This product slowly dissolves for long term scale/corrosion protection. This paper describes the chemical management system that reviewed: statistical interpretation of the results, laboratory methodologies, software simulations to calculate (a) the amount of encapsulated materials (b) frequency of treatment, (c) the economic analysis.
Corrosion under insulation (CUI) is a major problem for petroleum and petrochemical process industries that affects the plant mechanical integrity and attacks assets. CUI can result in sudden and hazardous leaks (safety concern), and plant shutdowns with high losses of production (economical concern).
Traditional detecting methods of CUI to cut a window in thermal insulation used to inspect visually, to measure the thickness, and then return thermal insulation back, giving high chance for water and moisture ingress, accelerating CUI, moreover big amount of scaffolding erection along with thermal insulation removal required.
SHARQ (Eastern Petrochemical Company, one of SABIC companies) is pioneer to study CUI, evaluating many Non–Destructive techniques has proven Pulsed Eddy Current (PEC) as the most effective technique in terms of integrity and cost optimization.
Considering all available techniques, all aspects studied, such as range of applications, features, and limitations, it is concluded and verified to meet our inspection plan strategy needs.
PEC does not require thermal insulation removal; optimize scaffolding erection, has a wide range of applications related to thickness, and temperature. PEC approved by international codes and standards (API) to meet RBI Meridium software requirements.
The validation study results show cost savings of more than 50% compared to traditional thickness measurement methodology, moreover it reduces EHSS (Environment, Health, Safety, and Security) negative impact reduces the probability of safety incidents due to reducing labor, man-hours, and eliminating many associated activities with potential hazard and risk.
PEC has high productivity, easily operated, and provides comprehensive and professional inspection report
This paper will explore the process of conducting asset integrity management systems and the potential use for the existing facility data to analyze integrity status and predict any breach of integrity that would cause a direct major incident. In the dawn of the 4th industrial revolution and in the age of automation and artificial intelligence, asset integrity management systems are being integrated into a more sophisticated process of verification. Programs are being used to collect necessary risk-based data from inspection, maintenance programs and operational checklists in order to rationalize the integrity status and alert proponents of possible breach of integrity. These systems are more efficient than humans in predicting possible failures based on collective data from several critical elements from a facility and calculate the probability of failure based on the current integrity status. It is possible to optimize such systems to eliminate the human error factor and optimize inspection, maintenance and operation programs to better manage asset integrity. The result would be a software that would provide an overview of the plant’s integrity status and provide early alerts of any incoming incident event which allows the facility’s management to act accordingly and direct resources for effective prevention and mitigation.
Upstream oil production assets, including oil production pipeline network and gas oil water separation facilities, play a dominant role in sustaining production targets to meet customer requirements. Corrosion management of such assets encompasses various phases, such as design, construction, operation, and decommissioning. Proper engineering design and sound construction practices combined with effective monitoring are essential to manage and maintain the corrosion of these assets within acceptable limits. Some of the considerations taken into account during design include: safety, environment, pressure, temperature, material availability, delivery time, and cost. Operating these assets outside of the design boundaries could influence the corrosion process, significantly impacting integrity. Close monitoring of operating parameters, along with identifying the corrosion by employing appropriate inspection techniques, and implementing timely corrective measures, are of paramount importance to preserving the integrity of these critical assets, which otherwise could lead to safety and environmental issues. This paper highlights three case studies involving the importance of cathodic protection monitoring, and failure analysis of an oil pipeline, along with corrosion inhibitor optimization efforts carried out to ensure asset integrity.