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Due to the volatile nature of petro-chemicals, it is all the more criti-cal to ensure that corrosion doesnot get to this point. Should apipeline break, the subsequent leakcould result in a fatal explosion,environmental contamination,and substantial remediation costs.Even if it is only a matter of equip-ment failure and unexpecteddowntime on a rig or refinery, thecost of corrosion in terms of lost

production and assets can be enor-mous given the large scale of theindustry.

While pipeline corrosion protectionis encouraged and even required inregions around the world, manycompanies are unaware of the fullpotential of multi-phase corrosionprotection using Vapor phaseCorrosion Inhibitor (VpCI) tech-nology in all stages of gas and oilproduction.

Meeting Industry CorrosionChallengesOver 35 years ago, CortecCorporation began researchingand developing VpCI technology.Since then, Cortec has been award-ed over 50 patents in corrosioninhibiting technology and hasfound ways to implement VpCItechnology in countless applica-tions, with multiple resources tai-lored specifically to the oil and gasindustry.

The largest petrochemical compa-nies in the world have foundCortec to be a reliable source, notonly for the provision of effective

corrosion inhibiting products, butalso for expert guidance and assis-tance in applying the technology.

VpCI TechnologyVpCI technology is a unique, envi-ronmentally friendly method ofcorrosion protection that hasmany advantages over traditionalcorrosion inhibitors. The basicmechanism consists of VpCI mole-cules vaporising and diffusingfrom a source material until theyare evenly distributed throughoutan enclosed space. These vapourscondense on all metal surfaces inthe space and form a monomolec-ular protective layer that physicallyadsorbs on metal.

This protective layer creates amicroscopic, hydrophobic surfacethat safeguards the metal from theattack of aggressive ions otherwiseable to corrode the metal. It canalso neutralise the electrical sur-face potential of the metal toinhibit a corrosion initiation pointfrom starting. Because of thevaporising and diffusing potentialof the VpCI source, if a VpCI ion issomehow dislocated from the

metal’s surface, another VpCI mol-ecule can move in to replace it.

Multi-Phase ProtectionThe vapour action of VpCI technol-ogy broadens the scope of typicalcorrosion protection capabilities.Traditional corrosion inhibitorsare often limited by the ability toprotect a metal surface only whenapplied directly to it. This opensthe door for corrosion in hard toreach areas or on surfaces thatmay have been missed during theapplication of a corrosioninhibitor.

I N H I B I T I N G C O R R O S I O N

Operations in the gas and oil industry are inescapably prone to corrosion. The corrosivefluids flowing through pipes and equipment make it only a matter of time before corrosiondegrades surrounding metal surfaces to a point of failure.

BY JULIE HOLMQUIST

Multi-Phase Corrosion Protection for theMultiple Stages of Gas and Oil Production

Cortec has been awarded over 50 patents in corrosioninhibiting technology and has found ways to implement VpCItechnology in countless applications, with multipleresources tailored specifically to the oil and gas industry(photo: Shutterstock)

How VpCI Works. VpCI mole-cules vaporise, disperse,and condense on metal sur-faces inside an enclosedspace to form a monomole-cular protective layeragainst aggressive ions(illustrations: Cortec)

Pipeline section showingactive VpCI protection inthe interface, liquid phase,and vapor phase

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In the case of a pipeline filled witha mixture of liquids and gases, atraditional liquid phase corrosioninhibitor would only protect themetal directly in contact with thefluid, while the empty headspaceabove the fluid would go unpro-tected and still be under attackfrom moisture (top of line corro-sion). However, VpCI treatmentsdesigned for process industries likeoil and gas can offer combinedcorrosion protection in both theliquid phase and vapor phase, aswell as at the critical liquid-vaporinterface. This allows for protec-tion of a pipeline’s entire internalsurface.

Adapting to the NeedIn addition to, and in conjunctionwith, these multi-phase properties,VpCI technology is adaptable tomany different applications andcan be combined with multiplefeatures for greater versatility. Thisallows the application of VpCItechnology in both fluid systemsand dry metal storage. For exam-ple, VpCIs can be injected directlyinto a pipeline system, included inmachine lubricants, or incorporat-ed into film to wrap around equip-ment for easy protection duringstorage.

VpCI permanent and temporarycoatings add to the range ofoptions for adapting to the need athand. This versatility makes VpCItechnology useful in upstream,midstream, and downstreamprocesses in stages ranging fromconstruction to operation, mainte-nance, and decommissioning.

ConstructionWhen a rig, pipeline, or refinery isbeing built, chances are that someequipment will require preserva-tion during storage or shipment.In terms of facility construction, itis not uncommon for importantassets to sit unused at a new facili-ty for a year or more before instal-lation or plant commissioning.This gives oxygen and moistureample opportunity to start the cor-rosion process. If allowed to run itscourse, corrosion will present an

unwelcome surprise when it comestime to install the parts.This could create significant finan-cial loss in terms of degradedassets alone, which is even moredevastating when those assets hap-pen to be equipment requiring a 1-to 2-year lead time to replace.Corrosion like this would be a seri-ous setback to launching facilityoperations. With adequate plan-ning, VpCI technology helps thecommissioning process get startedon the right foot.

During pipeline construction, cor-rosion can begin on internal sur-faces even before piping reachesthe field. If pipe internals are inad-equately protected, they can beginto corrode immediately after man-ufacturing. VpCI technology solvesthese challenges by making corro-sion protection more effective andeasier to apply in these difficult toreach internal spaces.

Operation andMaintenanceIn some cases, putting equipmentinto operation only serves to

exacerbate exposure to corrosiveelements like crude oil and naturalgas. By injecting VpCIs internally,metal pipes are protected morethoroughly during operation. Thecombination of vapor phase andfilm forming corrosion inhibitorsinjected into the fluid inside thepipe protect pipeline walls directlyin contact with the fluid as well as void spaces where air and moisture fester.

VpCI can also be used duringmaintenance exercises such ashydro-testing. Whereas flushing apipe or tank with plain fresh orsaltwater would leave it damp andat risk for corrosion, adding VpCItechnology to the hydro-test wateroffers protection during the testingprocess and beyond.

Protecting Critical andOperational SparesAnother beneficial operationalpractice is maintaining rust-freeoperational or critical spares;replacement parts that would beready to go in case of criticalequipment failure. The last thing

that a facility wants is to find areplacement part unusable due torust, meaning operational down-time must continue longer thanexpected while a new part is on order.

It is important to have an effective,yet easy-to-remove method inplace to protect spare parts fromdeterioration. VpCI technologyenables this kind of protection,which may simply require rinsinga protective coating off a part orunwrapping it from a protectiveVpCI film before the part is readyto install. VpCI rust removal canalso be used to redeem parts thathave already begun to degrade. Inthis way, warehouses full of expen-sive assets can be rescued from significant loss.

Plant Layup andDecommissioningSimilar VpCI processes are avail-able for putting an oil or gas facil-ity into short or long-term storage.The aim is to preserve a partial orentire facility in such a conditionthat it can be restarted with verylittle time and effort. A number ofoffshore rigs have benefited byusing VpCI technology duringtemporary storage of equipment incorrosive conditions on deck.

When it came time to put theequipment back in service,

I N H I B I T I N G C O R R O S I O N

VpCI technology is useful in upstream, midstream, anddownstream processes in stages ranging from constructionto operation, maintenance, and decommissioning (photo: Shutterstock)

Outer surfaces of an off-shore platform top driveunit were washed with VpCIcleaner/degreaser and coat-ed with a VpCI outdoor cor-rosion inhibitor beforetemporary storage on deckfor one year (source: CortecCase History 303)

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removing VpCI technology fromthe protected equipment was easy.Even in cases where plants or facil-ities are being permanently closed,it is desirable to keep assets inresalable condition if possible.VpCI technology helps make thishappen by protecting from rust ina more cost-effective way thanmost treatments.

Environmentally FriendlyMethodsVpCI technology tends to be moreenvironmentally friendly thanother methods simply by its reduc-tion of wasted resources. It is alsoless reliant on harmful chemicals.One staple VpCI product contain-ing low toxicity levels was able tosimply be released into the NorthSea after being used for hydro-test-ing and protection of large pipesystem internals. Many VpCI tech-nology products can be easily cap-tured and safely discarded without

special permits required for haz-ardous waste disposal.

Preservation PotentialThe multi-phase, multi-facetednature of VpCI technology gives itincredible potential for preserva-tion in all phases of the gas andoil life cycle. This can in turn cre-ate compounded savings in termsof asset preservation, reduced laborcosts, diminished downtime, and safety. As awareness andimplementation of VpCI technolo-gy increase, it is expected that loss-es due to corrosion will continue todrop. In the meantime, VpCI appli-cations will likely find more waysto adapt to the multi-faceted needsof industries worldwide. n

Acknowledgements

The author wishes to acknowledge

the expert insights provided by

James E. Holden, P.E., and Bob

Boyle of Cortec Corporation from

their experience in the oil and gas

industry. Thanks also to Eric Uutala,

Cortec Technical Service Manager,

for additional input.

The Author:

Julie Holmquist is MarketingContent Writer at CortecCorporation, where she enjoyslearning about and addressing themany corrosion protection needs ofoil, gas, and other industries.

I N H I B I T I N G C O R R O S I O N

DC Motors on a mud pump were protected with VpCI foamand film during temporary lay-up on an offshore rig in theMediterranean (source: Cortec Case History 303)

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