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Erosion/Corrosion of Duplex Stainless Steel in Sweet Production with Sand Versus CaCO3

Picture for Erosion/Corrosion of Duplex Stainless Steel in Sweet Production with Sand Versus CaCO3
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In the Oil and Gas industry, carbon steel tubing, piping and process equipment may be susceptible to erosion-corrosion damage due to the erosive and corrosive nature of the flow. To minimize the harsh effects and costly losses of erosion-corrosion, corrosion resistance alloys (CRAs) and corrosion inhibitors are commonly used. CRAs such as stainless steels, nickel and titanium alloys have excellent CO2 corrosion resistance.

Product Number: 51323-19394-SG
Author: Anass S. Nassef, Michael W. Keller, Siamack A. Shirazi
Publication Date: 2023
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Erosion-Corrosion behavior of 2507 duplex stainless steel was studied in a CO2 saturated environment (sweet production) as it was impinged by CaCO3 and sand particles. Experimental data were collected with the objective of investigating the performance of 2507 duplex stainless steel on mitigating CO2 corrosion in erosive environments. Pure erosion, pure corrosion and erosion-corrosion tests were conducted in a flow loop with a direct impingement configuration. Weight loss (WL) and electrochemical linear polarization (LPR) methods were utilized in this study. While WL method was used to measure erosion and total erosion-corrosion, LPR was used to measure pure corrosion and to monitor corrosion part of total erosion-corrosion. The erosivites of particles were characterized at low and high flow velocities. The flowing solution’s pH was monitored and maintained in the range from 4 to 5 throughout corrosion and erosion-corrosion tests. For the experimental conditions considered, pure erosion and erosion-corrosion data showed no synergism between erosion and corrosion.

Erosion-Corrosion behavior of 2507 duplex stainless steel was studied in a CO2 saturated environment (sweet production) as it was impinged by CaCO3 and sand particles. Experimental data were collected with the objective of investigating the performance of 2507 duplex stainless steel on mitigating CO2 corrosion in erosive environments. Pure erosion, pure corrosion and erosion-corrosion tests were conducted in a flow loop with a direct impingement configuration. Weight loss (WL) and electrochemical linear polarization (LPR) methods were utilized in this study. While WL method was used to measure erosion and total erosion-corrosion, LPR was used to measure pure corrosion and to monitor corrosion part of total erosion-corrosion. The erosivites of particles were characterized at low and high flow velocities. The flowing solution’s pH was monitored and maintained in the range from 4 to 5 throughout corrosion and erosion-corrosion tests. For the experimental conditions considered, pure erosion and erosion-corrosion data showed no synergism between erosion and corrosion.

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Erosion of piping systems is a significant issue for many operators of hydrocarbon infrastructure causing a significant loss in revenue and an increase in installations, repair and maintenance costs. Currently, the use of erosion resistant coatings, reduction of flow rates and replacement/repair are the only mitigation controls against erosion. INTECSEA has been developing a novel Erosion Control Technology (ECT) that can reduce the impact of erosion on piping via the strategic placement of custom engineered inserts into the product stream. The two phases of ECT prototype testing under real-field multiphase conditions representing gas condensate fields have been performed at the E/CRC (The University of Tulsa). The superficial gas velocity (VSG) was varied from 31 m/s to 23 m/s with the superficial liquid velocity (VSL) fixed at 0.04 m/s and the sand particles were varied from 300 μm to 75 μm. The metal loss due to erosion was monitored using a set of UT probes in two consecutive elbows spaced 11D apart oriented in a vertical-horizontal loop. The erosion tests using prototype ECT inserts have shown a significant reduction in erosion at both the gas flow conditions. Computational Fluid Dynamics (CFD) has been a backbone in developing this technology and CFD results have shown good correlation with the physical tests. Discussions with leading operators for a field trial targeted for 2020 is ongoing.
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