Asset Corrosion Management in Oil and Gas Industry

Course Description

Corrosion is a major integrity threat for many industries. The traditional method of corrosion control has been based on the corrosion engineering concept. However, in the early 2000s it was revealed in the UK’s Offshore Industry that corrosion engineering by itself could not efficiently mitigate corrosion and some other parameters or factors were also required for comprehensive and efficient corrosion mitigation.

Thus, a modern method of asset integrity management which is based on the corrosion management concept was born. A corrosion management concept offers more options both during the corrosion root cause identification phase and the corrosion troubleshooting phase; compared with the traditional approach which is merely based on the corrosion engineering concept. Therefore, appreciating what exactly the corrosion management concept or process is, how it is implemented across an asset and what its application benefits are, is of paramount importance.

Consequently, attending a genuine corrosion management training course is absolutely crucial for the relevant personnel and their management.

Course Syllabus

Day One: Corrosion, Corrosion Engineering and Corrosion Management in the Oil and Gas Industry 

• Introductions (Audience, Instructor, Training Course)
• Pre-Course Assessment
• Main Root Causes of Corrosion in the Industry
• Asset Integrity Management Systems (AIMS)
• AIMS Components, Objectives and Benefits
• Corrosion and Corrosion Engineering (CE) in the Industry
• Typical Upstream Corrosion Damage Mechanisms
• The Main International Corrosion Management (CM) Models
• The CM Concept Definition

Day Two: The Corrosion Management Implementation Process 

• The Integrity Review Process
• Performance Monitoring and Assessing Effectiveness
• The CM Process Implementation
• A Brief Introduction to Risk-Based Inspection (RBI)
• Inspection Basics
• Risk Basics
• Risk-Based Inspection Basics
• Corrosion Loops and Process Flow Diagrams 

Day Three: Identification and Maintenance of Management Requirements 

• An Introduction to Management Requirements (12 Items)
• Registers, Strategies and Procedures
• Databases, Documentation and Data Management
• The Significance of Communication
• The Asset Corrosion Management Strategy Document
• Corrosion Control Matrices and Corrosion Key Performance Indicators
• Team Structure, Roles and Responsibilities
• The Significance of Competency

Day Four: Corrosion Management Shortcomings and Other CM Requirements 

• Corrosion Management Shortcomings
• Corrosion Failure Pre-emption
• Corrosion Cost Optimisation
• Other Important CM Requirements
• The Corrosion Management Audit
• The Management of Change Process
• Anomalies and their Management

Day Five: Corrosion Management Application Benefits and Implementation Recommendations 

• Leak Register, Failure Investigations and Learning
• Potential Benefits of Corrosion Management Applications
• Recommendations for Optimised Corrosion Management Implementation
• Main Conclusions
• Main Recommendations
• Post-Course Assessment

Training Course Objectives

• To understand what CM is and what it is not
• To make a distinction between the CE and CM concepts
• To explain the traditional asset integrity management approach (which was only based on the CE concept) and compare it with the modern asset integrity management approach (which is based on the CM concept)
• To learn how CM is implemented across an asset
• To appreciate the various benefits of CM applications
• To share international CM experience, case studies and best practice from some of the biggest engineering and operating companies in the world
• To learn how to optimize corrosion costs for an asset

Training Methodology

The course is taught by Ali Morshed (PhD, MSc, DIC, CEng), who is a corrosion engineer with more than 20 years of international experience across various industries. The main concepts, processes and applications will be introduced using PowerPoint slides containing a combination of text, tables, charts, photos and videos. Numerous international case studies will be shared throughout the course to facilitate the understanding and comprehension of the main concepts and applications.

 Training Course Benefits

• Improved personnel safety and environmental protection
• Longer asset up time
• Increased asset operational life
• Improved communication and reporting; hence, improved data sharing and corrosion troubleshooting and corrosion control
• Optimized corrosion costs
• Increased corrosion failure pre-emption capability
• Lesser number of corrosion failures

 What a Participant Can Expect to Learn from This Training Course

• How to differentiate between the CE and CM concepts
• How the CM approach to asset integrity management is more efficient than the CE approach
• How to create and improve the ‘corrosion failure pre-emption capability’ for one’s company
• How to use the corrosion engineering-based tools (e.g., design, materials selection, chemical treatments, coatings and CP) more efficiently
• How to create plant integrity windows and corrosion key performance indicators
• How to optimize corrosion costs