This document is for Coventry University students for their own use in completing their assessed work for this module and should not be passed to third parties or posted on any website. Any infringements of this rule should be reported to facultyregistry.eec@coventry.ac.uk.
Faculty of Engineering Environment and Computing – EEC
7136EXQ (Engineering Materials and Corrosion Management in Energy Industry) CW1 - Corrosion Management
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Module Title: |
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Individual |
Cohort: |
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Module Code: |
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Engineering Materials and Corrosion Management in |
Assignment |
1920JANMAY |
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7136EXQ |
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Energy Industry |
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Coursework Title: CW1 (Corrosion Management) |
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Hand out date: |
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Tuesday, 25 February 2020 |
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Lecturer: Dr Draco Iyi |
Due date: |
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Assistant Professor (Senior Lecturer) in Oil & Gas |
Upload presentation slides to the appropriate |
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Engineering |
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Moodle submission portal on or before 8 April 2020 |
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by 6pm. |
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Presentation Event: 10 am, Room TBC |
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Estimated Time: |
Coursework type: Presentation |
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Credits for this coursework: |
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40 hrs. |
(Design of presentation slides and presenting it in |
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5 credits |
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a presentation event) |
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Mode of CW1 handout: briefing in class and Moodle page.
Submission: upload one pdf file only to the appropriate submission portal on Moodle on or before the due date. Coursework submitted after the deadline will automatically score 0%. For those granted extension, the submission date will be rescheduled.
Mark and Feedback date: within 2 weeks of the submission date.
Mark and Feedback method: Verbal feedback will be provided at the end of the oral presentation and a written summative feedback may be provided via CU-Moodle Feedback. If necessary, you may also arrange meeting with the module leader to discuss your feedback.
Module Learning Outcomes Assessed:
1. Critically evaluate relevant engineering materials suitable for applications in the energy, oil, and gas product design with a particular focus on structure, properties and processing routes.
5. Identify corrosion management strategies in oil and gas and develop corrosion management strategies base on technical feasibility and economy viability.
Coursework Introduction:
This coursework is designed to enable deep learning by capturing the key learnings from the module through practical application in the assessment of corrosion risks and the development of an appropriate corrosion management strategy for a typical FPSO (Floating Production Storage and Off-loading) vessel operating in the offshore Niger Delta, Nigeria. Further details of the asset and its operation are provided in the appendices of this document.
Coursework background:
Your company has recently acquired an existing FPSO vessel (FPSO Mystras) that has been operating in the Gulf of Guinea since January 14, 2004 and you are part of the team assigned to prepare for the handover. The FPSO Mystras was designed for a crude oil throughput of 80,000 bopd and she received crude oil from Okono and Okpoho oil fields that are located in Nigeria, offshore Port Harcourt in Block OML
119. The OML Block 119 block is located in the offshore Niger delta, 55 km from Bonny Terminal at a water depth of 70 meters. Your company is a newcomer to operation of production facilities and your team of corrosion engineer have already identified that the previous owner has not managed the integrity of the Mystras FPSO in an optimal way prior to the sale, and there have been several significant corrosion related hydrocarbon leaks in recent years. You have also been made aware that inspection has been primarily time based and that a large number of pressure vessels have not been internally inspected since the start of operation. Corrosion management has been the responsibility of a contractor who has not been helpful so far. The Mystras FPSO is shown in Figure 1.
Page 1 of 9
This document is for Coventry University students for their own use in completing their assessed work for this module and should not be passed to third parties or posted on any website. Any infringements of this rule should be reported to facultyregistry.eec@coventry.ac.uk.
Figure 1: FPSO Mystras at work off the shore of Nigeria (T. Terpstra, et al., May 2004)
Assessment Questions:
Part I: Immediate response (25% of the mark)
As a senior corrosion engineer, you are required to prepare a briefing for your senior management that captures your concerns about the existing integrity of the Mystras FPSO with respect to corrosion management. This should include the following:
a) What monitoring you consider needs to be implemented in the short term, and any actions deemed necessary to maintain a safe and operational plant.
b) Define what information (reports/data) you require to be handed over by the existing Operator/ Contractor.
This part of your submission should not be more than 3 slides. An executive summary is not required for Part 1.
Part II: Setting out the strategy (60% of the mark)
Create a new Corrosion Management Strategy (CMS) document for the production facilities of the Mystras FPSO. Your CMS should adopt a number of corrosion management perspectives to cover in an explicit and appropriate manner the following:
a) Integrity Review Process map and process of implementation
b) Assessed and prioritised corrosion threats to the operating facilities
c) A Corrosion KPI dashboard that aligns with your corrosion threat assessment
d) Failure Risk Assessment and Mitigation methods and outcomes
e) Outline of a typical Risk-Based Inspection (RBI) regime for the FPSO
f) Recommendations for a suitable Protective Coating/Thermal Insulation maintenance plan for the topsides production facilities.
g) Definition of the organogram needed to manage corrosion on the Mystras FPSO.
The CMS should include subsea facilities and pipelines, where these are identified in Appendix 3.
An executive summary is required for Part 2 and the number of slides should not be more than 7 slides.
Mark proportion:
Part I = 25%, Part II=60% and 15% for presentation design and oral presentation (Details mark allocation are given in the Assessment Criteria table)
Page 2 of 9
This document is for Coventry University students for their own use in completing their assessed work for this module and should not be passed to third parties or posted on any website. Any infringements of this rule should be reported to facultyregistry.eec@coventry.ac.uk.
NOTE:
Further details of the FPSO, the simplified process conditions and materials of construction are given in Appendix 1, 2 and 3 respectively, and should be used as the basis for the corrosion assessments.
You are required to prepare and present a technical presentation covering Part 1 and Part 2.
Your submission must be in a single document and clearly identify Part 1 and Part 2.
Remember that the presentation is for a senior management team.
Assessment Criteria:
The grading scheme and criteria
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CW1 Assessment criteria |
Weightings |
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Part I: Immediate response |
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1. |
What monitoring you consider needs to be implemented in the short term, and |
15 |
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any actions deemed necessary to maintain a safe and operational plant. |
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2. |
Define what information (reports/data) you require to be handed over by the |
10 |
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existing Operator/ Contractor. |
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Part II: Setting out the strategy |
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1. |
Integrity Review Process map and process of implementation |
10 |
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2. |
Assessed and prioritised corrosion threats to the operating facilities |
10 |
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3. |
A Corrosion KPI dashboard that aligns with your corrosion threat assessment |
10 |
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4. |
Failure Risk Assessment and Mitigation methods and outcomes |
10 |
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5. |
Outline of a typical Risk-Based Inspection (RBI) regime for the FPSO |
5 |
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6. |
Recommendations for a suitable Protective Coating/Thermal Insulation |
5 |
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maintenance plan for the topsides production facilities. |
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7. |
Definition of the organogram needed to manage corrosion on the Mystras FPSO. |
10 |
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Presentations |
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Oral presentation covering Tasks Part 1 and Part 2 (tasks 1 to 7). The presentation |
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design and oral communication will be assessed on: |
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a) |
Meeting the objectives with stated assumptions and their justifications |
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b) |
Critical evaluation of the results and drawing a conclusion |
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c) |
Communication skills, structure and technical knowledge |
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d) |
The overall presentation of the poster will be marked on clarity, structure and |
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continuity, grammars, sketches, diagrams, figures, tables and referencing via |
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CU Harvard system. |
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The presentation must be submitted as a single pdf file (with Part 1 and Part 2 |
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combined) to Turnitin on Moodle and students will present their work in a |
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presentation event. The presentation will not be more than 15 minutes (i.e., 10 |
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minutes for the main presentation and 5 minutes for questions and answers) |
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Total (= /100%) |
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Page 3 of 9
This document is for Coventry University students for their own use in completing their assessed work for this module and should not be passed to third parties or posted on any website. Any infringements of this rule should be reported to facultyregistry.eec@coventry.ac.uk.
Appendix 1:
i. Background Information of the FPSO Mystras
The design life of the FPSO Mystras is 15 years and the design complies with recognized international standards for the process facilities. The current production profile indicates that an additional 10 years of service may be feasible. The FPSO receive crude oil from Okono & Okpoho oil fields, offshore Port Harcourt in Block OML 119 (previously OPL 91). The OML Block 119 is operated in a water depth of 70 meters approximately 55 km from Bonny Terminal located in the offshore Niger delta, Nigeria (Figure 2).
The FPSO unit is designed to receive production risers from the Okono field sub-sea completed wells and import and export risers from the Okpoho field with the opportunity to tie-in additional subsea fields in the future. One of the fields is producing H2S (40 ppm) because of souring of the reservoir. The CO2 content of the produced fluids is relatively high at 2 to 3 mol%. The water-cut is 5-10% but this is likely to increase in the future. The chloride content of the produced water is 50,000ppm.
The produced oil (API 40) is exported through a permanently stationed FPSO, Mystras FPSO, with offloading via a shuttle tankers at regular intervals via the offloading riser, subsea line and CALM buoy system as shown in Figure 3.
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Figure 2: Location OPL 91 field Offshore Nigeria |
Figure 3: Okono and Okpoho Field Layout |
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(Okono and Okpoho Field) |
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ii. Overview of Facilities and Process:
Four cargo pumps are used for offloading oil (5,600m³/h). Inert gas supply and tank purging closed systems are used to prevent the release of tank gas on the main deck area. The topside process design consists of a conventional three-stage crude oil stabilisation train. Two first-stage separators, each designed for 55,000bpd throughput, receive wellhead fluids separately. The associated gas is dehydrated and compressed prior to export. Produced water is treated to an oil-in-water specification of 20ppm by means of hydrocyclones.
The separators are aligned parallel with the vessel’s longitudinal axis and located amidships, where pitch and heave are lowest. The stabilised crude is routed to the wet crude reception tank for final dehydration prior to storage. Water injection facilities are provided to inject deaerated and treated seawater for reservoir pressure maintenance. The turret and swivel anchor the facility to the seabed, acting as the entry point for the well fluids and the exit points for gas exports and water injection.
The FPSO is designed to accommodate 14 risers for production, water injection, gas export, and control umbilical. Individual production lines from each field, along with the water injection lines, are manifold in order to reduce the number of flow paths required through the swivel stack. The primary separation and processing facilities of the FPSO include two first stage separators, a second stage and third stage separator. There are water treatment and seawater deaeration facilities, two HP water injection pumps, and seven oil cargo tanks with a storage capacity of 120,000 barrels each. Gas is handled using three gas compressors (HP, Flash gas & Export) and the platform has a designed gas processing capacity of 11,000 m³/d.
Page 4 of 9
This document is for Coventry University students for their own use in completing their assessed work for this module and should not be passed to third parties or posted on any website. Any infringements of this rule should be reported to facultyregistry.eec@coventry.ac.uk.
Multiphase oil is produced from two different fields each with a single subsea production pipeline to the riser base below the FPSO. One of the pipeline is fabricated with a corrosion resistant alloy (CRA). The other pipeline is carbon steel, which requires injection of corrosion inhibitor at the manifold for corrosion mitigation. All subsea manifold pipework and tie-ins are fabricated with CRA pipe except for the well jumpers, which use flexible pipe. The risers from the riser base to the FPSO turret are also flexible pipe. The topsides facilities make extensive use of corrosion resistant alloys. Further details of the materials selection per equipment/line are given in Appendix 3.
Appendix 2: Overview of typical production facilities and process
For further details please consult Terpstra, et al., May 2004 (see reference list in Appendix 4)
Figure 2 Process arrangement of FPSO Mystras
Figure 3: The Production Process
Page 5 of 9
This document is for Coventry University students for their own use in completing their assessed work for this module and should not be passed to third parties or posted on any website. Any infringements of this rule should be reported to facultyregistry.eec@coventry.ac.uk.
Appendix 3: Simplified process conditions of the FPSO
Note: The process conditions described below have been simplified for the purpose of this exercise.
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System |
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Equipment |
Description |
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Fluid |
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Material |
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Operating |
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Design |
Design |
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Operating |
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temp |
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temp range |
pressure (barg) |
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pressure (bar) |
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Deg C |
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Deg C |
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Subsea |
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Flexible jumper |
6/8" Jumpers from wells to |
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Multiphase |
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Inner carcass: 316L SS |
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100 |
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130 |
270 |
100 |
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(production) |
manifold |
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oil |
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Pressure sheath: PVDF |
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Wires: |
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High strength CS |
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Subsea |
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Tie-in spools |
Manifold pipework and Tie-in |
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Multiphase |
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25Cr SDSS |
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100 |
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118 |
380 |
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Spool-pieces between manifold |
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oil |
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and Subsea pipeline |
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Subsea |
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Subsea pipeline |
Subsea pipelines |
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Multiphase |
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25Cr SDSS |
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90 |
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270 |
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oil |
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Subsea |
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Subsea pipeline |
Subsea pipeline |
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Multiphase |
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CS - X65 |
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120 |
270 |
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oil |
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Subsea |
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Riser Base |
Riser Base Structures |
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Multiphase |
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25Cr SDSS |
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90 |
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118 |
380 |
60 |
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Structure |
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oil |
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Subsea |
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Riser |
Flexible riser between riser |
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Multiphase |
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Inner carcass AISI316L |
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90 |
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380 |
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base and topsides flange |
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oil |
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Pressure sheath PVDF |
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connection |
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Wires: High strength CS |
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Multiphase |
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Topsides riser |
ESDV Riser |
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Multiphase |
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25Cr SDSS |
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Connections |
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oil |
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120 |
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Multiphase |
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Topsides |
Flexible to turret |
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Multiphase |
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22Cr DSS |
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90 |
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-28 to |
380 |
60 |
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flowline A |
swivel |
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oil |
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Multiphase |
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Topsides |
Flexible to turret |
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Multiphase |
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22Cr DSS |
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flowline B |
swivel |
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oil |
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Multiphase |
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Topsides |
Flexible to turret |
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Multiphase |
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25Cr SDSS |
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90 |
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380 |
60 |
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flowline C |
swivel |
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oil |
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Multiphase |
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Topsides |
Flexible to turret |
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Multiphase |
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25Cr SDSS |
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380 |
60 |
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flowline D |
swivel |
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oil |
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Multiphase |
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Turret swivel |
Cook swivel/seal mechanism |
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Multiphase |
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22Cr DSS with sealing |
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90 |
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380 |
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oil |
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surfaces weld overlaid with |
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Alloy 625 |
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Multiphase |
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Pipework |
Turret to 1st Stage |
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Multiphase |
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22Cr DSS |
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-20 to |
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50 |
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Sep. A |
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oil |
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120 |
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Multiphase |
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Pipework |
Turret to 1st Stage |
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Multiphase |
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22Cr DSS |
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100 |
50 |
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Sep. B |
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oil |
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100 |
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Multiphase |
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Vessel |
1st Stage Sep. A |
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Multiphase |
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22Cr DSS |
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82 |
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-10 to |
100 |
50 |
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oil |
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100 |
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Multiphase |
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Vessel |
1st Stage Sep. B |
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Multiphase |
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22Cr DSS |
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82 |
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-10 to |
100 |
50 |
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oil |
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100 |
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System |
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Equipment |
Description |
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Fluid |
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Material |
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Operating |
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Design temp |
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Design |
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Operating |
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temp Deg C |
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range Deg C |
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pressure |
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pressure |
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(barg) |
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(bar) |
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Gas |
Pipework |
1st stage Sep. A to HP |
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Process |
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22Cr DSS |
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80 |
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-20 |
to 120 |
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100 |
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40 |
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gas Cooler |
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Gas |
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Gas |
Pipework |
1st stage Sep. B to |
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Process |
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22Cr DSS |
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80 |
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to 120 |
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100 |
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40 |
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HP |
gas Cooler |
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Gas |
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Gas |
Cooler |
HP |
gas Cooler |
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Process |
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316L SS tubes/clad |
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80 |
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to 200 |
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58 |
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40 |
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Gas |
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Gas |
Pipework |
HP gas Cooler to HP gas |
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Process |
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22Cr DSS |
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50 |
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-20 |
to 120 |
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58 |
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40 |
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suction Scrubber |
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Gas |
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Gas |
Vessel |
HP gas suction |
|
Process |
|
CS (Glassflake lined) |
|
50 |
|
|
|
-30 |
to 100 |
|
58 |
|
40 |
|||||
|
|
|
|
Scrubber |
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
|
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|
|
|
|
|
|
|
|
|||||
|
Gas |
Pipework |
HP gas suction scrubber |
|
Process |
|
22Cr DSS |
|
50 |
|
|
|
-20 |
to 120 |
|
58 |
|
40 |
|||||
|
|
|
|
to HP gas compressor |
|
Gas |
|
|
|
|
|
|
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|
|
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|
|
|
|
|||
|
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|
|
|
|||||
|
Gas |
Compressor |
HP |
gas compressor |
|
Process |
|
Various - materials |
|
159 |
|
|
n/a |
|
|
17 |
|
40 |
|||||
|
|
|
|
|
|
|
|
Gas |
|
tested up to 50ppm |
|
|
|
|
|
|
|
|
|
|
|
||
|
|
|
|
|
|
|
|
|
|
|
H2S |
|
|
|
|
|
|
|
|
|
|
|
|
|
Gas |
Pipework |
HP gas compressor to |
|
Process |
|
CS |
|
159 |
|
|
-20 |
to 200 |
|
100 |
|
80 |
||||||
|
|
|
|
HP gas cooler |
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
|
Gas |
Pipework |
2nd |
stage Sep. to |
|
Process |
|
22Cr DSS |
|
60 |
|
|
|
-20 |
to 120 |
|
20 |
|
10 |
||||
|
|
|
|
flash |
gas cooler |
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
Gas |
Cooler |
Flash |
gas Cooler |
|
Process |
|
316L SS tubes/clad |
|
48 |
|
|
|
-10 |
to 180 |
|
20 |
|
10 |
||||
|
|
|
|
|
|
|
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gas |
Pipework |
Flash gas cooler to flash |
|
Process |
|
22Cr DSS |
|
48 |
|
|
|
-20 |
to 120 |
|
20 |
|
10 |
|||||
|
|
|
|
gas suction scrubber |
|
Gas |
|
|
|
|
|
|
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|
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|
|
|||
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|
|
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|
|
|
|
||||
|
Gas |
Vessel |
Flash |
gas suction |
|
Process |
|
CS (Glassflake lined) |
|
48 |
|
|
|
-30 |
to 70 |
|
20 |
|
10 |
||||
|
|
|
|
scrubber |
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
|
Gas |
Pipework |
Flash |
gas suction |
|
Process |
|
22Cr DSS |
|
47 |
|
|
|
-20 |
to 120 |
|
20 |
|
1.5 |
||||
|
|
|
|
scrubber to Flash gas |
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
|
|
|
|
Compressor |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
Gas |
Compressor |
Flash gas Compressor |
|
Process |
|
Various - materials |
|
138 |
|
|
n/a |
|
|
5 |
|
1.5 |
||||||
|
|
|
|
|
|
|
|
Gas |
|
tested up to 50ppm |
|
|
|
|
|
|
|
|
|
|
|
||
|
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|
|
H2S |
|
|
|
|
|
|
|
|
|
|
|
|
|
Gas |
Pipework |
Flash |
gas comp to |
|
Process |
|
CS |
|
138 |
|
|
-20 |
to 200 |
|
58 |
|
40 |
|||||
|
|
|
|
flash |
gas cooler |
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
Gas |
Pipework |
Flash |
gas cooler to |
|
Process |
|
22Cr DSS |
|
49 |
|
|
|
-20 |
to 120 |
|
58 |
|
40 |
||||
|
|
|
|
HP |
gas Scrubber |
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
Gas |
Pipework |
HP Gas Coolers to |
|
Process |
|
22Cr DSS |
|
39 |
|
|
|
-20 |
to 120 |
|
58 |
|
40 |
|||||
|
|
|
|
HP |
gas Scrubber |
|
Gas |
|
|
|
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||
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Page 6 of 9
This document is for Coventry University students for their own use in completing their assessed work for this module and should not be passed to third parties or posted on any website. Any infringements of this rule should be reported to facultyregistry.eec@coventry.ac.uk.
|
Gas |
Vessel |
|
HP gas Scrubber |
|
Process |
|
|
CS (Glassflake lined) |
|
39 |
|
|
|
-40 |
to 50 |
58 |
|
40 |
|
||||||||||||
|
|
|
|
|
|
|
|
|
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gas |
Pipework |
|
HP KO Scrubber to |
|
Process |
|
|
22Cr DSS |
|
38 |
|
|
|
-20 |
to 120 |
58 |
|
40 |
|
||||||||||||
|
|
|
|
|
TEG Contacter |
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||||
|
Gas |
Vessel |
|
TEG Contacter |
|
Process |
|
|
CS (Glassflake lined) |
|
38 |
|
|
|
-10 |
to 50 |
58 |
|
40 |
|
||||||||||||
|
|
|
|
|
|
|
|
|
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gas |
Pipework |
|
TEG contacter to |
|
Process |
|
|
CS |
|
|
38 |
|
|
|
-20 |
to 120 |
58 |
|
40 |
|
|||||||||||
|
|
|
|
|
Export gas suction |
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||||
|
|
|
|
|
scruber |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
Gas |
Vessel |
|
Export gas suction |
|
Process |
|
|
CS (Glassflake lined) |
|
38 |
|
|
|
-40 |
to 50 |
58 |
|
40 |
|
||||||||||||
|
|
|
|
|
scrubber |
|
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
|
Gas |
Pipework |
|
Export gas scrubber to |
|
Process |
|
|
CS |
|
|
37 |
|
|
|
-20 |
to 120 |
58 |
|
39 |
|
|||||||||||
|
|
|
|
|
Export gas |
|
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
|
|
|
|
|
compressor |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
Gas |
Compressor |
|
Export gas Compressor |
|
Process |
|
|
Various - materials |
|
37 |
|
|
|
n/a |
|
|
58 |
|
39 |
|
|||||||||||
|
|
|
|
|
|
|
|
|
|
Gas |
|
|
|
tested |
up to 50ppm |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
H2S |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gas |
Pipework |
|
Export gas compressor |
|
Process |
|
|
CS sour rated |
|
176 |
|
|
-20 |
to 200 |
192 |
|
175 |
|
|||||||||||||
|
|
|
|
|
to Export gas Cooler |
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
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|
||||
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|
|
|
|
|
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|
|
|
|
|
|
|
|
|
|
||||
|
Gas |
Cooler |
|
Export gas cooler |
|
Process |
|
|
CS |
|
|
176 |
|
|
-10 |
to 200 |
192 |
|
147 |
|
||||||||||||
|
|
|
|
|
|
|
|
|
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Gas |
Pipework |
|
Export gas |
cooler to |
|
Process |
|
|
CS sour rated |
|
60 |
|
|
|
-20 |
to 120 |
192 |
|
175 |
|
|||||||||||
|
|
|
|
|
Export pipeline |
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||||
|
Gas |
Pipework |
|
3rd stage Sep. to |
|
Process |
|
|
22Cr DSS |
|
47 |
|
|
|
-20 |
to 120 |
10 |
|
5 |
|
||||||||||||
|
|
|
|
|
flash |
gas suction |
|
Gas |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
|
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|
|
scrubber |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
Gas |
Pipeline |
|
Export pipeline |
|
Export |
|
|
CS - X60 |
|
40 |
|
|
|
-50 |
to 120 |
192 |
|
172 |
|
||||||||||||
|
Export |
|
|
|
|
|
|
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|
Gas |
|
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|||||||
|
System |
|
Equipmen |
|
|
Description |
|
|
Fluid |
|
|
|
Material |
|
|
Operating |
|
|
Design temp |
|
Design |
|
|
Operating |
|
|||||||
|
|
|
t |
|
|
|
|
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|
|
temp Deg C |
|
|
range Deg C |
|
pressure |
|
|
pressure |
|
|||
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|||||||
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|
(barg) |
|
|
(bar) |
|
|
Oil |
|
Pipework |
|
|
1st stage Sep. B to 2nd |
|
|
Process |
Liquid |
CS |
|
80 |
|
|
-20 |
to 120 |
58 |
|
13 |
|
|||||||||||
|
|
|
|
|
|
stage Sep. |
|
|
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|
|||
|
Oil |
|
Pipework |
|
|
1st stage Sep. A to 2nd |
|
|
Process |
Liquid |
CS |
|
80 |
|
|
-20 |
to 120 |
58 |
|
13 |
|
|||||||||||
|
|
|
|
|
|
stage sep |
|
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|
|
Oil |
|
Vessel |
|
|
2nd |
stage Sep. |
|
|
Process |
Liquid |
22Cr DSS |
|
50 |
|
|
-10 |
to 100 |
17 |
|
10 |
|
||||||||||
|
|
|
|
|
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|
|
Oil |
|
Pipework |
|
|
2nd |
stage Sep. to |
|
|
Process |
Liquid |
CS |
|
35 |
|
|
|
-20 to 120 |
17 |
|
10 |
|
||||||||||
|
|
|
|
|
|
crude heater |
|
|
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|
|
|
|
|
|
|
|
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|
|||
|
Oil |
|
Vessel |
|
|
Crude Heater |
|
|
Process |
Liquid |
CS |
|
23 |
|
|
|
-10 to 190 |
11 |
|
1.9 |
|
|||||||||||
|
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|
|
Oil |
|
Pipework |
|
|
Crude heater to 3rd stage |
|
Process |
Liquid |
CS |
|
47 |
|
|
|
-20 to 120 |
17 |
|
1.4 |
|
||||||||||||
|
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Sep. |
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||||||||||
|
Oil |
|
Vessel |
|
|
3rd |
Stage Sep. |
|
|
Process |
Liquid |
CS (Glassflake |
|
47 |
|
|
|
-10 to 100 |
5 |
|
1.4 |
|
||||||||||
|
|
|
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|
lined) |
|
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|
|
|
|
|
|
|
Oil |
|
Pipework |
|
|
3rd |
Stage Sep to Crude |
|
|
Process |
Liquid |
CS |
|
47 |
|
|
|
-20 to 120 |
5 |
|
1.4 |
|
||||||||||
|
|
|
|
|
|
Cooler |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Oil |
|
Cooler |
|
|
Crude Cooler |
|
|
Process |
Liquid |
316L SS |
|
47 |
|
|
|
-10 to 100 |
5 |
|
1.4 |
|
|||||||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
tubes/clad |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Oil |
|
Pipework |
|
|
Crude Cooler to Wet |
|
|
Process |
Liquid |
CS |
|
35 |
|
|
|
-20 to 120 |
5 |
|
1 |
|
|||||||||||
|
|
|
|
|
|
crude tanks |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
|
Water |
|
Pipework |
|
|
1st stage |
Seps to |
|
|
Produced |
Water |
22Cr DSS |
|
- |
|
|
|
-20 to 120 |
58 |
|
13 |
|
||||||||||
|
|
|
|
|
|
Hydrocyclones |
|
|
|
|
|
|
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|
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|
|
|
|
|
|
|
|
|
|
|
|
|||
|
Water |
|
Vessel |
|
|
Hydrocyclones |
|
|
Produced |
Water |
22Cr DSS |
|
- |
|
|
|
-10 to 100 |
58 |
|
13 |
|
|||||||||||
|
|
|
|
|
|
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Water |
|
Pipework |
|
|
Hydrocyclones to |
|
|
Produced |
Water |
22Cr DSS |
|
- |
|
|
|
-20 to 120 |
58 |
|
3 |
|
|||||||||||
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|
Produced water flash |
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|||
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drum |
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Water |
|
Vessel |
|
|
Produced |
water flash |
|
|
Produced |
Water |
CS (Glassflake |
|
- |
|
|
|
-10 to 100 |
5 |
|
3 |
|
||||||||||
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drum |
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lined) |
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||
|
Water |
|
Pipework |
|
|
PW flash drum to |
|
|
Produced |
Water |
22Cr DSS |
|
- |
|
|
|
-20 to 120 |
5 |
|
3 |
|
|||||||||||
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Produced |
water plate |
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coolers |
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Water |
|
Cooler |
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PW |
plate coolers |
|
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Produced |
Water |
CS |
|
- |
|
|
|
-10 to 100 |
5 |
|
3 |
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||||||||||
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Water |
|
Pipework |
|
|
PW |
plate |
cooler to |
|
|
Produced |
Water |
CS |
|
- |
|
|
|
-20 to 120 |
5 |
|
4.8 |
|
|||||||||
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overboard |
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|||
|
Seawater |
|
Pipework |
|
|
Seawater pumps to |
|
|
Seawater |
|
|
25Cr SDSS |
|
15 |
|
|
|
-10 to 50 |
5 |
|
3 |
|
||||||||||
|
|
|
|
|
|
Seawater filters |
|
|
injection |
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|||
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||||
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|
||||||||||
|
Seawater |
|
Vessel |
|
|
Seawater filters |
|
|
Seawater |
|
|
CS internally |
|
15 |
|
|
|
-10 to 50 |
5 |
|
3 |
|
||||||||||
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injection |
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coated |
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|
||||||||||
|
Seawater |
|
Pipework |
|
|
Seawater filters to |
|
|
Seawater |
|
|
Cu-Ni |
|
15 |
|
|
|
-10 to 50 |
5 |
|
3 |
|
||||||||||
|
|
|
|
|
|
Deaerator tower |
|
|
injection |
|
|
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|||
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|
||||
|
Seawater |
|
Vessel |
|
|
Deaerator tower |
|
|
Seawater |
|
|
CS (Glassflake |
|
15 |
|
|
|
-10 to 40 |
|
Vacuum |
0.8 |
|
||||||||||
|
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|
|
injection |
|
|
|
lined) |
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|
|
|
|||||||||||
|
Seawater |
|
Pipework |
|
|
Deaerator tower to water |
|
Seawater |
|
|
CS |
|
15 |
|
|
|
-10 to 50 |
5 |
|
1.3 |
|
|||||||||||
|
|
|
|
|
|
injection pumps/ |
|
|
injection |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
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|
|||
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|
|
flowlines |
|
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|
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|
|
|
|
|
|
|
|
|
|
|
|
|
|
Seawater |
|
Pipework |
|
|
From seawater filters to |
|
|
Service Water |
316L SS |
|
15 |
|
|
|
-10 to 50 |
5 |
|
3 |
|
||||||||||||
|
|
|
|
|
|
Sprinkler system |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|||
|
Seawater |
|
Pipework |
|
|
Sprinklers |
|
|
Service Water |
Aluminium |
|
15 |
|
|
|
-10 to 50 |
5 |
|
3 |
|
||||||||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Bronze |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HP Flare |
|
Pipework |
|
|
Sep. B to |
HP flare |
|
|
Flare Gas |
|
|
Low temp C |
|
- |
|
|
|
-50 to 120 |
9 |
|
2.4 |
|
|||||||||
|
|
|
|
|
|
system |
|
|
|
|
|
|
|
|
steel |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
||
|
HP Flare |
|
Pipework |
|
|
HP |
flare |
system to HP |
|
|
Flare Gas |
|
|
Low temp C |
|
- |
|
|
|
-50 to 120 |
9 |
|
2.4 |
|
||||||||
|
|
|
|
|
|
flare drum |
|
|
|
|
|
|
steel |
|
|
|
|
|
|
|
|
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|
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|
||||
Page 7 of 9
This document is for Coventry University students for their own use in completing their assessed work for this module and should not be passed to third parties or posted on any website. Any infringements of this rule should be reported to facultyregistry.eec@coventry.ac.uk.
|
|
HP Flare |
|
Vessel |
HP Flare drum |
|
Flare Gas |
C steel with |
- |
-50 to 160 |
9 |
2.4 |
|
|
|
|
316L |
||||||||
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
SS boot |
|
|
|
|
|
|
HP Flare |
|
Pipework |
HP flare drum to |
HP |
Flare Gas |
Low temp C |
- |
-50 to 120 |
9 |
2.4 |
|
|
|
flare |
|
||||||||
|
|
|
|
|
|
|
steel |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HP Flare |
|
Pipework |
Sep. A to HP Flare |
Flare Gas |
Low temp C |
- |
-50 to 120 |
9 |
2.4 |
|
|
|
|
system |
|
||||||||
|
|
|
|
|
|
|
steel |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HP Flare |
|
Pipework |
HP Flare system |
|
Flare Gas |
Low temp C |
- |
-50 to 120 |
9 |
2.4 |
|
|
|
(header) |
|
||||||||
|
|
|
|
|
|
|
steel |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
|
HP Flare |
|
Vessel |
Flare tip |
|
Flare Gas |
Alloy 800 |
- |
- |
1 |
1 |
|
|
|
|
|
|
|
|
|
|
|
|
|
|
Materials Identifier |
Explanation and comments |
|
CS |
Carbon-manganese Steel (C-Mn) |
|
|
|
|
CS - X60 |
C-Mn pipeline steel with yield strength min 60,000 psi |
|
|
|
|
CS - X65 |
C-Mn pipeline steel with yield strength min 65,000 psi |
|
|
|
|
Low temp CS |
C-Mn steel typically suitable to -50C |
|
|
|
|
CS sour rated |
C-Mn steel fully compliant with ISO 15156/NACE MR-01-75 |
|
|
|
|
High strength CS |
High strength steel typically with yield strength > 120,000 psi |
|
|
|
|
316L SS |
Austenitic Stainless Steel with 18% chromium |
|
|
|
|
22Cr DSS |
Duplex Stainless Steel with 22% chromium |
|
|
|
|
25Cr SDSS |
Super-Duplex Stainless Steel with 25% chromium fully seawater resistant at ambient temperature. |
|
|
|
|
Cu-Ni |
Cupronickel (90% copper - 10% nickel) |
|
|
|
|
Alloy 625 |
High nickel alloy with circa 60% nickel and fully seawater resistant |
|
|
|
|
Alloy 800 |
Nickel-iron-chromium alloy with typically 30% nickel and good high temp oxidation resistance |
|
|
|
|
Aluminum Bronze |
Copper alloy with typically 5% aluminum |
|
|
|
|
PVDF |
Thermoplastic Polyvinylidene fluoride which is not permeation resistant |
|
|
|
|
Glass flake lined |
Epoxy coating pigmented with lamellar glass flake to increase abrasion resistance |
|
|
|
|
Internal coating |
Standard epoxy coating |
|
|
|
|
316L SS tubes/clad |
Heat exchanger with 316L SS tubes with tube sheet and channels clad with 316L SS |
|
|
|
Appendix 4: Bibliography
Institute Energy, 2008. Guidance for Corrosion Management in Oil and Gas Production and Processing: Corrosion and anti-corrosives. s.l.:Energy Institute.
T. Terpstra, I. G. E. B., G. Schouten, S. B. M. I. & L. Ursini, May 2004. Design and Conversion of FPSO Mystras. Houston, Texas, U.S.A.,, Offshore Technology Conference, pp. 3-6.
Energy Institute: Guidance for corrosion management in oil and gas production and processing, 2008.
Rigzone: How do FPSO’s work? https://www.rigzone.com/training/insight.asp?insight_id=299
Bluewater: What is an FPSO? http://www.bluewater.com/fleet-operations/what-is-an-fpso/
Map data for Oil and Gas Infrastructure - Links:
Ø https://www.google.com/maps/d/viewer?mid=1ASj7EoDpSqVuZESDe2zJIPIoL-M&ll=4.932441143929763%2C6.9418392423020805&z=7
Ø https://www.google.com/maps/d/viewer?mid=1ASj7EoDpSqVuZESDe2zJIPIoL-M&ll=3.5633716275172214%2C3.9506044325111134&z=6
Additional materials available in Moodle.
Page 8 of 9
This document is for Coventry University students for their own use in completing their assessed work for this module and should not be passed to third parties or posted on any website. Any infringements of this rule should be reported to facultyregistry.eec@coventry.ac.uk.
Appendix 5: Coursework support
Coursework support/clarification is through CU Moodle Forum
Notes:
1. You are expected to use the CUHarvard referencing format. For support and advice on how this students can contact Centre for Academic Writing (CAW).
2. Please notify your registry course support team and module leader for disability support.
3. Any student requiring an extension or deferral should follow the university process as outlined here.
4. The University cannot take responsibility for any coursework lost or corrupted on disks, laptops or personal computer. Students should therefore regularly back-up any work and are advised to save it on the University system.
5. If there are technical or performance issues that prevent students submitting coursework through the online coursework submission system on the day of a coursework deadline, an appropriate extension to the coursework submission deadline will be agreed. This extension will normally be 24 hours or the next working day if the deadline falls on a Friday or over the weekend period. This will be communicated via email and as a CUMoodle announcement.
Page 9 of 9
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