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5691-GEN-PI-RPT-0005
FRONT-END ENGINEERING DESIGN (FEED)
SERVICES FOR THIEN UNG FIXED PLATFORM REV. NO. 0
TABLE OF CONTENTS
1.0 INTRODUCTION 4
1.1 Background 4
1.2 Objectives 5
1.3 Definition Of Terms 5
1.4 Abbreviations 5
1.5 Design Life 7
1.6 Reservoir & Well Data 7
1.7 Produced Water 8
1.8 CO2 and H2S Content 9
1.9 Mercury 9
1.10 Sand 9
2.0 CORROSION MECHANISM 9
2.1 Internal Corrosion 9
2.2 External Degradation 14
3.0 MATERIAL MINIMUM TEMPERATURE LIMITATION 14
4.0 MATERIAL SELECTION FOR THIEN UNG FIXED PLATFORM FACILITIES15
4.1 Production System 15
4.2 Potable Water and Wash Water System 17
4.3 Seawater System 17
4.4 Instrument and Utility Air System 17
4.5 Waste Heat Recovery and Hot Oil System 18
4.6 Sewage System 18
4.7 Nitrogen System 18
4.8 Fuel Gas System 18
4.9 HP Flare System 18
4.10 LP Flare System 19
4.11 CPP Closed and Open Drain Systems 19
4.12 Aviation Fuel System 20
4.13 Diesel Fuel System 20
4.14 Methanol Injection System 20
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1.0 INTRODUCTION
1.1 Background
The Thien Ung field is located in the middle part of Block 04.3 in the Nam Con Son Basin,
offshore the Socialist Republic of Vietnam, approximately 15 km of Dai Hung field and
approximately 270 km southeast of Vung Tau. The block 04.3 covers an area of approximately
2600 km2. The Thien Ung field is including its 2 structural part. Thien Ung structure discovery
was made in 2004 with the 04.3-TU-1X well. Two subsequent appraisal wells (04.3-TU-2X and
04.3-TU-3X), drilled and tested respectively, delineated the field.
A Pre-FEED study was carried out to select the most viable platform configuration. The
configuration of two separate platforms, namely Fixed Drilling Platform (FDP) and Central
Processing Platform (CPP) bridge linked were selected for FEED. Drilling will be carried out by
self contained Modular Drilling Rig located at FDP.
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1.2 Objectives
This document defines the material selection basis and corrosion protection philosophy for Thien
Ung field development. It includes the minimum recommendations for the material selection for the
Fixed Drilling Platform (FDP) and Central Processing Platform (CPP) topsides.
Materials specified in the current design at this FEED stage are acceptable but
relatively conservative. A material selection study has been done to optimize the
materials utilization. Materials recommended in Although the piping in this system is not
NACE specified due to the low design pressure, it is recommended that the vessels to be NACE
specified.
this report for certain systems are less conservative as compared to the materials in the current
design and to be considered and further study during the next phase of Detail Engineering Design.
Materials are recommended based on the intended service and operation constraints as per the
H&MB. Any changes in the operating conditions during next project stage may require review and
modification of the selected materials.
COMPANY The party which initiates the project and ultimately pays for its
design and construction and owns the facilities. Here the
COMPANY is Vietsovpetro JV (referred to as VSP).
CONTRACTOR The party which carries out all or part of the design, engineering,
procurement, construction and commissioning of the project.
1.4 Abbreviations
The following key reservoir data for Thien Ung 04-3X block as given in document 5691-GEN-PR-
RPT-9901 shall be used to achieve the water analysis consistency.
Table 1.0: Key Reservoir Data for Thien Ung 04-3X Block [1].
Parameter Value
Reservoir Pressure (barg) 257 – 504 (254 – 497 atm)
Reservoir Temperature (°C) 112 - 153
The full well stream compositions are based on the well working pressure of 410 barg and
temperature of 148°C [1]. The full well stream compositions that are confirmed by VSP to be used
for process design are given in the following table. The compositions are based on year six
production [1].
Water analysis from Thien Ung 04-3X block field given by VSP is summarized in the following
table:
As tabulated in the table above, no acetic acid content is reported. For corrosion assessment with
Corplus software, recommended default acetic acid value shall be used is 59mg/L.
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CO2 in vapor phase composition value of each stream given by Process group shall be used
for corrosion assessment by Corplus.
There is no significant H 2S detected in any of the well tests. However for design purpose, the
design maximum H 2S for combined production will be taken as 20 ppmv [1].
1.9 Mercury
No significant mercury content was detected in any of the well test to date [1].
1.10 Sand
According to Process and Utility Design Basis, 5691-GEN-PR-RPT-9901, studies have indicated
a risk for low levels of solids production from wells during later years of field life. The sand control
philosophy will be to manage sand down-hole through the use of gravel packs or screens. There
is a small risk that sand may accumulate in the production separators during later years of field
life. These vessels should therefore be equipped with appropriate internal sand flushing from the
vessels during later years of field life. Peak predicted sand loading is less than 130 litres/MMscm
(16 -17 lb/MMscf) [1].
As per VSP clarification, influence of sand on abrasive damage is low where carrying out of sand
from gas wells is always low especially if sand traps use in wells [7].
CO2 Corrosion;
H2S Cracking;
Microbiologically Influenced Corrosion (MIC); and
Galvanic Corrosion.
Erosion Corrosion
Water chemistry, organics acids, pH, water wetting, hydrocarbon characteristics and
phase ratios;
CO2 and H2S content (and possible oxygen contaminants);
Temperature and pressure;
Steel surface including corrosion film morphology;
Fluid dynamics; and
Steel chemistry.
Water Wetting
Water in the hydrocarbon mixture can be entrapped completely in the oil emulsion or it can be
present as a separate water phase. In order for corrosion to occur; water must wet the steel
surface. The presence of water phase depends on:
Water cut;
Flow condition (velocity, flow regime, surface condition); and
Light or heavy hydrocarbon (water separation is easier in light hydrocarbon).
Effect Of Condensation
During hydrocarbon gas transportation, condensation of water vapor may occur on the internal
pipe wall due to some cooling effects of the fluid. If water is condensing, the water will be
saturated with the acid gas CO2 and acetic acid with pH typically <4.
High condensation rate could subsequently lead to high corrosion rates due to low pH of purely
condensing water. If the condensation rate is slow, the water film will be saturated with corrosion
product leading to a high pH and the formation of possibly protective iron carbonate film.
CO2 corrosion assessment of this project was performed using Corplus V21 Corrosion Evaluation
Tool. Refer Corplus evaluation result in Appendix 1.
Corplus is a CO2 corrosion prediction tool for Carbon steel materials. It also gives erosion
corrosion conditions and sour services conditions based on MR0175/ISO15156 severity diagram.
This model was developed by the Total Company based on the previous Cormed model from Elf
and Lipucor model from Total and verified by laboratory testing conducted in a Norwegian
Institute IFE under a JIP project (Joint Industrial Programs) where other operators were involved
including Statoil, Norsk Hydro, Shell etc.
The main characteristics of the two models at the origin were the data base which was extracted
from many feedback experiences of fields of production.
Corplus is mainly a pH and corrosion prediction tool for oil and gas production facilities. It
contains three main prediction modules:
pH calculations
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The Corplus model corrosion evaluation is based on past experiences and wide field data base.
It combines/improves capabilities of previous models from Cormed (ELF), Lipucor (Total) and
others like KFD2 JIP project.
The CO2 corrosiveness which is the most accurate predictive parameter provided Corplus can be
defined through different categories as indicated in the table below:
CO2 Practical
Typical corrosion rate Approximate lifetime vs design life (assuming no
Corrosiveness/Corrosion failure
-> CO2 corrosiveness preventive action) * ->CO2 Corrosion likelihood
likelihood likelihood
Very likely
A failure will occur after 25% of its design life, if no
High 1 to 3 mm/yr within a few
preventive action is undertaken
years
The system will not even resist ¼ of its design life, Certain and
Very high > 3- 5 mm/yr
if no preventive action is undertaken soon
* : Indicative only, since limits are dependent on wall thickness and design life. 10- 15 mm and
20- 25 yrs considered as default values.
Corrosion rate: This quantitative parameter is aimed at characterizing the corrosion rate of the
whole fluid (including oil and gas) to corrode the steel surface within the given calculation
conditions. It is determined from quantitative criteria considering pH, PC, corrective factors for
temperature, glycol, oil/ water wetting. On the other hand, no complementary qualitative
parameters referring to pitting tendencies and protectivity by corrosion products are considered,
as for the complete CO2 corrosiveness.
CO2 corrosiveness: It is the actual capacity of the water, if any, to corrode the steel surface
within the given calculating conditions. When compared to the quantitative corrosion rate
calculation described here above, this parameter:
Include additional qualitative criteria determined from a detailed review of field
experience, about practical pitting tendency or protectivity by corrosion products
Does not include any possible beneficial effect of oil wetting, so it is only related to the
corrosiveness of the produced water
Is provided in qualitative severity categories as indicated in the table
Microbiologically Induced Corrosion (MIC) is a mode of corrosion incorporating microbes like SRB
(Sulphate Reducing Bacteria) or TRB (Thiosulphate Reducing Bacteria) that react and form H2S
which cause corrosion. The most likely sources are from drilling campaigns, well service
activities, precommissioning or hydrotest activities, sump systems, vessel cleaning or
maintenance operations. The MIC normally occurs under deposits, in low velocity flow or
stagnant water. Activities like hydrotesting, vessel cleaning or any other activities which allow
ingress of water into the equipments or piping must only use treated (sea) water.
MIC could be monitored by doing sampling, however this method will assess bacteria of mostly
the mobile (planktonic) ones. It is recommended to do sampling at the inlet of the pipelines and at
the downstream of the open caisson and closed drain drum. It is crucial to monitor the sessile
(surface adhering) bacteria as it will adhere to the surface and has chances to reduce the sulphur
to acid and eventually corrodes the surface. One of the monitoring methods is by placing bio-
probes.
If bacteria are detected then biocides should be used to mitigate the bacteria growth. Common
biocides used are glutaraldehyde, quaternary ammonium or THPS. For treatment of vessels,
injection of certain amount of biocide into the vessel is necessary after each transfer of effluent to
the production facilities. When the vessel is full of liquid, at least 200ppm concentration of the
active product is required. Refer to the options below for the bacteria control of pipelines which
has been proven to be sufficient:
Option 1
Weekly pigging, inject Biocide for 2 hours, 3 times per week.
Option 2
8 hours of continuous injection on weekly basis immediately after pig launching.
Note: Injection rate given above is a practice of an operator in Sarawak oil and gas field which
may be a basis for Thien Ung Fixed Platform FEED. The injection rates have been proven to be
sufficient for Sarawak field but the concentration will vary according to projects. Injection rates for
Thien Ung will be confirmed prior to vendor’s discussion. The use of any biocides, oxygen
scavengers or combination chemicals should be qualified to assess the suitability prior to use.
For cases where sand is expected, excessive sand production may cause sand erosion
especially at components that experience sudden directional change (ex. elbow) or flow
restriction (ex choke and valve). Important factors that determine sand erosion sand erosion rate
including sand production rate, fluid properties (velocity, viscosity, and density) and sand
characteristics (size, hardness, shape).
The sand control philosophy of Thien Ung platforms will be to manage sand down-hole through
the use of gravel packs or screens. Due to the risk that sand may accumulate in the production
separators during later years of field life, these vessels should therefore be equipped with
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appropriate internal sand flushing and nozzles to enable sand handling and flushing from the
vessels during later years of field life.
As per VSP clarification, influence of sand on abrasive damage is low where carrying out of sand
from gas wells is always low especially if sand traps use in wells [7].
Other philosophy being implemented by other projects is to have a non-intrusive sand detector on
each flowline. If sand is detected, production from the well will be cut back or the well will be shut-
in manually or remotely and worked over to eliminate sand production.
It is recommended that the risk of erosion should be undertaken at susceptible areas e.g bend,
choke valves.
There is a risk of galvanic corrosion when connecting CRA and carbon steel pipes with existence
of corrosive free electrolyte (ex: water) flowing through the joints.
In order to minimize galvanic corrosion at these joints on wet service process piping, the following
rules shall be applied:
This solution applies to wet piping with corrosive fluid and it is not needed for dry gas, oil piping or
non corrosive service.
In order to ensure an internal corrosion protection, carbon steel vessels or tanks shall be
internally coated when continuous water phase can be present. This is particularly the case of
separators, drain sump tanks, water tanks and crude oil/ condensate storage tanks. Depending
on the working condition and also the size of the tank, the coating specification will be finalized on
case by case basis whether to be coated fully or only at the bottom part where water
accumulation may occur. It is recommended that the coating is associated with cathodic
protection provided by sacrificial anodes as precaution in case of any imperfection of the applied
coating. For the internal coating applied with GRP, in the range of 1 to 2mm thickness, sacrificial
anodes can be avoided as far as the quality of the applied coating is high. Common types of
sacrificial anodes are Zn and Al anode depending on the service condition.
Remarks:
The anode consumption will be verified during the internal inspection. The sacrificial anodes will
only be consumed if there is any imperfection of the applied protective coating.
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CSCC is a failure mode caused by the combined effect of tensile stress and corrosive
environment (presence of chloride ion, oxygen and high temperature). Austenitic stainless steel is
susceptible to external CSCC at temperature above 60°C while duplex stainless steel (DSS)
above 100°C. Austenitic stainless steel piping and equipment shall be externally painted if the
operating temperature is higher than 60°C. For DSS, painting shall be applied if operating
temperature higher than 100°C. Painting to be applied shall be qualified to assess the suitability
prior to use. The minimum acceptable austenitic SS is type 316/316L. The 316 materials exposed
to marine environment, shall have a minimum Mo content of 2.5%. This concerns mainly the
piping and tubing materials. For tubing connected to the main process lines & vessels that
warmer than 60°C, and piping of diameter less than 2”, the stainless steel material shall be
SS904L or 6Mo and no painting is required.
The piping supports shall be designed to avoid possible crevice corrosion of stainless steel at the
support locations, due to aqueous chloride environment. Direct supporting of non-painted SS
piping on either CS supports or even a plastic or elastomeric shoe is not recommended because
of high risk of crevice corrosion. Dedicated supporting systems must be applied on SS piping.
However, according to VSP experience stainless steel is not required for supporting of pipes,
carbon steel with plastic cover for prevention electrochemical and slot-hole corrosion is
admissible [7].
The recommendation is to apply local glass flake coating on the SS pipes (1mm thick) at the level
of the supports. Another system could consist on stratified shell composed of laminated epoxy
resin reinforced with fiber glass and glued to the pipe and finally, an elastomer sheet will be
placed between the SS pipe and the support.
The material selection must take into account the minimum operating temperature and that
predicted during blowdown to avoid brittle fracture. Minimum service temperatures of various
materials are given as follow:
Note 1: Carbon steel may be used in piping systems with a minimum design temperature down to
-29degC if the nominal wall thickness is less than 12.7mm, or as specified in ASME B31.3. For
lower design temperatures down to -46degC, impact testing shall be performed.
The overall approach to material selection for piping and equipments was initially to evaluate the
internal corrosivity of the fluids with respect to utilization of carbon steel. Corrosion resistance
alloys (CRA) or stainless steels shall be recommended for the cases where carbon steel with
corrosion allowance and corrosion inhibitor are still not sufficient to withstand the corrosion
throughout the design life. In cases where SS316L material being used at above 60°C and DSS
at above 100°C, painting shall be applied and painting shall be qualified to assess the suitability
to be used at certain design temperature.
CRA components e.g. 316SS and DSS purchased from reputable manufacturers and
manufactured in accordance with the appropriate ASTM product standard e.g. ASTM A240, A182
etc should be automatically compliant with the requirements of NACE MR0175 though this should
be confirmed prior to purchase.
The additional requirements required for CS and LTCS seamless and forged components to
comply with NACE MR0175, i.e. C.E and hardness limit if purchased from reputable
manufacturers and manufactured in accordance with the appropriate ASTM product standard
should be compliant with requirements of NACE MR0175, though this should be confirmed prior
to purchase.
In the case of CS and LTCS components made from plates HIC/SWC qualification testing of plate
is required in accordance TM0284. The cost of the qualification testing is dependent upon the
quantity of plate and the prevailing market conditions.
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The materials selection for the production system is based upon the production streams being
oxygen free. There is a proposal to route fluids from the LP flare KO drum/ open drain caisson to
the production separator. This will result in the possible introduction of seawater and oxygen into
the production system. This would have major implications on the materials of construction
proposed below and therefore it is recommended that the proposal for routing to the separator
should not be adopted.
Based on the Corplus corrosion evaluation results in Appendix 1, the CO 2 corrosiveness for the
streams of FDP facilities are classified as “Very High”. “Very High” corrosiveness corresponds to
the typical corrosion rate relatively beyond 3mm/yr. These streams include the flowline upstream
and downstream the choke valve going to the test separator (Stream 1A, 1B) and to the
production cooler on CPP (Stream 2) and also streams downstream the test separator (Stream
1C - 1F). From the corrosion assessments, it is indicated that the high corrosion allowance values
is beyond CS sufficiency. Since CS with 95% efficiency inhibition is insufficient to withstand the
corrosiveness and also highly unlikely to be achieved on a production piping system, CRA
material is recommended. DSS NACE is recommended for the FDP piping streams due to the
high corrosiveness and temperature. However, CS with SS316L cladded shall be recommended
for the FDP closed drain vessel due to the low design pressure where SS316L utilization is still
within the limit as per NACE MR0175/ISO15616-3. Material recommendation for FDP and CPP
facilities are summarized in Appendix 2.
Piping in the production cooler and the production separator system (Stream 102, 103) are
recommended to be in DSS NACE material. Recommendation is made based on the
corrosiveness and also by considering the high pressure piping. Due to the high pressure,
material will require higher mechanical strength to resist the pressure and this condition could be
achieved by increasing the pipe wall thickness. DSS has a higher mechanical strength compared
to SS316L and therefore will achieve a certain strength at a lower wall thickness as compared to
SS316L. DSS with lower wall thickness requirement will probably cost almost the same or maybe
slightly higher than SS316L with a higher wall thickness. The selection may have a slightly higher
CAPEX but the OPEX is reduced and also a higher mechanical strength and corrosion resistance
can be achieved.
The gas line downstream the production separator going to the TEG contactor (Stream 104, 109,
110) which contains non-dehydrated gas is recommended to be in DSS NACE material. Although
no free water is reported in the H&MB [2], but in reality water condensation on the pipe wall is
expected due to the high temperature difference between the internal pipe temperature and the
external temperature. For a 25 years design life facility, this condition may be a detrimental issue
in a long run and therefore DSS NACE is recommended. However, gas lines downstream the
TEG contactor (Stream 112, 128, 129, 140, 108,113, 107) are recommended to be in LTCS with
3mm CA NACE as the gas is dehydrated and no corrosion is expected.
Dehydrated gas lines in the export gas custody metering system (Stream 141, 115, 116, 117) up
to the production launcher are recommended to be in LTCS with 3mm CA NACE. As requested
by the Process Group, the H2S partial pressure shall be calculated based on the design pressure
instead of the operating pressure. The calculations show that the H 2S partial pressure for this
system is beyond the sweet service limitation of 0.003bar.
The condensate lines downstream the production separator up to the condensate dehydrator
(Stream 105, 119, 120, 121, 124) are recommended to be in DSS NACE. The corrosiveness of
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these lines is classified as “Very High” by Corplus. However, material selection of LTCS with
3mm CA NACE is recommended for the dehydrated condensate lines downstream the
condensate dehydrator up to the launcher (Stream 125, 134, 135, 126, 127, 142, 118). In the
condensate dehydrator, the dehydrated gas supplied from the TEG dehydration system will
absorb the moisture from the condensate producing dehydrated condensate. The moisture will be
carried to the rewetted stripping gas compression system and will be sent back to the TEG
dehydration system. The piping which carries the moisture (Stream 130, 131 133) is
recommended to be in DSS NACE as the wet vapour may reach its dew point and condensed on
the pipe wall.
LTCS with 3mm CA NACE is recommended for the whole Gas Compression System (Stream
143A/B, 136A/B, 138A/B, and 139A/B). Alternative of SS316L NACE is recommended in case if
there will be any condensation occurs due to the high temperature range between the upstream
and downstream of the gas compressor after cooler. According to the Process group, there
should not be any condensation since the gas is dehydrated.
Piping upstream the potable water maker package which carries seawater shall be in copper
nickel material or in GRP as alternative. Potable water piping shall be SS316L while wash water
system piping shall be in CS with 3mm CA. Potable water storage tank and pressurized potable
water vessel shall be in CS with 3mm CA and internally epoxy coated or in GRP material. The
coating shall be approved by HSE due to the potable water service. As alternative, CS with
SS316L cladded or solid SS316L shall be recommended for the potable water storage tank and
the vessel. Selection of the alternative shall depend on the tank and vessel dimension. The wash
water tank shall be in CS with 3mm CA and internally epoxy coated. Potable water pumps shall
be in SS316 while wash water pumps shall be in CS. For the potable water filter, the vessel and
internals shall be in SS316L.
Piping for the whole seawater system shall be in Cu-Ni and GRP as alternative material.
Seawater lift caisson shall be made from CS with 3mm CA internally and externally with glass
flake epoxy coating on both internal and external sides. Additional protection shall be applied by
placing internal sacrificial anodes at the bottom part of the open drain caisson. The seawater lift
pumps shall be from Super Duplex Stainless Steel (SDSS) or Nickel Aluminum Bronze as
alternative. Seawater strainer shall be made of SDSS. VSP clarifies that pipes with internal
anticorrosive coatings, protective inserts are necessary for welded seams [7].
The instrument and utility air system shall be in SS316L stainless steel or galvanized CS as
alternative material. Cleanliness concern for instrument air system is detrimental to avoid rust
particles that may plug the gas distribution header. Instrument gas contaminated with particles
will cause defaults and may damage the equipments.
It has been clarified by VSP that SS316L stainless steel is necessary for air before its cleaning
but it is possible and preferable to apply galvanized steel pipes after air cleaning [7], [8].
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Wet air and instrument air receiver can be in CS with 3mm CA with epoxy internal coating and CS
with SS316L cladded or solid SS316L as alternative. Selection of CS with SS316L cladded or
solid SS316L shall depend on the dimension of the vessel. We highly recommend CS with
SS316L cladded or solid SS316L to avoid corrosion in case if the dryers do not function well
causing the presence of water vapor in the line.
CS with 3mm CA is recommended for the piping of above system. The hot oil expansion vessels
and hot oil trim cooler shall be in CS with 3mm CA. Hot oil circulation pumps and the hot oil side
stream filter shall be in CS.
Sewage system piping shall be in GRP. The sewage water disposal caisson shall be made from
CS with 3mm CA internally and externally with glass flake epoxy coating on both internal and
external sides. Additional protection shall be applied by placing internal sacrificial anodes at the
bottom part of the caisson.
The piping for the nitrogen system shall be in CS with 3mm CA. The nitrogen receiver shall be in
CS with 3mm CA with internal coating.
Piping for fuel gas system shall be in CS with 3mm CA NACE. For piping with lower design
temperature below 0deg°C, LTCS with 3mm CA NACE shall be required. Piping from the filter to
the turbine shall be in SS316L [8].
Gases and liquid released from the HP equipment sources is routed to the HP flare KO drum via
HP flare header. Stainless steel LT is recommended for the HP flare header due to the very low
temperature. The painting system to be applied shall be qualified to assess the suitability to be
used at specific design temperature. As alternative, 6Mo is recommended for the header. HP
flare release separated from the drum is sent to the HP flare tip for disposal by combustion. The
same material as the header is recommended for this gas line going to the HP flare tip. The flare
tip shall be in SS310 for temperature exposed to oxidation/ scaling while SS316L minimum for
lower temperature zones. The material selection for the flare tip shall be confirmed with the
vendor.
Liquid separated in the HP flare KO drum is recovered to production separator by the HP flare KO
drum booster pumps and HP flare KO drum pumps. Liquid discharge outlet up to the shut down
valve (SDV) shall be stainless steel LT with painting due to the KO drum design conditions. As
alternative, 6Mo is recommended. Piping downstream the SDV to the HP flare KO drum pumps
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shall be in LTCS 6mm CA with coating and regular basis inspection. As alternative, the piping is
recommended to be in DSS to ensure the uniformity of material selection with the production line.
Piping downstream the HP flare KO drum pumps going to the production separator shall be in
DSS. The pumps shall be in SS316. HP flare KO drum is recommended to be in solid SS316L
coated with TSA (thermally sprayed aluminum) externally. 6Mo is recommended as the
alternative.
The materials are recommended by assuming no oxygenated seawater will be recycled back to
the production separator. Introduction of seawater and oxygen into the production system will
have major implications on the materials of construction proposed.
Besides acting as the hold up drum for HP flare gases and liquid, the HP flare drum also
functions as process liquid drains drum. The process drains are routed to HP flare KO drum
through the continuous process drains header. LTCS 6mm CA with coating and regular basis
inspection shall be recommended as the header.
Although the piping in this system is not NACE specified due to the low design pressure, it is
recommended that the vessels to be NACE specified.
The LP flare will take continuous hydrocarbon emissions and emergency release from the LP
equipment sources. The hydrocarbon release is routed to the LP flare KO drum via the LP flare
header. The header shall be in LTCS 6mm CA with coating and regular basis inspection.
Alternative shall be SS316L. LP flare gases separated from the drum are sent to LP flare tip for
disposal by combustion and the piping shall be in the same material as the header. The flare tip
shall be in SS310 for temperature exposed to oxidation or scaling while SS316L minimum for
lower temperature zones. The material selection for the flare tip shall be confirmed with the
vendor.
Liquid collected in the LP flare KO drum is recovered to HP flare KO Drum by the LP flare transfer
pumps. The piping is recommended to be in LTCS 6mm CA with coating and regular basis
inspection. Alternative shall be SS316L. The pumps shall be in CS.
Although the piping in this system is not NACE specified due to the low design pressure, it is
recommended that the vessels to be NACE specified.
Closed drain system shall be designed to collect only the maintenance drains from the
pressurized process and utility systems on CPP and not designed to collect intermittent or
continuous process drains from the topsides. Liquid collected in the CPP closed drain vessel is
pumped by the closed drain vessel pumps to the HP flare KO drum and the gas is routed to the
LP flare header. The liquid piping is recommended to be in CS 6mm CA with coating and regular
basis inspection. Alternative shall be SS316L. The gas line shall be in CS with 3mm CA. The
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pumps shall be in CS with 13Cr impeller and SS316 as the alternative. The caisson shall be
made from CS with 3mm CA internally and externally with glass flake epoxy coating on both
internal and external sides. Additional protection shall be applied by placing internal sacrificial
anodes at the bottom part of the caisson. Residual hydrocarbon with traces of oxygen contained
seawater will be pumped out from the caisson and therefore the fluid will be very corrosive. CS
6mm CA with coating is recommended and the piping shall be monitored by inspection program.
Usage of CRA material without inspection is possible for this line if the design temperature to be
reduced during the detail design engineering stage. 25Cr Super Duplex shall be further evaluated
as the option. If the design temperature to be maintained, the options could be Titanium or Nickel
alloys where no painting and inspection program are required. The pump shall be in SDSS or Ni-
Al-Br as an alternative.
Although the piping in this system is not NACE specified due to the low design pressure, it is
recommended that the vessels to be NACE specified.
Remarks:
The materials selection for the production system is based upon the production streams being
oxygen free. There is a proposal to route fluids from the open drain caisson to HP flare KO drum
and going back to the production separator. This will result in the possible introduction of
seawater and oxygen into the production system. This would have major implications on the
materials of construction proposed and therefore it is recommended that the proposal should not
be adopted.
Diesel piping shall be in CS with 3mm CA. The raw diesel coarse filter and the diesel filter
coalescers shall be in CS with 3mm CA and SS316L internal parts. Diesel storage tank shall be in
CS with 3mm CA. CS shall be the recommendation for the diesel transfer pumps.
Material recommended for the methanol injection system is CS with 3mm CA. Methanol storage
tank shall be in CS with 3mm CA.
Materials for corrosion inhibitors handling will be in SS316L to keep the chemicals clean.
However, based on VSP’s experience, GRP has been successfully applied for many years [7].
DOC NO. 5691-GEN-PI-RPT-0005
FRONT-END ENGINEERING DESIGN (FEED)
SERVICES FOR THIEN UNG FIXED PLATFORM REV. NO. 0
Chemical inhibitor injection is required to give protection to carbon steel piping. Corrosion inhibitor
availability measured by monitoring should be 95% or above. Chemical inhibitor injection is not
required for CRA piping. As for Thien Ung facilities, it has been studied that even with 95%
corrosion inhibitor availability, carbon steel with corrosion allowance is still not sufficient to
withstand the corrosiveness of this field. Therefore, CRA piping is recommended mostly and
corrosion inhibitor injection is not required for most of the piping system.
However, provision for corrosion inhibitor injection shall be provided for the pipeline. Corrosion
inhibitor shall be injected atleast 10 pipe diameters downstream the starting point of the carbon
steel pipeline. The 10(D) length is required to accommodate proper mixing of the corrosion
inhibitor with the production gas/ condensate. For this project, it is identified that the best location
for the CI injection point shall be upstream the gas/ condensate mixer.
Corrosion monitoring devices shall be installed to monitor the corrosivity, chemical treatment
efficiency and bacteria activity. Access fittings (standard 2”) should be provided for the use of
both ER probe and corrosion coupon (CC) as a minimum. Normally access fitting is located at 6
o’clock position. Corrosion monitoring devices shall be retrievable where a minimum clearance of
2m below the pipe is required for retrieving operation.
For cases where the pipeline is in carbon steel, ER probe, CC and SC to be installed at the
pipeline for monitoring. Coupon and probe shall be distant by 1m minimum. These devices shall
be located at the pipeline inlet upstream the barred tee.
Fluid coming from the HP flare KO drum will be monitored to trace any bacteria presence. Liquid
will be monitored by installing SC at the HP flare KO drum liquid outlet. Monitoring is necessary
because the liquid will be routed back to the production line.
Table 6.0 : Recommended Locations for Corrosion Monitoring of Thien Ung Facilities.
7.0 REFERENCES
5) NACE MR0175/ISO 15156-3 Petroleum and Natural gas Industries – Materials for Use in H2S
Containing Environments in Oil and Gas Production - Cracking-resistant CRAs (corrosion-
resistant alloys) and other Alloys, 2009
7) VSP Technical Sheet Comment for Material Selection and Corrosion Philosophy Report Rev. A,
Sheet No: TW-GEN-PI-RPT-0005.
Where:
Cri: Inhibited Corrosion Rate; Cru: Uninhibited Corrosion Rate; A: Inhibitor efficiency; CA: Corrosion
Allowance.
Process Equipment
20V105 Test Separator CS with Alloy 625 CS with SS316L *Usage of CS with SS316L
cladded cladded* cladded requires qualification
testing by the Client
20E115 Production Cooler DSS Tubes, CS with
Alloy 625 cladded
Header
20V110 Production Separator CS with Alloy 625 CS with SS316L *Usage of CS with SS316L
cladded cladded* cladded requires qualification
testing by the Client
22V105 TEG Contactor Inlet Scrubber CS with SS316L cladded
22V110 TEG Contactor CS with SS316L cladded
29M120 Gas / Condensate Static Mixer CS
30P105A/B/C Train 1 Condensate Booster Pumps HOLD
30S110A/B Train 1 Condensate Filters CS with SS316L cladded
30S115A/B Train 1 Condensate Coalescers CS with SS316L cladded
30V105 Condensate Dehydrator CS with SS316L cladded
30V110 Rewetted Stripping Gas Suction Scrubber CS with SS316L cladded
LP Flare KO HP Flare KO Header CS 6mm CA with SS316L Alternative of SS316L for robust
Drum coating and inspection application to accommodate
25yrs design life
LP Flare KO LP Flare Tip CS 6mm CA with SS316L Alternative of SS316L for robust
Drum coating and inspection application to accommodate
25yrs design life
LP Flare System Equipment
62V125 LP Flare KO Drum CS 6mm CA with CS with SS316L *Phenolic coating selection shall
Phenolic coating*. cladded be qualified during detail
engineering due to the high
design temperature.
62P135A/B LP Flare KO Drum Pumps CS
62A130 LP Flare Tip SS310 for temperature Material selection to be
exposed to oxidation/ confirmed with the vendor.
scaling; SS316L
minimum for lower
temperature zones.
DOC NO. 5691-GEN-PI-RPT-0005
FRONT-END ENGINEERING DESIGN (FEED)
SERVICES FOR THIEN UNG FIXED PLATFORM REV. NO. 0
Remarks: