30+ Years of Effective Internal Corrosion Management in the Presence of Acid Gases and Elemental Sulfur at the Labarge Production Unit
- Rotimi A. Ojifinni (ExxonMobil Production Company) | Mario J. Faverola (ExxonMobil Production Company) | Joe Penkala (Baker Hughes a GE Company) | Craig C. Monahan (ExxonMobil Production Company) | Gina Beans (Baker Hughes a GE Company) | Steve Bodnaryk (Baker Hughes a GE Company)
- Document ID
- NACE International
- CORROSION 2019, 24-28 March, Nashville, Tennessee, USA
- Publication Date
- Document Type
- Conference Paper
- 2019. NACE International
- Integrity Management, CO2 Corrosion, Sour Gas Corrosion, Elemental Sulfur, Internal Corrosion, H2S Corrosion, Sweet Gas Corrosion, Chemical Inhibition
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- 51 since 2007
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The severity of internal corrosion from the presence of high concentrations of acid gases (H2S and CO2) and elemental sulfur poses long-term integrity challenges that make carbon steel the unlikely material of construction. This paper presents a 30-plus-year history of an asset with excellent integrity despite using carbon steel in the presence of wet gas containing ∼5% H2S, ∼65% CO2, and elemental sulfur. This history includes a review of internal corrosion management data such as chemical qualification/injection history, corrosion inhibitor residual analysis, corrosion rate monitoring trends, and continuous improvement efforts.
Lessons learned are also provided to illustrate the evolutionary nature of the process that led to the robust corrosion management program described herein. Key success factors such as robust corrosion control program design and field implementation, continuous improvement through frequent review of monitoring data, excellent leadership support, and a multidisciplinary team approach are described.
The Labarge asset has a 30-plus-year history of carbon steel application in the presence of high concentrations of acid gases and elemental sulfur. Figure 1 shows the process flow and gas composition for this asset. This paper presents field data and lessons learned during this 30-plus-year period. A detailed review of this production unit, its unique materials and corrosion challenges, and the actions to address these challenges over the first 20 years of the asset life were previously reported.1,2 These authors also described the initial production and enhancements put in place to increase production.1,2 This current effort is a data-driven review of how effective the internal corrosion management program has been since start-up.
The use of carbon steel as the predominant material of construction despite the high concentration of acid gases (∼5% H2S and ∼65% CO2) and the presence of elemental sulfur was contingent on the ability to control internal corrosion effectively. Initial lab studies showed very high uninhibited general and localized corrosion rates due to the presence of acid gases and elemental sulfur. 1
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