Corrosion Control and Protection Core

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Corrosion Control and

Protection Core

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Introduction

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Learning Objectives

This section will cover the following learning objectives:

O

 Define corrosion
 Explain the significance of corrosion
 Describe corrosion threats and effects on the environment and
C

on business

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Why Learn about Corrosion

Hot water
Cars Bridges heaters

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Wells Tubing Pipeline Vessels

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Course Outline

 What is Corrosion
O

 What is the Significance of Corrosion

 How Corrosion Occurs
C

 Different forms of corrosion

 Corrosion Control Techniques
 Corrosion Monitoring and Inspection

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Definition of Corrosion

CORROSION
The deterioration of a material, usually a metal, that
results from a chemical or electrochemical reaction
with its environment
Nace International

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Definition of Corrosion
O

Electrochemical
C

Corrosion process involves electrical issues as

well as chemical issues.

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What is the Significance of Corrosion?

Assets in the oil and gas industry, such as well

completions, flowlines, vessels, are all exposed to
environments internally and externally that can cause
corrosion.

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Ref: NACE/ASTM G193-12d “Standard Terminology and Acronyms Relating to Corrosion
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What is the Significance of Corrosion?

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When considering the mechanical integrity

of assets, corrosion represents about 50%
C

of the main causes of failure (for static

equipment only).
- Carlos Palacios
NACE Corrosion Specialist &
Senior Corrosion Technologist

Ref: NACE/ASTM G193-12d “Standard Terminology and Acronyms Relating to Corrosion

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What is the Significance of Corrosion?

 Aspects that will affect the mechanical integrity of an

asset are:
• Third party damage
• Geotechnical issues
• Operational issues
• Manufacturing issues
• Construction issues

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 50% is due to corrosion

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IG
Ref: NACE/ASTM G193-12d “Standard Terminology and Acronyms Relating to Corrosion
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WHY DO I CARE?
O

 Why is corrosion important?

C

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Why do I care? Why is corrosion important?

 Financial Costs
• Affects capital and operating expenses
• Loss of production

 Financial costs can be divided in two sub costs:

• Direct (Money spent)
• Indirect (Money not saved)

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Financial Costs
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Direct (Money Spent) Indirect (Money Not Saved)

 Replacement  Unplanned shutdowns
 Installation  Loss of production (oil or gas)
C

 Maintenance  Over design (“corrosion

 Clean up of spills allowances”)
 Bad publicity/stock price

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Bad Publicity and Stock Price

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Why do I care? Why is corrosion important?

 Health and Safety Issues

O

• Releases/escape of contents
C

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August 19, 2000 – Carlsbad, New Mexico

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Carlsbad, New Mexico Pipeline Rupture

O

Rupture site
C

Vehicles and
campsite area

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Dry Gas

 Dry Gas Internal Corrosion Direct Assessment (ICDA)

• For non-piggable pipelines
 In corrosion, there is NO such thing as a dry crude oil
or a dry gas
 Dry crude oil is defined as crude oil that contains very
little water
• Normally < 1% BS&W (Basic Sediment and Water)

T
 Dry gas is defined as a gas where the water vapor has
been removed to levels where water should not be

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present in the pipeline
• Normally < 7 lbm / MMSCF (112 kg / MMSCM)

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2014 in India
O
C

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Why do I care? Why is corrosion important?

 Environmental Impact
• Leaks/spills

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July 2010 – Kalamazoo River

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C

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July 2010 – Kalamazoo River

1,100,00 Gallons
4.163.953 lts

> US $760,000,000

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Cost of Corrosion

 The cost of corrosion are steep.

O

 These costs are associated with:

• Equipment replacement
C

• Maintenance
• The use of paints and coating
• Other corrosion control measures
• Monitoring and inspection
 Just the cost of adding a corrosion allowance for
pipelines are extremely high

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API 5L Grade B Pipe Price List 2016

Pipe Diameter (inches)

10 16 24 36
PIPELINE GRADE 25.4 cm 40.64 cm 60.96 cm 91.44 cm
Cost of 1/16th of an inch (0.158 cm)
Corrosion Allowance
USD Per Mile (1 Mile = 1.6 Km)
API 5L GR.B Pipe 28,274 45,238 67,857 101,785

API 5L GR. X42 Pipe 34,557 55,291 82,936 124,404

API 5L GR. X46 Pipe 37,698 60,317 90,475 135,713

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API 5L GR. X52 Pipe 43,981 70,370 105,555 158,332

API 5L GR. X56 Pipe 45,552 72,883 109,325 163,987

H
API 5L GR. X60 Pipe 50,264 80,423 120,634 180,951

API 5L GR. X65 Pipe 67,542 108,068 162,102 243,153

API 5L GR. X70 Pipe 102,099 163,359 245,038 367,557

API 5L GR. X80 Pipe

IG 157,075 251,321 376,981

Source: http://www.tridentsteel.co.in/blog/price-rate-api5l-x52-pipes-x52-seamless-pipe-x52-welded-pipes.html
565,472
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A 2016 - NACE IMPACT Study

O
C

Ref: NACE International – Impact Study

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NACE IMPACT Study

Corrosion represents about 3.4 to 4% of the Gross

Domestic Product (GDP) of each country.

Corrosion
Country GDP (U$)
Cost (U$)
USA 1.742 × 1013 592,000,000,000
INDIA 2.066 × 1012 70,200,000,000

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Learning Objectives

This section has covered the following learning objectives:

O

 Define corrosion
 Explain the significance of corrosion
 Describe corrosion threats and effects on the environment and
C

on business

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Corrosion Control and

Protection Core

T
How Corrosion Occurs

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Learning Objectives

This section will cover the following learning objectives:

O

 Describe the basic aspects of electrochemical corrosion

 Describe the four necessary elements to form an electrochemical
corrosion cell
C

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Definition of Corrosion

CORROSION
The deterioration of a material, usually a metal, that
results from a chemical or electrochemical reaction
with its environment
Nace International

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Definition of Corrosion
O

Corrosion is a never ending process

C

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Natural Deterioration Process

 The natural deterioration process of corrosion
starts on how steels are manufactured.

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Energy Required for Production

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Amount of energy
required to produce
C

Aluminum 3
Magnesium 5

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Aluminum and Magnesium

 Both aluminum and magnesium will have more energy

than steel.

 Thus, when exposed to the environment they will

deteriorate or corrode much more rapidly.

 The magnesium will corrode first followed by the

T
aluminum.

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O

If we electrically couple aluminum or

magnesium to steel, they will corrode
C

preferentially to steel.

This is the principle of one form of

cathodic protection

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 The amount of energy to produce gold is 0.00000001,

thus the rate of the deterioration of gold is practically “0”.

No wonder gold lasts

more than many life times
and we are still finding

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ancient jewelry remains in
pristine conditions.

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 Manufactured steel structures are full of energy the energy

O

manifests in tiny charged surface locations called anodes and

cathodes.
 These are fundamental elements for corrosion to occur as well as
C

the metallic contact between them, which is the metal itself and
the environment in the form of an electrolyte.

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Definition of Electrolyte

An electrolyte is any chemical

O

substance containing ions that

migrate in an electrical field.
C

Water is the perfect electrolyte.

So does that mean that water

is corrosive?

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Water is not corrosive; it

YES is what is in the water
that makes it corrosive.

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What makes the water corrosive?

Total Dissolved Solids (TDS)

O

Sand
Flow velocity
C

Temperature
Pressure
Carbon Dioxide (CO2)
Hydrogen Sulfide (H2S)
pH
Bacteria
Oxygen
Acids

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Oxygen

 Oxygen is the worse corrosive agent in nature.

 However, oxygen is NOT naturally present in the
reservoirs
 If oxygen is in the installations it is because we put it in
there.
 How?
• Through pump seals

T
• Tanks with open or corroded roofs
• Water injection system where oxygen is allowed to come in.

H
In that case, oxygen would be in the reservoirs
• Untreated water used in drilling, fracking, or workover
operations

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Definition of pH
O

Is defined as the negative of the log

pH of the concentration of hydrogen
C

ions.
So the higher the amount of
hydrogen ions, the lower the pH.
1
pH log
H 
 

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Gases such CO2 and H2S when dissolved in

water, as well as, normally produced acids
(organic/inorganic) will decrease the pH.

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Carbon Dioxide (CO2) and Hydrogen Sulfide (H2S)

 Every reservoir in the world contains CO2, however not

O

every reservoir contains H2S or naturally occurring

organic acids
C

 H2S comes from two main sources:

1. Naturally produced in reservoir
2. Induced in the reservoir during drilling, fracking, or workover
operations

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Dissolved Solids

CO2 + H20 ↔ H2CO3

=
H2CO3 can dissociate into H++ HCO3

H2S + H20 ↔ H+ + HS-

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CH3COOH + H20 ↔ H+ + CH3COO-

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O

Inorganic acids, such as HCl, can be

introduced in the installations when
cleaning wells, for example.
C

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Components of Corrosion

 Anode
 Cathode
 Electrolyte
 Metallic contact
 Solutions causing corrosion:
• Hydrogen ions

T
• Oxygen

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Components of Corrosion

 The other parameters that make the rate of corrosion

O

higher as:
• Total Dissolved Solids (TDS)
C

• Flow Velocity
• Temperature
• Pressure
• Sand
• Many Others

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 The other parameters such as TDS, flow velocity,

temperature, pressure, sand, and many others will
make the rates of corrosion higher!
 The higher the TDS, the higher the conductivity. The
higher the conductivity, the higher the electrical
current, and therefore the higher the corrosion rate.
 The higher the TDS, the lower the dissolution of the

T
gasses.

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Temperature vs. Corrosion Rate

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C

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O
C

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C

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O
C

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H
The use of a stirrer in a pipeline would be equivalent to increasing the flow
velocity, thus the turbulence. When that happens the corrosion rate increases.

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With the simple corrosion cell we were able to

explain all these forms of corrosion:
O

 Flow Accelerated Corrosion

C

 Flow Induced Corrosion

 Flow Induced Localized Corrosion
 Erosion/Corrosion

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Learning Objectives

This section has covered the following learning objectives:

O

 Describe the basic aspects of electrochemical corrosion

 Describe the four necessary elements to form an electrochemical
corrosion cell
C

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Corrosion Control and

Protection Core

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Different Forms of Corrosion

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Learning Objectives

This section will cover the following learning objectives:

O

 Identify the different forms of corrosion encountered in oil and gas

facilities
 Define the basic corrosion principles which apply to cathodic
C

protection
 Describe the galvanic series of metals and its significance

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 The following can also be explained using this simple

cell model:
• Under Deposit Corrosion
• Crevice Corrosion
• Microbiologically Influenced Corrosion
 As we stated earlier, the metal surface is covered by
anodic and cathodic sites. And when the anodic sites
are fixed in one location gives rise to localized

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corrosion

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C

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 If on the metal surface a deposit is formed, this deposit

can be:
• Sand
• Inorganic scale
• Paraffin
• Asphaltene
• Biomass due to bacteria activity

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O
C

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Sessile bacteria is the bacteria attached to the
metal wall, the acids, and other metabolic

H
processes, that increase the rate of corrosion.

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O
C

Planktonic bacteria are free floating in the fluid

and are believed to not cause corrosion.

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Concentration Cells

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Crevice Corrosion
O
C

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Galvanic Corrosion
is a term commonly used to refer to the process in
which two different materials/metals are coupled
together.

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Galvanic Series
Noble Platinum When coupling a more active
Gold material to a more noble
O

Graphite material:
Stainless Steel (passive)
Nickel  The more active material
C

Monel will corrode behaving like

Bronze the anode
Copper
 The more noble behaving
Brasses
Tin as the cathode
Lead
Stainless Steel (active)
Mild Steel
Zinc
Aluminum
Active Magnesium

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Galvanic Series
Noble Platinum
Gold
Graphite
Stainless Steel (passive)
Nickel
Monel
Bronze
Copper
Brasses
Tin

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Lead
Stainless Steel (active)

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Mild Steel
Zinc
Aluminum
Active Magnesium
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 This film is resistant to specific environments and fluid

O

compositions.
 So changes in fluid composition, bacteria activity,
C

chlorides, and bad welding processes can affect the

integrity of the passive film and make it as corrosive as
carbon steel.

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Learning Objectives

This section has covered the following learning objectives:

 Identify the different forms of corrosion encountered in oil and gas

facilities
 Define the basic corrosion principles which apply to cathodic
protection
 Describe the galvanic series of metals and its significance

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O
C

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Corrosion Control and

Protection Core

T
Corrosion Control Techniques

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Learning Objectives

This section will cover the following learning objectives:

O

 Identify methods of corrosion control

 Recognize the use of coatings, corrosion inhibitors, biocides and
cleaning pigs and scrapers as forms of corrosion protection
C

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Controlling Corrosion

 We already mentioned the use of CRAs. However this

is normally chosen during the design stage.

 In general the whole science of controlling corrosion

relies on the modification of one of the aspects that
make corrosion happen.

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O
C

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Decrease the Anodic Sites

Mg Mg Mg

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Direct Current or Impressed Current Cathodic Protection

Buried Earth Connection

O

(Ground Bed)
C

Conductors
Interconnecting Pipeline, Source of Direct
Current Source, and Current Electricity
Ground Bed

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Coatings

 The use of coatings. Coatings form a barrier between the metal

surface and the electrolyte, isolating the anodes and cathodes.

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C

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O
C

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Corrosion Inhibitors
O
C

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Factors Affecting Corrosion Inhibitors

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Factors Affecting Corrosion Inhibitors

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C

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Definition of Biocides

Biocides are used in conjunction with scraper or

cleaning pig to mitigate microbiologically
induced corrosion (MIC)

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Cleaning Pigs / Scrapers

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C

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Corrosion Mitigation Techniques

W.L.CORROSION RATE Vs. PIG RUN

1,6
1,4
1,2
1
mm/y

0,8
0,6
0,4

T
0,2
0
Oct-01

Mar-02

May-02
Nov-01

Dic - 01

Ene-02

Feb-02
Sep-01
Ago-01

Abr-02
H
PIG RUN V CORROSION

IG
C.A. Palacios, D. Quintero, Paper No. 03178, NACE 2003, San Diego, USA.
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Corrosion Mitigation Techniques

W.L. CORROSION RATE VS.PIG RUN

O

2,5

2
C

1,5
mm/y

0,5

0
Dic - 01

Ene-02

Feb-02

Mar-02

May-02

Jun-02

Jul-02
Sep-01
Ago-01

Abr-02

PIG RUN V. CORROSION

C.A. Palacios, D. Quintero, Paper No. 03178, NACE 2003, San Diego, USA.

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Removing the Electrolyte (Water)

 In gas systems we can remove the water vapor by the

use of dehydration plants.

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Gas Dehydration
Dehydrated Gas –
7lbm/MMSCF
O
C

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Modifying the Environment – The Electrolyte

 Avoid the ingress of O2.

 If O2 is present, use dearation towers and/or oxygen
scavengers
 Use H2S scavengers to remove H2S from the fluid

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Corrosion Mitigation Techniques

 Design is another way of controlling corrosion.

O

 Designs should be done as aerodynamically friendly

as possible to avoid turbulences and thus localized
C

corrosion.

 Design systems with access to:

• Corrosion monitoring
• Fluid sampling
• Chemical injection
• Accessibility for these accessories

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Design as Corrosion Control

DESIGN

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Corrosion Monitoring and Inspection

 Corrosion Monitoring is a key element to manage

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corrosion
• These are leading indicators
C

 Inspection are also important to assess the health of

pipelines/equipment

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Learning Objectives

This section has covered the following learning objectives:

 Identify methods of corrosion control

 Recognize the use of coatings, corrosion inhibitors, biocides and
cleaning pigs and scrapers as forms of corrosion protection

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C

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