CORROSION AND

MATERIALS SELECTION
IN THE OIL AND GAS
INDUSTRY
by Liane Smith, Intetech Ltd, UK
Consultant to the
Nickel Institute

Cost of control of corrosion

in downhole tubing represents
34% of annual corrosion control
costs in the oil and gas industry*

* NACE corrosion survey 2000

2

H2S

CO2
T
Water
chemistry
Angle of
deviation

Diameter
Flowrate

Watercut

PARTIAL PRESSURES

CO2

H2S

Water
chemistry
Angle of
deviation
Diameter
Flowrate

Watercut

H2S
CO2

Vary with
depth

P
T

Water
chemistry

Angle of
deviation

Diameter
Flowrate

Watercut

pH

H2S
P
CO2

Water
chemistry
Angle of
deviation

Diameter
Flowrate

Watercut

H2S

CO2
T
Water
chemistry
Angle of
deviation

Diameter
Flowrate

Watercut

Mass transfer
effect
7

H2S

CO2
T
Water
chemistry

Angle of
deviation

Diameter

Watercut
Flowrate
Water wetting
8

Modes of water entrainment in wet oil

tubing

oil

mode III

mode II

mode I

water in oil
emulsion

oil/emulsion

stationary water
droplet

moving water
droplets

10

Inhibition Options Controlled by:

Baseline corrosion rate

Well lifetime

Phase balance

Continuous vs Batch
treatment

Bottomhole temperature
(wells)

Economics

11

ISO 15156/ NACE MR 0175

12

SSC

13

14

WHAT IF?
CORROSION RATE IS TOO HIGH?

COST OF INHIBITION IS TOO
GREAT?

INHIBITION IS PRACTICALLY OR
ENVIRONMENTALLY IMPOSSIBLE?

STRENGTH REQUIREMENT IS TOO
HIGH TO AVOID SSC?

15

13Cr
Super 13Cr
22Cr duplex
25Cr duplex
28Cr stainless steel
825 nickel alloy
625 nickel alloy
2550 nickel alloy
C276 nickel alloy
16

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18

Courtesy Sandvik Steel

19

Courtesy Butting GmbH

20

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HPHT wells
23,000ft deep
1 year to drill
>$35m

23

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Courtesy Voest Alpine

25

Courtesy Voest Alpine

26

Courtesy Japan Steel Works

27

NON-OPERATIONAL ENVIRONMENTS
(Full LIFE CYCLE Compatibility)

Protection of corrosion resistant alloys

during storage and transit

Installation offshore;

Hydrotesting water quality

Check for contaminants like mercury in
produced fluids.

Acidising fluid and corrosion inhibitor
compatibility with CRA

28

Life
Cycle
Costing

29

Transferring the Design to

Reality
Prepare good specifications for materials

Use experienced (CRA) material suppliers

Carry out correct welding procedure
development

Use good quality control practice at all
stages of procurement and fabrication

30

CONTROL OF CORROSION
REQUIRES:
Evaluation of the potential corrosion and
cracking risks

Consideration of control options principally
inhibition v.s. materials selection

Selection of cheapest, safe CRA

Check of whole life cycle suitability

Life cycle costing (LCC) to demonstrate
economic choice

Good QA at all stages

31