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Reactive to Proactive Transformation - A New Paradigm in Corrosion Management

Picture for Reactive to Proactive Transformation - A New Paradigm in Corrosion Management
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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.

Product Number: 51323-19106-SG
Author: Faisal M. Al-Mutahhar, Ibrahim A. Albrahim, Abdullah M. Alratoee, Rakan A. Al-Shebil, Ayman A. Alabdullatif, Ricardo S. Costa, Yousef A. Aldossary, Muntathir M. Al-Jumaah
Publication Date: 2023
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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.

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.

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Product Number: 51317--9438-SG
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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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Corrosion Data Management Using 3D Visualisation and a Digital Twin

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There is a gap between the Integrity management systems used by companies to manage their assets and the needs of the CP engineer. Integrity management systems do not fully meet the needs of the engineer responsible for corrosion as they do not provide access and visualizations of all the data the engineer needs to make fast and informed decisions. There is also often no easy way to see the trends in the data, or easily access the relevant video and photographic data also recorded during the survey.

Data from surveys is normally contained in reports and EXCEL spreadsheets often with different measurement locations and inconsistent naming of the locations between reports. In this paper a system is introduced which enables engineers to manage and visualise in 3D CP survey data and provide access to all the relevant information through a 3D visual interface to any member of the teams. The software gives the engineer the ability to visualize in 3D the historical and predicted CP protection on the structure and the status of the anodes in the CP system. It also provides information on long term trends in the survey data.

By integrating the corrosion data with a simulation model a “digital twin” of the structure can be created to make predictions of the present and future protection of all parts of the structure. For example the engineer can easily use the software to systematically monitor the differences between the model predictions and survey data to identify anomalies and give early identification of problems which will require action.

The paper will describe the system developed and present applications of both the 3D corrosion data visualisation and the simulation based digital twin
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Challenges in Developing, Deploying, and Transforming Online Corrosion Management Dashboards

Product Number: 51320-14757-SG
Author: Sami M. Al-Ghamdi, Hendrik J. Debruyn, Ricardo S. Costa, Lay Seong Teh
Publication Date: 2020
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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. 
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