HALFAYA PROJECT SURFACE FACILITY

EARLY FCP
Petrochina (Halfaya)
CPE Beijing

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 2 OF 47

CONTENT
1.0 INTRODUCTION......................................................................................................... 4

2.0 REFERENCES............................................................................................................ 4

3.0 PROJECT SUMMARY................................................................................................ 5

3.1 General ....................................................................................................................... 5

3.2 Major Facilities .......................................................................................................... 6

3.3 Implications/Considerations for Corrosion and Corrosion Control ..................... 6

4.0 CORROSION RATE ................................................................................................... 7

4.1 Introduction ............................................................................................................... 7

4.2 Corrosion Rate Determination ................................................................................. 7

4.3 Corrosion Rate Data.................................................................................................. 8

5.0 MATERIAL SELECTION ............................................................................................ 9

5.1 Introduction ............................................................................................................... 9

5.2 Trunk-line, Flow-line and Test Line ......................................................................... 9

5.3 Plant Piping.............................................................................................................. 10

5.4 Export Gas Pipeline ................................................................................................ 10

5.5 Equipment................................................................................................................ 10

6.0 CORROSION INHIBITION........................................................................................ 11

6.1 Introduction ............................................................................................................. 11

6.2 Inhibitor Type........................................................................................................... 11

6.3 Inhibitor Performance ............................................................................................. 11

6.4 Inhibitor Compatibility ............................................................................................ 11

6.5 Inhibitor Stability ..................................................................................................... 11

6.6 Testing...................................................................................................................... 12

7.0 CORROSION MONITORING.................................................................................... 12

 HALFAYA PROJECT SURFACE FACILITY
EARLY FCP
Petrochina (Halfaya)
CPE Beijing

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 3 OF 47

7.1 Introduction ............................................................................................................. 12

7.2 Monitoring Locations.............................................................................................. 12

8.0 COATING.................................................................................................................. 13

8.1 Effectiveness of Coatings as a Means of Corrosion Control.............................. 13

8.2 Coating Selection .................................................................................................... 13

9.0 CATHODIC PROTECTION....................................................................................... 14

9.1 Introduction ............................................................................................................. 14

9.2 Theory ...................................................................................................................... 14

9.3 Effect of the Coating on Cathodic Protection....................................................... 16

9.4 Cathodic Protection Method .................................................................................. 17

9.5 Items to be Cathodically Protected ....................................................................... 18

9.6 Insulating Facilities ................................................................................................. 19

9.7 Cathodic Protection Cable ..................................................................................... 19

9.8 Cathodic Protection Criterion ................................................................................ 20

9.9 Monitoring of Cathodic Protection Systems ........................................................ 20

10.0 RECOMMENDATIONS/CONCLUSION.................................................................... 20

APPENDIX – 1 ENVIRONMENTAL DATA .......................................................................... 22

APPENDIX – 2 PRODUCTION PROFILE FORECAST ....................................................... 23

APPENDIX – 3 WELL REPRESENTTIVE ZONE................................................................. 24

APPENDIX – 4 TYPICAL REPRESENTATIVE CRUDE ANALYSES ANDWATER ANALYSES

26

APPENDIX – 5 CORROSION RATE CALCULATION......................................................... 32

 HALFAYA PROJECT SURFACE FACILITY
EARLY FCP
Petrochina (Halfaya)
CPE Beijing

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 4 OF 47

1.0 INTRODUCTION

This document sets the ground rules for the design lifetime corrosion management
throughout the HALFAYA PROJECT SURFACE FACILITY （EARLY FCP）. To
that extent, it serves as a master document in all matters relating to corrosion for the
project facilities. The corrosion mitigation results are included for the entire system
from the wellheads to the end of the facility.
The purpose of this document is to introduce the corrosion control strategy for the
project, with detailed recommendations for corrosion mitigation for all major
components of design/construction. It is intended to summarize the material
selection and corrosion control recommendations while providing a background into
the decision-making that guided the strategy and recommendations.
The primary considerations in developing the approach were that the facilities should
be capable of safe and reliable operation during the 20 year design life, in a cost
effective manner. The recommendations regarding the selection of equipment and
materials were based on the assessment of the corrosive behavior of the process
streams and produced liquids as identified in Appendix 4.
The subjects analyzed within this report include implications for corrosion and
corrosion control, cathodic protection, corrosion inhibition, corrosion monitoring and
material selection based on assessment of these corrosion risks. These corrosion
risk assessments are verified with the addition of corrosion rate calculations on which
the material selection recommendations have been based.

2.0 REFERENCES

Throughout this document the following dated and undated standards/codes are
referred to. These referenced documents shall, to the extent specified herein, form a
part of this standard. For dated references, the edition cited applies. The applicability
of changes in dated references that occur after the cited date shall be mutually
agreed upon by the Company and the Vendor. For undated references, the latest
edition of the referenced documents (including any supplements and amendments)
applies.
NACE SP0169 Control of External Corrosion on Underground or Submerged Metallic Piping
Systems
NACE SP0173 Mitigation of Alternating Current and Lightning
Effects on Metallic Structures and Corrosion
Control Systems
NACE MR0175 Sulfide Stress Cracking Resistant Metallic Materials for Oilfield Equipment
NACE SP0286 Electrical Isolation of Cathodically Protected
Pipelines
NACE SP0572: Design, Installation, Operation and Maintenance of Impressed Current Deep
Ground Beds
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EARLY FCP
Petrochina (Halfaya)
CPE Beijing

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 5 OF 47

With ISO 9001, Quality Management and Quality Assurance Standards 9002
ISO 9000
& 9004
API Spec. 5L Specification for Line Pipe
API Spec. 6D Specification for Pipeline Valves (Steel Gate, Plug, Ball and Check Valves)
API 15LR Specification for Low Pressure Fiberglass Line Pipe and Fittings
API 15HR Specification for High Pressure Fiberglass Line Pipe and Fittings
API 610 Centrifugal Pumps for Petroleum, Petrochemical and Natural Gas Industries
API 650 Welded Storage Tanks for Oil Storage
ASME B31.3 Process Piping
ASME Sec VIII – Div 1 ASME Boiler & Pressure Vessel Code
API RP 651 Cathodic Protection of Above Ground Petroleum Storage Tanks
Standard Specification for Alloy-Steel and Stainless Steel Bolting Materials for
ASTM A193 / A194
High-Temperature Service
Cathodic Protection: Part 1: 1991 Code of Practice for Land and Marine
BS 7361
Applications

3.0 PROJECT SUMMARY

3.1 General

Halfaya oil field is situated in the southern part of Iraq, in the Missan Governorate, 35
km southeast of Amara city. The field is a NW-SE trending anticlinal structure about
30 km long, 10 km wide, total area is about 288km2.Major Facilities
The Halfaya field was discovered in 1976 and to date eight wells have been drilled in
the field. Significant oil accumulations have been discovered in the Tertiary
Jeribe/Euphrates/Upper Kirkuk formations and the Cretaceous Sa’di/Tanuma/Khasib,
Mishrif, Nahr Umr, and Yamama formations. Between April 2005 and November
2008, almost 8 million barrels (MMBbls) of oil had been produced from Halfaya
Contract Area.
PetroChina as operator and its partner signed development and production service
contract for the halfaya contract area with MISSAN OIL COMPANY in Jan.27, 2010.
The consortium lead by PetroChina guarantee achieve First Commercial Production
no later than three (3) Years from the approval date of the Preliminary Development
Plan; and achieve, no later than seven (7) Years from the Effective Date, a Plateau
Production Target at a Net Production Rate of five hundred and thirty five thousand
(535,000) BOPD for the Plateau Production Period.
The existing Degassing Station will be upgraded to CPF1 (Central Processing
Facilities). The design capacity is 70,000BOPD, and it can handle maximum
100,000BOPD. 5% water cut is considered, that inline with the reservoir engineering
till Y2015.
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EARLY FCP
Petrochina (Halfaya)
CPE Beijing

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The crude oil production reaches or exceeds 70,000BOPD to achieve the FCP
according to DPSC, which will be exported to FAO Terminal through the existing 18”
and 28” pipelines.
Associated gas production is estimated to around 50MMCFD, of which about 5.8
MMSCFD will be fuel gas for lease use, the rest will be transported to Kahla Power
Plant through a 20~30km, 24” gas pipeline

3.2 Major Facilities

¾ 24new wells tie-in to CPF1 (wellpad, flowline, trunkline, manifold)

¾ Upgrading Degassing Station to CPF1 (Crude Oil Treatment, Gas Compression,
Produced Water Disposal, Fire Fighting, Utilities, Instrumentation System,
Buildings, etc.)
¾ Intermediate Pumping Station in 28” Pipeline
¾ Raw Gas Pipeline to Kahla Power Plant
¾ Fresh Water Plant
¾ Fresh Water Pipeline to Base Camp and CPF1

3.3 Implications/Considerations for Corrosion and Corrosion Control

Corrosion is a chemical process and as such is affected not only by the metal but
also by the environment to which the metal is exposed and the manner of its
exposure (e.g. in a restricted area, under turbulent conditions, in mixed metal
systems, etc.).
To estimate the rate of corrosion for a given line or piece of equipment, the
environment and exposure conditions must be defined. By contrast, for many metals,
and particularly the so-called corrosion resistant alloys (CRA's), the corrosion rate is
as sensitive to metal composition as it is to the environment composition and the
circumstances of exposure. More importantly, relatively small changes in any one of
those parameters may introduce a change in corrosion morphology, which leads to
intense localized attack on an otherwise inert surface. Under these circumstances
the corrosion rate is rarely predictable.
3.3.1 Environments
The potentially corrosive environments are created internally, by the produced and
processed fluids, and externally by atmosphere and underground salty and moist soil.
The various environments are listed in Table 3.3-1.
TABLE3.3-1
LISTING OF POTENTIALLY CORROSIVE ENVIRONMENTSCLASS ENVIRONMENT
COMMENT
CLASS ENVIRONMENT COMMENT
External Land Atmospheric Surface Surface Facilities
Moist Salty Soil Buried Facilities
In-Process Produced Fluid Surface or Buried Facilities
CO2 , H2S, Water
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EARLY FCP
Petrochina (Halfaya)
CPE Beijing

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Separated Gas
In-Process Separated Water Surface or Buried Facilities
In-Process Recombined Fluids Surface or Buried Facilities
3.3.2 Process Environments
So far as corrosion is concerned, the significant components of produced fluids in oil
production are water (H2O), carbon dioxide (CO2), hydrogen sulfide (H2S) and
chloride ions (CI-). Each contributes to the corrosively and to some extent their
effects are synergistic. Increases in pressure will always, and elevated temperatures
will often, exacerbate the problem.
For the HFY Fields, each well has been assigned a representative crude for it's
production. This assignment for each well is presented in Appendix 3. The critical
corrosion data used for three of these typical zones is presented in Appendix 4. The
general pressure and temperature conditions at the major facilities for this field are
presented in Appendix 4.

4.0 CORROSION RATE

4.1 Introduction

The corrosion rate will be predicted and calculated by OLI soft. OLI's basic
electrolyte thermodynamic model (the AQ model) is based on a true speciation
model, a predictive equation of state (Helgeson EOS), an activity coefficient model,
and convergence heuristics. Combined with 38 years of R & D and a full-time staff of
four thermophysical modelers, the OLI AQ model covers 80+ elements of the
periodic table.
OLI's Corrosion Analyzer has been effectively used in combination with a fluid flow
model for pipelines, to calculate the chemistry effects on the corrosion rate for a
given T, P, and composition.
In this case, the fluid flow model output is used to steer the corrosion rate
calculations in Corrosion Analyzer.
Corrosion Analyzer can also supply dew point information, it can calculate the
condensate and the composition of the condensate at any point, and it can generate
real-solution Pourbaix diagrams that show the corrosive and passivating speciation
for a given T, P, and composition in contact with a metal surface.

4.2 Corrosion Rate Determination

Appendix 5 summarizes the predicted corrosion rates based on the produced fluid
chemical analysis and forecasted operating conditions. The rates were predicted
based on the following assumptions:
¾ Applied CO2 content by mole % is as indicated in the table in Appendix 5;
¾ H2S content by mole % is as indicated in the table in Appendix 5;
¾ Cl- content by mole % is as indicated in the table in Appendix 5;
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EARLY FCP
Petrochina (Halfaya)
CPE Beijing

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¾ The adopted inlet pressures & temperatures are as indicated in the table in
Appendix 5;
The rates were predicted using a relatively corrosive flow regime. Therefore the
corrosion rate predicted by the software might be higher than that which will actually
occur. In order to better predict the actual corrosion rates, an accurate prediction of
the future flow rates in the various lines is required. At this stage, only ranges of
anticipated flow are known. By assuming the more aggressive flow regime, but giving
credit to some conditions that the basic Thermodynamics, kinetics and diffusion does
not account for, an approximate expectation of corrosion has been obtained
OLI were used to predict the corrosion rates. OLI was found to be the least
conservative but most practical. The programs use variations of thermodynamics,
kinetics and diffusion. The variation incorporates the influence of the various other
factors (as listed above) that impact corrosion, other than those factors included in
the basic Thermodynamics, kinetics and diffusion.
According to the calculated corrosion rate for the flowlines, trunklines and export line
other piping carbon steel, with a corrosion allowance 3mm respectively, of will likely
not meet the 20 year design requirement for all areas. However, it is difficult to
accurately predict the actual expected rate and amount of total corrosion for any
given location because there are many (difficult to predict, ever-changing) factors
that influence the rate of corrosion:
¾ The maximum and minimum flow ranges provided are tremendous and
depending on the actual flow rate, the stream could be in various flow regimes.
The rate of corrosion is greatly impacted by the actual flow regime (ie. stratified
flow, annular mist, slug flow, etc.). Also, the degree and location of gas breakout
is dependent on the actual flow rate, because flow rate impacts pressure losses
and pressure loss impacts the point at which gas will begin to breakout;
¾ Actual stream conditions versus those that have been predicted by selecting
certain zones (including component mol fractions, ph levels, etc.);
¾ Oil wetting the surface will reduce corrosion rates, especially if velocity is below -
3 m/s;
¾ Changing stream constituents (i.e. water, oil, gas) will dramatically change the
corrosion rate. As the field depletes, the amount of oil, water, gas (including CO2,
H2O, and Cl-) will change dramatically and the rate of corrosion will also change.
(The thermodynamics, kinetics and diffusion does not adequately account for
this.

4.3 Corrosion Rate Data

The flowlines, trunklines, test lines and gas export pipeline, water supply line and
other in station piping are exposed internally to the produced fluid. As the soft ware
do not differentiate the different type of carbon steel, so the prediction of corrosion
rate base on ordinary carbon steel. And then the corrosion rate data should be
bigger than the actual situation. Also the data base on the condition with no
corrosion inhibitor. The corrosion rate data as following:
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EARLY FCP
Petrochina (Halfaya)
CPE Beijing

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 9 OF 47

4.3.1 Flowlines, trunklines and test lines

The internal corrosion rates predicted for the flowlines, trunklines, and test lines
ranged from 4.2 to 5.1 mm/yr depending on the various factors as discussed in
section Appendix 5.
4.3.2 Gas export pipeline
The corrosion rate in the gas export pipeline is predicted to range from 0.51 to 1.02
mm/yr depending on the various factors as discussed in section Appendix 5.
4.3.3 Water supply main line
The corrosion rate for water supply line is predicted to range to 0.026 mm/yr to
depending on the various factors as discussed in section Appendix 5.
4.3.4 Other piping
The other piping corrosion rate has been showed in APPENDIX – 5

5.0 MATERIAL SELECTION

5.1 Introduction

The corrosion control philosophy is predicated on the application of detailed design

to avoid introducing unnecessary corrosion risks. Within this section features of
design that are essential to the use of the material selected are noted. These may
well affect the detailed design. The Engineering Consultant is responsible for
ensuring that all these design requirements are met and incorporated into the
detailed design.

5.2 Trunk-line, Flow-line and Test Line

The Process parameter for trunk-line and flow-line is: PD=4.0MPa, TD=85 ℃ ;
PO=2.0MPa, TO=50℃.
The content of corrosion medium: H2S:0.5mol%; CO2:4.4mol%; Clˉ:130000ppm;
Water cut: 30%.
The maximum partial pressure encountered for H2S based on a maximum design
content of 0.5mol (%), and maximum design pressure of 4MPa result in maximum
H2S partial of 20 KPa which is above the threshold of 0.3KPa as defined in
MR0175/ISO 15156 as minimum requirement for sour service compliance. Therefore
sour and NACE conditions are applicable to this project as the fluids do contain and
fall in the sour region.
So for the trunk-line and flow-line piping material, we choose API 5L-PSL2-BNS
seamless pipe ordered for sour service.
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EARLY FCP
Petrochina (Halfaya)
CPE Beijing

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 10 OF 47

5.3 Plant Piping

For the piping in plants, if partial pressure for H2S is above the threshold of 0.3KPa
as defined in MR0175/ISO 15156 as minimum requirement for sour service
compliance, we choose API 5L-PSL2-BNS for pipe material.
For the piping in plants, if partial pressure for H2S is below the threshold of 0.3KPa
as defined in MR0175/ISO 15156 as minimum requirement for sour service
compliance, we choose API 5L-PSL2-GrB or ASTM A106 GrB for piping material

5.4 Export Gas Pipeline

The Process parameter for export gas pipeline is: PD=4.7MPa, TD=95℃; PO=3.9-
4.1MPa, TO=50-70℃.
The content of corrosion medium: H2S:0.5mol%; CO2:4.4mol%; Clˉ:130000ppm;
Water cut: 1%.
The maximum partial pressure encountered for H2S based on a maximum design
content of 0.5mol (%), and maximum design pressure of 4MPa result in maximum
H2S partial of 23.5KPa which is above the threshold of 0.3KPa as defined in
MR0175/ISO 15156 as minimum requirement for sour service compliance. Therefore
sour and NACE conditions are applicable to this project as the fluids do contain and
fall in the sour region.
So for the gas export line piping material, we choose API 5L-PSL2-X52NS SAWL
pipe ordered for sour service.

5.5 Equipment

5.5.1 General
All materials used in sour service shall comply with, but not be limited by, the
requirements of NACE MR-01-75/ ISO 15156.
For carbon steel, the specified yield strength shall be less than or equal to 355MPa,
the actual testing tensile strength shall be less than or equal to 630MPa.
Stainless steels/ nickel base alloy shall be stabilized and solution-annealed form.
Cold working shall not be allowed. Hardness of the finished product shall not exceed
HRC 22. Stainless steels of the 400 series or other martensitic steels shall not be
used.
5.5.2 Chemical composition
(a) The material shall comply with ASTM code.
(b) The typical maximum acceptable levels of sulfur in the steel for flat-rolled and
seamless products are 0,003 % and 0,01 %, respectively. Conventional forgings with
sulfur levels less than 0,025 %. P content shall be less than or equal to 0.015％, Mn
content shall be less than or equal to 0.9%, Ni content shall be less than 1%.
(c) Carbon equivalent Cev≤0.36; Cold cracking sensitive factor Pcm≤0.19.
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EARLY FCP
Petrochina (Halfaya)
CPE Beijing

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 11 OF 47

6.0 CORROSION INHIBITION

6.1 Introduction

Since the fluids within the pipelines and facilities has the character of high sulfide
content and high TDS, at elevated temperature and although high pressure
sometimes, they are potentially very corrosive to steel in the presence of an aqueous
phase. Injection of corrosion inhibitor will therefore be required from the date of
commissioning, to pre-condition the steel and minimize corrosion in order to achieve
the required design life of equipments and pipelines.
The inhibitor supplied shall, as a minimum, meet the requirements of design. At the
request of the Vendor, The OWNER will provide samples of production fluids to
enable performance testing by the Vendor.

6.2 Inhibitor Type

The inhibitor may be a blend of chemicals, formulated to give the optimum efficiency.
It shall be capable of transport by the oil phase and partitioning into any second
phase water. It shall be suitable for high sulphide content and high TDS conditions
and have a proven track record in high chloride and bicarbonate radical-containing
oilfield service. The chemical blend may include a diluent if required.

6.3 Inhibitor Performance

The inhibitor shall have a minimum efficiency of 90% when operating in the fluids of
Halfaya oilfield. The efficiency (E) shall be defined as:
E = 100 x (CRU - CRI)/CRU
Where:
CRU = Uninhibited corrosion rate of carbon steel in the test fluids
CRI = Inhibited corrosion rate of carbon steel in the test fluids

6.4 Inhibitor Compatibility

In addition to reducing the corrosion rates as specified above, the inhibitor blend
added shall not interfere with any aspect of the production fluid. Thus, as a general
requirement, the inhibitor blend must not react chemically or physically with the
production fluids, or any other process additives.

6.5 Inhibitor Stability

The inhibitor blend shall be stable during storage, either in the tote tanks in which it is
supplied or in the tanks forming part of the chemical injection skid. In particular it
shall not decompose chemically when in contact with the atmosphere, in the
temperature range 0℃ to 70℃. Further, the inhibitor blend shall not deteriorate
physically by phase transformation or separation, under such conditions.
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EARLY FCP
Petrochina (Halfaya)
CPE Beijing

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 12 OF 47

6.6 Testing

The OWNER may, at its discretion, test any inhibitor proposed or supplied by Vendor
to confirm conformance to the above minimum performance requirements. Failure of
the inhibitor to meet the requirements of above mentions shall result in the rejection
of the proposed or supplied material.

7.0 CORROSION MONITORING

7.1 Introduction

The on-line corrosion monitoring is required at strategic locations to give an early

indication of the effects of production changes, such as increase in water content
that might impact on the internal corrosion of pipelines and downstream facilities.
Since inhibitor injection is taking place from commissioning, the monitoring data will
prompt alteration of the dose rate or even a change of the chemical used. Thus the
monitoring system shall be designed such that its output information is directly
relevant to the inhibitor injection facilities.
The functional requirements of the monitoring system are to detect and quantify
trends in the corrosively of the fluid being carried, and it shall do so within a time that
is short enough to enable to instigate or adjust corrosion mitigating measures, and
before significant steel loss has occurred.

7.2 Monitoring Locations

The corrosion monitoring facilities shall be provided where fully corrosive conditions
in the produced fluid are anticipated at some time in the design life. The corrosion
monitoring shall be designed to indicate the corrosively of the fluid at the pipe wall;
recognizing that conditions may be more aggressive than those encountered in the
bulk of the flowing fluid.
The Engineering Consultant shall identify the exact locations of the necessary
access fittings for the corrosion monitoring devices. These locations shall be detailed
on schematic piping line drawings. The drawings shall also include the locations of
the access fittings for the corrosion inhibitor injection devices.
7.2.1 Inlet to Flowlines
One group (corrosion probe and coupon) of corrosion monitoring points should be
installed for each flowline at the CPF1 flowlines inlet manifold and pad3 manifold.
The details installation should as per P&ID.
7.2.2 Inlet to Trunklines
One group (corrosion probe and coupon) of corrosion monitoring points should be
installed for each trunkline at the CPF1 trunklines inlet manifold. The details
installation should as per P&ID.
7.2.3 Inlet to Test Lines
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EARLY FCP
Petrochina (Halfaya)
CPE Beijing

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One group (corrosion probe and coupon) of corrosion monitoring points should be
installed for each test line at the CPF1 test lines inlet manifold. The details
installation should as per P&ID.
7.2.4 Inlet to Gas Export Pipeline
One set of corrosion monitoring point should be installed at the inlet manifold of the
pipeline to monitor the base corrosion rate of the entering stream.
7.2.5 Inlet to Water Supply Line
One set of corrosion monitoring points should be installed at the water supply line.

8.0 COATING

8.1 Effectiveness of Coatings as a Means of Corrosion Control

First attempts to control pipeline, piping, equipment, vessel and tanks corrosion
relied on the use of coating materials and the reasoning that if the metal could be
isolated from contact with the surrounding earth, no corrosion could occur. This
concept is entirely reasonable and logical. Furthermore, a coating would be
completely effective as a means of stopping corrosion if the coating material:
¾ Is an effective electrical insulator;
¾ Can be applied with no breaks whatsoever and will remain so during the
backfilling process, and
¾ Constitutes an initially perfect film that will remain so with time.

8.2 Coating Selection

8.2.1 Pipelines Coating

As the corrosive of soil, the external coating shall be used to buried flowlines,
trunklines, water supply line, condensates pipeline and gas export pipeline. The
coating type as following:

Table 8.2.1-1 PIPELINE COATING

PIPE COATING FIELD JOINT COATING

Flow line FBE coating Solvent-free liquid epoxy coating

Trunk line FBE coating Solvent-free liquid epoxy coating
Water supply 3PE coating Polythene heat shrinkable tape coating
line
Gas export 3PE coating Polythene heat shrinkable tape coating
pipeline
Condensates 3PE coating Polythene heat shrinkable tape coating
pipeline
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EARLY FCP
Petrochina (Halfaya)
CPE Beijing

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8.2.2 Buried Piping Coating

The external coating for buried piping should be polyethylene adhesive tape; the
details requirements shall as per to specification HFY-CP-SP-00005.
8.2.3 Aboveround piping, Vessels, Equipment and Tanks Coating
The entire metal surface such as piping, vessels, equipment, tanks steel structure
etc. which expose to the atmosphere shall be coated. The coating should be as
following: Zinc rich epoxy primer 80μm+ Epoxy micaceous iron intermediate coating
70μm+ acrylic polyurethane top coating80μm. The details requirements for each
paints shall as per to specification HFY-CP-SP-00002.
8.2.4 Internal coating for tanks, vessels and equipment
The internal coating for the tanks, vessels and equipment shall be epoxy coating; the
minimum total dry film thickness is 300μm. The details for coating and each paints
shall as per to specification HFY-CP-SP-00001.

9.0 CATHODIC PROTECTION

9.1 Introduction

Cathodic protection is a widely accepted method of corrosion control. Corrosion of

steel structures contacting soil and/or water may be reduced or eliminated with
proper application of cathodic protection.

9.2 Theory

CP is a technique to reduce the corrosion rate of a metal surface by making it the

cathode of an electrochemical cell. This definition is explained in greater detail here.
In various cases, anodic areas and cathodic areas are present on the pipe surface.
At the anodic areas, current flows from the pipeline steel into the surrounding
electrolyte (soil or water) and the pipeline corrodes. At the cathodic areas, current
flows from the electrolyte onto the pipe surface and the rate of corrosion is reduced.
In light of the above, it becomes obvious that the rate of corrosion could be reduced
if every bit of exposed metal on the surface of a pipeline could be made to collect
current.
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Petrochina (Halfaya)
CPE Beijing

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 15 OF 47

Figure 1 basic CP installation

This is exactly what CP does. Direct current is forced onto all surfaces of the pipeline.
This direct current shifts the potential of the pipeline in the active (negative) direction,
resulting in a reduction in the corrosion rate of the metal. When the amount of current
flowing is adjusted properly, it will overpower the corrosion current discharging from
the anodic areas on the pipeline, and there will be a net current flow onto the pipe
surface at these points. The entire surface then will be a cathode and the corrosion
rate will be reduced. This concept is illustrated in Figure 1.A major activity of a CP
engineer is to determine the actual level of CP required to reduce the corrosion rate
to an acceptable level. Monitoring, in conjunction with the application of CP criteria,
are used for this determination.
If, as shown by Figure 1, current is forced to flow onto the pipe at areas that were
previously discharging current, the driving voltage of the CP system must be greater
than the driving voltage of the corrosion cells that are being overcome. The original
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Petrochina (Halfaya)
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 16 OF 47

cathodic areas on the pipe collect current from the anodic areas. Under CP, these
same cathodic areas (which were corroding at a negligible rate in the first place)
collect more current from the CP system.

9.3 Effect of the Coating on Cathodic Protection

In the discussion of coatings in 8.1, it was stated that better than 99% of the surface
of a well-coated pipe would be completely free of corrosion. Also, it was stated that
CP would be relatively easy to apply because only minute areas of exposed steel
would require protection.

Figure 2 Cathodic protection of a coated pipeline

Figure 1 illustrates the pattern of current flow that is expected for protection of a
section of bare pipeline. The picture is quite different with a high-resistance barrier
coating between the pipeline and the environment, as illustrated by Figure 2.
In Figure 2, current from the CP groundbed shown flowing to all areas where pipe
metal is exposed. In so doing, the original corrosive current discharge from defects in
anodic areas is reduced. In addition to the current shown flowing to defects, current
also flows through the coating material itself. No coating material is a perfect
insulator (even when absolutely free of any defects whatsoever) and will conduct
some current. The amount will depend on the electrical resistivity of the material
(expressed in ohm-cm) and its thickness. When a high-resistivity coating is used, the
current passing directly through the coating will be negligible compared with that
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 17 OF 47

flowing to coating defects unless the number and size of the defects are unusually
small.

9.4 Cathodic Protection Method

The following two methods of applying cathodic protection to buried and immersed
surfaces of metallic structures are used:
9.4.1 Sacrificial Anode Systems
i) Features
Sacrificial anode systems use a metal more active than the steel structure to be
protected; in to supply the current required to stop corrosion. The more active metal
is called a sacrificial anode. The anode is electrically connected to the steel
structures to be protected. A galvanic corrosion cell develops and the active metal
anode corrodes (is sacrificed) while the steel structure (cathode) is protected. As the
protective current enters the structure, it prevents the flow of corrosion current from
the steel structure surface. Current then returns to the sacrificial anode through a
metallic conductor.
ii) Advantages
- No external power supply is required
- Installation is relatively easy
- Capital investment is relatively low when there are only a few buried steel
structures
- Maintenance costs are minimal
- Interference problems (stray currents) are rare
- Less frequent monitoring is required
iii) Disadvantages
- Driving potential is limited
- Current output is low
- Method is limited to be used in low-resistivity soils
- Method is not practical for protection of large bare steel structures
- Method is unreliable for protection of pipelines that have insulation (due to current
shielding)
iv) Anode materials
Typical sacrificial anode materials include Magnesium, Zinc and Aluminum.
9.4.2 Impressed Current System
i) Features
Impressed current systems use direct current usually provided by a rectifier attached
to an AC power source. The rectifier converts alternating current to direct current.
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 18 OF 47

Direct current from the rectifier is conducted to the buried impressed current anode,
through the soil electrolyte, and into the steel structure to be protected.
ii) Advantages
- Availability of large driving potential
- High current output capable of protecting large steel structures
- Capability of variable current output
- Applicable to almost any soil resistivity
iii) Disadvantages
- Interference problems (stray currents) on foreign steel structures
- Loss of AC power causes loss of protection
- Higher maintenance and operating costs
- Higher capital cost for small installations
- Safety aspects of rectifier location
- Safety aspects of negative lead connection
- More frequent monitoring required (than for anode system)
- Method is unreliable for protection of pipelines that have insulation (due to current
shielding)
iv) Anode materials
Satisfactory anode materials include mixed metal oxides, graphite, high-silicon
chromium-bearing cast iron, platinized niobium and titanium.

9.5 Items to be Cathodically Protected

The items to be cathodic protected shall include:

¾ External surface of buried flow lines, trunk lines, test line, water supply line,
export gas pipeline and condensates pipelines.
¾ External surfaces of ground tank bottoms contacting soil.
¾ Internal tank and equipment surface.
The design life for cathodic protection system shall be as the pipeline or equipment
service life.
9.5.1 The External Surface of Buried Flow Lines, Trunk Lines, Test lines,Water
Supply Line, Export gas pipeline and Condensates Pipeline
Because of the relatively large amount of buried steel structures season, an
impressed current cathodic protection shall be required for external surfaces of
buried flow lines, trunk lines water supply line and the gas pipeline.
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 19 OF 47

The impressed current cathodic protection system consists of transformer/rectifier

unit, anode bed, cable, anode junction box and test facilities, etc. Deep well anode
will be applied.
The impressed current anodes shall be High Chromium Silicon Iron type and their
chemical composition shall be as follows:
Element Content
Silicon 14.25~15.25
Manqanese 0.5~0.8
Carbon 0.8~1.4
Chromium 4.0 - 5.0
Phosphorus 0.25 max
Sulphur 0.1 max
Iron Remainder

9.5.2 The External Surfaces of Ground Tank Bottoms Contacting Soil

Because of high sand resistivity in the tank foundation, an impressed current
cathodic protection shall be required for external surfaces of ground tank bottoms
contacting soil.
An anode bed including a gird anode system shall be provided, comprising of mixed
metal oxide coated titanium ribbon and titanium conductor bar, placed below the tank
in the foundations during construction with intermediate layer of clean washed sand
(free of chlorides and sulphates).
9.5.3 Internal Tank and Equipment surface
The internal surface of tanks and equipment such as separator shall be protected by
sacrificial anode. The material of anode shall be aluminium alloy.

9.6 Insulating Facilities

Electrical isolation facilities shall be installed in order to isolate flow lines, trunk lines
and pipelines cathodic protection from wellhead, WSP and/or CPF1 above ground
manifold tie-ins.
Lightning protection system or surge arrestors shall be required to avoid dangerous
sparkovers

9.7 Cathodic Protection Cable

All cables for positive & negative headers, bonding, jumpering potential and current
measuring shall be annealed copper conductor, 600/1000 Volt grade HMWPE (High
Molecular Weight Polyethylene) or PVC/XLPE insulated cables. The cables shall be
tagged appropriately and permanently.
The minimum size of the copper conductor shall be as follows:
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 20 OF 47

6mm2 - For current measurement, potential measurement reference cells and zero
cable.
10mm2 - For anode tail cables. The anode tail cables shall not be armored and
length shall be sufficient for termination on anode/lead junction box without any joint.
25mm2 - For anode and cathode cables, bonding / grounding. The cable shall be
armored.

9.8 Cathodic Protection Criterion

The buried steel structures will be protected in accordance with NACE International
standard SP0169 (latest edition).
The potential shall be -0.85V to -1.5V versus a saturated copper-copper sulfate
reference electrode.

9.9 Monitoring of Cathodic Protection Systems

After a cathodic protection system has been installed, it should be checked

periodically; records should be maintained to ensure that the equipment is
functioning correctly and that the protected structure is being maintained at the
required potential. These checks should be done for all of the equipment in the
system and used as a trending tool to assure consistent reliability. This data will
assure that the system is working within the design parameters and is not providing
over-protection or insufficient supply (both of which will lead to corrosion). Once the
trend and workability of the system has been established, the periods between
gathering data can be lengthened (but must be continued).

10.0 RECOMMENDATIONS/CONCLUSION

Although the system exhibits various potential hazards with respect to corrosion, H2S,
CO2, Cl- related corrosion appears to be the only significant threat at these operation
conditions. The corrosion can be mitigated through a combination of the following
strategies:
i. Material selection – it is the fundamental method to avoid the corrosion as much as
possible.
1）Pipeline
Material for flowlines, trunklines and test lines is PSL2 BNS API5L, for gas export
pipeline and condensates pipeline is PSL2 BNS API5L.
2) Piping
For the piping in plants, if partial pressure for H2S is above the threshold of 0.3KPa
as defined in MR0175/ISO 15156 as minimum requirement for sour service
compliance, we choose API 5L-PSL2-BNS for pipe material.
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 21 OF 47

For the piping in plants, if partial pressure for H2S is below the threshold of 0.3KPa
as defined in MR0175/ISO 15156 as minimum requirement for sour service
compliance, we choose API 5L-PSL2-GrB or ASTM A106 Gr B for piping material
3）Equipment
The following table lists the minimum requirement of materials for use in sour service.
Plate SA516 Gr 60 N
Pipe SA106 Gr B, SA333 Gr 6
Flanges (weld neck only) SA105N, SA350 Gr LF2
ii. Corrosion inhibition- for flowlines, trunklines, test lines, gas pipelines and other
piping system.
iii. Corrosion allowance - for all of the pipelines, equipment and piping system which
contains Cl- and H2S.
iv. Cathodic protection - for external protection of the pipelines and tanks external
surface of bottom.
Ⅴ. Monitor - to avoid excessive capital investment at the beginning, problem areas
can be targeted in the future, the corrosion coupon and corrosion probe shall be
installed at flowlins, trunklines, gas export piplines, water supply pipeline and other
piping.
Overtly exotic (and costly) corrosion protection materials are not required for this
system.
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 22 OF 47

APPENDIX – 1 ENVIRONMENTAL DATA

Environmental Data

Altitude M ASL 4~10

Atmospheric Pressure KPa 102
Max Temp. ℃ 55
Black Bulb Temp. ℃ 80
Min. Temp. ℃ -2
Max. Speed Wind m/s 40
Prevailing Direction Wind winter NW-SE
Prevailing Direction Wind summer NW-SE
Max. Relative Humidity 80%
Min. Relative Humidity 25%
Rainfall mm/a 177.4
Soil Temp. @ Depth 1.2-1.6 m ℃ 15 in winter
Seismic Zone 2B
Evaporation Rate mm/a 3054.4

Notes: The data above is from the Email- Confirmation for climate data on Mar. 10th, 2010,
Email- Confirmation for climate data on June 30th, 2010 and Internet.
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 23 OF 47

APPENDIX – 2 PRODUCTION PROFILE FORECAST

Production Profile Forecast (70,000BOPD)

Sadi- Nahr
Mishirif Halfaya
Khasib Umr
FOPR FOPR FOPR FOPR FGPR FWPR FWCT GOR
DATE
B/D B/D B/D B/D MSCF/D B/D % SCF/BBL
2011-10 3019 19200 50000 72219 49723 67 0.09 688.5
2011-11 3019 19200 50000 72219 49723 177 0.24 688.5
2011-12 3019 19200 50000 72219 49723 220 0.3 688.5
2012-1 3019 19200 50000 72219 49723 252 0.35 688.5
2012-2 3019 19200 50000 72219 49723 281 0.39 688.5
2012-3 3019 19200 50000 72219 49723 303 0.42 688.5
2012-4 3019 19200 50000 72219 49723 330 0.45 688.5
2012-5 3019 19200 50000 72219 49723 356 0.49 688.5
2012-6 3019 19200 50000 72219 49723 382 0.53 688.5
2012-7 3019 19200 50000 72219 49723 408 0.56 688.5
2012-8 3019 19200 50000 72219 49723 435 0.6 688.5
2012-9 3019 19200 50000 72219 49725 461 0.63 688.5
2012-10 3019 19200 50000 72219 49725 489 0.67 688.5
2012-11 3019 19200 50000 72219 49740 523 0.72 688.7
2012-12 3019 19200 50000 72219 49745 561 0.77 688.8
2013-1 3019 19200 50000 72219 49723 595 0.82 688.5
Notes: The data is from the Development Plan provided by Petrochina (Halfaya) in 2010.
6.12.
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 24 OF 47

APPENDIX – 3 WELL REPRESENTTIVE ZONE

Wellpads Coordination for FCP (70,000BOPD)

No. Pad name X Y Formation Production well
Nahr Umr 2 4001,4002
1 7--01 730784.5624 3508364.6153
Mishrif 1 3250(V)
Nahr Umr 2 4003,4004
2 7--02 733475.1146 3506632.3419
Mishrif 1 3001
Nahr Umr 2 4005,4006
3 7--03 732700.6672 3508514.6419 Mishrif
Sadi 1 2001
Nahr Umr 2 4010,4011
4 7--04 734294.9833 3509383.5591
Mishrif 1 3255(V)
Individual Well
1 HF-1 735807 3505938 Nahr Umr 1 Existing
Mishrif 1 Existing
2 HF-2 731357 3506188
Sadi 1 Existing
3 HF-3 724857 3512988 Mishrif 1 Existing
4 HF-6 729197 3509741 Nahr Umr 1 Existing
5 HF-7 730910 3509745 Nahr Umr 1 Existing
6 HF-8 733310 3508774 Mishrif 1 Exiting

Notes: The data is from the Development Plan provided by Petrochina (Halfaya) in
2010.5.11/6.12.
Well Production and Gas/ Oil Ratio

Formation Well Production(BOPD) Gas/ Oil Ratio(SCF/ BBL)

Nahr Umr 8000 730
Mishrif-H 5000 650
Mishrif-V 2500 650
Sadi 2000 340

Notes: The data is from the Development Plan provided by Petrochina (Halfaya) in
2010.5.11.
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 25 OF 47

Shut-in Pressure of Wellhead Prediction

Minimum Shut-in Pressure Maximum Shut-in Pressure
Formation
psi psi
Sadi 1624 3509.71

Tanuma 1673 3620.92

Khasib 1879 3764.33

Mishrif 1680 3755.57

Nahr Umr 1918 4359.49

Wellhead Condition
Wellhead Temperature
Formation
(℃ )
Nahr Umr 63.0~16.7
Mishrif-H 77.9~59.7
Mishrif-V 63.1~38.5
Sadi 45.2~33.9
Khasib 47.6~27.6
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APPENDIX – 4 TYPICAL REPRESENTATIVE CRUDE

ANALYSES ANDWATER ANALYSES

Well Fluid Component

Well No. HF-1 HF-1 HF-1 HF-1 HF-3

Formation Mishrif Mishrif Mishrif Nahr Umr Nahr Umr
Date of Sample 11.04.1976 20.04.1976 04.05.1976 11.06.1976 04.06.1980
Sample Depth
(m) 2731.3~2746 2905~2886 3034~2998 3690.5~3699.5 3762.6
Nitrogen 2.56 0 0.67 0.64 0
CO2 0.04 1.22 0.35 0.43 1.24
Methane 15.8 36.19 36.83 32.92 42.89
Ethane 11.11 11.95 11.72 8.66 9.35
Propane 7.68 6 6.67 4.4 6.02
i-Butane 1.58 1.47 1.79 1.6 0.86
n-Butane 5.99 4.36 4.72 5.8 3.7
i-Pentane 2.98 1.06 1.58 1.4 1.01
n-Pentane 3.27 1.12 2.29 2.18 2.1
H2S 0 0.11 0 0 0
H2O 0 0 0 0 0
C6+ 48.99 36.52 33.38 41.97 32.83
TOTAL 100 100 100 100 100
SP.GR.15.5 ℃
0.9132 0.9945 0.9514 0.8817 0.8704
/15.5℃ C6+

MOLECULAR
290 302 450 210 203
WEIGHT(C6+)

Notes: The data above is from the data package provided by IRAQ PCLD.
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 27 OF 47

Crude Oil Property

Collection Date 1980-7-19 1980-8-3 1980-8-22 1980-9-8 1980-6-3

Formation Mishrif Mishrif Mishrif Mishrif Nahr Umr

2982~2986m
3010~3021m
Interval 3029~3036m 2989~2992m 2966~2973m 3787~3792m
3029~3036m
2995~2998m

o
API 22.8 22.3 23.2 21 30.3

Spec. Gravity
0.9169 0.9198 0.9146 0.9280 0.8744
15.6/15.6 ℃

H2S, ppm 227 97.7 67 62 Nil

Sulphur, %W 4.24 4.24 3.89 4.08 2.16

Asphaltenes %W 8.5 8.6 - - 1.1

Pour Point, ℃ -31 -30 -31 -31 -30

Wax, %w 2.41 2.8 - 2.3 2.1

Viscosity
10 ℃ 185 128 127 24.1
cst

20 ℃ 95.02 104.80 72.86 75.00 15.16

40 ℃ 47.21 40.80 31.20 34.38 8.117

60 ℃ 23.81 20.10 16.00 18.25 5.136

80 ℃ 12.94 11.20 9.50 11.35 3.49

90 ℃ 10.25 8.95 7.65 9.04 3.043

Notes:
1. The data above is from the data package provided by IRAQ PCLD.
2. The data above is information only.
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 28 OF 47

Crude Oil Property

Formation Mishrif Sadi Nahr Umr

API Gravity 21.4 20.2 28.1

Sepc.Gravity@20℃，kg/m3 0.9255 0.9305 0.8845

Water, %V 0.0 0.0 0.0

Freezing Point, ℃ ＜-20 ＜-20 -15

Sulphur, %W 4.62 3.90 2.33

Asphaltenes, %W 9.44 8.53 3.24

Pour Point, ℃ ＜-20 ＜-20 -12

Wax, %w 1.96 1.69 3.85

Viscosity, cp 10℃ 405.1 284.4 73.3

20℃ 190.2 130.6 42.1

30℃ 106.4 74.7 25.8

40℃ 66.1 46.6 17.4

50℃ 40.7 31.6 12.6

60℃ 25.7 21.4 9.5

70℃ 17.8 15.0 7.8

80℃ 13.8 12.0 6.2

Notes:
1. The data above is tested in 2010.5.24 and 2010.7.22.
2. The data above is as design basis.
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 29 OF 47

Gas Composition
Stage No. Test 1st 2nd 3rd
HF HF HF
Well on Stream HF2(T)
(2A,1.3,6(A+T),7) (2(A+T),1.3,6(A+T),7) ((2A+T),1.3,6(A+T),7)
Nahr Nahr
Formation Mishrif Nahr Umr+Saadi
Umr+Saadi+Mishrif Umr+Saadi+Mishrif
2
Gas Pressure(kg/cm ) 12 11.6 3.80 0.500
Gas Temp.( ℃) 33 35 40 39
Component (Gas Vol. %)
Nitrogen(N2) 0.87 0.57 0.29 0.24
Carbon Dioxide(CO2) 3.85 2.23 2.74 1.83
Hydrogen Sulphide (H2S) 0.50 0.02 0.09 0.14
Methane(C1) 70.29 72.18 50.27 14.69
Ethane(C2) 14.94 14.33 21.54 25.33
Propane(C3) 6.36 6.72 15.89 31.72
i-Butane(iC4) 0.70 0.85 1.91 5.12
n-Butane(nC4) 1.65 1.94 4.36 12.97
i-Pentane(iC5) 0.33 0.41 1.02 2.34
i-Pentane(nC5) 0.30 0.42 1.05 2.43
Hexanes(C6) 0.17 0.25 0.61 2.21
Heptanes(C7) 0.04 0.08 0.21 0.85
Octanes(C8) Trace Trace 0.02 0.13
Total 100.00 100.00 100.00 100.00
Sp. Gr. Calculated (15.6℃) 0.7857 0.7787 0.9946 1.4419
Gas M. Wt. Calculated 22.76 22.56 28.81 41.76
Density LBS/SCF 0.0598 0.0593 0.0757 0.1097

1. The concentration of H2S was measured on site.

2. Trace mean <0.01%.

Notes: The data is from the analysis report provided by MOC in May 5, 2010.
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 30 OF 47

Produced Water Analysis

HF-5 HF-3 HF-3
Formation Mishrif Nahr Umr Mishrif
Cations
Sodium ,Na+(mg/l) 60369.4 67268.8 67257.3
2+
Calcium,Ca (mg/l) 8000 11600 9200
2+
Magnesium,Mg (mg/l) 1944 1458 2430
Potassium, K+ (mg/l) 1707.3 858.0 2081.4
2+
Strontium,Sr (mg/l) 497.9 386.1 1140.5
Iron ,Fe (mg/l) Nil 137.3 Nil
Anions
Chloride ,CI-(mg/l) 114487.5 129575 129575
Sulphate,SO42- (mg/l) 360 360 320
Carbonate ,CO32-(mg/l) Nil Nil Nil
Bicarbonate,HCO3- (mg/l) 451.4 329.4 427.0
Other properties
PH 6.9 6.0 6.6
Specific Gravity@15.6℃ 1.1382 1.1440 1.1405
Resistivity ohm-meter@25℃ 0.0519 0.057 0.0523
Dried @180℃(ppm) 166840 185340 192450
Reference
Unit Surface sample DST No.1
Depth(m) 3102.4—3122.5 3801-3805 3093-3095
Type of water Formation water Formation water Formation water
Colour Grey Yellow Orange
Odour Sweet Sweet Sweet
Date of sample 18-05-1980 30-05-1980 13-06-1980

Notes: The data is from the data package provided by IRAQ PCLD.
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 31 OF 47

Produced Water Analysis

(HF7- Nahr Umr)

IETM RESULT
-
CI (mg/l) 104883
Ca2+(mg/l) 6334
2+
Mg (mg/l) 2909
SO42-(mg/l) 0
-
OH (mg/l) 0
HCO3-(mg/l) 315
CO32-(mg/l) 0
Na+(mg/l) 86405
Total (mg/l) 200846

Notes: The data is tested in 2010.6.12.

Alkahla River Water Analysis

Max Permissible
Test Raw Water, ppm Max Recommend Com, ppm
Com, ppm
PH 8.4 7-7.5 6-9.2
Turbidity (FTU) 4.5 5 25
Total Suspension Solid 11.5 12 60
-
Chloride Cl 262 200 600
2+
Ca 280 75 200
2+
Mg 53 50 150
NaCl 423 200 600
CO32- 18
HCO3- 128
SO42- 327
Total Hardness 480 200 500

Notes: The data is from the email- Alkahla River Water Analysis in 2010.2.24.
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 32 OF 47

APPENDIX – 5 CORROSION RATE CALCULATION

1. Flowlines test lines and trunklines

1) Design pressure: 4.0MPa
Design temperature: 85℃，
Pipe material: API 5L-PSL2-BNS
Operating pressure: 2.0MPa
Operating temperature: 25~75℃
Water cut: 5%
Oil gas ratio: 730scfd/b
Pipe diameter: 8”
Velocity: 1.5m/s
Property of oil gas and water in table A5.1-1
2) Design pressure: 4.0MPa
Design temperature: 85℃，
Pipe material: API 5L-PSL2-BNS
Operating pressure: 2.0MPa
Operating temperature: 25~75℃
Water cut: 30%
Oil gas ratio: 730scfd/b
Pipe diameter: 8”
Velocity: 1.5m/s
Property of oil gas and water in table A5.1-1
Table A5.1-1

Crude Oil Property

API Gravity 21.4

3
Sepc.Gravity@20℃，kg/m 0.9255
Water, %V 0.0
Freezing Point, ℃ <-20
Sulphur, %W 4.62
Asphaltenes, %W 9.44
Pour Point, ℃ <-20
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Wax, %w 1.96
Viscosity, cP 10℃ 405.1
20℃ 190.2
30℃ 106.4
40℃ 66.1
50℃ 40.7
60℃ 25.7
70℃ 17.8
80℃ 13.8
Gas Composition

Component (Gas Vol. %)

Nitrogen(N2) 0.87
Carbon Dioxide(CO2) 3.85
Hydrogen Sulphide (H2S) 0.50
Sp. Gr. Calculated (15.6℃) 0.7857
Gas M. Wt. Calculated 22.76
Density LBS/SCF 0.0598

Produced Water Analysis

Cations
Sodium ,Na+(mg/l) 67268.8
2+
Calcium,Ca (mg/l) 11600
Magnesium,Mg2+ (mg/l) 1458
+
Potassium, K (mg/l) 858.0
2+
Strontium,Sr (mg/l) 386.1
Iron ,Fe (mg/l) 137.3
Anions
Chloride ,CI-(mg/l) 129575
Sulphate,SO42- (mg/l) 360
Carbonate ,CO32-(mg/l) Nil
Bicarbonate,HCO3- (mg/l) 329.4
Other properties
PH 6.0
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CPE

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 34 OF 47

Specific Gravity@15.6℃ 1.1440

Resistivity ohm-meter@25℃ 0.057
Dried @180℃(ppm) 185340

Figure A5.1.1 Flowline corrosion rate

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CPE

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 35 OF 47

Figure A5.1.2 Trunkline corrosion rate

2. In station wet sour gas pipe
1) Gas outlet of low pressure gas separator
Design pressure: 0.8MPa
Design temperature: 105℃，
Pipe material: API 5L-PSL2-BNS
Operating pressure: 0.3MPa
Operating temperature: 40~65℃
Pipe diameter: 16”
Velocity: 10m/s
Chloride (in water), CI-(PPM):130000ppm
Gas component in table A5.2-1
Table A5.2-1 Gas component
S.N. Composition Mole fraction
1 Nitrogen 0.0011
2 CO2 0.0154
3 Methane 0.1876
4 Ethane 0.1799
5 Propane 0.1900
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 36 OF 47

6 i-Butane 0.0511
7 n-Butane 0.1807
8 i-Pentane 0.0403
9 n-Pentane 0.0565
10 H2S 0.0024
11 H2O 0.0754
12 C6+ 0.0196
Total 1.0000
2) Gas outlet of low pressure compressor
Design pressure: 1.6MPa
Design temperature: 90℃，
Pipe material: API 5L-PSL2-BNS
Operating pressure: 1.1MPa
Operating temperature: 40~65℃
Pipe diameter: 12”
Velocity: 9m/s
Medium: wet sour gas
Chloride (in water), CI-(PPM):130000ppm
Gas component in table A5.2-2
Table A5.2-2 Gas component
S.N. Composition Mole fraction
1 Nitrogen 0.0012
2 CO2 0.0174
3 Methane 0.2125
4 Ethane 0.2016
5 Propane 0.2077
6 i-Butane 0.0537
7 n-Butane 0.1858
8 i-Pentane 0.0377
9 n-Pentane 0.0508
10 H2S 0.0026
11 H2O 0.0221
12 C6+ 0.0068
Total 1.0000
3) Gas inlet of high pressure compressor
Design pressure: 1.6MPa
Design temperature: 90℃，
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CPE

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 37 OF 47

Pipe material: API 5L-PSL2-BNS

Operating pressure: 1.1MPa
Operating temperature: 40~65℃
Pipe diameter: 12”
Velocity: 11m/s
Medium: wet sour gas
Chloride (in water), CI-(PPM):130000ppm
Gas component in table A5.2-3
Table A5.2-3 Gas components
S.N. Composition Mole fraction
1 Nitrogen 0.0157
2 CO2 0.0310
3 Methane 0.5409
4 Ethane 0.1907
5 Propane 0.1025
6 i-Butane 0.0196
7 n-Butane 0.0587
8 i-Pentane 0.0114
9 n-Pentane 0.0135
10 H2S 0.0040
11 H2O 0.0105
12 C6+ 0.0014
Total 1.0000
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CPE

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 38 OF 47

Figure5.2.1 Wet sour gas pipe corrosion rate

3. Liquid outlet of low pressure compressor
Design pressure: 0.8MPa
Design temperature: 105℃，
Pipe material: API 5L-PSL2-BNS
Operating pressure: 0.3MPa
Operating temperature: 40~65℃
Pipe diameter: 2”
Velocity: 1.5m/s
Medium: oily sewage
Water cut: 97.8%
Hydrogen sulphide (H2S): 0.0014 %( mol)
Carbon dioxide (CO2): 0.002 %( mol)
Chloride (in water), CI-(PPM):130000ppm
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EARLY FCP
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CPE

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 39 OF 47

Figure A5.3.1 Liquid outlet of low pressure compressor corrosion rate.

4. Gas export pipe
Design pressure: 4.7MPa
Design temperature: 95℃，
Pipe material: X52NS SAWL- API5L
Operating pressure: 2.8-3.5MPa
Operating temperature: 40~65℃
Pipe diameter: 24”
Velocity: 1.5~12m/s
Gas component in table A5.4-1
Table A5.4-1 Gas components
S.N. Composition Mole fraction
1 Nitrogen 0.0151
2 CO2 0.0303
3 Methane 0.5358
4 Ethane 0.1885
5 Propane 0.1040
6 i-Butane 0.0207
7 n-Butane 0.0626
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 40 OF 47

8 i-Pentane 0.0132
9 n-Pentane 0.0156
10 H2S 0.0040
11 H2O 0.0077
12 C6+ 0.0025
Total 1.0000
H2S considered as 0.6%, CO2 3.85%
The components not all inclusive the result may be lower approximate value

Figure A 5.4.1 Gas export pipeline corrosion rate

5. Oily sewage pipe (water and gas suppose)
Design pressure: 2.0MPa
Design temperature: 85℃，
Pipe material: API 5L Gr B
Operating pressure: 1.5MPa
Operating temperature: 60℃
Pipe diameter: 20”
Velocity: 1.0~1.5m/s
Oil cut: 1000mg/l
Total salt content: 190000 mg/l(cl-:130000mg/l)
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CPE

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 41 OF 47

Sulphur content: 14ppm (w)

Figure A5.5.1 Oily sewage pipe corrosion rate

6. Gas outlet of first stage separator (suppose the piping diameter 10’’)
1) Design pressure: 1.6MPa
Design temperature: 85℃，
Pipe material: API 5L PSL2
Operating pressure: 1.1MPa
Operating temperature: 45℃
Velocity: 12m/s
Property of oil gas and water in table A5.6-1

Table A5.6-1 Property of oil gas and water

1 Vapour Fraction 1 13 Comp Mole Frac(Nitrogen) 0.021
2 Temperature(℃） 44.81 14 Comp Mole Frac(CO2) 0.0379
3 Pressure(Mpag) 1.05 15 Comp Mole Frac(Methane) 0.5664
4 Molar Flow(Nm3/d(gas)) 6.76E+05 16 Comp Mole Frac(Ethane) 0.1993
5 Mass Flow(kg/h) 3.27E+04 17 Comp Mole Frac(Propane) 0.0912
6 Std Ideal Liq Vol Flow(m3/h) 82.43 18 Comp Mole Frac(i-Butane) 0.0152
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7 Actual Gas Flow(ACFM) 1613 19 Comp Mole Frac(n-Butane) 0.0396

8 Molecular Weight 26.01 20 Comp Mole Frac(i-Pentane) 0.008
9 Mass Density(kg/m3) 11.93 21 Comp Mole Frac(n-Pentane) 0.0076
10 Molar Enthalpy(kh/kgmole) -94740 22 Comp Mole Frac(H2S) 0.0053
11 Viscosity(cP) 1.17E-02 23 Comp Mole Frac(H2O) 0.0086
12 Cp/Cv 1.249 24 Comp Mole Frac(NBP[0]94*) 0.0001

2) Design pressure: 1.6MPa

Design temperature: 85℃，
Pipe material: API 5L PSL2
Operating pressure: 1.1MPa
Operating temperature: 55℃
Velocity: 12m/s
Property of oil gas and water in table A5.6-2

Table A5.6-2 Property of oil gas and water

1 Vapour Fraction 1 13 Comp Mole Frac(Nitrogen) 0.0204
2 Temperature(℃） 54.8 14 Comp Mole Frac(CO2) 0.0372
3 Pressure(Mpag) 1.05 15 Comp Mole Frac(Methane) 0.5504
4 Molar Flow(Nm3/d(gas)) 6.98E+05 16 Comp Mole Frac(Ethane) 0.1972
5 Mass Flow(kg/h) 3.45E+04 17 Comp Mole Frac(Propane) 0.0944
6 Std Ideal Liq Vol Flow(m3/h) 85.64 18 Comp Mole Frac(i-Butane) 0.0167
7 Actual Gas Flow(ACFM) 1722 19 Comp Mole Frac(n-Butane) 0.0448
8 Molecular Weight 26.56 20 Comp Mole Frac(i-Pentane) 0.0098
9 Mass Density(kg/m3) 11.78 21 Comp Mole Frac(n-Pentane) 0.0095
10 Molar Enthalpy(kh/kgmole) -95700 22 Comp Mole Frac(H2S) 0.0053
11 Viscosity(cP) 1.20E-02 23 Comp Mole Frac(H2O) 0.014
12 Cp/Cv 1.237 24 Comp Mole Frac(NBP[0]94*) 0.0001
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CPE

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 43 OF 47

Figure A5.6.1 Gas outlet of first stage separator corrosion rate

7. Outlet of heat conducting oil heater (suppose the piping diameter 4’’)
Design pressure: 1.6MPa
Design temperature: 105℃，
Pipe material: API 5L PSL2 Gr.BNS
Operating pressure: 0.3MPa
Operating temperature: 90℃
Velocity: 2m/s
Medium: oil gas water:
Water cut: 5%、10%、20%、30%
Property of oil gas and water in tableA5.7-1

Table A5.7-1 Property of oil gas and water

1 Vapour Fraction 0.0932 13 Comp Mole Frac(Nitrogen) 0.000187
2 Temperature(℃） 90 14 Comp Mole Frac(CO2) 0.002284
3 Pressure(Mpag) 0.3 15 Comp Mole Frac(Methane) 0.012043
4 Molar Flow(Nm3/d(gas)) 16 Comp Mole Frac(Ethane) 0.017757
5 Mass Flow(kg/h) 2.18E+04 17 Comp Mole Frac(Propane) 0.024679
6 Std Ideal Liq Vol Flow(m3/h) 247.2 18 Comp Mole Frac(i-Butane) 0.009645
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 44 OF 47

7 Actual Gas Flow(ACFM) 19 Comp Mole Frac(n-Butane) 0.034389

8 Molecular Weight 132.9 20 Comp Mole Frac(i-Pentane) 0.016531
9 Mass Density(kg/m3) 159.8 21 Comp Mole Frac(n-Pentane) 0.020513
10 Molar Enthalpy(kh/kgmole) -369100 22 Comp Mole Frac(H2S) 0.000850
11 Viscosity(cP) 23 Comp Mole Frac(H2O) 0.447758
12 Cp/Cv 1.003 24 Comp Mole Frac(NBP[0]94*) 0.413364

Figure A5.7.1 Outlet of heat conducting oil heater corrosion rate water cut 5%
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CPE

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 45 OF 47

Figure A5.7.2 Outlet of heat conducting oil heater corrosion rate water cut 10%

Figure A5.7.3 Outlet of heat conducting oil heater corrosion rate water cut 30%
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CPE

BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 46 OF 47

8. Water outlet of electric dehydrator (suppose the piping diameter 4’’)

Design pressure: 1.1MPa
Design temperature: 105℃，
Pipe material: API 5L PSL2 Gr.BNS
Operating pressure: 0.55MPa
Operating temperature: 90℃
Velocity: 2m/s
Medium: oily sewage
Chloride (in water), CI-(PPM):130000ppm
Property of oil gas and water in table A5.8-1

Table A5.8-1 Property of oil gas and water

1 Vapour Fraction 0 13 Comp Mole Frac(Nitrogen) 0
2 Temperature(℃） 89.24 14 Comp Mole Frac(CO2) 0.000014
3 Pressure(Mpag) 0.3 15 Comp Mole Frac(Methane) 0
4 Molar Flow(Nm3/d(gas)) 16 Comp Mole Frac(Ethane) 0
5 Mass Flow(kg/h) 1.66E+04 17 Comp Mole Frac(Propane) 0
6 Std Ideal Liq Vol Flow(m3/h) 16.65 18 Comp Mole Frac(i-Butane) 0
7 Actual Gas Flow(ACFM) 19 Comp Mole Frac(n-Butane) 0
8 Molecular Weight 18.02 20 Comp Mole Frac(i-Pentane) 0
9 Mass Density(kg/m3) 957 21 Comp Mole Frac(n-Pentane) 0
10 Molar Enthalpy(kh/kgmole) -281200 22 Comp Mole Frac(H2S) 0.000015
11 Viscosity(cP) 3.14E-01 23 Comp Mole Frac(H2O) 0.999971
12 Cp/Cv 1.173 24 Comp Mole Frac(NBP[0]94*) 0
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BASIC DESIGN DOC. NO.: HFY0-CP-RP-00001 REV.: A PAGE 47 OF 47

Figure A5.8.1 Water outlet of electric dehydrator corrosion rate.