Internal Lining of Pressure Vessels

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Abu Dhabi Company for Onshore Oil Operations


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Introduction

History

1st & 2nd Catastrophic Failures

New Selection Criteria

New Lining Systems

Inspection of the New Lining Systems

Conclusion & Recommendations

Internal Linings of High Pressure Vessels

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Operating Pressure : 100 Bar

Operating Temperature : 105 C

Date in Operation : April 2000

Material of Const. : CS-HICN 516-60 N

Design Code : ASME VIII

Shell Thickness : 114 mm

Inner Diameter : 2000 mm

Tang./Tang. : 6500 mm

Fluid : Wet Sour gas

H2S : 3.5 mole %

Chloride : 1500 ppm

CO2 : 4.5 mole %

INTRODUCTION OPERATING CONDITIONS

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INTRODUCTION OPERATING CONDITIONS

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Typical 4 Nos. Test Separators


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Factory Applied Internal Lining by Ceramic Filled epoxy in Nov. 1998.

Test Separators Commissioning in Nov. 2000.

Catastrophic Failure in April 2001

Inspection

Initial Failure Route Causes

Field Re-lining Using the Same Lining

Same Pattern Catastrophic Failure After 45 Days

Inspection

Failure Route Causes

HISTORY

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1St Failure Inspection Findings:

Peel off and flaking on 80% of the entire surface

Total removal on 30% of the entire surface

Superficial rust under flaked off areas

2ndFailure Inspection Findings:

Peel off and flaking on lesser extent of the entire surface

Total removal on 30% of the entire surface

Superficial rust under flaked off areas

1st & 2nd CATASTROPHIC FAILURES

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7

Shell

Internal

Surface.



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8

Shell

Internal

Surface.

Manway Nozzles Internal.



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Failure Mechanism:i. High polymer X-linking materials above critical

value

ii. Broad thermal cycling effect

iii. Explosive Decompression due to dense polymerX-linking

iv. Aggressive environment


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No track records found for similar services.

Documented compliance with the requested materialperformance technical data sheet.

Unconditional full recovery of the contractvalue if the applied system exhibits any of thefollowing defects after 12 months of services.

i. Lining De-lamination.

ii. Blister free for single layer system.

iii. 10% surface blisters for multi-layer system.

NEW SELECTION CRITERIA

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

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

iv. 20% reduction in the adhesion forces between any two

adjacent layers or to the substrate, compared to thatmeasured prior to boxing up.

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NEW SELECTION CRITERIA


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11 proposed lining systems.

8 Lining Manufacturers declined.

3 Manufacturers accepted the set criteria.

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

Vinyl Ester Glass Flake applied on GRS-2 Test

Separator.

Solvent free two components hybridized epoxyapplied on GRS-3 & 4 Test Separators.

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NEW LINING SYSTEMS


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INTERIM INSPECTION:

i. Conducted interim inspection within 3 monthsexposure.

ii.

GRS-1 Test Separator lining system was found insound conditions and fully meet the acceptancecriteria.

iii. Minor surface cracks within the acceptance

criteria were found on the GRS-2 TestSeparator.

iv. Catastrophic total failure was found on GRS-3 &4 Test Separators.

INSPECTION OF NEW LINING SYSTEMS

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INTERIM INSPECTION:

v. Decision made to continue the service on theGRS-1 & 2 Test in services for additional periodof six months and re-inspect.

vi. Postpone the decision on GRS-3&4 TestSeparators to get more concert data from GRS-1& 2 within 6 months. The two Separators wereout of services.


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Final Inspection:

i. GRS-1 Test Separator lining system was found insound conditions and fully meet the acceptancecriteria.

ii. Propagation of the surface cracks within theacceptance criteria were found on the GRS-2 TestSeparator.


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GRS 2 Sepa ato Inte im Inspection Findings


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GRS-2 Separator Interim Inspection Findings

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Coating in good condition at shell 9 OclockCoating in good condition at 2nd side man way

Small defects on the manway Small Surface crack

GRS 3 & 4 Separators Interim Inspection Findings


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111/12/2003 12:03 PM

GRS-3 & 4 Separators Interim Inspection Findings

Deposits and foreign broken metals parts

Peeled off coating at Demister Peeled of coating at buffle plate

Irregular coating at the top (looks like sagging)



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Peel off at the dish end manway Cracks and peel off at the demister

Peel of at the demisterBlisters at 3 Oclock and 9 Oclock

GRS 3&4 CATASTROPHIC FAILURES


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Failure Mechanism:

i. High polymer X-linking materials above criticalvalue

ii. Broad thermal cycle effect

iii. Explosive Decompression due to high polymerX-linking

iv. Aggressive environment

GRS-3&4 CATASTROPHIC FAILURES

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CONCLUSION & RECOMMENDATIONS


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Both Epoxy Novolac resin and Glass Vinyl Ester lining

systems are acceptable for high pressure &temperature wet sour gas services.

Carry out the minor repairs on GRS-2 Test Separator

and return to services.

Box up GRS-1 Test separator and return to services.

Apply Epoxy Novolac resin lining system on GRS-3 &

4 test separators.

Conduct Off-stream inspection every two years.

CONCLUSION & RECOMMENDATIONS

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Abu Dhabi Company for Onshore Oil Operations

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Internal Lining of Pressure Vessels