Documente Academic
Documente Profesional
Documente Cultură
net/publication/325857475
CITATIONS READS
0 557
2 authors, including:
Edgar Iyasele
Michael Okpara University of Agriculture, Umudike
7 PUBLICATIONS 0 CITATIONS
SEE PROFILE
Some of the authors of this publication are also working on these related projects:
Finite Element Analysis of the Mechanical Behaviour of Alumina Silicon Carbide Particulate Reinforced Cast Aluminum Alloy Composite View project
All content following this page was uploaded by Edgar Iyasele on 19 June 2018.
ABSTRACT
The problem of carbon dioxide (CO2) corrosion is of primary concern in Nigeria’s oil and gas industry. The work aimed to develop
a Visual Basic Algorithm, implement the algorithm, simulate and validate it against operating field data.
Existing models for CO2 corrosion prediction were accessed. Modification of one of the models; the NORSOK M-506 model was
carried out to suit the Nigerian light crude oil. The entire model was implemented using Visual Basic to create an algorithm. With
the developed computer algorithm, simulation and prediction of CO2 corrosion rate, the analysis of the effects of various parameters
were carried out using the operating field data in the Nigerian oil and gas industry.
The effects of various parameters (e.g. temperature) on corrosion rate along the pipeline length were analyzed using the developed
algorithm. It was observed that the temperature gradually decreased as the oil flows through the pipeline. Other results obtained
were in agreement with similar works done in this field of study. The developed computer algorithm also predicted corrosion rates
that are in agreement with measured corrosion rates from operating field data. In addition, the developed algorithm prediction had
a good agreement with HYDROCOR. It had a standard error (SE) of 0.18. And at 95% confidence level, confidence interval (CI)
of the model was between 0.70 and 1.41 mm/year mean corrosion rate predicted.
1.0 INTRODUCTION Rajput (2010) reported that many corrosion phenomena are
The increasing cost of pipelines failures due to corrosion in essentially electrochemical (wet) and chemical (dry)
the oil and gas industry has increased interest in corrosion corrosion.
problems and their solutions. Materials reliability is Pipelines transporting crude oil containing components such
becoming ever more important in our society, particularly in as CO2 and H2S have suffered internal corrosion due to the
view of the liability issues that develop when reliability is presence of these gases dissolved in water. One of the most
not assured, safety is compromised, and failure occurs prevalent internal corrosion problems in Nigerian oil and gas
(Revie and Uhlig, 2008). industry is carbon dioxide corrosion (also called sweet
The problem of CO2 corrosion is the primary concern in corrosion). The use of carbon steel for pipework and
Nigeria’s oil and gas industry. Corrosion constitutes a equipment with chemical inhibitors still tends to be
leading cause of pipeline failure and a main component of favourable choice for the control of corrosion, compared to
the operating and maintenance costs of oil and gas changing materials to corrosion resistant alloys
industries (Oyatogun et al., 2011). Revie and Uhlig (2008) (CRAs).Carbon steel is by far the most important alloy used
defined corrosion as the destructive attack of a metal by in the petroleum industry and it accounts for over 98% of the
chemical or electrochemical reaction with its environment. construction material, especially oil and gas transportation
Rajput (2010) stated that corrosion usually occurs because pipelines (Bodude et al., 2012).
the general tendency of metals is to return to their native The use of computational software by engineers for the
form, which results in the lowering of their free energy and analysis of the effect of CO2 corrosion on pipeline materials
attainment of a more thermodynamically stable state. both at the design and operational stages has been reported
Dynamic and static mechanical equipment like pipelines, (Guidelines for Prediction of CO2 Corrosion in Oil and Gas
vessels, tanks, turbines and so forth have been periodically Production Systems, 2009). However, developed computer
subjected to degradation and failure due to corrosion (Ossai, algorithms with the Nigerian content are scarce. Hence, this
2012). study.
Notwithstanding the many years over which university, The specific objectives of this research are to develop the
college, and continuing education courses in corrosion have algorithms for CO2 corrosion rate prediction; implement the
been available, high-profile corrosion failures continue to algorithm developed; and simulate and validate it against
take place (Revie and Uhlig, 2008). operating field data. This research work is expected to
develop a Visual Basic algorithm that will predict CO2
corrosion rate for the Nigerian oil and gas industry.
*Corresponding Author: e-mail: edgaromons2003@yahoo.com Tel:
+234-8135359855 2.0 MATERIALS AND METHODS
There are different forms of corrosion but it is rare that a
corroding structure or component will suffer from only one.
UJET VOL. 2, NO. 2, DEC 2016 www.ujetmouau.com Page 170
UMUDIKE JOURNAL OF ENGINEERING AND TECHNOLOGY (UJET), VOL. 2, NO. 2, DEC 2016 PAGE 170 - 181
The materials used for this work include a HP Laptop The Temperature Distribution Model:
installed with a Visual Basic program and corrosion rate data 𝐓𝐞(𝐱) = 𝐓𝐬 + (𝐓𝐢 – 𝐓𝐬) ×
collected from a multi-national company in Nigeria. 𝐗
𝐓𝐞(𝐋)– 𝐓𝐬 𝐋
The NORSOK STANDARD M-506 corrosion model shown ( (𝐓𝐢 ) (2.2)
– 𝐓𝐬)
in equation (2.1) was obtained from literature (NORSOK
STANDARD M-506, 2005) (CO2 Corrosion Rate The Fugacity Model:
Calculation Model, Rev. 2, 2005).
𝐂𝐎𝟐 = 𝐚 × 𝐏𝐂𝐎𝟐
𝐂𝐊 𝒕 = 𝐊 𝒕 × (𝐜𝐨𝟐)𝟎.𝟔𝟐 ×
𝐒 (𝟎.𝟏𝟒𝟔+𝟎.𝟎𝟑𝟐𝟒𝐥𝐨𝐠(𝐜𝐨𝟐))
( ) × (𝐩𝐇)t (2.1) 𝐚 = 𝟏𝟎(𝐏 × (𝟎.𝟎𝟎𝟑𝟏 –
𝟏.𝟒
𝐓
))
𝐟𝐨𝐫 𝐏 𝟐𝟓𝟎 𝐛𝐚𝐫 (2.3)
𝟏𝟗
The wall shear stress (S) model was modified. The following
𝟏.𝟒
assumptions were made in developing the wall shear stress 𝐚 = 𝟏𝟎(𝟐𝟓𝟎 × (𝟎.𝟎𝟎𝟑𝟏 – 𝐓 )) 𝐟𝐨𝐫 𝐏 > 250 𝑏𝑎𝑟 (2.4)
model: we assumed only the case of stratified and dispersed
flow of oil-water in the pipeline, the three – layer flow model 2.1 Development of the algorithm:
for horizontal oil-water stratified flow was considered, etc. Figures 1 to 10 below shows the developed algorithms:
PrivateSub Button7_Click(ByVal sender As System.Object, ByVal e As System.EventArgs) Handles Button7.Click
Const Pi AsSingle = 3.142
Dim Density, Velocity, Diameter, Area, MassFlowRate AsDouble
Density = Val(TextBox12.Text)
Velocity = Val(TextBox13.Text)
Diameter = Val(TextBox7.Text)
Area = Pi * (Diameter ^ 2) / 4 'calculate Area
MassFlowRate = (Density * Velocity * Area) 'calculate mass flow rate
TextBox18.Text = Str(MassFlowRate)
Dim OilFlowRate, WaterFlowRate, WaterCut AsDouble, X AsSingle
OilFlowRate = Val(TextBox15.Text)
WaterFlowRate = Val(TextBox14.Text)
WaterCut = WaterFlowRate / (WaterFlowRate + OilFlowRate) 'calculate water cut
X = WaterCut * 100
TextBox20.Text = Str(WaterCut)
TextBox25.Text = Str(X)
Figure 1: The Mass Flow Rate and Water Cut Calculation Algorithm
Figure 10: The Temperature Dependent Constant and pH Factor Calculation Algorithm
Figure 11: The User’s Interface of the Computational CO2 Corrosion Rate Prediction Software
STAR
60 47
40
34
40 29
24
20 20 20 20
20
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Pipe Distance (m)
Figure 13: A Graph of Pipe Distance Versus Temperature
3.0 RESULTS AND DISCUSSION Pipeline Length; Figure 16 shows a graph of comparison of
3.1 Results the developed algorithm with HYDROCOR at different
Figure 13 shows the graph of Distance Versus Temperature operating conditions; and Figure 17 shows a graph of
along the total pipeline length; Figure 14 shows the graph of comparison of the developed algorithm with OML 61 at
Corrosion Rate along the pipeline length; Figure 15 shows a different temperatures.
graph of Corrosion Rate Versus Temperature along the
2.5 1.94
1.51 1.67
2 1.395
1.18 1.18 1.18 1.18
1.5
1
0.5
0
0 1000 2000 3000 4000 5000 6000 7000 8000 9000 10000
Distance (m)
Figure 14: A Graph of Corrosion Rate along the Pipeline Length
3
CORROSION
2.692
RATE VS TEMPERATURE, OTHER VARIABLES NOT CONSTANT
2.456 ALONG THE PIPE
2.275
Corrosion Rate (mm/yr)
2.5
1.94
2 1.67
1.51 1.395
1.5 1.18 1.18 1.18 1.18
0.5
0
66 56 47 40 34 29 24 20 20 20 20
Temperature (oC)
Figure 15: A Graph of Corrosion Rate versus Temperature along the Pipeline Length
DEVELOPED ALGORITHM VS
1 DEVELOPED
HYDROCOR
Corrosion Rate (mm/yr)
0.8 SOFTWARE
0.6
0.4
0.2
0
1 2 3
Operating Condition
Figure 16: A Comparison of the Developed Algorithm with HYDROCOR at Different Operating Conditions
1.4
1.2
0.96 0.939
1
0.727 0.729
0.8
0.6 0.494 0.482
0.409
0.4 0.259
0.2
0
46 59 61 64 70
Temperature (oC)
Figure 17: A Comparison of the Developed Algorithm with OML 61 at Different Temperatures
3.2 Discussion of Simulation Results pipelines (where no intermediate heating stations are
It was observed that the temperature gradually decreased installed to warm the oil) and in pipelines without heat
as the oil flows through the pipeline, see Figure 13 This can insulation, the temperature will eventually decline to the
be ascribed to the gradual decrease in temperature from surrounding temperature some kilometres after the inlet
inlet temperature at distance (0 metres) due to heat transfer point depending on many factors such as the surrounding
from the heated oil to the surrounding. In isothermal
temperature, the overall heat transfer coefficient, velocity, confidence interval (CI) was calculated. At 95% confidence
and fluid heat capacity (Mohyaldin et al., 2011). level, the developed algorithm had a CI between 0.70 and
From Figure 14, it was noticed that there was a change of 1.41 mm/year. This means that we are 95% confident that
corrosion rate as the fluid flowed via the total pipeline length. the mean corrosion rate predicted is between 0.70 and 1.41
Also, Figure 15 showed a similar result as the temperature mm/year.
was varied with corrosion rate. It was observed that from
Figure 14 and Figure 15, the corrosion rate increased to a 3.0 CONCLUSION
particular temperature and distance (56oC and 1,000 metres A Visual Basic Algorithm for determining the corrosion rate
in this case) and decreased as the fluid flows over the of oil pipelines in CO2 environment using modified NORSOK
pipeline distance until it remained constant at a particular M-506 model has been developed. The NORSOK M-506
temperature and distance (20 oC and 7,000 metres in this model has been modified to include a temperature
case). This is in agreement with the findings of (Nesic, 2007) distribution model that predicts the temperature at any point
who found that the peak in the corrosion rate is usually seen along the oil pipeline. The entire model has been
between 60oC and 80oC, depending on water chemistry and successfully implemented using an enhance-able; user
flow conditions. friendly Visual BASIC to create a computational Algorithm
that can run under any Microsoft windows.
3.3 Discussion of Validation Results Simulation and validation using the developed algorithm was
Figure 16 showed the comparison of the developed carried out. The simulation and validation results showed an
algorithm with SHELL’S HYDROCOR. The results are in acceptable agreement. The validation done by comparing
good agreement. To ascertain the statistical accuracy of the the Algorithm prediction with SHELL’S HYDROCOR was
predicted values, standard error (SE) calculation was satisfactory. The developed computational algorithm when
performed. HYDROCOR had a SE of 0.08 while the implemented is user friendly and has a computation time of
developed software had a SE of 0.2. less than one minute for the user to input data and see the
To ascertain the reliability of the predicted values, output.
confidence interval (CI) calculation was carried out. At
confidence level of 90%, HYDROCOR had a confidence REFERENCES
interval between 0.04 mm/year and 0.32mm/year. This is to
say that at 90% confidence level, it can be said, we are 90% Bodude, M., Adeosun, S. and Ayoola, W. (2012)
confident the mean corrosion rate is between 0.04 and “Comparative Studies on Mechanical and Corrosion
0.32mm/year. At the same confidence level of 90%, the Characteristics of API 5LX60 Steel and RST 37-2 Steel”
developed algorithm had a confidence interval between 0.04 Journal of Emerging Trends in Engineering and Applied
and 0.73 mm/year. This is to say also that at 90% confidence Sciences (JETEAS) 3(1): 137-143.
level, it can be said, we are 90% confident the mean
corrosion rate predicted is between 0.04 and 0.73mm/year. CO2 Corrosion Rate Calculation Model, Rev. 2 (2005)
Furthermore, the developed algorithm prediction was NORSOK standard No. M-
compared with operating field data obtained from a Nigerian 506,http://www.standard.no/en/Sectors/Petroleum/NORSO
oil and gas company (OML 61). The results are shown in KStandard Categories/MMaterial/M-5061, Standards
Figure 17. Norway.(August,2013)
To ascertain the accuracy of the model prediction, the
average percent error (APE) and average absolute percent Guidelines for Prediction of CO2 Corrosion in Oil and Gas
error (AAPE) of the data source used were calculated. AAPE Production Systems (2009), Institute for Energy Technology
is used to evaluate the prediction capability of the model. (IFE). Report No. IFE/KR/E -2009/003, ISSN 0333 – 2039,
The lower the value of AAPE; the better the precision of the Norway.
calculated values that can be achieved from the model. The
APE for the developed algorithm was 19.74%, meaning the Mantell, C. (1958) Engineering Materials Hand Book.
model over predicted compared to the operating field data. McGraw Hill Company, New York (First Edition), pp.37.
Often times, predicted values and measured values are
never exactly the same. The developed algorithm also had Mohyaldin, M., Elkhatib, N. and Ismail, M. (2011) Coupling
an AAPE of 19.74%. This value cannot be said to be NORSOK CO2 Corrosion Prediction Model with Pipelines
accurate or not since the range of percentage error where it Thermal/Hydraulic Models to Simulate CO2 Corrosion along
is regarded as accurate or not accurate is a function of Pipelines. Journal of Engineering Science and Technology,
application. Vol. 6, No. 6, 709 – 719.
To measure the statistical accuracy of the predicted values,
SE was calculated. The developed algorithm had a SE of Nesic, S. (2007) Key Issues Related to Modeling of Internal
0.18. To determine the reliability of the predicted values, Corrosion of Oil and Gas Pipelines – A Review. Elsevier
UJET VOL. 2, NO. 2, DEC 2016 www.ujetmouau.com Page 180
UMUDIKE JOURNAL OF ENGINEERING AND TECHNOLOGY (UJET), VOL. 2, NO. 2, DEC 2016 PAGE 170 - 181