AT THE FORE­FRONT OF IN­NO­VA­TION

Oil and Gas - - CONTENT -

Bel­zona’s cut­ting-edge R&D al­lows de­vel­op­ment of the lat­est in poly­mer sys­tems.

Bel­zona’s cut­ting-edge R&D al­lows de­vel­op­ment of the lat­est in poly­mer sys­tems. A brief case-study on how the com­pany has pro­vided the best in class cor­ro­sion so­lu­tion for the third-largest oil­field in the world

Lo­cated in South­ern Iraq near the Kuwaiti bor­der, Ru­maila oil­field spreads over 1,800 sq. km. In 2009, a $15bn ser­vice con­tract was signed for its de­vel­op­ment. A group of as­set own­ers have taken a lead­ing role in de­vel­op­ing the field with the most ad­vanced tech­nolo­gies of en­hanced oil re­cov­ery (EOR) by wa­ter in­jec­tion.

RU­MAILA OIL­FIELD: FAST FACTS

Dis­cov­ered: 1953

Con­tains: 17 bil­lion bar­rels of oil

Daily pro­duc­tion: 1.3 mil­lion bar­rels per day

Cur­rent sit­u­a­tion: Deals agreed to ex­pand op­er­a­tions

Tar­get pro­duc­tion: 2.1 mil­lion bar­rels per day

EX­PAN­SION: PHASE 1

In 2011, FEED work com­menced on the Pro­duced Wa­ter Re-In­jec­tion (PWRI) Project Phase 1. PWRI is an im­por­tant strat­egy for de­riv­ing value from waste wa­ter and is im­ple­mented due to in­creas­ing dis­charge treat­ment costs and the tight­en­ing of en­vi­ron­men­tal reg­u­la­tions.

PWRI in turn con­sists of two pack­ages:

Clus­ter Pump Sta­tions and an In­te­grated Pro­cess­ing Com­plex (IPC). The IPC pack­age in­cludes not only the cen­tral pro­cess­ing fa­cil­ity for oil, gas, con­den­sate and wa­ter sep­a­ra­tion, but also wa­ter treat­ment fa­cil­i­ties. Due to the field’s sub­stan­tial size, there will be two wa­ter treat­ment fa­cil­i­ties for re-in­jec­tion, one in the North and one in the South.

PROCESS VES­SELS

New process ves­sels were re­quired to de­liver the IPC pack­age in­clud­ing 10 de­salters, 10 de­hy­dra­tors and 20 de­gassers. Man­u­fac­tured in China, de­sign tem­per­a­ture for each of these ves­sels is 100°C / 212°F with a pres­sure of 15Bar.

Pro­duced from car­bon steel, ad­di­tional cor­ro­sion pro­tec­tion in­side these ves­sels was a must. Al­loy 625 cladding was first con­sid­ered for pro­tect­ing new­build ves­sels as a fa­mil­iar so­lu­tion. How­ever, the client wanted to re­duce cap­i­tal in­vest­ment cost with­out com­pro­mis­ing on qual­ity. They wanted a re­li­able ves­sel lin­ing so­lu­tion, which could be de­liv­ered in any part of the world.

EX­PE­RI­ENCE WITH BEL­ZONA LIN­INGS

Be­tween 1996 and 2014, over 830 new­build process ves­sels around the world have been pro­tected with a Bel­zona lin­ing. Bel­zona’s largest sin­gle

To sup­ple­ment anec­do­tal ev­i­dence from the field, a Euro­pean En­gi­neer­ing De­sign house once com­pared eco­nomic gain over the life­time of the slug catcher. A tra­di­tional 625 stain­less steel cladding was com­pared to a Bel­zona lin­ing. As­sum­ing that cladded steel would re­main main­te­nance­free over the life­time of the as­set, they fac­tored in touch-up re­pairs for the Bel­zona-lined steel ev­ery five years. Adding up CAPEX and OPEX, the Bel­zona op­tion turned out to be 3.5 times more cost-ef­fec­tive

project to date con­sisted of lin­ing 143 pres­sure ves­sels op­er­at­ing at the oil and gas field off the north east coast of Qatar in the Per­sian Gulf.

BEL­ZONA SO­LU­TION FOR PROCESS VES­SELS

For these 40 new­build ves­sels, Bel­zona lin­ing was ul­ti­mately found to be the most cost-ef­fec­tive cor­ro­sion pro­tec­tion so­lu­tion.

Based on the tem­per­a­tures, pres­sures, type of me­dia and pre­ferred ap­pli­ca­tion method (hand-ap­plied), Bel­zona 1391T was cho­sen along­side inserts man­u­fac­tured from Bel­zona 1111 (Su­per Metal) for small bore noz­zle pro­tec­tion. More than 800 noz­zle inserts were re­quired.

AP­PLI­CA­TION METHOD

Ves­sels were in­ter­nally lined with a twocoat Bel­zona 1391T sys­tem. Small bore noz­zles were pro­tected by bond­ing in pre­formed Bel­zona 1111 noz­zle inserts. All ves­sels were coated at the fab­ri­ca­tor yards in China be­fore ship­ment and in­stal­la­tion on site.

AP­PLI­CA­TION FACTS

• Us­ing Bel­zona in­ter­nal coat­ing in­stead of al­loy 625 helped the client save 65% of their in­vest­ment on this ma­jor project phase.

• In to­tal, 25 tonnes of Bel­zona 1391T were used.

• The ap­pli­ca­tion was com­pleted in ac­cor­dance with Bel­zona In­ter­na­tional stan­dards and fully in­spected by Bel­zona-cer­ti­fied in­spec­tors.

IPC Pack­age de­salter ves­sel

Process ves­sels: where they were pro­tected and where they op­er­ate

Bel­zona-pro­tected de­salter trav­el­ing to the field

Bel­zona 1391T ap­pli­ca­tion in ac­tion

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