Premature Failure of Tubing Joint used in a Crude Oil Production Well (original) (raw)
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Premature failure of tubing used in sweet Extra Arab Light grade crude oil production well
Engineering Failure Analysis, 2015
A 30 feet long and 3.5 inch diameter joints tubing used in wet sweet Extra Arab Light grade crude oil production well failed after 3 years of service. The bottom-hole temperature and pressure were, 82°C and 170 atm, respectively. The tubing had a nominal wall thickness of 6.45 mm and was located at starting depth of 1465 m. The average production rate and water cut of the oil well during the last 3 years of operation were 8761 BPD (barrel per day) and 7.72%, respectively. Failure occurred due to corrosion resulting in leaks of three out of 5 consecutive joints of the tubing. On the other hand, rest of the 120 joints did not show any leaks. All failures occurred close to the joints. Various sections of the failed joints were metallurgically evaluated using scanning electron microscopy coupled with energy dispersive
Root cause analysis of the corrosion-related coiled tubing failure
Journal of Electrochemical Science and Engineering, 2022
Coiled tubing (CT) is widely used in the oil and gas industry. However, corrosion-related failures are frequently reported. Research into the causes of failures leads to improvement in the design of components and processes. In this study, a new CT sample and a CT sample with perforated wall that had failed after a few acidizing operations were selected for analysis. Scanning electron microscope (SEM) images at the fracture site showed that CT damage was caused by the low cycle fatigue. In addition, light and scanning electron microscopy (SEM) showed that a corrosion pit acted as the initiator of the crack. Elemental analysis using energy dispersive X-ray spectroscopy (EDS) indicated the presence of an iron oxide layer and a layer associated with the Sb containing inhibitor. The corrosion damage investigation showed that the internal CT wall pits likely formed during storage due to the acidizing operations in the areas where the remaining liquid was still at the tube bottom.
Characterization of Corroded Tubing Under CO2 Environment
Convegno Igf Xiii Cassino 1997, 2008
Carbon dioxide corrosion is one of the most important problems, in the Oil and Gas Industry, for production tubing and line pipes. The main types of corrosion are:-Generalized corrosion (Loss of weight).-Mesa-type corrosion (Localized corrosion under form of mesetas).-Localized corrosion. The main factors affecting the corrosion resistance are metallurgical (microstructure, heat treatment and presence of some elements like Chromium) and operational (flow rate temperature and partial pressure of CO 2 in the corrosive environment). Two field experiences are presented, representing two different situations of the used materials. The first is relevant to C-Mn and C-Mn-B steels, the second to 1% Cr steels with different microstructures. Better results were obtained with 1% Cr steel (J55), normalized and with perlite-ferrite microstructure. For higher grades of tubings (like N80 or C95), the quenched and tempered (Q + T) materials are the only possibility ; thus, it's necessary to explore the role of different alloy additions like Cr, Cu, Ni to enhance the resistance CO 2 corrosion.
2019
Abstract: AISI316/316L is an Alloy Widely Regarded as One of the Favorite Corrosion Resistant Alloy(CRA) for Offshore Operators in Oil and Gas Sector. A recent failure occurred to a hydraulic oil tubing for wellhead inside a remote controlled offshore platform that leads to unplanned shut down and huge production loss. This study was made to know the root cause of such failure and find out possible mitigation. The study employed visual examination together with photography, Scanning Electron Beam Microscopy (SEM) and Xray Diffraction Spectroscopy (EDS) to do the metallographic and fractographic analysis. Result of the analysis shows the sign of development of pinholes due to external surface corrosion created by deposits (due to sea water exposure) specially at the clamps, leads to leakage. Reliability of the hydraulic control always dependent on containment of hydraulic fluid within the system. A leakage can jeopardize the operation of oil and gas producing organization added cost ...
Corrosion, 2014
Deep water oil production tubing materials are exposed to high carbon dioxide (CO2) pressure and temperature conditions that can affect the corrosion performance of such materials. The present study evaluated the corrosion behavior of carbon steel exposed to supercritical CO2/oil/brine mixtures at different water cuts (0, 30, 50, 70, and 100%), CO2 partial pressures (8 MPa and 12 MPa), and temperatures (65°C and 90°C) in a flowing 25 wt% sodium chloride (NaCl) solution. Corrosion behavior of carbon steel was evaluated by using electrical resistance (ER) measurements, weight-loss measurements, and surface analytical techniques (scanning electron microscopy [SEM] and energy-dispersive x-ray spectroscopy [EDS]). The corrosion rates of carbon steel increased with increasing water cut. There was no indication of corrosion attack with 0% water cut. At lower water cuts (30% and 50%), the steel surface was covered by iron carbonate (FeCO3), while iron carbide (Fe3C) was present on the steel...
Process piping play an extremely important role in Petroleum refineries throughout the world as a means for carrying Hydrocarbons from one location to other. These process piping are subjected to Corrosion over a period of operational time, which is the destructive attack of material by reaction with its service fluids containing corrodents such as Sulphur, H2S, HCl, CO2, organic and inorganic acids and external environments thus causing a natural potential hazard associated with oil and gas transportation facilities. Various potential damage mechanisms are identified for pre-heated crude inlet piping to atmospheric distillation column using American Petroleum Institute standards such as API 581 and API 571. These damage mechanisms consist mainly of High Temperature Sulfidic and Naphthenic acid corrosion. Corrosion rates for this damage mechanism is identified for two crudes namely Kuwait crude and Arab Extra Light Crude using API 581. Retirement thickness for this piping is calcula...
A corrosion failure analysis of heat exchanger tubes operating in petrochemical refinery
Engineering Failure Analysis, 2021
The aim of this study was to analyze corrosion failure of heat exchanger tubes used in petrochemical refinery. Thermodynamic and kinetics analysis showed that the major chemical substance playing role in electrochemical corrosion of the tubes is solute CO 2 present in crude methanol passing by the tubes. However, polarization tests revealed that corrosion caused by CO 2 is not so significant to produce cavities observed on the outer surface of the tube. By further investigation of the morphology and previous processes in producing crude methanol, it was revealed that crude methanol contains significant amount of suspended solid particles with relatively high hardness, which were detached from the catalysts of the previous phases. Therefore, besides the electrochemical corrosion, the main mechanism of tubes corrosion was attributed to the erosion-corrosion. According to the corrosion cause, appropriate methods were proposed for corrosion prevention or corrosion reduction of the tubes.
Corrosion problems during oil and gas production and its mitigation
In order to ensure smooth and uninterrupted flow of oil and gas to the end users, it is imperative for the field operators, pipeline engineers, and designers to be corrosion conscious as the lines and their component fittings would undergo material degradations due to corrosion. This paper gives a comprehensive review of corrosion problems during oil and gas production and its mitigation. The chemistry of corrosion mechanism had been examined with the various types of corrosion and associated corroding agents in the oil and gas industry. Factors affecting each of the various forms of corrosion were also presented. Ways of mitigating this menace with current technology of low costs had been discussed. It was noticed that the principles of corrosion must be understood in order to effectively select materials and to design, fabricate, and utilize metal structures for the optimum economic life of facilities and safety in oil and gas operations. Also, oil and gas materials last longer when both inhibitors and protective coatings are used together than when only batch inhibition was used. However, it is recommended that consultations with process, operations, materials, and corrosion engineers are necessary in the fitness of things to save billions of dollars wasted on corrosion in the oil and gas industries.
Corrosion Problems in Petroleum Industry and their solution
2014
Corrosion costs the oil industry billions of dollars a year, a fact that makes the role of the corrosion engineer an increasingly important one. Corrosion affects every aspect of exploration and production, from offshore rigs to casing, and reviews the role of corrosion agents such as drilling and production fluids. Methods of control and techniques to monitor corrosion, along with an explanation of the chemical causes of corrosion are discussed.