A comprehensive review of corrosion in oil and gas pipelines: mechanisms, mitigation strategies, and future directions

Abstract

Abstract This review provides a comprehensive analysis of pipeline corrosion, a critical issue threatening the safety, environmental sustainability, and economic efficiency of oil and gas operations. It consolidates current knowledge on corrosion mechanisms, advanced mitigation strategies, and future directions for risk management. The analysis first details prevalent corrosion forms, such as uniform, pitting, and stress corrosion cracking, and quantitatively explains how corrosion rates, often ranging from 0.1 to 10 mm/year depending on service conditions, are governed by a complex interplay of fluid chemistry, operational parameters, and pipeline materials. Subsequently, the review assesses the performance of established and emerging prevention strategies, including protective coatings that can reduce corrosion rates by >90%, and inhibitor systems achieving >95% efficiency in controlled environments. We argue that an integrated, multi-layered approach is essential for effective management. A critical evaluation of monitoring techniques, from non-destructive testing to smart inline inspection tools, demonstrates that modern sensor-based systems can detect wall loss with an accuracy of ±0.1 mm, while predictive models integrating this data achieve reliability metrics ( R 2 ) above 0.85. Unlike prior focused studies on specific mechanisms or predictive modeling, this work offers a unique, integrated synthesis that bridges fundamental science with applied engineering solutions across the asset lifecycle. Finally, the review explores future trends, focusing on innovations in AI-driven predictive modeling, remote monitoring networks, and digital twin technologies for proactive integrity management. It concludes that continuous research and technological integration are imperative to address evolving challenges and ensure the long-term integrity of global pipeline infrastructure.