Champion_Corrosion
-
Upload
nalco-champion -
Category
Documents
-
view
231 -
download
0
description
Transcript of Champion_Corrosion
CORROSION MITIGATION FORCOMPLEX ENVIRONMENTS
champ-tech.com
Markets Served:Arctic | Conventional | Deepwater | Enhanced Oil Recovery | Heavy Oil | Industrial | Midstream | Offshore | Oil Sands | Refinery | Shale
Corrosion is complicatedAlmost any aqueous environment can promote corrosion,
which occurs under numerous complex conditions in oil
and gas production, processing, and pipeline systems. No
metal surface or metal-alloy component is totally immune
to corrosion issues, like top-of-line corrosion, under-deposit
corrosion, or pitting, so production tubing and equipment,
processing equipment, separators, pumps, and flow lines are
at risk at literally every step in the production-handling process.
Over the life of a field, irregular fluid flows or evolving
production characteristics can alter corrosion conditions or
even change potential corrosion mechanisms. Multiphase
flows can complicate the task of mitigating corrosion. Oilfield
chemicals applied to remedy other production, processing,
or handling problems could also increase corrosion issues.
Even improper design or misapplication of corrosion mitigation
measures can increase the potential for corrosion.
Expertise is criticalChampion Technologies has worked for over 59 years to
advance the science of corrosion mitigation. Our industry-
leading corrosion experts are among the most well trained
and most experienced in the oil and gas industry.
Through our technology research and development
organization, Champion Technologies creates new corrosion-
fighting chemicals, new treatment strategies, and new service
capabilities to remedy corrosion problems of all types.
Our global corrosion team can be trusted to detect and
treat corrosion issues before they threaten your business
or the environment.
Corrosion is a multi-billion dollar problem. Champion Technologies predicts it, prevents it, and produces chemistries to combat it.
Corrosion costs the oil and gas industry tens of billions of dollars in lost income and
treatment costs every year. In worst-case scenarios, corrosion-induced failure can cause
environmental pollution, property damage, or endanger public safety. Proactive treatment
costs are insignificant compared to the income that can be lost due to unmitigated corrosion.
Corrosion challengesCommon problems addressed by Champion Technologies’
corrosion mitigation programs include:
• Electrochemical reactions involving water and oxygen,
high operating temperatures, or galvanic reactivity
between two metals immersed in an electrolyte
• Acidic gases such as hydrogen sulfide (H2S)
and carbon dioxide (CO2)
• Biological activity of microbes contained in
produced fluids
• Deposition of solids, sludge, biomass or
reactive liquids
• Any oxygen-containing environment
CORROSION
We analyze your production and processing operations, and
only after developing a thorough understanding of the range
of conditions expected during the life of the project, do we
design a corrosion management plan.
Asset auditWhen you first begin working with Champion Technologies,
we will ask about your asset’s historical and current operating
practices, including:
• Productionrates,temperatureandpressuredata
• Theevolutionoffielddevelopmentandconstructionof
production and processing infrastructure
• Treatmentpatternsofexistingchemicalprograms
• Previouslyexistingcorrosionissues,systemfailures,
associated costs, and the results of root cause analyses
Data analysis and forecastingChampion Technologies uses a variety of software models
to forecast fluid dynamics in production tubing and surface
pipelines, including:
• Topographicalfluiddynamicsanalysis
• Pipelineheatlossdetermination
• Phasebehaviorofproducedliquidsandgases
• Internalcorrosionrisks,corrosionrates,scaledeposition,
wall-shear stress, and elemental sulfur deposition
Additional analytical capabilities to determine corrosion
inhibitor properties include dispersibility and emulsion
tendency testing, materials compatibility testing, foaming
tests, viscosity tests, freeze/thaw stability, and pour
point testing.
By working closely with you, our corrosion experts can
recommend a specialty chemical solution designed for your
specific corrosion issues. We do this by learning and gaining
full knowledge of your production operations and studying
empirical evidence revealing the interrelationships
of dynamic corrosion forces at play.
Diagnosing corrosion conditions and mechanisms
Controlling corrosion mechanism, or mitigating their effects, can be as complex as the
conditions in which corrosion occurs. Champion Technologies begins a corrosion mitigation
program by immediately initiating a collaborative and comprehensive investigation to assess
the situation in the field.
CORROSION
Chemicals and services for the life of your assetChampion Technologies is a committed, capable
partner for the duration of your project
execution. We:
• Assess corrosion problems, recommend
solutions and define treatment objectives
• Manufacture corrosion inhibitors precisely,
blend corrosion-chemical treatments, and
implement and manage treatment programs
• Monitor, measure and evaluate results,
reassess evolving production parameters, and
adjust corrosion mitigation measures to fit
current conditions
CORROSION
Champion Technologies’ state-of-the-art lab testing equipment includes:• Bubbletestapparatustoevaluatethepartitioning
properties of water-soluble and/or dispersible formulations
• Staticautoclavestoevaluatecorrosioninhibitorsat
elevated temperatures and pressures, and under
conditions simulating stagnant areas in natural gas and
crude oil production equipment
• Rotatingcylinderelectrodestorapidlyscreencorrosion
inhibitors under low shear conditions
• Rotatingcylinderautoclavestoreplicatehighflowvelocity
conditions, to simulate partial pressures of CO2 and H2S at
elevated temperatures, and to determine general corrosion
rates by mass loss and localized attack by coupon surface
inspection
• Flowloopstosimulateflowhydrodynamicsoffield
pipelines for evaluation of corrosion inhibitors under
defined shear stress conditions
• Jetimpingementtoevaluatecorrosioninhibitorsunder
extremely high shear conditions
Lab testing
Champion Technologies’ global team of corrosion experts develops and executes field tests
and laboratory testing procedures to validate the accuracy of our initial assessment. Lab tests
simulate actual system operating conditions whenever possible, although some factors, such
as the condition of metal surfaces, random fluctuation of process parameters, or the exact
nature of flow conditions, can be very challenging to simulate.
CORROSION
Additional testing equipment and methods used to evaluate corrosion issues include: optical microscopes, laser profilometer, corrosion
morphology identification, ecoclaves, pit tests, weld tests, Orbisphere tests, EDX analysis,
XRD analysis, cross sectional analysis, scale analysis, 13C and 1H NMR analysis, and
GC/MS analysis.
CORROSION
For decades, Champion Technologies has solved corrosion
challenges by drawing upon the technical, human, and
knowledge resources within our global network of corrosion
scientists and engineers, surface-scientists, material
scientists, application specialists, field sales representatives,
and business development specialists. Resulting empirical
results and lessons learned – both quantitative and
qualitative – have led to the best practices implemented
by our integrated team and outlined below.
Identifying organizational roles and responsibilitiesChampion Technologies’ commitment to our customers’
successes is evident in the communication networks we
have established. Through open dialogue and continuous
familiarization with your organization and culture, we
are positioned to understand your business drivers and
operational challenges, and to better deliver critical
information to the right people as early as possible.
Criticality and risk assessmentChampion Technologies employs industry standard
computer models to predict corrosion rates that we then
validate against field data and experience from other assets.
Together with our proprietary assessment methodology, our
total system analysis gives customers a holistic view of their
operations, pinpointing at-risk corrosion areas that are
often overlooked.
Implementing corrosion mitigation best practices
Chemical and corrosion control matricesControl matrices form the basis of our proactive approach
to corrosion management. These are primarily used to track
and trend the myriad of input measurements that constitute
a comprehensive management program. Key metrics and
performance indicators included in the matrices are
designed around customer goals and objectives to
ensure strategic alignment.
Monitoring and inspectionAlthough monitoring and inspection are essentially
output measurements, they are critical to determining the
effectiveness of a corrosion control program. Comprehensive
monitoring tracks results in the short and medium term that
are ultimately validated by a thorough risk-based inspection
program. Champion Technologies collects, analyzes and
reports data to keep you constantly informed, working as your
partner to preserve system integrity throughout field life.
We know corrosion mitigation is only a small part of an oil or gas asset integrity program,
but the right corrosion mitigation strategy can be the difference between efficient, profitable
operations and chronic unscheduled downtime.
Incorporating experience and practical knowledgeOver several decades of mitigating and remediating corrosion issues,
Champion Technologies has built an extensive collection of practical
knowledge. Housed in a repository of effective practices, this important
information is accessible to our technical staff via a global information
technology network.
Continuous monitoring Champion Technologies thorough, well-implemented monitoring program will help:• Optimizeacorrosionmitigationprogram
• Managetheintegrityofyourproductionsystem
• Facilitatetheimplementationofnewcorrosionchemistry,applicationmethods,
or chemical-delivery points in response to evolving field conditions
CORROSION
Oilfield corrosion challenges are not static phenomena.
Fluid characteristics change over time, resulting in
systems becoming less responsive to established
corrosion mitigation programs. Champion Technologies’
asset integrity management programs go beyond
simply monitoring metal loss. We include multiple
water analyses and microbial monitoring together with
ongoing system and data analysis, allowing us to predict
increases in corrosion risk and respond accordingly.
Our proactive approach is one reason why, time and
again, customers turn to us for help with their corrosion
control strategies.
A Champion Technologies’ asset integrity management
program includes tracking and trending system inputs
and outputs, such as chemical injection rate, and
corrosion monitoring data. Available corrosion monitoring
techniques range from the traditional (corrosion
probes, coupon tests, copper-iron displacement,
water analyses, and other non-destructive inspection
methods) to more advanced, real-time techniques that
may include technologies to accurately quantify metal
loss or measuring parameters indicative of corrosion
rate, such as hydrogen flux in sour environments. As no
single approach provides a comprehensive analysis, we
implement several and rely on the collective strengths
of various techniques to compensate for individual
limitations.
Champion Technologies identifies trends and establishes
key performance benchmarks by a constant revalidation
of two key factors - corrosion inhibitor effectiveness and
application method. We provide fit-for-purpose solutions
that add value to your business while continuing to
advance our corrosion mitigation technologies and
strategies to your benefit. Most importantly, we help
optimize the service life of your oil and gas production
and processing facilities.
Champion Technologies is a true partner in the
achievement of your business objectives.
Optimizing corrosion mitigation and asset performance
The powerful professional and personal relationships we
develop underpin our steadfast commitment to providing
customized, durable corrosion-related production and
processing solutions. We listen. We work shoulder-to-
shoulder with you every step of the way. We demonstrate
the focus and attention to detail such critical work demands.
Backed by our global knowledge organization, our specialists
become valued members of your asset teams.
Pushing corrosion mitigation forwardChampion Technologies actively supports and participates
in professional associations and education, training and
technology-development programs sponsored by industry
consortia, colleges and universities. Through these
affiliations, we collaborate with other members of the global
corrosion community to advance corrosion science through
joint research projects and peer-reviewed technical papers,
and by showcasing our corrosion chemicals, applications
and services at major industry trade shows and conferences.
Through these activities, we stay connected to best practices
in the corrosion mitigation industry and continually augment
our knowledge and understanding of corrosion processes
and mechanisms.
Trusted advisors of corrosion mitigationChampion Technologies has grown to become one of the world’s largest and most
successful oilfield specialty chemical companies because – throughout our existence –
we have focused on understanding the specific needs of each of our customers.
Through our work, we strive to protect our people, our customers, the environment, and the communities in which we operate. We pledge to create chemical corrosion solutions our customers can trust.
Corrosion mitigation in actionCase histories:
Situation:Uncontrolledlocalizedcorrosioninoilsalesline traversing mountainous, environmentally sensitive terrain.
Solution:Replace continuous injection with site-specific Cortron® RU-248 batch treatments. Assess changing well conditions via modeling, inspections and coupons.
Results:Reduced corrosion rates and exposure to environmental risks. Decreased operator’s costs by 75 percent (USD $3,580,000).
Situation: Installation of 400-mile NGL line requires environmentally safe, effective and biodegradable hydrotest chemicals for source water.
Solution:Add oxygen scavenger Cortron® RU-206 five miles downstream of injection pump and environmentally friendly biocide Bactron® K-95 downstream of scavenger.
Results:Hydrotest procedure of filtered source water, gas blanket and cost-effective hydrotest chemicals resulted in non-significant levels of bacteria.
Situation: Corrosion offshore requires environmentally friendly inhibitor that treats overboard discharge and does not form emulsions or cause foam.
Solution:Perform rigorous laboratory and ecotoxicological tests. Continuously apply Cortron® CP-3070, labeled GOLD by a European regulatory agency.
Results:Corrosion was controlled, foam and emulsions were not present and oil-in-water values for discharged water were 15-55 percent lower than the environmental standard.
CORROSION
About Champion Technologies is a global specialty chemical company with 3,100+ employees in
over 50 locations in more than 30 countries delivering innovative and engineered programs
for upstream, midstream, and downstream oil and gas markets. Our integrated offering mixes
sustainable chemistry, technology, and service to enhance your world.
Markets Served:Arctic | Conventional | Deepwater | Enhanced Oil Recovery | Heavy Oil | Industrial | Midstream | Offshore | Oil Sands | Refinery | Shale
Regional Headquarters: Aberdeen, Scotland, UK+44 (0) 1224-879022North Africa, Europe, Middle East Operations Technology Center, Manufacturing
Buenos Aires, Argentina+54 11-4343-1100South America Operations
Calgary, Alberta, Canada+1 403-234-7881Canada Operations Technology Center, Manufacturing
Corsicana, Texas, USA+1 800-477-5353 Manufacturing
Delden, The Netherlands+31 743-775-281 Technology Center, Manufacturing
Dubai, UAE+971-4-2146121
Fresno (Houston), Texas, USA+1 281-431-2561Technology Center, Manufacturing
Geismar, Louisiana, USA+1 225-673-2436Water Solutions Moscow, Russia+7 (495) 981-2558Russia, Caspian, Sakhalin Operations
Odessa, Texas, USA+1 432-363-9105Manufacturing Perth, Australia+61 (8) 9472-9400
Port Harcourt, Nigeria+1 713-627-3303West Africa Operations
Rio de Janiero, Brazil+55 22-2106-6666
Sherwood Park, Alberta+1 780-417-2720 Technology Center
Singapore+65 6733-9482Asia-Pacific Operations
Corporate Headquarters:3200 Southwest FreewaySuite 2700Houston, Texas, USA 77027+1 713-627-3303
champ-tech.com
© 2012 Champion Technologies, Inc.