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Document Title: Pipeline Material Selection, Corrosion Protection and Monitoring Philosophy
ASSUMPTIONS ....................................................................................... 5
2.1
GENERAL ....................................................................................................... 5
INTERNAL CORROSION.................................................................................... 6
3.1.1
3.1.2
3.1.3
3.2
3.3
3.4
3.5
3.6
3.7
3.8
Hydro-Testing .................................................................................................... 7
Operation-CO2 Corrosion ................................................................................... 7
Mothballing-MIC ........................................................................................................... 8
SUPPORTING REFERENCES............................................................... 13
5.1
5.2
Table of Figures
Figure 1-1: Outline System Schematic.................................................................. 3
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Table of Holds
HOLD No.
Description
Section
4.2
3.7
Propagating fracture
3.8
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1.1
Scope of Document
This document presents the design philosophy, assumptions and design guidelines to be developed
during FEED for the material selection, corrosion protection and monitoring of the CO2 pipeline from
the Kingsnorth Power Station to the Hewett field. Figure 1-1 is an outline schematic of the overall
system.
The limits for the application of this document are defined as follows:
1.2
Definitions
COMPANY
CONTRACTOR
WORK
Shall
Should
May
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1.3
Abbreviations
BLEVE
BS
British Standard
CMP
DNV
FEED
FGD
FJC
HSE
IID
IVI
ISO
MIC
MMscmd
Mt
Million Tonnes
N/A
Not Applicable
NII
Non-Intrusive Inspection
NPS
ppbv
ppmv
PWA
PWHT
SI
System International
SRB
1.4
System of Units
Units to be used throughout the FEED design are defined in ref. [M29], Overall Project Units.
During the injection and production regimes, the CO2 may exist in the gas, liquid or dense phases
with varying densities. As a result, the flow rate in this report is given in tonne/day and Mt/year (as
opposed to MMscmd). Specific assumptions made to adapt this mass flow rate to its equivalent
volume flow rate will be clearly stated in the relevant reports.
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2
2.1
ASSUMPTIONS
General
Pipeline will be required to cater for both gas and dense phase flow;
Dryness spec is 24 ppmv with 100 ppmv for short, upset conditions to ensure that liquid
water will not dropout in the line resulting in corrosion. This figure is the minimum
requirement and may change during FEED 1A. However, the gas specification delivered to
the pipeline will ensure that no free water or hydrate potential will exist in the pipeline or CO2
transport system;
Standard conditions that will govern the design flowrate are assumed as 1.01325 bara, and
15 C;
It is assumed that the pipeline system will have a design life of 40 years.
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DESIGN REQUIREMENTS
3.1
Internal Corrosion
With respect to internal corrosion, the initial design basis is that CO2 gas will be dehydrated to a level
where condensation is avoided, otherwise severe corrosion problems would be expected even
without the presence of oxygen 1 . If the oxygen level is reduced to 50 ppbv or less, as a result
general O2 corrosion cant occur.
The anticipated high concentrations of CO2 (99.6 mol %) will give significant corrosion problems with
carbon steel if there is liquid water present. Initial estimates have put the potential oxygen level in the
CO2 to be as high as 200ppmv which also suggests high corrosion potential. However, as with CO2,
if there is no liquid water present then no corrosion can occur.
Clearly avoiding free water in the system is critical to avoid corrosion. The dryness spec detailed in
Section 2.1 is an extreme case requirement to avoid hydrates at the offshore choke, and that
temporary higher water content may be completely acceptable in the pipeline, subject to confirmation
during FEED 2.
As a result, the control and instrumentation system will be designed to monitor the water content of
the export CO2 and will shut down export if the water content exceeds permissible levels. The
possible responses to a "high water content" observation in the pipeline may be to set an alarm and
require operator action. During FEED 2 consideration will be given to the need for oxygen stripping
(or injecting scavengers) at Kingsnorth for planned shutdown activities.
In the absence of production pressure and temperature profiles a preliminary corrosion allowance of
1.5mm may be assumed (for delivery/construction and upset conditions), as there should be no
corrosion during operation. This assumption shall be validated during FEED 2, in particular due to 40
year design life.
The potential internal corrosion threats and their means of control are summarized in Table 3.1.1-a.
Corrosion
Threat
Control
Control Management
Oxygen
corrosion
Oxygen scavenger
Hydro-test water quality
MIC
Biocides
Operation
CO2 corrosion
O2 corrosion
Dewatering
Dehydrating
Corrosion monitoring
Gas dryness
Inspection
Upset
conditions
CO2 corrosion
Corrosion allowance
Corrosion monitoring
Inspection
Mothballing
MIC
Biocides
Sampling
Analysis
Phase
Hydrotesting
Similar work is required to determine the impact of SOX, NOX and H2S. It is presumed that the
FGD plant will remove these to the required level.
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3.1.1
Hydro-Testing
3.1.1.1
Oxygen Corrosion
3.1.1.2
MIC
3.1.2
Operation-CO2 Corrosion
3.1.2.1
Risks
CO2 corrosion of carbon steel is the dominant threat to the integrity of the pipeline over its
operational life-time. The material selection made during the conceptual phase, ref. [S1], is
made on the basis of the susceptibility of carbon steel to CO2 corrosion.
3.1.2.2
Management
Corrosion management is that part of the overall management system, which is concerned
with the development, implementation, review and maintenance of the corrosion strategy.
The corrosion strategy provides a structured framework for identification of risks associated
with corrosion, and the development and operation of suitable risk control measures.
It is stressed that the development of the CMP will need to progress in parallel with the
design of the project.
Kingsnorth CCS Demonstration Project
The information contained in this document (the Information) is provided in good faith.
E.ON UK plc, its subcontractors, subsidiaries, affiliates, employees, advisers, and the Department of Energy and Climate Change (DECC) make no
representation or warranty as to the accuracy, reliability or completeness of the Information and neither E.ON UK plc nor any of its subcontractors,
subsidiaries, affiliates, employees, advisers or DECC shall have any liability whatsoever for any direct or indirect loss howsoever arising from the use of the
Information by any party.
KCP-GNS-PLD-DPR-0002
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Kingsnorth Carbon Capture & Storage Project
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Document Title: Pipeline Material Selection, Corrosion Protection and Monitoring Philosophy
A Corrosion Assessment needs to be performed as the fluid composition data or projected
operating conditions for the line are confirmed.
A well designed and implemented CMP will pay dividends in terms of the integrity of the
line.
3.1.2.3
Corrosion Monitoring
3.1.2.4
Inspection
The pipeline system will be equipped with a pig launcher at the Kingsnorth pipeline inlet
and a receiver at the inlet to the offshore platform. These vessels will be specified to
accommodate intelligent pipeline inspection devices (IID) that will need to be designed
specifically for use in the flowing CO2 pipeline. There also may be a requirement to provide
pigging heads at the landfall location, HOLD 10.
Studies shall be carried out during FEED 2 to develop tools that will be compatible with and
reliable in the CO2 environment. The devices will be equipped with an ultrasonic inspection
tool along with other equipment and will be run frequently. The device will be designed to
seek any evidence of localised or general internal/external corrosion or damage to the pipe
wall. An operating strategy will be agreed in consultation with the suppler of the IID
inspection services during product development and this will generate recommendations
for the frequency of IID use.
The pipeline is required to undergo periodic, statutory inspection to ensure continued safe
and reliable operation. There can be significant cost advantages if inspections are
performed from the outside of the pipeline without breaking containment i.e. non-invasively.
However, there needs to be a balance between achieving these benefits and obtaining the
information required to ensure continued safe and reliable operation. While it may often be
the preferred option, Non-Intrusive Inspection (NII) represents a relatively new approach by
comparison to Internal Visual Inspection (IVI) and many engineers responsible for
inspection planning have yet to build up experience with and confidence in its application.
In addition, there are a wide variety of techniques available, each with its own specific
capabilities and limitations and these require to be discussed further during later stages of
the project. For more information on NII refer to DNV-RP-G103, ref. [S13].
Refer to Full System Commissioning Philosophy, ref. [M27] for more information on
pipeline pigging philosophy.
3.1.3
Mothballing-MIC
During FEED 2 consideration will be given to the need for oxygen stripping (or injecting
scavengers) at Kingsnorth for planned shutdown activities.
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MIC becomes a risk for the production pipeline if SRB activity has previously been allowed
to develop in the system. If it becomes necessary to mothball a line that is already infected
with SRB then a very stringent biocide treatment package will need to be introduced.
During temporary shut downs (1-3 months) pipeline shall be filled with dry pressurised
(greater than 7 bar) CO2.
3.2
Linepipe Material
Carbon steel linepipe is the economical choice for CO2 transport. Subject to any additional
requirements such as those discussed above with respect to low temperature capability/toughness
and internal corrosion mitigation, a high strength grade of carbon steel is expected to be generally
suitable for construction of the onshore and offshore pipeline. Direct depressurisation of dense
phase could lead to temperatures lower than the minimum design temperature of carbon steel;
hence this issue will need to be addressed as part of the pipeline depressurisation/blowdown
studies.
3.3
Although the main pipeline is expected to be fabricated from carbon steel, there is likely to be a
requirement for corrosion resistant alloys (CRAs) at particular locations in the system, for example
valve materials, or spoolpieces subject to particularly low temperatures. Selection of suitable CRAs
shall take into consideration all relevant aspects of the service environment, including the
pre-commissioning and commissioning phases.
3.4
Non-Metallic Materials
When operating in CO2 dense phase mode, the potential for leakage leading to temperatures below
minus 70 C imposes onerous conditions on non-metallic materials such as seals. Due to liquid CO2
phase acting as a solvent swelling of elastomers may occur due to solubility/diffusion of the
pressurised CO2 into the elastomer. With dense phase CO2 explosive decompression of the
elastomer can occur if the system pressure is rapidly decreased.
All non-metallic materials shall be tested in order to validate their suitability for the CO2 service under
normal operating and transient/upset conditions.
3.5
The pipeline shall be protected against external corrosion using a standard anti-corrosion coating.
Insulation is not required. Where the linepipe is to be subsequently concrete coated for
hydrodynamic stability and/or protection, the anti-corrosion coating shall be compatible with the
application of the concrete weight coating.
Field joint coating (FJC) type shall be determined during FEED 2. The FJC including in-fill material
shall provide an equivalent level of corrosion protection as the parent coating.
The onshore pipeline will be cathodically protected using an impressed current system. Test posts
will be located at a nominal spacing of 1km along the entire route of the onshore section. Isolating
joints will be located at the shoreline and at Kingsnorth.
The offshore pipeline shall be cathodically protected using Al-Zn-In sacrificial bracelet anodes. The
cathodic protection design shall be primarily to DNV-RP-F103 supplemented by ISO 15589-2.
Anti-corrosion and insulation coatings and anodes shall be compatible with the design temperatures.
Kingsnorth CCS Demonstration Project
The information contained in this document (the Information) is provided in good faith.
E.ON UK plc, its subcontractors, subsidiaries, affiliates, employees, advisers, and the Department of Energy and Climate Change (DECC) make no
representation or warranty as to the accuracy, reliability or completeness of the Information and neither E.ON UK plc nor any of its subcontractors,
subsidiaries, affiliates, employees, advisers or DECC shall have any liability whatsoever for any direct or indirect loss howsoever arising from the use of the
Information by any party.
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Document Title: Pipeline Material Selection, Corrosion Protection and Monitoring Philosophy
3.6
Condition Monitoring
The main focus of monitoring will be to identify conditions that could give rise to internal and external
corrosion and to confirm that the operating conditions are being maintained in a way that corrosion is
being successfully inhibited.
The pipeline will also be monitored for leaks and a pipeline monitoring system should be considered
so that the operating conditions can be compared continuously to expected behaviour (i.e. both
simulations and historical). Particular care will be required when the system is taken from gas phase
to dense phase operation.
The pipeline will also be monitored for leaks (acoustic monitoring). The onshore section of the
pipeline will be protected from external corrosion in its buried location by appropriate coatings and/or
wrappings with holiday detection being used to confirm the coating integrity during the pipe laying
process. A cathodic protection (impressed current) system will be used to inhibit external corrosion
over the life of the onshore pipeline.
3.7
When operating in dense phase mode, a leak from a CO2 transportation pipeline could chill the pipe
material locally and or generally (dependent upon the type of leak) to temperatures below -70 C,
and material selection will need to take this into account for fracture resistance.
DNV is in the process of organising research into this subject as part of its CO2PIPETRANS
initiative. In the event that material needs to be selected before focused research results are
available, E.ON will make a selection based on advice from a number of pipe mills and fabricators
that will be reviewed by E.ON and its advisors. The recommendations and decisions will be made in
consultation with the HSE. HOLD 2
3.8
Propagating fractures in pipelines may potentially initiate at sites where an initial flaw, most often the
result of corrosion or impact damage has exceeded the critical length or crack tip opening
displacement. Due to the phase change that occurs at the release point of a CO2 pipeline, the
depressurization may be relatively slow therefore indicating that the distance a ductile failure may
run before it arrests may be significant.
Should a pipeline propagating fracture occur, the contents of a pipeline can be released within a very
short period. Consequently, current CO2 pipelines are fitted with mechanical crack arrestors to
address this issue; however fracture propagation control could also potentially be addressed by
increased linepipe toughness and thickness. This feature of CO2 pipeline design shall be addressed
during FEED 2.
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MANDATORY REFERENCES
4.1
Pipeline construction and burial requirements shall comply with all related directives from the
appropriate Port Authorities and Councils. In addition, the following acts and regulations shall be
complied with:
[M1]
[M2]
[M3]
[M4]
[M5]
[M6]
[M7]
[M8]
Offshore Installations and Wells (Design and Construction, etc.) Regulations 1996;
[M9]
[M10]
[M11]
The Chemicals (Hazard Information and Packaging for Supply) Regulations 1994 (SI 1994
No. 3247);
[M12]
Pipeline Works Authorisation shall comply with all related Pipeline Inspectorate (Department of
Energy) directives. In addition, the following guidelines and regulations shall be complied with:
[M13]
Department for Business Enterprise and Regulatory Reform (BERR), Petroleum Act 1998:
Offshore Pipelines, Guidelines for the completion of pipeline works authorisations (PWA's);
[M14]
[M15]
[M16]
[M17]
FEPA Part II (as amended) 1985 Food and Environmental Protection Act 1985, Part II
Deposits in the Sea (as amended);
[M18]
[M19]
[M20]
[M21]
[M22]
[M23]
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[M24]
4.2
Project Documentation
[M25]
[M26]
[M27]
[M28]
[M29]
4.3
Design Codes
[M30]
BS PD 8010:2004 Code of Practice for Pipelines Part 1: Steel Pipelines on Land and Part 2:
Subsea Pipelines;
[M31]
[M32]
ASME B31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids;
[M33]
[M34]
[M35]
[M36]
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SUPPORTING REFERENCES
5.1
Project Documentation
[S1]
[S2]
[S3]
Kingsnorth Phase
80011-RPT-PL-001;
[S4]
II
CO2
Pipeline
Project,
Offshore
Pipeline
Routing
Report,
5.2
Design Codes
[S7]
BS EN ISO 16708 Petroleum and Natural Gas Industries- Pipeline Transport SystemsReliability-based Limit State Methods;
[S8]
BS 7361-1:1991 Cathodic Protection. Code of Practice for land and Marine applications;
[S9]