1.What is Corrosion Monitoring?..........................................................................................................

2
2. Why Monitor Corrosion?...................................................................................................................2
3. Monitoring Equipment and Methods.................................................................................................3
4. Electrical Instruments........................................................................................................................3
4.1 Linear polarization Resistance (LPR)..........................................................................................3
4.2 Electrical Resistance (ER)...........................................................................................................4
4.3 Galvanic Probes...........................................................................................................................4
5. Hydrogen Probes...............................................................................................................................5
6. Newer Monitoring Techniques..........................................................................................................6
6.1 AC Impedance Monitoring..........................................................................................................6
6.2 Electrochemical Hydrogen Patch Probes....................................................................................7
6.3 Electronic Hydrogen Probes........................................................................................................8
6.4 Acoustic Emission.......................................................................................................................8
7. Corrosion Coupons............................................................................................................................9
7.1 Strip Coupons..............................................................................................................................9
7.2 Disc Coupons.............................................................................................................................10
7.3 Rod Coupons.............................................................................................................................10
7.4 Coupons With Applied Stress....................................................................................................10
7.5 Coupons With Residual Stress...................................................................................................10
8. Chemical Analysis...........................................................................................................................11
8.1 Analysis of Suspended Solids....................................................................................................13
9. Flow Velocity...................................................................................................................................14
10. Inspection and Failure Analysis.....................................................................................................15
11. Biological Analysis........................................................................................................................15
12. Access to the System.....................................................................................................................15
12.1 Water Source Wells..................................................................................................................16
12.2 Water Injection Stations...........................................................................................................16
12.3 Water Injection Headers......................................................................................................16
12.4 Water Injection Wells...............................................................................................................16
12.5 Oil Wells..................................................................................................................................17
12.6 Oil Flow Stations.....................................................................................................................17
12.7 Oil Pipelines............................................................................................................................17
12.8 Gas Pipelines...........................................................................................................................17
12.9 Bypasses (sidestreams)............................................................................................................18
13. The Role and Importance of Corrosion Monitoring......................................................................18

THE IMPORTANCE OF
CORROSION MONITORING IN
OILFIELD SYSTEMS
1.What is Corrosion Monitoring?
In oilfield production systems, we can define internal corrosion monitoring as the
sue of physical measurements and chemical analysis, to measure the characteristics
of the metal surface and its environment, in order to determine the rate of
mechanism of internal corrosion in the system.

2. Why Monitor Corrosion?

The rate of corrosion is related to the useful life of the part of the system where the
measurement is made. This will enable us to relate the rate of corrosion to the
capital and operating costs of the system, such as repairs, replacement and loss of
production.
The mechanism of corrosion must be determined, so that rate controlling
factors can be isolated and controlled. This may require all types of physical and
chemical analysis, observation and measurements, together with a rigorous
diagnostic interpretation.
The effect of corrosion control methods on all of the physical and chemical
data should be recorded, to recorded, to show the degree of control, and the
economy of the method used. This should also show up rate controlling factors not
controlled by the method selected.
Measurements should take place in a definite time framework, to show
which of the measurements represent constant conditions, and which represent time
variable conditions, and which represent time variable conditions in the system. In
a once through system, certain changes are both progressive and irreversible. Time
variable factors are of extreme importance, for both diagnosis and long term
economic control of corrosion in oilfield production systems.
The purpose of monitoring corrosion is to enable the economic losses, due
to the corrosion of equipment and installations, to be minimized in a controlled and
efficient manner.

3. Monitoring Equipment and Methods

The following test methods, types of equipment and studies are examples of
corrosion monitoring procedures. It is not suggested that this is an exclusive list, or
that any one test or procedure is necessarily useful by itself.
-

Measurements with electrical instruments

Hydrogen probes
Corrosion coupons
Chemical analysis of system water
Chemical analysis of dissolved gases
Chemical analysis of corrosion deposits
Chemical analysis of suspended solids
Biological analysis
Suspended particle studies by filtration
Flow velocity and pressure survey in the system
Temperature survey in the system
Spools and in line inspection methods
External thickness measurements
Failure analysis

Each of the above procedures can make a valuable contribution towards the
understanding and control of a corrosion problem. In large systems, it becomes
economical to make sue of all of the above types of procedures. In smaller systems,
appropriate procedures can be combined to form an economical monitoring
program.
As a minimum, corrosion coupons and water analysis are the least
dispensible, and are normally combined with an appropriate instrumental
measurement. Filtration studies yield such valuable data that they should be carried
out wherever practical, and if chemical analysis suggests the necessity biological
analysis, it may become the most critical element in the monitoring program.

4. Electrical Instruments
4.1 Linear polarization Resistance (LPR)
LPR is a widely used electrochemical technique. It can be used on line to provide
an instantaneous, or continuous measurement of the corrosivity of the process
stream, and is widely used in the oilfield, particularly in water systems.
A small potential or current perturbation is applied to the test electrode in
order to determine the corrosion current density, and hence rate. For a corroding
electrode, the applied potential and current density are, to a close approximation,
linearly related. Thus their ratio the LPR, or polarization resistance (R p) can be
related to the corrosion current density by the following relationship:

This relationship only holds if the electrode is polarized well away from the
corrosion potential, and a linear Elogi relationship is obtained, indicating that the
electrochemical reaction is under activation control.
The technique has been extended to cover other electrochemical situations,
such as concentration polarization. LPR is best suited to aqueous electrolytes, such
as in waterflood systems. The presence of surface films limits response, and can
produce erroneous readings. Correlation with other methods such as weight loss
coupons seems to be best at low corrosion rates controlled by inhibitors. However,
much valuable diagnostic information on film characteristics, and the localization
of attach, can be obtained by an experience or well trained operator. The presence
of oxygen or bacterial activity can affect the readings in a predictable manner, so
the useful information available from an LPR type measurement is not limited to
the corrosion rate.
4.2 Electrical Resistance (ER)
This technique is based on the change in resistance of a wire, tube, strip or other
shaped element exposed to a corrosive environment.
Unlike LPR technique, the ER readings increase over the exposure time of
the element, until the circuit is broken.
The resistance of the element is measured using a Wheatstone Bridge
circuit, and is plotted on a graph. A simple formula converts a pair of readings,
over a time interval, to MPY corrosion rate.
Also unlike LPR techniques, where the readings in MPY tends to agree
(especially at low corrosion rates) with averaged corrosion rates based on weight
loss. ER readings give a better correlation with maximum pit depth, as the
resistance of a wire depends on the minimum cross-sectional area along the wire.
Strip elements can be mounted flush with the pipe surface, simulating the
flow conditions across the pipe surface, and the conditions of deposit formation in
the system. Elements can be left installed indefinitely, to measure extremely low
corrosion rates, and readings are not affected in the same way as LPR probes, by
deposit build up on the metal surface.
ER technique is applicable to systems without a continuous water phase,
poorly conductive environments, gas phases and can also be used in the atmosphere
ER monitoring is popular in gas systems. However, ER monitoring can also be
used in water systems.
4.3 Galvanic Probes.
Galvanic probes consist of two dissimilar metals, immersed in the corrosive
environment and connected by an ammeter. The corrosive medium must have a
continuous water phase.

Under strongly oxidizing conditions, corrosion rate tends to vary with the
degree of anodic polarization, which in turn varies with the oxygen concentration.
The use of a steel anode, with a brass cathode, produces a current flow which
relates closely to the oxygen concentration. This behavior is the basis for the use of
galvanic probes to monitor oxygen scavenger treatments in the drilling industry,
which is highly successful and popular.
In oilfield production, internal corrosion more commonly takes place under
reducing conditions, with the rate dependant on factors which influence the cathode
reaction, such as cathodic depolarizers and cathodic corrosion inhibitors. Galvanic
probes using steel as the cathode, and a Zn/Hg/Al electrode as the anode, have been
used to study the effect of inhibitors on the cathode reaction in production systems.
With general corrosion attack taking place on a metal surface, the anode and
cathode areas are roughly equivalent in size, whereas with localized corrosion the
anodic areas are much smaller than the cathode areas, and the cathodic areas have a
much lower current density than the anodic areas.
In order to stimulate low current density on the cathode, the electrodes are
connected via a large resistance (4600 ohms has been used). Using a separate cell
as a potential reference, the effects of inhibitor concentrations on the potential of
the cathode surface, under conditions of continuous current flow at low current
density, have been studied.
This method is of use in studying inhibitor filming behavior, and the effects
of inhibitors under the electrical conditions associated with pitting corrosion.
This method is not widely used, because there are few oilfield production
personnel in the field, who are qualified to draw the proper conclusions from the
results.
The introduction of foreign metals, such as brass, into the system can result
in chemical reactions (e.g. with amine corrosion inhibitors) taking place, and
interfering with the measurement of the characteristic behavior of steel surfaces in
the system. Bacterial activity may also have a selective influence on certain non
ferrous metals, and the same applies to sulfide ion concentration. These factors
increase the general difficulty of interpretation, of the results of galvanic monitoring
in oilfield production systems.

5. Hydrogen Probes
The absorption of nascent hydrogen by steel may initiate hydrogen induced failure
by various mechanisms, notably by causing blistering or embrittlement. The
formation of nascent hydrogen at the cathode has been found to occur more readily
when hydrogen sulfide, arsenic or cyanides are present in the corrosive
environment.
To detect hydrogen permeation in practice and to monitor remedial
measures, the hydrogen probe was developed. It is essentially a slender steel tube
with internal lamination. The atomic hydrogen, liberated at the outer surface of the

tube, migrates through the shell and reaches the annular space, where gaseous
hydrogen molecules are formed. Continued accumulation of hydrogen molecules
results in increased pressure, which registers on the pressure gauge.
Early models were relatively insensitive, and leakage interfered with their
reliability. In many systems, types were installed which were not retrievable under
pressure, so that system shutdown was required for service of a leaking probe.
Newer models became much more sensitive invariably reliable, and newer
installations were almost invariably retrievable under pressure, so that hydrogen
probes using the conventional principle are now more useful and practicable.
A new principle is discussed under Newer Monitoring Equipment, section 6

6. Newer Monitoring Techniques

6.1 AC Impedance Monitoring
LPR techniques measure the corrosion resistance, between the two electrode
surfaces, via the solution and any deposits or film present on the surface.
Erroneous results are often obtained due to low conductivity of the environment,
masking of the polarization effect in strong redox systems, and to lack of dynamic
response due to absorption or diffusion. Any DC measurement assumes that steady
state conditions can be achieved during the measurement. This is often not
possible, because of the measured polarization resistance.
The overall impedance at a metal/electrolyte surface is due to the following
factors:
-

Firstly, the ionic and electronic resistances of the solution and the bulk
of the electrode film.
Secondly, the capacitance of the electrical double layer (e.d.l.) and the
film/solution capacitance.
Thirdly, the charge transfer resistance (analogous to LPR) arising from
the anodic and cathodic electrochemical reactions.

The use of AC current allows the charge transfer resistance to be

determined, by a method which eliminates the ionic and electronic resistance, of the
solution and the bulk of the electrode film. This represents a distinct advantage
over LPR techniques, and substantially reduces the interference of solution
conductivity, and surface films and deposits.
The AC Impedance Monitoring instrument became practicable for field use,
due to recent developments in the field of electronics, and the application of digital
techniques to the design of the instrument. Previously, measurements of surface
impedance were carried out using AC bridge techniques, making experimental
measurements and interpretation difficult.
In the instrument, sinusoidal waveforms are generated by a transfer function
analyzer (TFA). For each frequency the impedance is determined, as a vector
comprising both resistance and capacitance components. The variation of

impedance with frequency is then plotted as a series of points on a Nyquist diagram

(with capacitance as the imaginary component on the Y axis, and resistance as the
real component on the x axis).
The following is a typical plot:
The charge transfer resistance is determined by measuring the maximum
phase angle (A) and calculating the length of the perpendicular to the tangent,
which is the radius and equal to half Rc is determined independently of Re.
The diagram shown represents a simple corrosion reaction. Under real
conditions, the curve will not be a true semicircle, but the perpendicular to the
tangent at maximum phase angle will normally be a useful approximation to half of
the charge transfer resistance.
It is expected that AC Impedance measurements will become increasingly
popular for oilfield production applications.
6.2 Electrochemical Hydrogen Patch Probes
Conventional hydrogen probes, which measure an accumulation of hydrogen by
means of a pressure gauge, have several disadvantages, which have already been
discussed. They also require an access point and a retriever device, and a limited
number of locations can be monitored without causing unacceptable damage to the
system. They also measure the diffusion of hydrogen from the probe surface, which
is a different environment from the wall of the vessel where corrosion is taking
place. Because the hydrogen pressure gradually builds up, the instantaneous
diffusion rate is not determined, but rather an average over a period of time.
Recent developments included a hydrogen patch probe, which used the
conventional principle of pressure buildup, but was attached to the outside of the
pipe. The measurement then reflected the diffusion rate of hydrogen due to the
corrosion of the actual pipe wall under normal operating conditions, undisturbed by
the installation of a probe into the system. Access points were not required, and the
probes could be applied to any number of locations. However, the patches were
difficult to relocate, and suffered from the same sensitivity problems as
conventional hydrogen probes.
The latest development is the Electrochemical Hydrogen Patch Probe. This
has two unique advantages. The principle of operation is the oxidation of the
diffusion hydrogen, in an electrochemical cell. The current necessary to oxidize the
hydrogen, is directly proportional to the amount of hydrogen present. This method
has the important advantage that, as the current can be measured instantaneously
and sensitively, so can the diffused hydrogen. The implications of this are very
important, as the measurement can easily and sensitively be recorded on a
continuous basis.

The second advantage is that the attachment of the Patch to the pipe wall is
not permanent, so the probe can easily be moved from one location to another in the
system.
6.3 Electronic Hydrogen Probes
The conventional hydrogen probes have also been considerably improved, and
pressure gauge readings are now unnecessary with the Electronic Hydrogen Probe.
This probe uses a pressure sensitive transducer, completely sealed with
epoxy resin to reduce leakage. The instrument compensate for temperature, and
produces volume readings directly.
Due to improved leakage control and digital readout, the conventional
hydrogen probe is now a much more practicable instrument, with improved
sensitivity.
6.4 Acoustic Emission
Sound waves are emitted from metals during various physical and chemical
phenomena. The most commonly observed are metals failing under stress (e.g. tin
cry), but sound is also emitted during the progress of corrosion reactions.
The sounds are generated in pulses, and may be detected by listening
devices, such as piezoelectric transducers.
Much work has been carried out on correlating emissions with corrosion
reactions. In the case of hydrogen evolution from iron wire in hydrochloric acid
solution, it was found that emission counts were recorded before any visible
hydrogen evolution took place, thereby giving evidence of corrosion initiation.
In practice, in an oilfield system it would be necessary to monitor acoustic
background before the start of reaction in order to obtain base line data for
interpretation. Some examples of the use of acoustic emissions with success are as
follows:
Inhibitors have been screened. Successful inhibitors supress the acoustic
emissions.
Filiform corrosion has been detected under coatings, and active and dormant
filiform corrosion may be distinguished. These emissions normally occur as
burst type singnals, thought to be due to the pressure effects on an organic
coating.
Acoustic emissions have also enable detection of the entrapment of
corrodents which might give rise to localized corrosion, such as in crevices in
honeycombed structures in aircraft.
The use of acoustic monitoring has obvious applications in oilfield
production. Internal corrosion may be located inside vessels, tanks and pipelines

where other methods could identify the mechanism, but not the location of
corrosion attack.

7. Corrosion Coupons
Corrosion coupons are extremely valuable as a monitoring tool. They have both
advantages and disadvantages. If corrosion coupons are used in combination with
other monitoring procedures, and if the interpretation of the results takes into
consideration the location and orientation of exposure, the composition of fluids
and flow pattern, then they will provide valuable information.
Several types of coupons are available:
- Strips
- Discs
- Rods
- Coupons with applied stress
- Coupons with residual stress
The advantages of coupons include:
- Visual interpretation
- Deposits can be observed and analyzed, and layer effects studied
- Weight loss can be determined
- The degree of localization of corrosion can be observed and measured
- Pit depth can be measured
- Inhibitor film effects can be observed
Coupons are visual, but also a scientific tool, and their use should be
properly exploited.
There is no reason to standardize the duration of the cleaning procedure for
exposed coupons, as a standardized severity of cleaning will produce a greater error
at low corrosion rates, and a smaller error at high corrosion rates.
Sufficient severity should be used, to clean the particular coupon to a
standard degree of cleanness. The error will then be smaller with lower corrosion
rates, and proportionally small with high corrosion rates.
7.1 Strip Coupons
Strip coupons are normally exposed edge on to the flow, in any position in the line
or vessel. Strip coupons have no special advantage, but they are most commonly
used type of corrosion coupon, as they are easy to install.
The flow pattern over the coupon surface is different from the flow pattern
over the vessel or pipe wall, the composition of fluids may not be uniform over the
coupon surface, and edge attack is quite commonly observed.
A common fault with strip coupons, is that the number is often stamped on
the face of the coupon, and is easily removed by corrosion. If the number is
stamped at the end of the coupon least exposed to the flow, it tends to be legible
even after exposure in a highly corrosive environment.

7.2 Disc Coupons

Disc coupons are normally installed through a vertically aligned access point, were
a series of discs oriented in the horizontal plane.
They are particularly useful for multiple phase flow, as separation due to
gravity will expose certain discs to a more corrosive environment. Discs are used
in gas pipelines, or oil pipelines, to determine the height to which the line is
contacted by corrosive fluids.
A single disc may be mounted flush with the line, and the conditions of
exposure (except electrical contact with the line surface, and the historical exposure
factor) will be very close to the conditions on the line surface. Closer
approximations are achieved with longer exposure periods, of the order 2 3
months.
Flush mounted probes also have the advantage that they do not have to be
withdrawn from the line for pigging.
The circular shape tends to reduce the severity of the edge attack effect.
7.3 Rod Coupons
Road coupons are normally used for locations where installation and retrieval under
pressure is not required. A number are place on a steel plug.
The advantage of this type of plug type coupon holder is that a larger
number of coupons can be installed, and they can be replaced sequentially, so that
regular checks can be made but with longer exposure periods.
For example, if six coupons are installed, two can be changed each month,
and an exposure time of three months achieved.
With certain types of corrosion in reducing environments, the temporary
removal of the plug could influence the long term results, due to exposure to the air,
and disturbance of the deposits.
7.4 Coupons With Applied Stress
Coupons with applied stress can be used in pressurized equipment, or stressed parts
of the system in order to measure the effect of the stress on the susceptibility to
corrosion, and to monitor the success of treatments to control stress corrosion.
The coupon is clamped in a device, which bends the coupon and creates an
applied stress. The installation equipment is designed to handle the device, and to
install and retrieve it under pressure.
7.5 Coupons With Residual Stress
Residual stresses increase the local susceptibility of the material to corrosion, by
localizing anodic areas. Residual stresses also greatly increase the susceptibility of

the material to catastrophic failure where the stress is located, especially where
nascent hydrogen is available for embrittlement.
Prestressed coupons consist of hardened or high strength steel, which has
been cold worked using a definite force, to create a permanent residual stress in the
material. In an embrittling environment, failure of the coupon will occur over a
relatively short time in interval, thus enabling accelerated determination of inhibitor
effectiveness.

8. Chemical Analysis
In chemistry, an equilibrium condition is normally associated with a constant
composition of reactive components. In an oilfield production system, the closest
we can expect to get to an equilibrium condition, is a situation is an accelerating, or
decelerating rate of change.
The changing conditions are dependent on several factors.
Firstly, all oilfield systems are based on once through flow. The fluid stays
in the system for a relatively long time, compared with once through cooling
systems. As the flow passes through the system, its physical properties and
chemical composition are changed, due to changing pressure and temperature,
phase separation and chemical and electrochemical (corrosion) reaction with the
exposed metal surfaces.
Secondly, deposits in the system buildup in stagnant or low rate parts of the
system, may be removed partly or completely by periodical pigging, and change in
character (layer effects) with time. At constant flow rate, without pigging and in a
corrosive environment, deposits tend to buildup over a period of time, creating
mini-environments underneath, which contain fluid of changing composition, and
which cause localized attack. More constant conditions apply where deposits are
removed immediately by cavitation or where acid or intergranular attack produces
metal loss without an increasing thickness of deposits. As the thickness of deposits.
As the thickness of deposits increases in an aerobic environment, reducing bacteria
become increasingly viable under the deposits.
Thirdly, few oilfield sources supply fluid of constant composition.
Changes tend to be progressive. For example, water sources well can produce
water of constantly and progressively changing salinity, and the proportion of
different ions will also change over a period of time. With oil wells, not only does
the produced water tend to change progressively in salinity and general
composition, but injection water breakthrough will tend to accentuate this change.
The water cut tends to increase with time, and changes in reservoir will affect the
GOR, and alter the cavitation and erosion factors where local problems are
observed.
Fourthly, inhibitor treatments, even if it may appear so from short term
exposure corrosion coupons, do not achieve corrosion control overnight. The
system surfaces may have already built up deposits, and developed pits before
treatment was started, and in this case several months will be required for the

corrosion to be brought under control at an economical dosage. The lowest dosages

may not be achieved for up to two years, in a corroded system. The progressive
action of the corrosion inhibitor will cause gradual changes in the results of
chemical analyses.
For all these reasons, chemical analysis is an essential part of a corrosion
monitoring program. Chemical analysis measures the concentrations of the ions
involved in the corrosion reactions, and repeated analysis at the same point helps to
identify the types of changes taking place in the system, and measures the amount
of changes on a definite time scale.
Analysis at different points in the system (always moving downstream) will
measure the amount of interaction between the fluid composition, and the surface.
In order to obtain meaningful results, it is necessary to carry out a series of
analyses, at different times of the day, at a particular point, in order to measure the
effect of changing external temperature on the chemical composition of the fluid.
Then, by calculating the time taken for the flow to reach the next analysis point in
the system, analyses at the two points can be compared, with minimum interference
from the changes in the source composition of the fluid.
This may sound complicated, but in practice a good initial analysis survey
can be done on several points in a system, by a good analyst, in a few days. For
years, many oilfield analyst have assumed that system conditions were constant, or
at the other extreme, that they were totally unpredictable. In fact, a thorough initial
analysis survey, followed by careful monitoring of certain ions every month or two,
will take less time, and produce more meaningful data, than a far greater number of
haphazard tests.
Chemical analysis includes the following:
- Analysis of water
- Analysis of deposits (e.g. on coupons)
- Analysis of dissolved gases (oxygen, carbon dioxide and hydrogen
sulfide)
- Analysis of suspended solids
For corrosion monitoring purposes, the most important species to determine in
solution are the following:
- pH
- Temperature
- Total dissolved sulfides
- Hydrogen sulfide gas in solution
- Ferrous and Ferric iron (as a proportion of the total iron)
- Oxygen (down to 1 part per billion)
- Alkalinity
- Carbon dioxide in solution
- Trace metals are useful, but generally not determined on field samples.
All the above should be determined at the sampling point.

These species are useful for comparative analysis purposes. Deposits

should be analyzed particularly for iron sulfide, especially next to bare metal. The
presence of carbonates, bicarbonates and magnetite should also be checked. Iron
carbonate can be distinguished from calcium carbonate in some cases.
Deposits should be analyzed on site, to avoid loss of oxidizable components
on exposure to the air, before arrival at the laboratory. Iron sulfide should be
determined as early as possible. Very much more detailed X-ray analysis can be
carried out later.
8.1 Analysis of Suspended Solids
Corrosion products, such as iron sulfide, tend to be present in both solution and
suspension, at concentrations, which depend on solubility product relationships.
Ferrous sulfide is more soluble than ferric sulfide, which tends to precipitate
as ferrous ions are converted to ferric by the air, or oxygen present in the system.
Amounts of ferrous or ferric sulfide, which are produced in excess of the solubility
product, will be present as deposits or suspended solids in any case. Sulfides are
more soluble at lower pH. Sulfides also tend to become oil wet, which increases
their adherence to surfaces. This may also be related to the fact that sulfate
reducing bacteria can use oil as a carbon source, when it is present as a contaminant
in a water injection system.
In systems containing high concentrations of dissolved iron, the entry of
oxygen to the system can cause precipitation of iron oxides or hydroxides.
Suspended solids can be chemically analyzed both quantitatively and
qualitatively, in order to relate the total iron to the suspended and dissolved iron,
and the total sulfides to the suspended and dissolved sulfides. This information,
particularly when used to compare different points in a system, is extremely useful
to help locate particular problems, such as oxygen entry to the system.
However, suspended solids also have physical effects on the operation of
system equipment, such as filters, and can cause plugging of injection formations.
Apart from the economic effects of corrosion products on the operation of the
system have to be monitored (cost of stimulation or work over).
This can be done using filtration equipment with very small pore sizes. A
typical size used in 0.45 microns. The techniques and equipment are well known,
and widely used in the industry, but this is not used very widely, as a part of the
corrosion monitoring program.
The method we have found most useful involves filtering about two litres (if
low flow rates are observed) or three litres (if high flow rates are observed) of water
through a standard filter, using a standard differential pressure such as about
1.5Kg/sq.cm (20 psi). Times are measured at regular volume intervals, and a plot is
made on 2 cycle logarithmic/linear graph paper, of the averaged flow rate over each
volume interval (y, logarithmic axis, in ml/sec.) against the total volume filtered in
the middle of the same volume interval (x, linear axis, ml).

Interpretation of the graphic data is well developed, and the trace shows the
variation in the rate of change of the flow rate, as different types of particle
successfully pack on to the filter. Practical applications include visual observation
of changes in redox conditions in the system, from the color of the filter
immediately after the test. Plugging tendency can be concluded from the data, as
well as changes in the wetting of the suspended particles. Much of this data is
valuable for corrosion monitoring.
Both biocide and corrosion inhibitor treatments have also been monitored
using this method, and startup of treatment shows a progressive and dramatic
change in the slope and shape of the curve.
Particle size analysis is helpful when studying water supply wells, and
tracing the path of formation solids through the system. For corrosion monitoring
purposes, we are more interested in the composition, and packing of the solids on
the filter.

9. Flow Velocity
A flow velocity survey forms an essential part of a corrosion monitoring program.
The flow velocity controls erosion and cavitation problems, the formation of soft
deposits in flowlines, the stability of inhibitor films and the flow condition (laminar
or turbulent) in the pipe. It has a strong influence on coupon edge effects.
The flow velocity, combined with the length of a line, will tell us the time of
exposure of the flow to the metal surface, between two points in the system. If the
time is short, we can expect a small variation in the chemical analysis results,
between the two points. If the time is longer, the variation should be greater.
As described above, the flow velocity influence both corrosion rate, and
inhibitor film formation. At lower velocities, deposit layers buildup, and localized
corrosion tends to increase, and the access of the inhibitor to the surface is limited.
What is often not realized, is that in ling lines with a slow flow there is actually less
inhibitor available to protect the surface. At a given ppm dosage, doubling the flow
velocity will double the quantity of chemical supplied to the line. In fact, at low
velocities (less than 1m/sec.) it is often necessary to increase the inhibitor dosage,
to maintain an appropriate level of inhibitor (in ml/square meter of surface/day) in
the particular line.
At higher flow velocities, erosion/cavitation increase, and with turbulent
flow inhibitor effectiveness in terms of film forming is likely to be reduced.
For these reasons, there is an optimum range of flow velocities in water
systems to minimize soft deposit formation, supply inhibitor efficiently to the
surface and prevent erosion effects reducing inhibitor performance.

10. Inspection and Failure Analysis

The aim of corrosion monitoring is to know what is happening in the system, and
prevent failures. However there are occasions when an unexpected factor causes a
failure.
Inspection and failure analysis are extremely valuable in identifying the
unexpected factor, so that proper preventive measures can be taken. Even with an
exceptionally good monitoring system, it is not possible to locate every area of poor
or inconsistent quality materials in the system, while failure analysis techniques can
readily identify substandard materials, or areas with residual stresses caused by
mechanical damage.
Inspection of equipment confirms the predictions based on monitoring
techniques, as pits can be seen and their depth measured, and deposits from the
system can be compared with the shorter-term deposits on corrosion coupons.

11. Biological Analysis

Microbiological activity, including a variety of types of bacteria, is intimately
involved in corrosion processes in oilfield production systems.
On site sampling, and subculture techniques, are an essential part of a
corrosion monitoring program. Particular interest and effort is devoted to the many
types of sulphate reducing bacteria (S.R.B) which commonly cause serious
corrosion problems.
Variations in the redox potential cause variations in the type of bacteria
growing most readily. Synergistic effects can result from alternate types of
oxidizing and reducing bacteria, growing in a system with strong variations in the
oxygen concentration.
Procedures include Phenol Red cultures for aerobic, acid forming bacteria in
liquid form, API Serum bottles for culturing sulphate reducers, and API sulphate
Reducer Agar, which is the more reliable method of culturing sulphate reducing
bacteria.

12. Access to the System

Access to the system is required for both sampling, and the installation of corrosion
monitoring equipment. Because hot tapping and welding of access points, not in
the original design, generally weakens the system and can lead to failure, it is
preferable for all monitoring installations to be included at the design stage.
With an increasing awareness of the economics of corrosion, due to the high
price and low availability of tubular goods on the world market over the past few
years, access points are increasingly planned for at the design stage. Many older
systems in the Middle east were built without any provision for corrosion

monitoring, and all of the access points had to be added while the systems were in
operation.
The following are some suggested guidelines for the location of monitoring
points in oilfield production systems.
12.1 Water Source Wells
General:
- Upstream and downstream filters
- In flowline downstream of wellhead, not too close to the well
- Where will cannot easily be shutdown to change or service equipment,
install with retriever through valve. Recommended minimum ID of
valve 1
Gas lift wells:
- Install from side of line, if water level permits
- Otherwise from bottom of line
- Avoid dry exposure at top, or sand erosion at bottom of line
Electrical, submersible pumps:
- Vertically into tubing head, with probe well into system
- Otherwise in flowline near wellhead, from top to near bottom of line
Mechanically driven, submersible pumps:
- In flowline near wellhead, from top to near bottom of line.
12.2 Water Injection Stations
Installation to be located between pieces of equipment and vessels, such as boots,
surge tanks, pumps and headers, to aid in locating problems such as oxygen entry.
Main inlets and outlets to the station should also be monitored.
If water contains oil, avoid installing probes from the top of lines. In all
cases, major station inlets and outlets should have bottom sampling points, for
suspended solids studies.
12.3 Water Injection Headers

In systems with long headers, particularly if the diameter is reduced further from
the station, additional monitoring points should be placed in the header further from
the station.
12.4 Water Injection Wells
Preferably not in wellhead, or in section under vacuum.
Preferably in straight section(not meter run).
Preferably between two valves. Replacement of probes can be done in less
than 10 minutes shutdown, using plug type probes.

Best installed from side of line, to centre of flow, to avoid oil/solids.

12.5 Oil Wells
In flowline near wellhead. Vertically down to near bottom. Not too close to the
wellhead or valve, to avoid turbulence.
In flowline near station (to pick up corrosion from free water)
Must be retrievable under pressure, rated for system pressure.
12.6 Oil Flow Stations
General:
- Bottom of incoming pipelines or headers
- Drain line of three phase separators upstream of water drain/pump
valves
- Tank bottoms/surge tank bottoms
- Drain lines of desalters/heater treaters upstream of water drain/dump
valves.
- Gas outlets from two phase separators to flare/compressors
- Gas main to compressors (vertically down to near bottom, or from
bottom)
Tank bottom:
- Close to bottom of tank, typically 0.5m
- If water dumped automatically, excellent in dump line, upstream of flow
control valve
- Above level of paraffin or sediment in tank, especially electrical probes.
- Not in downcomer inside tank, in static environemtn where oil collects
- Not in coffer dam
- Valve should be close to tank, to permit maximum entry to tank
12.7 Oil Pipelines
Normally all installations are vertically downwards, at beginning and end of line,
and intermediate points for long lines, preferably at low spots if accessible.
All devices must be completely retractable under pressure to permit pigging.
12.8 Gas Pipelines
Preferably immediately prior to (upstream of) chemical injection points, in long
lines.
All installations from top of line, in general.
In wet lines, probes installed at top and to bottom of line
In dry lines, bottom devices only, except hydrogen probes and ER devices.

Top devices should generally be flush mounted if possible, and bottom

devices retractable for pigging.
In condensate traps, installation must be retrievable under pressure, without
major digging operations or line shutdown, and must not add weakness to line or
trap.
Monitoring equipment should not be installed at bends or junctions, or at
other locations where the access point could dangerously increase the susceptibility
to corrosion.
Devices should not be installed close to the opposite wall of the line, where
the proximity of the probe could aggravate localized corrosion.
The above guidelines are not intended to be definitive as each system has its
peculiarities, and requires its own arrangement of monitoring equipment.
Monitoring installations should be sufficient, but not excessive, in line with
the economic requirements of the system.

12.9 Bypasses (sidestreams)

Bypasses are a means of access to a system, without placing probes directly into the
main system, and can be used where hot tapping cannot be carried out.
A bypass is a section of pipe (generally 2) connected across a pressure drop
in the system, such as a flow control device. It is generally connected to the system
using small diameter tubing, but care must be taken to avoid short circuiting
insulating gaskets in the cathodic protection system.
Coupons and probes can be installed into the 2 section.
By passes can also be used to pilot test corrosion inhibitor treatments.

13. The Role and Importance of Corrosion Monitoring

Corrosion prevention and control involves every stage in the life of an oilfield
production system, including selection of materials, design, storage and transport of
materials, construction, commissioning, protective coatings, operation of the
system, corrosion monitoring and chemical treatment.
This discussion has presented some of the ways in which corrosion
monitoring can increase the understanding, and facilitate the control of corrosion
during the operation life of an oilfield production system.
Inevitably, at the operational stage, all of the errors made at all of the
preceding stages are a matter of history, and built into the system. Monitoring plays

a large part in the location and identification of these built in problems, and in
measuring the effectiveness of corrective action.
Chemical treatments cannot be used economically, with a knowledge of
their optimum method of application and dosage, and good and meaningful
measurements indicating the cost performance of the treatment.
Corrosion monitoring must be versatile enough to measure the progressive
changes in system conditions and fluid composition, and their effect on the degree
of corrosion control, so that control methods can be adapted, if necessary, to
maintain optimum, control of corrosion in the system.