Professional Documents
Culture Documents
:nt
3.S-
By ' _
HOWARD J. ENDEAN
CONSULTANT
Published By
CHAMPION CHEMICALS, INC.
Houston, Texas
1989
m-
he
of
:d.
ACKNOWLEDGEMENT
The writer appreciates the support and encouragement of the management
of Champion Chemicals, Inc. in the preparation of this manual. Also, myassociate Mr. Raymond Shelton for review and permission to include his compilation of Champion's Cortron Corrosion Inhibitors in Chapter V. The
cheerful cooperation of Ms. Debbie Burroughs in the frequent re-working of
the drafts required in the preparation of this manual is greatly appreciated.
TABLE OF CONTENTS
DESCRIPTION
ITEM
DESCRIPTION
ITEM
PAGE
General
13
A.
13
B.
14
C.
15
D.
16
General
A.
Defmition of Corrosion
B.
Electrochemical Environment
1. Metallurgical Factors
2. Mill Fabricating Factors
3. Field Operating Factors
2
3
3
3
C.
E.
16
D.
4
4
5
5
5
6
6
F.
17
G.
17
H.
E.
Corrosivity vs pH of Water
18
18
18
18
18
F.
7
8
8
I.
19
J.
20
G.
K.
21
H.
10
L.
I.
Hydrogen Embrittlement
11
J.
11
11
21
21
22
22
M.
22
22
23
23
23
K.
Hydrogen Blistering
12
N.
24
L.
Galvanic Corrosion
12
O.
24
..
II
'--
PAGE
- - -- - - -
11
11
11
11
11
iii
DESCRIPTION
ITEM
PAGE
24
Q.
25
25
25
27
R.
26
J.
General
28
A.
28
B.
29
C.
30
D.
31
32
32
E.
33
34
34
34
F.
34
35
35
35
36
G.
36
H.
37
1.
37
30
PAGE
37
38
38
38
General
39
A.
39
B.
40
40
41
c.
42
D.
43
E.
44
iv
DESCRIPTION
ITEM
P.
43
43
44
44
45
45
45
47
48
49
50
50
51
DESCRIYfION
ITEM
PAGE
G.
51
Inhibiting Sales Gas Pipelines
1. Type 1 Treatment (See E,3,a Type 1 Treatment) 52
52
2. Type 2 Treatment (Continuous Injection)
H.
52
53
53
53
53
54
54
54
55
55
55
56
56
I.
56
57
A.
58
B.
58
C.
58
D.
59
E.
59
F.
60
G.
60
H.
60
vi
ITEM
DESCRIYfION
1. Scavenging and Inhibiting of Oxygen
2. Gas Refluxing or Vacuum for Oxygen Removal
PAGE
61
61
A.
62
B.
62/63
C.
63
D.
63
E.
63/64
F.
64/65
66
A.
67
B.
68
68
69
69
C.
70
70
70
70
70
71
D.
71
E.
72
vii
ITEM
DESCRIPTION
1. Non-Metallic Materials
a. Extruded Plastic Pipe
b. Glass Filament Wound Epoxy Pipe
c. Plastic Liners in Steel Pipe
d. Baked on Coatings
e. Cement Linings
F.
G.
PAGE
72
72
73
73
73
74
74
75
76
76
79
74
75
75
76/77
77
78
FOREWORD
Serious corrosion in production and pipelines began in the 30's with
widespread drilling of wells west of the Mississippi River. In many of the fields
the oil and gas contained significant amounts of the acidic gases, Hydrogen
Sulfide and Carbon Dioxide. In addition, some fields had active water drives
or mobile water tables and were completed in non-consolidated formations
that further intensified corrosion. While the 30's incidents of corrosion were
widespread the actual number of fields in which it was occurring was limited.
However, by the mid 40's corrosion failures had reached epidemic level.
Well and pipeline corrosion was classified as a field problem with the responsibility for its solution at the descretion of the field operators and their staffs.
In cooperations with production chemical companies widespread field testing began, mostly based on intuitive guesses at solutions. Also many ad-hoc,
off the record meetings were held for comparing of results. By the early 50's
the widespread testing and interchange of results had developed "Rules of
Thumb" for both detecting a corrosive condition and limiting the rate of metal
loss. Since the 50's, through continued testing and the formulation of superior chemicals, t'reatments have been further improved. Considerable of the
information in this manual is today's versions of these original programs.
While by technical definition they would still be classified as "Rules of
Thumb" based on years of successful application they can be applied with
confidence.
There is no way the many operating and production chemical company personnel that contributed to the developments can be acknowledged. In the
late 40's the NACE was still in the formative stages with the formal reporting and cataloging of field work in the beginning stage. The NGAA Corrosion
Research Project, one ad-hoc committee comparing and analyzing field
studies lists 22 production companies and service organizations a~tive in fi~ld
studies. The minutes of this committee refers to many of the studies bllt With
only limited reference to the personnel involved. However, this manual attests to the thoroughness of studies and the technical proficiency and objectivity of the personnel that undertook these investigations.
viii
ix
CHAPTER I
CAUSES OF CORROSION IN OIL FIELD EQUIPMENT
GENERAL
It has been estimated that 80% of failures occurring in production and
pipeline operations are caused by corrosion. This is either of the metal loss
type or of the stress types with corrosion developing the stress raisers or
atomic hydrogen associated with Hydrogen Embrittlement. The primary objective when failure occurs is to establish that if corrosion is the cause, what
are the specific reasons and how can it be prevented in the future.
Since corrosion is generally suspected as the cause, it is essential the operator
have a general understanding of the corrosion phenomena, its appearance
and operating conditions that can initiate the attack. Since most equipment
is manufactured from Ferrous metals the corrosion of steels etc., are of
primary concern. The two principal corrodents associated with oil and gas
are Hydrogen Sulfide and Carbon Dioxide. Oxygen is also of major concern
when produced or injection waters are in contact with air. While there are a
wide variety of operating conditions under which corrosion may occur, the
electrochemical reaction is always the underlying cause. Once these factors
controlling corrosion are understood and the types of failures recognized,
corrosion can be readily established as the probable cause. Usually a review
of operating conditions coupled with relatively simple tests will confirm the
condition.
The following reviews the basic concepts of oil field corrosion and other pertinent information to field failure analysis.
A. DEFINITION OF CORROSION
The "CORROSION HANDBOOK" by Herbert H. Uhlig states:
CORROSION:
In routine production and pipeline operations only the electrochemical reaction applies. Depending on metallurgy, cor rodents and operating conditions
the appearance of the corrosion and failures can be quite differerent,
however the underlying cause is the electrochemical component of the definition.
-1-
Fe+ +
Fe+ +
B. ELECTROCHEMICAL ENVIRONMENT
Fe++~iNtH:1w
(ELECTROLYTE)
The figure below is an idealized representation of the electrochemical environment with a clean, perfect steel surface without internal or external imperfections. Each grain is minutely different in structure and composition
and markedly different from the grain boundary alloys that precipitated as
the steel cooled from the molten to the solid state. When the surface is filmed
with an electrolyte, always water in routine field operations, there is a minute
current flow between the anodic and cathodic areas of the surface.
~
G R A : : : : J GRAINBOUNDARIES
MAYBE
/~
H+
ANODES OR CATHODES
SIMULATED STEEL MICROSTRUCTURE
X'S 1,OOO'S
-2-
-3-
~ ~" "~.~\'_
. ..
1;#'0;....
~'.~..
",*,:;'::.i...&/" ;.
.
,
~"'..
=- ;:.;,~
,,;
':.i..Jo ...
' .. ; , . ,' . \
'
'J.,..,.,.
...
"
1, -,.,
~.
~t
~ ""
".
~,_!:";~:,~~
"~ _ '\','
~.
..
'
. -
"
Jlt~'~}~~~~'Hi:{'itl~I~~?':~~~~:/~~~n;
: "f.
',', .',:, , )~~~~~.;i:~"~:'.\~" ,~, ~~1{ ?t . t '. ~!~~~:\
'f
J ~'
1/. "
"".-
"
,;.'
.~~
~j~~~~~i~~~'
. ~~~. ~
J'1!;of.
~/., / ,r>i,;>~
I-.I! 1>
(, .. ,' .
I .,
I'
'.1,;)"
t .
~ .'
, .
..
r-
'.
':
'
"
- ,
"
.'
-4-
....
-5-
\.'~
....
"\~.-~,'
... ,
....~(
E. CORROSM1Yvs pH OF WATER
With water wetting of field equipment being a primary requirement for corrosion, its acidity - pH, is a readily made measurement for determining the
significance of the attack. For solids free water of velocities of 3 FPS or less
the following "Rules of Thumb" are applicable.
pH 7.0 or higher
pH 7.0 to 6.5
pH 6.5 to 6.0
pH 6.0 or less
The figure indicates the effect of increasing velocity on the corrosion rate.
From approximately 3 to 7 FPS, water is in a transition range between laminar
and total turbulent flow and the relative corrosion rate will be between the
Dormant Water and the Corrosion/Erosion Condition. The upper curve will
be the limiting condition up to velocities where erosion of the metal will begin.
RELATIVE CORROSION VS pH & VELOCITY
>-
I-
:;:
Ui
o
a:
gj
6
5
i=
:3w
DORMANT WATER
(No Flow)
a:
12
10
ALKALINE - p H -
ACIDIC
-6-
-7-
The examples below are from laboratory tests performed at low pressures
and room temperature. As such, specific values would have no relation with
field operating conditions. However, the rate of change shown can be considered reasonable approximations of the change of the corrosion rate that
could be anticipated for similar changes in the variables in operations.
w 5
le(
a:
(j)
a:
a: 3
> 2
i=
e(
...J
W
a:
le(
a:
pH 4.5
pH 5.0
()
w
i=
e(
>
10
15
20
25
iii
0
a:
a:
pH 6.25
....I
a:
The following figure illustrates the effect of both velocity and temperature
increases on the rate of metal loss. The tests on sea water in a closed system
would be for a pH in the 7.0 - 8.0 range, without oxygen present. The type attack for flow rates below 3 FPS would be similar to that illustrated in 4,C. The
temperature rate increases would be of the same order of magnitude for all
corrosive conditions. However, the effect of velocity could be markedly increased for more corrosive conditions due to the corrosion/erosion phenomna.
e::-:::
-
pH 9.0
0
500
1000
1500
2000
SULFIDES AS H2 S, ppm
2500
Ie(
a:
(j)
./
0
0
w 2
>
i=
e(
...J
W
a:
./
V
V
-<
a
co
~
V V
./
a:
a:
-8-
V-
V V
,/'" ~
aC\J
;;:..-V
V V
...--
V ~
a
<0
2
4
6
VELOCITY IN FT.!SEC.
-9-
10
I. HYDROGEN EMBRITTLEMENT
The principal cause of all corrosion failures in oilfield operations is the pitting type attack. In operations where the equipment is under continuous or
repeated strains, due to pressure or mechanical action, pitting can be the
principal cause of premature failure. Pits under these conditions develop the
stress raiser affect which markedly reduces the theoretical, calculated failure
stress of an item. This stress raiser type failure is widely recognized and where
it can occur every effort is made to minimize corrosion.
There are several hypothesis for hydrogen embrittlement and all are in agreement that the phenomena is initiated by hydrogen di~fus~on into .the st~e.l.
While the hydrogen can be from a number of sources, l~ OIlfield faIlures It ~s
normally associated with water wet ferrous metals. While the electrochemical reaction is also the cause of metal loss corrosion, where steel are susceptible to hydrogen embrittlement and under sufficient tensile stress, failures
are quite rapid and before any significant metal loss has occurred. Rese~ch
and field testing has established rigorous specifications for preventmg
hydrogen embrittlement. Details of the phenomena are. beyond the scope .of
this presentation. The following lists the factors controlhng hydrogen ~mbnt
tlement and Chapter VI lists the of API grades of sucker rods and tubmg and
their susceptibility to this type failure.
J.
+-+--
--+-+
+--
--+-
-+-
-+-+
Anodic
area
decreases,
cathodic area extends down
~ide of pit. Rate of penetration
mcreases.
1. Yield Strength - Steels with yield strengths of 90,000 psi or lower are
-10-
-11-
K. HYDROGEN BLISTERING
CHAPTER II
While low strength, ductile steels are not susceptible to hydrogen embrittlement occasionally hydrogen blistering can occur. Normally the atomic
hydrogen entering the steel along the grain boundaries will defuse through
the metal. Occasionally, an inclusion or other anomoly in the grain structure
will stop the diffusion of the hydrogen with the combining of atoms to form
the much larger molecules of hydrogen. This will cause internal cracking that
with continuing molecule formation develops blisters. Generally this occurs
in low pressure equipment and few failures have been reported from the
cause. When the conditions develops to where blisters are noted the equipment should be replaced.
L. GALVANIC CORROSION
One source of failures frequently overlooked in field equipment where water
is involved is that associated with the coupling of dissimilar metals. Failures
from galvanic attack are usually associated with small piping and control
items and not of serious consequence. However, this corrosion can easily be
avoided. The following table lists the Galvanic Series for the metals normally used in oil field equipment. Every effort should be made to select metals
in close proximity in this series. Where metals are widely separated it is mandatory, an insulating arrangement is to be used between the metals.
-12-
-13-
100
Fatigue Cracks
xr---
t;'
:e
0
0
0
....
r-....
!!
x 1'10
60
\l~ l-
40
'"
Air
en
en
~en
iii
c
i!
f'.. "
....... 80
STRESS OR ENDURANCE
LIMIT FAILURES
""r--"
,"
);
r-\r--.
II
Water- V
20
10'
10'
I I
10'
II
!
10'
10'
10'
Rod Bend
..!
'~~I_~fJ&oo
~"
~.
~
.- . -"
~
..... ,;
0,
",.
",
-14-
-15-
i
I
I-x
Ir
Of
:I
CAUSE
Smooth Surface
(area of slow separation)
corrosion, wear,
Origin of Break
LOCATION
OF BREAK
handling damage,
manufaduri n9
defect
Rough Granular
(area of rapid separation)
Smooth Surface
(area of slow separation)
Origin of Break
Tensile Break
(modified cup or cone)
Rou h Gran ular
(area of rapid separation)
Smooth Surface
(area of slow separation)
Origin of Break
-16-
-17-
I.
In most fields the initial water rate is low and corrosion protection is not required. However, in many fields it is obvious corrosion will eventually develop
and it is desirable to detect and inhibit as soon as possible. The following are
"Rules of Thumb" that have been used for early detection and beginning treating programs.
1- 2/YR
2& Up/YR
6.0 - 6.5
6.0 & Less
pH
6.0 TO 65
NOTE: With new strings, failures in first 3 months are probably mill defects
and should not be considered.
7.0& Up
6.5 -7.0
CORROSION POSSIBLE
I
pH LESS
THAN 6.0
o-1/YR
WATER CUT
25% OR OVER
pH
OVER 7.0
CORROSION
PROBABLE
pH
65 TO 7.0
CORROSION
UKELY
CORROSION
CORROSION
UNUKELY
I~'~ALLOOAAO"ON OO~";
COUPON
DATA
I
COUPON
DATA
MORE'THAN
5MPY
LESS THAN
5MPY
NO PITS
LESS THAN
5MPY
PITS (3)
COlOSIO~
INHIBLON
PROGRAM DESIRABLE
(2)
CORROSION INHIBmON
PROGRAM PROBABLY DESIRABLE
pH
pH
.!l:.1
1.:..!1.
X
X
X
X
-18-
CORROSION
No
Uncertain
Doubtful
Yes
Possible
1. Corrosion occasionally occurs above a pH of 7.0. Where field experience indicates possibility of corrosion.
2. When equipment becomes water-wet, corrosion will occur. Maintain a
planned monitoring program.
3. Check systems for air entrainment. If air entrainment is found,
eliminate and re-test.
-19-
J.
Once the start of significant corrosion has been detected the object is to
quickly control the attack with a cost eff~ctive inhibitin~ program. I~iti<l:lly
many programs are ineffective due to faIlure to recognize how filmmg mhibitors function and the required solubility characteristics in the well fluids
being produced. Another factor overlooked in older fields is the necessity of
a special treatment to quickly establish an initial film of inhibitor. Occasion:uly effective treatments are also discredited by faill!re to r~cognize ~hat e9Ulp ment corroded prior to the start of a program will contmue to fail. Failures
that occur during the first three months after beginning a program should be
discounted. These generally reflect either equipment that is already corroded
or with new equipment, damaging mill defects, not rejected in mill inspections.
1. Does well need to be cleaned? (NOTE 1)
Type of Treatment
Periodic Batch
Yes
Possible
Note 1
Yes
Yes
Note 1
Continuous Injection
Yes
Yes
Note 2
Squeeze Treatment
Note 3
Note 3
Yes
Note 1:
3. What inhibitor should be used? (NOTE 2)
4. In batch and squeeze treatments what frequency is needed? (NOTE 3)
Note 2:
-20-
1YPE COMPLETION
Open
Tubing On
Annulus
Packer
Iii&!! Fluid Level Low Fluid Level
Note 3:
-21-
a)
(BOD
= 2.6 gallons/week
3. Squeeze Treatments
Treatment down tubing.
Apply Item 1, b) to treat rods.
b) Treatment down annulus.
Apply Item 2, a) or b) at the rate of 1 gallon of inhibitor
per 1,000' of tubing.
a)
Treating Period
Up to 150 BFPD
150 to 300 BFPD
300 to 800 BFPD
(Barrels Oil
Treating Rates
25 ppm for mild field corrosion
35 ppm standard Permian Basin Recommendation
50 ppm for severe field corrosion
ppm
BFPD
Gallons of Inhibitor
= 1,000,000 Gallons of Production
-22-
-23-
Failures
1 Well
Failures
+S Wells
SECOND YEAR
Failures
1 Well
Failures
+SWells
Very
Effective
0.5-1 Avg.
1-2 Avg.
Partially
Effective
1-2 Avg.
2-3 Avg.
Not
Effective
3-4
3-4 Avg.
NOTE: New rod strings typically contain 3% to 8% rods containing potentially damaging defects. Generally rod failures occurring in the first 60 days
will be caused by mill or handling defects.
=T
(.!'..-
Q =
T =
F =
G =
1,000
...Q...8)
-24-
-25-
b) Significance of Results
Corrosion
Control
30 Days
MPY
Very
Effective
0-2
Partially
Effective
2 - 5 To be considered effec-
tive,coupons must be
free of pits.
Not
Effective
5&Up
3000
500
500
400
300
200
300
100
00
Corrosion
Control
2000
- - - - -_ _ _-1_30
20
100
EXAMPLE:
300 barrels
Iron Count
Iron Loss
10
Pipeline carries
of water daily.
= 200 ppm
= 21.0 Ibs/day
Very
Effective
Oto 50
50
40
0.5
Partially
Effective
50 to 150
30
0.3
0.2
0.1
150& Up
0.05
0.03
0.02
10
0.01
0.005
0.003
0.002
0.001
pounds of iron
removed daily
ppm-iron
-26-
30
20
20
Not
Effective
50
-27-
barrels
water per
day
LIMITING VELOCITIES
CHAPTER III
GAS/CONDENSATE WELL CORROSION AND PREVENTION
GENERAL
The flow stream of gas, condensate, and water from the reservoir through the
tubing to the surface separating equipment is a continually changing process
stream. The pressure, temperature, ratios of gas, condensate, water, and
velocity continuously changes. Furthermore, the composition of the water
changes as the formation water entrained in the gas is diluted by condensate
water separated from the gas, with reduction in temperature, as it flows up
the tubing. All of these factors can affect the type and location of corrosion
and should be considered in a corrosion control program. As previously
noted the basic cause of the metal loss is the electrochemical reaction. With
at least trace amounts of formation water always initially entrained in the gas,
another corrosivity factor frequently overlooked is the flow patterns for the
two phase flow variations with velocity changes. The velocity controls the slip
and holdup of the liquid in the gas stream and the degree of turbulence, all
of which affect the corrosivity. The following reviews the effect of these factors and corrosion inhibiting procedures for gas/condensate production.
Specific Champion Cortron corrosion inhibitors for the programs are listed
in Chapter VI.
WELL STREAM
CONDITION
TUBING PRESSURE
1,000 psi
5,000 psi
Wet
Non-Corrosive
Wet
Corrosive
Wet Corrosive
& Abrasive
-28-
50fps
40fps
30 fps
25 fps
75 fps
85 fps
MSCFD
OR
= MSCFD x OR x Z =
Px3600
Cu. Ft./Sec.
Compressibility Factor
CFS
Tubing Area in Square Feet
-29-
.10
:I:
Q.
w
Q
C)
.09
.08
PRESSURE
PSI
150F
1,000
2.97
2,000
5.93
DENSITIES @
200F
250F
300F
2.74
2.55
2.38
5.48
5.10
4.76
3,000
8.90
8.22
7.65
7.15
4,000
11.87
10.96
10.19
9.53
5,000
14.84
13.70
12.75
11.91
iii .07
6,000
17.80
16.45
15.29
14.29
u. .06
7,000
20.76
19.19
17.84
16.67
~
~
~ .05
'wCo
~
.04
w .03
en
c(
w
a: .02
0
~
.01
EXAMPLE
T.H.P. 3000 psi - Depth 9000'
Factor 3000 psi
.07 psi/ft.
C.I.S.H.P.
3000+(.07X9000)
C.I.S.H.P. = 3630 psi
0
12345
CLOSED IN TUSING HEAD PRESSURE - psi X 1000
The limiting velocity in a gas/condensate well defines the fluid flow rate above
which the rate of metal loss by abrasion will result in a markedly premature
failure. In wells where the water is non-corrosive all metal loss will be due to
abrasion of the steel by the entrained water droplets. When the water is corrosive the limiting velocity is lower due to rapid erosion of the corrosion
product, exposing clean steel with its higher susceptability to corrosion attack. This rate is further reduced when the flow stream entrains formation
fmes which are frequently hard sand particles.
The relative volumes of gas, condensate and water vary from the formation
face to the well head. Also as the gas expands with reduction of pressure the
velocity is continually increasing. The velocity will determine the flow patterns and in combination with the volume of liquids establishes the extent of
liquid holdup. The slip and holdup dictate that the tubing wall will be wetted
over the entire length of the tubing and at lower velocities result in a water
leg buildup, with gas flowing as bubbles or small slugs through the buildup.
At higher velocities, usually over 10-15 fps, all water and gas remain
entrained. Within the gas stream the liquids will be in the spray form and
there will be a film of liquid on the tubing wall. The thickness of the film will
be a function of the velocity and rate of liquids being produced. From corrosion consideration, with the continuous water wetting of the tubing, C02
and/or H2S present in the gas and the limiting velocity are the items of concern. The following is an overview of Flow Patterns and Slip and Holdup factors for consideration in designing a corrosion control program.
The table lists approximate densities at various temperatures for a typical gas
entraining only traces of water ( 5 bblsIMMCF). The curves give maximum
allowable velocities for three conditions. For the corrosive/abrasive condition the limiting Velocity can be increased with a good corrosion control
program. However, the corrosive limit of velocity would be considered maximum for maintaining an inhibitor film for any batch treating type program.
-30-
-31-
From corrosion considerations, the presence of water not its volume, is the
critical factor. As noted in Item 1 - Flow Patterns, water will be continuously
present. At low velocities the Holdup will dictate the length of the water leg,
in gas well depletion periods or with low formation pressures, the buildup may
result in killing of the well. A major consideration in inhibiting treatments for
wells with water legs is designing a treatment that assures displacing of the leg
and filming of the tubing covered by the water leg. The following curve illustrates the typical holdup conditions for ambient temperatures and low
pressure. While the range for typical tubing is indicated literal interpretation
would not be representative of gas wells.
500.-----..----,------.--,-----.--",
SLUG
FROTH
FLOW PATTERNS
Superficial Water Ve
VSL ftlsec
IIIIIIIIIIIIIIIIIII
c
D
n
li [J
>
......
V\
....a.
....
ex:
......
Q)
01
to
a::
:=I
V)
0.1
.. ,-.
)?:~
-
;.~
........
x:
";j:'jf,::'-
\'F;,
10.
c
c
ex:
HOLDUP
RATIO:
tt:
0.
"'0I"
10~--~~~~-~-~~-T_~-~~
.~
/ /
tI
10.0.
. ~. :-..~
-32 -
c5
Ii:
:n
;::
:/:J;-/
.\~:~
::J
I I I
10.
G
'
to
V)
.. '"!'!r.'~~'
[J A
.
a:: c
3
0
V\
01 ,
::J
....
lJ...
a:: 0
0.01/
100
lJ...
E
"'0:
0
...J L.n
:>
ity
~ ..:.;;;;:.-_
0
' .'
'f..--
10
10 Tubing
Range of Typical
E.
The geologic processes that resulted in the forming of gas reservoirs dictates
that all produced gas will entrain water. The water will be of two types. Formation water stripped from the water wetted reservoir rock and condensate
water that evolves from the water saturated gas. The formation water composition can vary widely dependi?g upon ~hether the w~ter.in the ori~nal
sedimentary basin was fresh or sahne but wdl always contam d1ssolved sohds.
Condensate water is always solids free. The composition of the produce?
water will be a function of the ratio of the two types of water. The compOS1tion of the water may vary widely over the producing life of a we~l depend~ng
on the type of reservoir. The corrosivity of the produced water 1S a functlon
of the acidic components (H2S and/or CO2) contained in the gas stream. The
following reviews the water production sequence in typi~al gas depletions.
These are based on the initial production from completlons above the gas
water interface zone in the reservoir.
-33-
SOUR GAS
H2S - 250 ppm & Up
pH - 6.5 & Less
COUPONS
COUPONS
SAND,ETC
WATER
VELOCITY
SWEET GAS
C02 - 7.0 PSI P.P. & Up
pH - 7.0 & Less
Fe - 100 ppm & Up
Pitted
5MPY&Up
Any
2BBLS/MMCF & Up
25FPS& Up
CHLORIDE
CONTENT
PPM
IRON
COUNT
PPM
POSSIBILITY
OF SERIOUS
CORROSION
NO
0-250
50
0-250
50 -150
POSSIBLE
0-250
150& UP
PROBABLE
2-5
250 - 500
2-5
250 - 500
50 -150
PROBABLE
2-5
250 - 500
150& UP
YES
5&UP
500& UP
150& UP
YES
50
POSSIBLE
-34-
-35-
EXPOSURE
PERIOD
DAYS
TYPE
ATTACK
POSSIBILITY
OF SERIOUS
CORROSION
0-5
30 Min.
General
No
0-5
30 Min.
Pitting
Yes
5 -lO
30 Min.
General
Possible
5 -lO
30 Min.
Pitting
Yes
lO&Up
30 Min.
Any
Yes
2.
3.
4.
5.
6.
7.
I.
The following batch treating rates are based on field experience in typical corrosive wells where the rates do not exceed the limiting curve (in Item C).
Where these velocities are exceeded a continuous injection procedure will
provide partial inhibition.
1. BATCH TREATING PER 5000 FEET OF 2" - 3" TUBING
NOTE 1: Items 1 & 2 are interchangeable. The inhibitor will usually dictate
the treatment or vice versa.
NOTE 2: Monitoring should be for meaningful results and not require extensive field and laboratory time.
RATEMMCF/D
0-2
2 -5
5 -10
10&Up
INHIBITOR GALS.
25
25
25
25
INTERVAL MONTHS
3
2
1
1/2
NOTE 3: Squeeze treatments may cause skin damage and should not be
recommended if other treating methods are possible.
OPTIMUM RUN DOWN TIME - 1 HOUR/lOoo FEET.
MINIMUM RUN DOWN TIME - 1 HOUR/15oo FEET.
DILUENT WHEN REQUIRED - 1;1 TO 1:4 INH. TO DILUENT.
PRE OR OVERFLUSH WHERE REQUIRED - 2 TO 10 BBLS.
-36-
-37~
'I'I
CHAPTER-IV
PIPELINE CORROSION AND PREVENTION
_F
(1,000
+~ -
G)
8
-38-
GENERAL
As with all metal loss corrosion the occurrence in pipelines is controlled by
the electrochemical reaction. This dictates the presence of water and the
water wetting of the pipe wall. With this condition satisfied the electrochemical reaction will occur. However, the rate of metal loss and type is controlled by other factors. A pitting type attack can be caused by mill scale, slag
inclusions or slugs, improper heat treatment, heat run out zone effects or use
of unsuitable welding rod. The corrosion/erosion effect can be caused by too
high fluid velocity. Water and sludge buildups will develop with too Iowa
flUld velocity that may cause pitting and bacteria infestations. With low
velocity water, sludge segregatIon invariably occurs and scheduled pigging
programs are desirable. The rate and type of attack is also a function of the
corrodents present. When corrosion is not controlled, depending on wall
thickness and operating conditions, time to first corrosion type failure will be
from three to twelve years. However, with a well desigIled corrosion inhibition program placed 10 operation"at the same time the line is commissioned,
corrosion failures can be prevented indefinitely.
The following reviews the effect of these factors and inhibiting procedures
for pipelines. Specific Champion Cortron corrosion inhibitors for the
programs'are listed in Chapter VI.
I{
IMPROPER
WELDING
TOO HIGH
TOO LOW
VELOCIlY
INADEQUATE _ __
PIGGING
SCALE BUILDUP
LIQUID BUILDUP
BACTERIA GROWTH
INHIBITOR
WRONGlYPE
LOW VOLUME
-39-
,It
7 FPS& Up
All water remains suspended as droplets in oil stream.
NOTE: Tendency of water entrained in oil stream to water wet pipe is a function of oil gravity and surface tension. Assume that with oil gravity under 40
API, pipe IS oil wet; and over 40 API, pipe is water wet.
The following are conservative "Rules of Thumb" that can be used to approximate Flow Patterns and degree of water segregation.
2. WET GAS LINES - (WATER: TRACE T05 BBLS/MMCF)
Em NO
0-71/2 FPS
All water quickly drops from gas stream flows to low spots and builds up
pools. As area over 1'001 is reduced, water becomes turbulent and is displaceo
up dil'. Eventually slug is ~tripped fr.om t?P of pool and flows with gas. Pool
flows back to bottom of dip and agambUlIOs up.
E DRY :::;7~
';::_---0
DORMANT POOLS
/
DORMANT WATER POOLS
Most water drops from gas stream and collects in turbulent pools on up hill
side of dips. Slugs are stripped from tops of pool and flow with gas. Minor
spray flow persists with droplets continuously wetting pipe waIl and entering
pools and being stripped from pipe walls ana pools and entering spray.
SP.ZtZ,;:;:,,<
7112 -15 f .p.s.
{IMiNOR
AGITATED POOLS
AGITATED WATER POOLS
-40-
-41
~~_ _-:--~
""
1.
15 - 25 FPS
Water dropping out forms a continuous flowing stream along bottom of pipe.
Minor} turbulent pools build up on up hill side of dips with frequent small
slu,g displacement. Continuous spray with water alternately depositing and
belOg stripped from pipe walls and stream.
15 -
-e;SPRAY; :'~'''
'
-:. .
.- > .'
.-
25 f.p.s .
~:':~ <:'hn
. :':: ':~
:. ~
' _.,fir
..............
SMALL
AGITATED
POOLS
~.
CONTINUOUS
STREAM
NOTE: With only trace amounts of water, above 15 FPS velocity all water
remains in spray regime.
25 FPS& UP
All liquids remain in spray regime, continuously wetting and being stripped
from pipe wall.
2.
Area
Sq.Ft.
Diameter
Ins.
Area
Sq.Ft.
.0218
12
.7853
.0490
16
1.3963
.0872
20
2.1817
.1963
24
3.1416
.3491
30
4.9087
10
.5454
36
7.0685
NOTE: Calculations give order of magnitude velocities suitable for use with
FLOW PATTERNS 10 pipelines illustrated in Item B. With two phase lines
always include gas volumes, however when CFS (liquid) is less than 5% of
total fluid volume, it can be deleted from gas velocity calculations.
BWPD
+ BOPD
CFS
MSCFDXOR
PX3060
Velocity in feet/second
15400
CFS
-42-
-43-
Flow patterns in Pipelines, Item B, are "Rules of Thumb" for water wetting
in pipelines. In operating lines where corrosion is known to be occurring, the
fonowing listing indicates factors for review prior to determining the
desirability of an inhibition program.
Option 1:
If sludge in receiving trap shows large amounts of corrosion product, repeat cleaning run with pig.
Option 2:
Displace 50 to 100 foot slug of alcohol between two batching pigs to dry line.
Pig line with batching pig to remove any water build-up, then clean line
with cleaning pig.
1.
Option 2:
Option 3:
a. NEW PIPELINES:
After displacing of test water, blow line down to remove any by-passed
water. Then pig line with cleaning type scrapper.
Option 1:
Option 1:
-44-
Option 1:
2.
Oil pipelines are of two types. Field lines between the wells and tank batteries' ,generally flowing oil, gas and water. This flow will be turbulent at
velocities of 3 1/2 fps and over. ~en water c}lts are 25% or less, C?il. or gas
will be the external phase and senous corrosion would not be antiCipated.
However, when water cuts are over 25%1 the piping will probably be water
wetted, and regardless of velocity, corrosion may occur.
-45-
100
200
300
400
500
Inhibitor Rate-ptslD
1.4
2.8
4.2
5.6
7.0
20
40
60
80
100
1.4
2.8
4.2
5.6
7.0
NOTE: With lines with low thru-puts batch treating can be used. Inject at
rate of 1.0 gallon per 10,000 barrels of oil transported between treatments.
-46-
-47-
I'
Gallons of Inhibitor = 3 X D X L
D = Nominal Pipe Diameter in Inches
L = Length of Pipeline in Miles
"
\,I
CJ
UJ
..J
- en
~ en
UJ
a:
UJ z
a.
20
,I"" "
()
a: I 15
0 lt:
~
OJ
..J
LL
u::
~ ..J
10
en UJ
z 0z
..J
..J
<l:
CJ
a:
UJ
a.
""
""
"
"
"
"
""
"
"
""
""
,,"
,,'" "
"
"
"
LL
()
en
~
a:
UJ
a.
a:
UJ
I-
<l:
3::
LL
en
..J
~ 4
a:
<l:
OJ
5
24
36
48
10
12
14
16
\\\\"~'
11I\\"'~l"
1\
1\ \\ \ \ \ \" ' ,", ' ,
\\\'
I \ \ \ '\ \
1\\\\
1\ \ \ \
1\ \ \ \
i
\
1\
\
\
I \
\
\
I I
\
\
I\
! I
I \
I \
\-~
\
\
\
~.
20
,',
,','",
" '~',
'"
\ \ ' ,,' " ' ....
\
' ,,, "
\
\
\
", "
\'
I'. "
\
,
\
\.
~\
\
\ 1
30
,"f,'
,
j:1
'",
,, " ',"'",
"',
\~
, ,, ,,, ",'."",
,, , , , , '""
r, "
I' \'1.
\
40
'.1
1 \
50
60
70
-48-
,-
\\ \ \ \\1'\' ,,~,
5 10
12
6
1
~'"
f\'\~~~~
en
<l:
LL
-49-
80
"
I",
90
100
GAS VELOCIlY
oto 7 FPS
7to ISFPS
IS& UPFPS
G. INHIBITING SALES GAS PIPELINES
Sales gas is always dehydrated and will generally be stripped of most of the
LPG components a~d the Sales Gas is highly undersaturated with regard to
?ot~ :-vater and th~ hght~r hydrocarbon components. This dictates a special
mhlbltor formulatIon usmg a carrier that will not flash, i.e. dissolve, into the
~a~ stream. Attempting to apply typical inhibitor formulas will not only result
m madequate filmIng but also cause the heavy viscous inhibitor to gunk out
in the line.
'
~he pri~cipal objectives for inhibiting Sales Gas Pipelines is to assure protec-
tI.on In Instances of plant upsets and to assure government regulatory agenCI~S that all possible safety precautions are being taken to prevent pipeline
failures.
Sales Gas lines can be effectively protected with either a periodic Type 1
Treatment or a Type 2 Treatment.
-50-
-51-
>25%
NO
YES
<25%
YES-?
YES
0-31/2FPS
31/2-5FPS
5& UpFPS
YES
YES
NO- ?
-52-
-53-
GAS
VELOCI'IY
0-71/2FPS
71/2 -15 FPS
15& UPFPS
YES
YES
NO
NO
YES
YES
8.
!!!!!.t.
0-5
0-5
5 -10
5 -10
10&Up
Pitting
COUPON RESULTS
Comment
Corrosion Level Not Serious
Corrosion Level Serious
Corrosion of Concern - Watch
Corrosion Serious - Inhibit
Corrosion Serious - Inhibit
NO
YES
NO
YES
Yes or NO
NOTE: The measurements required for a corrosivity evaluation are pH, iron
count and CC or salt content. While water samples at both ends of a pipeline
are desirable, generally samples are obtained only at the terminal of a system
and the following is based on terminal samples.
For accuracy the pH measurements should be made on fresh samples at the
sampling site. When samples are transported to the laboratory for testing,
some of the acid gases evolve and reading will be higher. Laboratory pH
values should be reduced by 0.5 to 1..0 for more realistic values.
The water in either a Custody Transfer Crude or Wet Gas Pipeline should
be principally of the condensate type that evolves from the fluids with
temperature reduction. The salt content in the water should be > 500 ppm;
salt content over this amount indicates a carryover of produced water and
the iron count should be discounted since it reflects carryover of dissolved
iron from the production equipment.
-54-
0-25%
0-6.0
6.0 -7.0
7.0 -14
possible
unlikely
unlikely
!Yi!l~r ~Yl
25%-45%
45&UP
possible
possible *
unlikely
probable
probable *
unlikely
*Where wells are inhibited, feed back of well treatments may protect
flowlines.
b. CUSTODY TRANSFER LINES
-55-
The following are data normally reviewed in water sample studies and
the significance of the numerical results.
d. WATER SAMPLES - CORROSION MONITORING
pH
0-7.0
7.0
7.0 -14.0
Water Corrosive
Water Neutral
Water Non-Corrosive
(scaling possible)
Iron
Count
ppm
0-50
50 -100
100 - Up
Minor Corrosion
Moderate Corrosion
Significant Corrosion
Chlorides
mgll
>1,000
1,000 - 5,000
<5,000
Low Carryover
Average Carryover
High Carryover
Daily
Water
Bbls/MMCF
>.50
.50 - 2.5
<2.5
GAS
VELOCIIT
FPS
INHIBITOR
RESIDUAL
PPM
COMMENT
0-71/2
71/2 - 15
15- Up
250 - 500
150 - 250
50 -150
250 Minimum
200 Preferred
100 Preferred
-56-
CHAPTER V
-57-
A more frequent source of air entrainment in wells that are operated in the
pumped off condition is the polish rod stuffing box. In this operating condition pump efficiency is low and a slight vacuum will occur at the wellhead
with each pump stroke. Typical polish rod seals are designed for internal
pressure on the seals. Unless the stuffing box seal is tight and will hold a
vacuum, air will intermittantly enter the well fluids. This type of leakage can
also occur in other packing type seals between the wellhead and flowline
check valve. It is important in stripper production that all wellhead connections and packing gland items be able to hold a vacuum.
B. AIR ENTRAINMENT IN TANKS
The produced water tank in the battery, unless protected with a gas blanket,
is the most frequent source of air contamination. While these tanks will
generally develop a thin oil blanket, this quickly oxidizes after which the
oxygen passes through the film and enters the water. A thick oil blanket, frequently replaced, is reasonably effective. However, the oil entrained in the
water is generally inadequate for effective blanketing. Gas blanketing the
tanks is the recommended procedure. This should be maintained at a pressure of several inches of water. The gas supply line must be large enough to
maintain the blanket pressure when the water is discharged from the tank.
Many lease vessels develop bottom layers of water and sludge. While this
water may be oxygen free, this is an ideal zone for sulfate reducer bacteria
incubation and growth. When bacteria are detected, periodic slug treatments
with a biocide will prevent bacterial corrosion.
C. AIR ENTRAINMENT IN TRANSFER AND INJECTION PUMPS
Pump installations are frequent sources of air contamination. This is generally caused by failure to recognize that for a given set of pumping conditions,
a pump will endeavor to deliver a specific volume of liquid. When the liquid
is not available at the pump suction in an adequate volume and pressure,
cavitation with accompaning partial vacuum occurs within the pump. Unless
packing glands on pump and adjacent valving are vacuum tight, air is drawn
-58-
into the system and the oxygen dissolves into the water. This source of air is
easily prevented when the following specific installation specifications are
followed.
a. Suction piping one size larger than size of inlet to pump
b. Valves to be through ported and full opening.
c. Changes in flow direction minimized.
d. Flow direction changes with 45 ells or long radius fittings.
e. Suction system as short as possible.
f. Maintain 6 to 10 feet of head on suction.
g. Apply surge suppressors on suction side of high speed piston pumps.
4. AIR ENTRAINMENT IN INJECTION SYSTEM
If ~ate~ is kept air-free through the injection pump and a positive pressure
mamtalOed to the formation face, air contamination will not occur in a pressure tight system.
The corros~on problem ~ost frequently encountered on the injection side of
the system IS ca1!sed by faIlure to seal mating components. The slightest seep
~roV1des a CO?tlOU~>US water phase between the atmosphere and the injechon. water which wIll quickly corrodea joint. This is because oxygen dissolves lOtO the w~ter at the se~p ~nd diffusesinto the wetted joint section. While
t~e amount will not be a slgruficant quantity in the total injection stream, it
will create an extremely C?rro~i~e fluid in the: joint which quickly deVelops a
l~ak. Absolute pr~ssure-tIght jomts and seahng surfaces through the injection system are prlIDary requirements for trouble free operations.
E. POTENTIAL SOURCES OF AIR CONTAMINATION
PRODUCING
WELLS
PRODUCTION
FACILITIES
INJECTION
FACILITIES
Well Annulus
Polish Rod
Stuffmg Box
Wellhead Valves
-59-
The approximate solubility range for oxygen in water is from 10 ppm at 32F
(freezing), to 0 ppm at 212F (boiling). Where the specific oxygen content
has not been measured, the following can be used for conservatively estimating the oxygen content.
ppm oxygen
= 10
- .0555 (T OF - 3QF)
(D)
T OF
r-_(A_)O_R-,-(B-,-)_ _ ~
(A)OR(B)
(GASOUT)
(GAS IN)
(C)
..
::.'~ '
(A)
(D)
(A)
(A)
(A)
-=--- -~
-
SCREEN~
(MONEL)
(D)
SUGGESTED MATERIALS
(A)-FIBER GLASS EPOXY PIPE
(B)-LINED WITH BAKED ON COATINGS
(C)-COAL TAR EPOXY COATING
(D)-METALLURGY AS INDICATED IN
"GUIDELINES FOR SELECTION OF
MARINE MATERIALS"
70 '
--t10 '
-60-
-61-
CHAPTER VI
INHIBITORS
NOH2S
~
Continuous
Injection
R-2263
RN-63
RU-19
R-2263
RN-63
RU-19
350-500 BFPD
Semi-Weekly
Batch
RH-147
RD-46
RH-147
350-500 BFPD
Semi-Weekly
Batch
R-2375
R-129
R-2314
R-129
R-2375
PRODUCTION
RATE
>5OOBFPD
50BFPD
Monthly
Batch
Weekly
Batch
RH-147
RD-46
150-350 BFPD
Weekly
Batch
R-2375
R-129
R-2314
R-129
R-2375
Weekly
Batch
Bi-Weekly
Batch
R-2375
R-2255
R-2314
R-129
R-2255
R-2300
R-129
R-2239
R-2375
R-2255
R-2314
R-129
R-2255
R-2300
R-129
R-2239
-62-
All
Continuous
Injection
RU-161
R-2255
R-2314
R-129
RU-161
R-2300
R-129
R-2239
All
Tubing
Displacement
1 t03 Month
R-66
R-66
R-68
R-2255
R-2258
R-2345
R-2300
R-68
R-2255
R-2258
R-2345
R-2314 ~. R-129
Batch
R-129
R-68
R-2258
R-129
R-68
R-2258
Power Water
Systems
Continuous
Injection
R-2263
RN-63
RN-82
R-2263
RN-63
RN-82
Water Supply
Systems
Continuous
Injection
R-2263
RN-63
RU-19
R-2263
RN-63
RU-19
Power Oil
Systems
R-2255
R-2300
R-2300
R-2239
150-350 BFPD
R-2375
R-2255
R-2314
R-129
Continuous
Injection
Ru-156
RU-161
RU-163A
R-2302
RU-156
RU-161
RU-163A
R-2302
5 -lOMMCF/D
or
VaNe = 0.7-0.9
Batch
3-6 Weeks
R-66
R-2258
R-2345
R-66
Treat at rate of 1
drum/lO,ooo ft. for up to 3"
tubing. Dilute 1:1 to 1:4
with diesel or equivalent.
-63-
R-2258
R-2345
2-5 MMCF/D
or
VaNE = 0.5-0.7
0-2MMCF/D
or
VaNe = 0.2-0.5
Tubing
Displacement
3-6 Weeks
R-2255
R-2258
R-2255
R-2258
Treat at rate of 1
drum/lO,OOO ft. Dilute 1:1 to
1:10
with
diesel
or
equivalent. Displace to bottom of tubing with diesel or
atomize
mixture
into
nitrogen and displace to
bottom of tubing.
Batch
6-8 Weeks
R-66
R-2258
R-2345
R-66
R-2258
R-2345
Tubing
Displacement
6-8 Weeks
R-2255
R-2258
R-2255
R-2258
Batch
8-12 Weeks
R-66
R-2258
R-2345
R-66
R-2258
R-2345
Tubing
Displacement
8--12 Weeks
R-2255
R-2258
R-2255
R-2245
Continuous
Injection
RN-63
RN-82
RU-19
RN-63
RN-82
RN-97
RU-19
Continuous
Injection
RN-63
RN-82
RU-19
RN-63
RN-82
RN-97
RU-19
Dehydrated
Gas Pipelines
Velocity-All
Continuous
Injection
RN-177
RN-I77
Batch
As Required
R-129
R-2255
R-2239
R-2231
R-129
R-2255
R-2239
R-2300
R-2231
Continuous
Injection
RN-63
RN-82
RU-19
RN-63
RN-82
RN-97
RU-19
Continuous
Injection
RN-63
RN-82
RU-19
RN-63
RN-82
RN-97
RU-19
Custody
Transfer Oil
Pipelines
Velocity> 3 fps
Continuous
Injection
RN-63
RN-82
RU-19
RN-63
RN-82
RN-97
RU-19
-64-
-65-
CHAPTER VII
MISCELLANEOUS TECHNICAL INFORMATION
SERVICE HISTORY
(Decision)
GENERAL
The following information while not directly related to corrosion is frequent1y desirable in studying a failure or reporting on the problem. The primary
objective in most studies is to isolate the reasons and if possible modify
producing operations to prevent their reoccurence. Statistics indicate that 80
to 90 percent of the failures in production and pipeline equipment are due
to metal loss corrosion. When corrosion has been isolated as the cause, it is
frequently probable that the condition causing the attack is present
throughout the operation. Research and field studies have identified most of
the reasons for corrosion and the most likely location of corrosive zones. With
this information a corrosion engineer or experienced field operator can frequently, quickly solve a corrosion problem.
The 10 to 20 percent not readily identified as corrosion may require an indepth laboratory study to determine the cause. Such studies are generally
time consuming and frequently quite expensive. This requires a decision on
the operator's part as to whether a further investigation is warranted. Where
the failure is defmitely not due to corrosion but probably reflects a material
or operating anomaly, neither of which will reoccur, studies are probably unwarranted. Failures that cause either a catastrophic or hazardous operating
condition should always be studied.
A reoccurring inquiry on non-identifiable failures is "...not to specification".
Most wellbore equipment and piping is made to API specifications. These
are always precise as to dimensions. However, the API composition
specifications for steels are quite broad and generally limited to carbon, manganese, sulfur and phosphorous. Invariably the steels will be within specification. The physical strength specifications, except for materials designated for
sour service are also broad. Failure to meet API specifications within the
designated grade are rare. While failure to meet specifications are unusual,
there are occasional instances of heat treating, major surface imperfections
or API grade substitution or mistake causing failure. These conditions will
generally require laboratory tests to establish lack of specification as the
cause of failures. In addition to the following a number of references are listed
at the close of this chapter as further sources of information frequently pertinent to corrosion studies.
-66-
--------------------------- --------------------------------TESTING
METALLOGRAPHIC STUDY
ANALYSIS OF RESULTS
CAUSE OBVIOUS
The block diagram lists steps in a ~yPical failure analysis. In field operati?ns
the steps above the first decision line would n~rmally be per.forme~ at SIte.
If corrosion is recognized as the cause, an expenenced corrOSIon ~n~eer or
field operator can generally locate the reaso~ for the attack. ThIS Will complete the investigation and other than prepanng necessary reports no other
action is required.
If the first three items have not isolated the cause, the opera~ions betwee~ the
decision lines are the next considerations. Generally the testI?-~ branch w.Ill be
first considered. In view of API limited and broad compOSItIonal. specIfi~a
tions Chemical Analysis is not usually considered as desirable. Ph~slcal. testmg
will determine if rods and tubular goods are within grade speclfica~lOn: As
noted in Item B, non-destructive testing based on hardness determmatI~ns
will determine if laboratory tensile testing is warranted. T~e non-destruct~ve
hardness testing can generally be made in field labor atones and determme
whether destructive type tensile testing is warranted.
-67-
160,000
iii
As noted in Item A, with either Rockwell or Brinell hardness tests that can
usually be made in Field area locations, tensile and yield strengths can be estimated. Three to five hardness measurements, as close to the failure as
practical, should be averaged to assure to reasonably accurate result. This
hardness can then be used in conjunction with the following curves to estimate
the range of tensile and yield strengths of a steel.
140,000
Q.
i= 120,000
t!)
~ 100,000
l-
f/)
~ 80,000
iii
ffi
I-
60,000
40,000
Item 2 & 3 relate Tensile and Yield Strengths to Brinell Hardness. The curve
below converts Rockwell "e" to Brinell.
20,000
100
40
200
300
BRINEll HARDNESS
Using median tensile strength from Item 2 determine Yield Strength range.
""
If steel specifications range is outside these values, make standard tensile yield
-I
til
30
tests.
0
til
til
25
90
W
..J
a:: 20
iii
z
w
""
-I
-I
l-
w 15
3:
J:
u.
a::
/'
l-
t!)
zw
II:
l-
/'
::r::
10
/'
/'
f/)
..J
W
>=
200
230
260
290
BRINELL HARDNESS
320
350
50
75,000
100,000
125,000
150,000
-68-
-69-
175,000
= .;;Ba.;.;.IT;.;.e.;.;.l_so_f_L_iq....u_id...pe_r_D....
ay
=#
C
P
=
=
Operating Constant
Density in pounds per cubic feet
15,400
CFS
Pipe Area in Square Feet
100r--,--,----'-.---r--r---r---r----.
= 12 to 20 fps
Water (non-corrosive)
Water
(corrosive)
= 6 to 12 fps
Water
(corrosive + abrasive) = 4 to 6 fps
NOTE: Higher values fresh water, lower values brine.
oIII
3. LIMITING VELOCITIES FOR OIL IN STEEL PIPE
Crude Oil (dry)
= 30 to 35 fps
Crude Oil (wet)
= 20 to 25 fps
NOTE: Minimum velocity to entrain emulsion
Vel. = 31/2 to 5 fps
~
~
go
70
60
50
III
>
~ 40
ffl
30
20
10
1 fps
-70-
10
20
30
40
50
60
-71-
70
80
=
=
TOTAL
BOPDXO.234
BWPDX0.234
MSCFD X 1.18 X oR X Z
=
=
=
TOTAL
SG
Specific Gravity
d. BAKED ON COATINGS
3.
-72-
In smaller pipe and injection lines, the baked-on coating is the most widely
used procedure for corrosion protection. Laboratory tests have established
that if properly applied, all of the baked-on coatings, whether they are of the
thin or thick film types, will give good protection in oil and water handling
operations. In practically all instances where failures occur these are due to
either improper cleaning, coating'application, baking of the coatings or fieldinduced failures resulting from improper transporting or laying procedures.
Where the baked-on coatings are properly applied and handled, good service can be expected in oil and water piping.
In many instances baked on coatings have been unsatisfactory in high pressure gas piping. Service has been particularly poor in lines subject to frequent
pressure fluctuations. The failures are due to blistering and the coating flaking off the steel. The failures are attributed to the coating being permeable
to gas, which diffus through the coating. With pressure reduction the gas
expands, forming bl sters, which spall from the pipe wall. Baked on coatings
are not recommended for high pressure gas service.
e. CEMENT LININGS
In large diameter piping (6" plus) cement is a widely used lining system for
handling water. With present laboratory proved specifications excellent performance can be anticipated from cement type linings. The major problem
area is in the joints. However, such failures are usually due to improper welding or chalking practices. When the laying of the cement lined pipe is supervised to assure proper welding and sealing of the joints excellent service can
be expected. There are a number of special joint systems that can also be
used to assure line integrity.
-73-
b. STAINLESS STEELS
The term stainless steel used with many tradenames is a misnomer. These alloys may resist corrosion for some specific operating condition but unless the
chromium content is above 9% - 10% they do not meet the AISI designation
for stainless steel. The following figure is the designation of the alloys as based
on the chromium content.
45
40 ~Steel
35
.l:
.ll'
30
..
.!: 25
E
.,
~
u
~
20
15
l~
-'",
Stainless steels
"""""-
"
D..
10
5
00
12
16
C~rome_
Iron
I'
4
Chromium steels
Chromium is the principal alloying element for increasing the corrosion resistance of steel. The resistance of the steel to attack is developed by a very thin
fIlm of chromium oxide that forms on the surface. Even though this film can
be ruptured or destroyed, in the atmosphere or in a highly oxidizing environment, it is self healing and the stainless condition is maintained. However, in
the presence of certain acids, chlorides, etc. the film may be destroyed and
not reestablish. The condition of the alloy is then designated as active and
the metal corrodes like plain carbon steels.
20
24
33.5
....,.
28
32
-74-
-75-
F.
K
C
D
CHEMICAL
COMPOSITION
AISI46XX
AISI1536*
CARBON/ALLOY**
TENSILE STRENGTH
MIN.PSI
MAX.PSI
85,000
90,000
115,000
115,000
115,000
140,000
-76-
CLASS
HARDNESS
ROCKWELL-C
16 Min. - 23 Max.
GRADE
The following specifications cover the various grades of tubing and casing
with industry specifications, also including information on drill pipe. As
noted in Item A, Failure Analysis Procedure, specifications for composition
are quite broad and seldom considered in failure studies. The following lists
the Physical Specifications, the first consideration, when failures not attributable to corrosion are investigated. In the H2S column, "YES" indicates
the Grade is suitable for sour service.
GRADE
STRENGTH
YIELD
TENSILE
MIN.
MAX.
MIN.
SPEC.
60,000
YES
5A
H-4O
40,000
J-55
55,000
80,000
75,000
YES
5A
K-55
55,000
80,000
95,000
YES
5A
N-8O
80,000
110,000
100,000
5A
C-75
75,000
90,000
95,000
YES
5AC
L-80
80,000
95,000
95,000
YES
5AC
C-95
95,000
110,000
105,000
5AC
P-105
105,000
135,000
120,000
NO
5AX
P-ll0
110,000
140,000
125,000
NO
5AX
? - Where maximum stress does not exceed 90,000 psi or downhole temperature is in excess of 1500 F, sulfide stress cracking would not be expected.
-77)
GRADE
30,000
48,000
35,000
60,000
X42
42,000
60,000
X46
46,000
63,000
X52
52,000
66,000*
72,000**
X56
56,000
71,000*
75,000**
X60
60,000
75,000*
78,000**
X65
65,000
77,000*
80,000**
X70
70,000
80,000*
82,000**
1.
2.
3.
4.
5.
6.
* For pipe less than 20" O.D. with any wall thickness and for pipe 20"
O.D. and larger with wall thickness greater than 0.375".
** For pipe 20" O .D. and larger with wall thickness 0.375" and less.
-78-
-79-