Real-time corrosion monitoring for oil and gas industry

Real-time corrosion monitoring enables upstream operators to continuously track equipment degradation, allowing them to detect issues early, extend equipment lifespan, and schedule maintenance based on actual equipment condition. By combining continuous sensor data with digital analytics and predictive models, teams can reduce leaks, unplanned downtime, and safety incidents across wells, pipelines, and production facilities.
Upstream operations rely on high-pressure wellbores, gathering lines, and surface equipment. These assets handle corrosive produced fluids, operate under constantly changing flow regimes, and function daily in harsh environments. Traditional inspection methods leave significant gaps between checks, meaning corrosion can initiate and accelerate undetected.
Regarding external corrosion—particularly under insulation—LCH employs ultra-thin, specially designed flexible ER (Electrical Resistance) corrosion rate sensors and EIS (Electrochemical Impedance Spectroscopy) technology to monitor for pitting, edge corrosion, and the degradation of coatings or insulation materials in real time. Internal corrosion monitoring technology is, of course, already well-established.
Real-time systems bridge this gap by continuously tracking corrosion rates and environmental conditions, enabling operators to intervene before wall loss reaches critical thresholds or minor defects escalate into leaks and failures.
Currently, corrosion detection—especially for corrosion under insulation—often relies on periodic visual assessments, non-destructive testing (NDT), and laboratory analysis to measure existing damage; these evaluations typically occur at intervals of several years.
Corrosion monitoring utilizes sensors, probes, and field devices to measure metal loss, corrosivity, and process conditions continuously or at frequent, regular intervals. Data is then transmitted to a central system for analysis.
Operators relying solely on periodic inspections often detect corrosion only after it has reached a level visible to the naked eye or measurable by standard means. This compresses the timeframe for repairs and may force them to make conservative decisions regarding equipment replacement.
Integrating corrosion monitoring into an integrity program allows for trend analysis of real-time data, enabling the detection of early changes in corrosion rates, highlighting the impact of process upsets, and verifying the effectiveness of mitigation measures.
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