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CNS Gas Integrity Review

ELE Chemical Systems Overview


April 2004
Ref Doc: FIMS A-210X-08-02-0216

System Contact:

Claire McAlinden (Nalco)

System Numbers: 36 (Chemicals)

Presentation Summary

1- System Description & Process Flow Diagram

2- Materials Review and Operating parameters

3- General Integrity Threats

4- Mitigation & Monitoring

5- Inspection Activities/Results/Recommendations

6- Any Mods/ Failures etc.

7- Strategies- Inspection/Monitoring/Mitigation

8- System Action Summary

9- Chemical System Integrity Statement

System Description
Everest, EPM and Lomond have facilities to inject chemicals to mitigate against potential problems and improve plant
efficiency. Chemicals can minimise effect on wells due to reservoir formation damage, impact of subsea or well
intervention on topsides production facilities, as well as prevent potential plant upsets. However, their main function is
to guarantee good quality export oil and gas and produced water to overboard while having minimal impact on the
environment or plant integrity.

The Everest and Lomond bulk chemical storage area can hold up to 5 tote tanks and bund can hold the full contents of
one tote tank if required. The standard chemicals supplied from the chemical package include corrosion inhibitor for
specific systems on the platform and methanol. The Lomond also has facilities to inject corrosion inhibitor for the
multiphase import fluids, anti-foulant and scale inhibitor for use on the EPM.

The main items that comprise the Chemical System are;


Bulk chemical storage area for atmospheric chemical tanks
Chemical injection package & pumps (X-3600)
Methanol storage tank & pumps (V3602/P3602 or V3615/P3615)

Chemicals - System 36
CHEMICAL INJECTION
BULK STORAGE AREA

To Hazardous Area
Open Drains

To HP Flare Header

Gas Blanket

MEOH
STORAGE
VESSEL
V-3602

CHEMICAL INJECTION
PACKAGE
X-3600
(CORROSION INHIBITOR)

Nev chemical system is an identical layout


to this but has a methanol storage tank for
supply to South Everest (V3615)
To Gas Coolers
To HP Separator
To IP Separator
To Wells

To Closed Drains

METHANOL INJECTION PUMP


P-3602
To Hazardous Area Open Drains

To Closed Drains

To LP Discharge Scrubber Fuel Gas Outlet

To IP VR Discharge Cooler Inlet

To LP Separator Gas Outlet

Legend
CS
316L SS

To IP Separator Gas Outlet

To IP Separator Inlet

Chemical Usage Summary


Chemical

Product

Users

Treat Rate

System / Injection

Comments

Point
Corrosion Inhibitor

Everest

30 ppm (GF)

Split 50:50 IP:LP seps

Everest produces more water than Lomond.

EPM

25 ppm (PW)

HP sep

Erskine produces the most. Partitions in

Lomond

30 ppm (GF)

IP sep

EC1071A

Erksine

75 ppm (GF)

NUI

Oil soluble mainly partitions in HC

EC1017B

Everest

10 l / day

Reboiler overheads from

Lomond - injected from 205 litre barrel

EPM/Lomond

10 / l day

barrel

EC1152A

(PW)

Corrosion inhibitor

the water phase.

(Multiphase)
Corrosion Inhibitor
(glycol overheads)
Corrosion Inhibitor

EC1389B +

Everest

Maintain 0.5 0.8%

Heating and cooling

Glycol & inhibitor premix. EC1389B can be

(HM/CM)

EEHC1

EPM/Lomond

(>1000ppm nitrite)

medium system

used alone for system top ups

DRA

LPTM100

Lomond

1.5 gal/hr

Erskine condy injection

Can be ramped up on pigging if required.

quill for Lomond to


Everest condy line
Wax Dispersant

EC6368A

Everest

As required

Pig trap / PCHE

After pig run or to soak PCHE as required.

150 ppm

NUI

Reduced to 100ppm 1/2Q 2004 second

EPM/Lomond
Wax Inhibitor

EC6453A

Erskine

phase planned to reduce to 75ppm Oil


soluble mainly partitions in HC.
Scale inhibitor

EC6348A

EPM

30ppm (PW)

EPM

EC6359A

Erskine

70 ppm (PW)

NUI

Looking to change chemical to EPM type.

EC1010B

EPM

1-2L per mmscf

EPM

Reduced to 0.7 l per mmscf June Oct

(ZnS)
Scale inhibitor
(Carbonate)
Anti-foulant

2004

Chemical Usage Summary


Chemical

Product

Users

Treat Rate

System / Injection

Comments

Point
TEG

Everest

As required

Glycol skid

CM

EPM/Lomond
Methanol

Everest

As required

Wells / pipeline

Lithium hypochlorite

Everest

Use on well start up if hydrate risk


mainly used on South Everest

EPM/Lomond
Hypochlorite

Top up as required and maintain 30% in

0.5 0.8 ppm

Seawater (measured at

Generators continue to be high

EPM/Lomond

discharge pumps)

maintenance items

Everest

Potable water

Stored in A3305 (see utilities 2 review)

Potable water

Stored in A3303 (see utilities 2 review)

Seawater coolers

Not usually required unless hypochlorite

Lomond
Sodium

hexametaphosphate
Biocide

Everest
Lomond

EC6199A

(seawater)

Everest

500 ppm as required

injection down long term but planned

EPM/Lomond

for May with scale dissolver treatment


(EC6312A) for SW coolers

Biocide

EC5309A

(diesel)

Everest

As required

Diesel storage tanks

audit results

EPM/Lomond

Biocide

TROSTICK

Everest

(drains)

670

EPM/Lomond

Not usually required dependent on

As required

As required

Not usually required dependent on


audit results

Materials Review: Chemical Storage Tanks


Tag

Chemical

Skid/ platform

Material

Comment

A-3691

EC1010B (EPM anti foulant)

LO-X-3691 (EPM)

316 SS

In use

A-3692

Spare

LO-X-3691 (EPM)

316 SS

Not is use

A-3693

EC6348A (EPM scale inhibitor)

LO-X-3691 (EPM)

316 SS

In use

A-3694

EC1152A

LO-X-3691 (EPM)

316 SS

In use

A-3695

EC6368A (EPM wax dispersant)

LO-X-3691 (EPM)

316 SS

In use (as required)

A-3696

Wax solvent drain tank

LO-X-3691 (EPM)

316 SS

Not is use

A-3697

Potable water

LO-X-3691 (EPM)

316 SS

Pot water injection for P3694 not used

A-3698

DRA tank

LO-X-3691 (EPM)

316 SS

Ref # for decommissioned system temp system


tote tank has no # designation

A-3601/3

EC1152A CI liquid/gas

LO-X-3600

316 SS

Connected together effectively one tank for CI


on Lomond and Everest

NE-X-3600
A-3602A/B

EC6368A Wax dispersant

Everest

316 SS

Connected up effectively one tank

V-3602

Methanol

Lomond

316 SS

In use on Lomond

V-3615

Methanol (SE)

Everest

316 SS

In use on Everest

Materials Review: Piping

The chemical piping from the bulk storage area is 316 stainless steel.

The chemical injection package piping to process (X-3600 and X-3691) is 316 SS apart from the package and bund
drain lines which are CS.

Hypochlorite piping is UPVC or GREP.

Methanol piping is 316 stainless steel.

Operating Conditions

Atmospheric pressure up to injection

Ambient temperature

Threat

Current threats Area


to system integrity
Probability

General

Actions

Mainly 316s/s operating at ambient temperature

Low

Inspect as required

Stainless steel storage tanks no history of extensive pitting.

Low

PIR remaining tanks

corrosion
Pitting
corrosion
External

History of paint breakdown and fabric maintenance

corrosion

requirements within system e.g chemical pumps.

Galvanic

Crevice/pitting corrosion at interface between tanks and pipe

Medium

Ensure COs raised have


correct start dates

Medium

Opportune inspection

Low

UT survey of Injection

work and under clamp supports.


Injection
points

Materials
issues
Vibration /

Quills mainly used on EPM and Ev/Lom. Corrosion - improper


mixing or pumps not switched off during downtime or if

Points. Confirm if every

pumps not restarted.

injection point uses quills.

PTFE coated B7 tank bolts those seen in preserve rather

Low

than replace condition, Neoprene gaskets on man ways for CI


Small bore piping, unsupported piping

CO raised for bolt


preservation

Medium

JMD survey: 2 jobs raised

Fatigue
CUI
Erosion
PWC

Tanks are not insulated

Low

Inspect as required

Current injection rates do not pose an erosion concern

Low

Inspect as required

Mostly oil soluble chemicals used, CI water soluble

Low

Inspect CS drain lines from


skids as per priority (CI 1st)

Dead legs /
MIC

Most sampling points used are for inhibited fluids


(CM/HM/TEG/seawater). Diesel sampling point could be risk.

Low

Dead legs to be identified


& inspected

Mitigation and Monitoring


Mitigation
Design

Material selection.

Use of correct injection fittings (quills etc)


Process

No processing of chemicals

QA ACC (authorisation of chemical change) used for new chemical which addresses all risks (CHARM/MSDS)
Supply checks for chemicals: standard chems every batch pH, density & appearance,
: high risk chems performance tested 6 monthly (CI/SI)

Monitoring
There are no on-line corrosion monitoring facilities within the ELE chemicals systems - not deemed necessary.
There are on-line chemical sampling facilities through out the platforms.

Stock control levels monitored by the platforms

When plant shuts down, pumps may or may not s/d automatically dependant on the extent of the s/d. Ops techs
monitor operating regime and act accordingly.

The following are included in the compliance KPIs;

CI injection rates (+ SI for Erskine)

CM/HM nitrite/chloride and pH levels


TEG chloride, water and pH levels
Seawater chlorine levels
Diesel water content

Inspection monitoring is also carried out in these systems, and has mainly been visual to date.

Current Inspection Regimes EPM/ Results

System review Output

Item from Maximo

Current usage

Insp

Results

Insp Recommendation / Due

Comments

LOM-A-3691

Anti foulant (EPM)

EVI 2001

No anomalies

Inspection scheduled 2004

3 yearly frequency, no IVI record


opportune during MLP move as

Spare chemical storage tank

sample
LOM-A-3692
Spare chemical storage tank

Not in use - spare

EVI 2001 &

(EPM)

2003

Satisfactory

Inspection scheduled 2006

3 yearly frequency, no IVI record


opportune during MLP move as
sample

LOM-A-3693

Scale inhib (EPM)

EVI 2001

No anomalies

Inspection scheduled 2004

3 yearly frequency, no IVI record


opportune during MLP move as

Scale inhibitor storage tank

sample
LOM-A-3694

Corrosion inhibitor

Reverse emulsion breaker storage tank

(EPM)

EVI 2001

No anomalies

Inspection scheduled 2004

3 yearly frequency, no IVI record


opportune during MLP move as
sample

LOM-A-3695

Wax dispersant

Storage tank wax solvent

(EPM)

EVI 2001

No anomalies

Inspection scheduled 2004

3 yearly frequency, no IVI record


opportune during MLP move as
sample

LOM-A-3696

Not used

No scheduled inspections

PM set to zero

Not used

EVI 2001

No anomalies

Tank blasted and repainted

3 yearly frequency, no IVI record

2003. Inspection scheduled

opportune during MLP move as

2004

sample. Will require Maximo PM

Wax solvent drain tank


LOM-A-3697
Potable water storage tank

update
LOM-A-3698

Decommissioned

DRA package atmos tank

system

Temp system tank has no

Will this be given a permanent

number designation as used via

tank?

tote tank connected to pump as


required.

Current Inspection Regimes LOM/ Results

System review Output

Item from Maximo

Current usage

Insp

Results

Insp Recommendation / Due

Comments

LOM-V-3602

Methanol

EVI& IVI 1993,

Satisfactory

EVI in 2005

No concerns

Methanol storage vessel

EVI 1999 & 2001

LOM-A-3601

Corrosion

Corrosion inhibitor tank (cond)

inhibitor

LOM-A-3603

Corrosion

Corrosion inhibitor tank (gas)

inhibitor

--

CO in system for
painting on p/w

--

CO in system for
painting on p/w

Current Inspection Regimes NEV/ Results

System review Output

Item from Maximo

Current usage

Insp method & Freq

Inspection Results

Insp Recommendation / Due

Comments

NEV-V-3602

Not in use

EVI & IVI 1993

Satisfactory

EVI in 2005, bolts in preserve

PM set to zero as

min wt. 9.8mm

condition

mothballed in 2001

Satisfactory

IVI 2010

PM set to 10 yearly

No PM against X-3600

EVI & UT 1997

Methanol storage vessel

MPI and dye pen on


davit arm welds 2001
Bolts replaced 2003
NEV-V-3615

Methanol

SE methanol storage vessel

Installed in 2000
EVI 2003

NEV-A-3601

Corrosion

EVI 2000

EVI in 2005, bolts in preserve

Corrosion inhibitor tank (cond)

inhibitor

Bolts replaced 2003

condition

NEV-A-3602A

Wax dispersant

EVI 2002

Inspection scheduled 2005

work in good condition

Dispersant storage tank


NEV-A-3602B

SS tank, bolts and pipe

Wax dispersant

EVI 2002

SS tank, bolts and pipe

no IVI history
Inspection scheduled 2005

work in good condition

Solvent storage tank


NEV-A-3603

Corrosion

Corrosion inhibitor tank (gas)

inhibitor

EVI 2000

Now 4 yearly frequency,

Now 4 yearly frequency,


no IVI history

EVI 2005

No PM against X-3600

Pipe work UT Inspection summary


Platform

Line No

Location

Everest

02"-GF-36001-GC4-N

Everest

02"-GF-36001-GC4-N

Everest

02"-GF-36001-GC4-N

Everest

02"-GF-36001-GC4-N

Everest

02"-GF-36001-GC4-N

V-3602 (N5) to 03"-GM-35122-JC2


(PSV-36017)
V-3602 (N5) to 03"-GM-35122-JC2
(PSV-36017)
V-3602 (N5) to 03"-GM-35122-JC2
(PSV-36017)
V-3602 (N5) to 03"-GM-35122-JC2
(PSV-36017)
V-3602 (N5) to 03"-GM-35122-JC2
(PSV-36017)

36 Chemical Systems

Everest

Lomond

36 Chemical Systems

Lowest M easured WT (mm)


and Feature

Date

3.91

0.151

6.4

02/05/2001

3.91

0.151

7.8

02/05/2001

3.91

0.151

5.6

02/05/2001

3.91

0.151

5.3

02/05/2001

3.91

0.151

02/05/2001

2
22
0
41
1
11
1

49

Carbon Steel not insulated


Carbon Steel insulated
Stainless / Duplex not insulated
Stainless / Duplex insulated
Vessels not insulated
Vessels insulated
Carbon Steel not insulated
Carbon Steel insulated
Stainless / Duplex not insulated
Stainless / Duplex insulated
Vessels not insulated
Vessels insulated

NWT (mm) M AWT (mm)

76

Carbon Steel not insulated


Carbon Steel insulated
Stainless / Duplex not insulated
Stainless / Duplex insulated
Vessels not insulated
Vessels insulated

36 Chemical Systems

EPM

CA (mm)

1
3
0
45
0
1
0

51

1
1

0
0
33
13
0
5

Inspections have been performe

System Correctives/Overdues
Maximo Integrity Corrective WO: number : description : date raised
Lomond
115669 Prep and paint pipe work on corrosion inhibitor tank (A3601) 23/11/02
130008 LT-36857 and LT- 36859 EPM chemical Injection skid indicators not operating correctly. 12/1/03
1462263 Overhaul chemical injection pump pulsation damper. 5/1/04
1543828 Complete JMD anomaly report repairs to DRA inlet to condensate export pipe work - block valve on DRA inlet line, or
support free end of valve from parent pipe work in horizontal and vertical directions. ref: AC-LT-FE-00409-01. For further
details contact Bill Murphy or Tony Starmer. 29/02/04
1543843 JMD anomaly report repairs to be completed for LP Separator water outlet pipe work unsupported chemical injection
point. Ref: AC-LT-FE-00301-01. For further information contact Bill Murphy or Tony Starmer. 29/02/04

NEV
1229597 - Remedial painting to corrosion inhibitor pumps 26/6/03
1287585 - Repair / replace broken adjustment cover on corrosion inhibitor pumps. 23/8/03
1286994 - Carry out fabric maintenance to corrosion inhibitor injection pump. During monthly chemical checks & at the
monthly integrity meeting it has been reported that the pump requires a little love & attention as it is looking shabby.
22/8/03
Overdues (Inspection):
Lomond none overdue 5 pending in look ahead for August 2004 (in use EPM tanks)
Everest none overdue none pending in look ahead

System Modifications & Failures


Modifications to Date

Additional tank for South Everest methanol supply 2001.

Original methanol tank (V3602) mothballed in 2001.

Glycol overheads inhibitor injection via tank since drains failures in 2001.

MLP has not altered chemical injection rates to date.

Erskine has ongoing chemical optimisation plan.

Looking into changing scale inhibitor used on Erskine to negate need for EPM SI addition.

Movement of EPM tanks for MLP work.

DRA injection on Lomond trial started in 2002 now permanent but original tank decommissioned DRA
supplied via tote tank so has no tag number designation. WGE starting to engineer new set up with tote
tank on EPM weather deck at this time.

DRA trial for South Everest planned for 2004.

Failures and Anomalies

Quills: No blockages recorded.

Pumps: Lomond CI pump (poor condition & difficult to calibrate identical Everest pump calibrates easily).

General: Fabric maintenance.

System Strategies
Chemical and Monitoring Strategy

Corrosion control matrices revised and issued (March 04) no specific activities identified for
maintaining/assessing the integrity of the chemical system. (KPIs exist for chemical injection).

Inspection Strategy

Vendor chemical injection skids (vessels and piping) to be scheduled correctly in Maximo

Expand inspection scope to include UT checks opposite chemical injection points and tank inspections
as per PIR recommendations to date based on sampling for EPM tanks.

Summary for System

No corrosion monitoring devices required in this system.

No historic failures reported within the system.

Temp set up for glycol overheads (pump skid & drum) and Lomond DRA addition (tote tank) Swires responsible for
inspection?

DRA injection on Lomond to be made permanent as chemical has been successful WGE progressing tank set up.

MSDS sheets show chemicals to be compatible with tank and all supply pipe work materials.

Checks required to confirm chemical compatibility for all in service elastomers and metals that could be in contact.

Potentially changing NUI scale inhibitor so EPM chemical may not be required and EPM chemical storage tanks
movement for MLP work.

Main threats are external corrosion and vibration.

Limited inspection history for tanks and no UT information opposite injection locations.

Opportune inspection of EPM tanks due to repositioning for MPL work to be under taken.

Maximo update for tank inspection required.

Fabric maintenance seems to be an ongoing issue within this system for tanks, pumps, and skid pipe work.

No register for regular sampling and injection points for each platform available onshore.

System Review Output


Integrity Statement
April 2004

THE THREATS AGAINST THE ELE CHEMICALS SYSTEM (INCLUDING PIPING & VESSELS) WERE
CONSIDERED AND INSPECTION & MITIGATION ACTIVITIES/ RESULTS/ACTIONS REVIEWED

BASED ON THE ABOVE, IT IS THE OPINION OF THE ELE INTEGRITY TEAM THAT THE CHEMICALS
SYSTEM IS CURRENTLY CONSIDERED FIT FOR SERVICE.
A NUMBER OF ACTIONS HAVE BEEN IDENTIFIED TO MITIGATE AGAINST THE HIGHER RISK AREAS
IDENTIFIED DURING THIS REVIEW. THE ACTIVITIES IDENTIFIED IN THE CORROSION CONTROL
MATRICES MUST BE ADHERED TO.
ANY DETERIORATION IDENTIFIED THROUGH INSPECTION, MONITORING OR SAMPLING,
CHANGES IN PROCESS CONDITIONS/PLANT OPERATIONS OR UNSATISFACTORY CLOSURE OF
ACTIONS WILL BRING THE REVIEW DATE FORWARD.
THE NEXT SCHEDULED CHEMICAL SYSTEM REVIEW MEETING IS SCHEDULED FOR
APRIL 2006.

Actions to be closed out by 2Q 2004


1.

Prepare a register of injection and sampling points. (EH 1439)

2.

UT to be carried out opposite injection points and RAD of any deadlegs. (JM
1440)

3.

Complete chemical tank (including those not currently in use) and injection
piping inspection scheduling. (TS 1441)

4.

Increased compatibility checks required for some chemicals to include elastomers


and more types of pipe work. (CM 1442)

Present
Bill Murphy CNS Integrity Team Leader
Tony Starmer CNS Division Team Leader
David Duguid CNS Integrity Engineer
Claire McAlinden ELE Production Chemist for distribution
Chris Williams CNS Senior Corrosion Engineer
Elizabeth Hillier CNS Corrosion Engineer
Christopher East Lomond platform for distribution
John Douglas Everest platform for distribution

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