OVERVIEW

Corrosion Management Background

Corrosion is a major integrity threat for many industries including oil and gas. To control and mitigate the associated corrosion threat, corrosion engineering had been used as virtually the sole solution for a very long period of time and up to early 2000s. However, beginning with the UK’s North Sea Offshore Oil and Gas Industry it became increasingly evident that the corrosion engineering discipline (through its three main components of design, materials selection and controlling environment) could not efficiently mitigate corrosion. Simultaneously, it became clear that there were various non-corrosion engineering-based integrity management measures which played a crucial role in corrosion mitigation. They included:

·       Communication

·       Competency

·       Risk-based inspection

·       Documentation

·       Procedures

·       Corrosion control matrices

Such findings resulted in the advent and evolution of the corrosion management concept and models in the UK. The best two examples of such models include:

1.     The UK HSE Corrosion Management Model, which was published by the UK’s Energy Institute in May 2008

2.   The Morshed Corrosion Management Model, which was published by the NACE International in May 2012 – which is taught at our corrosion management training courses in India

Over the past decade or so, corrosion management services (e.g., training and consultancy) have experienced a phenomenal growth due to soaring demands for such services – both within the oil and gas and the non-hydrocarbon industries. Nevertheless, there are many individuals within the oil and gas industry and beyond who still deem the corrosion management term as a mere synonym for the corrosion engineering discipline. Such an erroneous approach has continuously deprived these individuals and their associated organisations to successfully identify and address the exact root causes of a considerable portion of their corrosion failure cases, when the main culprit had been a non-corrosion engineering-based integrity management measure. Consequently, in a significant percentage of the encountered integrity cases, the issue had continued over many years, culminating in numerous failure and leak incidents along with the increasing associated costs.

On the contrary, when a ‘real’ corrosion management approach is taken or utilised, it takes into account both corrosion engineering-based and non-corrosion engineering-based integrity management measures. Thus, it is considerably more likely to identify and then to rectify the root cause, whether it belong to the former category or the latter.

Intro

Corrosion Management Implementation Benefits

Proper and timely implementation of the corrosion management concept/process – covered in our training courses – could bring about many different benefits including:

·       Enhancing the corrosion failure pre-emption capability of the organisation

·       Optimising corrosion and integrity costs

·       Increased asset uptime

·       Extending asset’s operational life

·       Improving personnel safety and environmental protection

·       Enhanced communication and reporting

·       Optimising corrosion rate monitoring, fluid sampling and chemical treatments

Industries Targeted

While the corrosion management concept was initially associated with the oil and gas industry; nevertheless, the process itself and its tools are ubiquitous and equally applicable to any other industry where corrosion is a major integrity threat. Therefore, the industries which could benefit from a corrosion management training course include:

  • Hydrocarbon (Upstream, Midstream and Downstream): That is production and processing sites, refineries, the associated pipelines and petrochemical units
  • Marine
  • Military
  • Nuclear
  • Water and Waste Water Management
  • Power & Utilities
  • Chemicals

Corrosion Management Misconceptions and Abuses

Due to its freshness, the term and concept of ‘Corrosion Management’ is still often mistaken for ‘Corrosion Engineering’. As such, many of the training courses and consultancy services with the title ‘Corrosion Management’ are actually ‘Corrosion Engineering’ training courses and consultancies. Such misconception and misunderstanding are sometimes inadvertent, but in many occasions intentional. Therefore, anybody or any organisation interested in receiving corrosion management training and services should be careful to distinguish between the two. This if often done by reviewing the course or proposed services contents and details. It they focus on design, materials selection, deterioration mechanisms, basics of electrochemistry, corrosion monitoring techniques and CP basics then they are corrosion engineering courses or services. Otherwise, they could be regarded as corrosion management content and material if they comply with the aforementioned corrosion management definition.

Corrosion Management Main International References

  • Energy Institute, Guidance for Corrosion Management in Oil and Gas Production and Processing, 2nd Edition, March 2019,  May 2008, ISBN 9781787250635
  • Ali Morshed, An Introduction to Asset Corrosion Management in the Oil and Gas Industry, NACE International, May 2012, ISBN 1-57590-246-X (An international bestseller!)
  • Ali Morshed, An Introduction to Asset Corrosion Management in the Oil and Gas Industry, 2nd Edition, NACE International, Oct. 2016, ISBN 978-1-57590-338-5
  • Ali Morshed, An Introduction to Asset Corrosion Management in Industry, NACE International, Jul. 2017, ISBN 978-1-57590-364-4
  • Ali Morshed, A Complete Guide to Corrosion Management Implementation in Industry, NACE International, May 2018, ISBN 978-1-57590-371-2
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