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<p>A substantial reduction in wall thickness was observed in the wellhead process piping of a shale gas platform 11&#xa0;months after commissioning. Damage was mainly concentrated in circumferential weld zones and square elbows in the outlet sections. Electrochemical tests showed a markedly higher corrosion current density in the weld zone than in the base metal (16.544 × 10<sup>−5</sup> vs. 3.1485 × 10<sup>−5</sup>&#xa0;A/cm<sup>2</sup>), accompanied by a shift of the corrosion potential from − 689.00 to − 695.63&#xa0;mV, indicating accelerated corrosion at welds. CFD simulations predicted a maximum thickness loss of 1530&#xa0;μm at the weld, consistent with the observed corrosion morphology. The failure was attributed to the combined effects of wet CO<sub>2</sub> corrosion, chloride-accelerated localized corrosion, and erosion by grit-laden gas, leading to erosion–corrosion synergy. Chemical analysis showed a higher Mn content in the weld (1.204&#xa0;wt.%) than in the base metal (0.446&#xa0;wt.%), which may increase galvanic heterogeneity. This study provides guidance for corrosion mitigation and integrity management of shale gas gathering pipelines.</p>

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Study on the Failure Causes of a Shale Gas Platform Process Pipeline

  • 期刊论文

  • 发表日期：

    2026年4月30日

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  • Yong Chen,
  • Yan Wang,
  • Dongyin Meng,
  • Zhaoran Zhang,
  • Ziyi Liu,
  • Qiliang Wang

摘要

A substantial reduction in wall thickness was observed in the wellhead process piping of a shale gas platform 11 months after commissioning. Damage was mainly concentrated in circumferential weld zones and square elbows in the outlet sections. Electrochemical tests showed a markedly higher corrosion current density in the weld zone than in the base metal (16.544 × 10−5 vs. 3.1485 × 10−5 A/cm2), accompanied by a shift of the corrosion potential from − 689.00 to − 695.63 mV, indicating accelerated corrosion at welds. CFD simulations predicted a maximum thickness loss of 1530 μm at the weld, consistent with the observed corrosion morphology. The failure was attributed to the combined effects of wet CO2 corrosion, chloride-accelerated localized corrosion, and erosion by grit-laden gas, leading to erosion–corrosion synergy. Chemical analysis showed a higher Mn content in the weld (1.204 wt.%) than in the base metal (0.446 wt.%), which may increase galvanic heterogeneity. This study provides guidance for corrosion mitigation and integrity management of shale gas gathering pipelines.