Abstract

In order to combat the rising costs attributed to corrosion in PDO's oil production operations, an initiative was undertaken to develop a Corrosion Management System. A description is given of the functionality of the developed system, Pacer-CM, which has been designed to capture all monitored data deemed relevant to corrosion control for all facilities exposed to a corrosion risk. The financial benefits that have been accrued in the relatively short time frame that the system has been operational are also discussed.

Introduction

Information technology plays an increasingly important role in optimizing oil production operations from the reservoir to the point of sale. A practical demonstration of the emerging importance of information technology is in the area of corrosion management. Over the past 18 months PDO has acted, in collaboration with the system vendor, Strategic Information Systems, as the execution site for the development and subsequent implementation of a comprehensive Corrosion Management System. The major aim was to provide an effective contribution to integrity management by making readily available to the user the information required to conduct a comprehensive corrosion analysis and to provide a traceable and auditable means of managing the condition of such facilities.

Corrosion Management

Corrosion Management (CM) is the process which deals with material selection (including the standards and fabrication procedures), operational limits, corrosion monitoring, insection, data analysis and feed back of experience to new projects. The full context of Corrosion management is portrayed in Figure 1.

Materials Selection.

Materials selection, in general, takes place during the design phase of a project. The choices of materials will depend upon many factors:

  • process data; what are the temperatures, pressures, flow rates, etc that the materials have to resist

  • chemical data; to what kind of chemicals is the equipment exposed

  • environmental data; what are the outside conditions to which the equipment is exposed.

"Feed forward" of the materials and corrosion constraints of the design life is essential if the installation is to be operated successfully throughout its design life without corrosion damage becoming a problem.

Regular Monitoring and Inspection of Equipment During the Production Phase.

Regular monitoring and inspection of equipment during operations are necessary to:

  • Ensure that the facility can be operated safely

  • Predict accurately equipment life expectancy

  • Predict corrosion for budget purposes

  • Identify the cause of corrosion and prevent recurrence

  • Monitor the effectiveness of corrosion control techniques

  • Replace equipment which jeopardizes the process before failure occurs

Materials Selection.

Materials selection, in general, takes place during the design phase of a project. The choices of materials will depend upon many factors:

  • process data; what are the temperatures, pressures, flow rates, etc that the materials have to resist

  • chemical data; to what kind of chemicals is the equipment exposed

  • environmental data; what are the outside conditions to which the equipment is exposed.

"Feed forward" of the materials and corrosion constraints of the design life is essential if the installation is to be operated successfully throughout its design life without corrosion damage becoming a problem.

Regular Monitoring and Inspection of Equipment During the Production Phase.

Regular monitoring and inspection of equipment during operations are necessary to:

  • Ensure that the facility can be operated safely

  • Predict accurately equipment life expectancy

  • Predict corrosion for budget purposes

  • Identify the cause of corrosion and prevent recurrence

  • Monitor the effectiveness of corrosion control techniques

  • Replace equipment which jeopardizes the process before failure occurs

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