Corrosion Monitoring and Mitigation to Enhance The Facility Integrity in Oil and Gas Industry

1. CORROSION MONITORING AND MITIGATION
TO ENHANCETHE FACILITY INTEGRITY
IN OIL AND GAS INDUSTRY
Ir.Waldemar Husada MSc.

2. PRESENTATION OUTLINE
• Introduction
• Asset Life Cycle
• Asset Integrity Factors
• Material/Corrosion Design Control
• Operational Integrity Control for Asset Life Extension
• Online Sampling Control Design Strategy
• BS7910 Failure Assessment Diagram

3. INTRODUCTION
Mr. Waldemar Husada started his career as a piping and
mechanical equipment engineer for Floating Production Unit
Projects in GUSTO (currently SBM). Afterwards, years in
FLUOR added an experience onshore Petrochemical Project in
Saudi Arabia. He continued his offshore engineering career path
with INTECSEA and GDF Suez E&P. In 2013, he started his
career as an independent consultant for various companies .
Besides his professional engineer careers, Mr. Waldemar Husada is also dedicated his life as
lecturer for different international institutions. .
During his career, Mr. Waldemar Husada has gained hand-on engineering, construction and
operation experiences in various FPSO’s, SPAR’s, Subsea Pipelines, Platforms and
Polypropylene projects. Operating as independent consultant in various oil and gas blocks
and his expertise are in the areas of upstream oil & gas, (green) energy and chemical
technology solutions. .
Mr. Waldemar Husada now focuses on company’s technology, project management and new
business line development, and provides advise as a independent consultant to various
companies.
Mr. Waldemar Husada graduated from Technical University of Delft with a Master of Science
Degree in Mechanical Engineering, majoring in Process Equipment.

4. 0%
5%
10%
15%
20%
25%
30%
35%
40%
45%
50%
Others Third Party or
Outside Damage
Operation or Hot
Tap Errors
Construction or
Material Defect
Corrosion
EGIG DATA
US DOT OPS DATA
Introduction
(Causes of Asset Failure)

5. ASSET LIFE CYCLE
Investment
Design
ConstructionOperation
Decommissioning

6. ASSET INTEGRITY FACTORS
Integrity
Design
Material
Construction
Standards
Corrosion

7. (Material) Design (Control)
Corrosion Prediction Model
Internal corrosion occurs mainly by:
Water and a corrosion agent.
Hydrocarbon contaminants (corrosion
agent):
O2, CO2, H2S, or Chlorides.
Internal corrosion is a function of:
Concentration and Combinations. The prediction Model for Internal
Corrosion Rate:
Waard – Milliams Model
Norsok M506 Model
Other parameters of influence are:
Pressures, Temperatures.
Dimension Shape Erosion Corrosion

8. CORROSION
MORPHOLOGIES
(Material) Design (Control)

9. H2S CORROSION
MORPHOLOGIES
(Material) Design (Control)

10. Operational Integrity Control
• Inhibitor Control (Flow & Material)
• Operational Cleaning (Flow & Material)
• WT and Corrosion Measurement (Material)

11. Operational Integrity Control
Compatibility with:
• Hydrate Inhibitor;
• Demulsifier;
• Scales Inhibitor;
• Oxygen Scavengers;
• Biocides.
• Corrosion (Defect)
Inhibitor
Frequent operational
cleaning for:
• Water swabbing
• Batch inhibitor
• Cleaning and
removal of debris
(either mechanically of
chemically)
Operational
Cleaning
Inhibitor Control Operational
Material
Inspection
•Measure the
Corrosion Growth
by coupon and / or
ER Probe
•Measure the WT
reduction and metal
anomaly to ensure
material integrity by
UT

12. (Material) Design (Control)
Material Specification
• Project definition
• Scope
• Referenced documents (codes, project specifications)
• Definitions
• Manufacturing procedures
• Chemical composition
• Corrosion resistant
• Mechanical properties
• Weldability (and NDT acceptance)
• Mill pressure test
• Dimensional tolerances
• Residual Magnetism
• Marking
• Quality control
• Inspection and test
• Handling
• Documentation

13. ONLINE SAMPLING STRATEGY
DESIGN
• Conceptual samples design
• Field operation data survey
• Detailed design assessment facilities
• Development of a monitoring system
• Development of operational monitoring strategies

14. STRESS STRAIN CURVE RELATION
TO FRACTURE FAILURE PROCESS
• Deformation
• Fracture process

15. UNIVERSAL TESTING MACHINE

16. MATERIAL CAPABILITY TO ABSORB
DEFORMATION “CHANGE” (ENERGY)

17. CRACK ORIENTATION SAMPLING
Weld Middle CTOD
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
1
0 20 40 60 80 100 120
Temperature [°C]
CTOD[mm]
Min
Avg
Max
Fusion Line CTOD
0
0.1
0.2
0.3
0.4
0.5
0.6
0.7
0.8
0.9
0 20 40 60 80 100 120
Temperature [°C]
CTOD[mm]
Min
Avg
Max

18. CEM INVESTIGATION

19. ONLINE MONITORING CONTROL
• Online Condition Monitoring (Flow Transmitter,
Pressure Transmitter,Temperature Transmitter,
Chemical composition sample)
• Custom Made Sampling Strategy
• Corrosion Coupon
• CEM

20. THE GOAL OF ONLINE SAMPLING
MONITOR
• The design of tailor made coupon online sampling will enable to
monitor the major material degradation behaviour due to internal
condition and corrosion in the particular relevant oil/gas field asset.
• The data results describe the effect of temperature, pressure, water
concentration, H2S and CO2 partial pressure, and other field flow
composition to the corrosion growth behaviour and the material
properties degradation model related to the asset integrity character.
• The method will ensure the accuracy of the model to guaranty the
asset integrity character prediction related to the oil/gas development
condition in the field and the future engineering design method.
• The design of tailor made coupon will ensure that the asset integrity
assessment will be performed in cost effective manner.

21. BS 7910 FAILURE ASSESSMENT
DIAGRAM (FAD)
FAD from actual stress-strain curve
0
0.2
0.4
0.6
0.8
1
1.2
0 0.5 1 1.5 2
Lr
√δr
FAD Level 2B
BS7910 cut-out
FAD Level 2A

22. RELEVANT MATERIAL PROPERTY
RELATED TO CRACK BEHAVIOUR
• Toughness (fracture resistance) property
• Material CTOD (CrackTip Opening Displacement) or J
• Material Stress Intensity (Kmat)

23. STATIC AND DYNAMIC MODEL
Project No. 31045301 Pipe Grade
Project Name SP12-Sealines & SPM
Client Name IOEC Analysis 2B
Case Description Operational Design
Calculation Number X=1.4, CTOD=0.339 Program Calculations Find Life
Environment of Pipe Marine
Cathodic Protection User Defined Number of Data Sets 3
Solution Type Plane Strain
Additional bending stresses considered primary Yes Outside Diameter 813 mm
σref calculated using Eqn. P.4
X65
Failure Assessment Diagram and Crack Growth
0
0.2
0.4
0.6
0.8
1
0 0.2 0.4 0.6 0.8 1
Lr
rootδr
FAD Deep 1 Tip 1 Deep 2 Tip 2 Deep 3 Tip 3
Deep 4 Tip 4 Deep 5 Tip 5 Deep 6 Tip 6 Deep 7
Tip 7 Deep 8 Tip 8 Deep 9 Tip 9 Deep 10 Tip 10
Project No. 31045301 Pipe Grade
Project Name SP12-Sealines & SPM
Client Name NIOC Analysis 2B
Case Description Operational Design
Calculation Number X=1.4, CTOD=0.339 Program Calculations Find Life
Environment of Pipe Marine
Cathodic Protection User Defined Number of Data Sets 3
Solution Type Plane Strain
Additional bending stresses considered primary Yes Outside Diameter 813 mm
σref calculated using Eqn. P.4
X65
Failure Assessment Diagram and Crack Growth
0
0.2
0.4
0.6
0.8
1
0 0.2 0.4 0.6 0.8 1
Lr
rootδr
FAD Deep 1 Tip 1 Deep 2 Tip 2 Deep 3 Tip 3
Deep 4 Tip 4 Deep 5 Tip 5 Deep 6 Tip 6 Deep 7
Tip 7 Deep 8 Tip 8 Deep 9 Tip 9 Deep 10 Tip 10

24. Q & A

25. ThankYou
Ir.Waldemar Husada MSc.
Independent Consultant
waldemar.husada@gmail.com
M / WA: +628993119499
Toplis Energi