Do you know the annual cost of corrosion in industrialized countries?
It is 3-5% of the GDP of those countries…Surprised?
More relevant fact: The total annual cost of corrosion in the Oil and gas industry is estimated to be $1.372 billion. Yes, a billion with a “B.” This is just the direct cost, not counting the lost income and treatment/mitigation costs each year.
This figure includes:
- $589 million on surface pipeline and facility costs
- $463 million annually in downhole tubing expenses
- $320 million in capital expenditures related to corrosion
These costs can rise further as new hydrocarbon sources are found in more challenging environments, such as deeper reservoirs with higher temperatures and pressures.
Effective corrosion management is crucial for reducing these costs and ensuring safety and environmental protection. Proper corrosion control practices can lead to significant cost savings and operational efficiency.
So why is it essential to select the right materials to prevent corrosion?
Choosing the right materials to prevent corrosion is critical for several reasons:
- Safety: Corrosion can lead to structural failures, leaks, and other hazardous conditions. Selecting materials resistant to corrosion ensures personnel safety and the environment.
- Longevity: Corrosion-resistant materials can significantly extend the lifespan of equipment and infrastructure. This reduces the need for frequent replacements and repairs, leading to cost savings.
- Operational Efficiency: Equipment that suffers from corrosion can experience downtime and decreased performance. Using the right materials helps maintain consistent and efficient operations, minimizing interruptions and maintenance needs.
- Cost Savings: Preventing corrosion through material selection can reduce direct costs associated with repairs and replacements and indirect costs such as production losses and environmental cleanup.
- Environmental Protection: Corrosion can cause leaks and spills of hazardous substances, leading to environmental damage. Selecting appropriate materials helps mitigate these risks and ensures compliance with environmental regulations.
By investing in the right materials and corrosion prevention strategies, industries can safeguard their assets, enhance safety, and optimize their operations.
Selecting the right materials for corrosion prevention in the oil and gas industry depends on several factors, including the specific environment and conditions to which the materials will be exposed. Here are some commonly used materials and their applications:
- Stainless Steel: Known for its excellent corrosion resistance, stainless steel is often used in environments exposed to seawater, chemicals, and high temperatures.
- Duplex Stainless Steel: This material combines the best properties of austenitic and ferritic stainless steels, offering high strength and excellent resistance to chloride-induced stress corrosion cracking.
- Nickel Alloys: Inconel and Monel are highly resistant to oxidation and corrosion, making them suitable for harsh environments, including high-temperature and high-pressure conditions.
- Titanium: Titanium is highly corrosion-resistant by seawater, chlorides, and other chemicals. It is often used in offshore applications and the production of corrosive fluids.
- Copper-Nickel Alloys: These alloys are resistant to seawater corrosion and are commonly used in marine environments.
- Corrosion-Resistant Coatings: Applying protective coatings such as epoxy, polyurethane, and zinc-rich primers can help prevent corrosion on metal surfaces.
- Corrosion Inhibitors: Chemical compounds added to fluids can significantly reduce the corrosion rate by forming a protective layer on the metal surface
When selecting materials, consider your project’s specific conditions and requirements. Consulting with a corrosion engineer or materials specialist can help you choose the most appropriate materials.
Metallurgists can help select materials for products by considering their properties and how they will be used. They also examine why materials fail and how to improve designs.
The material selection process consists of:
- Identifying design requirements which includes reviewing material’s performance, reliability, size, shape, and cost.
- Review of screen materials, including their chemical, electrical, physical, and mechanical properties.
- Review of rank materials, including comparing the materials against the design requirements.
- Documentation of results, including recording the chosen material and the reasons for the selection.
Furthermore, metallurgists review mechanical properties to ensure that products have strength, stiffness, toughness, ductility, and appropriate hardness.
Having a metallurgist on staff is essential because they bring specialized knowledge in optimizing metal selection, manufacturing processes, and quality control. This expertise ensures the proper use of metals in a company’s products, minimizing issues like metal failure or corrosion. Metallurgists maximize efficiency, improve product quality, and achieve significant cost savings by identifying the best materials for specific applications. Essentially, they act as technical experts on all aspects of metal usage within the company.
At Legacy Tubular, we assist you with all your product needs. With a skilled metallurgist and engineer on our team, we provide expert guidance tailored to your requirements. Whether you need material recommendations, have specific product inquiries, or are looking for the perfect solution to your challenges, we’re here to help.
Our team ensures you receive the best possible experience and support. Let us know how we can assist you, and we’ll work with you to find the ideal solution for your needs.
Reach out to our expert team today by filling out our contact form.