimum 0.1 % salinity mass fraction.
Galvanic probes Water supply/injection/disposal systems
To be installed downstream inhibitor injection points,
Electrical Resistance (ER)
(but as far downstream as feasible) see Figure 4 below
Erosion & sand Systems with sand or solid particles susceptible to
monitoring probes erosion damage
Hydrogen probes For sour service conditions
The corrosion coupons/probes readings should be used to create a corrosion rate loss
indicator through the trending of data. Whenever this indicator shows an upwards
trend, the corrosion inhibition and process parameters of the pipeline shall be reviewed
by skilled corrosion engineer.
The following means should be considered for achieving quality corrosion monitoring
& control and increasing the service life of the pipeline systems:
Page 21 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
Selection of sampling locations for stream analysis and monitoring locations for
corrosion assessment
Specification of sampling/monitoring frequency
Application of the established operating procedures for stream analysis and
corrosion monitoring
Management of corrosion data and analysis
Correlation of corrosion data with the inspection and operation data.
Metal loss coupons in the Oil and Gas industry are normally made from cold
rolled mild steel, typically AISI 1018 or 1020 steel. They can be fabricated in
many different sizes and shapes to fit a variety of applications. The design of
the coupon usually matches the objective of the test, simple flat sheets for
general corrosion or pitting, welded coupons for local corrosion in weldments,
stressed or pre-cracked test specimens for stress corrosion cracking. The most
common use of corrosion coupons is the determination of general corrosion
rates.
To certain extent, metal loss coupons can provide information regarding pitting
corrosion using a variety of techniques including visual/optical inspection or
scanning electron microscopy. Information about pitting that can be useful
includes the determination of pit shapes (known as morphology: profile, depth
and diameter) and density (pits/unit area). They can be analyzed to determine
the chemical nature of corrosion films and any deposits in pits.
Page 22 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
The coupons can be designed to intrude some distance into the fluid as in the
strip coupons (intrusive styles) or be flush mounted with the surface of the
pipeline as shown in Figure 1. This enables the monitoring to be positioned
within the middle of the process stream or immediately adjacent to the pipe wall.
Figure 2 shows an example of both strip and flush mounted coupons.
Page 23 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
Strip Coupons
Page 24 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
The average corrosion rate is calculated from a metal loss of corrosion coupons
while the pitting rate is calculated from the pit depth measurements. Using the
weight loss and exposure interval, an average corrosion rate expressed in mpy
can be mathematically calculated as follows:
Pit depths may be measured with a depth gauge or micrometer caliper with
sharp, pointed probes. A microscope calibrated for depth measurement may
also be used. Depth of deepest pit in mils times 365 and divided by exposure
time in days will give an effective calculation of pitting rate.
Calculated corrosion and pitting rates may be interpreted as shown in the Table 2.
*mpy = mils per year (one thousandth of an inch per year or 0.001 inch)
For chemically inhibited pipeline, the primary location of the monitoring point
incorporated by industries, in order to get a better representation of the corrosion
on the pipeline, is to place the coupons at the inlet of the pipe, to establish a base
line for corrosion, and at the end of the pipelines where it is anticipated that the
least amount of corrosion chemical will be present. The monitoring point
upstream of the corrosion inhibitor injection can monitor the uninhibited fluids
(worst case exposure). Where the downstream monitoring location provides
Page 25 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
information on the treated system corrosion rates (Figure 4). Chemical injection
volume should be adjusted, such that an acceptable corrosion rate is obtained at
the downstream end of the line. For long lines intermediate injection and
monitoring may be required. In that case, the positioning of the monitoring and
injection fittings would be as illustrated for Facility A.
Chemical
Injection
Facility A Facility B
Monitoring Monitoring
Location Location
For corrosion monitoring coupons/probes the nature of the insertion into the
pipeline to be monitored and the orientation of access point affect the quality of
the data obtained. Coupons/probes for corrosion monitoring shall be located
where there is a high probability of corrosion taking place, e.g., bottom of line in
stratified flow pipeline, top of line in condensing pipeline and elsewhere in the
corrosive phase.
In oil pipelines, periodically stratified flow conditions can develop at low flow
rates where the brine separates from the oil leading to an increase in corrosion
activity at the 6 oclock position in the pipeline. A similar situation is found for
reportedly dehydrated gas pipeline systems that were susceptible to periodic
dew point conditions where the condensate (water and hydrocarbon) will be
accumulated at the bottom of the gas pipeline.
Page 26 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
Page 27 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
If a strip coupon will be selected, it should protrude further into the process
stream, and part of the coupons/probe sensing element might not be wetted,
unless it happens to be at a low spot along the pipeline, where water can
accumulate. If bottom of the line monitoring points have not been established, it
may be advantageous to survey the layout of the pipelines, such that any low
spots and possible monitoring points can be identified since water tends to
accumulate at low spots.
The most common method in the oil & gas industry involves the use of an
access fitting which is welded or bolted onto the equipment. These fittings
provide an opening into the fluids through which a monitoring device can be
inserted. The most common fitting, known as a 2 inch access fitting, has a
2 inch opening through it and can be purchased to contain pressures as high as
6,000 psig. High pressure access fittings are designed to permit safe, relatively
easy insertion and retrieval of the monitoring equipment while under full
operating pressure. The fittings can be attached onto the equipment wherever
there is a suitable space.
The monitoring components, other than the access fitting body, shall be made
out of 316L stainless steel or better and shall be suitable for sour service and
Page 28 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
The access fitting shall be placed on the pipelines so that it will have the best
chance to monitor the corrosion mechanism in question. However, once that
location is determined the access fitting shall be conveniently located for
extraction and replacement of the monitoring instrumentation. When more than
one access fitting multiple coupons/probes is installed in one location, the
fittings must be separated by a minimum three (3) feet in order to avoid flow
interference. In order to operate the retriever, a minimum of twelve (12) inches
clearance is required around the access fitting body and a minimum of eight (8)
feet is required above or to the side of the pipe for top and side mounted fittings,
respectively as shown in Figure 7. Care should be taken to insure that adjacent
equipment does not encroach on the exclusion zone around a fitting. Although,
temperature, pressure and other process monitoring devices may have their tap
point the required 12 inches from a fitting, valve handles, tubing, and cabling
must also remain outside the 12 inch exclusion area so as not to adversely
impact retrieval operations.
Page 29 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
The typical design of the corrosion monitoring point is shown in the Library
Drawing DA-950035 2-Inch High Pressure Access System Chemical Injection
and Corrosion Monitoring.
Page 30 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
8.7 Sampling
The sampling frequency must take into account the potential corrosivity and flow
pattern changes due to shifts in production practices or well declines. For this
reason, a yearly sampling program is not suitable. Chemical sample analysis of
the fluids and gases going into the pipeline should be made on regular basis. Any
debris from the scraping runs should be also sampled and analyzed.
Page 31 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
monitors are about the only methods of obtaining a water sample from a dry
pipeline system.
Samples shall be sent to the lab for corrosion inhibitor residual analysis using
the specific vendor analysis procedure. Trending of the data is an important tool
to monitor any change in the corrosion inhibitor residuals. Samples shall be
analyzed on a monthly basis or as recommended by the area corrosion engineer.
With all the data being collected from the pipelines, it is important to turn that
data into meaningful results. Any inspection or corrosion monitoring data can
provide useful information. However, the real benefit is gained when these
programs are combined and correlated with each other. Corrosion monitoring
provides an early indication of problems while inspection measures the actual
extent of any damage done. Moreover, availability of both corrosion monitoring
and operational data history will enhance the level of confidence in the asset
integrity and be the basis for optimization of scraping, chemical injection and
inspection frequency.
The corrosion engineers along with inspection personnel should review the
collected data, analyzes the monitoring, aids in technical support and reviews
injected chemical. The data gathered from corrosion monitoring system, and
analyzed by the pipeline corrosion engineer, shall be also shared with operations
personnel and chemical company personnel to continue to refine the corrosion
mitigation efforts. The chemical vendors play an important role to ensure
ongoing performance testing, check that inhibitor rates are set correctly and help
troubleshoot increases in corrosion.
Page 32 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
can be rapidly assessed and mitigated. With this level of control in place, it is
possible to enhance equipment reliability, availability and operational efficiency.
The AER probes are available in two element forms, flush and cylindrical.
Flush probes are suited for pipelines, where pigging may occur, and for bottom
off-line monitoring in oil and gas, or multiphase flows where the corrosive water
phase exists. Cylindrical probes with their all-welded construction are suited for
more chemically aggressive environments. The AER instruments include high
resolution transmitters, data loggers, 24 VDC power supply to power the
transmitters, and special recording and retrieval software permits easy data
acquisition and display. Multi-channel systems employ Amulet software,
permitting interfacing of the AER with any process variables and parameters.
Page 33 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
A single multi-drop cable is used to connect the transmitters with the 24 VDC
and the RS-485 communication bus. For remote communications, a transmitter
is hardwired using copper-core cable to an RS-485 to RS-422 converter and then
to an RS-422 to fiber optic converter connected to the fiber optic OTN system.
A fiber optic communications system has been installed throughout the Facility
area and is used to link the field AER probe/transmitter combinations to the
central corrosion server in the control room. At a remote location, a solar power
system is installed to provide the 24 VDC power along with a fiber optic cable
running to the fiber optic backbone (ring) to provide the communications link.
Page 34 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
The AER can be integrated in all pipelines. Due to the high corrosivity level
predicted on carbon steel material in some fields, a corrosion inhibition program
is implemented. Flush strip type AER probes are installed at both top of line
(TOL) and bottom of line (BOL) positions to monitor the efficiency of the
treatment program. At TOL positions, the probe element sits at the 12 oclock
position while at the BOL a special trap is used and the AER probe projects into
the body of a Tee. These corrosion monitoring stations are located on the inlet
and outlet laterals of transmission pipelines running between the main manifolds
and the gas plant. In some cases, these probes can be installed at the middle of
the pipelines in the aboveground sections.
AER sensor system can be used to assess and quantify the effectiveness of a
chemical treatment program in gas and oil pipelines. The implemented system
can function in sour or sweet environments. Moreover, the integrated AER
system offers additional benefits:
Indicator of equipment efficiency
Quantify the effectiveness of the implemented inhibition program
Remote data access with alarming capability
Continuous monitoring
Ability to network unlimited probes
Data trending
Page 35 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
8.11 CP Monitoring
9 Validation
Validation of pipelines are meant to test their integrity to hold the required pressure.
There are two periods when pipelines are validated or revalidated: 1) during new
pipeline commissioning (initial validation) and 2) pipelines that are in operation
(revalidation). Hydrotesting is normally used to validate new pipelines and In Line
Inspection (ILI) is normally used to revalidate existing and scrapable pipelines already
in operation. Pipelines Department is no longer using hydrotesting for revalidation of
existing pipelines with scraping facilities. Unscrapable pipelines are initially validated
with hydrotest and revalidated with On Stream Inspection (OSI) method using manual
ultrasonic (UT) inspection. However, pipelines with known stress corrosion cracking
(SCC) damage or severe hydrogen induced cracking (HIC) are revalidated either with
hydrotest or with EMAT (Electro-Magnetic Acoustic Transducer) ILI tool in scrapable
Page 36 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
lines. Pipelines revalidation frequency typically is every three to five year except for
the OSI program which is done annually.
9.1 Hydrotest
Pipelines are typically revalidated using ILI method unless the pipeline has
known cracking damages (especially stress corrosion cracking) which then
requires hydrotest or EMAT tool inspection. ILI can actually pinpoint the
location of the anomalies for further inspection and fitness for service (FFS)
repair evaluation. ILI tools perform inspection qualification and not pressure
revalidation.
Typically, Magnetic Flux Leakage (MFL) tools are used to find external and
internal corrosion. UT tools are used to find external and internal corrosion, as
well as mid wall defects such as HIC. EMAT tool can find external and internal
corrosion, HIC, coating disbondment, and SCC damage.
Given the size and depth of flaws found through ILI, an FFS calculation can
now be done to determine if the flaws require repair or not. The FFS calculation
may utilize one of three popular methods such as the B31G, RSTRENG, or LPC
equations.
Page 37 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
For effective monitoring the TML types should be selected according to the
anticipated damage mechanism types. Single TMLs are assigned locations
where corrosion and/or erosion are most likely to occur. Grid Points Multiple
TMLs are used for monitoring localized flaw and aggressive wall thinning
attack. Scanning points are normally employed for pitting corrosion where
isolated wall thinning is identified.
Page 38 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
Risk Based Inspection (RBI) is a systematic tool that helps plants to make
informed business decisions regarding inspection and maintenance spending.
RBI evaluates the risk and prioritizes the equipment for inspection activities. It
defines risk as a measure of loss in terms of both likelihood of a vent and
severity of the consequence.
RBI also used to aid the assessment results of inspection, testing and corrosion
monitoring programs. It can results in inspection effort being increasing,
decreasing or being directed to higher risk area. RBI studies are performed in
Page 39 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
10 Record Keeping
11 Contributor Authors
Name Affiliation
J. N. Al-Khamis Consulting Services Department
C. I. Cruz Consulting Services Department
M. M. Al-Qarni Consulting Services Department
A. S. Al-Omari Consulting Services Department
J. P. Perez Pipelines Department
F. M. Al-Abbas Inspection Department
B. W. Burgess NA Producing Engineering Department
Revision Summary
1 April 2008 New Saudi Aramco Best Practice.
8 March 2010 Editorial revision to add the Appendix.
Page 40 of 41
Document Responsibility: Materials and Corrosion Control SABP-A-019
Issue Date: 8 March 2010
Next Planned Update: TBD Pipeline Corrosion Control
Page 41 of 41