Kazakhstan journal for oil & gas industryKazakhstan journal for oil & gas industry2707-42262957-806XKMG Engineering10893510.54859/kjogi108935Research ArticlePractical implementation of an integrated corrosion monitoring system at the fields of the South Torgay Turgay Oil and Gas fields three independent measurement methodsKalymovaPerizat A.p.kalymova@kmge.kzhttps://orcid.org/0009-0006-2187-1739TurmaganbetSagat Ye.s.turmaganbet@kmge.kzhttps://orcid.org/0009-0004-5209-2127ChechinaYuliya V.y.chechina@kmge.kzhttps://orcid.org/0009-0006-2654-5561BaimenovSanzhar Ye.s.baimenov@kmge.kzhttps://orcid.org/0009-0004-7165-4180BerdyevArslanbek Zh.a.berdyev@kmge.kzhttps://orcid.org/0009-0000-3521-0700JaxylykovTalgat S.t.jaxylykov@kmge.kzhttps://orcid.org/0000-0002-1530-3974MardanovAltynbek S.a.mardanov@kmge.kzhttps://orcid.org/0000-0002-8342-3046Atyrau Branch of KMG Engineering300620268236470411202509042026Copyright © 2026, Kalymova P.A., Turmaganbet S.Y., Chechina Y.V., Baimenov S.Y., Berdyev A.Z., Jaxylykov T.S., Mardanov A.S.2026<p><strong>Background: </strong>The problem of internal corrosion in oil and gas pipelines remains one of the key challenges in ensuring industrial safety and reliable operation. Conventional monitoring methods, such as gravimetric and electrochemical techniques, provide only average corrosion rates and do not account for localized areas of accelerated metal loss or the influence of erosion. Therefore, the implementation of integrated corrosion monitoring systems combining several independent measurement techniques is an important and timely direction.</p> <p><strong>Aim: </strong>The aim of this study is to evaluatethe “Corrosion Monitoring System” technology under field conditions in the South Turgay Oil and Gas Basinemploying three complementary methods simultaneously – Electrical Resistance (ER), Ultrasonic Thickness Measurement (UT), and Gravimetric Control (Coupon Testing).</p> <p><strong>Materials and methods: </strong>The trials were conducted on the collectors of the Oil Processing and Pumping Shop (OPPS) “A” and the Oil Treatment Plant (OTP) “B”), operating under gas-liquid multiphase flow conditions with abrasive inclusions. Monitoring was carried out using stationary electrical resistance (ER) and ultrasonic thickness (UT) systems, as well as witness coupons. Signal acquisitionwas based on changes in the physical parameters of the sensors (electrical resistance, ultrasonic wave travel time, or mass loss), allowing real-time assessment of metal loss dynamics.</p> <p><strong>Results: </strong>Corrosion rates were greater than0.5 mm/year at CPPN “A” and reached 0.2 mm/year at UPN “B”. The agreement between ER and coupon testing reached8.73% and 0.68%, respectively, which falls within the reproducibility range (≤10%). Ultrasonic analysis revealed non-uniform wear across the pipe cross-section: the highest metal loss occurred in the lower section (“6 o’clock” position), where water and solid particles accumulated, while the side sections exhibited lower corrosion rates. This confirmed the sensitivity of the UT method to localized erosion–corrosion zones sensitive to localized areas not captured by averaged methods.</p> <p><strong>Conclusion: </strong>The combined use of three methods enables a comprehensive assessment of pipeline integrity – from overall corrosion rates to identification of local erosion–corrosion areas. The practical significance of this work lies in the potential to optimize inhibitor dosages, reduce the risk of pipeline failures, and improve operational reliability.</p>corrosionmonitoringelectrical resistanceultrasonic thickness measurementgravimetric controlpipeline integrityкоррозиямониторингэлектрлік кедергіультрадыбыстық қалыңдық өлшеугравиметриялық бақылауқұбыркоррозиямониторингэлектрическое сопротивлениеультразвуковая толщинометриягравиметрический контрольтрубопровод1.Mazraeh AA, Alnaimi FBI. Multi-diameter Pipeline Inspection Gauge for Long Distance Industrial Application. 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