The paper describes the Quality Assurance (QA) Program developed by ESSO Production Malaysia Inc. (EPHI) to ensure that its offshore production facilities remain in a safe operating condition through a monitoring and preventive approach. The program has to accomodate the different phases of hydrocarbon recovery at the different fields; the concerns associated with a significant amount of CO2, increasing watercut, and emergence of sulphate reducing bacteria (SRB); the weathering of facilities in a hot and humid environment; and the aging of the existing producing facilities.

The monitoring and control programs used by EPMI to address the above concerns are described. The monitoring programs include structural inspection with remote operated vehicles (ROVs) and divers using non-destructive testing (NDT), and facility inspection employing techniques such as water analyses for pH, iron count and SRB, ultrasonic thickness measurements, corrosion coupons and probes, caliper surveys and vessel/pipeline inspections. The corrosion control programs include the use of corrosion inhibitors, pigging, cathodic protection and coatings.

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