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TPA
Performance-Based
Internal Corrosion Management Plans
CMP-IC

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A Game-Changing Approach for Designing & Maintaining Hazard-Optimized Corrosion Mitigation Strategies

With TPA / CMP-IC's you can experience a more efficient and effective way to manage internal corrosion in your pipelines by assuring consistent alignment between mitigation activities and the corrosion hazard profile
Internal Corrosion Management Plan (CMP-IC)
 

1.  Corporate Program Management

  • Oversees the entire CMP-IC process

  • Ensures alignment with corporate goals

2.  Corrosion Profiling Assessment

  • Identifies potential corrosion hotspots

  • Uses advanced modeling techniques

3.  Plan

  • Inventory & POMM (Pipeline Operation and Maintenance Manual)

  • Schedule Tasks

4.  Execute Tasks

  • Field Operations

  • Implement mitigation strategies

5.  Field Data Validation

  • Validate field data accuracy

  • Ensure compliance with standards

TPA within quality integrity management program

CMP - IC

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Internal Corrosion Management Plan (CMP-IC)
 

6.  CMP Validation & Implementation

  • Review and validate corrosion management strategies

  • Implement CMP recommendations

7.  Direct Examination (ILI/AUT)

  • Inline Inspection (ILI)

  • Automated Ultrasonic Testing (AUT)

8.  Assess

  • Compliance & Effectiveness

  • Review performance data

9.  Improve

  • Continuous improvement cycle

  • Update CMP based on findings

10. Adjust

  • Implement revised Hazard Assessment and Plan

CMP-IC's rely on the advanced TPA - Corrosion Hazard Modelling to identify potential corrosion hotspots and implement mitigation strategies to ensure compliance and alignment to the corrosion hazard profile.
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Quality Integrity Management in the Oil and Gas Industry:
A Forward-Looking and Performance-Based Approach

1. Introduction

Quality Integrity Management (QIM) is crucial for ensuring the safe, efficient, and reliable operation of pipelines in the oil and gas industry. This document outlines a forward-looking and performance-based approach to QIM, structured around the Plan-Do-Check-Act (PDCA) cycle.

2. Plan-Do-Check-Act (PDCA) Cycle

The PDCA cycle is a continuous improvement model used to systematically manage and enhance processes. It consists of four stages:

  1. Plan: Define objectives, identify potential risks, and develop strategies for quality and integrity management.

  2. Do: Implement the strategies and solutions developed in the planning stage.

  3. Check: Monitor and evaluate the effectiveness of the implemented solutions and strategies.

  4. Act: Take corrective actions based on the evaluation to improve and refine the process.
     

3. Forward-Looking Approach

A forward-looking approach in QIM involves anticipating future challenges and opportunities to proactively manage the integrity of pipelines. Key elements include:

  1. Predictive Maintenance: Utilizing advanced analytics and monitoring tools to predict and prevent potential failures before they occur.

  2. Technology Integration: Incorporating cutting-edge technologies, such as smart pigs and inline inspection tools, to enhance the detection and analysis of pipeline conditions.

  3. Risk Management: Continuously assessing and mitigating risks associated with pipeline operations to prevent incidents and ensure long-term reliability.
     

4. Performance-Based Approach

A performance-based approach focuses on achieving specific outcomes and continuously improving performance metrics. Key components include:

  1. Key Performance Indicators (KPIs): Establishing measurable KPIs to monitor the effectiveness of QIM strategies.

  2. Data-Driven Decision Making: Leveraging data collected from monitoring and inspection activities to make informed decisions.

  3. Continuous Improvement: Regularly reviewing performance data and implementing changes to enhance pipeline integrity and operational efficiency.
     

5. Implementing the PDCA Cycle

  1. Plan:

    • Conduct a comprehensive risk assessment to identify potential threats to pipeline integrity.

    • Develop a detailed QIM strategy that includes objectives, KPIs, and performance targets.

    • Create a timeline and allocate resources for implementing the strategy.

  2. Do:

    • Deploy advanced monitoring and inspection technologies, such as corrosion sensors and smart pigs.

    • Implement predictive maintenance programs to address identified risks.

    • Train personnel on new technologies and procedures to ensure effective execution.

  3. Check:

    • Regularly collect and analyze data from monitoring and inspection activities.

    • Evaluate the effectiveness of the QIM strategy by comparing actual performance against KPIs and targets.

    • Conduct periodic audits and reviews to ensure compliance with industry standards and regulations.

  4. Act:

    • Identify areas for improvement based on performance data and evaluation results.

    • Implement corrective actions to address deficiencies and enhance the QIM strategy.

    • Update the risk assessment and QIM strategy to reflect changes in operating conditions and emerging threats.
       

6. Conclusion

Quality Integrity Management in the oil and gas industry requires a proactive, forward-looking, and performance-based approach.

 

By adopting the PDCA cycle, organizations can systematically manage pipeline integrity, continuously improve performance, and ensure the safe and reliable operation of their assets.

 

Leveraging advanced technologies and data-driven decision-making, the industry can anticipate and address future challenges, maintaining the highest standards of quality and integrity.

Corrosion Management Planning -
Internal Corrosion (CMP-IC)

1.0 Introduction

1.1 Objectives

The primary objective of the Corrosion Management Plan for Internal Corrosion (CMP-IC) is to ensure the long-term integrity and reliability of oil and gas pipeline systems. This is achieved through systematic risk assessment, monitoring, and implementation of effective mitigation strategies to control internal corrosion mechanisms.

1.2 Scope

The CMP-IC covers all aspects of internal corrosion management, including:

  • Identification and assessment of internal corrosion risks.

  • Development and implementation of monitoring and mitigation strategies.

  • Continuous evaluation and improvement of corrosion management practices.
     

2.0 Internal Corrosion Risk Assessment
 

2.1 Pipeline Operating Conditions

A detailed assessment of pipeline operating conditions, such as temperature, pressure, flow rates, and the chemical composition of transported fluids, is essential to identify potential corrosion risks. Key factors include:

  • Fluid Composition: Water content, CO₂, H₂S, chlorides, and other corrosive agents.

  • Flow Regime: Turbulent vs. laminar flow and its impact on corrosion rates.

  • Temperature and Pressure: Influence on corrosion mechanisms and inhibitor performance.
     

2.2 Corrosion Mechanisms

Understanding the specific corrosion mechanisms affecting the pipeline is crucial for effective management. Common mechanisms include:

  • CO₂ Corrosion (Sweet Corrosion): Formation of carbonic acid leading to metal loss.

  • H₂S Corrosion (Sour Corrosion): Sulfide stress cracking and pitting corrosion.

  • Microbiologically Influenced Corrosion (MIC): Caused by microbial activity, particularly sulfate-reducing bacteria (SRB).

  • Erosion-Corrosion: Accelerated metal loss due to the combined effects of corrosion and mechanical wear.
     

2.3 Hazard Assessment

Utilize advanced models like TRIAGE to assess the internal corrosion hazard. This includes:

  • Corrosion Rate Prediction: Based on operational data and corrosion models.

  • Likelihood of Corrosion: Severity scoring system to evaluate risk levels.

  • Potential Consequences: Assessing the impact of potential corrosion-related failures on safety, environment, and operations.
     

3.0 Monitoring Strategies
 

3.1 Inline Inspection (ILI)

Periodic inline inspections using smart pigs to detect and quantify internal corrosion features. This provides direct evidence of pipeline condition and effectiveness of mitigation measures.
 

3.2 Corrosion Coupons and Probes

Installation of corrosion coupons and electrical resistance probes to monitor real-time corrosion rates within the pipeline.
 

3.3 Fluid Sampling and Analysis

Regular sampling and chemical analysis of pipeline fluids to detect corrosive species and evaluate the performance of corrosion inhibitors.
 

4.0 Mitigation Strategies
 

4.1 Chemical Inhibition

Continuous or batch injection of corrosion inhibitors tailored to specific pipeline conditions and fluid compositions. Effective inhibitor management includes:

  • Selection: Choosing inhibitors based on compatibility with pipeline materials and transported fluids.

  • Dosage: Optimizing inhibitor dosage to balance cost and effectiveness.

  • Performance Monitoring: Regular assessment of inhibitor performance through field trials and laboratory tests.
     

4.2 Pigging Operations

Routine pigging to remove accumulated water, solids, and other corrosive materials from the pipeline. Pigging strategies include:

  • Frequency: Determined by pipeline operational data and corrosion risk assessments.

  • Type of Pigs: Selection of appropriate pig types (e.g., foam, brush, scraper) for different cleaning purposes.
     

4.3 Material Selection and Coatings

Use of corrosion-resistant materials and internal coatings to minimize corrosion rates. Material selection criteria include:

  • Compatibility: With transported fluids and operational conditions.

  • Cost-effectiveness: Balancing initial investment with long-term maintenance savings.
     

5.0 Data Management and Analysis

5.1 Data Collection

Comprehensive data collection from monitoring and inspection activities, including ILI data, corrosion probe readings, fluid analysis results, and pigging records.
 

5.2 Data Analysis

Advanced data analysis techniques to identify trends, assess mitigation effectiveness, and predict future corrosion risks. This involves:

  • Trend Analysis: Identifying changes in corrosion rates over time.

  • Predictive Modeling: Using historical data and corrosion models to forecast future conditions.
     

6.0 Continuous Improvement

6.1 Review and Update

Regular review and updating of the CMP-IC based on new data, technological advancements, and changes in pipeline operating conditions.
 

6.2 Training and Awareness

Ensuring that personnel involved in pipeline operations and maintenance are adequately trained in corrosion management practices and the importance of CMP-IC.
 

6.3 Regulatory Compliance

Maintaining compliance with relevant industry standards and regulatory requirements for pipeline integrity management.

Ongoing Review of CMP-IC -
Corrosion Monitoring Strategies

Introduction

Corrosion monitoring is a critical component in maintaining the integrity and safety of pipelines, particularly in the oil and gas industry. It involves the use of various techniques and tools to detect, measure, and analyze the extent of corrosion over time. Here are some of the key methods and tools used for corrosion monitoring in pipelines:

1. Corrosion Coupons:

  • Description: Small, standardized metal samples that are placed inside the pipeline and periodically retrieved to measure the weight loss due to corrosion.

  • Advantages: Simple, cost-effective, and provides direct measurement of corrosion rates.

  • Limitations: Time-consuming and provides historical data rather than real-time monitoring.
     

2. Electrical Resistance (ER) Probes:

  • Description: Devices that measure the change in electrical resistance of a sensor element as it corrodes.

  • Advantages: Provides real-time corrosion data and can be used in various environments.

  • Limitations: May not be as accurate in detecting localized corrosion.
     

3. Linear Polarization Resistance (LPR) Probes:

  • Description: Electrochemical devices that measure the polarization resistance of the pipeline metal to determine the corrosion rate.

  • Advantages: Provides real-time data and can be highly sensitive to changes in corrosion rates.

  • Limitations: Requires a conductive medium and is generally used in aqueous environments.
     

4. Ultrasonic Testing (UT):

  • Description: Non-destructive testing technique that uses high-frequency sound waves to measure the thickness of the pipeline wall and detect corrosion.

  • Advantages: Accurate, non-invasive, and provides immediate results.

  • Limitations: Requires access to the pipeline surface and can be affected by surface conditions.
     

5. Inline Inspection (ILI) Tools (Smart Pigs):

  • Description: Devices that travel through the pipeline, using various sensors to detect and measure corrosion, metal loss, and other anomalies.

  • Advantages: Provides comprehensive data on the internal condition of the pipeline.

  • Limitations: Expensive and requires interruption of pipeline operations for deployment.
     

6. Hydrogen Probes:

  • Description: Sensors that measure hydrogen permeation through the pipeline wall, indicating the presence of corrosion.

  • Advantages: Can detect the presence of hydrogen-induced cracking and sulfide stress corrosion cracking.

  • Limitations: May require calibration and careful interpretation of data.
     

7. Radiographic Testing:

  • Description: Non-destructive testing technique that uses X-rays or gamma rays to create images of the pipeline interior, revealing corrosion and other defects.

  • Advantages: Provides detailed images and can detect internal and external corrosion.

  • Limitations: Requires safety precautions due to radiation exposure and can be expensive.
     

8. Acoustic Emission Testing:

  • Description: Monitors the release of energy from within the pipeline material due to the growth of cracks or corrosion.

  • Advantages: Can detect active corrosion and crack growth in real-time.

  • Limitations: Requires sophisticated equipment and data analysis.
     

9. Fluid Analysis:

  • Description: Regular sampling and chemical analysis of the pipeline fluids to detect corrosive agents like water, CO₂, H₂S, and chlorides.

  • Advantages: Provides information on the corrosive potential of the fluid environment.

  • Limitations: Indirect method that requires correlation with other monitoring techniques.
     

10. Combining Techniques:

To achieve a comprehensive corrosion monitoring strategy, it's often beneficial to combine multiple techniques. This approach provides a more accurate assessment of corrosion activity and helps in identifying potential issues before they lead to significant damage.
 

11. Data Management:

Effective corrosion monitoring requires robust data management systems to collect, store, and analyze the data from various monitoring tools. Advanced software solutions can help in trend analysis, predictive modeling, and decision-making processes to enhance pipeline integrity management.
 

By implementing a well-rounded corrosion monitoring program, pipeline operators can significantly extend the lifespan of their assets, ensure safety, and reduce maintenance costs.

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