QP-STD-L-009 R1 TechSpecfor Corrosion Monitoring System

7/23/2019 QP-STD-L-009 R1 TechSpecfor Corrosion Monitoring System

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STANDARDS PUBLICATION

QP TECHNICAL STANDARD FOR

CORROSION MONITORING SYSTEMS FOROIL AND GAS PRODUCTION FACILITIES

DOC. NO.: QP- STD- L- 009

REVISION 1

FACILITIES QUALITY ASSURANCE DEPARTMENT



Doc. File No.: STD.L009.R1 Page 1 of 35 Custodian Dept.: FQAD

STANDARDS PUBLICATION

QP TECHNICAL STANDARD FORCORROSION MONITORING SYSTEMS

FOR OIL AND GAS PRODUCTION FACILITIES

DOC. NO.: QP- STD- L- 009



QP TECHNICAL STANDARD FOR CORROSION MONITORING SYSTEMSFOR OIL AND GAS PRODUCTION FACILITIES

Doc. No.: QP-STD- L-009 Rev. 1


TABLE OF CONTENT

Page No.

FOREWORD……………………………………………………………………….. 4

1.0 OBJECTIVE………………………………………………………………………… 5

2.0 SCOPE……………………………………………………………………………… 5

3.0 APPLICATION……………………………………………………………………… 5

4.0 GENERAL……………………...…………………………………………………… 5

5.0 TERMINOLOGY……………………………………………………………………. 6

5.1 Definitions…………………………………………………………………………… 6

5.2 Abbreviations……………………………………………………………………….. 8

6.0 REFERENCE STANDARDS AND CODES…………………………………….. 8

7.0 HEALTH, SAFETY AND ENVIRONMENT……………………………………... 10

8.0 MONITORING STRATEGY PLAN……………………………………………….. 10

8.1 General………………………………………………………………………………. 10

8.2 Existing Plant/Facility…..…………………………………………………………. 10

8.3 New Plant/Facility (Under Design)……………………………..………………. 11

8.4 Monitoring for Inhibitor Trials…..……………………….……………………… 11

8.5 Monitoring Equipment Selection………………………………………………. 11

9.0 MONITORING TECHNIQUES…………….….………………………………….. 12

9.1 General………………………………………….………………………………….. 12

9.2 Corrosion Coupons (CC)……....…………….…………………………………. 13

9.3 Electrical Resistance Probe (ER)..…………………………………..………… 13

9.4 Other Monitoring Techniques……………………………………..…………… 14

9.5 Side Stream Monitoring…………………………………………………………. 15

9.6 Corrosion Product Analysis………………………………………….………… 16

10.0 DESIGN AND INSTALLATION REQUIREMENTS……………………………. 17

10.1 Monitoring Locations……………………………………………………………. 17

10.2 Access Fitting Design and Installation…………………………………….… 18

10.3 Distribution of Access Fittings………………………………………………… 19

10.4 Installation and Retrieval of Monitoring Devices………………………….. 20






11.0 AUTOMATED MONITORING SYSTEM……………………………………….. 21

11.1 General…………………………………………………………………………….. 21

11.2 Manual Monitoring Methods…………………………………………………… 22

11.3 Automated Monitoring Methods……………….……………………………… 22

11.4 Data Analysis and Reporting………………………………………………….. 22

12.0 PAINTING, MARKING AND SHIPMENT……………………………………….. 23

13.0 INSPECTION AND TESTING……………………………………………………. 23

13.1 General Requirements……………………………………………………………. 23

13.2 Inspection and Testing Plan Requirements……………………………………. 23

13.3 Test Certificates…………………………………………………………………… 24

14.0 SPARE PARTS AND MAINTENANCE DATA.……………………………….. 24

15.0 QUALITY ASSURANCE/QUALITY CONTROL..……………………………… 25

16.0 DOCUMENTATION……………………………………………………………….. 26

17.0 APPENDICES…………………..…………………………………………………. 27

17.1 Appendix A: Corrosion Monitoring Equipment Supply Datasheet………. 27

17.2 Appendix B: Side Stream Monitoring Supply Datasheet……..…………….. 30

17.3 Appendix C: Access Fitting Installation and CommissioningProcedures…………………………………………………………..

31

17.4 Appendix D: Figures 1 and 2…………………………..………………………… 34

REVISION HISTORY LOG…………………………………………………..……………. 35






FOREWORD

This document has been developed by Facilities Quality Assurance Department, reviewed by UserDepartments and endorsed by QP Management for use as QP Technical Standard for CorrosionMonitoring Systems for Oil and Gas Production Facilities

This document is based on QP Topsides Improvement Philosophy for Corrosion Mitigation andMonitoring (IE14R002.206/Ins), related QP project specifications, latest market research andinternational/national standards/codes on corrosion monitoring. This document will specify the QPrequirements and serve as a technical guide for generating project specifications on corrosion inhibitorpackages for oil and gas production.

This document, in its present numbering, layout and format was prepared in accordance with thecorporate endorsed Standardisation Procedure for Identification of QP Technical Standards (QP-PRC-A-001) and the Guideline for Drafting QP Technical Standards (QP-GDL-A-003). It reflects, asfar as possible, the current QP requirements taking into account the known available industrypractices, QP experience and the applicable latest national and international codes and standards.

This document is published for QP Departments/ Contractors/ Consultants utilisation. It should beemphasised that the document is intended to be used for QP operations wherever applicable andappropriate.

This document is subjected to periodical review to re-affirm its adequacy and to conform to any

changes in QP requirements or to include new developments on the subject.

It is recognised that there will be cases where addenda, data sheets, or other clarifications need to be

attached to the standard to suit a specific application or service environment. As such, the content of

the document shall not be changed or re-edited by any user (QP or its Contractors, suppliers, agents,etc.), but any addenda or clarifications entailing major changes shall be brought to the attention of the

Custodian Department.

The Custodian of this document is Quality Assurance Department. Therefore, all technicalcomments, views, recommendations, etc on this document should be forwarded to:

MANAGER FACILITIES QUALITY ASSURANCE DEPARTMENTQA DEPARTMENT, BUILDING NO. 5, RAS ABU ABOUDDOHA

FAX NO. 4402207






1.0 OBJECTIVE

The objective of this Standard is to define QP requirements for the corrosion monitoringsystem for oil and gas production facilities. Also, to provide technical guidance fordeveloping project specifications and to ensure compliance in monitoring device selectionand performance with contract requirements.

2.0 SCOPE

2.1 This document specifies the QP minimum requirements for corrosion monitoring systemfor oil and gas production facilities. This will include corrosion monitoring techniques andequipment, access fitting design/installation, and data gathering, storage and retrievalunits. It also specifies the minimum requirements for coupon/probe retrieval andevaluation.

2.2 This document is intended to cover inspection/testing, quality control and supply of thespecified corrosion monitoring system package

2.3 Corrosion inhibitor and inhibitor package requirements for oil and gas production facilitiesare covered in QP-STD-L-008.

3.0 APPLICATION

3.1 This document shall be used for the monitoring of internal corrosion in QP oil and gasproduction facilities (i.e., topside piping, flow-lines and pipelines handling corrosivehydrocarbon products, seawater and formation water) installed in the State of Qatar.

3.2 This document shall be used in conjunction with the QP approved project specifications,associated data sheets and project drawings.

3.3 All materials and equipment used in corrosion monitoring shall satisfy the requirements ofthis Standard and the referenced standards/codes mentioned herein.

4.0 GENERAL

4.1 All corrosion monitoring package requirements explained in this Standard and thereference standards/codes shall be followed, except as modified or supplemented byproject specification or datasheet and provided that the project specification/datasheet isof higher specification level. All modifications/supplements shall be brought to theattention of the Custodian Department for approval for each individual application.

4.2 All issues associated with corrosion monitoring pa ckage manufacturing shall be describedin a Manufacturing Procedure Specification (MPS) conforming to this document. TheSupplier/Contractor shall submit the MPS to QP for approval prior to supply/installation. Itshall include but is not being limited to the details of materials (properties, handling,storage and safety), equipment/package (design, supply, control and calibration process),inspection/testing (parameters, equipment, personnel), Quality Assurance/Quality Controland documentation.

These details shall be based on QP standard requirements, QPapproved project specifications and datasheets.






4.3 The Supplier/Contractor shall perform a Pre-supply/installation Qualification Test (PQT)for the corrosion-monitoring package; this test shall be based on the approved MPS. ThePQT shall be submitted to QP for approval, prior to supply and installation of themonitoring package, against the acceptance criteria specified in this document/MPS. PQT

inspection and testing results shall be fully documented and compiled in PQT report.

5.0 TERMINOLOGY

5.1 Definitions

For the purpose of this specification the following definitions shall apply:

5.1.1 Contractor

Company, firm or party appointed by QP to perform the works in accordance with thisTechnical Standard.

5.1.2 Corrosivity

The ability of the environment (fluid/atmosphere) to cause corrosion of the appropriateconstructional materials used for a facility.

5.1.3 Corrosion Rate

It is the corrosion effect on a metal per unit of time. Corrosion rate is usually measuredeither in mpy (mils per year) or mmpy (mm per year), where 1 mpy = 0.0254 mmpy.

5.1.4 Corrosion Inhibitor

It is a chemical substance, which decreases the metal corrosion rate to an acceptablelevel when present in the corrosion system at a suitable concentration, withoutsignificantly changing the concentration of any other corrosive agent. A corrosion inhibitoris generally effective in low concentrations.

5.1.5 Corrosion Coupon (CC)

A pre-weighed standard sized and shaped piece of metal/alloy, that is exposed the lineprocess fluids in a specially designed holder for a specific period of time. The averagecorrosion rate is measured by the loss in coupon weight after exposure to the processfluid and the pattern of metal loss indicates the tendency to localised corrosion.Susceptibility to pitting, galvanic corrosion, SCC, crevice corrosion, weldments corrosion,scaling, erosion and cavitation may be determined using special coupons suitable to thephenomena to be evaluated.

5.1.6 Corrosion Engineer

The person or persons responsible for carrying out the corrosion monitoring and theinterpretation of the data produced.

5.1.7 Electrical Resistance Probe (ER)

A wire, strip or tubular element, of known electrical resistance, that is exposed to the lineprocess fluids at the end of a specially designed probe. The average corrosion rate is






measured by the change in electrical resistance of the exposed element relative to areference element, sealed within the probe body, over a fixed period of time for which ithas been exposed. This change in the electrical resistance is directly proportional to theaverage corrosion rate for that period.

5.1.8 Hazardous Area Classification (HAC)

HAC is the classification of an installation, facility or equipment into hazardous area.Hazardous area is the zone in which flammable atmosphere may be presented duringnormal operation or under abnormal or fault conditions and as such it would requirespecial precautions for construction and use of electrical equipment. Hazardous area canbe classified into various zones (zone 0, 1 or 2). For details on this subject, see QP-PHL-S-001.

5.1.9 Hot Tapping

Making repairs, modifications requiring cutting, drilling etc to make a connection with

pressurised equipment or pipe work whistle it is in service and contains the process fluids.

5.1.10 Linear Polarisation Resistance (LRP)

A corrosion monitoring technique based on the measurement of the ‘apparent resistance’of a corroding electrode when it is polarised by a small voltage of the order of 10 mill volts.The ‘apparent resistance’ is determined from the current flowing as a consequence of thesmall-applied voltage and is inversely proportional to the corrosion rate.

5.1.11 Manufacturer

The party that manufactures, fabricates, or produces materials, equipment or products.

5.1.12 Online Corrosion Monitoring

The direct (on-site) assessment of the equipment/pipe metal/alloy degradation caused bythe action or reaction with the surrounding environment, when it is exposed to the lineprocess fluids during operation.

5.1.13 Produced Water

The water emanating from wells together with crude oil /gas, that usually settles at thebottom of pipelines /vessels.

5.1.14 Side Stream Monitoring

Monitoring by using a by-pass spool or off-take from the main process line beingmonitored in order to provide supplementary corrosion monitoring information. It may beused for corrosion inhibitors field trials or chemical analysis.

5.1.15 Supplier

Company, firm or party appointed by QP to supply material, equipment or other productsin accordance with this Specification.






5.1.16 Works

The works to be executed in accordance with the Contract, as defined in the particularconditions and shall incorporate the permanent works together with the temporary works.

5.2 Abbreviations

CC Corrosion Coupon EMS Environmental Management SystemER Electrical ResistanceHIC Hydrogen Induced Cracking HSE Health, Safety and EnvironmentLPR Linear Polarisation Resistance MMPY Millimetres Per Year MPS Manufacturing Procedure SpecificationMPY Mils Per YearMPI Magnetic Particle Inspection MSDS Material Safety Data Sheet

NDT Non-Destructive TestingPTFE Poly-Tetra-Fluoro-Ethylene PQT Pre-Supply/Installation Qualification TestingQP Qatar Petroleum and its inspectors, engineers or representativesQA/ QC Quality Assurance/ Quality Control SCC Stress Corrosion Cracking SMAW Submerged Metal Arc Welding SMS Safety Management SystemSPIR Spare Parts and Interchange-ability UT Ultrasonic Examination

6.0 REFERENCED STANDARDS AND CODES

6.1 Where reference is made to the following standards and codes, the latest edition shall beapplicable.

6.1.1 International and National Standards and Codes

ASTM G170 Standard Guide for Evaluating and Qualifying Oilfield andRefinery Corrosion Inhibitors.

ASTM G46 Standard Guide for Examination and Evaluation of PittingCorrosion.

ASTM A 350/A350 Standard Specification for Carbon and Low Alloy SteelForging, Requiring Notch Toughness Testing for Piping

Components.

ASME B 31.1 Power Piping

ASME B 31.3 Process Piping

NACE RP 0775 Preparation, Installation, Analysis and Interpretation ofCorrosion Coupon in Oil Field operations.

NACE MR 0175 Sulphide Stress Cracking Resistant Metallic Materials for OilField Equipment.






NACE TM 0173 Methods of Determining Water Quality for Subsurface InjectionUsing Membrane Filters.

IEC 60079 Part 0

(CENELEC EN 50014)

Electrical Apparatus for Potentially Explosive Atmosphere –General Requirements.

IEC 60079 Part 11

(CENELEC EN 50020)

Electrical Apparatus for Potentially Explosive Atmosphere –Intrinsic Safety “ i “ (To be read in Conjunction with IEC 60079Part 0/ CENELEC EN 50014)

BS EN 10204 Metallic Products – Types of Inspection Documents.

ISO 8044 Corrosion of Metals and Alloys – Vocabulary.

6.1.2 QP Standards and Specifications

IE14R002.2506/Ins QP Topsides Improvement Philosophy for Corrosion Mitigation

and Monitoring

QP-PRC-A-001 Procedure for Identification of QP Technical standards.

QP-GDL-A-003 Guidelines for Drafting QP Technical Standards.

QP-SPC-L-008 QP Technical Standard for Corrosion Inhibitors and theirInjection Package for Oil and Gas Production Facilities.

QSP-QC-09 Quality Requirements for Projects.

QP-SPC-L-002 QP Technical Specification for Painting and Wrapping of MetalSurfaces (New Construction and Maintenance).

QP-STD-R-001 QP Technical Standard for Materials for Sour Service

QP-PHL-S-001 QP Corporate Philosophy for Fire and Safety.

QP-REG-Q-001 QP Lifting Equipment Technical Regulations.

QP-SPC-V-001 QP EMS Specifications for Waste Management.

ES-L-22(ES.S.14.0010)

Specification for Fabrication, Inspection and installation ofProcess Pipe-work in Carbon Manganese and Low Alloy Steel.

ES-L-23(ES.S.14.0020)

Specification for Fabrication, Inspection and installation ofProcess Pipe-work in Austenitic Stainless steel, Copper Baseand Nickel Base Alloys.

6.2 In the event of conflict between this document and the standards/ codes referenced hereinor other purchase or contractual requirements, the most stringent requirement shall applyunless otherwise specified. For any modifications/supplements, User Departments shallapply to the Custodian Department for guidance/direction and approval.






7.0 HEALTH, SAFETY AND ENVIRONMENT

7.1 All necessary health, safety and environmental procedures shall be employed to protectpersonnel and the surrounding environment during on-site/field corrosion monitoring works.

The Contractor/Supplier shall submit his HSE/SMS manual for QP approval. The approvedrecommended procedures for the safe on-line retrieval and installation of coupons andprobes shall be strictly followed.

7.2 All relevant safety requirements of QP Corporate Philosophy for Fire and Safety (QP-PHL-S-001), QP Safety Regulations for Contractors, and QP Lifting Equipment Regulations (QP-REG-Q-001) shall be adhered while performing works within QP operation areas.

7.3 Materials Safety Data Sheets (MSDS) for all chemicals to be used within QP operation areasshall be submitted by the Supplier to QP for review and approval. Health and safetyprecautions shall be clearly described on each chemical container/package.

7.4 All wastes resulting from supply and installation, within QP operation areas, shall be

contained, collected and properly disposed of in accordance with the relevant clauses of QPEMS Specification for Waste Management (QP-SPC-V-001) and the state of QatarEnvironmental Protection Standards/Regulations.

8.0 MONITORING STRATEGY PLAN

8.1 General

8.1.1 Planning of corrosion monitoring scheme for existing or new plant/facility plays animportant role in a successful control system. When selecting a monitoring system, it isimportant to consider financial implications like the effects of downtime, replacementpolicy and security of production on the overall cash flow of the operation.

8.1.2 The overall management decision to install or not to install a comprehensive monitoringscheme should be based on the best available technical and economic evaluation. Thefollowing clauses describe the planning requirements for corrosion monitoring system forexisting and new plant/facilities based on technical evaluation.

8.2 Existing Plant/Facility

8.2.1 A comprehensive review of the process plant materials, corrosion allowances andoperating/service conditions should be carried out to identify the following:

a) All areas that may be susceptible to significant corrosion within the projected lifespanof the plant/facility.

b) The consequences of marked corrosion leading to equipment failure.

c) The specific corrosion process as that are likely to occur (to identify the most suitableon-line corrosion monitoring technique to be used.

d) The parameters, which are instrumental in causing corrosion or are likely to influencethe corrosion rate.






8.2.2 The results of the above review should be used to develop a corrosion monitoring strategyplan comprising the following:

a) Most suitable monitoring techniques

b) Selection and location of monitoring devices.

c) Prescribed mon itoring frequencies.

d) QP approved monitoring procedures.

e) Allocation of responsibilities, which include the following:

• Ensuring that corrosion monitoring is carried out in accordance with the QPapproved procedures.

• Interrogation, storage and retrieval of the information recorded.

• Presentation of detailed reports at required frequency.

8.3 New Plant/Facility (Under Design)

The corrosion monitoring requirements for new plant/facility shall be established duringthe early development of project design. The Supplier/Contractor shall prepare aproposal/study for the monitoring strategy plan for QP review and approval. Theproposal/study shall be based on the process design and plant layout. Thestudy/proposal shall comprise the items mentioned under sub-clause 8.2.1. Specialconsideration should be observed for corrosion monitoring of new plants, as it should beinstalled after commissioning stage.

8.4 Monitoring for Inhibitor Trials

Where corrosion inhibitors need to be evaluated at plant/site (inhibitor trials), the inhibitorsupplier will be appointed to undertake the required corrosion monitoring to determine theeffectiveness of the product under operating conditions. In this case, the inhibitor suppliershall have a proven track record of carrying out such duties and shall submit detailedcorrosion monitoring procedures for QP review and approval. All requirements for inhibitortrials shall be in accordance with QP-STD-L-008.

8.5 Monitoring Equipment Selection

8.5.1 The selection of the specific on-line corrosion monitoring equipment is usually determinedby the known or perceived corrosion mechanism taking place, the process conditions andthe availability of access. Appendix A shows a recommended supply datasheet forcorrosion monitoring equipment. These data sheets may be modified to suit projects

specific requirements. The selection of monitoring equipment shall be evaluated andapproved by QP Corrosion Engineer.

8.5.2 Individual corrosion monitoring techniques provide only a limited amount of information. Aminimum of two techniques (i.e., Coupons and ER probes) should be used to monitorcorrosion wherever possible, in order to provide complementary data.

8.5.3 In addition to the information provided by corrosion monitoring devices, the followingadditional information/data should be provided to help in interpretation/analysis.






a) Detailed plant/facility operational data for the monitoring period.b) Chemical analysis of process fluids extracted through a relevant sample points.c) Monitored equipment visual and NDT records.

8.5.4 On-line internal corrosion monitoring should be undertaken using proprietary accessfittings, which permit the installation and removal of probes and coupons without the needfor plant shut down. The design, material and mechanical properties of such fittings mustmeet the requirements of the standards and codes used for the design and construction ofthe plant being monitored, including QP -STD-R-001 and NACE MR 0175 whereappropriate.

8.5.5 Intrusive probes/coupons should be installed where they can remain in place for extendedperiod, rather than having to be removed to support pigging. Thus an intrusive probeshould be installed upstream of any pig launcher and down stream of any pig receiver, soas not to block the path of the pig. Where this is not possible, flush-mounted probes shallbe installed.

8.5.6 Corrosion coupon data is usually obtained in the laboratory by weight loss method.Corrosion probe data gathering units vary from handheld, direct-reading analogue ordigital corrosion meter, with no data storage facility, to multi-channel data-loggers linkeddirectly to microprocessor driven data storage, analysis and retrieval units. The selectionof data collectors (manual or automatic) shall be governed by factors mentioned underclause 11.1 of this document.

9.0 MONITORING TECHNIQUES

9.1 General

9.1.1 Corrosion monitoring techniques are used for various applications. The most commonapplication is to record and assess inhibitor performance after injection. Also, they can be

used for monitoring internal corrosion in the main gas and oil transfer lines to checkwhether the material corrosion rate, in susceptible areas, is within acceptable limits Thereare various monitoring techniques used for this purpose, intrusive techniques, such ascoupons and probes, which are exposed directly into the flow streams shall be adopted asthe primary means of corrosion monitoring..

9.1.2 Intrusive techniques used are based on the principle that the monitoring devices can bereadily installed and retrieved at system pressure, without having to interfere with plantoperations. These techniques employ permanent “ Access Fittings” welded to the pipe -work, through which monitoring devices (coupons/probes) can be manipulated usingspecial high-pressure retrievers.

9.1.3 If two monitoring techniques are selected to monitor corrosion, the two access fittingsemployed shall be separated by at least six to 10 pipe diameters. This is to ensure thatany turbulence immediately downstream from the first probe or coupon does not affect themonitoring results from the second monitoring location.

9.1.4 The following sub-clauses describe the monitoring techniques to be used in QP operatingareas. The recommended techniques are: Corrosion Coupon s and Electrical Resistanceprobes for hydrocarbon fluid and Linear Polarisation Resistance for water. Selection of thetechnique(s) used will be subject to the operating/services conditions and monitoringrequirements. Coupons and probes shall only be installed in essentially horizontal pipework unless otherwise specifically approved by QP.






9.1.5 The corrosion monitoring equipment (probes and portable instrument) shall be intrinsicallysafe certified Exia or Exib for use within an intrinsically safe circuit in accordance with therequirements of IEC 60079 part 0 and IEC 60079 part 11 standards. The selection of

protection type category (ia/ib) shall be based on the specified hazardous areaclassification. The location and the applicable hazardous area cla ssification will bespecified in the project specification/datasheets.

9.2 Corrosion Coupons (CC)

9.2.1 Corrosion coupons are used to determine the average fluid corrosivity by measurement ofweight loss. Susceptibility to pitting, galvanic corrosion, SCC, crevice corrosion,weldments corrosion, scaling, erosion and cavitation may also be determined usingspecial coupons suitable for the phenomena to be evaluated.

9.2.2 The weight loss coupon method facilitates an assessment of the corrosivity of anenvironment with respect to the specific material of construction of that part in which

corrosion monitoring is taking place. Careful consideration should be given to theproposed monitoring location and coupon position during the development of thecorrosion monitoring strategy (see clause 8.2).

9.2.3 The recommended weight loss coupons to be used shall be flush-disc or strip type.. Othertypes (rods, tube or rings) may be used in a certain circumstances/cases defined by QPand in accordance with the manufacturer recommendations. For pipelines subject topigging, only flush-disc type shall be used The coupon selection, handling, nominaldimensions, exposure times and evaluation shall be in accordance with the projectspecification/datasheets. Guidance on the same is explained in NACE RP0775.

9.2.4 Each coupon shall be checked to make sure that it carries its own individual identificationmark. Prior to coupons exposure to the environment, they shall be degreased and

weighed.

9.2.5 Coupons shall be attached to holders suitable f or installation in low pressure or high-pressure access fittings systems as appropriate. The diameter of the access fitting shallbe 2.0 inch. The orientation of the access fitting and the length of the coupon holder shallbe such as the coupons can be exp osed to the appropriate portion of the process stream.

9.2.6 Exposed coupons shall always be visually examined for the type of the attack both beforeand after chemical cleaning. Samples of corrosion product should be removed for possibleanalysis. Where pitting is the predominant form of attack, the extent of pitting may beevaluated in accordance with ASTM G46.

9.3 Electrical Resistance Probes (ER)

9.3.1 Electrical resistance probes may be used to measure corrosivity of both conductive andnon-conductive liquids and vapours. The ER probes used are: Tubular element, wire loopor flush mounted type. The recommended type is the flush high pressure element type.The probe element seals shall be selected/designed in such a way as to avoid anypreferential crevice attack at the steel element/potting compound interface. Tubularelement probes and wire loop probes are more susceptible to mechanical damage. Theiruse should be limited to special cases/ circumstances as defined by QP.






9.3.2 Under high velocity process cond itions, tubular element and wire loop probes, if used,may require velocity shields for protection. The use of velocity shields should be limited asthey are prone to debris accumulation and this may lead to spurious results from theprobe. Wire loop or tubular element probes, fitted with velocity shields, which extend the

full length of the probe body, shall not be used in conjunction with low-pressure accessfitting in hydrocarbon service.

9.4 Other Monitoring Techniques

9.4.1 Linear Polarisation Resistance (LPR)

This method can only be used to measure the immediate corrosivity of “clean” lowresistivity process fluids under conditions of continuous immersion. Therefore they aresuitable for measuring the corrosion rate in formation water or where continuous waterphase exists. LPR probes may suffer “shorting” due to the accumulation of conductivedebris or corrosion products bridging the gap between the electrodes. The use of thistechnique in oil and gas production is limited and shall be subject to QP requirements for

specific applications.

9.4.2 Hydrogen Permeation Monitoring

Hydrogen permeation monitoring using gas pressure build-up or electrochemicaltechniques (patch probes) is appropriate for tracking hydrogen activity in piping andvessels handling wet sour gas streams. These probes require no direct internal access tothe system and may be secured to the outer surface of the vessel or pipe section undertest. Locations at which hydrogen related corrosion damage such as HIC and SCC islikely to occur are appropriate sites for hydrogen permeation monitoring. Whenconsidering hydrogen permeation monitoring, QP Corrosion Engineer should beconsulted.

9.4.3 Scale and Bacteria Detecting

The corrosion of mild steel as a consequence of the growth of sulphate reducing bacterialaction is characterised by the formation of iron sulphide scale, which can be readilydetached to reveal shiny, almost hemispherical steep sided pits. Generally, bio-films canbe removed from standard strip coupons protruding into the process stream.

Bio-probes exposed to the process stream shall be used to assess the population ofsessile (surface adhering) bacteria. As sessile microbial populations tend to developpredominantly in areas where flow rates are very low, these probes should be fitted intodead-legs and other stagnant locations. The use of this monitoring technique is subject tospecific QP requirement. If adopted by QP, details of probe selection, locations andcharacteristics shall be as specified in the pro ject specification/datasheet.

9.4.4 Galvanic Corrosion Monitoring

This monitoring method can assess the possibility of corrosion between two differentmetals. A probe containing two electrodes (each electrode of a metal of question) isexposed to the line process fluid. A zero resistance meter is used to measure the currentproduced by the galvanic cell. Probes can be read by either portable or automaticinstrumentation, and can be inserted or removed from on -line plant/equipment.






9.4.5 Spool Pieces

To obtain a direct assessment of the corrosivity of a process stream and subject to QPapproval, the use of short length (0.3 – 1 meter) of selectively located flanged spool,

which can be periodically removed for internal inspection should be considered. Suchinspection spools should be used where conventional techniques would not be reliable.The spools should be fabricated from an identical piping material of the adjacent pipe-work. The inspection spool shall be cleaned, prior to exposure and may also be weighed,where the measurement of weight loss is considered practical. Sectioning of the spool willbe required to enable detailed visual assessment of the metal loss to be made. Localisedcorrosion should be evaluated in accordance with ASTM G 46.

9.4.6 Non-intrusive Monitoring Techniques

Where it is not possible or desirable to install corrosion monitoring access fittings, non-intrusive monitoring techniques can be used, such as manual/automatic NDT techniques,which comprises a number of methods like ultrasonic (UT), eddy current, Magnetic Flux

Leakage (MFL), acoustic emission and radiographic examination. Visual examination andfluid debris analysis can also be used

The UT examination should be used to measure the residual wall thickness in pipe -workand vessels handling potentially corrosive fluids. The measurement accuracy dependsupon the actual wall thickness and the condition of the outer surface of the pipe or vesselin contact with the probe. In critical situations where high corrosion rates are anticipatedover small area, solid coupled probes may be welded directly onto the pipe or vessel atsuspect locations in order permit continuous monitoring of wall thickness.

As an alternative to UT examination, radiography may be used to examine the internalcondition of process pipe -work (change wall thickness) and supplement the information onfluid corrosivity received from other monitoring methods. It is particularly useful for the

examination of preferential corrosion at weldments and erosion at bends

9.5 Side Stream Monitoring

9.5.1 General

Side stream monitoring may be used to examine the effect of chemical additives/corrosioninhibitors or process change upon electrochemistry of the plant material- process fluidsystem.

It should be used to supplement standard on-line corrosion monitoring methods andshould not be used in isolation unless on-line methods are not practical. The generalrequirements for the selection of monitoring locations shall be in accordance with Clause

10.1 of this Standard. Identification of specific monitoring locations shall be as per therecommendations of QP Corrosion Engineer.

9.5.2 Side Stream Equipment

The side stream equipment should be portable, easily assembled/disassembled andsuitable for safe use in on/offshore oil/gas production facilities. It shall comprise thefollowing:






a) One or more probe or coupon monitoring devices. The type and number of devicesand their distribution shall be as identified in the QP approved specification/datasheetprepared for this task. Corrosion Coupons (CC) and ER probes are generally used forhydrocarbon fluid environment and LPR probe for waters.

b) Access fittings suitable for installation of the above mentioned monitoring devices.Identification of the lines in which tapping is required and distance between inlet andoutlet shall be as specified in the QP approved specification/datasheet prepared forthis task.

c) Monitoring equipment loop/by-pass rack (size 2 “) constructed from PVC, carbon steelor stainless steel. If PVC is used, it shall withstand the operating pressure,temperature and fire hazard and shall be corrosion resistant to formation water ofsalinity up to 28g/L as NaCl and saturated with CO2 and H2S. The selection of loopmaterial shall be subject to parent pipe/equipment material, process environment andservice conditions (i.e., flow velocity, pressure, temperature). The selected materialwill be identified in the QP approved specification/data sheet prepared for this task.

If a corrosion inhibitor or other chemical additives injected into the process stream, thefollowing additional requirements will be required.

a) Electric/air operated portable chemical injection pump mounted in a skid. It should beequipped with injection flow measurement and control devices. The injection rateshould be as per the QP provided specification/datasheet.

b) Internal static mixer (installed directly downstream of the chemical injection point).

c) Flow-metering device to measure the flow rate of process fluid.

d) Pressure gages near the inlet and outlet locations.

e) Air/electric-driven pump capable of maintaining a positive pressure at the outlet wherethe fluid can be re-injected back to the system at a flow velocity and flow ratespecified by QP.

The side stream monitoring equipment should be easily adaptable for monitoring other on-line features such as PH, scaling, bio filming, solid accumulation/filtration, etc. Appendix Bshows an example of corrosion monitoring side stream supply datasheet as guidance.

9.6 Corrosion Product Analysis

9.6.1 The measurement of fluid corrosivity using probes and coupons should, where possible,be supplemented by chemical analysis of any corrosion products or deposits which are

found either on the probes or coupons or the internal surface s of the process equipmentduring plant inspections at shutdowns.

9.6.2 The collection, handling and storage procedure for corrosion products should be such asto avoid contamination and/or degradation of the sample. Detailed examination should becarried out as soon as possible after removal from the system.

9.6.3 The corrosion monitoring Contractor shall provide procedures for collection andidentification of corrosion products for QP approval. The procedures shall be inaccordance with NACE RP 0173.






9.6.4 The most commonly used techniques for corrosion product evaluation and analysis are asfollows:

a) Visual examination

b) Magnetic examinationc) Microscopyd) Wet chemical analysise) Spectroscopyf) X-ray diffraction and element analysis

10.0 DESIGN AND INSTALLATION REQUIREMENTS

10.1 Monitoring Locations

10.1.1 Monitoring locations shall be selected such that they, as far as possible, represent theareas where the most sever corrosion activity is likely to occur, such as:

a) Immediately downstream of exchangers, where the marked cooling of the processstream that could lead to aqueous condensation, occurs.

b) Starts of horizontal pipe runs where the flow has changed from the verticalimmediately downstream of the bends.

c) Turbulent, high velocity areas, such as downstream of mixing points and pumpoutlets.

d) Downstream end of pipelines in which aqueous condensate formation could occur.

e) Laminar, low velocity areas where water can settle down.

10.1.2 In addition, monitoring shall be used to assess the effectiveness of corrosion inhibitortreatment. It shall only be used for corrosion resistant alloy piping where a particularcorrosion has been identified. Unless used for assessing the distribution of inhibitor,monitoring by intrusive techniques into vertical pipe runs shall be avoided.

10.1.3 Identifying Monitoring Location

The selection of monitoring points requires careful consideration. Corrosion is likely tooccur where water can accumulate at relatively low spots in individual lines/vessels andsuch areas are most likely to provide useful monitoring information. Not all lines/vesselsneed to be monitored. A single monitoring station may represent a group of lines/vesselsoperating under similar process conditions in the same area.

The following guidelines should be adopted when considering the location, type andorientation of monitoring installation:

a) The lines/facilities subjected to potentially high corrosion risk should be identified andspecified. This is usually based on line/facility configuration, process characteristics(particularly where piping upgrades are being undertaken) past operating/service andcorrosion experience. The typical locations for monitoring corrosion in pipe-work areas follows:

• Areas where water condenses as a discrete phase.






• Starts of long horizontal pipe runs

• Area of high velocity or turbulence, especially after mixing points

• Low flow areas

• Lines receiving inhibitor treatment, downstream of the injection point (or on a line

Where, inhibitor-dosed liquids are knocked out or separated).

b) On flow lines and pipelines, at least two corrosion monitoring access fitting shall beinstalled at low points at each end of the line. The access fitting shall not be installedin the piggable section of the pipeline but shall be installed upstream of any piglauncher and downstream of any pig receiver, unless flush mounted probes/couponare used for monitoring.

c) Access fittings shall not be permitted in lines where they are within such close proximitythat they either affect the flow regime of sensitive equipment (flow meters or controlvalves) or are affected by the vibration of rotating equipment (pumps or compressors).

10.2 Access Fittings Design and Installation

10.2.1 The intrusive monitoring system to be used in QP facilities shall be based on a fullyretrievable 2-inch system, using high-pressure access-fitting assemblies welded directly tothe piping. The access fitting system shall permit the installation and removal of probes andcoupons without the need for plant shutdown. It shall be located where adequate clearanceis available for installation and operation of service valve and retriever (see sub-clause10.4.1a.

10.2.2 Access fitting assemblies shall be of flare -weld type acme thread outlet, with heavy-dutyprotective covers (without hole) complete with weldolet, essential spare, service equipmentand tools. Material selection of access fitting bodies shall conform to the materialspecification of the pipe or equipment, to which it is welded. Also, it shall be suitable for sour(H2S) fluid service and shall conform to the requirements of NACE MR 0175 and QP-STD-R-001. Plug assembly shall be as follows:

a) Solid plug assemblies for corrosion coupons

b) Hollow plug assemblies for ER probes.

The access fitting design shall be suitable for full range of operating conditions of piping/equipment (i.e., changes in pressure, flow-rate and molecular weight). The elastomericcomponents used for pressure sealing shall be demonstrated to have satisfactoryperformance in the expected process fluids and at the operating temperature of piping orequipment.

The diameter of the access fitting shall be 2 inch. Details of the fitting specification shall be asexplained in the project specification/datasheet.

10.2.3 The access fitting shall be welded to the pipeline/piping or vessel, in accordance with the

engineering design requirements and the Contractor’s established procedures. Welding shallbe qualified for all welded joints in accordance with the design code plus the additionalrequirements of the relevant QP standard. Prior to start of welding, all procedures shall beapproved by QP. Welding procedures previously qualified by the Contractor may besubmitted for approval as long as they meet the requirements of the applicable standards.

10.2.4 For reasons of accessibility, flanged, instead of welded, fittings may be used subject to QPapproval. The recommended access fitting installation and commissioning procedure isexplained in Appendices C. The procedure for installation of plug assemblies shall be in






accordance with the engineering design requirements and the Contractor’s/Manufacturer’sprocedure approved by QP.

10.2.5 Where practical and appropriate, particularly with wet gas and large lines (i.e., greater than14 inch diameter), access fittings sha ll be welded directly to the underside of the pipe (6

O’clock location). Where this is not practical and for smaller lines, top of the line mounting offittings (12 O’clock location) shall be used in conjunction with wire, tube/rode or strip typeprobes, with monitoring devices positioned as close to the pipe bottom (water phase) aspossible. The advantage of bottom (6 O’clock) location of the line fittings are as follows:

a) It provides more representative monitoring -information as the monitoring device willmeasure the corrosion rate in the produced water phase.

b) Shorter retrievers can be used.

c) Low risk of monitoring devices becoming detached.

The main disadvantage is that, generally, because of line debris, retrieval operations aremore complicated and may require back flushing of the access fittings.

10.2.6 Where practical, all monitoring stations should comprise a pair of access fittings installed at300 mm centres. The upstream fitting shall contain a hollow plug suitable for installing acorrosion probe and the downstream fitting shall contain a solid (gauge) plug suitable forholding corrosion coupons.

10.2.7 Sufficient space should be allowed around the fittings to enable the safe attachment of thehook-up valve and to permit the full extension of the retriever. Clearance required (from topof access fitting) should be based on the retriever dimension (see figure1). Whereverpossible, permanent access platforms shall be installed adjacent to monitoring stations.

10.2.8 All monitoring access fittings assemblies shall be identified by a discrete tag number and thelocation code marked on the pipe.

10.3 Distribution of Access Fittings

10.3.1 Crude Oil Systema) Access fittings should be installed upstream of gas/oil separators, at low points, as close

to oil inlets as practical.

b) Access fittings are required on incoming wet crude oil (gas-lifted) flow-lines in horizontalpipe runs, where practical.

c) Because of restricted access, it is unlikely that production headers can be monitoredusing intrusive methods.

d) Long crude oil lines running between platforms should have access fittings installed atthe downstream end, preferably at low points.

10.3.2 Gas and NGL Systems

a) In wet process gas off-takes from the gas/oil separators, the access fittings shall belocated:

• On horizontal pipe section as close to the outlets of vessels as practical.

• At the outlet lines from exchangers or vessels in which process stream cooling couldlead to aqueous condensation occurs.

• At low points on bridge crossings, upstream of vertical pipe-runs.

b) No access fittings are required in:






• Gas lines away from the separators having continuous horizontal pipe runs of lessthan 20 m.

• Dry fuel gas systems, unless there are concerns about dryer operation.

10.3.3 Other Systemsa) Access fittings in compressor discharge lines should be positioned downstream of

coolers.

b) Gas lines, downstream of the final separation stage prior to the dehydration facilities,shall have access fittings as near to the glycol contactor as possible.

c) The small bore NGL and wet condensate discharge lines to the surge vessel, exportpumps, or glycol regeneration plant should be monitored using access fittings mountedtop of line above liquid traps.

d) The selection and distribution of corrosion monitoring access fittings on specific facilities/locations shall be defined in the specification/datasheet prepared for this task and shallbe reviewed and approved by QP Corrosion Engineer.

10.4 Installation and Retrieval of Monitoring Devices

10.4.1 Retrieving Equipment

High-pressure retrievers shall be used for installation and retrieval of monitoring devices(probes/coupons) without interrupting the process operation. The retriever shall be oftelescopic type (see Figure 1) comprises the following:

a) Retriever kit stroke complete with repair and seal kit. The horizontal clearance shall be 1meter (in all direction) from the end of the retriever handle. The vertical clearancerequired shall be based on the retriever dimension using the fully extended telescopicretriever The stroke dimension shall be suitable for the specified clearance from top ofaccess fitting. The following vertical clearances are recommended for various strokedimensions.

Retriever Stroke Clearance (from the top of Access Fitting)

Inches (mm) Inches (mm)

18 (457) 65 (1651)

25 (635) 72 (1829)37 (940) 98 (2490)

49 (1245) 120 (3048)

b) Service valve kit (Figure 2), complete with valve assembly with extension lever, brasshammer, spare face – to – access fitting, O – ring, heavy duty field service box, essentialrepair and seal kit.

10.4.2 Installation/Retrieval of Plug Assembly

a) Installation/Retrieval Procedure

The installation and retrieval of plug assemblies under pressure shall be in accordancewith the QP approved Supplier’s procedure. The procedure shall be prepared inaccordance with the retriever’s manufacturer instructions. It shall include all detailsrelated to the equipment components, work planning, workshop checks, and operationsteps.






b) Operation Safety Instructions

The installation and retrieval of plug assemblies from live pressurised processequipment shall be done in safe manner. The following shall be observed before andduring installation and retrieval operation:

• QP’s Permit to Work Certificate (PTW) shall be obtained prior to commencement ofwork (inside and outside facilities).

• Before entering a pit for work, ensure that gas tests (H2S and O2) are carried out.

• Always wear safety glasses when using a brass hammer.

• During pressurisation of the retriever, it must be fully extended, i.e., the outer barrelmust be at its outermost limit.

• Never stand in a direct line with the access fitting when initially loosening the plugassembly. A damaged or heavily corroded plug can fly out of the access fitting at veryhigh velocity and can cause severe injury.

• All installation and retrieval operations must be carried out standing beside theretriever. Never stand behind, below or above the retriever.

• Under no circumstances is it permitted to seal the hollow plug assembly by installinga stainless steel pipe plug.

11.0 MONITORING SYSTEM AUTOMATION

11.1 General

11.1.1 The adoption of a monitoring system, which incorporates the use of electrical probes,provides the opportunity to introduce a fully automatic instantaneous corrosion datagathering and processing programme. The methods for interrogation of corrosion probesrange from handheld analogue or digital meters to multi-channel data collection data-loggers

linked directly to microprocessor driven data analysis units.

11.1.2 The decision to select automatic monitoring in preference to manual monitoring, for datacollection, involves of a combination of technical, economic and manpower related factors.These factors are as follows:

a) The number, range and distribution of corrosion monitoring devices.b) The required frequency of data collection.c) The availability of manpower for data gathering.

d) A comparison of the capital and operating costs associated with various options

11.1.3 In general, where corro sion rate is governed by oxygen ingress or the presence ofaggressive contaminant species, or where the interruption of mitigation measures, or anexcursion in process condition would quickly lead to rapid corrosion, an automatic orcontinuous monitoring is recommended.

11.1.4 Where distributed control systems (DCS) are being planned to gather and analyse processor production data, it is generally economic and desirable to incorporate a fully integratedcorrosion data-gathering package within the system.

11.2 Manual Monitoring Methods

11.2.1 Hand held instruments for the interrogation of corrosion probes varies from simple directreading meters dedicated to one probe type and with no data storage to stand-alone multi-






channel meters with direct read out, data storage and retrieval and microprocessor interfacecapabilities for optimum data recording and analysis.

11.2.2 Rack mounted instruments, which provide direct analogue or digital read out of the corrosivityreadings from a number of monitoring probes are also available.

11.2.3 The selection of one of the instruments mentioned above shall be subject to project/plantrequirements and QP approval.

11.3 Automated Monitoring Methods

11.3.1 Automated monitoring systems generally use data loggers, transmitting units andMicroprocessors. The probe information can be continuously transmitted by either hard wireor telemetry through interface modules to continuously record data logging (single or multi-channel) units. Removable memory modules allow manual transfer of the recorded data tothe office where it can be downloaded to a microprocessor for interrogation. Single channelunits have the advantage that they may be mounted local to the monitoring point to minimisethe length of the cable run.

11.3.2 Individual or multi-probe transmitter units are available, which are mounted local to the probeand used to receive, process and transmit the probe signals to a remote interrogation unit.This unit may be either a dedicated chart recorder or digital display unit or a microprocessor.

11.3.3 Microprocessors dedicated for corrosion monitoring may be used to receive data frommonitoring probes via transmitter units. The microprocessor facilities enable selection ofrecording frequency and alarm setting. They are primarily concerned with data collection,display and storage. Capabilities can vary according to manufacturer specifications.

11.3.4 The selection of suitable automated equipment shall be subject to the project/plantrequirements and QP approval.

11.4 Data Analysis and Reporting11.4.1 The methods used to analyse the corrosion monitoring data will be determined by the

number, location and variation in monitoring devices used and the method of data gathering(See above clauses).

11.4.2 The frequency and format of reporting the results of corrosion monitoring activities should beagreed between the QP corrosion Engineer and the Contractor. The reports should makereference to significant processing parameters and any chemical/inhibitors treatmentprograms carried out during the time interval covered and highlight any significant change influid corrosivity. Corrosion monitoring reports should be issued at frequent periods asspecified by QP or when on- line monitoring is used to assist plant control.






12.0 PAINTING, MARKING AND SHIPMENT

12.1 All monitoring equipment, i.e., access fitting/probes coupon holders, retrievers and relatedsteel work/piping shall be protectively painted. The painting system shall either be inaccordance with QP -SPC-L-002 or the manufacturer standard providing it gives the same

or better degree of protection. The Supplier/Contractor shall provide the details of thepainting system used or to be used for QP review and approval.

12.2 All items shall be properly packed and protected to avoid damage duringhandling/shipment, in crates.

12.3 Each access fitting shall be provided with a stainless steel nameplate incorporating; dateof manufacture, tag number, manufacturer name, item serial number, size, rating andcoupon type. The serial number shall be cross-referenced to all required documentationand certificates in accordance with BS EN 10204.

13.0 INSPECTION AND TESTING

13.1 General Requirements

13.1.1 As part of his proposal, the Supplier/Contractor shall include details of all inspections andtesting needed to ensure that the equipment to be used meets the requirements of thisStandard and the other referenced standards/codes. QP will review these details and mayask for further inspection and testing before approval of the Supplier’s proposal.

13.1.2 The inspection and testing shall be performed or witnessed by a reputable third partyinspection agency appointed by the Supplier and approved by QP. The Supplier shallprovide all inspection and testing results for equipment for QP review and approval. Theinspection and testing shall be carried out in accordance with the relevantstandards/specifications.

13.2 Inspection and Tests Plan Requirements

13.2.1 Tests and inspection plan should include the following items in add ition to those foundnecessary by the supplies to assure the quality of the corrosion monitoring products.

a) A check of equipment, instrument, devices and all accessories in accordance with therequirements of this document, referenced documents and the approved datasheetsand drawings.

b) All probes and coupon heads shall be checked for performance (i.e., check ofresistance value of ER probe heads).

c) Full functional tests and issue of test certificate of non-mounted equipment.

d) Full unload and download tests on field probes/data units and non-field mountedequipment.

e) A check on the nameplate data in accordance with this document and the approveddata sheets and drawings.

f) A check on the painting and protection and suitability for the environment andoperation/service condition.






g) A check on the tagging in accordance with this document and data sheets.

13.2.2 The supplier shall provide, as part of the documentation, inspection and testingprocedure(s) for QP review and approval, at least 6 weeks before supply.

13.3 Test Certificates

13.3.1 The Supplier shall provide the following test certificates for QP review and approval. Thesubmitted test certificates shall be in accordance with BS EN 10204 31C.

a) Mill test certificates relevant to the chemical analysis and me chanical properties of thematerials used in the manufacture of coupons, probes, access fittings and accessoriesaccording the relevant standard. Report on any heat treatment carried out on materialsshall also be provided.

b) Test certificates of hydrostatic and pneumatic testing with duration and pressure recordsof each test.

c) Test reports of ultrasonic, radiography, MPI and any other test as applicable for therequired items.

d) Test report on operation of “ Retriever Kit” as per the Manufacturer’s standard.

13.3.2 Test certificates will be valid, only when approved by QP inspector. Only those items, whichhave been certified by QP inspector, shall be dispatched from the Supplier area.

14.0 SPARE PARTS AND MAINTENANCE DATA

14.1 The Manufacturer/Supplier shall reco mmend and supply the required spare parts for start-up,commissioning and first year for normal operation. The recommendation for the supply ofrequired spare parts for two years of normal operation should also be provided. Relevantcertification and details of any storage requirements shall be provided with all spare parts.

14.2 Spare parts shall be clearly identified with the following:

• Item description

• Manufacturer part number

• QP order number and item number (when applicable)

• Project/contract number

14.3 The Manufacturer/Supplier shall recommend all accessories and special tools required for theoperation and maintenance of the corrosion monitoring system.

14.4 The Contractor/Supplier shall complete the QP standard Spare Parts List and Inter-changeability Record (SPIR) provided by QP with the purchasing documentation and submits

this with the tender documentation.






15.0 QUALITY ASSURANCE/QUALITY CONTROL

15.1 The Manufacturer/Contractor/Supplier shall operate a Quality Management System basedon the relevant part of ISO 9000 series of standards to satisfy the requirements of this

Specification.

15.2 The Manufacturer/Contractor/Supplier shall demonstrate compliance by providing a copy ofthe accredited certificate or the Manufacturer's/Contractor's/Supplier’s Quality Manual.

15.3 Prior to commencement of works, the Contractor shall submit his QA/QC documentation forQP approval as per the requirements of QSP- QC-09. This shall include the Quality Planand Quality Control System including, inspection and testing methods andreporting/recording formats.

15.4 The Contractor shall prepare and submit to QP for approval a detailed procedures manualof all works, sufficiently in advance of commencement of, outlining, but not limited to, thefollowing:

a) Manufacturer’s details, equipment full details, characteristics, data sheets, testcertificates.

b) Full details of past projects record of proposed corrosion monitoring/ side streamequipment (to evaluate different inhibitors), where it was successfully used in similarconditions. Such information shall include the name of the project/pipeline, serviceconditions and any other details required by QP.

c) Certification from an independent QP approved testing laboratory that the monitoringequipment has been tested and meets or exceeds an internationally recognizedstandard and QP requirements.

d) Inspection and testing plan for monitoring equipment to satisfy QP requirements.

e) Sample log-sheets of material receipts, measurement, logging, and despatches.

The work/supply shall commence only after QP approval of the Quality System ProceduresManual and supply datasheets. After approval, no change shall be made unlessauthorised, in writing, by QP.

15.5 Only skilled and experienced personnel shall be used to meet the required duties in thisStandard, CV’s of these personnel shall be provided for QP approval. Adequatesupervision shall be employed at all times.

15.6 QP reserve the right to conduct a Quality Audit at the Manufacturer’s /Suppliers/Contractors facilities at any stage during work execution or supply.






16.0 DOCUMENTATION

16.1 All correspondence, drawings, instructions, data sheets, design calculations, and all otherwritten information shall be in English language. In the case of dual languages, one

language shall be English and the other Arabic.

16.2 All dimensions, measurements, physical constants, etc. shall be in SI units, unless otherwisespecified.

16.3 The Contractor/Supplier shall provide QP with work proposals/supply documentation, QA/QCplan, Quality Manual, procedures, materials datasheets, assembly drawings, spare Parts lists(SPIR), operating/maintenance manual, material test results and test certificates.

16.4 The Contractor shall maintain a comprehensive recording and reporting system on allaspects related to the implementation of this document including Quality Assurance,inspection and testing. A final report shall be submitted to QP summarising works performedand inspection and testing results for review and approval.

16.5 All documents (texts, specifications, data sheets, drawings etc.) shall be provided withelectronic files in the approved software (i.e., MS Word, Excel, Auto-Cad). Designcalculations shall be submitted in the approved and widely used software agreed by QP.






17.0 APPENDICES

17.1 Appendix A: Corrosion Monitoring System Equipment Datasheets

The Supplier shall complete the following data sheets in accordance with this Standard and

QP approved Project Specifications. The completed datasheets shall be reviewed andapproved by QP prior to any dispatch of any item. These datasheets are subject tochanges/additions in order to include specific or service environment requirements. All suchchanges/additions shall be brought to the attention to the Custodian Department.

Supplier: Sheet of

Project Title: Prepared by:

Project No.; Reviewed by:

Project Spec. No.: Approved by:Drawing No.

Location: Date:

I - Corrosion Monitoring Device (Probe/Coupon)? Corrosion Coupon

Type……………………………………………………….

Dimension……………………… Weight……………….

Serial/Model No………………………………………….

No of Items………………………………………………

? ER Probe,

Type……………………………………………………..

Dimension………………………………………….…..

Serial/Model No………………………………………..

No of Items……………………………………………..

1 Type of Monitoring Device

? Other (specify)………………………………………

Type……………………………………………………….Dimension…………………………………………….…..

Serial/Model No…………………………………………..

No. of Items……………………………………………….

2 Detailed Datasheet Provided ……………………………………………………………..

3 Manufacturer Name ……………………………………………………………..

4 Intrinsically Safe to IEC 60079 -11 ? Yes ? No

5 Test Certificate to BS EN 10204 ? Yes ? No

6 Probe/Coupon Material ……………………………………………………………..

7 Material to NACE MR 0175 andQP-STS-R-001

? Yes ? No

8 Process Stream Environment ? Crude ? Gas ? Water ? Other…………

9 Process Stream Velocity/Pressure ………………………………………………………………10 Process Stream Temperature ……………………………………………………………..

11 Probe/Coupon Location ………………………………………………………………

12 Probe/Coupon Tag Number ……………………………………………………………….

13 Probe/Coupon Position ? 6 O’clock ? 12 O’clock ? 3/9 O’clock

? Other………..

Remarks:






17.1 Appendix A: Corrosion Monitoring Equipment Supply Datasheet, Cont.

II – Access Fitting Assemblies

Type of Access Fitting ? Flare weld, 2 inch System

? Other (Specify………………………….)

Body Style ? Non Tee ? Tee

Dimension………………………………

Plug Assembly ? Hollow ? Solid

1

Heavy Duty Protective Cover Provided ? Yes ? No

2 Detailed Datasheet (Body & Plug) Provided ? Yes ? No

3 Spares/Service Equipment/Tools Provided ? Yes ? No

4 Access Fitting Serial/Model No. ………………………………………

5 Manufacturer Name ………………………………………

6 Body Material ? Carbon Steel ? Other………………

7 Material to NACE MR 0175 & QP-STD-R-001 ? Yes ? No

8 Process Environment ? Crude ? Gas ? Water

9 Service Pressure ? High Pressure Rating………………..

10 Service Temperature Temperature Rating………………..………


12 Access Fitting Location ………………………………………………

13 Access Fitting Position ? 6 O’clock ? 12 O’clock

? 3/9 O’clock ? Other position………

Remarks:

III – Retrieval Tool and Service ValveRetriever Type ? High Pressure Telescopic 2 inch System

? Hydraulic System

Stroke Dimension ………………………………………………

Stroke Plug Type ? Solid Hollow ? Other (Specify………)

Retriever Kit with all Accessories Provided ? Yes ? No

Temperature /Pressure Rating ……………………/……………………….

Field-proven Service Life ..…………………………………………….

1

Optional Accessories/Spares Provided ? Yes ? No

Service valve Kit Type ? 2 inch System

Repair and Seal Kit Provided ? Yes ? No

Body Material ……………………………………………….

Material to NACE MR 0175 & QP-STD -R-001 ? Yes ? No

Pressure/Temperature Rating ………………………/……………………….

Provided with Blanking Valve ? Yes ? No

2

Optional Accessories Provided ? Yes ? No


4 Datasheets (Retriever Kit/Service Valve) ? Yes ? No

5 Retriever Serial/Model No. …………………………………………….

6 Service Valve Serial/Model No. …………………………………………….

7 Manufacturer Name …………………………………………….

Remarks:






16.1 Appendix A: Corrosion Monitoring Equipment Supply Datasheet, Cont.

IV – Corrosion Data Gathering, Storage and Retrieval Equipment

Type of Monitoring Method ? Manual ? Automatic

Manual Monitoring Equipment ? Hand Held corrosion Meter (one probe)

Type…………………………………….

Model…………………………………..

? Multi Channel corrosion meter

Type…………………………………….

Model…………………………………..

No. of Probes………………………….

? Data Storage Facility………………….

? Data Retrieval Facility…………………

? Microprocessor Interface……………..

? Rack Mounted Instrument……………

1

Manufacturer Name ………………………………………………

Automatic Monitoring Equipment ? Data Logger (Single/Multi -Channel)

Type…………………………………….

Model…………………………………..

? Transmitting Units (Individual/Multi -

probe)

Type…………………………………….

Model…………………………………..

? Removable Memory Modules

Type…………………………………….

Model…………………………………..

? Microprocessor

Type…………………………………….

Model…………………………………..

2

Manufacturer Name ………………………………………………

3 Intrinsically Safe to IEC 60079 Part 11 ? Yes ? No


5 Approved Manufacturer Datasheets Provided ? Yes ? No

Remarks:






16.2 Appendix B: Side Stream Monitoring Supply Datasheet

The Supplier shall complete the following data sheet in accordance with this Standard andQP approved project specifications. The completed datasheet shall be reviewed andapproved by QP prior to dispatch of any item. This datasheet is subject to

changes/additions in order to include specific or service environment requirements. Allsuch changes/additions shall be brought to the attention to the Custodian Department.

Supplier: Sheet of

Contract/Project Title: Prepared by:

Contract/ Project No.; Reviewed by:QP Spec. No.: Approved by:Drawing No.:Location: Date:

Side Stream Equipment Minimum Requirements

1 Side Stream Type ? Portable, easy assembles/de -assembled

? Non Portable

Critical Lines Need(s) Tapping …………………………………………………

Distance Between Inlet and Outlet

Tapping

2 No of Fittings - Down Stream ………………………………………………..

3 No of Fitting - Up Stream ………………………………………………..

4 Type of Fittings Used ………………………………………………..

5 Pressure Rating ………………………………………………..

6 Temperature Rating .………………………………………………

7 Type of Monitoring Device Used ? Coupon ? ER Probe

? Others………………………………….

8 Coupon Monitoring Locations ……………………………………………….9 Probe Monitoring Locations ……………………………………………….

10 Monitoring Loop Type ? Spool Shape ? Rack Shape

11 Loop Size ? 2” ? Other…………

12 Loop weight …………………………………………….

13 Side Stream Loop material ? PVC * ? Carbon Steel ? Stainless Steel? Other…………….

14 Material to NACE MR 0175 and QP-STD-

R-001

? Yes ? No

15 Portable Chemical Injection Pump ? Air Operated ? Electric operated

16 Injection Flow measurement Device ? Yes (Range………….) ? No

17 Injection Control Measurement Device ? Yes ? No

18 Fluid Velocity …………………………………………19 Internal Static Mixer Provided ? Yes ? No

20 Air-driven Pump for Fluid Re-injection. ? Yes ? No

21 Manufacturer Name ………………………………………………..

Remarks:

* PVC shall be corrosion resistant to formation water of salinity up to 28g/L as NaCl andsaturated with CO2 and H2S, and shall withstand operating pressure, temperature andfire hazard.






17.3 Appendix C: Access Fitting Installation and Commissioning Procedure

17.3.1 Location of Fittings - Clearance Needed Around Access Fittings

• Fittings must be located on pipe-work and vessels in such a way as to allow enoughroom for an operator to work on the fittings using the approved Retriever in safety andwith complete freedom of movement. Figure 1 shows the minimum clearancesrequired around a fitting for the safe operation of retrieval tools on various sizes ofpipe-work.

• This is particularly important when fittings are to be installed on newly constructedpipe-work in the fabrication yard.

• The position of fittings must be selected with a clear understanding of the intendedfinal configuration of the installed section of pipe -work or vessel in relation to adjacentplant or equipment to ensure subsequent complete and safe accessibility.

• For bottom of the line-mounted fittings, the 18 -inch stroke retriever is used. For top ofthe line fittings the minimum clearance should be designed to allow the removal ofmonitoring devices whose lengths span the pipe bore.

• Fittings should not be located within 150mm of a pipe circumferential weld.

• The original selection of the location for corrosion monitoring fittings should be basedon the need to obtain corrosion data representative of the worst system condition.

• If it is not practical, for whatever reason, to locate the fittings to within 2m of eitherside of the original position as identified on the construction drawings, and then arevised location must be approved by QP.

17.3.2 Hole Cutting

a) New Construction or Un -pressurized Equipment

• For new construction work or un -pressurized and purged installations, the accesshole can be made before or after installing the fitting.

• To ensure positive alignment of the cut hole and the fitting, it is preferable to cutthe hole after welding.

• In cutting the hole before welding, care must be taken to align the cut hole with the

access-fitting bore of 35 mm. To gain tolerance on the alignment, it isrecommended that a 36.5 mm diameter hole be cut.

• For holes cut before welding, it will be necessary to check the alignment afterwelding using approved reaming tool and, where necessary, carry out furtherdrilling, cutting or reaming through the fitting, once installed to achieve the requiredalignment.

• The work of cutting holes to match the bore of the fitting can be made easier byrough cutting openings of 25 – 35 mm diameter.






• Prior to welding the fitting in place, such openings should be made as near circularas possible and the fittings aligned concentrically over them. Rough -cut openingsmust always be cut, drilled or reamed to the specified diameter through the

installed fitting to ensure correct concentricity.

• For all drilling, cutting or reaming operations carried out through the fitting, careshould be taken to avoid damage to the bore and seat area of the fitting.

b) Pressurized, Live Equipment.

For pressurized live installations, the hole must be cut after welding the fitting, usingan approved hot tap kit. Hot tapping must be carried out in accordance with arecognised international standard and approved by QP before use.

17.3.3 Fitting Preparation

Before welding, the fitting must be stripped down to the fitting body. The internal bore,seal threads, seat, as well as the external bore, seal threads, seat, as well as the external

Acme thread must be protected to prevent the effects of heat and weld spatter on thesystem components.

17.3.4 Welding

Welding shall be carried out in accordance with the requirements of the piping/vesseldesign code and the relevant QP standards.

d) Follow-Up Inspection

Upon completion of welding and stress relief, where required, the following inspectionshould be under taken:

e) Inspect the external Acme threads to ensure freedom from weld spatter. If there isany evidence of weld spatter this should be carefully removed by filing.

f) Inspect the internal threads, bore and seat to ensure freedom from weld spatter. Ifthere is any evidence of weld spatter on the internal threads, appropriate toolsshould be used to chase or re-tap the threads. Weld spatter in the fitting bore or onthe seat may be removed using the approved ball end mill assembly.

g) Carry out MPI checks, (or dye-penetrant checks for stainless steel), on the externalsurface of the fitting to pipe weld. The methods to be used and criteria for

acceptance shall be in accordance with the requirements or design code and QPrelevant Standards.

d) Upon completion of the above inspection and any stress relieving, the fitting shouldbe pressure tested as per the QP approved manufacturer procedure or a solid orhollow plug assembly should be threaded into the body and fully seated, as per aQP approved procedure.






17.3.6 Pressure Testing of Fittings

a) Drilled/Cut Fittings

This is applicable to fittings installed during new construction work or un-pressurizedequipment. Fittings should be installed with their access holes cut or drilled throughthe pipe or vessel, before the overall system pressure test is carried out. This willensure that the integrity of both the fitting weld and the internal plug assembly aretested against design pressure during the overall system hydro test, and this willobviate the need for a separate hydro test of the fitting.

Pressure testing shall be carried out in accordance with a QP approved procedure.

For the overall system hydro test, the internal plug assembly shall be installed inaccordance with a procedure approved by QP.

b) Un-drilled/Uncut Fittings

For those cases where fittings are installed prior to a system hydrostatic test, but arenot cut or drilled in time for the test, there still remains a need to pressure test thefitting weld.

The following requirements should be drawn up to cover this need, for both de-pressurized and pressurized equipment. Both situations involve use of the QPapproved hydrostatic test assembly. This device should provide a means of testingthe fitting weld integrity prior to hot tapping. It can be used on fittings mounted in allorientations.

The assembly shall be screwed into the fitting in the same way as the internal plug. Ifdifficulty is experienced with installing the assembly, the fitting should be re-tapped

using QP approved thread tap assembly.

When re -tapping, the tap assembly shall be screwed into the fitting. If this cannot beachieved manually, the high-pressure retriever may be fitted with the tap assemblyand used to tap the fitting.

This method guarantees correct alignment of the tap assembly in the fitting since theretriever is screwed onto the external Acme thread of the fitting body.

After installing the test assembly, the fitting should be hydrostatically tested to 1.5times the line pressure using the relevant QP approved procedure.

17.3.7 Installation of Access Fittings on Live Pressured Equipment

It is unlikely, in QP operations, that the installation of corrosion monitoring access fittingswill be required to be carried out whilst the system is operational and pressurized. In theevent that this becomes necessary, hot tapping may be used. As hot tapping is ahazardous activity it must be carried out in accordance with a QP approved Contractor’sprocedure based on a recognised international standard.





REVISION HISTORY LOG

Revision Number: 1 Date: 12/12/2002

Reason for Change/Amendment: Generating New document Item Revised:

Changes/Amendments Made:

This is a new standard based on the project specifications,International/national standards and other publications as referenced in thisdocument. This Standard was prepared to satisfy the requirements of thestandardization documents (QP-PRC-A-001 and QP-PRC-A-003).

It was also prepared to include the latest developments on the worldwide

standards referenced in the document, latest market research on corrosionmonitoring systems and the QP specific requirements on this subject.

Note:

The revision history log shall be updated with each revision of the document. It shall contain awritten audit trail of the reason why the changes/amendments have occurred, what thechanges/amendments were, and the date at which the changes/amendments were made.

QP-STD-L-009 R1 TechSpecfor Corrosion Monitoring System

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Transcript of QP-STD-L-009 R1 TechSpecfor Corrosion Monitoring System