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Maximizing asset uptime and reducing maintenance costs are essential in any process facility. Effective corrosion management is a key driver to achieving these goals. Corrosion management involves monitoring and controlling corrosion to maintain the integrity of equipment and improve availability and safety.
Corrosion management continues to be a worldwide challenge, stretching the capabilities of institutions across various fields around the globe. One such industry is the Oil & Gas which accounts for approximately 60% of the worldwide cost of corrosion that is estimated to be $2.5 trillion per year. The main challenge facing the industry is the reactive nature of corrosion management and the consequences of the lack of a holistic management approach. Although some tools claim to assist in managing corrosion, their effectiveness and usefulness are always questioned by the failures that occur in their presence. With this in mind, Saudi Aramco has developed an in-house web-based technology known as the Corrosion Management Solution (CMS), which is an integrated solution for monitoring corrosion parameters through real-time data. CMS intends to shift corrosion management from a reactive to a proactive process. This in return has served the company in its corporate strategy of being on the global forefront of the Fourth Industrial Revolution (4.0IR) applications, while also enhancing the asset integrity and reliability across its operating facilities. This paper details the approach the team took to develop the CMS driving forward a new paradigm in corrosion management and establishing the platform for an intelligent machine learning-based system.
A system approach for cost-effective corrosion controls by incorporating corrosion management into a company’s existing systems. It will improve communication, resourcing, and funding allocation such that corrosion control investments result in positive returns while minimizing costly failures.
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This paper illustrates fifty (50) Key Perfomance Indicators (KPIs) that were developed based on industry surveys and failure analysis; application of these 50 KPIs using 10 case studies and explains cost effectiveness of various KPIs.
This paper discusses the journey Saudi Aramco took during the last decade to introduce the concept of an integrated CM and the associated digital challenges. The focus will be on the online Corrosion Management Dashboard (CMDB) development, deployment, maintenance, and finally transformation. The CMDB scope was recently shifted from monitoring the compliance of corrosion-related parameters to predict CM performance by using the combined effect of different parameters. However, with a void in CM digitalization mandate, effort may not be focused or they do not eventually achieve their full potential.