Accurate corrosion prediction and protection are feasible.

Material degradation in oil and gas production is driven by carbon dioxide, hydrogen sulfide, oxygen, organic acids, and fluctuating water chemistry. Accurate corrosion prediction relies on reliable data regarding pH, gas partitioning, and salinity; by integrating these factors with advanced electrochemical modeling sensors, precise corrosion rate predictions can be achieved.
Corrosion rates depend on electrochemical reactions that are highly sensitive to chemical speciation, temperature, partial pressure, and water composition. Changes in pressure and temperature cause brine condensation or evaporation and the redistribution of gases across phases, thereby altering the drivers of corrosion. Empirical safety factors fail to account for these chemical transformations, necessitating quantitative modeling.
Calculations of average corrosion rates must account for the risk of localized pitting—where pits typically measure 0.5 to 1.0 mm in diameter and approximately 250 µm in depth. Our sensor design incorporates a strategy to mitigate the impact of localized pitting: the configuration ensures that even if a pit forms, the resulting increase in local resistance does not compromise the overall resistance measurement.
Temperature significantly affects resistance; our design addresses this by using a resin-encapsulated reference electrode alongside an identical working electrode. Comparing the two allows us to eliminate temperature-induced errors in ER (Electrical Resistance) corrosion rate measurements.
Regarding moisture, we employ water-film corrosion monitoring. High humidity or condensation readily leads to water-film formation, which can cause separation between the substrate and the conductive layer. When a conductive layer forms, the potential difference between the layers generates a current, driving corrosion of the substrate. Modeling the high-humidity water film allows us to eliminate its interference with ER corrosion rate accuracy.
By combining real-world corrosion rate data with the client's reliable pH, gas partitioning, and salinity measurements, accurate corrosion prediction and effective protection become achievable.