A REVIEW OF CORROSION–RELATED PROCESS SAFETY HAZARDS IN OIL AND GAS FACILITIES: MECHANISMS, CONSEQUENCES, AND MITIGATION STRATEGIES

ABSTRACT

Corrosion in oil and gas facilities presents significant safety, environmental, and economic challenges, necessitating advanced mitigation strategies to ensure operational integrity. This comprehensive review systematically examines corrosion mechanisms, including Sweet (CO₂), Sour (H₂S), Chloride induced-stress corrosion cracking (SCC), Oxygen corrosion, Galvanic, Crevice and microbiologically influenced corrosion (MIC), Corrosion under insulation (CUI) and their consequences, such as leaks, explosions, and structural failures, while evaluating economic impacts like production downtime and regulatory penalties, and environmental impact. Through a synthesis of literature published in the domain of Oil and Gas production, processing, transportation, and storage, we identify critical gaps in current corrosion management practices, particularly in aging infrastructure and extreme operating environments. Recent advancements in corrosion-resistant alloys (CRAs), smart coatings, and green inhibitors demonstrate improved performance, complemented by emerging technologies such as real-time monitoring, machine learning-based prediction models, and risk-based inspection (RBI) methodologies. Despite progress, implementation challenges persist, highlighting the need for integrated, data-driven corrosion management systems. This review concludes with actionable recommendations for optimizing corrosion management, enhancing asset longevity, and improving process safety in hydrocarbon operations through sustainable, predictive approaches.

Keywords: corrosion mitigation, oil and gas, process safety, predictive maintenance, materials science, risk management

.Corresponding Author: Ohimor E.O.