Novel Downhole Corrosion Coupon System Paving the Way for Effective Well Construction and Integrity Management
Authors: Tyagi Himanshu 
Published: February 2025

Corrosion is a common problem in oil, gas, and water wells. It has ability to cease the deliverability of oil wells and has significantly affected ultimate recovery from existing oil fields. Due to the limitation of continuous downhole corrosion monitoring or use of corrosion logging tools which are not continuous determination of precise rate of corrosion becomes extremely challenging. To overcome this shortcoming, a novel downhole corrosion system has been devised.

This paper outlines a strategy for the successful implementation of a distinctive approach to measure downhole corrosion and scale using a mechanical cylindrical coupon system with noteworthy enhancement in the life of completions jewelry at one of the largest onshore oilfields.

Methods, Procedures, Process

This rig-less technique incorporates introduction of downhole corrosion coupon which is installed inside an exclusively designed corrosion monitoring valve or gauge hanger with lock mandrel or high expansion gauge hanger with non-explosive setting tool. These distinctive systems are developed not only to overpower the technological drawbacks of conventional systems, but also accurately measure downhole corrosion and scale in oil, gas and water wells which are completed with gas lift completions, nipple less completion or completions with profile nipples to transform well lifecycle. Formulation of well selection criteria, individual well sampling and assessment, proper data gathering, data analysis, application methodology and custom-made design of well programs have made it possible to operate wells under safe condition and are capable to function continuously to achieve the targeted production requirements.

Results, Observations, Conclusions

A pilot project on nine wells for a major operator in the middle east exhibited a significant improvement to measure downhole corrosion rates and enhance well life by designing an effective chemical treatment program to mitigate downhole issues. This reduced the frequency of workovers worth savings of $50M and eradicated downtime for production operations. Application of this technology has broken the barrier in evaluation of these wells and provides an effective means of diagnosing the wells with well integrity issues beyond the capability of standard corrosion and scale monitoring methods. It is a cost-effective technology to identify downhole integrity issues and enhance the field value from existing wells.

Additive Information

This paper considers selection methodology and scenarios that help to estimate potential well integrity challenges and formulate downhole chemical treatment program for elevation of downhole tubulars run life and recommends suitable actions which allow well integrity engineers to take timely actions for sustaining production from oil and gas wells. The paper will also discuss the role of this technology in the overall well construction workflow.

With the increased complexity of mature fields, each next step to improve recovery comes with increased cost. Therefore, novel horizons of affordable technology will play a pivotal role to maximize economic recovery and meet rising demand in the current business environment.