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The purpose of this paper is to emphasize the current advancements of monitoring the integrity level of the processing facilities using means of Integrity Operating Window (IOW) program. In our company, integrity and material & corrosion departments across the upstream and downstream businesses successfully implemented a well oriented and constructive IOW programs to manage the corrosion risks and monitor the integrity level of the capital assets and proactively assess the situation to prevent loss of primary containment. The technology that sets behind this success is the digitalized approach that gathers information from process, operations, lab services and inspection programs and converts them all into a high-level real-time tracking system that asses the current status of corrosion threats and integrity level.
Proactive corrosion monitoring programs are playing a key role in determining the operating life and health of the capital assets. One of the most critical programs that is being implemented in the oil and gas processing facilities is the Integrity Operating Window (IOW) program. Such a corrosion management program is mainly intended to provide an instant approach to assess the integrity level of the assets by gathering information from operations, lab services, process, and inspection data in order to produce out a systematic corrosion control program that elaboratively impact the prevention of integrity threat and further prevent loss of primary containment. However, the challenge in IOW programs is centered around rendering a full cycled corrosion management strategy that is communicated through an auto generated alarm system. At one of the leading energy companies in Oman, engineers from various disciplines were successful in configuring a full real time IOW corrosion management program using digitalization tools and pre-set IOW key performance indicators (KPIs).
Shown on Figure 1 is a typical impressed current CP diagram. When the rectifier is first turned on, i.e. time t=0, there is no polarization yet. At that moment, the applied DC voltage is fully consumed by IR drops at anode (IRa0) and cathode (IRc0), plus original potential difference between anode and pipe (Eoca- Eocc). When t=0, the current is at the greatest value. Over time when polarization kicks in, due to adding polarization resistance, the current is gradually reduced.
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A recent review provided an overview of current microbiologically influenced corrosion (MIC) research. It established that despite extensive study and numerous publications, fundamental questions relating to MIC remain unanswered and stress the lack of information associated with MIC recognition, prediction, and mitigation (Little et al., 2020). On the other hand, bibliometric analysis on the MIC of engineering systems conducted a knowledge gap analysis to focus research efforts and to develop a roadmap for MIC research (Hashemi et al., 2018).
To ensure the safe operation of a gas processing plant, monitoring the Critical Process Variables (CPV) against the Integrity Operating Window (IOW) is a key element for compliance with the corrosion management framework. This paper is the operator’s experience in setting up the IOW management system in a gas processing plant and benefits gained.