Mecorr Services Co.
Cathodic Protection Services
Internal Corrosion
D E S I G N PA C K A G E
Study
Study Name Internal Corrosion Analysis and Prevention
Owner Capital Gas Co.
Contractor Middle East Corrosion Control Co. (Mecorr)
CLIENT REFERENCE
NUMBER
MECORR REFERENCE REV. SUBMISSION DATE MECORR DOC. CONTROL #
P L I C - 0 1 0 5/10/2020
COMMENTS
PRELIMINARY VIEW REVISED AS NOTED FINAL SUBMISSION
DESIGN BY REVIEWED BY APPROVED BY
Ahmed Ibrahim
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Rev. No. :
Internal Corrosion Analysis and Prevention
Rev. Date : 5-Oct.-2020
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TABLE OF CONTENTS
1. INTRODUCTION ............................................................................................................ 3
2. ASSESSMENT OF SCC ................................................................................................ 3
3. CORROSION CONTROL METHOD .............................................................................. 7
4. CORROSION MONITORING ......................................................................................... 8
5. RECOMMENDATION: ................................................................................................... 9
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Rev. No. :
Internal Corrosion Analysis and Prevention
Rev. Date : 5-Oct.-2020
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1. INTRODUCTION
The current study is performed to assess the internal corrosion behavior for 8-inch
new pipeline gas transmission line from El Hamed field to Ras-Gharib gas plant .
The overall length of the cited pipeline is 14.2 km. The pipeline is consisted of 1189
girth weld. The material of pipeline is API5L A106 GRB with internal ceramic
insulation. The cladding material, which used to clad the internal surface of the
pipeline, is ceramic material, which frequently used because of their resistance to
corrosion.
The problem in most cladded material is the girth weld between each two joints,
because the internal circumferential weld is very difficult to be cladded which means
the internal surface of the weld act as anodic area. This area is subjected directly to
the transmitted gas however the whole internal surface of the pipe is protected
through the cladding material.
Consequently, the current study will be divided into two parts: the first part is to
study the gas analysis components and figure out its effect on the corrosion
behavior and the second part provide recommendation for corrosion control and
monitoring the corrosion rate.
2. ASSESSMENT OF SCC
Sulfide Stress Cracking (SSC) is defined as cracking of metal under the combined
action of tensile stress and corrosion in the presence of water and H2S. SSC is a
form of hydrogen stress cracking resulting from absorption of atomic hydrogen that is
produced by the sulfide corrosion process on the metal surface. [Reference: API:
571]
NACE MR0175/ISO 15156 provides the requirements and the recommendations for
the selection and qualification of carbon and low-alloy steels for service in equipment
used in oil, natural gas production and natural gas treatment plants in H2S-containing
environments, whose failure can pose a risk to the health and safety of the public
and personnel or to the environment. [Reference: NACE MR0175/ISO]
The behavior of carbon and low-alloy steels in H2S-containing environments is
affected by complex interactions of parameters, including the following:
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Internal Corrosion Analysis and Prevention
Rev. Date : 5-Oct.-2020
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• Acidity (pH) of the water phase.
• H2S partial pressure.
• Total tensile stress (applied plus residual).
• Hardness of the material.
Acceptable maximum hardness values for carbon steel, carbon manganese steel
and low alloy steel welds are given in Table A.1. As-welded carbon steels, carbon
manganese steels and low alloy steels that comply with the hardness requirements
of Table A.1 do not require post weld heat treatment.
Table 1 – Maximum acceptable hardness value for carbon steel, carbon magnesium steel and low alloy steel welds
Doc No. : PLIC010-CG
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Internal Corrosion Analysis and Prevention
Rev. Date : 5-Oct.-2020
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The below table shows the sample of gas analysis from EL Hamed field. The gas
analysis revealed that the gas contains hydrogen sulfide (H2S) with about 5.89
Mole%, carbon dioxide (CO2) and water content. H2S in presence of water is known
to cause sour corrosion.
Components (Mole %) El Hamed
Expected Flow (MMSCFD) as per GPC 5.00
Pressure (Psig) 15.60
Temp (⁰C) 27.50
N2 Nitrogen 0.91
CO2 Carbon Dioxide 2.28
H2S Hydrogen Sulfide 5.89
C1 Methane 68.88
C2 Ethane 9.07
C3 Propane 6.94
iC4 iso Butane 0.92
nC4 normal Butane 2.47
iC5 iso Pentane 0.74
nC5 normal Pentane 0.77
C6 Hexanes 0.67
Methyl Cyclo Pentane 0.00
Benzene 0.05
C7 Heptane’s 0.26
Toluene 0.02
C8 Octanes 0.10
Ethyl Benzene 0.02
m-Xylene 0.01
p-Xylene 0.13
o-Xylene 0.02
C9 Nonanes 0.02
C10 Decanes 0.00
H2O - Water Content (ppm) 7905.00
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Internal Corrosion Analysis and Prevention
Rev. Date : 5-Oct.-2020
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The following assessment for the risk of Sulfide stress-cracking (SSC) is performed
according to NACE MROl75/ISO
Working pressure H2S, Mole % Co2, Mole %
200 psi 5.89 2.3
Partial pressure of Co2 = (2.3x200)/100 = 4.6 psi
Partial pressure of H2S = (5.89x200)/100 = 11.78 psi
= 81.2 KPa.
Total partial pressure of (Co2+H2S) = 4.6+ 11.78 = 16.38 psi
= 113 KPa.
(Enter with this value Fig. D.2 to obtain in situ pH)
Figure D.2: pH of condensate water (wet gas) containing H2S and CO2
From figure D.2 the in situ pH = 4 @ 60 °C (Enter Fig.1 with this value and partial
Pressure of H2S to obtain regions of environmental severity)
Regions of environmental severity= Region 3
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Region 0: No precautions are required for the selection of steels for use under these
conditions
Region 1: Apply annex A NACE MROl75/ISO (A.2-A.3-A.4)
Region 2: Apply annex A NACE MROl75/ISO (A.2-A.3)
Region 3: Apply annex A NACE MROl75/ISO (A.2)
Figure-1 - Regions of environmental severity with respect to SSC of carbon and low alloy steels
3. CORROSION CONTROL METHOD
Addition of corrosion inhibitors should be considered as corrosion mitigation
technique when corrosive gases or liquids are transported in pipelines. The
inhibitors are considered one of the corrosion control methods that forms a
protection film on the internal surface of the pipeline, which prevent the fluid to
contact directly with the base metal. Cationic inhibitors containing nitrogen and
carrying a positive charge (e.g., amine-containing compounds) are used to mitigate
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Internal Corrosion Analysis and Prevention
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H2S and CO2 corrosion. In the current case, water base inhibitor is preferred due to
water content and condensate. The chemical inhibitor vendor provides the injection
rate of the gas corrosion inhibitor; it ranges from 0.31 to 0.06 G/D for each (1)
MMSFC. The gas corrosion inhibitor is injected through the injection access fitting
such as 2 inch COSASCO access fitting as shown in the below figure.
Flow
direction
4. CORROSION MONITORING
The practical method that used to monitor the corrosion rate is using the corrosion
coupon and the coupon is retrieved periodically based on the condition of the
corrosion as shown in the above figure. The corrosion condition is ranging from low
to severe corrosion where: below (1) mpy the corrosion condition is low, below (5)
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mpy the corrosion condition is moderate, below (10) the corrosion rate is high, and
more than (10) mpy the corrosion rate is severe. It is preferred that the corrosion
coupon be welded coupon to figure out the effect of the corrosion on the weldment.
Shear wave ultrasonic could be used periodically to examine the weldment.
Corrosion condition Retrieving frequency Recorded Corrosion rate
Low Every 6 month Below 1 mpy
Moderate Every 3 months 1 to 5 mpy
High Every 2 months 5 to 10 mpy
Severe Every 1 months More than 10 mpy
.
5. RECOMMENDATION:
The current study is performed to protect 8” gas pipeline from El Hamed field, and
the recommendations could be summarized as the following:
1. The gas analysis revealed that there is about 5.89 Mole % of hydrogen sulfide
(H2S) causing sour corrosion in addition to 2.4 Mole% of carbon dioxide causing
sweet corrosion.
2. The feasible method of the corrosion control s using the corrosion inhibitor to
form a protection film on the internal surface which will provide corrosion
protection for the girth weld from H2S and CO2 corrosion, with recommended
injection rate ranging from 0.031 to 0.062 G/D and shall be confirmed by the
chemical inhibiter vendor.
3. Monitoring the corrosion rate shall be done by installing monitoring access fitting
and evaluating the corrosion rate through the corrosion coupons periodically.
4. If there are any available joints above ground in the beginning of the pipeline, use
the shear wave ultrasonic test periodically to examine the weldment on those
areas to as a guide reference for the rest of the pipeline weld joints.
