A Typical Material Selection Report

CONTENTS
1.
INTRODUCTION............................................................................................................... 1
1.1
Objective of Document...................................................................................................... 1
1.2
Scope................................................................................................................................ 1
1.3
Abbreviations..................................................................................................................... 2
1.4
Units of Measurement....................................................................................................... 3
1.5
Codes and Standards........................................................................................................ 4
2.
SUMMARY........................................................................................................................ 5
3.
DESIGN DATA................................................................................................................. 11
3.1
Sources of Data............................................................................................................... 11
3.2
Design Life....................................................................................................................... 11
3.3
Fluid Compositions.......................................................................................................... 11
3.3.1
Oil Composition................................................................................................... 11
3.3.2
Gas Lift Composition...........................................................................................11
3.3.3
Produced Water Analysis....................................................................................12
3.4
Pressures and Temperatures.......................................................................................... 13
3.5
Availability....................................................................................................................... 14
3.6
Corrosion Model Cases................................................................................................... 14
4.
3.6.1
Gas Lift (3) Pipeline........................................................................................... 14
3.6.2
Gas Lift (4) Pipeline........................................................................................... 16
3.6.3
Gas Lift Header and Flowlines............................................................................18
3.6.4
Production Flowlines (6 off) and Test Headers....................................................19
3.6.5
Production Headers............................................................................................ 21
3.6.6
Export Pipelines (Seamless Linepipe, Grade 415 MPa).....................................23
3.6.7
Export Pipelines (HFI Linepipe, Grade 415MPa)................................................25
3.6.8
Produced Water Effect Modelling........................................................................26
METHODOLOGY............................................................................................................ 28
4.1
Potential for Corrosion..................................................................................................... 28

4.1.1
Corrosion Mechanisms and Considerations.......................................................28
4.1.2
CO2 Corrosion..................................................................................................... 28
4.1.3
Top of Line Corrosion.......................................................................................... 29
4.1.4
Sulphide Stress Corrosion Cracking...................................................................29
4.1.5
Hydrogen Induced Stress Cracking....................................................................30
4.1.6
Hydrogen Embrittlement.....................................................................................30
4.1.7
Chloride Stress Corrosion Cracking....................................................................31
4.1.8
Erosion................................................................................................................ 32
4.1.9
Subsea External Corrosion.................................................................................32
4.1.10 Topside Atmospheric Corrosion..........................................................................32

4.1.11 Corrosion of the Line Pipe During Transportation...............................................33
4.1.12 Microbially Induced Corrosion.............................................................................33
4.1.13 Under Deposit Corrosion....................................................................................34
4.1.14 Galvanic Corrosion............................................................................................. 34
4.1.15 Corrosion in Dead Legs and Stagnant Zones.....................................................35
4.2
4.3
5.
Selection of a Corrosion Model.......................................................................................35

4.2.1
General............................................................................................................... 35
4.2.2
Limitations of the Corrosion Model.....................................................................37
4.2.3
Prediction of Top of Line Corrosion.....................................................................37
Mechanical Material Selection......................................................................................... 38

4.3.1
Brittle Facture and Embrittlement.......................................................................38
4.3.2
Fatigue................................................................................................................ 39
CORROSIVITY ASSESSMENT AND CORROSION MITIGATION..................................40

5.1
Corrosivity Assessment Results......................................................................................40
5.2
Corrosion Inhibition Philosophy.......................................................................................43
6.
5.2.1
General............................................................................................................... 43
5.2.2
Chemical Performance.......................................................................................45
5.2.3
Chemical Injection System Design.....................................................................45
5.2.4
Operation and Reliability.....................................................................................48
PIGGING REQUIREMENTS........................................................................................... 49
6.1
Operational Pigging......................................................................................................... 49
6.2
Intelligent Inspection Pigging........................................................................................... 50
7.
6.2.1
General............................................................................................................... 50
6.2.2
Intelligent Pigging Requirements........................................................................50
6.2.3
Pigging Frequency.............................................................................................. 50
SPECIFIC MATERIAL APPLICATIONS...........................................................................52

7.1
Use of Corrosion Resistant Alloys...................................................................................52

7.1.1
Grade 304/304L Austenitic Stainless Steels.......................................................52
7.2
7.1.2
Grade 316/316L Austenitic Stainless Steels.......................................................52
7.1.3
6Mo Super-Austenitic 254 SMO (UNS S31254).................................................54
7.1.4
Duplex Stainless Steel........................................................................................ 54
7.1.5
Selection of CRA for Pipe and Vessels...............................................................56
Use of Glass Reinforced Plastic (GRP)...........................................................................56

7.2.1
Piping Systems................................................................................................... 56
7.2.2
GRP Tanks and Vessels.....................................................................................57
7.3
Selection of Elastomeric Seals........................................................................................ 61
7.4
Bolting Materials.............................................................................................................. 61
8.
MATERIALS SELECTION AND XX PLATFORM...........................................................63

8.1
Wellhead Equipment (Including Chokes and Flowline Isolation Valves)..........................63
8.2
Process Equipment......................................................................................................... 63
8.3
9.
8.2.1
General............................................................................................................... 63
8.2.2
Gas Lift First Valve On (FVO), Gas Lift Header and Flowlines...........................64
8.2.3
Production Flowlines........................................................................................... 64
8.2.4
Test Header........................................................................................................ 67
8.2.5
Production Header, Pig Launcher and Last Valve Off.........................................69
Utility Equipment............................................................................................................. 71
8.3.1
Fuel Gas Systems.............................................................................................. 71
8.3.2
Open Drains........................................................................................................ 72
8.3.3
Vent and Closed Drains and Vent Scrubber........................................................73
8.3.4
Chemical Injection Package................................................................................74
8.3.5
CCVT Power Generation....................................................................................74
8.3.6
Hydraulic Piping Systems...................................................................................74
8.3.7
Instrumentation................................................................................................... 74
8.3.8
Wash Down Water System.................................................................................77
MATERIAL SELECTION - PIPELINES............................................................................78

9.1
Materials and Corrosion Allowance.................................................................................78

9.1.1
Linepipe Manufacturing Processes.....................................................................78
9.1.2
Pipelines & Risers - Export.................................................................................79
9.1.3
Pipelines & Risers Gas Lift..............................................................................80
9.1.4
Pipeline Fittings.................................................................................................. 81
9.1.5
Chemical Injection line (Flat-Pack).....................................................................81
9.1.6
9.2
9.3
10.
Clamping and Strapping materials......................................................................81
Coating Systems............................................................................................................. 82
9.2.1
Pipeline Anti-Corrosion Coating System.............................................................82
9.2.2
Riser Coating Systems.......................................................................................82
Cathodic Protection......................................................................................................... 83
9.3.1
Sacrificial Anode System....................................................................................83
9.3.2
Corrosion Protection System Isolation MIJs....................................................83
ASSET INTEGRITY MANAGEMENT..............................................................................85

10.1
General Philosophy..................................................................................................... 85
10.2
Recommended Routine Maintenance Activities..........................................................85
10.3
Possible Unplanned Activities.....................................................................................86
11.
CORROSION MONITORING.......................................................................................... 87
11.1
Aim.............................................................................................................................. 87
11.2
Monitoring and Testing Facilities.................................................................................87
11.3
Monitoring Methods.................................................................................................... 88
11.4
Corrosion Monitoring Techniques and Equipment.......................................................89

11.4.1 Electrical Resistance (ER) Probes......................................................................89
11.4.2 Coupons............................................................................................................. 89
11.4.3 Bacterial Monitoring and Bioprobes....................................................................90
11.5
Process Stream Monitoring......................................................................................... 91
11.6
Corrosion Monitoring Instrumentation.........................................................................91
12.
CORROSION DATA MANAGEMENT AND ASSESSMENT............................................92

12.1
General Requirements................................................................................................ 92
12.2
Data Collection Frequency.......................................................................................... 92
12.3
Data Storage............................................................................................................... 92
12.4
Data Assessment........................................................................................................ 92
12.5
Corrosion Reporting.................................................................................................... 92
13.
14.
CORROSION PERFORMANCE TRACKING..................................................................94

13.1
General Requirements................................................................................................ 94
13.2
Key Performance Indicators........................................................................................ 94
13.3
Corrective and Preventative Action.............................................................................95

REFERENCES................................................................................................................ 96
APPENDIX 1 TEMPERATURE AND PRESSURE PROFILES (2 PAGES)

APPENDIX 2 CORROSION MODEL RESULTS (2 X A3 PAGES)
APPENDIX 3 LIST OF UNINHIBITED EVENTS (2 PAGES)
APPENDIX 4 CHEMICAL DATASHEETS (5 PAGES)
APPENDIX 5 LABORATORY TEST OF HFW SEAM CORROSION SUSCEPTIBILITY (1 PAGE)
1.
INTRODUCTION
1.1
Objective of Document
1.2
Scope
The scope of this document is to select suitable materials for the construction of platform topside
equipment, riser, production and the gas lift pipelines and risers; and, chemical injection tubing (Flat
Pack) based on the available fluid and process data.
Scope of the subsea component of this study also includes the review and recommendation of:
Anticorrosion coating for the riser and pipeline submerged zone;
Riser splashzone;
Riser atmospheric zone;
Anode material selection;
Piping flanges and fittings;
Clamping and strapping materials.
Scope of the platform topside component of this study also includes the review and recommendation
of:
Selection of materials for process equipment and piping;
Selection of materials for utility and ancillary topside equipment;
Specification of corrosion allowances to be applied across all equipment;
Specification of materials for bolting and polymeric seals.
This document recommends a Corrosion Management Plan to manage the corrosion of the assets
within the bounds described in this document.
1.3
Abbreviations
The following abbreviations have been used in this document:
CA
Corrosion allowance
CO2
Carbon dioxide.
CP
Cathodic protection.
CR
Corrosion rate
CSCC
Chloride Stress Corrosion Cracking
EN
Electrochemical noise
ER
Electro-resistance
H2S
Hydrogen sulphide.
Page 1
HAZ
Heat Affected Zone.
HDPE
High Density Polyethylene
HE
Hydrogen embrittlement.
HISC
Hydrogen Induced Stress Cracking
ID
Inside diameter.
IP
Intelligent pig
KP
Kilometre point.
LPR
Linear polar resistance
NORSOK
Norwegian Technical Standards for Petroleum Operations
OD
Outside diameter.
pCO2
Partial pressure of CO2.
pH2S
Partial pressure of H2S.
ppm
parts per million
PVDF
Polyvinyldene Fluoride
ROV
Remotely operated vehicle
SCNF
Strain concentration factor
SSCC
Sulphide Stress Corrosion Cracking
TOLC
Top of line corrosion.
TSA
Thermal Sprayed Aluminium
UDC
Under Deposit Corrosion
WT
Wall thickness.
1.4
Units of Measurement
The following units of measurement have been used in this document:
temperature, degrees Celsius.
bar
system pressure, bar.
g/l
solids concentration, grams per litre.
g/m2s
condensation rate, grams per sq meter per second.
HV
hardness, Vickers.
km
linear measure, kilometres.
kPag
gauge pressure, kiloPascals.
m3
volume, cubic metres.
mg/l
solids concentration, milligrams/litre.
Page 2
mm
linear measure, millimetres.
mm/year
corrosion rate, millimetres per year.
MMscfd
gas flowrate, million million standard cubic feet per day.
MPa
pressure or stress, megaPascals.
MSm3/day
gas flowrate, million standard cubic metres per day.
Pa
fluid wall shear, Pascal.
Sm3/day
liquids flowrate, standard cubic metres per day.
1.5
Codes and Standards
The following Codes and Standards have been used in this document:
API 5L
Specification for Linepipe
API 6A
Specification for Wellhead and Christmas Tree Equipment
ASTM A193
Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials

for High Temperature or High Pressure Service and Other Special Purpose
Applications
ASTM A194
Standard Specification for Carbon and Alloy Steel Nuts for Bolts for High
Pressure or High Temperature Service, or Both
ASTM A320
Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials

for Low-Temperature Service
ASTM A694
Standard Specification for Carbon and Alloy Steel Forgings for Pipe
Flanges, Fittings, Valves, and Parts for High-Pressure Transmission
Service
ASTM G4
Conducting Corrosion Coupon Tests in Plant Equipment
ASTM G31
Laboratory Immersion Corrosion Testing of Metals
ASTM G46
Practice for Examination and Evaluation of Pitting Corrosion
ASTM G81
Practice for Preparation of Metallurgical Specimens
DNV OS-F101
Offshore Standard - Submarine Pipeline Systems 2000
NACE MR-0175
(now also ISO 15156)
Sulfide Stress Cracking Resistant Metallic Materials for Oilfield Equipment
NACE RP 0775
Preparation and Installation of Corrosion Coupons and Interpretation of

Test Data in Oilfield Operations
Page 3
2.
SUMM ARY
A summary of the materials selected, as part of this study, is included in Table 2 -1.
Table 2-1
Summary of materials xx platforms and pipelines selected as part of this study.
Equipment Name
Recommended Material
Wellheads
API 6A Material Class FF-13.8kPa

Stainless Steel (XX)
Alternatives

Choke Valves

Gas Lift Pipeline
DNV OS F101 Grade 450 ISPD (coiled line

pipe) + 3mm C.A.
Gas Lift Riser
DNV OS F101 SML Grade 415 ISD + 3mm

C.A. External splash zone protection using
polychloroprene rubber 12mm thick.
Gas Lift First Valve

On
Carbon Steel Body with 316L trim
Gas Lift Pig

Receiver
Carbon Steel + 3.0mm C.A (Sour)
Gas Lift Header
Gas Lift Flowlines
Production Flowlines
22Cr Duplex Stainless Steel. External

coating to be 180m thick Thermally
Sprayed Aluminium and sealed with an
Alkyd Silicone.
DNV OS F101 SML Grade 415

ISD + 3mm C.A.
1: Carbon Steel + (7mm XX,

6mm XX) C.A (Sour)
externally coated with
180m Thermally Sprayed
Aluminium and sealed using
an Alkyd Silicone topcoat.
2: Carbon Steel + 3mm C.A
(Sour) externally coated with
180m Thermally Sprayed
Aluminium and sealed using
an Alkyd Silicone top coat. -
Flowline Isolation
Valves
Solid 22 Cr Duplex valve body
Carbon steel body with Inconel

625 overlay for wetted parts.
Production Header
Carbon Steel + 6mm C.A (Sour) externally

coated with 180m Thermally Sprayed
Carbon Steel + 3mm C.A (Sour)

externally coated with 180m
Page 4
Equipment Name
Alternatives
Aluminium and sealed using an Alkyd

Silicone topcoat.
Thermally Sprayed Aluminium

and sealed using an Alkyd
Silicone top coat -
Test Header
Carbon Steel + 7mm C.A (Sour) externally

coated with 180m Thermally Sprayed
Aluminium and sealed using an Alkyd
Silicone topcoat.
Carbon Steel + 3mm C.A (Sour)

externally coated with 180m
Thermally Sprayed Aluminium
and sealed using an Alkyd
Silicone top coat. -
Export Pig Launcher
Export Last Valve

On
Carbon steel body with Inconel 625 overlay

for wetted parts.
Export Pipeline

C.A. (i.e. Seamless, X60 strength linepipe
for sour service and improved dimensional
control).
1: DNV OS F101 SML Grade

415 ISD + 3mm C.A. (i.e.
Seamless, X60 strength
linepipe for sour service and
improved dimensional
control
2: DNV OS F101 HFW Grade
415 ISD + 6mm C.A. (i.e.
High Frequency Welded,
X60 strength linepipe for
sour service and improved
dimensional control)1.
Export Pipeline Riser

CS sleeve 12mm with Monel 400 cladding
(3mm)

ISD + 3mm C.A. External
splash zone protection using CS
sleeve 12mm with Monel 400
cladding (3mm) -
Export Pipeline Riser

at XX

CS sleeve 12mm with Monel 400 cladding
(3mm)

ISD + 3mm C.A. - streams (due
to lower arrival temperatures <
80C) External splash zone
protection using
polychloroprene rubber 12mm
thick.
Fuel Gas System
Carbon Steel + 3mm (Sour)
Fuel Gas System

Valves
Carbon Steel with 316L trim
Open Drain Lines
GRP-C
Carbon Steel + 6mm C.A
Page 5
Equipment Name
Alternatives
Open Drain Valves
Nickel Aluminium Bronze
Rubber lined carbon steel
Open Drain Vessel

(Sump)
UNS S32205 Duplex Stainless Steel
If a larger diameter vessel can

be accommodated. Then a
heavy wall thickness carbon
steel drain vessel, with
removable weirs, and internally
coated with a Glass Flake
epoxy will be acceptable.
Open Drain Pump
Carbon Steel with Stainless Steel impeller
Vent and Closed

Drain Lines
Carbon Steel + 3mm C.A
Closed Drain Valves
Carbon steel with 316L trim
Vent Scrubber
Vessel
Carbon steel with internal glass flake epoxy

coating or Belzona 1391 coating
Vent Scrubber Pump
Carbon Steel with Stainless Steel impeller
Hydraulic Piping
ASTM A269 Grade 316L with min 2.5% Mo
If T>60C
25 Cr super duplex (UNS
S32750)
or
Hastelloy C276 (UNS N10276)
Instrument Tubing
ASTM A269 Grade 316L with min 2.5% Mo
If T>60C
25 Cr super duplex (UNS
S32750)
or
Hastelloy C276 (UNS N10276)
Instrumentation
Refer to Table 8 -12 on page 63
Wash Down Water

Tank and Piping
GRP-C with 316L tank fittings
Polypropylene
Wash Down System

Valves
Nickel Aluminium Bronze
Polypropylene
or;
GRP
The current design basis does not provide for permanent gas lift launchers and receivers; this
arrangement is satisfactory if corrosion inhibition is continuously injected into the gas lift pipelines. If
the corrosion inhibition is to be only injected when the gas lift gas goes off dew point (wet gas
operation) then it is recommended that permanent launchers and receivers are installed to permit
periodic sweeping of free water from the gas lift pipeline and running batch corrosion inhibitor. The
Page 6
corrosion allowance for the gas lift pipelines assume that the pipeline will be operated for no more
than 60 days per year with off-specification gas. Operation of the pipeline with wet gas for periods
longer than 60 days per annum will result in corrosion damage greater than 3.0mm over the 20-year
design life.
Section 8 and 9 present further detail on the topside and pipeline material selection.
It is also noted that as the basis of the pipeline design is to be DnV OS F101 then it is a requirement
to produce a Fracture Control Plan to define the minimum material property requirements (eg Charpy
values) for the line pipe specification.
Page 7
3.
DESIGN D ATA
3.1
Sources of Data
The following data was used to build the corrosivity models and to review corrosion reliability models
and total corrosion damage / corrosion allowance calculations. Flowrates and temperatures have
been obtained from the Design Basis [Ref 1]. Temperature and pressure profiles were obtained from
the base case temperature-pressure profiles provided in Appendix 1 of this report. Pipeline sizing for
the gas lift and export pipelines were obtained for Grade 415MPa linepipe from calculation sheet
3.2
Design Life
Design life is 20 years. Production profiles and hence corrosion rates have been modelled for the
following periods over the design life:
Years 1 and 2 (2008-2010);
Years 3 to 7 (2011-2015); and
Years 8 to 20 (2016-2028).
3.3
Fluid Compositions
3.3.1
Oil Composition
A basis composition of the produced fluids has been assumed in accordance with Table 6.3 in the
Design Basis [Ref 1]. The critical components are as follows:
CO2 Content = 5 - 10 wt%, assumed 10% for corrosion models.
H2S Content = 20 - 1000ppm.
3.3.2
Gas Lift Composition
Gas lift composition is in accordance with Design Basis Section 5.1 [Ref 1] and the critical
components are as follows:
CO2 Content = 8 wt%;
H2S Content = 1000ppm.
3.3.3
Produced Water Anal ysi s
A produced water analysis based on PF filed data is presented Design Basis]. The critical
components for corrosion modelling and materials selection are as follows:
Bicarbonate = 1690.82 mg/L and 1726.54mg/L, assumed applicable for XX and XX platforms
respectively for corrosion modelling purposes;
Ionic Strength = 50 g/L
Density = 1.0524 g/L, assume 1050 kg/m3, which is the NORSOK model limit and model found
to be tolerant of large changes in density without effect on the corrosion rate, so model limit is
not significant.
Page 8
Chloride content = 4212.34 mg/L to 4650.43mg/L, taken as 4500mg/L for materials selection
purposes.
Table 3-2 Produced Water Analysis
ANALYSIS NO.
2/06293
2/06303
PB # 7
PG # 3
Lithium (Li) mg/l
8.13
9.89
Boron (B) mg/l
59.98
70.38
Silicon (Si) mg/l
15.07
15.27
Aluminium (Al) mg/l
0.060
0.11
Phosphorous (P)
N.D.
N.D.
Zinc (Zn)
N.D.
N.D.
Lead (Pb)
N.D.
N.D.
Calcium (Ca) mg/l
64.40
50.29
Magnesium (Mg) mg/l
12.22
21.17
Barium (Ba) mg/l
0.24
0.24
Strontium (Sr) mg/l
8.53
6.50
Total Iron mg/l
0.062
0.31
Sodium (Na) mg/l
4031
4023
Potassium (K) mg/l
67.13
124
Carbonate (mg/l)
46.85
58.56
Bicarbonate (mg/l)
1690.82
1726.54
Chloride (Cl) mg/l
4212.34
4650.43
Density (gm/l)
1.0524
1.0532
Resistivity (ohms)
0.0737
0.066
7.78
7.59
Total Dissolved Solids
10072.0
11416.0
Dissolved CO2 (mg/l) **
34.35
42.94
Dissolved H2S mg/l*
N.D.
N.D.
<0.1
<0.1
N.D.
N.D.
Taken from (source)
pH
Determination of residual phosphates

(Test method for residual phosphate = Champion 2121)
Organic Acid
Formic acid content
Page 9
Acetic acid content
0.23 mg/l
0.25 mg/l
Propionic acid content
N.D.
N.D.
Butyric acid content
N.D.
N.D.
Note: N.D. = not detected, detection limit 0.010 mg/l, detection limit 0.1 mg/l for * and detection limit
1.0 mg/l for **
3.4
Pressures and Temperatures
Temperature and pressure profiles for the pipelines were obtained from the base case temperaturepressure profiles provided in Appendix 1 of this report. The following pressures and temperatures
were used for the topsides and wellhead assessments
1_STHP = 2000 psig
2_STHP = 2100psig
3_FTHP = 280psig
4_FTHP = 280 psig
separator pressure = 230 psig
Maximum FTHT and topside temperatures = 110C
3.5
Availability
Equipment availability is stated in the Hydra Design Basis as 98% for the topsides facilities and
therefore a utilities and process equipment availability of 99% is required. The use of 98% availability
has been adopted for the corrosion inhibition system. The facility requirement to achieve a 98%
corrosion inhibition system availability is discussed in Section 5.2.3.
3.6
Corrosion Model Cases
3.6.1
Gas Lift (3) Pipeline
xx Platform
2008 to 2010
2011- 2015
Pipe Diameter
88.9mm
Pipe Wall
Thickness
5.1mm
Inside Diameter
78.7mm
Wt% CO2
2016 & Beyond
8.0
8.0
8.0
Temperature
Inlet
40C
40C
40C
Temperature Outlet
27C
27C
27C
Page 10
Gas / Liquid /
Multiphase
Dehydrated gas,
possibility of intermittent
wet gas.
Dehydrated gas,
wet gas.
Dehydrated gas,
wet gas.
1250 psig
1250 psig
1250 psig
0.17 MSm3/d
0.17 MSm3/d
0.17 MSm3/d
Oil Rate
Water Rate
0.01 Sm3/day
0.01 Sm3/day
0.01 Sm3/day
Water Cut
0%
0%
0%
Inhibitor
Efficiency2
95%
95%
95%
2008 to 2010
2011- 2015
2016 & Beyond
Pressure
Gas Flowrate
Liquids Flowrate1
xx Platform
Pipe Diameter
88.9mm
Pipe Wall
Thickness
5.1mm
Inside Diameter
78.7mm
Wt% CO2
8.0
8.0
8.0
Temperature
Inlet
40C
40C
40C
Temperature
Outlet
27C
27C
27C
Gas / Liquid /
Multiphase
Pressure
Dehydrated gas,
wet gas.
Dehydrated gas,
wet gas.
Dehydrated gas,
wet gas.
1250 psig
1250 psig
1250 psig
0.17 MSm3/d
0.17 MSm3/d
0.17 MSm3/d
Oil Rate
Water Rate
0.01 Sm3/day
0.01 Sm3/day
0.01 Sm3/day
Water Cut
Inhibitor
Efficiency2
95%
95%
95%
Gas Flowrate
Liquids Flowrate1
Notes:
Page 11
1. For NORSOK M506, liquids flowrate must be greater than 0. Assumed 0.01 Sm 3/day for
worst-case considerations. Gas lift gas will be dehydrated on the xx platform and may from
time to time be exported over the dew point specification for the gas.
2. Inhibitor efficiency assumed to be lower than is typical for the Champion Technologies Cronox
inhibitors used throughout the xx and xx fields as continuous inhibition is not anticipated for
this line. Inhibition should be slugged dosed periodically and continuously injected only when
it is exported from xx over the gas lift dew point specification.
3.6.2
Gas Lift (4) Pipeline
xx Platform
2008 to 2010
2011- 2015
Pipe Diameter
114.3mm
Pipe Wall
Thickness
6.4mm
Inside Diameter
Wt% CO2
2016 & Beyond
101.5mm
8.0
8.0
8.0
Temperature
Inlet
40C
40C
40C
Temperature Outlet
27C
27C
27C
Gas / Liquid /
Multiphase
Pressure
Dehydrated gas,
wet gas.
Dehydrated gas,
wet gas.
Dehydrated gas,
wet gas.
1215 psig
1215 psig
1215 psig
0.17 MSm3/d
0.17 MSm3/d
0.17 MSm3/d
Oil Rate
Water Rate
0.01 Sm3/day
0.01 Sm3/day
0.01 Sm3/day
Water Cut
0%
0%
0%
Inhibitor
Efficiency2
95%
95%
95%
2008 to 2010
2011- 2015
2016 & Beyond
Gas Flowrate
Liquids Flowrate1
xx Platform
Pipe Diameter
114.3mm
Pipe Wall
Thickness
6.4mm
Inside Diameter
Wt% CO2
101.5mm
8.0
8.0
Page 12
8.0
Temperature
Inlet
40C
40C
40C
Temperature
Outlet
27C
27C
27C
Gas / Liquid /
Multiphase
Dehydrated gas,
wet gas.
Dehydrated gas,
wet gas.
Dehydrated gas,
wet gas.
1175 psig
1175 psig
1175 psig
0.17 MSm3/d
0.17 MSm3/d
0.17 MSm3/d
Oil Rate
Water Rate
0.01 Sm3/day
0.01 Sm3/day
0.01 Sm3/day
Water Cut
Inhibitor
Efficiency2
95%
95%
95%
Pressure
Gas Flowrate
Liquids Flowrate1
Notes:
worst-case considerations. Gas lift gas will be dehydrated on the xx platform and may from
3.6.3
Gas Lift Header and Flow lines
xx Platform
2008 to 2010
2011- 2015
Pipe Diameter
88.9mm
Pipe Wall
Thickness
5.1mm
Inside Diameter
78.7mm
Wt% CO2
2016 & Beyond
8.0
8.0
8.0
Temperature
Inlet
27C
27C
27C
Temperature Outlet
Page 13
Gas / Liquid /
Multiphase
Dehydrated gas,
wet gas.
Dehydrated gas,
wet gas.
Dehydrated gas,
wet gas.
Pressure
1215 psig
1215 psig
1215 psig
Gas Flowrate
0.17 Sm3/d
0.17 Sm3/d
0.17 Sm3/d
Oil Rate
Water Rate
0.01 Sm3/day
0.01 Sm3/day
0.01 Sm3/day
Water Cut
0%
0%
0%
Inhibitor
Efficiency2
95%
95%
95%
2008 to 2010
2011- 2015
2016 & Beyond
Liquids Flowrate1
xx Platform
Pipe Diameter
88.9mm
Pipe Wall
Thickness
5.1mm
Inside Diameter
78.7mm
Wt% CO2
8.0
8.0
8.0
Temperature
Inlet
27C
27C
27C
Temperature
Outlet
Gas / Liquid /
Multiphase
Dehydrated gas,
wet gas.
Dehydrated gas,
wet gas.
Dehydrated gas,
wet gas.
1175 psig
1175 psig
1175 psig
0.17 Sm3/d
0.17 Sm3/d
0.17 Sm3/d
Oil Rate
Water Rate
0.01 Sm3/day
0.01 Sm3/day
0.01 Sm3/day
Water Cut
Inhibitor
Efficiency2
95%
95%
95%
Pressure
Gas Flowrate
Liquids Flowrate1
Notes:
Page 14
worst-case considerations. Gas lift gas will be dehydrated on the XX platform and may from
3.6.4
Production Flow lines (6 off) and Test Headers
xx Platform
2008 to 2010
2011- 2015
Pipe Diameter
168.3mm
Pipe Wall
Thickness
10.97mm
Inside Diameter
146.36mm
Wt% CO2
2016 & Beyond
10%
10%
10%
Temperature
Inlet
110C
110C
110C
Temperature Outlet
110C
110C
110C
Gas / Liquid /
Multiphase
Multiphase
Multiphase
Multiphase
19.4 Bar
19.4 Bar
19.4 Bar
Gas Flowrate
0.1 MSm3/day
0.13 MSm3/day
0.12 MSm3/day
Oil Flowrate
954 Sm3/day
795 Sm3/day
477 Sm3/day
Water Flowrate
1272 Sm3/day
4769.6 Sm3/day
3179.7 Sm3/day
Liquids Flowrate1
2226 Sm3/day
5564.6 Sm3/day
3656.7 Sm3/day
Water Cut
Note 2
Note 2
Note 2
Inhibitor
Efficiency3
95%
95%
95%
2008 to 2010
2011- 2015
2016 & Beyond
Pressure
xx Platform
Pipe Diameter
168.3mm
Pipe Wall
Thickness
10.97mm
Inside Diameter
146.36mm
Wt% CO2
10%
10%
Page 15
10%
Temperature
Inlet
110C
110C
110C
Temperature Outlet
110C
110C
110C
Gas / Liquid /
Multiphase
Multiphase
Multiphase
Multiphase
19.4 Bar
19.4 Bar
19.4 Bar
0.083 MSm3/day
0.11 MSm3/day
0.10 MSm3/day
Oil Flowrate
477 Sm3/day
318 Sm3/day
159 Sm3/day
Water Flowrate
477 Sm3/day
2385 Sm3/day
1272 Sm3/day
Liquids Flowrate1
954 Sm3/day
2703 Sm3/day
1431 Sm3/day
Water Cut
Note 2
Note 2
Note 2
Inhibitor
Efficiency3
95%
95%
95%
Pressure
Gas Flowrate
Notes
1. Liquids flowrate is divided evenly over 6 flowlines, i.e. 954Sm 3/day divided by 6 =
159Sm3/day.
2. Water cut provided in the design basis as 10-90%. A review of the effect on water cut on the
corrosion model was performed and found to have insignificant effect. Assumed to be 50%.
3. Inhibitor efficiency assumed to be 95% (also modelled for 90% and 95%) as mixing will still be
occurring from the choke valves and may not provide complete coverage for the first 5 to 10
diameters of the flowline.
3.6.5
Production Headers
xx Platform
Up to 2010
2011- 2015
Pipe Diameter
323.9mm
Pipe Wall
Thickness
17.48mm
Inside Diameter
288.94mm
Wt% CO2
2016 & Beyond
10%
10%
10%
Temperature
Inlet
110C
110C
110C
Temperature Outlet
110C
110C
110C
Gas / Liquid /
Multiphase
Multiphase
Multiphase
Multiphase
Page 16
Pressure
20.68 Bar
20.68 Bar
20.68 Bar
Gas Flowrate
0.1 MSm3/day
0.13 MSm3/day
0.12 MSm3/day
Oil Flowrate
954 Sm3/day
795 Sm3/day
477 Sm3/day
Water Flowrate
1272 Sm3/day
4769.6 Sm3/day
3179.7 Sm3/day
Liquids Flowrate
2226 Sm3/day
5564.6 Sm3/day
3656.7 Sm3/day
Water Cut
Note 2
Note 2
Note 2
Inhibitor
Efficiency(3)
95%
95%
95%
xx Platform
2008 to 2010
2011- 2015
2016 & Beyond
Pipe Diameter
323.9mm
Pipe Wall
Thickness
17.48mm
Inside Diameter
288.94mm
Wt% CO2
10%
10%
10%
Temperature
Inlet
110C
110C
110C
Temperature Outlet
110C
110C
110C
Gas / Liquid /
Multiphase
Multiphase
Multiphase
Multiphase
19.4 Bar
19.4 Bar
19.4 Bar
0.083 MSm3/day
0.11 MSm3/day
0.10 MSm3/day
Oil Flowrate
477 Sm3/day
318 Sm3/day
159 Sm3/day
Water Flowrate
477 Sm3/day
2385 Sm3/day
1272 Sm3/day
Liquids Flowrate1
954 Sm3/day
2703 Sm3/day
1431 Sm3/day
Water Cut
Note 2
Note 2
Note 2
Inhibitor
Efficiency3
95%
95%
95%
Pressure
Gas Flowrate
Notes
159Sm3/day.
3. Inhibitor efficiency assumed to be 95% - refer to section 5.2.1.
Page 17
3.6.6
Export Pipelines (Seamless Linepipe, Grade 415 MPa)
xx Platform
Up to 2010
2011- 2015
Pipe Diameter
355.6mm
Pipe Wall
Thickness
16.4mm
Inside Diameter
322.8mm
Wt% CO2
2016 & Beyond
10%
10%
10%
Temperature
Inlet
110C
110C
110C
Temperature Outlet
58C
72C
76C
Gas / Liquid /
Multiphase
Multiphase
Multiphase
Multiphase
19.4 Bar
19.4 Bar
19.4 Bar
Gas Flowrate
0.1 MSm3/day
0.13 MSm3/day
0.12 MSm3/day
Oil Flowrate
954 Sm3/day
795 Sm3/day
477 Sm3/day
Water Flowrate
1272 Sm3/day
4769.6 Sm3/day
3179.7 Sm3/day
Liquids Flowrate1
2226 Sm3/day
5564.6 Sm3/day
3656.7 Sm3/day
Water Cut
Note 2
Note 2
Note 2
Inhibitor
Efficiency3
99%
99%
99%
2008 to 2010
2011- 2015
2016 & Beyond
Pressure
xx Platform
Pipe Diameter
355.6mm
Pipe Wall
Thickness
16.4mm
Inside Diameter
322.8mm
Wt% CO2
10%
10%
10%
Temperature
Inlet
110C
110C
110C
Temperature Outlet
27C
38C
34C
Gas / Liquid /
Multiphase
Multiphase
Multiphase
Multiphase
19.4 Bar
19.4 Bar
19.4 Bar
0.083 MSm3/day
0.11 MSm3/day
0.10 MSm3/day
Pressure
Gas Flowrate
Page 18
Oil Flowrate
477 Sm3/day
318 Sm3/day
159 Sm3/day
Water Flowrate
477 Sm3/day
2385 Sm3/day
1272 Sm3/day
Liquids Flowrate1
954 Sm3/day
2703 Sm3/day
1431 Sm3/day
Water Cut
Note 2
Note 2
Note 2
Inhibitor
Efficiency3
99%
99%
99%
Notes:
159Sm3/day.
3. Inhibitor efficiency assumed to be 99% as mixing will be performed upstream of the choke
valves and flow will be annular / slug flow that provides full pipe wetting.
3.6.7
Export Pipelines (HFI Linepipe, Grade 415MPa)
See Note 1 for this service

xxPlatform
Up to 2010
2011- 2015
Pipe Diameter
355.6mm
Pipe Wall
Thickness
13.0mm
Inside Diameter
329.6mm
Wt% CO2
2016 & Beyond
10%
10%
10%
Temperature
Inlet
110C
110C
110C
Temperature Outlet
58C
72C
76C
Gas / Liquid /
Multiphase
Multiphase
Multiphase
Multiphase
19.4 Bar
19.4 Bar
19.4 Bar
Gas Flowrate
0.1 MSm3/day
0.13 MSm3/day
0.12 MSm3/day
Oil Flowrate
954 Sm3/day
795 Sm3/day
477 Sm3/day
Water Flowrate
1272 Sm3/day
4769.6 Sm3/day
3179.7 Sm3/day
Liquids Flowrate
2226 Sm3/day
5564.6 Sm3/day
3656.7 Sm3/day
Notes 3
Note 3
Note 3
Pressure
Water Cut
Page 19
Inhibitor
Efficiency
xxx Platform
99%
99%
99%
2008 to 2010
2011- 2015
2016 & Beyond
Pipe Diameter
355.6mm
Pipe Wall
Thickness
13.0mm
Inside Diameter
329.6mm
Wt% CO2
10%
10%
10%
Temperature
Inlet
110C
110C
110C
Temperature Outlet
27C
38C
34C
Gas / Liquid /
Multiphase
Multiphase
Multiphase
Multiphase
19.4 Bar
19.4 Bar
19.4 Bar
0.083 MSm3/day
0.11 MSm3/day
0.10 MSm3/day
Oil Flowrate
477 Sm3/day
318 Sm3/day
159 Sm3/day
Water Flowrate
477 Sm3/day
2385 Sm3/day
1272 Sm3/day
Liquids Flowrate2
954 Sm3/day
2703 Sm3/day
1431 Sm3/day
Water Cut
Notes 3
Note 3
Note 3
Inhibitor
Efficiency4
99%
99%
99%
Pressure
Gas Flowrate
Notes:
1. Modelled only once to review effect of larger ID on wall shear. Effect found to be negligible.
159Sm3/day.
4. Inhibitor efficiency assumed to be 99% as mixing will be performed upstream of the choke
valves and flow will be annular / slug flow that provides full pipe wetting.
3.6.8
Produced Water Effect Modelling
The effect of produced water chemistry can be profound on the corrosion rate due to the pH buffering
as a result of the bicarbonate content of the produced water. The effect of produced water chemistry
has been investigated as part of this corrosion study. Initial modelling described by the scenarios
above assumed only water of condensation is present in the produced liquids and this results in low
pH predictions. Separate models have been run for all the production side assets with produced
Page 20
water, which is closer to the true production scenario and less conservative. The NORSOK M506
model uses bicarbonate concentration and ionic strength to characterise the produced water
chemistry. A bicarbonate concentration of 1691 mg/l for xx and 1726 mg/l for xxhas been used for the
models and an ionic strength of 50 g/l, which is a typical value for produced water. To further
characterise the produced water, an increase in density has been included in the corrosion model,
density is 1052 kg/m3 for xxand xx, but was limited to 1050 kg/m 3, the models water density limit.
The produced water chemistry described in Section 3.3.3 is typical of the xx fields and was taken from
the xx and xx well analysis. To understand the sensitivity of the corrosion model to variations in the
produced water chemistry additional models have been run to show the effect on the xx production
export pipeline at 90% bicarbonate level and 75% bicarbonate level.
Page 21
4.
METHODOLOGY
4.1
Potential for Corrosion
4.1.1
Corrosion Mechanisms and Considerations
The following sections discuss the corrosion mechanisms that could be experienced during the life of
the xx field. The factors that contribute to these mechanisms are highlighted along with an
assessment of the possibility of the corrosion mechanism occurring and what can be done to mitigate
the corrosion risk.
4.1.2
CO 2 Corrosion
The xx production fluids contain approximately 8 Wt% CO 2 [Ref 1] along with water of condensation
and later in the field life, produced water. The reaction of CO 2 with water in the pipeline can result in
the formation of carbonic and acetic acid. The carbonic and acetic acid reduces the pH of the
production stream and at collection points (i.e. topographic low points, dead legs and stagnant zones
or at miscibility gaps) the acidified solution can cause general corrosion, pitting corrosion and mesatype corrosion of steels.
Localised corrosion may take many forms, from pitting to mesa type attack, where corrosion appears
as large, flat-bottomed localised areas of damage. Pitting may occur over the full range of operating
temperatures under stagnant to moderate flow conditions. Pitting rates are a function of temperature,
pressure, flow velocity and characteristics and CO2 concentration, with the propensity for pitting highly
dependent on the chemistry and surface finish of the steel. Pitting may arise close to the dew point
temperature, and can be associated with water of condensation and is often referred to as Top of Line
Corrosion (TOLC), refer to Section 4.1.3. There is no real way of predicting the occurrence and extent
of pitting as opposed to general corrosion mechanisms for steel.
Mesa type attack is a form of localised CO2 corrosion that occurs under moderate flow conditions
where carbonate scales may form but are not strongly stable. This form of attack results from
localised spalling of the carbonate scale, exposing the underlying bare metal surface that then
corrodes. The scale, when formed, may experience high intrinsic stresses within the scale film,
resulting in repeated spalling of the same area. This type of attack generally occurs at 60C to 100C,
as the scale formed tends to be less adhesive than those formed at temperatures greater than 100C.
Mesa attack may also result from self-sustaining galvanic reactions between passive and active
corrosion films.
Flow induced localised corrosion in CO2 corrosion systems starts from corrosion pits, welds or other
surface discontinuities where localised turbulence may be created. The localised turbulence, in
addition with stresses contained within the growing scales, may result in the destruction of existing
scales, and prevent the reformation of further protective scales. This type of corrosion is typically
observed as parallel grooves extending in the flow direction. Flow induced localised corrosion may
occur in systems with relatively high flowing velocities.
The CO2 corrosion mechanism is considered to be the dominant corrosion mechanism for the Hydra
development. A model has been used to calculate the corrosion as the result of CO 2 corrosion of
steel. The model is discussed further in Section 4.2 and the results presented in Appendix 2.
Page 22
4.1.3
Top of Line Corrosion
Top of line corrosion (TOLC) is not a large problem in general, but is known to occur in specific
production situations. TOLC is the result of wet gas cooling and allowing water and hydrocarbon to
condense on the top of the pipe. For stratified flow, liquid hydrocarbons and chemical inhibitors
protect the lower portion of the pipe, whereas the top section is unprotected. TOLC depends on
temperature, rate of water condensation, distribution of corrosion inhibitor and the flow regime. At
very high condensation rates the corrosion product on the top surface of the pipe is continuously
washed away and therefore there is nothing to stifle the corrosion rate. Under high condensation
rates the rate of corrosion is directly related to the condensed water pH. At lower condensation rates
the corrosion products formed on the top of the line will stifle the corrosion rate.
TOLC may only be considered for the gas lift lines if the gas exported from the XX platform is not
dehydrated properly due to process upsets or the like. The exposure to TOLC is therefore considered
low in this case. The export pipelines will have annular/slugging flow regimes that will ensure
corrosion inhibitor and oil is splashed around the entire annulus of the pipe thereby stifling corrosion
reactions.
4.1.4
Sulphide Stress Corrosion Cracking
The H2S level of the Hydra fluids is significant. The environmental conditions described by ISO 15156
/ NACE MR0175 specify that SSCC is not a risk for carbon steel materials when the partial pressure
of H2S is less than 0.05 psi (0.35kPa). For the gas lift the H 2S partial pressure is 8.6kPa and for the
produced liquids the H2S partial pressure is 0.22kPa. It is therefore assumed that sour service
conditions prevail for the gas lift (even though it is only intermittently run wet) and it is considered
good practice to assume the produced fluids are sour given the accuracy of data provided at this time.
One of the causes for field souring is the result of poor practices during well intervention work (eg. the
use of drilling mud infected with sulphate reducing bacteria), which contaminates the formation.
Controls should be implemented by xx to prevent this from occurring.
Linepipe designed in accordance with DNV OS F101 shall be specified with the 'S' supplementary
requirements.
The commonly used oil and gas industry materials have varying responses to the presence of H 2S.
These responses are generally complicated by factors such as pH, temperature, and the presence of
chlorides and free sulphur. Accordingly, ISO 15156 should be consulted to ensure materials used in
sour service conditions are acceptable under the prevailing xx conditions.
4.1.5
Hydrogen Induced Stress Cracking
HISC occurs when atomic hydrogen generated by a corrosion reaction diffuses through the steel and
then accumulates as gaseous (molecular) hydrogen at non-metallic inclusions, particularly when
these have been flattened by rolling or drawing operations. As more hydrogen enters the voids the
pressure rises, deforming the surrounding steel so that blisters become visible on the surface. The
steel around the crack or inclusions in the microstructure becomes highly strained and this can cause
linking of adjacent cracks to form what is know as step-cracks or induce further cracks to form in the
surrounding stress field. Carbon steels are susceptible to HISC. This can occur when carbon steel is
exposed to H2S. HISC can occur in steel at much lower H2S levels than SSC limits set by NACE MR
0175 / ISO 15156. There is no minimum pressure limit where HISC will not occur.
Page 23
The risk of HISC can be reduced by ensuring linepipe carbon steel is specified for sour surface under
DNV OS F101. This will ensure there is control of elemental sulphur (and hence inclusions) in the
steel as well as subjecting the steel to testing to EFC Publication 16 [Ref 4].
4.1.6
Hydrogen Embrittlement
Hydrogen induced cracking caused by adsorption of hydrogen formed at the cathode site (bare metal
being protected) as a result of cathodic protection is known to embrittle and in some circumstances
crack the parent material when sufficient residual or service stresses are present. The propensity for
cracking is known to be crystal structure sensitive, with face centred cubic materials (eg austenitic
stainless steels) being more resistant than body centred cubic materials (e.g. carbon steel) and not
likely to crack unless very high levels of strength/cold work are developed. Body centred and related
cubic structures are know to be susceptible depending upon strength (hardness) and degree of cold
working (plastic strain), with hardness usually accepted as the defining property as far as propensity
to cracking is concerned.
Normal carbon steels such as those used to manufacture DNV OS F101 line pipe are essentially not
susceptible to HE, due to the strength levels of these materials, provided the hardness of the heat
affected zones of welds are less than about 350 HV. Hardness levels above this may result in
cracking in the HAZ if the hardened area is uncoated and thus exposed to the CP system. It is
prudent therefore to specify hardness levels less than 350 HV in HAZ of weld procedure qualification
tests and HFW linepipe manufacturing specifications.
Duplex stainless steels contain microstructures that are susceptible to HE. There are known failures
of uncoated super duplex and duplex stainless steel equipment due to HE. These failures are
exceptional as there have been many successful, relatively long service life subsea installations of
pipelines, manifolds and similar equipment fabricated from 22Cr duplex stainless steel. The failure
details are not widely published, however from recently published information (Ref. 8), hydrogen
embrittlement induced cracking in these types of materials appears to be due to a number of factors.
These factors include:
Susceptible microstructures that are bare surfaces where hydrogen can adsorb
Plastic deformation produced during fabrication, installation and in-service caused by stresses,
which were not predicted or incorrectly calculated.
It should be noted however that plastic deformation occurring whilst the CP system is applied (when
submerged) has been considered the most critical factor to cause cracking (Ref. 8). It would appear
that a high integrity coating system and design to ensure absence plastic deformation in service, (for
example due to pipeline instability/thermal stresses) are essential to mitigate this risk in duplex
stainless steel materials.
In October 2005, NORSOK published a Workshop Agreement as the Design guideline to avoid
hydrogen induced stress cracking in subsea duplex stainless steels (Ref. 9). The key design
considerations for avoiding HISC in duplex stainless steel are as follows:
Global principal strain to be limited to 0.4% for duplex stainless steels;
Local peak strain (total strain) due to SCNFs and residual strains to be limited to 0.7%;
Forgings shall be forged as closely as practicable to the specified shape and size;
Transition fillet welds shall have a radius not less than one third of the wall thickness;
Page 24
Polymeric coating shall not be relied upon to reduce current demand and hence HISC as
holidays in the coating will cause excessive hydrogen production and hence HISC.
CP potential is to be limited to 600mV (Ag/AgCl) where the duplex elements are completely
isolated from items protected at 1050mV
Austenite spacing in the duplex stainless steels is to be limited to 30m. For heavy forgings
an austenite spacing of 60m should be aimed for
The subsea use of duplex stainless steel is not envisaged for the Hydra development at this stage.
4.1.7
Chloride Stress Corrosion Cracking
Chloride stress corrosion cracking occurs when a susceptible material is placed under a tensile load
in a chloride rich environment, i.e. seawater. Nearly all fabricated items contain stresses, be it
operating pressure stresses, thermal stresses or residual stresses from welding and forming. So it
should be assumed that all materials used on the topsides or subsea will have a certain tensile load
on them for the purpose of considering whether CSCC is a risk. Carbon steel is resistant to chloride
stress corrosion cracking in the temperature range that the xx field will be operating in. The use of
stainless steels is described in Section7.1, and these materials vary considerably from one grade to
the next. Other alloys that may be selected for use as flowlines and for the subsea completions
should be selected in accordance with data supplied by the material suppliers.
It is important to note that on platform topside service all materials will be coated with a layer of
chlorides from sea spray. Surfaces heated by internal process temperatures or solar radiation tends
to dry the chlorides on the surface thereby concentrating the salt over time. So selection of materials
must assume a critical amount of chloride is always present and that temperatures may exceed the
critical CSCC temperature for the material through being heated up by solar radiation.
4.1.8
Erosion
The effect of erosion from entrained solids in the process stream on the candidate materials is less
well defined as the amount of entrained solids is not yet known.
The erosion velocities should be calculated in accordance with DNV RP0501 (Ref. 5) to confirm the
materials selected for various components throughout the production and transportation systems are
acceptable. A more detailed study will be required later once more information about the well fluids is
obtained to determine actual erosion velocities. Erosional velocity limits for CRA materials are
provided in Section 7.1 for information purposes. In general terms duplex stainless steels show
superior erosion resistance over carbon steels.
4.1.9
Subsea External Corrosion
External corrosion due to exposure to oxygenated seawater is expected for the pipelines and
especially the risers. All of the candidate linepipe materials require external coatings and cathodic
protection to protect them from external corrosion from the seawater environment. Special coating
systems for the risers are provided in Section 9.2.2.
4.1.10 Topside Atm ospheric Corrosion

The topside equipment and structures will be exposed to a marine environment, which can typically
result in corrosion of steel at a rate of approximately 0.15 to 0.20 mm/year (3mm to 4mm in 20 years).
Therefore, all carbon steel shall be protected with anti-corrosion coatings. Where items are located
Page 25
such that maintenance of the coating system is difficult them it is recommended that either a CRA
material is used or a suitable corrosion allowance is applied to account for external corrosion as well
as internal corrosion.
4.1.11 Corrosion of the Line Pipe During Transportation

Linepipe materials are invariably transported from Asia and Europe via a separate coating yard. It is
during the trans-shipment activities that some materials are exposed to a corrosive marine
environment and sometimes even raw seawater. Carbon steel when exposed to a marine
environment will corrode, however the rate is such that the exposure time would have to be several
years before significant damage is incurred.
All of the potential corrosion mechanisms described above can be prevented by the application of end
caps (not just bevel protectors) that are firmly fixed to the pipeline. Stowing the line pipe below the
deck of the ships hold can also reduce corrosion risk. The vessel hold should be checked to ensure
it is dry and the hold doors should be proven to be watertight. The application of a water repellent oil
or corrosion inhibitor is also recommended as part of the transportation procedure.
4.1.12 Microbiall y Induced Corrosion

Contamination of flowlines with anaerobic bacteria and the resultant microbially induced corrosion
(MIC) can render flowlines unserviceable in very short periods. The microbial contamination of
subsea pipelines is commonly attributed to bad well work-over practices where contaminated drilling
muds are used and sulphate-reducing bacteria is introduced to the formation. Another recognised
cause is the inappropriate or non-existent treatment of seawater used for pre-commissioning. That is
to say insufficient biocide concentrations have been applied to the water used to flood the flowline and
the bacteria establish themselves once the production fluids are transmitted through the flowline.
In order to establish them and cause MIC they must have an anaerobic environment and some
nutrient source; typically sulphate ions from produced water, in the case of sulphate reducing bacteria.
These microbes typically become active at temperatures below about 45C, and are known to corrode
corrosion resistant alloys as well as carbon steels. As such all the candidate materials are equally
susceptible to this type of corrosion mechanism. The only way of preventing this form of attack in
anaerobic flowline environments below 45C is by excluding the bacteria from the flowline
environment or preventing nutrient from being provided. Once these microbes become established
and form colonies and associated bio-masses, the only way of managing their presence is by the
introduction of biocides in order to control their numbers and therefore the corrosion rates. Typically
this is done by continuous injection of biocides at appropriate concentrations of the order of 20-40
ppm depending upon raw chemical activity. They can also be controlled through batch dosing by
introducing very high concentrations of biocide in slugs between pigs or introduction of concentrated
amounts of biocide into relatively low volumes of produced water (>2,000 ppm).
The largest risk comes from pre-commissioning flooding of the pipeline with seawater. Condensed
water will not contain sulphate ions or other nutrient sources and should serve to flush any bacteria
through the pipeline. Carbon steel linepipe should be cleared of any internal scale by pigging as part
of the commissioning procedures. This will reduce the amount of sites where bacteria can become
lodged. Where duplex or super duplex stainless steel is used, the flushing effect of the fluids will be
enhanced, as there will be no surface scale where the bacteria can lodge. As a contingency there
needs to be facilities made available to inject biocide into the pipeline via the chemical injection lines.
In order to mitigate the risk in general the installation procedures need to be cogniscent of the issues
of bacteria contamination, with measures to ensure appropriate levels of biocide within the flooding
Page 26
water, control measures during tie-ins to ensure raw seawater ingress is kept to a minimum and that
residual biocide levels are sufficient to kill bacteria introduced in this manner. Other measures such
as introducing slugs of biocide between pigs during the dewatering activities are also recommended.
Operational procedures need to ensure that water produced within the first few months of production
is checked for bacteria and if found, appropriate treatment procedures applied.
4.1.13 Under Deposit Corrosion

Under deposit corrosion is where solid materials such as reservoir sands, corrosion products and
scale or mill scale settle out of solution in areas of low or stagnant flow. The deposits of solid material
tend to shield the material below from the beneficial effects of corrosion inhibitors and protective
scales. The deposits also create a galvanic differential potential between the covered area and the
areas covered by the surrounding bulk fluids, this leads to accelerated corrosion of the underlying
material. The deposits are also known to be good starter sites for microbial populations and can
result in rapid corrosion rates due to MIC as discussed in Section 4.1.12.
UDC is commonly incurred by carbon steels and the austenitic steels, but can also be found, to a
much lesser extent due to their higher tolerance, in the higher alloy duplex stainless steels and nickel
alloys.
The governing design principle for avoiding UDC is to firstly eliminate solids from the system where
possible through the use of slug catchers, separators or filters. The elimination of dead legs and
stagnant zones is also considered an important part of reducing the UDC risk and this is discussed in
Section 4.1.15. Where solids are expected to drop out of solution then facilities should be provided to
allow the clean-out of that area or for pipelines then the pipelines should be routinely cleaned using a
cleaning pig.
4.1.14 Galvanic Corrosion

Galvanic corrosion occurs when two, or more, dissimilar metals are placed in electrical contact in the
presence of a conductive and corrosion electrolyte (eg sea water or high humidity marine
atmospheres). The material that is more electronegative will corrode in preference to the adjoined
material when in the presence of an electrolyte. This results in corrosion forming around the joint
between the two materials. The rate and extent of the corrosion is governed by the following factors:
The galvanic potential difference between the materials;
The resistance of the contact between the materials and resistance of the electrolyte;
The electrochemical kinetics of the corrosion processes in the electrolyte;
The relative exposure of the materials to the electrolyte, i.e. exposure of cathodic material
versus anodic material (the material that will corrode) and the distances between the exposed
materials);
The presence of barriers between the exposed materials such as coatings and films that
prevent ionic flow through the bulk electrolyte between the bulk materials;
Dissimilar metal joints should be avoided wherever practical. Where it is unavoidable then the
individual joint details should be assessed. Options such as the provision of insulating joints or
coatings should be considered. Isolating joints are often inadvertently short circuited on offshore
platforms due to bridging the isolated joint between pipe supports or racks, which are electrically
continuous with the underlying structure.
Page 27
Coatings are used to reduce the relative cathodic to anodic surface area. It is often a good idea to
coat the cathodic material (the more noble material) instead of the anodic material so that should a
holiday form in the coating covering the anodic material it does not suffer corrosion from a large
differential in current density created by a very large cathode versus a small anode.
4.1.15 Corrosion in Dead Legs and Stagnant Zones

In wet gas systems corrosion can be abnormally high where water of condensation is collected in
areas of low flow or vertical dead legs. In wet oil systems water can set out of the main flow and be
captured in stagnant areas or vertical dead legs. Corrosion inhibitors often do not protect these areas
of low flow or stagnancy and corrosion is exacerbated by the presence of deposits and/or
microbacteria.
The design of piping and process equipment should ensure that instrument lines and tees to areas
not normally flowing be oriented vertically upward and not downwards. Where lines are slow flowing,
then the line should be designed to self-drain and vessels should be designed such that there are no
stagnant zones or are capable of being drained. Areas of intermittent flow such as the open and
closed drain systems are often affected by stagnant areas and particular care should be taken to
make the system free draining.
4.2
Selection of a Corrosion Model
4.2.1
General
There are a number of models used to predict corrosion caused by CO 2 in wet gas. Most models are
proprietary and generally owned by one of the major oil companies. Of the non-proprietary models
available, one of the most popular is the NORSOK M506 CO 2 corrosion model [Ref 3]. Revision 2 of
the NORSOK M506 model was issued in July 2005 and has been used for the calculation of CO 2
corrosion in this document.
The NORSOK model is an empirical model mainly based on laboratory data for the low temperature
range and a combined laboratory and field data set for temperatures above 100C. The model is
available via the NORSOK web site and is based on MS Excel spreadsheet routines. The model was
developed by the Norwegian oil companies: Statoil; Norsk Hydro; and Saga Petroleum. The basis of
the model is grounded in the same work as the DeWaard, Milliams and Lotz [Ref 7] studies (i.e. from
the Institute for Energy (IFE) Laboratory in Norway). The difference between the NORSOK model
and DeWaard et al comes from the empirical data developed for temperatures greater than 100C. A
more in depth discussion on the other CO2 corrosion models used around the world is provided by
Nyborg [Ref 10]. The other models tend to be proprietary systems available only to the Universities
and oil companies responsible for their development. Only the Predict software from InterCorr and
HydroCorr software from Shell takes account of the effects of H 2S scales on stifling CO2 corrosion. All
the other programs used, including NORSOK, do not take H 2S scale formation into account. By not
accounting for the scales formed by H2S the corrosion rates predicted by NORSOK M506 are
therefore regarded as conservative.
The uninhibited corrosion rates have been used to calculate an overall corrosion rate based on the
inhibitor availability and life cycle approach described by Rippon [Ref 6]:
CR
= f CRi + (1-f) CRU
where:
CR
= overall corrosion rate (mm/year);
Page 28
CRi
= inhibited corrosion rate (mm/year, assumed for gas lift to be 0.05 mm/year in
accordance with Table 6 of Rippon [Ref 6], ie a corrosion rate in the temperature range
< 70C and for production piping and export pipelines to be 0.1mm/year. i.e a corrosion
rate in the temperature range 70C T120C);
CRu
= uninhibited corrosion rate as calculated using NORSOK M506 (mm/year);
= inhibitor injection system availability factor (0.90, 0.95, 0.98 and 0.99, for 36.5 days,
downtime per year, 18.75 days downtime per year, 7.3 days downtime per year and
3.65 days downtime per year respectively).
This is a simplified approach that takes no account of the inhibitors persistency and assumes that
production will continue during this downtime as well. The availability chosen for XX and XX will be a
trade off between the amount of steel required for the pipeline corrosion allowance and the amount of
equipment required for a high reliability inhibitor injection system.
4.2.2
Limitations of the Corrosion Model
The NORSOK M506 corrosion model is regarded throughout the industry as being conservative, i.e. it
over estimates corrosion rates. The corrosion rates predicted by the model do not take into account
the effects of H2S, free oxygen, etc. Furthermore, the model is based on empirical data collected from
the Kjeller Sweet Corrosion research program at Institute for Energy Technology in Norway.
Therefore, the range of temperatures is limited (20C to 160C), CO2 fugacity (Note 2) is limited (0-10
bar) and pH is limited (3.5 to 6.5). The Hydra process parameters used for the corrosion models all fit
within the bounds of the model and therefore the results should be within the reliable range of the
model.
4.2.3
Prediction of Top of Line Corrosion
In order to predict the probability of TOLC a process model needs to be developed to predict the point
of condensation for each well. Once the point of condensation is known and a rate of condensation is
calculated then a modified de Waard-Milliams [Ref 7] method can be used as shown below:
CRTOLC
= Fcondensation.CR
where:
Fcondensation = 0.4 (Condensation Rate, g/m2s)
CRTOLC
= Top of Line Corrosion Rate
CR
= overall corrosion rate calculated by the CO2 corrosion model.
The process data at this stage for Hydra is not sufficient to enable the development of condensation
models. TOLC may be an issue when the gas lift gas is exported from the XX platform over the dew
point specification. TOLC is not expected to be a problem on the production side of the platform as
A measure of the tendency of a gas to escape or expand. Fugacity (f i) is the pressure value needed
at a given temperature to make the properties of a non-ideal gas satisfy the equation for an ideal gas,
i.e.,
fi = iPi
where i is the fugacity coefficient and P is the partial pressure for component i of the gas. For an ideal
gas, i =1.
i
Page 29
multiphase liquid with an annular type flow is expected. This will ensure that corrosion inhibitor is
evenly distributed across all internal surfaces of topside production piping and the export pipeline.
The only practical means of determining whether TOLC is a corrosion risk worthy of consideration in
this case is to run OLGA dynamic process simulations to determine the rate of water condensation on
the top of the pipeline. The OLGA model should also be able to show where the maximum
condensation occurs. For Hydra the TOLC risk should only be considered significant if the following
criterion is exceeded:
Condensation rate is less than 7.5 g/m2s (Note 3) in the carbon steel pipeline;
Methods to mitigate TOLC include the use of diethylamine based inhibitors combined with the
ordinary amine based filming inhibitor and injected as one product at a treatment rate of ~0.5 - 0.8L
per MMSCF/day. Alternatively, where TOLC is deemed to be a major risk then CRA materials can be
used for the first section of the pipeline until after the condensation has completed and the production
fluids are at equilibrium with the seabed temperature. However, this is an expensive option and can
extend the condensation zone due to the different thermal conductivity of the CRA materials.
4.3
Mechanical Material Selection
4.3.1
Brittle Facture and Embrittlement
Brittle fracture is the rapid fracture of metals without appreciable deformation. The risk of brittle
fracture is increased when a material is exposed to temperatures below its ductile/brittle facture
transition temperature. This temperature varies from material to material and is reliant on the
crystallographic structure of the material. For materials such as aluminium, austenitic stainless steels
and nickel alloys, they have a face centred cubic (FCC) structure, which contains a greater degree of
slip planes. These slip planes improve the materials resistance to brittle fracture and as such FCC
materials are generally immune to brittle fracture.
Materials such as steels, and duplex stainless steels (50% is ferritic) have a body centred cubic
(BCC) structure, which has only limited slip planes and therefore is prone to shear failures. The
temperature at which the material is unable to slip to adjust to external forces is called the ductile to
brittle transition temperature.
Material selection should be based on the minimum design temperature of the component under
consideration. For gaseous service, the effects of the Joules-Thompson effect should be considered
when deciding on the minimum design temperature for the material. The design codes all specify a
minimum temperature for materials. These materials can then only be used at lower temperatures if
they are impact tested at the lower temperature using the Charpy V-notch impact test and /or the Drop
Weight Tear Test (DWTT) (mainly used for plate and pipeline steels).
For the pipeline design to DNV OS F101 there is a requirement to produce a fracture control plan. It
is recommended that the principals described in PRCI document PR-3-9113 [Ref 11] be considered
when developing a pipeline fracture control plan.
From the equations in 4.2.3, Condensation Rate = F/0.4 and F = CRTOLC/CR where CRTOLC is
assumed to be the corrosion allowance 3mm / 20 years and CR is 0.05 mm/year from the corrosion
model
F = 0.15 / 0.05 = 3.
Condensation Rate = 3.0 / 0.4 = 7.5 g/m2s
Page 30
4.3.2
Fatigue
Thermal and vibration induced fatigue can be prevented by the use of appropriate design standards
and materials and through maintenance and inspection. Vibration induced fatigue can be
experienced by pipe work attached to rotating equipment or where very high flows are experienced
through piping with flow upsets such as orifice plates and / or bends etc. This can be prevented
through the use of adequate pipe supports, correct material sizing or the use of pulsation dampeners.
A system should be regularly monitored once operation begins to ensure areas not considered at risk
during design dont begin to vibrate due to harmonics from adjacent equipment or remote sources.
Also, the design details such as pipe supports are often left off during construction or become loose
with time, resulting in excessive vibration of the piping. It is for this reason that a regular inspection
regime should be put in place to check for vibration and areas that are insufficiently supported or
restrained.
Page 31
5.
CORROSIVITY ASSESSMENT AND CORROSION MITIG ATION
5.1
Corrosivity Assessment Results
The corrosivity assessment showed that the corrosion rates for the gas lift pipeline, gas lift piping,
production piping and export pipelines can be manufactured using carbon steel with a corrosion
allowance and continuous (98%availability) corrosion inhibition. The results of the corrosion
modelling are provided in Appendix 2.
A conservative approach has been taken with the gas lift service assuming that there will be water
carry over into the pipeline from time to time. The NORSOK model assumes that the gas lift gas is
saturated with water all of the time that the gas lift line is flowing. However, this will not be the case
and therefore corrosion will not be active all of the time. To adjust the NORSOK corrosion model to
account for the duration that gas is off specification (i.e. wet gas operation) it has been assumed that
the gas is wet for 20% of the time the gas lift operates (i.e approximately 70 days per year). During
wet gas operation it is assumed that the corrosion inhibitor system is operational and that the pipeline
will corrode at the inhibited rate assuming an inhibitor efficiency of 95% and an inhibitor availability of
100%. Inhibitor efficiency is assumed at 95% as the corrosion inhibitor will only be intermittently
injected and therefore there will be a delay until full film thickness and inhibition is achieved.
It is believed that with the measures described by this report regarding operational pigging and routine
corrosion inhibition, then it is possible that the corrosion allowance for the gas lift system could be
kept to 3mm or less.
A lot of work was done to review the corrosion allowance for the production flowlines and the
production and test manifolds. These lines run very hot (110C) and therefore corrosion rates can be
slightly higher than expected due to corrosion inhibitor performance dropping. This drop in
performance is taken into account using the life cycle approach adopted to calculate the corrosion
allowances for the xx and xx assets. A corrosion inhibitor efficiency of 95% for flowlines and headers
and 99% for riser and pipelines has been considered and a corrosion inhibitor system availability of
98% has been adopted in line with the Equipment Availability, section (7.4.1) of the Project Basis of
Design [Ref 1], which requires topside facilities to be design for 98% up time. A full discussion of the
inhibitor injection philosophy is provided in Section 5.2.3.
The Hydra corrosion model was developed on the basis of:
a) conservatively ignoring the pH buffering due to bicarbonate content of any produced water
being present; and,
b) including effects of pH buffering due to presence of bicarbonates in the produced water
(based on xx and x produced water composition).
The produced water analysis used in the model was provided by xx and is understood to be taken
from PB#7 and PG#3 well analyses. WorleyParsons make no comment as to the reliability of the
produced water analysis or likelihood of the produced water chemistry used in this analysis being
appropriate at xxand xx over their design life. The corrosion allowances for the topside production
equipment is described in Table 5 -3. Table 5 -3 shows the calculated corrosion allowance with and
without the benefit of buffering from produced water.
Table 5-3 WHP Topside Production Equipment Corrosion Allowances
Equipment
Calculated Metal Loss and Corrosion Allowance (mm)
Page 32
Model a) Water of
Condensation Only
Model b) Water of Condensation +

Produced Water
Internal Metal
Loss
Total CA
Internal Metal
Loss
Total CA
Production Flowlines
- xx
- xxP
5.14
4.55
7.0
6.0
1.33
1.26
3.0
3.0
Test Header
-xx
xx
5.14
4.55
7.0
6.0
1.33
1.26
3.0
3.0
4.73
4.17
6.0
6.0
1.29
1.23
3.0
3.0
Production Header
-xx
- xx
The corrosion of the topside equipment should also account for external corrosion where piping
running at an elevated temperature will be prone to coating breakdown and hence exposure of the hot
steel surface to a marine environment. Considering that bothxx and Sxx wellhead platforms are
unmanned it is considered that a 1.5mm external corrosion allowance be added to the production
piping. The total corrosion allowance (CA) for the flowlines and headers for the two corrosion model
cases are presented in Table 5 -3.
The corrosion allowances for the production export pipelines on xx and xx are described below in
Table 5 -4.
Table 5-4
Production Export Pipeline Internal Corrosion Allowances (20 years)
Pipeline
Inlet Accumulated
Corrosion (mm)
Outlet Accumulated
Corrosion (mm)
Corrosion Allowance
(mm)
Model a) Water of Condensation Only

xx Production Export
4.51
5.53
6.0
4.16
4.27
6.0
Model b) Water of Condensation + Produced Water

1.28
1.54
3.0
1.23
1.90
3.0
Refer to Section 8.2.3 for recommendation of alternative materials.
The corrosion rate for the export pipelines from xx and xx to xx are very sensitive to the pH buffering
effect of the produced water. Variability in the bicarbonate concentration in the produced water
analysis (as provided by XXEPIL) was found to have little effect on the corrosion rate and this is
demonstrated in Table 5 -5.
Page 33
What is unknown about the produced water chemistry is how much H 2S and CO2 will react with the
water during the long exposure time along the pipelines length. The typical produced water chemistry
provided in Section 3.3.3 is a separator chemistry and was not exposed to a long duration of mixing
with a CO2 (10wt%) and H2S (100ppm) laden production liquid which may become more acidic and
hence more corrosive over time. It is also important to note that the NORSOK M506 corrosion model,
as is the case for most CO2 corrosion models, does not account for the effect of H 2S on the overall
corrosion rate. The corrosion rate including H2S varies through different temperature zones, which is
mainly because the different scales that form on the steel have different structures and hence have
varied porosity and adhesion properties. All of which effects the passivation of the steel and whether
it corrodes or not.
Table 5-5 Sensitivity Analysis of Produced Water Chemistry (xx Export Pipeline)
Bicarbonate Level
Accumulated Corrosion Damage (20 years)

(98% inhibitor availability and 99% inhibitor efficiency)
100% Chemistry (1691 mg/l)
1.28mm
90% Chemistry (1522mg/l)
1.28mm
75% Chemistry (1268mg/l)
1.29mm
5.2
Corrosion Inhibition Philosophy
5.2.1
General
Corrosion inhibitor will be assessed as the primary means of corrosion management in wet process
streams and pipelines to allow the use of carbon steel with an acceptable corrosion allowance,
provided the chemicals used and the method of injection can effectively and reliably control the
corrosion rate.
The inhibitor effectiveness comprises the efficiency of the chemical in the process (how much it
reduces the native uninhibited corrosion rate when dosed properly), and the reliability of the injection
process (how often inhibitor is actually injected and available to inhibit corrosion in the process). For
this project, the values for the inhibited corrosion rate and inhibitor availability to be used for material
selection and corrosion allowance determination purposes for the xx (or xx) to xx subsea pipelines will
be in accordance with the following Table 5 -6 from Rippon [Ref 6]:
Table 5-6 Inhibited Corrosion Rates and Inhibitor Availability [Ref 6]
Temperature Range
(C)
Inhibited Corrosion Rate

(mm/y)
Specified Inhibitor Injection Availability

(%)
Manned Platform
Unmanned Platform
Up to 70C
0.05
99%
95%
> 70C and 120C
0.1
99%
95%
> 120C and 150C
0.2
99%
95%
Above 150C
Inhibition not recommended without specific testing
For unmanned facilities with chemical storage and injection facilities located on the platform Rippon
recommends a 95% mechanical availability of the chemical injection system. However, in this case it
Page 34
is the current design premise to have the chemical injection pumps and chemical storage located on
the xx platform, which is manned. For this scenario it is considered good practice to assume a
corrosion inhibitor availability of 98%. Projects such as BHP Billiton Minerva (Australia, Otway Basin),
Nexus Energy Longtom (Australia, Bass Strait) and Santos Casino (Australia, Otway Basin) are
remote subsea developments controlled by onshore facilities (up to 60km) away and these projects all
assume 99% chemical injection availability. A field arrangement similar to xx is used in the Kerr
McGee China Petroleum Development in Bohai Bay, Northern China. KMGCP have unmanned
wellhead platforms that are supplied with inhibitor and other chemicals from remote manned
production platforms and FPSO. KMGCP operate using 98% corrosion inhibitor availability for their
unmanned wellhead platforms.
For the topside production and test headers through to the export pipeline the corrosion inhibitor will
be supplied through multiple injection points (i.e. one per flowline, upstream of the choke valve) and
therefore a complete unavailability of inhibitor would require multiple failures of the injection points.
For the individual flowlines, when the injection system fails, the flowline will go without corrosion
inhibition and therefore the 98% availability may not be obtainable and hence either a CRA material or
a large corrosion allowance (>6mm) is to be considered for the flowlines. A list of possible uninhibited
events is provided in Appendix 3 with suggested control options.
Pipelines operate under fairly well defined flow regimes with constant pipe diameter; whereas topside
production and process plant systems operate with variable pipe diameters, flow regimes and fluid
velocities. They can also possess areas of high flow, flow disturbances, impingement, dead legs,
crevices, etc., that can reduce the performance of the corrosion inhibitor. Consequently, an inhibitor
overall inhibitor effectiveness (i.e. taking account of the inhibitor efficiency and inhibitor availability)
limit of 95% is recommended for topside pipework.
As part of the materials selection process, the inhibitor effectiveness required to allow a desired
corrosion allowance to be achieved for the design life has been calculated for each process stream.
Should the inhibitor fail to achieve the performance standard assumed in the materials selection,
excessive corrosion may occur giving rise to the risk of premature failure.
It is critical that the target inhibitor availability and effectiveness is achieved, by:
Ensuring that the inhibitor chemical specified is able to achieve the specified inhibited corrosion
rate (e.g. 0.05mm/yr for T<70C) irrespective of the corrosivity of the environment (see
Section 5.1).
Ensuring that the dose of chemical is sufficient to be able to achieve this level of protection
throughout the system to be protected, and that facilities to check this effectiveness (corrosion
monitoring and sample points) are provided at appropriate positions in the process.
Ensuring that the inhibitor is injected in a manner that the full performance efficiency of the
chemical can be achieved throughout the system, by the appropriate location of injection
points, and the specification of the proper injection axxratus (i.e. quills/atomiser).
Ensuring that the chemical injection system is sufficiently reliable to provide chemical injection
for a defined percentage of the design life (e.g. at least 98% of the time for an unmanned
platform), usually by the use of motor (not air/gas) driven pumps, provision of alarms or
indicators when injection stops, regular operator surveillance, etc. (see Section 5.2).
Ensuring that the onsite facilities are equipped with sufficient chemical storage capacity to
provide continuous supply of chemical for the maximum duration between supplies, taking into
account such factors as storms preventing offloading.
Page 35
Failure to ensure the target inhibitor effectiveness is met will reduce the life of the system, potentially
below the required 20-year design life.
5.2.2
Chemical Performance
The chemicals currently used in the xx and xxfields are as follows:

Corrosion Inhibitor: Champion Technologies Cronox ML-5694;
Scale Inhibitor: Champion Technologies Grypton IT-266.
Details of these chemicals are provided in Appendix 4. The chemicals ability to achieve the target
inhibited corrosion rate must be proven for the xx and xx conditions prior to deployment, particularly in
highly corrosive systems, where the consequences of not meeting the specified inhibition target could
be very high.
5.2.3
Chemical Injection System Design
The detailed design of the system (i.e. placement of injection points, design of injection quills, design
of chemical supply systems, availability of pumps, potential for blockages, provision of alarms and
backups, quality of equipment purchased) will dictate the base mechanical reliability of the system,
and so have a strong effect on the overall effectiveness of the inhibitor treatment over the life of the
field.
The Inhibitor System Design Criteria given in Table 5 -7 must be incorporated into the overall facility
design to meet the required target system availability (see Section 10) for the remote, unmanned
xxand xx wellhead platform. For comparison, the table provides the inhibitor system design criteria
that would be required to achieve a 95%, 98% and 99% availability targets.
Table 5-7 Criteria for Inhibitor System Design to Meet a Specified System Availability
Item
Inhibitor Availability
95%
98%
99%
Standard
High reliability
High reliability
Automated Preferable for

Remote Sites
Automated
Check that pump is operating
Daily Manual Check
Automated Alarm for

Remote Sites
Automated Alarm
Pump planned maintenance
Annual
Annual
Annual
Daily Manual Check
Automated Alarm for

Remote Sites
Automated Alarm
Inhibitor demonstrated as
suitable for the application
Inhibitor injection pumps
Back up pumps
Inhibitor tank levels
Page 36
Item
95%
98%
99%
Monthly
Weekly
Weekly
Quarterly manual check on

pump injection rate
No flow alarm (zero

differential pressure across a
critical component, or in line
flow meters)
Liquid samples for analysis of

residual inhibitor levels and
water chemistry
Monthly
Monthly
Monthly
Corrosion monitoring system

response time.
Response time such

that total number of
events x time to
respond is <18 days
Response time such that

total number of events x
time to respond is <8
days
Response time such

that total number of
events x time to
respond is <4 days
Typical choices for corrosion

monitoring equipment and
system response times
At least annual
manual corrosion
measurements
On line ER probes;
response time 1-4 days
and daily inhibitor
injection concentration
On line ER probes;
response time 1-4
days and daily inhibitor
injection concentration
Desirable
Required
Required
Persistency taken into

account
Allowed days inhibitor system

downtime per year
18
Shut-in if inhibition system

goes down for greater than a
defined period of time
Effectively never an
issue
Possibly (depending on
corrosivity of system)
Possibly (Note:
Probably for high
corrosivity systems)
Check for worst-case

corrosion in shutdown
conditions
Effectively never an
issue
Possibly (depending on
corrosivity of system)
Possibly (Note:
Probably for high
corrosivity systems)
Report on inhibitor used (or

report on compliance with key
performance indicators) to
responsible corrosion
engineer
Comprehensive review of
uninhibited events
Identify Operations Technician

with responsibility for the
inhibition injection system
for Remote Sites
Page 37
Item
Corrosion Engineering
Involvement
Key Performance Indicators
set for Operations Technicians
and Corrosion Engineers
95%
98%
99%
Monthly Review
Fortnightly Review
Weekly Review
As indicated in Section 5.1, carbon steel is viable for a 20 year design life. If carbon steel flowlines
are used on xx and xx, corrosion inhibitor would need to be injected upstream of the choke on each
wellhead, which would provide thorough mixing and distribution of the inhibitor into the fluids.
If the corrosion inhibitor is prone to clogging the injection lines and fittings then dilution of the inhibitor
in diesel oil to improve the inhibitors viscosity should be considered. The dilution of the inhibitor and
the effect on its effective injection rate should be calculated in conjunction with the fields chemical
supplier, Champion Technologies. If the inhibitor is diluted with diesel then a larger volume of fluid will
have to be pumped and hence the injection pump sizes should be increased accordingly.
If CRA flowlines are used and corrosion inhibitor is required for protection of the xxto xx pipeline and
xx-xx pipeline, an atomising injection quill should be used downstream of the production flowline to
ensure that the inhibitor is effectively distributed in the gas phase. This system can be designed with
automatic back-up pumps to improve the system reliability, as opposed to the use of multiple injection
pumps for each wellhead.
Provision will need to be made for corrosion inhibitor injection on xx for protection of the dehydrated
gaslift pipeline in the event of dehydration upsets. This should be coordinated with dewatering pigs to
remove water that may have settled at low spots in the pipeline.
5.2.4
Operation and Reliabilit y
The quality of operation of the chemical injection system is critical to the effectiveness of the inhibitor
treatment and therefore to the reliability of carbon steel systems. Factors include the quality and
consistency of chemical supply, regular operator checks / control room surveillance, pump and
injector maintenance, injection adjustment and performance verification.
Page 38
6.
PIGGING REQUIREMENTS
6.1
Operational Pigging
Pipeline pigging can have a major impact on the operational and technical integrity of a pipeline.
Pigging can have a number of operational purposes:
Cleaning of the pipeline prior to an intelligent pig inspection;
Intelligent pig runs;
Cleaning to prevent flow restrictions (wax, asphaltene and scale build-up);
Liquids inventory management;
Internal corrosion control; and
Inhibitor distribution.
The subsea production pipelines will have pig launchers and receivers fitted to enable operational
pigging.
The current design basis does not provide for permanent gas lift launchers and receivers; this
arrangement is satisfactory if corrosion inhibition is continuously injected into the gas lift pipelines. If
the corrosion inhibition is to be only injected when the gas lift gas goes off dew point (wet gas
operation) then it is recommended that permanent launchers and receivers are installed to permit
periodic sweeping of free water from the gas lift pipeline and running batch corrosion inhibitor.
Pigging for corrosion control may be required for a number of reasons:
For new and existing lines, the lines should be cleaned and batch pigged with a filming inhibitor
prior to commencement of continuous inhibitor injection to ensure access of the inhibitor to the
pipe wall to maximise inhibitor effectiveness from start up. The continuous inhibitor takes a
finite time to travel down the pipeline from start-up and the batch inhibitor will prevent any
corrosion from occurring.
Pigging should be performed during commissioning in order to remove any mill scale and loose
surface corrosion from the pipe walls. This will help to improve corrosion inhibitor efficiency by
reducing the surface area available in the pipe where corrosion inhibitor can be adsorbed and
removed from the corrosion inhibition of the steel.
Distribution of inhibitor containing bottom fluids to the top of the line (TOL) where TOL corrosion
is a concern.
Removal of stagnant water pools in stratified flow regimes, where continuously injected inhibitor
may be less effective and/or require higher dose rates than more turbulent systems.
Removal of sand and other solids that may adversely affect the performance of the inhibitor.
Scraper pigs are generally sent through the pipeline ahead of intelligent pigging operation to ensure
that the intelligent pig does not get stuck in the pipeline. The debris collected by the scraper pig will
be deposited in the pig receiver. Samples of this material should be taken and analysed.
Page 39
6.2
Intelligent Inspection Pigging
6.2.1
General
Deterioration of the pipeline is primarily a result of corrosion by aggressive contaminants. Control of

the deterioration will be through chemical treatment. To ensure the integrity of the pipeline, it may be
necessary to undertake a number of maintenance and inspection pigging routines throughout the life
of the pipeline.
6.2.2
Intelligent Pigging Requirements
Under a safety case regime, there are no definitive inspection periods for intelligent pigging. The
requirements for intelligent pigging are determined through a consultative process whereby the
regulator and pipeline license holder set an agreed inspection period, based on the following
parameters:
Predicted corrosion rate;
Corrosion management program;
Corrosion monitoring program;
Operating history; and
Operator experience.
The base intelligent pigging frequency will be based on a set interval (typically 5 years), minimum,
with additional IP runs performed as needed based upon the above parameters.
6.2.3
Pigging Frequency
There are two approaches to determining the requirements for intelligent pigging. To get the
maximum benefit from performing intelligent pigging inspections, the inspection tool shall only be run
when it is expected that anomalies are present at levels detectable by the inspection tool. For typical
high-resolution magnetic flux leakage tools, this detection limit is generally 10% of wall thickness or 1
mm, whichever is greatest.
Therefore, in determining the pigging frequency, the expected corrosion rate should be used to
ensure that intelligent pigging is not performed unnecessarily. The corrosion rate used in determining
the frequency of pigging is typically the uninhibited corrosion rate.
However, the pipeline shall be designed so that the corrosion inhibitor is injected continuously and
should approach 100% availability.
If this corrosion management philosophy is confirmed by in-line corrosion monitoring devices (e.g. the
probes or sensor spools), then potentially regular intelligent pigging will not be required for the life of
the pipeline based on the detection limit and a maximum inhibited corrosion rate.
Generally, the local regulatory body insists on intelligent pigging of wet CO 2 pipelines on a regular
frequency. This frequency is typically every 3 to 5 years, depending on the history of the pipeline, the
experience of the operator, and the corrosion monitoring and mitigation programs in place.
Page 40
7.
SPECIFIC M ATERI AL APPLIC ATIONS
7.1
Use of Corrosion Resistant Alloys
7.1.1
Grade 304/304L Austenitic Stainless Steels
Grade 304/304L stainless steels shall not be used in critical service for pipework, tubing, vessels,
equipment, bolting or fixings exposed to marine or salt-laden air, or aerated chloride-containing water,
due to the risk of pitting, crevice corrosion or chloride-induced stress corrosion cracking at any
temperature above ambient.
Rogue 304 stainless steel materials regularly turn up on offshore facilities due to its use in vendor
standard valve bolting. All valves used offshore in pressure containing service should be specified as
No 304 Stainless Steel (B8) materials permitted.
7.1.2
Grade 316/316L Austenitic Stainless Steels
Grade 316/316L shall not be used in critical service for any piping or for the externals of equipment
above a temperature of 60C due to the risk of external chloride-induced pitting and stress corrosion
cracking (CSCC).
Consideration should be given to the use of 316L clad carbon steel rather than solid 316L vessels
(particularly in a marine environment) unless cladding is shown to be significantly less economic.
Grade 316L may be used as a cladding material or for vessel internals in sweet (i.e. only CO 2)
hydrocarbon service providing oxygen and/or H2S are not present.
Before solid material is used (particularly in a marine environment), consideration shall be given to the
possibility of an increase in the external skin temperature above 60C due to solar radiation or heat
from surrounding equipment, which may also cause chloride concentration due to surface
evaporation. In these conditions, 316L is not acceptable for critical service. Consideration can be
given to the use of factory applied thermal spray aluminium (TSA) as an external coating to act as a
surface barrier and shift the stainless steel potential out of the SSC regime, but the effectiveness of
such a coating over a 20 year design life shall be considered for critical service. Consideration shall
also be given to the practicality of site application of TSA at field joints, since this has been shown to
be problematical and to adversely affect the performance of the coating.
In the absence of CO2 and H2S, Grade 316L stainless steel shall not be used in critical service for
process or utility streams containing oxygen above 60C if the chloride content is above 300 ppm.
The material shall not be used for any heat transfer surface applications in such streams at any
temperature or chloride content due to the risk of chloride concentration effects.
Grade 316/316L stainless steel piping for pressure retaining purposes may be used above 60C if it is
not insulated and is located indoors under HVAC control. For un-insulated instrument tubing
downstream of a shut-off valve, normally no extra precaution is required providing there is no flow in
the instrument piping and the process media temperature is less than 85C.
Material limits and manufacturing controls for 316/316L stainless steel are summarised in Table 7 -8.
Page 41
Table 7-8 Material Limits and Manufacturing Controls for 316/316L Stainless Steel
Type of Service
Produced
Fluids
Oil (no
water)
Wet
Gas
Dry
Gas
Produced
Water
Temperature Limits (C)

Min Service Temp Without
Impact Testing
All thicknesses
-105
-105
-105
-105
-105
Min Service Temp With Impact

Testing
All thicknesses
-196
-196
-196
-196
-196
Max Service Temp - Uncoated
Atmospheric
Marine (Low
Hazard)
60
60
60
60
60
50
50
50
70
50
2.5
2.5
2.5
2.5
2.5
YES
YES
YES
YES
YES
Flow Velocity Limits Without Sand (m/s)

Flow Velocity Limit
Manufacturing Limits & Controls
Compositional Constraints
Min
Molybdenum
for thin wall
tubing
Solution Anneal & Quench for

Pipe & Fittings
7.1.3
6Mo Super-Austenitic 254 SMO (UNS S31254)
6Mo super-austenitic stainless steel such as 254 SMO (UNS S31254) can be regarded as resistant to
CO2 corrosion but shall be limited to an operating temperature of 120C in an external saliferous (i.e.
salt laden air) environment. The minimum design temperature shall be -101C without impact testing
or -196C with impact testing.
7.1.4
Duplex Stainless Steel
Duplex stainless can be considered resistant to external chloride induced stress corrosion cracking
(CISCC) up to temperatures of 100C for 22Cr duplex and 110C for 25Cr super duplex stainless
steels. Cracking above these temperatures is only likely if the vessel or pipework is lagged and
saline/seawater gets trapped under the lagging or is dripped continuously onto hot pipework.
Nevertheless, as a precaution, it is recommended to TSA coat duplex stainless steel equipment
operating above these temperatures in an offshore marine environment.
Duplex stainless steels can be considered to be resistant to weight loss corrosion and pitting
corrosion in sweet hydrocarbon production environments (i.e. CO 2 only) at CO2 partial pressures up to
100 bar, temperatures up to 200C and up to 20,000 ppm (200g/l) NaCl.
Page 42
Material limits and manufacturing controls for 22Cr duplex stainless steel are summarised in Table 7
-9 below. Typically throughout this document when 22Cr is referenced, the basic specification UNS
S31803 is inferred. However, where a higher pitting risk is perceived then the higher specification
22Cr, UNS S32205, will be specified as it contains a guaranteed minimum molybdenum content of
2.5%, which ensures a greater pitting resistance than the base grade duplex stainless steel.
Table 7-9 Material Limits and Manufacturing Controls for 22Cr Duplex Stainless Steel
Type of Service
Produced
Fluids
Oil (no
water)
Wet
Gas
Dry Gas
Produced
Water

Impact Testing
6mm
-50
-50
-50
-50
-50

Impact Testing
> 6mm

Testing
> 6mm
-50
-50
-50
-50
-50
Atmospheric
Marine
100
100
100
100
100
Max Temp Due to

Embrittlement
ASME B31.3
Table A-1
315
315
315
315
315
50
50
50
70
50
35 65%
35
65%
35
65%
35
65%
35 65%
33
33
33
33
33
Minimum Nitrogen Content (%)
0.15
0.15
0.15
0.15
0.15
Solution Anneal & quench for

Pipe & Fittings
YES
YES
YES
YES
YES

Flow Velocity Limit
Metallurgical Constraints
Ferrite Content
Minimum PREn
Material limits and manufacturing controls for 25Cr super duplex stainless steel are summarised in
Table 7 -10 below.
Page 43
Table 7-10 Material Limits and Manufacturing Controls for 25Cr Super Duplex Stainless Steel
Type of Service
Produced
Fluids
Oil (no
water)
Wet
Gas
Dry
Gas
Produced
Water

Impact Testing
6mm
-50
-50
-50
-50
-50

Impact Testing
> 6mm

Testing
> 6mm
-50
-50
-50
-50
-50
Atmospheric
Marine
120
120
120
120
120
Max Temp Due to Embrittlement
ASME B31.3
Table A-1
315
315
315
315
315
50
50
50
70
50
35 65%
35
65%
35
65%
35
65%
35 65%
40
40
40
40
40
YES
YES
YES
YES
YES

Flow Velocity Limit
Metallurgical Constraints
Ferrite Content
Minimum PREn
Solution Anneal & quench for
Pipe & Fittings
7.1.5
Selection of CRA for Pipe and Vessels
The use of CRA clad carbon steel is becoming increasing difficult due to the high worldwide demand
for clad steel and there being only 4-5 manufactures in the world to provide the materials. It is for this
reason that clad pipe and vessels are not considered as part of this material study.
7.2
Use of Glass Reinforced Plastic (GRP)
7.2.1
Piping Systems
The properties and performance characteristics of glass-reinforced plastic (GRP) are dependent on
the resin used for the composite matrix and the method of manufacture. Such factors shall be taken
into account when selecting a particular product for a service application.
GRP pipe may be considered for open drains, produced water piping, injection lines, potable water,
systems, sanitary systems and drain lines subject to confirmation of the suitability of the resin type for
Page 44
the intended service and the pressure and temperature rating for the pipe. Examples of pressure
ratings and resins used in GRP pipe from various manufacturers are show in Table 7 -11
Temperature ratings are usually of the order of 90C for epoxy based systems, but can be up to
~120C for polysiloxane-phenolic based systems.
It should be emphasised that design, fabrication and installation of GRP systems, including pipe
supports, joining systems and expansion bellows, are specialised processes and require experienced
personnel to ensure good quality and performance. It is extremely important that GRP pipe be
installed by bonders and inspectors who have been trained and certified to a specification approved
by the owner.
Engineering analysis of GRP piping systems is critical to the prevention of premature failures due to
inadequate support, improper location of supports, water hammer, etc. ISO 14692 (Parts 1 to 4) is
now recognised as the Industry Standard for the design, purchase, manufacturing, qualification
testing, handling, storage, installation, commissioning and operation of GRP piping systems in the
petrochemical and natural gas industries. It provides terms and definitions, describes the philosophy
and provides guidance on the range of suitable applications, and defines limitations to the materials of
construction for the specification, manufacture, testing and installation of glass-reinforced plastic
(GRP) piping installations. Its primary focus is associated with offshore applications on both fixed and
floating topsides facilities for oil and gas industry production and processing, but may also be used as
guidance for the specification, testing and installation of GRP systems in similar onshore applications,
such as firewater and produced water systems.
Severe impact events can cause crazing in the pipe wall and therefore GRP pipe should be located to
reduce the occurrence of impact loads wherever possible, or physically protected.
Although industry standards are available to govern the specification of GRP piping systems, GRP
pipe manufacturers will provide system engineering assistance, supply material, fabricate spools,
provide onsite construction and inspection, and conduct proof tests. It is advisable to use the services
of the manufacturer as much as possible.
7.2.2
GRP Tanks and Vessels
Typical applications for GRP vessels include water filters, water storage, and chemical storage. GRP
vessels can be used to store hydrocarbons such as diesel fuel, gasoline and lube oil when approved
by the governing regulatory body.
Vessel manufacturers include Forbes, Balmoral, Garlway, RL-Industries, Inc., Ershigs, Inc., and
Lincoln Composites. Generally, the cost of GRP is between that of carbon steel and stainless steel.
Low-pressure GRP vessels and tanks are available for storage or process applications. Lowpressure vessels can be very large. Pressure ratings go up to 15 psig plus the hydrostatic head.
Governing standards are ASME RTP-1 and BS 4994.
High-pressure GRP vessels are also available. High-pressure vessels must be qualified to ASME
Section X. Class I vessels may have pressure ratings to 150, 1500 or 3000 psig, depending on the
construction of the vessel, and are qualified by test of a prototype to destruction. Class II vessels may
have pressure ratings ranging from 15 to 200 psi depending on the diameter and the design method.
Class II vessels are qualified by non-destructive testing.
Design and fabrication of nozzles and other attachments with good durability is an engineering issue.
Good procurement specifications are important. The fabrication quality control plan and user
inspections are important considerations.
Page 45
Table 7-11 Examples of Pressure Ratings and Resins Used in GRP Pipe
Manufacturer
Product
Series
Typical Application
Resin
Pressure Rating
(PSI)
Ameron
International
Bondstrand
2000M
General Application & Firewater Ring

Main
Epoxy
250
225
(1 to 16)
(18 to 40)
2000M-FP
Dry Deluge Piping
Epoxy
250
(1 to 16)
2420
Potable, saltwater, brackish water

and seawater lines
Epoxy
290
(2 to 40)
Fire protection systems

Waste water, drainage and sewage
systems
EDO Speciality
Plastics
Fiberbond
5000M
Seawater Chlorination
Vinyl Ester
450
350
250
150
(2)
((3 & 4)
(6 to 8)
(>12)
7000M
Antistatic piping for Refined Products
Epoxy
250
225
(1 to 16)
(18 to 40)
PSX-L3
Firewater Ring Main
Polysiloxane-Phenolic
250
225
(2 to 6)
(8 to 16)
PSX-JF
Dry Deluge Piping
Polysiloxane-Phenolic
225
(1 to 12)
20 HV
General Application
Iso Polyester
20 FRE
Firewater Ring Main
Vinyl Ester
200
150
100
(2 to 12)
(14 to 18)
(20 to 24)
20 JF
Dry Deluge Piping
Vinyl Ester
200
(2 to 10)
Page 46
Manufacturer
Product
Series
Typical Application
Resin
Pressure Rating
(PSI)
Smith Fibercast
Green Thread
175
General Application
Epoxy
175
(2 to 26)
250
General Application & Firewater Ring

Main
Epoxy
250
(1 to 36)
250 -F
Dry Deluge Piping
Epoxy
250
(1 to 24)
EST 20
General Application
Epoxy
250
Future Pipe
Waivistrong
Page 47
7.3
Selection of Elastomeric Seals
The following materials may take up product and are therefore susceptible to explosive
decompression. They should not be used for O-rings in hydrocarbon service:
Viton A
NBR (Nitrile Butadiene or Standard Rubbers)
Elast-O-Lion 101 HNBR (does not perform on larger sections)
Materials with proven and acceptable performance in hydrocarbon service include:
James Walker 58/90 (Viton B)
James Walker 58/98
Dowty 9730
Greene Tweed 826
Nitrile (NBR) and hydrogenated nitrile (HNBR) elastomers are acceptable in non-hydrocarbon service
with low levels of H2S if the temperature remains below 60C.
PTFE is a plastic which has excellent chemical (and H2S) resistance, but account should be taken of
the fact that plastics require different sealing configurations to elastomers.
In all instances, elastomer selection should take into account the complete operating conditions to be
encountered, especially the presence of amines from corrosion inhibitors. Amines are curing agents
for Buna and Nitrile rubbers causing such products to over-age and embrittle. As a result, glass-filled
PTFE seals are required for inhibitor handling equipment such as pumps and valves, and good amine
resistance of TFEP or FFKM elastomers may be required in critical locations in hydrocarbon service
where high amine/inhibitor concentrations could be encountered.
Viton is rapidly degraded by methanol and should not be used in any system that will be exposed to
methanol.
7.4
Bolting Materials
Bolting for carbon steel piping is normally specified as low alloy, quenched and tempered Cr-Mo
steels to either ASTM A193 Gr B7 and/or A320 Gr L7, but additional protection is required for offshore
marine applications.
Carbon steel bolting is commonly cadmium plated and PTFE coated. However, the PTFE coating is
only partially effective, since damage will always occur during installation and maintenance. These
coatings usually comprise only 30m of PTFE and 8m of plated cadmium, so limited protection is
afforded where the PTFE is damaged. Some operators have experienced corrosion of the bolts by
the time of commissioning or within 1-2 years, leading to seizing of the nuts in the long term.
The use of hot dip spun galvanized steel (HSG) bolting to ASTM A193 grade B7 (nuts to ASTM A194
grade 2H) should also be considered, since a number of operators have had poor performance with
electroplated Zn/Cd and PTFE coatings in aggressive marine environments. HSG bolting provides a
much thicker coating than the Cd/Zn electroplate and offers a cost-effective alternative in the long
term.
Page 48
BS 14713 gives the average corrosion rate of zinc in a highly saline atmosphere as 4-8 m/yr,
whereas the minimum zinc thickness when galvanizing to BS 729 is 43 m. This would give an
average life expectancy of the galvanized layer of 5 and 10 years before the galvanic protection from
the zinc is lost and corrosion of the steel substrate commences. In practice, the galvanizing thickness
tends to be greater than 43 m, which provides longer coating life.
Apart from corrosion, the main issue that is frequently raised with galvanized steel is liquid metal
embrittlement (LME) of adjacent stainless steels. This is mainly an issue with austenitic stainless
steels, but can affect duplex stainless, which have an austenite/ferrite matrix. It requires the
simultaneous presence of molten zinc, high tensile stress and temperatures over 750C. However, in
the event of a fire that could lead to these temperatures, the mechanical properties of the stainless
steel will have been greatly reduced before the critical LME temperature is reached. The additional
risk of failure due to LME is therefore low and the use of galvanized bolting on stainless steel piping is
regarded by some operators (e.g. BPAmoco) as acceptable.
If galvanised steel bolting is used, bolts with a diameter above 25mm should be impact tested to the
same requirements as for the steel to be bolted. Extra clearance is required on the threads to allow
for the zinc coating thickness and it must be ensured that galvanised nuts are not fitted to
PTFE/electroplated bolts.
Bolting for subsea service shall be in accordance with the requirements of DNV OS F101 Table 7-2 as
amended in January 2003.
Page 49
8.
M ATERI ALS SELECTION XX AND XX PL ATFORM
8.1
Wellhead Equipment (Including Chokes and Flow line

Isolation Valves)
Wellhead equipment is defined in the xx Design Basis [Ref1] and is a proprietary supplied item. The
materials shall be selected in accordance with the requirements of API 6A. According to API 6A for
the conditions prescribed for xx and xx the API Material Class will be FF, which is moderately
corrosive sour service. Sour service has been prescribed in this case based on the STHP (2000psi
for xx and 2100psi for xx) and the upper figure for H2S in Section 3.3.1, i.e. 1000ppm. This results in
a H2S partial pressure of 13.8kPa for xxand 14.5kPa for xx. The protocol for specifying wellhead
material class is to state the material class with the H2S partial pressure added as a suffix, eg. FF1.5kPa. Therefore, the specification for the wellheads, chokes and flowline isolation valves shall be
as follows:
XX = FF-13.8kPa Stainless Steel.
XX = FF-14.5kPa Stainless Steel
8.2
Process Equipment
8.2.1
General
The following tables summarise the materials to be used for the process equipment on both the xx
and xx wellhead platforms. Unless specifically stated, these recommendations apply equally to both
platforms.
Page 50
8.2.2
Gas Lift First Val ve On (FVO), Gas Lift Header and Flow lines
Operating
Service
Dehydrated natural gas with composition defined in Section 3.3.2.
Maximum
Temperature
40C
Pressure
1250 psi (8620kPa)
Corrosion
Damage
Mechanism(s)
Internal corrosion due to wet gas from intermittent process upsets or residual
water from pre-commissioning. See corrosion rates in Appendix 2 calculated
using NORSOK M506 and discussion in Section 5.1. Corrosion will only be due
to occasional upsets of the XX platform dehydration unit. So corrosion is
expected to be marginal.
Topside piping exposed to marine environment.
H2S partial pressure is 8.6kPa, which is greater than the level prescribed by
NACE MR0175 / ISO 15156 for sour service (0.3kPa). So sour service rated
materials are required.
External corrosion from marine environment. Mitigate corrosion using protective
coatings.
Materials
Piping, Flanges and Fittings: Carbon Steel

Valves (First Valve On): Carbon Steel Body with 316L trim.
Fasteners: Refer to Section 7.4 for guidance.
Corrosion
Allowance
3.0mm
Other Internal
Corrosion
Protection
The piping should be isolated from the incoming gas lift riser using a Monolithic
Isolation Joint (MIJ) located before the First Valve On.
Page 51
8.2.3
Production Flow lines
Page 52
Operating
Service
Multiphase fluid containing oil, produced water and gas with composition
described in Section 3.3.
High temperature topside piping exposed to marine environment.
Maximum
Temperature
110C
Pressure
280 psig (19.4 barg)
Corrosion
Damage
Mechanism(s)
Corrosion from high temperature saturated hydrocarbon with high CO 2 and H2S
composition.
H2S partial pressure is 0.22kPa system, which is less than the level prescribed by
NACE MR0175 / ISO 15156 for sour service (0.3kPa). However, given that the
H2S composition is close to the sour level it is good industry practice to specify
sour service requirements to allow for accidental well souring etc.
External corrosion of high temperature piping in a marine environment. Piping
will be prone to high coating breakdown and when coupled with the fact the
piping is on unmanned platforms, then an external corrosion allowance of 1.5mm
should be considered.
Instead of using carbon steel, duplex stainless steel may be used. The duplex
stainless steel must be coated to operate at 110C.
Materials
Carbon steel according to the corrosion model outputs shown in Appendix 2

shows good resistance to corrosion with a predicted metal loss between 1.35.2mm. However, the inhibitor system injects corrosion at one point for each
flowline. If this single point fails then the flowline will go without inhibition for a
short period of time (as it is an unmanned platform) and this will lead to high
amounts of corrosion than was predicted by the NORSOK models. Also, due to
the high external temperatures there is a concern with the use of organic coatings
due to high coating breakdown factors and that maintenance will be minimal
given that the flowlines are on an unmanned platform. The use of 22Cr duplex
stainless steel at 110C would not require an internal corrosion allowance but
would still have to be coated to guard against severe pitting corrosion. A 22Cr
duplex stainless steel has a critical pitting temperature of 80C and should not be
used above this temperature without an external coating. The cost difference to
go to a 25Cr super duplex stainless steel is prohibitive (ie Carbon steel versus
22Cr DSS and 25Cr SDSS is US$1500/tonne, US$28,500/tonne. and
US$32,000/tonne respectively) and not warranted in this case.
At elevated temperature the organic coatings tend to break down and resultant
external corrosion can be quite severe. Many operators tend to use a Thermally
Sprayed Aluminium coating on high temperature piping in a marine atmosphere.
The thickness of the coating is a compromise of obtaining suitable pore overlap
whilst maintaining thermal expansion compatibility with the substrate. In this
case a coating of 180m thick is deemed suitable. The coating shall be sealed
using a alkyd silicone topcoat.
1. Piping flanges and fittings: The recommendation is externally coated duplex
stainless steel; external coating to be 180m thick Thermally Sprayed Aluminium
Page 53
and sealed with an Alkyd Silicone.

Valves: 22Cr duplex solid valve body.
As an alternative (if schedule and cost become a project driver):
2. Piping, flanges and fitting: Sour service carbon steel with a corrosion
allowance and externally coated with 180m thick Thermally Sprayed Aluminium
and sealed with an Alkyd Silicone.
Valves: Carbon steel body with Inconel 625 overlay of wetted areas and
externally coated with 180m thick Thermally Sprayed Aluminium and sealed with
an Alkyd Silicone.
Corrosion
Allowance
Other Internal
Corrosion
Protection
1.
0 mm if the recommended duplex is selected
2.
(7mm XX, 6mm XX) if the alternate (option 2) described above is selected
and no credit given to pH buffering from produced water.
3.
3mm if the alternate (option 2) described above is selected and XXEPIL

accept credit due to pH buffering from produced water.
Corrosion inhibition to be injected upstream of the choke valve.
Page 54
8.2.4
Test Header
Page 55
Operating
Service
Maximum
Temperature
110C
Pressure
Corrosion
Damage
Mechanism(s)
composition.
piping is on unmanned platforms, then an external corrosion allowance of 1.5mm
should be considered.
Materials
Carbon steel according to the corrosion model outputs shown in Appendix 2

shows good resistance to corrosion with a predicted metal loss between 1.35.2mm.. The corrosion model is known to be well within its limits for the flowline
conditions presented here. The test header will be supplied with corrosion
inhibitor from multiple flowlines and therefore inhibition effectiveness should
remain high.
At elevated temperature the organic coatings tend to break down and resultant
external corrosion can be quite severe. Many operators tend to use a Thermally
Sprayed Aluminium coating on high temperature piping in a marine atmosphere.
The thickness of the coating is a compromise of obtaining suitable pore overlap
whilst maintaining thermal expansion compatibility with the substrate. In this
case a coating of 180m thick is deemed suitable. The coating shall be sealed
using a alkyd silicone topcoat.
Piping, flanges and fitting: Sour service carbon steel with a corrosion allowance
and externally coated with 180m thick Thermally Sprayed Aluminium and sealed
with an Alkyd Silicone.
Valves: Carbon steel body with Inconel 625 overlay of wetted areas and
externally coated with 180m thick Thermally Sprayed Aluminium and sealed with
an Alkyd Silicone.
Corrosion
Allowance
1.
(7mm xx 6mm xx) if no credit given to pH buffering from produced water.
2.
3mm if xx accept credit due to pH buffering from produced water.
Other Internal
Corrosion
Corrosion inhibition to be injected upstream of the choke valve to ensure header

is covered by the inhibition.
Page 56
Protection
Page 57
8.2.5
Production Header, Pig Launcher and Last Val ve Off
Operating
Service
Maximum
Temperature
110C
Pressure
Corrosion
Damage
Mechanism(s)
composition. The diameter of the lines that make up the production header and
pig launcher are bigger than those for the flowlines and test header (exposed to
the same conditions) which means the amount of shear along the wall is lower
and hence the inhibition is more effective. Also, the corrosion inhibitor is supplied
to the production header through multiple injection sites, so if one injector goes
down, there is still a good supply of corrosion inhibitor supplied through the other
flowlines. Refer to Appendix 2 for the corrosion model results.
piping is on unmanned platforms, then a corrosion allowance of 1.5mm should be
considered.
Instead of using carbon steel, duplex stainless steel may be used. The duplex
stainless steel must be coated to operate at 110C
Materials
Piping, Flanges and Fittings: Sour service carbon steel with corrosion allowance
and externally coated with 180m thick Thermally Sprayed Aluminium and sealed
with an Alkyd Silicone.
Valves, (including LVO): Carbon steel body with Inconel 625 overlay of wetted
areas and externally coated with 180m thick Thermally Sprayed Aluminium and
sealed with an Alkyd Silicone.
Corrosion
Allowance
Other
Corrosion
Protection
1.
6.0mm Including (1.5mm external) if no credit given to pH buffering from

produced water.
2.
3mm if xx accept credit due to pH buffering from produced water.
Corrosion inhibitor to be injected upstream of the choke valves.

The piping should be isolated from the incoming gas lift riser using a Monolithic
Isolation Joint (MIJ) located after the Last Valve Off.
Page 58
8.3
Utility Equipment
8.3.1
Fuel Gas Systems
Operating
Service
Dehydrated natural gas with composition defined in Section 3.3.2.
Maximum
Temperature
40C
Pressure
1250psi (8620kPa)
Corrosion
Damage
Mechanism(s)
Internal corrosion due to wet gas from intermittent process upsets or residual
water from pre-commissioning. See corrosion rates in Appendix 2 calculated
using NORSOK M506 and discussion in Section 5.1. Corrosion will only be due
to occasional upsets of the XX platform dehydration unit. So corrosion is
expected to be marginal.
Topside piping exposed to marine environment.
H2S partial pressure is 8.6kPa, which is greater than the level prescribed by
NACE MR0175 / ISO 15156 for sour service (0.3kPa). So sour service rated
materials are required.
External corrosion from marine environment. Mitigate corrosion using protective
coatings.
Materials
Piping, fittings and flanges: Sour service carbon steel with corrosion allowance.
Valves: Carbon Steel Body with 316L trim.
Corrosion
Allowance
3.0mm
Other Internal
Corrosion
Protection
Nil
Page 59
8.3.2
Open Drains
Page 60
Operating
Service
Spillages from chemical injection system, lubricants, fuel gas skid pans, pig
receiver debris.
Topside piping exposed to marine environment
Maximum
Temperature
40C
Pressure
Atmospheric
Corrosion
Damage
Mechanism(s)
The open drain system is to be resistant to a variety of hydrocarbons and

chemicals. The drains will be exposed to acidified water from process trains.
Corrosion rates are not expected to be high given the drains are at ambient
temperature and atmospheric pressure. The drains will collect solid matter and
therefore will be exposed to under deposit corrosion.
Due to the intermittent use of the drains there is a risk that the piping will be
exposed to stagnant fluids. Open drains are often contaminated with
microbacteria, which leads to fouling and blockage and MIC failure of most
metals.
Materials such as GRP-C will provide suitable corrosion resistance and require
less inspection. Open drain systems are often left off inspection programs.
Alternatively heavy wall carbon steel can be used.
The open drain vessel is 2000mm long x 900mm diameter and contains 2 weirs
and a downcomer. Due to the size of this vessel and the complexity of the
internal appurtenances, it is recommended that the vessel be made of duplex
stainless steel. UNS S32205 is recommended in this case as it is supplied with a
minimum guaranteed molybdenum content which will help impart better corrosion
resistance.
If a larger diameter vessel can be accommodated on the XX and XX platform
topsides, then the vessel may be manufactured using heavy wall carbon steel.
The inside of the vessel is to be coated with a glass flake epoxy or Belzona 1391.
The weirs shall be made to be bolted into place after the vessel is coated. The
edges of the weirs should be rounded to ensure and an even coating over the
edge which will be susceptible to damage if not thick enough. The weirs shall be
coated using the same system used for the vessel internal coating.
Materials
Piping: Glass Reinforced Plastic (GRP-C)

Heavy wall carbon steel.
Valves: Nickel aluminium bronze is common for GRP piping systems.
For carbon steel piping used rubber lined carbon steel valves
Open drain vessel should be fabricated form UNS S32205 Duplex Stainless
Steel.
Pump: Carbon steel with martensitic stainless steel impellers.
Corrosion
6mm for carbon steel.
Page 61
Allowance
Other Internal
Corrosion
Protection
Piping to be free draining and free from low spots and dead legs.
Provision for the intermittent dosing of biocide shall be included on each drain
leg.
Internal weirs of the carbon steel vessel to be removable for easier coating.
8.3.3
Vent and Closed Drains and Vent Scrubber
Operating
Service
Collection of liquid and vapour stream from flowline drains and vents, and liquids
from the open drain sump.
Maximum
Temperature
40C
Pressure
150 psi.
Corrosion
Damage
Mechanism(s)
Fluids entering the closed drains from the process should be at low pressure,
thus allowing the use of carbon steel with a 3mm corrosion allowance.
Materials
Piping, flanges and Fittings: Carbon steel
To reduce the risk of damage from stagnant fluids the pipe work must be design
to be free draining avoiding low spots and dead legs.
Vessel and Piping Valves: Carbon steel with 316L trim

Vent scrubber: Carbon steel and internally coated with a Glass Flake Epoxy or
Belzona 1391.
Pump: Carbon steel with stainless steel impellers
Corrosion
Allowance
3.0mm
Other Internal
Corrosion
Protection
Piping to be free draining and free from low spots and dead legs.
8.3.4
Chemical Injection Package
Chemical injection will be from the xxx platform with only piping, distribution manifold, chokes and
injection points provided on the xx and xx platforms. Piping shall be ASTM A269 Grade 316L with a
guaranteed minimum2.5% Molybdenum and maximum Rockwell B hardness of 80. Fittings shall also
be 316L with a guaranteed minimum2.5% Molybdenum.
Page 62
8.3.5
CCVT Pow er Generation
The Closed Cycle Vapour Turbines (CCVT) is a proprietary supplied items and the vendor shall be
responsible for ensuring the materials of construction are suitable. As a minimum the CCVT shall be
supplied in UNS S31603 austenitic stainless steel in compliance with ISO15156.3 / NACE MR0175.
8.3.6
Hydraulic Piping Syst ems
Hydraulic piping shall be ASTM A269 Grade 316L with a guaranteed minimum 2.5% Molybdenum and
maximum Rockwell B hardness of 80. Fittings shall also be 316L with a guaranteed minimum2.5%
Molybdenum. If piping is to be exposed to temperatures greater than 60C then tubing and fittings
shall be 25Cr super duplex stainless steel or Hastelloy C276 (UNS N10276).
8.3.7
Instrumentation
Due to the sour service conditions in the xx field, the instrumentation used in direct contact with the
production and gas lift equipment and piping shall be constructed out of materials in compliance with
ISO 15156. In all cases, the instrument supply vendor shall check the materials of their instrument for
compatibility with the process conditions.
Instrumentation piping (including compression fittings, and screen devices) is acceptable for XX and
XX in UNS S31600, provided the exposure temperature of the tubing is maintained below 60C. If the
exposure temperature is greater than 60C, then the tubing, compression fittings and associated
tubing elements, shall be 25Cr super duplex stainless steel (UNS S32750) or Hastelloy C276 (UNS
N10276). All tubing shall comply with the requirements of ISO 15156-3 for maximum sour service
exposure conditions (temperature, and pH2S) and material hardness. UNS S30400 (Grade 304 and
its derivatives) shall not be used for any equipment on xx or xx. UNS S30400 is susceptible to
chloride stress corrosion cracking at temperatures close top ambient conditions and therefore cannot
be used for pressure containment. UNS S30400 is highly susceptible to pitting in marine
environments and therefore is not appropriate for instrument enclosures or junction boxes.
Materials selection information for all other instrumentation is provided in Table 8 -12.
Table 8-12 Instrumentation Material Selection Chart
Instrumentation
Thermowell
Pressure Gauge/
Switch / Element
/ Socket
Level
Instruments
Service
Material
Temp < 60C
UNS S31600
Temp > 60C
UNS N10276 (Hastelloy C276)
Temp < 60C
UNS S31600
Temp > 60C
UNS N10276 (Hastelloy C276)
Temp < 60C
Body / Chamber UNS S31603 (316L)

Displacer / Float UNS S31603 (316L)
Temp > 60C
Body / Chamber N10276 (Hastelloy C276)

Displacer / Float N10276 (Hastelloy C276)
Transmitter /
Temp < 60C
Body - UNS S31603 (316L)
Page 63
Instrumentation
Service
Controller
Material
Element - UNS S31603 (316L)
Temp > 60C
Body - N10276 (Hastelloy C276)

Element - N10276 (Hastelloy C276)
Control Valves /
Mono-Block
Valves
Temp < 60C
Body - UNS S31603 (316L)

Trim - UNS S31603 (316L)
Temp > 60C
Body Carbon Steel (Sour Service)

Trim - N10276 (Hastelloy C276)
Safety Valves
Temp < 60C
Body/Bonnet - UNS S31603 (316L)

Nozzle / Disc UNS S31603 (316L)
Spring / Bellows UNS N06625 (Inconel 625)
Temp > 60C
Body/Bonnet Carbon Steel (Sour Service)

Nozzle / Disc UNS N10276 (Hastelloy C276)
Spring / Bellows - UNS N06625 (Inconel 625)
Orifice Plate
Temp < 60C
Flange Body - UNS S31603 (316L)

Plate - UNS S31603 (316L)
Temp > 60C
Flange Body - UNS N10276 (Hastelloy C276)

Plate - UNS N10276 (Hastelloy C276)
Multiphase
Flowmeter
Materials to be advised by the vendor for approval by XXEPIL.
Page 64
8.3.8
Wash Dow n Water Syst em
Operating
Service
Water collected from the helideck
Maximum
Temperature
Ambient
Pressure
Atmospheric
Corrosion
Damage
Mechanism(s)
Water from the helideck will contain chlorides washed from the surface.
Materials
Tank: GRP or Polypropylene (PP) with UNS S31603 austenitic stainless steel
fittings.
Topside marine environment.
Valves: GRP, PP or Nickel aluminium bronze for GRP piping

Piping: GRP or PP.
Corrosion
Allowance
Nil
Other Internal
Corrosion
Protection
None
Page 65
9.
M ATERI AL SELECTION - PIPELINES
9.1
Materials and Corrosion Allow ance
9.1.1
Linepipe Manufacturing Processes
For the linepipe sizes (DN80, DN100, D350) considered for the Hydra development there are two
linepipe manufacturing processes commonly used, they are:
Seamless linepipe manufacture by Pilger or Mannesmann processes;
High Frequency Induction (or Resistance) Welded linepipe (HFW).
Both processes are extensively used through the oil and gas industry for the transport of oil and gas
products in both sour and non-sour applications. Traditionally, HFW linepipe has not been the
preferred choice for gaseous service due to the risk of the welded seam splitting. There have been
very few incidents of subsea HFW pipelines splitting along the seam since welding frequencies have
increased to well above 80kHz in the early 1970s. Common welding frequencies are now of the
order of 150-300kHz and this produces consistent high quality welds. However, it has not been until
2000s that HFW pipe has been used extensively for gaseous service. There are several examples in
Australia where HFW has been used for gaseous service; these include sales gas in the Tasmania
Gas Pipeline (300+ km long) and raw gas at the Santos Patricia Baleen development (42km long). A
review of the supply records of two Japanese linepipe mills and one Korean linepipe mill shows that
sour HFW linepipe has been used offshore by Arco in the UK, Woodside in Australia and Norsk Shell
in Norway with strength levels equivalent to those considered for the Hydra development (X60 to
X65). These were ordered as early as 1990. Specific details about the chemistry for these fields are
not detailed on the mills supply history sheets. Nippon Steel in Hikari City, Japan, claim to be
producing a lot more sour service DNV linepipe with 250 tonnes of sour linepipe produced per month
by this mill (20% of production). Problems such as preferential corrosion of the weld seam under high
CO2 and sour service conditions are no longer a problem due to the improved homogeneity achieved
with modern linepipe welding machines, this is demonstrated in the laboratory report from Nippon
Steel in Appendix 5. Modern mill NDT techniques utilise automatic ultrasonic testing to inspect the
strip edges prior to welding, the full pipe body and then the weld seam to ensure the weld seam is
defect free. This level of NDT is unprecedented for any other linepipe form. Oil has been long
transported subsea in HFW pipes. When HFW pipe is used to and from platforms it is a normally
accepted practice to make the risers out of seamless linepipe in place of the HFW.
With the cost of HFW in 2007 currently at $US950/tonne and seamless linepipe currently at $US2200US$2500/tonne the use of HFW is increasing within the oil and gas industry. If cost and schedule
become priority drivers for the Hydra project then it is recommended that further investigation be
carried out on the viability of HFW pipe in sour multiphase service by surveying the various linepipe
mills supplying DNV OS F101 compliant HFW linepipe. Until such further investigation can be
undertaken to demonstrate the suitability of HFW for the xx project then it is recommended that the
FEED proceeds on the basis of seamless line pipe throughout.
9.1.2
Pipelines & Risers - Export
The pipelines and risers for the xx and xx export pipelines to xxshall be designed and manufactured in
accordance with DNV OS F101. The linepipe shall be rated for sour service even though the H 2S
partial pressure is just below the critical level defined in ISO 15156 / NACE MR0175. The linepipe will
Page 66
require a 6mm corrosion allowance based on the conservative corrosion modelling (refer to Appendix
2) results and not taking credit for potential benefit of pH buffering from any produced water that may
be present in the production stream. This corrosion allowance is based on a corrosion inhibitor
efficiency of 99% and availability of 98%, which is in line with the production up time specified in the
Hydra Design Basis for equipment availability [Ref 1. Section 7.4.2]. The choice of process of
manufacture is at xx discretion, the DNV OS F101 designations are summarised below.
DNV OS F101 SMLS Grade 415 ISD
DNV OS F101 HFW Grade 415 ISD.
According to the designations above the linepipe has the following supplementary requirements:
SMLS, seamless linepipe;
HFW, High Frequency Welded linepipe;
Grade 415, 415MPa SMYS or equivalent to API 5L X60;
Level 1 NDT, required for gaseous and multiphase service;
Sour service supplementary requirement (S);
Enhanced dimensional properties (D), to assist with constructability.
The riser splash zone shall require protection over and above that for the submerged riser and the
topside piping due to the wet, chloride aerated environment.
An external corrosion allowance for the atmospheric and splash zones based on the following rule of
thumb:
Riser corrosion allowance = 2mm+1mm [(T-20)/10]
So for the xx and xx risers at 110C, the extra corrosion allowance would require to be 11mm. This
corrosion allowance is impractical and conventional polychloroprene (neoprene) coatings are not
suitable for operating continuously at high temperatures as they will age harden and fracture.
Therefore it is proposed to install a Monel clad steel sleeve in the riser splash zone using a carbon
steel sleeve between the Monel and the riser pipe, the carbon steel sleeve in effect becomes the
corrosion allowance. It is proposed that the sleeve be fabricated from a 12mm rolled plate and the
Monel cladding be 3mm.
For the risers at xx, the external corrosion allowance for the XX riser can be reduced due to the lower
arrival temperature of 38C at XX and 76C at XX. However, given the importance of these risers and
the severity of the corrosion environment it is recommended to duplicate these Monel clad sleeves at
all production risers.
XXEPIL have directed that the pipeline and riser material wall thickness should be identical.
9.1.3
Pipelines & Risers Gas Lift
The pipelines and risers for the xx gas lift pipelines to xx and xx shall be designed and manufactured
in accordance with DNV OS F101. The linepipe shall be rated for sour service. . The corrosion
modelling (refer to Appendix 2) results have over-estimated the corrosion rate as the model assumes
the gas is saturated, which is not the case. In order to temper the over-estimation of the corrosion
allowance a value for the amount of time the pipeline will be exposed to wet gas was derived and
used to proportion the corrosion rate down. In this instance it was assumed that the pipeline will be
exposed to up to 60 days per year (16%) of off-specification gas and hence will be exposed to
Page 67
corrosive conditions. The corrosion allowance was derived as 16% of the calculated corrosion rate
assuming that the corrosion inhibitor injection system is 100% available for the short durations the gas
is off-specification. The model for the gas pipeline does not assume the gas lift pipeline will be
operated when the gas is off-specification and the inhibitor system is offline, as this would be
considered double jeopardy. It is recommended that if the inhibition is offline and the gas dehydration
train also goes down, then production is shut in until either unit is brought back on line. The corrosion
allowance derived for the gas lift line is 3.0mm based on the outlet conditions. The pipeline will
transport for most of the time with dehydrated sales gas. In case of upsets it is recommended that the
pipeline be pigged to clear any water out of low lying areas in the pipeline. For a small diameter gas
pipeline it is recommended that the pipe be manufactured using the seamless process.
DNV OS F101 SMLS Grade 415 ISD (Double Random Length); or,
DNV OS F101 Grade 450 ISPD Coiled Line Pipe with DNV OS F101 SML Grade 415 ISD for
the risers.
According to the designations above the linepipe has the following supplementary requirements:
SMLS, seamless linepipe;
Grade 415, 415 MPa SMYS or equivalent to API 5l X60;
Level 1 NDT, required for gaseous and multiphase service;
Sour service supplementary requirement (S);
Enhanced dimensional properties (D), to assist with constructability;
Line pipe exposed to plastic deformation exceeding 2% supplementary requirement (P)
required for Coiled Line Pipe.
The gas lift risers at xx and xxwill operate continuously at temperatures less than 40C, and a
splashzone coating provided by a high quality polychloroprene will be sufficient. As for the export
pipeline, the ID of the riser should be matched to that of the pipeline to ensure free passage of pigs.
For the gas lift pipelines it may be required to procure a small order of riser pipe (DRL) if pipeline is
procured as coiled line pipe. In this case the riser procurement will be less than 50 tonnes and
according to DNV OS F101 the linepipe mill is not required to conduct manufacturing procedure
qualification testing. This is acceptable provided the mill performs Charpy V-notch impact testing over
a range of temperatures form +20C to -60C to show that the risers have sufficient low temperature
toughness at the minimum design temperature for the pipeline.
9.1.4
Pipeline Fittings
Pipeline fittings shall be manufactured in accordance with DNV OS F101 Section 7 and shall be
forged in accordance with the requirements of ASTM A694. Any subsea flanges shall have a ring
groove type gasket. The gasket shall be manufactured from Inconel 625 and the ring groove shall be
weld overlayed with Inconel 625.
9.1.5
Chemical Injection line (Flat-Pack)
The chemical injection system will be supplied from the xx using either a flat pack or conventional
umbilical. The flat pack umbilical is a simple four steel hose umbilical with a polymeric outer sheath.
It is recommended that the flat pack be made up using continuous 316L tubing and a polypropylene
outer sheath, if the vendor cannot guarantee the performance or quality of the external coating of the
Page 68
tubing over the design life then consider duplex stainless steel. The umbilical vendor shall warrant
the design of the flat-pack, including material performance.
9.1.6
Clamping and Strapping materials
The Flat-Pack may be piggybacked from xxto xx and xx on the gas lift pipeline. If this is done, then
the Flat-Pack should be strapped using a compliant, yet tough strapping material. A metallic strap is
not recommended if the strap is to contact the Flat-Pack outer sheath as the metallic strap can cut
into the umbilical outer sheath. Other operators installing piggyback lines have used Kevlar tm 4 straps
to secure the pipes together. The Kevlar is very strong and tends not to have the sharp edges that
metallic straps create. Kevlar strapping is more expensive than metallic banding.
9.2
Coating Systems
9.2.1
Pipeline Anti-Corrosion Coating System
FBE coatings become increasingly hydroscopic with increase in operating temperature this leads to
disbondment of the coating from the steel substrate. It is for this reason that FBE applied to
submarine pipelines is limited to a maximum continuous operating temperature somewhat lower than
that specified in dry conditions.
The maximum operating temperature of FBE in submersed wet service is some 20 degree lower than
for dry service; it is not recommended to consider FBE coatings for subsea service at continuous
operating temperatures in excess of 90C.
As the production pipeline operates at a temperature over 100C then the practical choice of linepipe
coating recommended is a 2mm 3-layer polypropylene coating.
The temperature profiles generated during the flow assurance studies show that the production line
temperature will not drop below 90C for at least 3000m from the xxriser base and 2000m from the
XX riser base. Anti- slip bands may be necessary to be fixed to the polypropylene coating to stop the
concrete weight coating from slipping off the pipe during installation.
For the low temperature gas lift pipelines (maximum continuous operating temperature~40C) the
recommended coatings are:
2mm 3LPE for coiled line pipe installation
0.5mm FBE for risers and double random length line pipe
The gas lift pipeline will not be concrete weight coated.
9.2.2
Riser Coating Systems
ATMOSPHERIC ZONE
The atmospheric zone above the riser hang-off flange shall be coated using an Ultra High Build
epoxy. The coating shall be applied to a DFT of 1000-1500m and shall be applied to a Class 2.5
(near white metal) blast cleaned surface with a 75-100 m angular profile. The atmospheric zone
between the top of the splash zone coating / sheath system to the (and including) the riser hang-off
flange shall be coated using a flame sprayed polypropylene. The flame sprayed coating shall be
2500m thick and be free from porosity (test using a holiday tester). The flame spraying procedure
4
Kevlar is a registered tradename of the DuPont organisation.
Page 69
shall be qualified and tested prior to application to the xx and xx risers. The Coating Procedure
Qualification shall be witness by xx or its representative.
S P L AS H Z O N E
Riser splash zones are typically coated with Polychloroprene rubber for temperatures up to 90C and
for temperatures above this, then Monel 400 (UNS N04400 cladding or sheaths and used). For xxand
xx where temperature of the export riser is 110C, then Monel 400 is the best choice for splash zone
protection. If external Monel cladding is used the minimum thickness shall be 3mm clad over carbon
steel rolled plate of 12mm thickness. The bottom end (500mm) of the Monel sheath shall be shop
coated using the same coating system as the submerged zone coating to minimize the potential for
galvanic attack. Similarly, the top section. shall be coated for a distance of 300mm with the
atmospheric zone coating to avoid galvanic attack.
For the gas lift risers it is recommended that Polychloroprene rubber be used for the riser splash zone
protection.
SUBMERGED ZONE
The submerged zone shall be coated in accordance with the coating used for the main pipeline
coating.
0.5mm FBE for gas lift risers
2.0mm for the 3-layer polypropylene risers.
9.3
Cathodic Protection
9.3.1
Sacrificial Anode System
The pipeline systems shall be protected using sacrificial anodes. The anodes shall be of the bracelet
type made of Galvanum III. The design of the amount and position of bracelet anodes shall be in
accordance with DNV RP B401; this is more conservative than DNV RP F103 [Ref 12] but will provide
greater protection should coating application not be in strict accordance with DNV RP F106, which RP
F103 is dependent.
9.3.2
Corrosion Protection System Isolation MIJs
The subsea pipeline and riser shall be electrically isolated from the platform jacket CP system and the
topside piping. The insulation should be made using high integrity insulation joint such as a
monolithic isolation joint. Care shall be taken to ensure that the MIJ is not short circuited by pipe
supports or through contact between the riser and the jacket clamps. Riser clamps shall be lined with
Neoprene rubber to ensure the riser is electrically isolated from the jacket CP system.
Insulating gaskets sets shall be used to isolate the duplex stainless steel flowlines from the production
and test headers. Any drain or vent connections made to the duplex stainless steel flowlines shall
also be electrically insulated using insulating gasket kits.
Page 70
10.
ASSET INTEGRITY M AN AGEMENT
10.1
General Philosophy
There should be an integrity management plan developed for the xx Platform based and subsea
assets. This integrity management plan should aim to provide the following outcomes:
Provide a documented and auditable system that enables owner to measure and manage the
on-going risk of the xx and xx platforms and intrafield pipelines;
Ensure that the environmental and safety integrity of the system is maintained by detecting any
deterioration before leakage of production fluids;
Ensure that the assets remain fit for purpose;
Ensure that the assets function in accordance with the legislative approvals for the
development;
To ensure the assets continue to meet the production requirements of the development;
To prevent breakdowns and unplanned outages;
To enable corrective action to be carried out in a timely manner and to maintain the systems
failure risks to As Low as Reasonably Possible (ALARP).
These outcomes should be obtained by documenting a system that considers all of the corrosion
activities as part of the system operation. The following activities are considered core corrosion
engineering activities, which form a part of the Integrity Management Plan:
Corrosion mitigation (refer to Sections 8 and 9);
Corrosion monitoring (refer to Section 11);
Corrosion data collection and assessment (refer to Section 12).
This system is best documented prior to the commissioning of the system and should incorporate
input from both the corrosion / inspection engineer as well as operations staff who will be responsible
for a lot of the data gathering and corrosion mitigation equipment operation.
10.2
Recommended Routine Maintenance Activities
Planned/routine activities are defined as those activities that have defined intervals and locations in
which they are carried out. This section details the type of activities that shall be included as part of
the Panna integrity management system.
The type of activities, locations and intervals in which they are conducted can vary depending on the
following:
Variation in operating conditions;
The detection of anomalies/failures;
Advent of new technology.
It is recommended that xxL prepare a risk based inspection plan to assist in the preparation of a
traceable and auditable platform and pipeline management plan. Such a plan shall document and
justify activities, locations and return periods required to manage on-going risk.
Page 71
It is the responsibility of the Corrosion and/or Inspection Engineer to have the most up to date
knowledge of the process, corrosion mechanisms and monitoring technologies available and
references in the xx and xx integrity management system.
10.3
Possible Unplanned Activities
Unplanned or non-routine activities relate to items such as corrosion failures (i.e. leaks, ruptures or
loss of facilities/utilities), and unplanned or opportunistic inspections (such as having an ROV
available during subsea interventions). While it is impossible to provide long term plans for these
situations, it is possible to have in place procedures, or response plans, that enable the capture and
assessment of inspection results arising from these activities.
Opportunistic inspections may result from an anomaly generated from other inspections or monitoring
activities. Information from these activities should be processed in the same manner as the routine
inspections, including the use of the data as input into the corrosion risk assessment.
Page 72
11.
CORROSION MONITORING
11.1
Aim
The aim of corrosion monitoring is to ensure that the design life will not be adversely compromised
during service and to ensure the safe and economic operating life of a facility. The monitoring may
also be used to optimise inspection intervals as part of a risk-based inspection (RBI) programme and
to detect changes in corrosivity that will invalidate inspection periods or endanger the plant.
The primary philosophy is that corrosion monitoring will be specified when:
1. Changes in the operating environment can lead to significant increase in the corrosivity of the
environment towards carbon steel, either with or without corrosion inhibitors.
2. Loss of corrosion inhibition will lead to rapid metal loss.
3. The outcome of corrosion monitoring can lead to timely re-assessment and adjustment of the
system of corrosion management.
4. Monitoring could lead to optimisation of inhibitor dosing.
The functional requirement of the corrosion monitoring system is that it shall detect and quantify
trends in the corrosivity of the fluids and shall do so within a time frame short enough to enable the
Operator to instigate or adjust corrosion mitigation measures before significant metal loss has
occurred.
11.2
Monitoring and Testing Facilities
Systems potentially at risk of corrosion will require corrosion monitoring facilities, such as corrosion
coupons or corrosion probes. Where monitoring is required, two access fittings should be installed for
the purpose of monitoring with electrical resistance (ER) probes and corrosion coupons. The probes
and coupons shall be of a type and dimension such that the sensitive element shall be in the water
phase.
The following points shall also be taken into consideration:
Some systems will also need sampling points for chemical analysis.
Systems at risk of bacteria contamination will require bio-probes and/or sample points.
Other testing facilities relevant to corrosion and integrity management will be necessary in the
appropriate system.
All carbon steel systems will require Non Destructive Testing at some point in their service life.
Some systems will require routine (e.g. monthly or quarterly) NDT at Sentinel points.
All equipment should be designed and located considering the requirement for corrosionmonitoring technician and/or inspector access.
All locations for corrosion monitoring and sampling should be clearly marked on P&IDs and
Isometric drawings. Locations for Key Point UT at Sentinel points should be marked on
Isometric drawings.
Page 73
11.3
Monitoring Methods
Corrosion monitoring should not rely on just one method and should use any method that enables an
operator to estimate or measure the corrosion rate occurring in service of an item of plant, or the
corrosivity of a process stream. The main methods fall into the following categories:
1. On-line corrosion monitoring techniques to assess corrosion rates and changes in corrosivity
with time, such as electrical resistance probes, electrochemical probes, field signature
monitoring (FSM), flexible ultrasonic transducer mats (Fleximats), bio-probes and corrosion
coupons.
2. Analysis of process streams for pressure, temperature, production rates, fluid chemistry, CO 2
and H2S gas concentrations, water content, dew point, dissolved oxygen, pH, corrosion
product (Fe and/or Mn) concentrations, bio-activity, chemical treatments (e.g. dose rate,
frequency and residual levels).
Monitoring and inspection are overlapping tasks that need to be put in place to confirm:
1. Actual versus predicted corrosion rates
2. Process parameters are within design limits
3. Correct operation of control measures
4. Current condition of equipment
Monitoring encompasses the ongoing monitoring of the corrosion process and the measures taken to
control it, whereas inspection provides mechanical integrity assurance and datum points against
which corrosion monitoring can be related, calibrated and quantified.
Inspection techniques to assess changes in wall thickness, calibrate on-line corrosion monitoring and
detect material defects, pitting and cracking, include ultrasonics (UT), radiography, thermography,
visual examination, dye-penetrant, eddy current and magnetic particle inspection. Detailing of
inspection requirements is outside the scope of this document.
11.4
Corrosion Monitoring Techniques and Equipment
The following monitoring techniques shall be used. Where corrosion monitoring is to be performed at
an identified location, access fittings should be provided for the use of both an ER Probe and a
corrosion coupon.
11.4.1 Electrical Resistance (ER) Probes

ER probes shall be used in hydrocarbon process environments such as gas and condensate
lines.
Flush mounted ER probes mounted at the 6 oclock position may be used in sweet (i.e. nonH2S containing) gas/oil/water environments.
Tubular ER probes shall be used if space access prevents the location of access fittings for
flush mounted probes at the 6 oclock position (or where there are concerns in produced water
lines that iron sulphide deposits may cause bridging and crevice corrosion). Where tubular ER
probes are used, particularly for gas circuits and if mounted at the 12 oclock position, they shall
be of sufficient length that the sensitive element is positioned at 5mm above the bottom of the
line.
Page 74
Probes shall be of the retractable type, with elements manufactured from steel of the same type
as the piping system being monitored, rated for the pressure of the system being monitored.
The probes shall be supplied complete with a probe adaptor to make cable connection to the
probe.
For each probe supplied an identical probe shall be supplied as a spare. All spare elements
shall be properly protected in VCI paper to eliminate corrosion or contamination prior to use.
Remote Data Collectors (RDCs) should be used in remote locations and/or in critical systems
where loss of corrosion inhibition or process control could result in rapid metal loss.
Measurement frequencies should be set initially at 60-minute intervals, but this can be
increased or decreased (down to 5-15 minutes if required) depending on the service
experience. For highly critical systems, such as at the inlet to the MTA-TCPP pipeline, the use
of data transmitters linked to the TCPP control room should be considered in order to provide
audible and visual alarms and initiate corrective action if preset KPIs are exceeded.
11.4.2 Coupons
Coupons should be installed wherever ER probes are used to provide supplementary
information, particularly for corrosion morphology (e.g. pitting, erosion/erosion-corrosion).
Coupons should be removed at intervals of 1 to 3 months depending on the corrosivity of the
environment and or the likelihood of loss of inhibition or process control.
Coupons may be strip type, ladder type or flush disc type.
Where strip type coupons are used in access fittings mounted at the 12 oclock position, the
length of the coupon and coupon holder should be ordered such that tip of the coupon is held
approximately 5mm from the pipe bottom.
Each coupon holder shall be a retractable type and allow positioning of the coupons as
required to obtain the optimum position at the bottom of the pipe where the corrosive aqueous
phase is most likely. Coupon holders should be supplied without coupons. Strip and ladder
type coupon holders shall be capable of holding twin coupons.
Each coupon shall be supplied pre-weighed with a serial number and the weight clearly shown.
For each coupon holder, 4 (four) pairs of coupons should be supplied to provide a minimum of
one years monitoring. Coupons should be supplied individually wrapped and protected.
Industry accepted standards for the use of coupons covering coupon preparation, cleaning and
inspection, and reporting of information include:
a. ASTM G4
Conducting Corrosion Coupon Tests in Plant

Equipment
b. ASTM G46
Practice for Examination and Evaluation of Pitting

Corrosion
c.
Practice for Preparation of Metallurgical Specimens
ASTM G81
d. ASTM G31
Laboratory Immersion corrosion Testing of Metals

(covers cleaning of coupons)
e. NACE RP 0775
Preparation and Installation of Corrosion Coupons

and Interpretation of Test Data in Oilfield Operations
Page 75
11.4.3 Bacterial Monitoring and Bioprobes

In order to detect and quantify the propensity for microbially induced corrosion (MIC) it is necessary to
quantify both the planktonic (mobile) and sessile (surface adhering) bacteria in accordance with API
RP 38. Bacterial monitoring using bioprobes will not be required for the xx and xx pipelines, but
planktonic bacteria should be assessed periodically (e.g. 6 monthly) by removing a sample from the
respective pig receivers on xx after pigging operations into a sealed standard serial dilution kit at the
sample site.
11.5
Process Stream Monitoring
Process stream monitoring for the production system should comprise:

Flow rate (gas/condensate)
Temperature and pressure
CO2 in the gas phase
Water chemistry and iron/manganese counts in the water from the pipelines
Solids production
Production chemical additions (rate and type) and periodic measurement of inhibitor residuals
Planktonic and sessile bacteria monitoring in the water from the pipelines
Corrosion product examination and bacteria analysis after cleaning pig runs
Process stream monitoring for dehydrated gas streams systems should also comprise testing
of the water dew-point of the gas.
11.6
Corrosion Monitoring Instrumentation
Where specified, corrosion measurements for ER probes should be taken by either hand-held
portable instruments or fixed instrumentation, as follows:
Portable instruments used to take periodic readings for temporary storage and download to a
personal computer or laptop computer. This may be appropriate for ER probes located at the
xxplatform where there will be sufficient staff to perform the required duties, but fixed
instruments would be more appropriate for an unmanned wellhead platform such as xand xxP.
Fixed instruments (Data Collection Units) for continuous monitoring at regular intervals and the
storage of the corrosion data to removable memory module for subsequent download to a
personal computer or laptop computer. This is highly recommended for an unmanned offshore
platform such as xx and xx
Page 76
12.
CORROSION D ATA M AN AGEMENT AND ASSESSMENT
12.1
General Requirements
Data management is an important part of the corrosion management system. The overall purpose is
to maintain records of relevant data for analysis purposes.
12.2
Data Collection Frequency
Data collection will be dependent on the inspection program developed for the Panna and Mukta
assets and the sampling rate for the process conditions and corrosion monitors. It is recommended
that this data be stored on a database that interfaces with the plant control systems for operational
data. Corrosion data should be managed as part of the overall pipeline integrity management system.
12.3
Data Storage
Data storage shall be controlled in accordance with the quality assurance requirements of the
operation and the relevant legislative requirements. Most data will be electronic and therefore should
be backed-up as part of the routine disaster recovery system for the operations computer system. A
database is recommended for collating inspection and process data as well as controlling hard copy
inspection records, photographs and reports.
12.4
Data Assessment
Data assessment should include the review of process trends and corrosion monitoring equipment
results. In addition to the operational data, an assessment of the field inspection and maintenance
performance with regard to the inhibitor injection system availability should also be carried out. The
trends and instantaneous results should be reviewed against a benchmark or KPI for the asset.
Where adverse trends are starting to form then corrective action needs to be put into place by the
field corrosion/inspection engineer in conjunction with other disciplines involved in operating the
assets as appropriate. Procedures should be developed to ensure standard methods are employed
that are industry based and ensure repeatability.
12.5
Corrosion Reporting
Corrosion reporting shall include all the latest data and comparisons of this data with the historical
data. The report should detail the current operational conditions if different from normal, if there are
any corrective actions required and follow-up to corrective actions made previously. A standard report
format is recommended to make the report easier to read by the various end users and to allow
repeatability and comparison of previous data. The report should have a section for conclusions and
recommendations
Page 77
13.
CORROSION PERFORM ANCE TR ACKING
13.1
General Requirements
It is important to be able to monitor and evaluate the performance of the corrosion management
system. The methodology below presents one possible evaluation standard.
The process of performance measurement includes consideration of:
Setting performance measures (key performance indicators (KPIs));
Frequency; and
Corrective Actions.
13.2
Key Performance Indicators
KPIs take into account five key performance areas, these being:
Health, Safety and Environment KPIs.
Operational KPIs.
Budget KPIs.
People KPIs.
Transition KPIs.
The specific KPIs are unique to each process, and are outside the scope of this document.
In particular, the following KPIs are recommended:
Chemical corrosion inhibitor system availability, target 98%.
Off-specification gas lift gas (i.e. wet), target < 60 days per annum.
Scale inhibitor system availability, target 99%
Sand detection measurement and system availability, target 99%.
Pipeline corrosion monitoring availability and temperature and corrosion rate correlations to
predictions, target 99%.
Pig run plan performance, planning and analysis, target plan completion including analysis
within 4 weeks of planned activity.
Process sample monitoring and analysis (including gas, liquid and solids sample analysis),
target analysis and reporting within 1 week of planned activity.
Typically, the KPIs shall be used to report against during the quarterly and annual reporting to
Management.
13.3
Corrective and Preventative Action
Substandard performance shall be investigated and reported if improvements are to be made and
mistakes eliminated. It shall follow the formal Technical Change Management processes.
Page 78
Where KPIs have not been achieved it is important that the cause(s) are identified and that any
necessary measures to ensure that the system can be improved are implemented. It is the constant
re-examination and incorporation of lessons learnt that leads to improvement of any integrity
management system.
Page 79
14.
REFERENCES
Page 80
Appendix 1 Temperature and Pressure Profiles (1 Page)
Appendix
Appendix 2 Corrosion Model Results (2 x A3 Pages)
Appendix
Appendix 3 List of Uninhibited Events (2 Pages)
Appendix
UNINHIBITED EVENTS
A listing of potential uninhibited events that should be considered is given in the table below. This is
not an exhaustive list; other event may occur in specific installations.
Table 1:
Uninhibited Events
Event
Detection system
Control system
options
Incorrect inhibitor arrives at site:
Physical tests on
inhibitor when it
arrives on site.
QC system on
inhibitor supply
Inhibitor formulation changed by supplier

(or their suppliers)
Supply mix up from supply base
Comment/
Impact
Probably detectable
by inhibitor residuals
Interference in supply
Inhibitor runs out at the wellsite due to
inadequate stock levels on site or supply
base
Monitoring amounts
used and cross
checking
Stock control
system
KPIs
Automatic level
gauges
Tie in to control
room alarms
Wrong inhibitor loaded into tank by

operators
Probably detectable
by inhibitor residuals
Training and
Procedures
KPIs
Inhibitor tank allowed to run empty
Inhibitor returns
Training and
Procedures
KPIs
Tie in to control
room alarms
Inhibitor incorrectly diluted
Monitoring amounts
used and cross
checking
Training and
Procedures
Inhibitor Pump Breakdown
Inhibitor returns
Manual
checking
Flowmeters
Power failure to pump, with production

still continuing
Pump could be
alarmed
Manual
checking
Inhibitor returns
Flowmeters
Page 1
Backup pump
options (none,
available in store,
available on site,
automatically
switched over)
Final option is to
shut down
production
Event
Detection system
Control system
options
Comment/
Impact
Power failure to pump, with which also

stops production
Pump could be
alarmed
Manual
checking
May have little or

no impact
(depends on
corrosion rate and
inhibitor
persistency in
non-flowing
conditions)
Flowmeters
Inhibitor delivery from tank to injection

location fails (line blockage, failure)
Inhibitor returns
Flowmeters
Inhibitor selection
related.
Use portafeed
type tanks
(cleaned
regularly), rather
than permanent
tanks which may
build up deposits
Injection rate incorrectly set
Monitoring amounts
used and cross
checking
Training and
Procedures
Operating conditions change, requiring a

change of injection rate which is not
carried out
Training and
Procedures
Pigging required for distribution of

inhibitor and not carried out.
Training and
Procedures
Oxygen allowed to enter the system;

corrosion inhibitor ineffective against
Oxygen corrosion
Bacteria allowed to enter the system;
corrosion inhibitor ineffective against
Microbiologically induced corrosion
KPI
Cultures from water

samples
Operating environment changes and

inhibitor becomes totally ineffective
KPI
replacement
inhibitor has to be
selected
Page 2
Appendix 4 Chemical Datasheets (5 pages)
Appendix
Appendix 5 Laboratory Test of HFW Seam Corrosion

Susceptibility (1 page)
Appendix

A Typical Material Selection Report

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CONTENTS

Codes and Standards........................................................................................................ 4

Gas Lift Composition...........................................................................................11

Produced Water Analysis....................................................................................12

Pressures and Temperatures.......................................................................................... 13

Corrosion Model Cases................................................................................................... 14

Gas Lift (3) Pipeline........................................................................................... 14

Gas Lift (4) Pipeline........................................................................................... 16

Gas Lift Header and Flowlines............................................................................18

Production Flowlines (6 off) and Test Headers....................................................19

Export Pipelines (Seamless Linepipe, Grade 415 MPa).....................................23

Export Pipelines (HFI Linepipe, Grade 415MPa)................................................25

Produced Water Effect Modelling........................................................................26

Potential for Corrosion..................................................................................................... 28

Corrosion Mechanisms and Considerations.......................................................28

Top of Line Corrosion.......................................................................................... 29

Sulphide Stress Corrosion Cracking...................................................................29

Hydrogen Induced Stress Cracking....................................................................30

Chloride Stress Corrosion Cracking....................................................................31

Subsea External Corrosion.................................................................................32

4.1.10 Topside Atmospheric Corrosion..........................................................................32

Selection of a Corrosion Model.......................................................................................35

Limitations of the Corrosion Model.....................................................................37

Prediction of Top of Line Corrosion.....................................................................37

Mechanical Material Selection......................................................................................... 38

Brittle Facture and Embrittlement.......................................................................38

CORROSIVITY ASSESSMENT AND CORROSION MITIGATION..................................40

Corrosivity Assessment Results......................................................................................40

Corrosion Inhibition Philosophy.......................................................................................43

Chemical Injection System Design.....................................................................45

Operation and Reliability.....................................................................................48

Intelligent Inspection Pigging........................................................................................... 50

Intelligent Pigging Requirements........................................................................50

SPECIFIC MATERIAL APPLICATIONS...........................................................................52

Use of Corrosion Resistant Alloys...................................................................................52

Grade 304/304L Austenitic Stainless Steels.......................................................52

Grade 316/316L Austenitic Stainless Steels.......................................................52

6Mo Super-Austenitic 254 SMO (UNS S31254).................................................54

Duplex Stainless Steel........................................................................................ 54

Selection of CRA for Pipe and Vessels...............................................................56

Use of Glass Reinforced Plastic (GRP)...........................................................................56

GRP Tanks and Vessels.....................................................................................57

Selection of Elastomeric Seals........................................................................................ 61

MATERIALS SELECTION AND XX PLATFORM...........................................................63

Wellhead Equipment (Including Chokes and Flowline Isolation Valves)..........................63

Production Header, Pig Launcher and Last Valve Off.........................................69

Fuel Gas Systems.............................................................................................. 71

Vent and Closed Drains and Vent Scrubber........................................................73

Chemical Injection Package................................................................................74

CCVT Power Generation....................................................................................74

Hydraulic Piping Systems...................................................................................74

Wash Down Water System.................................................................................77

MATERIAL SELECTION - PIPELINES............................................................................78

Materials and Corrosion Allowance.................................................................................78

Linepipe Manufacturing Processes.....................................................................78

Pipelines & Risers - Export.................................................................................79

Pipelines & Risers Gas Lift..............................................................................80

Chemical Injection line (Flat-Pack).....................................................................81

Clamping and Strapping materials......................................................................81

Pipeline Anti-Corrosion Coating System.............................................................82

Riser Coating Systems.......................................................................................82

Sacrificial Anode System....................................................................................83

Corrosion Protection System Isolation MIJs....................................................83

ASSET INTEGRITY MANAGEMENT..............................................................................85