Process Vessel Internal Corrosion

Management Solutions
David Blackwell – Engineering Director
Content:

• Why think about lining a

vessel?
• Erosion/corrosion
management strategies
• Organic lining solutions
• Organic composite
Solutions
• Conclusions
Why Vessel Lining?
Limitations of Conventional Materials of Construction

• Carbon steel • Stainless steel

• Overlaid carbon steel • Duplex steels

Corrosion Galvanic Pitting

Crevice SCC Bacterial

Erosion/Corrosion
Management Strategies
Corrosion Allowance
• Weight, design life, root cause

Metal Cladding / Weld Overlay

• Weight, cost, availability, chemical resistance

Cathodic / Anodic Protection

• Cost effectiveness, reliability

Internal Lining
• Reliability, application quality, resilience
 Material Selection

Separator Vessel Material Investment (£)

Specification Steel Lining Total
ID 3.6 m Carbon steel
S/S 18 m + 140,000 N/A 140,000
Cladding 316
Operating temperature 80.3 °C
Carbon steel
Operating pressure 2.6 Barg + 373,000 N/A 373,000
Cladding 625
Design temperature 144 °C
Design pressure 16 Barg
Carbon steel shell +
Vessel weight 45 t 74,000 46,600 120,600
Belzona lining 1391
Vessel internal area 234 m2
 Material Selection

Material Investment (£)

Steel Lining Total

Carbon steel shell +

74,000 46,600 120,600
Belzona lining 1391

Combination of
Belzona 1391/5892 74,000 20,168 94,168
Linings
Lining vs Cladding

Finger Type Slug Catcher:

Large surface area – 5100 m³ volume capacity
Operating Conditions – CO2, H2S, Chlorides
Design Life - 25 years

Corrosion Management Options at FEED stage (CAPEX + OPEX):

- Option 1: Carbon Steel construction + 6 mm Corrosion Allowance +
Internal Lining for the majority (Belzona 1591)
- Option 2: Carbon steel alloy 625 Clad

Other parameters:
• 5 year entry interval and maintenance required to remove ‘black
powder’ and internal/external coating inspection & repair
operations
Lining vs Cladding

Component Option 1 Option 2

CapEx USD 57.1 million USD 211.6 million

OpEx (External inspection) USD 2.0 million USD 2.0 million

OpEx (Clean out)

USD 3.0 million USD 3.0 million

OpEx (Maintenance)
USD 0.75 million -

Total USD 62.9 million USD 216.6 million

“Ultimately the difference in capital expenditure between

the two options far outweighs the estimated difference in
total operational expenditure.”
HT – HP Service
Considerations for the Selection of a Non Metallic Lining

• Design and operating temperature & pressure

• Fluid composition
• Presence of acid gases ( H2S and CO2)
• Erosion from solids content
• Shutdown procedures
• Chemical treatment
• Thermal gradient across the lining
• Thermal shock situations
Internal Lining Reliability
Prequalification Tests

• Adhesion on to steel
• Heat resistance
• Dry and wet (immersed)
• Resistance to rapid decompression
• Thermal cycling
• Erosion resistance
• Chemical resistance
• Resistance to cathodic disbondment
• Edge retention and flexibility
(pipeline coatings)
Application Quality - Delivering the Solution:
Risk Control Systems

• Vessel design

• Internal lining material selection

• Applicator quality control

• Application quality control

• Inspection plan and design life

Organic Lining Solutions
Case Study, Beryl Alpha Platform
North Sea, UK, 1998

Oil and gas test separator

Beryl Alpha Platform Separator
Coated in 1998 inspected 2006
Innovations in Organic Linings
“Spray friendly” Abrasion Resistant Linings

Spray friendly Erosion resistant

Reduced wear to piston Belzona 1331 Sliding abrasion
Reduced wear to tip Belzona 1381 Impact abrasion
Innovations in Organic Linings
“Spray friendly” Abrasion Resistant Linings

• Full immersion service at

ambient and 95°C

• Outstanding erosion
resistance

• Negligible wear to spray

equipment

• Suitable for brush and spray

application

• Excellent corrosion and

chemical resistance
Application Example
Total Elgin, UK North Sea - Newly Fabricated Discharge Caisson

Design life of the caisson 35 years

Belzona 1381 applied as 2 x 1000 microns to maximise the

longevity of the internal lining
 Innovations in Organic Linings
High Temperature Immersion Linings: Belzona 1523, Belzona 1593
• Two coat application without frost
blasting

• Greatly improved flexibility

• Light colours for ease of inspection in

dark vessels

• Film thickness testable, spark testable

• Excellent chemical resistance

• Maximum overcoat window up to 24

hours

• Good cure at ambient temperature -

post curing normally occurs in service
 Composite Solutions for
Protecting Small Bore
Nozzles and Flange Faces
Problems with Internal Corrosion
Small Nozzles and Flange Faces

Loss of containment and replacement

could have been prevented by using
a composite solution.
Nozzle Insert Technology
Small Bore Nozzle Protection System
Corrosion Protection
Small Bore Nozzle Inserts
Belzona 1111 insert

Belzona coating grade

used to bond in Belzona
insert
Flange Face Forming
Belzona Flange Face Protection System
Flange Repair Kit

ANSI 300#, STD, 40,

Flanges to 80, 120, 160, XXS
repair
2” XS, 3” XS, 4” XS
ANSI 300# rated RF
Operating
flange faces operating
pressure and
at 120oC 248oF or
temperature
below
Flange Face Forming Testing
Tested in 2003 and 2015
• Flange face forming has been tested in detail over the years both internally and externally
Belzona External
Product Testing 2015 Sheet
Specification
Wood Group 2003
Test Number Nominal Tested By Tested pressure Test Comments
Bolt Torque
Pressure Schedule Flange size(bar) Target pressure
Temperature Pressure
(Bar) (°C) achieved

1 10.34
1600 ft lbs OIS Limited
1500# 8”30 barg (start) 255 15 60 minutes soft gasket
255
Thickness Compressive Strength (Yield) Cure Temperature
30 barg (end) 15 No Leaks
2 in (6.0 mm)
0.24 20.68 Motherwell Bridge90.3 Mpa81 barg (start) 19.5 30 minutes
20°C
Inspection Limited
113.4 Mpa 121°C
81 barg (end) 19.5 Soft gasket no leaks
3 41.37 Motherwell Bridge 160 barg (start) 19.5 30 minutes
0.12 in (3.0 mm) 102.5 Mpa 20°C
Inspection Limited
130.4 Mpa 121°C
159 barg (end) 19.5 Spiral gasket, No leaks
Application Example
High Temperature Immersion Linings

Desulphurisation unit Reboiler

Natural Gas Purification Plant Belzona 1511 and Belzona 1593

The vessel operates at 150°C (302°F) and 1.6 MPa (232 psi) pressure.
The amine media, rich in H2S, is extremely corrosive.
Inspection after 2 years
High Temperature Immersion Linings

Desulphurisation unit Reboiler

Natural Gas Purification Plant Belzona 1511 and Belzona 1593

The vessel operates at 150°C (302°F) and 1.6 MPa (232 psi) pressure.
The amine media, rich in H2S, is extremely corrosive.
Conclusions
 Process Vessel Internal Erosion/Corrosion
Management with Internal Organic Linings:
Low Risk – High Value Solutions

• Qualified materials
• Trained and validated application team
• QC procedures
• Design life inspection plan

Long Term Protection of Assets

Process Vessel Internal Corrosion
Management Solutions

Opportunities in the
North Sea?