Oil and Gas



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.


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


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.


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.


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.


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.


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.


• 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
IPC Package desalter vessel
 ??  ?? Process vessels: where they were protected and where they operate
Process vessels: where they were protected and where they operate
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 ??  ?? Belzona-protected desalter traveling to the field
Belzona-protected desalter traveling to the field
 ??  ?? Belzona 1391T applicatio­n in action
Belzona 1391T applicatio­n in action

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