G—

SOCIETY OF PETROLEUM ENGINEERS OF AIME

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Dallas, Texas 75206

THIS IS A PREPRINT --- SUBJECT TO CORRECTION

Well Casing Corrosion and Cathodic Protection

By

Elmer L. Curry> General Corrosion Services Corp.

@ Copyright 1970
American Institute of Mining, Metalhzrgical, and Petroleum Engineers, Inc.

This paper was prepared for the Rocky Mountain Regional Meeting of the Society of Petroleum
Engineers of AIME, to be held in Casper, Wyo., June 8-9, 1970. Permission to copy is restricted
to an abstract of not more than 300 words. Illustrationsmay not be copied. The abstract should
contain conspicuous ackiimtiled~~ierlt
Cf wbiere~..u.~
and hV w~.~rn ~.he paper is presented. Publication
elsewhere after publication in the JOURNAL OF PETROLEUM TECHNOLOGY or the SOCIETY OF PETROLEUM
ENGINEERS JOURNAL is usually granted upon request to the Editor of the appropriate journal
provided agreement to give proper credit is made.

Discussion of this paper is invited. Three copies of any discussion should be sent to the
Society of Petroleum Engineers office. Such discussion may be presented at the above meeting and,
with the paper, may be considered for publication in one of the two SPE magazines.

IiBSTRACT

One of the problems concerning the through proven results with the success-
prevention of corrosion of oil and gas ful application of cathodic protection.
well casings is that of determining the
current requirements for cathodic pro-
tection. A. CAUSES OF EXTERNAL CASING CORROSION ON
OIL AND GAS WELLS
This paper discusses the causes of
corrosion on well casings, suggests well There are five (5) major items which
completion practices that would minimize are normally thought to be the cause of
corrosion problems, and explains and dis - well casing corrosion. These are:
cusses two methods of determining current
requirements for cathodic protection. 1. Dis-similar metals
Graphs and drawings are included to des- 2. Dis-similar soil
tribe and substantiate both methods. 3. Differential aeration
4. Bacteria
The casing potential profile tool 5. “Stray current” interference
is the most used tool to locate and eval-
uate external casing corrosion. It Can Dis-similar metals cause a form of
also be used to determine the current corrosion brought about by the use of
requirements for cathodic protection. different metals electrically coupled
together (such as steel pipe and brass
The E-Log-I survey (sometimes re- gate vaives); th use Of Fu=t=iS *~nim+ant-
. ... .... ..
ferred to as the log-current-potential ionally caused to be dis-similar by the
method) cannot locate or evaluate exter- manufacturing process in either the steel
nal casing corrosion, but is a relatively or the pipe: the use of “old” and *’new”
inexpensive method of determining current pipe in the same casing which can include
requirements for cathodic protection. oxide scales, etc., and marks and
It’s accuracy has been verified in tests scratches on the pipe left by tools.
with the casing profile tool and it’s
depei~~~iiity h,=~beem siabsk~ntiated Dis-sim ilar soils cause corrosion by
the nature of the chemicai composition of
References and illustrations at end of the soil in one area of contact with the
paper.
2 WELL CASING CORROSION AND CATHODIC PROTECTION
casing being different than the soil in
contact with another portion of the cas-
ing. As an example, dissolved minerals
in one area of soil might cause a differ-
ence of potential to exist between that
area and an area absent from such dis-
solved minerals.
Soil resistance changes from one
strata to another sets up corrosion cells
which normally cause corrosion currents
to flow fEOM the lower resistance soil
area to the higher resistance soil area.
-*.*”.”..
n+-+n.nn+ia~ --- A~~~~~Qn is a cause Of
corrosion in which the pipe or casing in
the more aerated soil will become cath-
odic to that portion of the structure in
the less aerated soil. The most preval-
ent example is that corrosion cell in
which the well casing becomes the anode
and the flow line becomes the cathode.
Bacterial corrosion on well casings
can OCC*Ur involving two forms of
bacteria. Aerobic bacteria can exist
where there is no free oxygen. These
bacteria change the environment in which
they exist, thereby, setting up minute
corrosion cells when such contamination
c~es in contact ‘W-itFI tPLa casirbg.
“Strav current” interference can be
defined as the action of a direct current
which causes an unwanted effect of a
detrimental nature on a structure not
directly associated with the source.
Rectifiers associated with other cathodic
protection systems are generally the
primary causes of interference currents;
however, other current sources are not to
be precluded.
R
-. WAYS TO MJTXGATE WELL CASING
CORROSION
Well casing corrosion can be miti-
gated through good well completion pract-
ices, the use of cathodic protection, and
/or a combination of the two.
Good completion practices include
the use of drilling mud with an alkline
Ph; the circulation of cement for the
entire length of the casing; use of
similar metals in all parts of the struc-
~~=e ; and the insulation Qf the well line
from the casing.
c. CATHODIC PROTECTION CRITJ3RIA
There are four acceptable criteria
~f determining cathodic protection. It
SPE 2910
is said that a structure is under
cathodic protection when at least one
of these criteria can apply.
L When a steel structure has its
potential shifted in a negative
dire=ticrl to a peter.tial of not
less than -850 millivolts with
reference to a copper-copper
sulfate half-cell anywhere along
its surface, it is catholically
protected.
2. When a steel structure has its
potential shifted in a negative
direction by an impressed direct
current by a minimum amount of
300 MV in a negative direction
(from its native state) in refer-
ence to a copper-copper sulfate
half-cell anywhere alongs its
surface, it is catholically pro-
tected.
3. When a steel structure has its
potential shifted in a negative
direction until it has become
completely polarized with hydro-
gen ions, it is catholically pro-
tected.
4. When a steel structure has its
potential shifted in a negative
direction in such a manner so as
to cause electron flow from its
environment to the steel in all
places on the structure, it is
catholically protected.
D. CATHODIC PROTECTION CRITERIA POR
WELL CASINGS
The use of -850 W potential or the
-300 MV shift of potential cannot be
applied (by themselves) as a criteria of
measurement in order to determine the
adequacy of cathodic protection of a
well casing.
The obvious reason for such a state-
ment is the physical impossibility
(economically) of placing the reference
electrode (copper-copper sulfate half-
cell) at all Points aloncr the structure.
Some engineers use the reference
electrode at a ‘remote earth” point in
reference to the well casing and take
all potential measurements to that
reference point. This is, in effect,
measuring the “average” potential of the
structure. It is entirely possible to
have the “average” potential obey either
of the criteria mentioned and yet have a
SPE 2910 ELMER
~c=tien of the casing below the minimum
criteria, and with a possibility of
having corrosion proceed in such areas.
Another point which would disallow
a potential criteria of -850 MV is the
fact that some wells have a more nega-
tive potential than this in its’ “native
state”. (We have observed potentials
greater than -1100 M’V.)
This leaves the two remaining
criteria availabie for use in detecmifi-
ing the extent of cathodic protection;
that is, complete hydrogen polarization
or determining that the direction of
electron fiow”is into the casing for its
entire length.
E. CURRENT FLOW DETERMINATION
There are possibly some “exotic”
ways of determining the direction of
electron flow in a well casing, but at
the present time, there is only one
method which is still being used to any
extent.
If one could measure the direction
and magnitude of current flow in the
walls of the casing, he could, through
analysis of the resulting data, define
both the cathodic and anodic areas of
the casing. This is possible by measur-
ing the potential difference between twc
points on the casing, 0----~--._...———
-“-k mn+em~~al
difference being caused by the result of
current flow through the resistance of
that portion of the casing (IR drop).
If sufficient accuracy is obtained,
the magnitude (and direction) of current
flow can be calculated; provided the
resistance of the tested section of
casing is known. The general circuit
for such measurement is shown in Figure
1.
If the IR drop in the casing is
taken at constant intervals (such as 25’
and plotted in graph form, with the
difference in potential between the
contractors in such a direction that
current flow toward the top of the
casing causes the “curve” to slope to
the right, and current flow down the
casing causes the “curve” to slope to
the left, the resulting data would look
something like Figure 2.
Figure 3 is a drawing showing a
typical “head” of a casing profile tool, ~agnitude, whether such anodic areas
CURRY 3
Figure 4 shows a graph of a
typical” profile curve showing an ancdic
rea.
Figure 5 is a graph showing profile
urves with eazzer~t applzed to the
asing.
If direct current were applied to
he casing in such a manner and magni-
ude so as to cause the current to flow
p the casing in all areas, cathodic
--~---:-- ..,n..l~
I%vucvv+ws wwwa-
be amhiaved.
---------- see
‘igure 6.
In this type of survey the follow-
ng points are to be considered.
1. The casing must be free and
clear of all obstacles (tubing,
rods, etc.).
2. The casing must be free of low-
resistivity fluids and vapors.
3. The contractors must be built in
such a way so as to give posit-
ive contact with a minimum of
positioning and yet allow
reasonable freedan of movement
of the tool.
4. One of the necessary components
of the tool is a device on the
lower portion which will give
immediate and accurate indica-
tion of the presence of a low
resistance media.
5. The cable must be of sufficient
strength and flexibility so as
to provide dependable operation.
6. The electrostatic shielding of
the cable and instrument must be
adequate so as to allow record-
ing of accurate data, free of
“outside” influence.
7. The recording instrument must be
within accep&ble accuracy on
all scales and have sufficient
input impedance so as to mini-
mize errors due to “IR drop” in
the contactor leads. It must
have a reasonable degree of
sensitivity and ought to have a
“zero-center scale”.
The casing profile as described can
.ooate anodic areas of reasonably small
4 SPE 2910
WELL CASING CORROSION AND CATHODIC PROTECTION
I
exist as an environmental condition of in the same place where the permanent
the casing or as a result of interfer- ground bed is to go. The reason is
ence currents. It can also indicate obvious. A ground bed in a different
current requirements for cathodic pro- location (not completely remote from the
tection or check the reliability of an well) will produce an entirely different
existing cathodic protection system. set of results. (Both should give an
accurate determination of current
required for cathodic protection ~
F. POLARIZATION DETERMINATION applied from its respective point
sour cc.)
If a method of measurement could
be used in which potential measurements Again, if the location of the
taken on the surface of the ground ground bed is changed the current
(measured between the well casing and a required for protection will change.
remote electrode) would indicate not
only the shift of potential, but would The reference electrode must be
=~~~ -..--=-
inclkat-ta.- ~~.~ hvdrcxren --x—-=-.. ~Qn ~—_—_—— nolari- Ifim.+-aa+
*“-U.=- -.
a --------
-
A~a+anmn Fvnm
-..—
tha
----
wnll
-----
zation potentials, hydrogen gas evolu- equal to or more than one-tenth the
tion potentials, etc.; it would be depth of the well and in such a direct-
possible to use a classic polarization ion (generally on the side of the well
cell measurement technique in order to opposite the ground bed) which would
determine the minimum amount of current give the least “interference” from
--u:-= ---.
wn~cn wwuxa nave
--2 L---- L- L- ---3 2-a ~sk~~~a~~y
Ku U= app~~=u
:-:& 4-1 1..
other structure; such as flow lines,
in order to achieve polarization. Such Qth-erwells; foreign ————— lines; etc.)=
a circuit is shown in Figure 7.
The “interrupted” potentiai reading
Through the use of this circuit, must be taken across a condenser with a
current is applied to the structure in sophisticated circuit such that the
predetermined increments (0.1 amps, 0.2 potential across the condenser is
.-. n
“.-
A amnm
wt.yo,
II
“.”
Q arena n+m \ with
..--.. = Ilk.. :1&_..
uuA4b-up
- II.1... -.4. AUaLcu4Laba=uuDAy
auuuau.
4-”t!9%+s9maA. .“1..
*
ar*~

G%krit time of appi’iX{iX-t&sually 2 which has a discharge rate abnormally

minutes). At the end of that time long in comparison with the charge rate,
interval, the circuit is interrupted High resistance voltmeters will produce
momentarily and the structure-to-earth errors which are not within the range
potential is read and recorded. The of acceptable limits.
amount of current is immediately in-
creased to the next higher increment, The current source must be of
left on for another 2 minutes, and the sufficient size so that more than 25-
reading and recording is repeated. Thi amperes of current can be realized
procedure should be followed until the from a temporary ground bed with as
potential magnitude indicates the much as 4 ohms resistance. Flow lines,
structure has reached or passed the etc., cannot be used as a temporary
potential threshold for hydrogen evolu- ground bed.
tion. The current requirement can be
determined through interpretation of th
——-—-
resuiting curve. A ‘Stypicai$’ curve is G. E-LOG-I (POLARIZATION) culzms
shown in Fim”re 8. The current require
for cathodi= protection in that initial If a circuit such as shown in
current which must be applied in order Figure 7 were to be duplicated in a
te r----’=
mv&t~~a hi>ilvafiam
J*x-’-*~*~
~nm rY------”--*-
----
mml aviva+inn Qf 111 -&---&------
Acuxwakvky
....--!1
masuLcA .
~.,a~ “
Ls ●
if ~y~e

the structure. It should be understood casing environment were homogeneous

that the current required to maintain (surrounding media of the same resist-
polarization can be far less than that ivity, constant PH values, the same
required to achieve polarization amount of moisture available to the
initially. entire length of casingt etc.)t a
curve plotted from data taken during an
There are certain guidelines which E-Log-I current requirement test should
must be followed in order to produce look similar to that shown in Figure 9.
~~dable, reproducible, and accurate
-v~Ywnm+ Aa+nvm-i
e-**Q**- -e ---**--------- nstinn pcz.~ar~ 11=* ~f ~pae m**F*7n
b-. “G
wanwanam+.
*=&*=”sa*.-

a function of current vs. potential

The temporary “ground bed”, used as lineal in nature, occurring as a result
a point source from which the current of electron flow from the ground bed to
for the test is applied,nust be located the casing. This portion of the curve
SPE 2910 ELMER ;

5oes not include any polarization.

ml
Portion “b” of the curve represents
3 function of current vs. potential
occurring as a result of electron flow
from the ground bed to the casing, modi-
fied by the effects of hydrogen ion
polarization on the casing as a result of
current flow of sufficiently large magni-
tude.
Portion “c” of the curve represents
a function of current Vs. pcteiltia~
Qgcurring as a result of electron flow
from the ground bed to the casing, hydro-
gen ion polarization and modified as a
result of the hydrogen gas formations and
evolution.
portion “d” results when the entire
structure has reached a saturation point
of hydrogen gas and dissolution, causing
the only additional potential change to
be a result of the applications of the
current such as that portion of the ~rve 4
designated “a”.

It should be clearly understood

that such a clearly defined E-Log-I
curve will most probably not occur in
actual testing, not only because of the
variations of the soil media, but also
due to the differential availability of
1
the hydrogen ion within the various
strata, as well as that effect of anodic
polarization possibly present in those
areas where corrosion is occurring.

Because of the many conditions

encountered in current requirement test-
ing on well casing, it becomes apparent
that the E-Log-I test is reliable only if
correct instrumentation and methods are
used, even though the theory of the test
is basic in nature.

ACKNOWLEDGMENTS

The author wishes to thank all of

his compatriots who have so generously Fig. 1 - Illustrationof
contributed to the concepts and develop- electron flow from an
ment of the data pzeser~ted. anodic area through the
soil to the casing, then
REI?ERENCES within the steel casing
wall to its noint of
1. Titterington, Y. W. : “Casti9 origin. The “meter”
at the top of the casing
Corrosion and its Mitigation in Gas
measures the direction
Storage Wells”, AGA Conference,
and magnitude of the
May, 1959.
“voltage drop” in the
casing wall which is a
direct result of the
current flow.
 ME6ATIVE POSITIW
l— CONDUCTOR cABLE
MICF?OVOLT5
-DOWN CASING UP CA51N6—

I
INSTRUMENT HEhD—

Y
KNIUES—
}

ELECTRICALLY
INSULATED
n SECTIONS

Fig. 2 - Illustrationof a potential Fig. 3 - Drawing of a typical well

profile superimposedover a casing profile tool.
representativedrawing of a well
casing showing right and left slope
of profile curve in relation to
current flow in the well casing.

Fig. 4 - Plotted curve of a

well casing potential
profile showing anodic
sections (left slope) and
cathodic sections
(right slope).
 M ICROVOLTS MICROVOI..T5
- Dowt.1 UP aSlN6—

~
I ,, ‘c
cOPRER-
WLFATC
UW-cEIL

6= CURRENT’ SOURCE
R = VARIAOLE RESISTOR.
A = AMMETER
~ : tiOLSME.TER

W’ WITCH

C z COUPCNSER

Fig. 5 - Casing profile curves
showing two different amounts
of current being applied to
the casing in an effort to
achieve cathodicprotection.
(The objective is to remove
all “left slope” below’the
surface casing.)
Fig. 6 - Casing profile curve
showing static condition of
casing (zero current) and
the change of slope as a
result of the applicationof
1.3 amps of current. (Note
current flow is toward the
top of the casing after the
1.3 amps of current is
applied.
Fig. 7 - Illustrationof the c!urrent
application circuit and the
potential measuring circuit clfthe
General Corrosion Services E-.Log-I
method of determiningcurrent
requirementfor cathodic protection
of a well casing.

,
 IMPRESSCO CURRENT - AM PCRRS

Fig. 8 - Results of E-Log-I current requirementstests.

(Casingprofile results shown in Fig. 6.)

lMPRIESSEO CURRENT - AMP=R=S

Fig. 9 - Theoreticalpolarization curve.