Қазақстанның мұнай-газ саласының хабаршысыҚазақстанның мұнай-газ саласының хабаршысы2707-42262957-806XKMG Engineering10893510.54859/kjogi108935Practical implementation of an integrated corrosion monitoring system at the fields of the south torgay petroleum basin using three independent measurement methodsKalymovaPerizat Askarkyzy<p>Senior Engineer of the Department for Combating Complications in Field Development</p>perizatkalymova25@gmail.comhttps://orcid.org/0009-0006-2187-1739TurmaganbetSagat Yerlanuly<p>Expert of the Department for Combating Complications in Field Development</p>s.turmaganbet@kmge.kzhttps://orcid.org/0009-0004-5209-2127ChecinaYuliya Valerevna<p>Lead Engineer for the Management of the System for Collection, Transportation and Preparation of Products</p>Y.Chechina@kmge.kzhttps://orcid.org/0009-0006-2654-5561BaimenovSanzhar Yerlanuly<p>Senior Engineer of the Department of Oil and Gas Production Engineering and Technology</p>S.Baimenov@kmge.kzhttps://orcid.org/0009-0004-7165-4180JaxylykovTalgat S.<p>First Deputy Director of the Branch for Geology and Development</p>t.jaxylykov@kmge.kzhttps://orcid.org/0000-0002-1530-3974MardanovAltynbek S.<p>Branch Director</p>a.mardanov@kmge.kzhttps://orcid.org/0000-0002-8342-3046Atyrau branch of KMG Engineering820411202509042026Copyright © , Kalymova P.A., Turmaganbet S.Y., Checina Y.V., Baimenov S.Y., Jaxylykov T.S., Mardanov A.S.<p><strong>Background.</strong> The problem of internal corrosion in oil and gas pipelines remains one of the key challenges for ensuring industrial safety and reliable operation. Conventional monitoring methods, such as gravimetric analysis, provide only average corrosion rates and do not account for local zones 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 was to test the “Corrosion Monitoring System” technology under field conditions of the South Torgay petroleum basin using three complementary methods — 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 pipelines of CPPN “A” and UPN “B”, operating under multiphase flow conditions containing abrasive particles. Monitoring was carried out using stationary electrical resistance (ER) and ultrasonic thickness (UT) sensors, as well as corrosion coupons. Signal registration was 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 exceeded 0.5 mm/year at CPPN “A” and reached 0.2 mm/year at UPN “B”. The correlation between ER and coupon testing methods was 8.73% 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 that cannot be detected by averaged methods.</p> <p><strong>Conclusion.</strong> The combined application of three independent techniques 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>corrosion, monitoring, electrical resistance (ER), ultrasonic thickness measurement (UT), gravimetric control, pipeline integrityкоррозия, мониторинг, электрлік кедергі (ЭК), ультрадыбыстық қалыңдық өлшеу (УД), гравиметриялық бақылау, құбыр.коррозия, мониторинг, электрическое сопротивление (ЭС), ультразвуковая толщинометрия (УЗ), гравиметрический контроль, трубопровод1.Mazraeh A.A., Alnaimi F.B.I. 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