Updated: Feb 12
Corrosion degradation in oil & gas industries
Introduction
Corrosion is an inevitable process that affects materials over time, especially in industrial environments. However, with a well-structured corrosion management strategy, assets can be protected, ensuring their longevity, safety, and reliability. Understanding corrosion and implementing robust mitigation measures lay the foundation for effective monitoring and inspection programs, ultimately safeguarding production and enhancing asset performance.
Understanding Corrosion and Its Impact
Corrosion occurs when materials, primarily metals, deteriorate due to environmental interactions. This can result from exposure to moisture, chemicals, extreme temperatures, or other corrosive elements. If not managed properly, corrosion can lead to structural weaknesses, equipment failures, costly repairs, and even catastrophic incidents.
Industries such as oil and gas, chemical processing, and maritime operations face significant corrosion threats due to harsh operating conditions. Without proper corrosion management, assets become vulnerable to degradation, impacting both operational efficiency and safety.
The Role of Corrosion Threat Identification
Effective corrosion management begins with a thorough understanding of the threats specific to an asset. Corrosion threats vary depending on the type of material, operational environment, and service conditions. Identifying these threats accurately allows for the development of targeted mitigation strategies at the right location and frequency for monitoring as well as inspection.
Some common corrosion mechanisms include:
Uniform Corrosion – A general loss of material over large areas due to environmental exposure.
Pitting Corrosion – Localized, highly aggressive corrosion that creates deep cavities.
Crevice Corrosion – Occurs in confined spaces where moisture and chemicals accumulate.
Stress Corrosion Cracking (SCC) – A combination of mechanical stress and corrosive environments leading to sudden failures.
Microbiologically Influenced Corrosion (MIC) – Caused by microbial activity in environments such as pipelines and storage tanks.
Developing Robust Mitigation Strategies
Once corrosion threats are identified, appropriate mitigation measures must be implemented. These strategies should be tailored to the asset’s specific operating conditions and may include:
Material Selection – Using corrosion-resistant materials such as stainless steel or coatings to protect vulnerable surfaces.
Protective Coatings and Linings – Applying coatings to act as a barrier against corrosive elements.
Cathodic Protection – Employing sacrificial anodes or impressed current systems to prevent metal loss.
Chemical Injection – Using chemicals such as corrosion inhibitors, biocides, oxygen scavengers, H₂S scavengers, and scale inhibitors to slow down the corrosion process.
Process and Operational Controls – Adjusting environmental factors such as temperature, humidity, velocity, and fluid composition to minimize corrosion risks.
Building a Solid Foundation for Monitoring and Inspection
Upon proper corrosion threat identification and mitigation, establishing a robust monitoring and risk-based inspection program is of great importance. The frequency and technique used for monitoring and inspection are strongly dependent on the accuracy of the corrosion threat and mitigation identification. Implementing the right tools and frequency for monitoring and inspection will help determine the effectiveness of mitigation measures and enable timely corrective actions, forming a solid preventive maintenance program.
With an effective corrosion mitigation strategy in place, a well-designed monitoring and inspection program is essential for maintaining asset integrity. Regular inspections help detect early signs of corrosion and enable timely intervention before significant damage occurs.
Common monitoring and inspection techniques include:
H₂S and CO₂ Gas Monitoring – Checking for any deviation from the design.
Water Sample Analysis – Measuring pH, bacteria levels, organic acids, and residual chemicals (corrosion inhibitors, biocides, etc.).
Pig Trash Analysis – Examining wax, scale, bacteria, and solid deposits.
Cathodic Protection and Coating Surveys – Assessing the effectiveness of protective measures.
The inspection technique deployed depends on the morphology of the degradation mechanism, ensuring an effective detection method supports early identification of material deterioration and indication of insufficient mitigation. For example, techniques for inspecting pitting corrosion differ from those for crack detection. Likewise, inspecting corrosion under pipe supports requires different methodologies compared to pipes without obstructions. The use of radiography for a 20-inch pipe may not be as effective as for a 6-inch pipe.
Ensuring Safe Production and Asset Reliability
A comprehensive corrosion management strategy not only prolongs the life of assets but also ensures safe production and operational reliability. By proactively addressing corrosion threats, companies can:
Enhance Asset Availability – Reduce unplanned downtime and increase overall efficiency.
Improve Safety Performance – Minimize the risk of failures and accidents.
Optimize Maintenance Costs – Lower long-term maintenance expenses by preventing severe damage.
Ensure Regulatory Compliance – Meet industry standards and avoid legal consequences related to asset failures.
Conclusion
Corrosion management is a critical aspect of asset integrity, impacting safety, efficiency, and profitability. A proper understanding of corrosion processes is a fundamental building block that enables the development of robust identification and mitigation strategies, forming the backbone of effective monitoring and inspection programs. By prioritizing corrosion management, assets can achieve safe production, increased reliability, and optimized long-term operational success. Investing in proactive corrosion control today will lead to a more sustainable and resilient future for industrial assets.
At MAES Integrity Solutions, we offer our expertise in this field. We work with you to develop a corrosion management plan that reflects your process conditions and supports asset owners in establishing robust monitoring and inspection programs.