Corrosion & Materials Management: Downhole and Subsea

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Upcoming Course

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Past Course

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        Aaron A. Zick, Ph.D. 
PST0089-201701  25 Sep 2017  28 Sep 2017  Kuala Lumpur, Malaysia  SGD 4495  Dr. Anthony Cole 
PST0089-201801  29 Oct 2018  01 Nov 2018  Kuala Lumpur, Malaysia  SGD 4495  Dr. Anthony Cole 

Oil and gas reserves are gradually depleting and the limited resources currently being exploited tend to be more costly to develop and to contain more corrosive fluids. For these reasons maintaining cost effective safety, reliability of equipment and fluid containment is becoming an ever greater challenge.

With cost pressures on there is an increasing demand for better reliability, efficiency and safety, the technological development has been massive. It is critical to understand and learn the latest knowledge on corrosion and material selection to ensure you make the correct choices first time around to keep your production flowing, equipment in optimal working condition and to avoid costly downtime, wastage and replacements.

In addition, as wells become more complex and hydrocarbons are being sourced at ever higher pressures Operators are facing complex issues of producing highly sour fluids in locations where intervention costs are high and constantly rising.

PetroSync is presenting an intensive four day program in this Corrosion & Materials Management Best Practice Series.

The Program is structured to provide industry specific corrosion and materials knowledge, including methods to monitor and measure corrosion across all industry application. This provides the foundation for all related activities regardless of application. It then narrows in on two areas of particular concern in the industry, downhole corrosion issues and subsea production equipment and facilities design, operation and maintenance. Discussions will cover approaches, technique and tools suitable to specify, monitor, control, and troubleshoot asset performance.

This training course is recommended for both discipline- and project-focused engineers who require a more thorough knowledge of materials to optimise their output.

A combination of lecture, examples, and interactive sessions will be utilized, providing the attendees with an opportunity to engage in discussions and to participate in an effective learning experience together with Dr. Anthony Cole.

Day 1 - Corrosion and Spesific Concerns

The first sessions of the course provide the basic building blocks required for all attendees to comprehend Days 2 to 4. Industry specific corrosion and materials are introduced to ensure that all participants are familiar with the fundamental corrosion, materials and component technologies which underpin the remaining days. Following a team quiz the day concludes with an overview of the specific types of corrosion commonly found in downhole applications and methods to mitigate these:

  • General principles of corrosion and materials
  • Corrosion mitigation including coatings and cathodic protection
  • Corrosion monitoring and inspection
  • Monitoring and Inspection, NDT

Day 2 - Materials in Well Construction

Day two kicks off with a review of the previous days quiz before detailing the types and properties of steels, corrosion resistant alloys and non-metallics used in downhole applications, including an overview of OCTG connection testing.

  • Wells and General Well Design
  • Various Downhole Corrosion Mechanisms and Effecton Materials Properties
  • Materials forming and the impact on corrosion resistance
  • Quiz
  • Specific Types of Downhole Corrosion - Case studies
  • Corrosion Prevention – Casing and Tubing
  • Materials for Casing and Tubing
  • Drilling and completion fluids
  • The Wellhead and Christmas Tree
  • Connections and Connection Testing
  • Corrosion mitigation during acid stimulation
  • Quiz

Day 3 - Downhole Materials Selection

  • For day three of focus moves materials selection for a variety of wells from simple producing wells in relatively benign environments to HPHT, sour service wells and includes consideration of water injections and alternative production and injection swells. To cement understanding of the selection process the day finishes with a Materials Selection group exercise, which requires the candidates to consider a variety of well types and environments
  • Materials Selection
    • Steel Casing and Tubing Materials
    • CRA Casing and Tubing Materials
  • Everything Else: Ancillary equipment, such as seals, water-alternate-gas (WAG)wells and discussion on topics raised during the preceding days
  • Daily quiz and Materials Selection Exercise
  • Round-up and review
  • Wells, wellheads, xmas trees and manifolds.

Day 4 - Subsea Corrosion and Metallurgy: Equipment & Materials Selection

Day four of this course turns to individual components in the subsea system and highlights particular concerns and failure mechanisms which need to be addressed for each of them; the major components of such systems are then detailed and materials selection decisions proposed. At the end of the day attendees will be confident to discuss subsea corrosion and materials.

  • Flowlines and risers
  • Valves
  • Fasteners, seals and gaskets
  • Umbilicals and flexibles
  • Hydraulic control and chemical injection systems
  • Insulation
  • Quiz results, group photos, certificates and prize giving
  • UPDATE on the latest research and development of deepwater material & corrosion
  • UNDERSTAND and LEARN best practices developed and implemented by leading companies
  • INDENTIFY and MONITOR the causes of corrosion and material failure
  • MITIGATE internal and external corrosion
  • SPECIFIY cost effective materials for safe operations
  • BENEFIT from real life case histories and AVOID expensive material-related equipment failures
  • LEARN the latest subsea recommendations of EEMUA 194
  • GAIN INSIGHTS to new technologies like TubeFuse™, Expendables & Smart Wells Technologies
  • SHARE experience and NETWORK with peers

This program is intended for:

  • Materials and Corrosion Engineer
  • Subsea Engineer
  • Maintenance &/or Inspection Engineer
  • QA/QC Engineer
  • Integrity Engineer
  • Well & Completions Engineer
  • Production Technologists who would like a more thorough knowledge of well related corrosion
  • Production Chemists and others involved in well-centric activities

And technical personnel that specify, operate, maintain and repair subsea production equipment & facilities.

These personnel typically have a basic understanding of some part of the process, but want to increase their understanding on the best practices and be updated on the latest R&D achievement.

Aaron A. Zick, Ph.D.

Founder and President


President, Zick Technologies (Since 10/93).

Petroleum engineering consulting and software development, specializing in the area of reservoir fluid phase behavior modeling. References available on request. Key achievements:

-Developed numerous equation-of-state and black-oil fluid characterizations for various major oil companies and as a sub-contractor for Pera A/S.

-Recommended phase behavior experimentation and modeling guidelines for several major oil companies.

-Wrote PhazeComp, a new, state-of-the-art program from Zick Technologies for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Wrote Streamz, unique Petrostreamz A/S software for translating, manipulating, and managing vast quantities of fluid stream information.

-Designed and helped write Pipe-It, unique Petrostreamz A/S software for managing and manipulating petroleum resources, processes, and projects.

-Taught numerous industry courses on phase behavior, equations of state, reservoir fluid characterization, and miscible gas injection processes.

-Designed and helped implement a new set of equation-of-state routines for the in-house reservoir simulator of a major oil company.

-Advised the architects of a major commercial reservoir simulator on ways to significantly improve their equation-of-state routines.


Director of Research, Reservoir Simulation Research Corporation (6/91–10/93).

Responsible for the research and development of more efficient, accurate, and reliable techniques for modeling reservoir fluid phase behavior within MORE® (a fully-compositional, equation-of-state reservoir simulator). Also responsible for improving three-dimensional visualization of reservoir simulator output, and for occasional consulting work. Key achievements:

-Designed and implemented new equation-of-state solution algorithms for MORE®, improving both efficiency and robustness while using less memory.

-Developed a powerful and flexible interface between MORE® and TECPLOT™ (three-dimensional surface contouring software from AMTEC Engineering).


Senior Principal Research Engineer, ARCO Oil and Gas Company (9/83–5/91).

Developed expertise in reservoir fluid phase behavior, phase behavior modeling, compositional reservoir simulation, and relative permeability modeling.  Designed and analyzed PVT experiments. Created equation-of-state reservoir fluid characterizations. Developed ARCO’s phase behavior modeling software and relative permeability modeling software. Helped develop several of ARCO’s compositional and limited compositional reservoir simulators. Key achievements:

-Discovered the true, condensing/vaporizing mechanism of oil displace­ment by enriched hydrocarbon gases.

-Represented ARCO on the Prudhoe Bay co-owners’ Enhanced Oil Recovery Task Force for the Prudhoe Bay Miscible Gas Project.

-Designed and analyzed most of the PVT and slim-tube experiments for the Prudhoe Bay Miscible Gas Project.

-Created the equation-of-state reservoir fluid characterization adopted by the operating companies for the Prudhoe Bay Miscible Gas Project.

-Developed the miscibility pressure correlations used by the facility operators for the Prudhoe Bay Miscible Gas Project.

-Developed EOSPHASE, a then state-of-the-art program for equation-of-state phase behavior modeling, reservoir fluid characterization, and the robust, efficient calculation of minimum miscibility conditions.

-Developed SLIMTUBE, a special-purpose, equation-of-state simulator for slim-tube displacements.

-Developed new, compositionally-consistent, three-phase relative perme­ability models for ARCO’s compositional simulators and wrote data-fitting software for those models.

-Developed the phase behavior and relative permeability routines for a new, limited compositional reservoir simulator and assisted on other aspects of it.

-Continually added improvements to various in-house reservoir simulators.

-Regularly taught in-house courses on the phase behavior of miscible gas displacement processes.



A. A. Zick, “A Combined Condensing/Vaporizing Mechanism in the Displacement of Oil by Enriched Gases,” presented at the 61st Annual Technical Conference and Exhibition of the Society of Petroleum Engineers, New Orleans, LA (October, 1986).

D. E. Tang and A. A. Zick, “A New Limited Compositional Reservoir Simulator,” presented at the 12th SPE Symposium on Reservoir Simulation, New Orleans, LA (March, 1993).