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Corrosion Inhibitors Use: Case Study For Guinea Gulf Assets Application

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Carbon steel (CS) material is widely used for the equipment in oil and gas production industry due to its mechanical properties associated with a relatively low cost, compared to other materials. Depending on the corrosiveness of the fluid that is vehiculated, the use of carbon steel is generally associated with the injection of a corrosion inhibitor (CI) in order to mitigate internal corrosion. Corrosion inhibitors are generally used in continuous injection at an injection rate that is depending on the corrosiveness of the fluid. Based on the operational feedback, the internal standards are recommending for multiphase pipelines CI injection rates in the range of 50 - 70 ppm for temperature below 80°C of and of 150 to 200ppm for temperatures above 100°C. These injection dosages are typical values that are considered in the laboratory tests for the qualification of the CI and they are adjusted on-site based on the monitoring results.

Product Number: 51322-17663-SG
Author: Alvaro Mpaka Sousa, Laurent Dehays, Francisco Mateus Garcia, Mioara Stroe, Raquel Eduarda Araujo
Publication Date: 2022
Industries: Cathodic Protection , Corrosion Monitoring and Control , Coatings and Linings , Coatings
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Traditional solution for oil and gas production equipment is the use of carbon steel (CS) due to its reduced cost, compared to more noble and corrosion resistant materials. To ensure the integrity of these equipment, the use of carbon steel needs to be accompanied by corrosion mitigation measures, like the use of Corrosion Inhibitors (CI). In the present context with more and more constraining environmental requirements and with the increase of water cut, the use of corrosion inhibitors become challenging. An optimized use of these chemicals is necessary to limit as much as possible, their impact on the environment, but also to limit the costs associated to their use, while the anticorrosion efficiency is kept sufficient to protect the carbon steel (CS) equipment.

The Company strategy is to use CI that are selected via laboratory testing programs. The corrosion inhibitors are evaluated through a series of tests aiming to be representative of the future use conditions. Parameters like carbon dioxide (CO2) content in the associated gas, temperature and produced water salinity, flow velocity and flow regime, presence of sand are considered when the anti-corrosion efficiency is evaluated. Nevertheless, the field conditions cannot be fully reproduced in the laboratory and some aspects like foaming and emulsion tendencies, are not fully assessed during testing. This can be assessed only during a field test, where the CI is exposed to the real conditions.

Traditional solution for oil and gas production equipment is the use of carbon steel (CS) due to its reduced cost, compared to more noble and corrosion resistant materials. To ensure the integrity of these equipment, the use of carbon steel needs to be accompanied by corrosion mitigation measures, like the use of Corrosion Inhibitors (CI). In the present context with more and more constraining environmental requirements and with the increase of water cut, the use of corrosion inhibitors become challenging. An optimized use of these chemicals is necessary to limit as much as possible, their impact on the environment, but also to limit the costs associated to their use, while the anticorrosion efficiency is kept sufficient to protect the carbon steel (CS) equipment.

The Company strategy is to use CI that are selected via laboratory testing programs. The corrosion inhibitors are evaluated through a series of tests aiming to be representative of the future use conditions. Parameters like carbon dioxide (CO2) content in the associated gas, temperature and produced water salinity, flow velocity and flow regime, presence of sand are considered when the anti-corrosion efficiency is evaluated. Nevertheless, the field conditions cannot be fully reproduced in the laboratory and some aspects like foaming and emulsion tendencies, are not fully assessed during testing. This can be assessed only during a field test, where the CI is exposed to the real conditions.

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Corrosion of pipelines made of carbon steel and exposed to wet hydrocarbons containing CO2 and H2S is a common but serious problem encountered in petroleum industry and its occurrence causes enormousexpense due to production downtime, accidental injuries, and replacement costs. Control and prevent corrosion using chemical treatment (e.g. corrosion inhibitor injection) is one of the most cost-effective solutions and commonly practiced methods to prevent corrosion failures in pipelines in oil and gas industry. Generally speaking, the active corrosion inhibitor (CI) components in commercial CI packages are usually organic, nitrogen-based surfactants such as amines, imidazoline and its derivatives. Due to the amphiphilic nature of surfactants, a good fraction of the injected CI will inevitably go into the oil phase through partitioning and to the oil/water interface.
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Corrosion inhibitors provide a critical barrier to internal corrosion, presenting the most cost-effective form of mitigation and enabling operators to use carbon steel where it would otherwise be impractical. The correct selection and validation of inhibitors is essential to ensure successful field deployment, providing safe and reliable operation. However, the selection and optimization of a corrosion inhibitor for a particular field application is not trivial.  
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