IBP1117_19

THE IMPORTANCE OF CRUDE OIL

CHARACTERISTICS AND INTERNAL
CORROSION FIELD DATA FOR LIFE
EXTENSION ASSESSMENT OF PIPELINES
Gustavo L. Vaz1, Pedro Altoé Ferreira 2, Victor G. Silva
3 3

Copyright 2019, Brazilian Petroleum, Gas and Biofuels Institute - IBP

This Technical Paper was prepared for presentation at the Rio Pipeline Conference and Exhibition 2019, held
between 03 and 05 of September, in Rio de Janeiro. This Technical Paper was selected for presentation by the
Technical Committee of the event according to the information contained in the final paper submitted by the
author(s). The organizers are not supposed to translate or correct the submitted papers. The material as it is
presented, does not necessarily represent Brazilian Petroleum, Gas and Biofuels Institute’s opinion, or that of its
Members or Representatives. Authors consent to the publication of this Technical Paper in the Rio Pipeline
Conference and Exhibition 2019.

Abstract

The CO2 corrosion is one of the key corrosion processes in many oil fields. It is also known
that the CO2 corrosion mechanism is affected by many parameters like: water chemistry,
scales, temperature, flow, steel type, and other contaminants like organic acids, H2S or O2,
condensation, chemicals, crude oil type and etc. Despite industry have made many advances,
from modelling standpoint, one of the key issues that remains not very well predicted in the
models is the crude effect. The petroleum type can modify water wettability or emulsion
properties or the water entrainment or even bring some inhibition effect by certain
components of the crude oil. However, the effect of water wetting/entrainment is better
understood from a hydrodynamic point of view. To minimize uncertainties, one strategy could
be to use two sources of data in order to calibrate the models: lab data using real crude and
field corrosion data. It was observed that after the emulsion break point the corrosion rate
increases exponentially. This paper shows an example of methodology based on actual field
cases, which combine lab data, corrosion field data and other assumptions necessary to allow
extending the life of the pipeline. A discussion about the importance and the achievements
based on laboratory data using real crude oil is also addressed.

Keywords: Corrosion Rate Prediction, CO2 Corrosion, Multiphase Flow, Integrity pipeline
management.

1. Introduction

As known, oil production rate declines as the production time increases. However,
when action is taken to improve the recovery of oil, such as fluid injection, fracturing, and
acidizing, the decline curve is postponed. In addition, it is common to find out nearby oil and
gas fields which production is routed to old facilities and pipelines, which may push the
operation beyond the original design planned life. The challenge is bigger when this happens
towards the end of a field's life because usually the water cut is high and this may lead to a
dramatic increase in the oil pipeline’s corrosion rate. Other normal scenario is when new
satellite fields are tied to the pipelines but not near the end of the original planned fields.

______________________________
1
Master, Petroleum Chemist - CENPES/PETROBRAS
2
Master, Petroleum Engineer – CENPES/PETROBRAS
3
Master, Equipment Engineer – CENPES/PETROBRAS
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When it happens, the pipeline operating conditions become more aggressive than anticipated,
leading to premature internal corrosion before the end of its design life. All this situations
require the engineers responsible for the asset's integrity to extend the life of the pipeline in
order to match the remaining life of the field.
In Brazil, after 2015 the Brazilian Petroleum Agency set a technical regulation for
offshore installations, which demands a life extension reassessment if the asset owner has the
intention to operate beyond the design life. The regulation for subsea system operational
safety management was released in 2015 (ANP n °41/2015). Such scenario makes operators
take many measurements, which include actions to ensure pipeline will operate safely and in
accordance with local legislations as well as requirements of international standards. In a
short time, the ANP n ° 41/2015 has immediate impact on offshore brown fields. One of key
steps to extending the lifetime of the oil pipeline is how to estimate the remaining wall
thickness and how to forecast or extrapolate the future internal corrosion rate, in order to
define which mitigation ought to be taken. Despite the pipeline may have different threats,
internal corrosion usually is one of the key issues if the upstream pipeline transport oil or gas
or both fluids in the presence of water. There are some models to predict corrosion rate in
upstream pipelines. However, the models are very conservative or present no accordance with
the monitoring field data.
According to De Waard et al. (2003) the oil flow in multiphasic pipelines can change
the corrosion rate and modify the effect of some parameters used to predict internal corrosion
rate. FERREIRA, KANG, VERA and et al. (2006) also observed the importance of flow
pattern on the corrosion in offshore risers. The CO2 corrosion is one of the key processes in
many oil fields. It is also known that the CO2 corrosion mechanism is affected by many
parameters like: water chemistry, scales, temperature, flow, steel type, other contaminants like
organic acids, H2S or O2, condensation, chemicals, crude oil type and etc. BECERRA et al.
(2000) presents a study with carbon steel corrosion in oil-in-water emulsions under controlled
hydrodynamic conditions showing the mechanisms involved and the equations to determinate
the shear stress under flowing condition. FERREIRA, KANE and et al. (1996) observed also
the influence of oil and water cut on the corrosion rate in lab tests for offshore brazilian
pipeline conditions during the assessment for the development of first fields discovered in
Santos Basin.
Despite industry have made many advances, from modelling standpoint, one of the
key issues that remains not very well predicted in the models is the crude effect. This paper
will present how to use monitoring field data and lab tests to adjust some models of corrosion
rate prediction.

2. Corrosion rate prediction methodology - the influence of crude oil and field data

A case-study for the methodology proposed to adjust the corrosion rate calculated
from standard CO2 corrosion models is presented. Based on the methodology proposed a
better estimation of life extension of the pipeline in this case-study can be done as well as the
results can be extrapolated to other pipelines on similar conditions.

First step – Field Data Monitoring

The case-study presented is an oil/water/gas production system which production

flows without previous treatment to remove the water content is pumped from different rigs to
a central platform using carbon steel and flexible pipelines, as showed in Figure 1. In this
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particular case-study, the oil, water and natural gas produced from four different offshore
production units are sent to be treated in a central platform PX-5. The aim is how to estimate
the remaining wall thickness in order to allow the extension life to be assessed for the
gathering line that receive all production in PX-5 from the subsea manifold (PLEM); The first
approach to achieve the target is to take into account the field data.
The field data is based on the production historical data for the subsea pipeline study.
It takes into account;

• Operational Parameters: Pressure, Temperature, Flow rate, etc;

• Monitoring information:
o Chemical analysis of fluids;
o Corrosion Rate of coupons or/and RE sensors.
• Inspection Information:
o Thickness measurement;
o PIG inspection registers.

On key information is the data from the internal corrosion monitoring. In this specific
case, the data is the corrosion rate calculated from weight loss intrusive coupons. Other very
important piece of information is the corrosion rate calculated from the corrosion pig run from
the last inspection. However, many offshore lines are not possible to run smart corrosion pigs
because the subsea architecture. The worst scenario, most challenged, is exactly when the
mission is to predict the remaining wall thickness of this pipeline and to run an inspection
with smart pig is not possible. The case-study presented has this situation and for that reason
the methodology assumes as main source of information the data from the internal corrosion
monitoring. Data from internal corrosion monitoring can be get using different techniques and
it can bring valuable information about the integrity of oil pipelines as mentioned by Ferreira
(2001) in some field experiences.
Figure 2 shows the internal corrosion rates obtained from the coupons since the
beginning of the operation from 1989 until 2018 for the gathering carbon-manganese steel
pipeline from a weight loss coupon located at its end in the topside of P-X5. The highest
corrosion rate recorded was 0.18 mm/y in 2016.

Figure 1. Field production system of an offshore pipeline configuration.

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Figure 2. Weight loss corrosion rate obtained in P-X5.

Second step - Corrosion Rate from Modeling

Assuming 0.18 mm/y as the worst case based on the field monitoring, the next step is
calculate the corrosion rate from modelling and see if there is some correlation. For the case-
study, it is possible to estimate internal corrosion rate using some commercial software as
CO2 corrosion is the main threat based on the fluid composition.
Figure 3 shows a simulation of the pipeline considering the scenario proposed in
Figure 1. The operational information used for this simulation was from the period when
maximum coupon corrosion rate was obtained in 2016 (0.18mm/y). Table 1 and Table 2
presents the input data assumed for the flow condition and fluid composition for year 2016 for
the simulation carried out.
As can be observed, the prediction model indicates 3 mm/y as maximum corrosion
rate at the end of the pipeline, which is the same local where the coupon recorded the 0.18
mm/y. As can be noted, 3 mm/y is a very conservative prediction when compared to the
weight loss corrosion rate. This big difference is because the modelling don’t take into
account some other parameters that can reduce the actual corrosion rate.

Figure 3. Corrosion rate prediction for multiphasic pipeline (PLEM – PX-5) using a software.

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Table 1. Operation conditions in the pipeline in 2016.

P (PLEM) T (PLEM) Qgas Qliquid Water cut

(kgf/cm2) (°C) (MMSm /d) 3 3
(m /d) (%)
60.0 27.4 0.05 1200 50

Table 2. Water and gas characterization in 2016.

CO2 H 2S Oxygen Chloride Alkalinity Organic Acids

(%) (ppmv) (ppb) (mg/L) (mg/L) (mg/L)

0.6 - <20 60000 430 150

Third step – Lab data

For the specific case-study, the key parameter added in the modelling and it may have
a significant impact in the final result is the wettability. The wettability depends the crude oil
type as it can create different sorts of emulsion. In order to adjust the prediction model and
use the field monitoring corrosion rate, some lab tests were carried out to mimic the effect of
the oil on the CO2 corrosion. For that, some tests using rotating cage (ASTM G184) with
carbon-manganese coupons were executed to check the influence of water cut in CO2
corrosion in the presence of field crude samples.
Figure 4 shows the effect of the emulsion in the decrease of the corrosion rate for two
different crudes. In this case it was defined the wettability emulsion factor (WEF). The WEF
is the factor that represents the fraction of reduction of the corrosion rate when compared to
the corrosion rate when the coupon is 100% in contact with the free water.
The field crude oil sample tested was a light crude with API ~ 30 which is represented
as a blue line in figure 4. During the tests were observed, that after the emulsion break point
the corrosion rate increased exponentially. Other production system close to the system
presented in figure 1, also operate at similar conditions where CO2 is the dominant corrosion
mechanism but transporting heavier crude (API 19). For that reason, lab tests were carried out
using different crude oil types but in similar condition: pressure, temperature, shear stress, and
water chemistry.

Figure 4. Wettability Emulsion Factor in function of watercut in multiphasic flow system.

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Most commercial software were developed only considering water as the only phase,
therefore the predicted corrosion rate may not represent a multiphasic flow system where the
steel is more oil wet. In our specific case-study where a water cut of 50% was assumed, the
wettability emulsion factor (WEF) obtained from figure 4 was applied to adjust the corrosion
rate according to equations 1-3.

CRadjusted = CRpredicted x Factor(wettability emulsion) (1)

CRadjusted = 3 (mm/y) x 0.08 (2)
CRadjusted = 0.24 mm/y (3)

On this way, using this methodology approach, an adjusted corrosion rate of 0.24
mm/y was calculated which value is close to 0.18 mm/y from the internal field monitoring.
Assuming the two values are very close considering all the uncertainties, the parameters for
future simulation can be set adding the WEF of 0,08. The high degree of correlation of these
values, strength the prediction of the calculations to predict the extension life for pipelines in
Figure 1 as well as for other pipelines under similar scenario and corrosion mechanism. The
methodology and assumptions allows a good accurateness despite the many variables
involved in these calculations.
This methodology approach for brown fields may be an important step for the future
integrity assessment for Pre-salt production pipelines in Santos Basin where production has a
high CO2 content for carbon steel lines. Corrosion challenges for pipelines in Santos Basin is
present since its discovery as mentioned by FERREIRA (1995) and it should remain in the
future with the perspective of new investments for Pre-salt production and therefore new
pipelines. Since 2015, the operators have being reassessing the pipeline life and other subsea
facilities in order to be in compliance with ANP’s regulation n °41/2015. Many of brown
fields were designed 25y, 30y or 35 years ago. In essence, the typical design life for an
offshore production facility is 25y or 30y. For that reason, in the 80’s or 90’s the typical
design usually don’t have subsea internal corrosion monitoring tools because the subsea
technology evolution for such devices came along this period and beyond. In addition to,
many of the subsea facilities are not piggable and ILI is very restricted. Such scenario poses a
complex situation for life extension assessment.
Despite there are many possible variations, the corrosion rate is restricted to weight
loss coupons and/or electric resistance probes immersed in the transported fluid at the topside
of the production rigs at the inlet or outlet of the pipeline. The data from monitoring is
valuable if the locations allows the coupon or probe to be wet on water or in an emulsion.
Those monitoring locations must feel some physical change in the system that may cause a
change in the internal corrosion. Unfortunately, many times the location don’t represent the
worst scenario along the pipeline from the corrosion standpoint.
The methodology for the case study presented in this paper was applied for a pipeline
where the CO2 corrosion mechanism is dominant. As mentioned by POTS, KAPUSTA and at
al. (NACE 2002) a high-quality lab data may be not get for CO2/H2S corrosion, MIC, organic
acid corrosion and oxygen corrosion. For these other corrosion mechanisms, other studies are
necessary in order to evaluate if the oil crude effect can adjust the corrosion rate prediction
models. The subsea system is complex as the pipeline may have different corrosion
mechanisms. For example, the steel catenary risers (SCR) used in some deep or ultra deep
water fields are under a different corrosion velocity when compared to pipeline section on the
bottom of the sea; Risers have differences in flow patterns as mentioned by FERREIRA
(2006) and therefore the effective corrosion rate is expected to be different from the subsea
gathering lines from the wellhead to the platform.

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5. Conclusion

According to the methodology approach proposed, the models for corrosion rate
prediction may be adjusted with high degree of accuracy using lab tests data when the end
result correlate well with the field monitoring data. Thus, it is possible to extend the life of a
multiphasic pipeline in a safe way despite the many variables and uncertainties. The literature
and industry have few guidelines and references describing the assumptions and steps how to
make such calculation in order to predict the life extension of the pipeline from internal
corrosion point of view. Therefore, the methodology approach presented in this paper is an
important step as internal corrosion is one of the threats that must be take into account in other
the offshore pipeline industry to comply with ANP’s regulation n °41/2015. Particularly, for
brown fields in Brazil.
Besides, the methodology approach for pipelines where the dominant corrosion
mechanism is not CO2 must be taken with caution. For those scenarios, it is important to
improve the methodology for subsea pipeline’s life extension. For that reason, it is a good
strategy to have more field monitoring data in order to obtain additional information to adjust
the predicted corrosion rate. With new advances in pipeline technology, IoT, digital
transformation and integrated database it is possible for the decision-makers get high grade of
safety and reliability in their predictions for a safety field operation. In this way, it is very
important the operators:

• pursue new sensor technologies;

• deploy more field monitoring systems including subsea devices;
• create pipeline internal corrosion Big Data for life extension prediction;
• pursue continuous improvement on the internal corrosion rate models;
• when possible, design piggable pipelines.

6. References

ASTM G184-06. Standard Practice for Evaluating and Qualifying Oil Field and Refinery
Corrosion Inhibitors Using Rotating Cage.

BECERRA, H. Q., RETAMOSO, C., MACDONALD, D. D. The corrosion of carbon steel in

oil-in-water emultions under controlled hydrodynamic conditions. Corrosion science, 42, p
561-575, 2000).

De WAARD, C., SMITH, L. M., CRAIG, B. D. The Influence of crude oil on well tubing
corrosion rates, NACE, n°. 03629, 2003.

R.D. KANE, D. ABAYRATHNA, and FERREIRA, P.ALTOE, Corrosivity Assessment of

Sour Acid Gas and Parrafin Oil Flow Lines Using Simulated Multiphase Environment Test,
NACE CORROSION 1997, Paper No. 3, NACE International, Houston, Texas, March 1997.

FERREIRA P. ALTOE, GOMES DECIO, FERREIRA C. V.M., Experiência de Campo com

a Aplicação de Técnicas de Monitoração no Controle da Corrosão Interna de Oleodutos com
Inibidores, XXI CONBRASCORR 2001, São Paulo, Brasil, 20 a 22 August 2001.

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FERREIRA P. ALTOE, Challenging corrosion problems in new Santos Basin field, Offshore
Magazine 1995, Latin America, January 1995.

FERREIRA P.ALTOE.(Petrobras), KANG C. (CC Technologies-a DNV Company), MORE

PARIMALP (CC Technologies-a DNV Company), VERA J. (CC Technologies-a DNV
Company), ARAUJO M. (Petrobras), BASTOS E.C. (Petrobras), Flow Patterns and
Characteristics in Multiphase Riser Pipelines, NACE CORROSION 2006, 12-16 March, San
Diego, California, 2006.

POTS Bernardus F.M., KAPUSTA S. D. (Shell Global Solutions US) | RANDY C. John
(Shell Global Solutions US) | M.J.J. Simon Thomas (Shell Global Solutions International) |
Ian J. Rippon (Shell Global Solutions International) | T.S. Whitham (Shell Research Ltd.) |
Magdy Girgis (Shell Canada Ltd.), Improvements on de Waard-Milliams Corrosion
Prediction and Applications to Corrosion Management, CORROSION 2002, April, Denver,
Colorado.