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RLs are susceptible to internal corrosion that is influenced mainly by fluid corrosiveness including factors such as temperature, pH, carbon dioxide (CO2) and hydrogen sulfide (H2S) content, water chemistry, flow stagnation, wettability, and presence of deposits.
Generally, for corrosion to occur there must be liquid water with sufficient quantity to wet the pipe surface. Once water wet, the line will corrode at a rate determined by the chemistry of the water, acidity and quantity of deposits.
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As facilities in the oil and gas industry age with time, corrosion mitigation and control become more important. Failure of processing equipment is likely to entail production loss, loss of containment, environmental impact, and/or human risk. Internal corrosion failures represent one of the major risks to process equipment and piping.
Variability of operation and practices can lead to mechanical integrity issues of equipment. A similar case was observed when an external UT survey was conducted on a biocide storage tank that showed localized areas of metal loss in the tank wall. The tank was opened for inspection and extensive internal corrosion damage was observed mainly in the form of large isolated pits. Three potential corrosion mitigation options were evaluated: upgrading the tank material from coated carbon steel to 316 stainless steel, installing a non-metallic lining, or keeping using the coated carbon steel and changing the operation practices. Each mitigation option was evaluated based integrity, feasibility, and economic factors. It was found that keeping the coated carbon steel and adjusting the operation practices can ensure the integrity of the tank while lowering the required economical investment. As such, a new operation manual was issued for the biocide storage tanks that ensured that the corrosion inducing environments are avoided.
Pipeline-D was built in 1997 and was used to transport crude to Gas-Oil Separation Plant-1 (GOSP-1). The pipeline continued operating until it was subjected to intermittent shutdown in 2009 when GOSP-2 was built. As part of the project, 900 meters were added to connect Pipeline-D to GOSP-2.