Abu Dhabi Company for Onshore Oil Operations

Internal Linings of High Pressure Vessels

Introduction

History
1st & 2nd Catastrophic Failures

New Selection Criteria

New Lining Systems

Inspection of the New Lining Systems

Conclusion & Recommendations
11/12/2003 12:03 PM

INTRODUCTION OPERATING CONDITIONS

Operating Pressure Operating Temperature

: 100 Bar : 105 C

Date in Operation
Material of Const. Design Code

: April 2000
: CS-HICN 516-60 N : ASME VIII

Shell Thickness
Inner Diameter Tang./Tang.

: 114 mm
: 2000 mm : 6500 mm

Fluid

: Wet Sour gas

H2S : 3.5 mole % : 1500 ppm

Chloride

CO2

: 4.5 mole %
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INTRODUCTION OPERATING CONDITIONS

Typical 4 Nos. Test Separators

HISTORY

Factory Applied Internal Lining by Ceramic Filled epoxy in Nov. 1998. Test Separators Commissioning in Nov. 2000. Catastrophic Failure in April 2001

Inspection Initial Failure Route Causes

Field Re-lining Using the Same Lining Same Pattern Catastrophic Failure After 45 Days

Inspection Failure Route Causes

1st & 2nd CATASTROPHIC FAILURES

1St Failure Inspection Findings:

Peel off and flaking on 80% of the entire surface

Total removal on 30% of the entire surface Superficial rust under flaked off areas

2nd Failure Inspection Findings:

Peel off and flaking on lesser extent of the entire surface

Total removal on 30% of the entire surface

Superficial rust under flaked off areas

1st & 2nd CATASTROPHIC FAILURES

Shell Internal Surface.

1st & 2nd CATASTROPHIC FAILURES

Shell Internal Surface.

Manway Nozzles Internal.

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1st & 2nd CATASTROPHIC FAILURES Failure Mechanism:

i.

High polymer X-linking materials above critical value

Broad thermal cycling effect Explosive Decompression due to dense polymer X-linking

ii. iii.

iv.

Aggressive environment

NEW SELECTION CRITERIA

No track records found for similar services.

Documented compliance with the requested material performance technical data sheet.
Unconditional full recovery of the contract value if the applied system exhibits any of the following defects after 12 months of services.
i. ii. iii.

Lining De-lamination. Blister free for single layer system. 10% surface blisters for multi-layer system.
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NEW SELECTION CRITERIA

iv.

>5% coating cracks on top layer of multi layer lining system and cracks free single layer lining system.

iv.

A reduction in average lining thickness in excess of 30%.

iv.

20% reduction in the adhesion forces between any two adjacent layers or to the substrate, compared to that measured prior to boxing up.

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NEW LINING SYSTEMS

11 proposed lining systems.

8 Lining Manufacturers declined.

3 Manufacturers accepted the set criteria.

Epoxy Novolac resin (VOC 27%) applied on GRS-1 Test Separator.

Vinyl Ester Glass Flake applied on GRS-2 Test Separator. Solvent free two components hybridized epoxy applied on GRS-3 & 4 Test Separators.
11/12/2003 12:03 PM

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INSPECTION OF NEW LINING SYSTEMS

INTERIM INSPECTION:
i.

Conducted interim inspection within 3 months exposure.

GRS-1 Test Separator lining system was found in sound conditions and fully meet the acceptance criteria. Minor surface cracks within the acceptance criteria were found on the GRS-2 Test Separator. Catastrophic total failure was found on GRS-3 & 4 Test Separators.

ii.

iii.

iv.

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INSPECTION OF NEW LINING SYSTEMS

INTERIM INSPECTION:
v.

Decision made to continue the service on the GRS-1 & 2 Test in services for additional period of six months and re-inspect. Postpone the decision on GRS-3&4 Test Separators to get more concert data from GRS-1 & 2 within 6 months. The two Separators were out of services.

vi.

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INSPECTION OF NEW LINING SYSTEMS

Final Inspection:
i.

GRS-1 Test Separator lining system was found in sound conditions and fully meet the acceptance criteria. Propagation of the surface cracks within the acceptance criteria were found on the GRS-2 Test Separator.

ii.

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GRS-2 Separator Interim Inspection Findings

Small defects on the manway

Small Surface crack

Coating in good condition at shell 9 Oclock

Coating in good condition at 2nd side man way

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GRS-3 & 4 Separators Interim Inspection Findings

Peeled off coating at Demister

Peeled of coating at buffle plate

Irregular coating at the top (looks like sagging)

Deposits and foreign broken metals parts

11/12/2003 12:03 PM

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GRS-3 & 4 Separators Interim Inspection Findings

Peel off at the dish end manway

Cracks and peel off at the demister

Blisters at 3 Oclock and 9 Oclock

Peel of at the demister

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GRS-3&4 CATASTROPHIC FAILURES Failure Mechanism:

i.

High polymer X-linking materials above critical value

Broad thermal cycle effect Explosive Decompression due to high polymer X-linking

ii. iii.

iv.

Aggressive environment

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CONCLUSION & RECOMMENDATIONS

Both Epoxy Novolac resin and Glass Vinyl Ester lining systems are acceptable for high pressure & temperature wet sour gas services. Carry out the minor repairs on GRS-2 Test Separator and return to services. Box up GRS-1 Test separator and return to services. Apply Epoxy Novolac resin lining system on GRS-3 & 4 test separators. Conduct Off-stream inspection every two years.
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Abu Dhabi Company for Onshore Oil Operations