Rut roh…Sour gas eating Kashagan oil profits
From http://news.yahoo.com/insight-sour-gas- ... nance.html I particularly like the part where they say: "Every corrosion engineer would have looked at that design and, hand on heart, have said it should be fine”. I wonder if those engineers went to the same uni as the ones on the Macondo well as well as the ones that designed the biggest refinery upgrade in US history at the Motiva plant in Port Arthur, Texas, which had to be shut down due to pipe corrosion as soon as they tried to start it up?
Reuters – “A pipeline inspection robot is set to join efforts to discover why the biggest new oilfield in decades is crippled and whether materials, construction methods, a design fault or all three are at the root of the problem. Its arrival at the Kashagan project on the Caspian Sea this week comes after the field's trouble-strewn 13-year, journey towards commercial production took another twist in September as it delivered its first oil but began leaking toxic gas from a processing pipeline. After costing nearly $50 billion, mostly paid by some of the world's top oil companies, Kashagan may now be delayed until 2015, jeopardizing a forecast budget boost for Kazakhstan of $28 billion - about a third - between 2014 and 2016.
Even at modest early rates of production, every day it sits idle costs millions of dollars in lost oil revenue. Industry jokers have nicknamed it 'Cash-All-Gone'. The robot or "intelligent pig" - device was dispatched this week, according to an industry source, to take part in an investigation officials said would last into December at the field, named after Kazakh poet-singer Kashagan Kurzhimanuly. The oil extraction structure has been built on artificial islands about 70 km (40 miles) off the coast in the remote and environmentally hostile northern Caspian Sea, which means fixing the problem may take months.
The Central Asian former Soviet state hopes the field will produce 1.66 million barrels a day at its peak, double the national oil output of 2012, and equivalent to the entire production of resource-rich Angola. But the location, high reservoir pressure, and other challenges such as high levels of corrosive and poisonous hydrogen sulphide associated with the crude oil have proved to be major difficulties.
The project is years late and billions of dollars over budget already. With output at just 70,000 barrels a day, it sprang leaks in a pipeline carrying the associated gas to an onshore processing plant. According to a senior executive at a large oil company with knowledge of the site, the leaks were most likely caused when the hydrogen sulphide - known in the industry as sour gas - ate through the pipeline. This could be because the metallurgy of the pipes has turned out to be wrong for the conditions, while welds could also be part of the problem, he said.
Some in the industry say the pipes might have deteriorated after being left in the open for an extended period during the long delays the project has experienced, making them more vulnerable to attack from the sour gas. Others rejected this explanation, saying the pipes are designed for just such exposure.
Doubt was also thrown on whether the welds could be the trouble. Unlike the reservoir itself, which is at very high pressure, the gas that comes off the crude as it reaches the surface is carried at low pressure to the processing plant. Whatever the cause, a shutdown for a leak just two weeks after startup on September 11 was followed by a second leak and interruption in October, backing the view expressed by the head of one project partner Total this week when he said: "It's more than just repairing pipes." Smith, the managing director of Wood Group's asset integrity division also said that from what she knows of the project, it used the right specifications for the job. "Every corrosion engineer would have looked at that design and, hand on heart, have said it should be fine," she said.”