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51314-3809-Corrosion Management and Mechanism Study on SAGD Brackish Water System

Picture for Corrosion Management and Mechanism Study on SAGD Brackish Water System
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Product Number: 51314-3809-SG
ISBN: 3809 2014 CP
Author: Jack Whittaker
Publication Date: 2014
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Brackish water is used to supplement boiler feedwater in SAGD processes. In Alberta water quality from the McMurray and Grand Rapids formations typically consists of approximately 1% salinity 750 ppm bicarbonate and15 ppm H2S. The carbon steel piping originally used in this service experienced severe corrosion and failures after only five years of service. General corrosion rates based on carbon steel corrosion coupons were as high as 8 mm/year (320 mpy)! Many of the failures occurred on elbows tees and reducers. A detailed analysis of the overall process and chemistry identified unique corrosion mechanisms that existed in certain process stages. Depending upon the needs of the process the corrosion could in fact be mitigated by controlling specific process parameters.Failure analysis showed siderite to be the main corrosion product. A novel mechanism of CO2 corrosion with impingement was proposed and manifested. In rotating cylinder electrode (RCE) tests bicarbonate/CO2 corrosion rates accelerated from 0.125 to 1.75 mm/year (5 to 70 mpy) by increasing the cylinder rotating speed from 2000 to 5000 rpm. These results supported the theory that CO2 cavitation was significantly aggravating corrosion. As a result a caustic injection program was implemented in the field to control pH to 9.0 to suppress the CO2 release from the aqueous phase. Subsequent corrosion coupon data indicates a dramatic drop in corrosion rates to a range of 0.025 to 0.125 mm/year (1 to 5 mpy). In piping stages where pH control wasn’t possible for process reasons the piping was replaced with duplex piping materials.Key words: brackish water SAGD CO2 corrosion impingement caustic corrosion coupon pH carbon steel duplex 
Brackish water is used to supplement boiler feedwater in SAGD processes. In Alberta water quality from the McMurray and Grand Rapids formations typically consists of approximately 1% salinity 750 ppm bicarbonate and15 ppm H2S. The carbon steel piping originally used in this service experienced severe corrosion and failures after only five years of service. General corrosion rates based on carbon steel corrosion coupons were as high as 8 mm/year (320 mpy)! Many of the failures occurred on elbows tees and reducers. A detailed analysis of the overall process and chemistry identified unique corrosion mechanisms that existed in certain process stages. Depending upon the needs of the process the corrosion could in fact be mitigated by controlling specific process parameters.Failure analysis showed siderite to be the main corrosion product. A novel mechanism of CO2 corrosion with impingement was proposed and manifested. In rotating cylinder electrode (RCE) tests bicarbonate/CO2 corrosion rates accelerated from 0.125 to 1.75 mm/year (5 to 70 mpy) by increasing the cylinder rotating speed from 2000 to 5000 rpm. These results supported the theory that CO2 cavitation was significantly aggravating corrosion. As a result a caustic injection program was implemented in the field to control pH to 9.0 to suppress the CO2 release from the aqueous phase. Subsequent corrosion coupon data indicates a dramatic drop in corrosion rates to a range of 0.025 to 0.125 mm/year (1 to 5 mpy). In piping stages where pH control wasn’t possible for process reasons the piping was replaced with duplex piping materials.Key words: brackish water SAGD CO2 corrosion impingement caustic corrosion coupon pH carbon steel duplex 
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51318-11002-Damage Mechanism Study of Severe Corrosion of Carbon Steel Pipe in SAGD Brackish Water Service

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The carbon steel lines carrying brackish water associated with a heavy oil SAGD (Steam Assisted Gravity Drainage) operation in Northern Alberta experienced severe localized corrosion. This is a continuation of a previous study of similar failures at a similar facility.
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