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Corrosion Assessment to Extend Vessel Continuous Operation Subsequent to Depleted Anodes Indications

Picture for Corrosion Assessment to Extend Vessel Continuous Operation Subsequent to Depleted Anodes Indications
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In gas-oil separation plants (GOSPs), multiphase crude is separated, degassed and then dehydrated before being shipped to stabilization plants for further processing. Typically, in ageing oil fields, the crude is accompanied by large volumes of formation water that is separated in GOSPs using three-phase production traps, which are large horizontal vessels, using a gravimetric separation process where water collects and settles at the vessel’s lower part.

Product Number: 51323-18992-SG
Author: Muntathir M. Al-Jumaah, Usman Shahzad, Mamdouh H. Hadi
Publication Date: 2023
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$20.00
$20.00

After six years in continuous operation, early indication of depleted sacrificial anodes inside a three-phase separation vessel was revealed by the vessel’s anode monitoring system (AMS). The vessel, which was constructed of carbon steel, has been subjected to a highly corrosive environment due to the presence of acidic gases (CO2 and H2S) and high-salinity formation water typically encountered in upstream crude processing plants.
A qualitative corrosion assessment was conducted to evaluate the need to open the vessel one year ahead of the scheduled turnaround and inspection (T&I). The study included a review of the previous inspection history and the existing corrosion protection layers; namely, internal coating, sacrificial anodes cathodic protection, and corrosion inhibition. It was concluded that the vessel can be safely maintained in continuous operation for the proposed period with a recommendation to conduct frequent external inspections to screen for any localized corrosion. Inspecting the vessel one year later (i.e., after seven-year continuous operation) revealed that the sacrificial anodes depletion was between 80-90%, providing the necessary protection to the vessel. Consequently, this assessment led to avoiding unplanned lengthy shutdowns and unnecessary production loss.

After six years in continuous operation, early indication of depleted sacrificial anodes inside a three-phase separation vessel was revealed by the vessel’s anode monitoring system (AMS). The vessel, which was constructed of carbon steel, has been subjected to a highly corrosive environment due to the presence of acidic gases (CO2 and H2S) and high-salinity formation water typically encountered in upstream crude processing plants.
A qualitative corrosion assessment was conducted to evaluate the need to open the vessel one year ahead of the scheduled turnaround and inspection (T&I). The study included a review of the previous inspection history and the existing corrosion protection layers; namely, internal coating, sacrificial anodes cathodic protection, and corrosion inhibition. It was concluded that the vessel can be safely maintained in continuous operation for the proposed period with a recommendation to conduct frequent external inspections to screen for any localized corrosion. Inspecting the vessel one year later (i.e., after seven-year continuous operation) revealed that the sacrificial anodes depletion was between 80-90%, providing the necessary protection to the vessel. Consequently, this assessment led to avoiding unplanned lengthy shutdowns and unnecessary production loss.

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