Improvement Of Sacrificial Anode Life For Internal Surface Of Process Vessels In Upstream of Oil & Gas Facilities

Saleh Al-Sulaiman Hasan Sabri Mohammed Abdul-Fatah Eugene Dsouza (Presenter)

Inspection and Corrosion Team,

Kuwait Oil Company

www.kockw.com

Presentation Overview Introduction Gathering Center Process Overview Types Of Separators Separator Construction and Operational Details Comparison between Separators

Case Study
Results Conclusions

Introduction
The Kuwait Oil Company is one of the major oil producing

companies in the world.

Company mainly executes exploration, drilling, and

extraction of oil and gas within the State of Kuwait.

Oil produced from several oil fields including

Burgan,

Ahmadi and Magwa.

Operates 21 Gathering Centers and 4 Booster Stations.

Oil Fields in Kuwait

Gathering Center Satellite Image

Gathering Center (GC)

Serves as a collection (Gathering) location of Crude Oil from wells Separates the Crude Oil, Gas and Water. Facilitates Oil Wells Testing Provides intermediate storage for the Crude Oil prior to pumping to the Tank Farms

Compresses Tank vapors for condensate recovery

Transports the gas for further compression at the Booster Stations.

Gathering Center Process in Brief

Wet Separators

Two Phase Separators

Three Phase Separators

General Arrangement Drawings

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Operation and function of an Two Phase Separators

The function of a two phase Separator is to separate the

associated gas and liquid (oil & water).

The liquid leaves at the bottom of the vessel and gas from top

through a mist eliminator to remove small liquid droplets from the gas.

Operation and function of an Three Phase Separators

The function of a three phase Separator is to separate the associated crude, gas and oily water.
It works on the principle that the three components have different densities allowing the gas being on top, the crude being in the middle and water remains at bottom.

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Comparison between of Two & Three Phase Separator

Two Phase Separator
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Three Phase Separator

The function of a 2-phase The function of a 3-phase Separator is to Separator is to separate the separate the associated crude , gas and associated gas and liquid (oil & oily water water) The liquid leaves at the bottom of the vessel and gas from top through a mist eliminator to remove small liquid droplets from the gas. Oily water resistivity 1000 ohm-cm. It works on the principle that the three components have different densities allowing the gas being on top, the crude being in the middle and water remains at bottom.

above Oily Water resistivity between 1 to 7 ohm-cm.

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Case Study

A Case study was performed on a three phase separator vessel which had been operated for less than year (six months) and found with sacrificial anodes consumption up to average 85%. The CP design for this vessel was prepared considering 10 years of service life.

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Separator Vessel Design Details

Diameter ID Length Heads Orientation Process Fluid Design pressure Design Temperature Operating Temperature MDMT MAWP Design /Construction code Internal Coating 3,048mm (10 ft) 15,420mm (50 ft) 2:1 Semi-Ellipsodial Horizontal (Saddle mounted) Crude oil/ Saline water/ Hydrocarbon vapour 9.7 bar (140 psig) 121 0C (250 0F) 60 0C (140 0F) -3 0C (27 0F) 9.7 bar (140 psig) @121 0C (250 0F) ASME (1)/U STAMP/API(2) Phenolic epoxy 3 coat of 100 micron thickness

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Vessel Material Specifications and Internal structure details

Shell (Material/thickness) Heads (Material/thickness) Nozzles Flange Nut and Bolts SA 516 Gr.60N / 18mm SA 516 Gr.60N / 20mm (nominal) 16.5 (minimum) SA 106 Gr.B SA 105N SA193 B8M/SA194 8M SS parts SA193 B7M/SA194 7M CS parts UNS K02100 UNS K02100 UNS K03006 UNS K03504 UNS S31254 SS parts UNS G41400 CS parts

Inlet momentum absorber Baffle(s) Coalescer pack(s) Mist eliminator Vortex breaker(s) Weir plate Sludge wash header(s) Sacrificial anodes

Inlet device/316L stainless steel 2 x Perforated Baffles/316L stainless steel 3 x Demisters /316L stainless steel 316L Stainless Steel Oil & water outlet/SA 516 Gr 60N / Epoxy coated Carbon steel/ Epoxy Coated Carbon steel/ Epoxy coated Aluminum Alloy

UNS S31603 UNS S31603 UNS S31603 UNS S31603 UNS K02100 UNS K02100 UNS K02100 -

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Separator Vessel Initial CP Design

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Observations & Findings

As part of routine shutdown program the following three phase separator was opened for internal inspection, during which the following was observed. Sacrificial anode installed at 6 oclock position was completely (100%) consumed. Sacrificial anodes installed at 5 and 7 oclock positions were consumed up to 80%.

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Observations & Findings Neoprene gasket used for isolating the internal fittings from the shell was completely deteriorated. Continuity test revealed all bare internal Fittings and structures were continuous with the vessel shell. Vessel shell internal coating was found with blisters between 3 to 9 oclock positions.

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Reasons for Premature Anode Consumption

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Reasons for Premature Anode Consumption

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Pittings Due to Galvanic Corrosion

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Alternative Approach Based on the observations and findings and as part of a remedial action the following plan was implemented. New CP design considering actual vessel operating conditions. Painting of vessel shell internal between 3 to 9 oclock positions.

Painting of all internal structures and fittings.

Change of isolating materials from Neoprene gasket to Poly Tetra Fluoro Ethylene (PTFE) based upon compatibility with service environment.
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Alternative Approach New CP design

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Alternative Approach

Coating of Vessel Shell and Internal Fittings/ Structures The vessel shell between 3 oclock to 9 oclock positions and the bare stainless steel internal structures/ fittings were blasted and painted with phenolic epoxy three coats of 100 microns each resulting to 300 microns dry film thickness coating

Coalescer Pack

Perforated Baffles

Inlet Device Assembly

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Results

After the alternative approach was implemented, the following vessel was reopened to inspect the internal fittings/structure and anode condition subsequently two year of operational period of the vessel during which the following observations were noted:
Drastic reduction in Anode Consumption

The isolation material was found in intact without any deterioration.

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Conclusion
Conclusion are based on the actual observation and finding mentioned above. It is evident that the initial Cathodic Protection design and construction practice required modifications to enhance the life of the cathodic protection and below are the modifications:

Cathodic Protection Design Considerations Surface Area considered in the design shall include immersed sections of vessel shell and internal fittings/structures. Electrolyte resistivity used for design purpose shall be physically measured.
Operational temperature of the vessel shall be considered to derive the actual required current density and to derate the anode electrochemical capacity. continued.
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Conclusion
Coating and Isolation Considerations Application of coating the bare internal fittings/ structures regardless of its material specifications could reduce the current requirement drastically in situation of failures in isolation.
The isolating gasket material used to isolate the internal fittings from the vessel shell shall be compatible with the service environment.

For internal structures where coating is impractical, positive isolation shall be achieved by isolation gasket or by increasing the coating thickness at contact locations between vessel and structure. After implementation of alternative approach the anode consumption reduced from 54.5 kg per year to 8 kg per year i.e. saving 85.3% of anode weight per year, resulting in increased anode life.
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Thank You
Sample Chart
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