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The past 20 years in the field of Cathodic Protection (CP) have ushered in the distinct shift from the assessment of conventional Direct Current (DC) corrosion mechanisms to the more complex world of electrochemistry influenced by Alternating Current corrosion mechanisms. In fact, traditional assessment of CP protection levels without taking cognizance of the AC interference on a structure can have catastrophic consequences for pipeline operators. The most common misnomer over the past 20 years has been the idea that a pipeline under suitable levels of CP cannot corrode in a High Voltage Powerline Right of Way.
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Microbiologically influenced corrosion (MIC) is a key risk to oil and gas infrastructure and confers great cost to asset owners. The AMPP 2021 IMPACT Canada study, which analyzed the energy, manufacturing, and mining sectors, shows the cost of corrosion in Canada is roughly $51.9 billion per year. To break this down further, MIC is estimated to make up roughly 20% of all corrosion which is roughly $10.4 billion in Canada alone, each year.
Upstream oil production assets, including oil production pipeline network and gas oil water separation facilities, play a dominant role in sustaining production targets to meet customer requirements. Corrosion management of such assets encompasses various phases, such as design, construction, operation, and decommissioning. Proper engineering design and sound construction practices combined with effective monitoring are essential to manage and maintain the corrosion of these assets within acceptable limits. Some of the considerations taken into account during design include: safety, environment, pressure, temperature, material availability, delivery time, and cost. Operating these assets outside of the design boundaries could influence the corrosion process, significantly impacting integrity. Close monitoring of operating parameters, along with identifying the corrosion by employing appropriate inspection techniques, and implementing timely corrective measures, are of paramount importance to preserving the integrity of these critical assets, which otherwise could lead to safety and environmental issues. This paper highlights three case studies involving the importance of cathodic protection monitoring, and failure analysis of an oil pipeline, along with corrosion inhibitor optimization efforts carried out to ensure asset integrity.