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1st Class Corrosion Solution for 3rd Largest Oilfield

30th November 2017

Located in Southern Iraq near the Kuwaiti border, the oilfield spreads over a 1,800km2 area. In 2009, a $15bn service contract was signed for its development.

Belzona 1391T application in action

The 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.

Fast Facts

Discovered:                                                        1953

Contains:                                                             17 billion barrels of oil

Daily production:                                              1.3 million bpd

Current situation:                                            Deals agreed to expand operations

Target production:                                          2.1 million bpd

*bpd = barrels per day

Expansion: Phase 1

In 2011, FEED work has 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.

IPC Package desalter vessel

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.

Process vessels: where they were protected and where they operate

Belzona’s largest single 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.

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 maintenance-free 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.

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.

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