Fitness-for-purpose failure and corrosion control management in offshore oil and gas development

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Fitness-for-purpose failure and corrosion control management in offshore oil and gas development

Price, J.C.

Corrosion science and materials engineering has become more complex because of the large number of variables and material choices that have become available as we begin this century. Nevertheless, corrosion and other related failures still cost the offshore oil and gas industry many hundreds of millions of dollars annually and US corporations dollar 170 billion industry wide. Many possibilities exist to reduce or minimize these costs including a better standardization of material selection, cathodic protection and fabrication design criteria. This includes the development of dedicated computer software that enables the designer to avoid costly errors in material applications. This paper discusses typical present-day corrosion management strategy and outlines the various controversies on predicting corrosion rates in hydrocarbon fluids. It also discusses material design condition limitations and precautions that should be taken to avoid failures in a variety of components with reference to actual example s. This includes the adoption of special fabrication practices as well as the development of dedicated corrosion or condition monitoring techniques and management systems. Design considerations and other preventative measures for each of the various corrosion mechanisms are also discussed.