Systematic internal corrosion monitoring, fluid analysis and on-stream inspection of process vessels and associated piping in operating plants at appropriate locations can provide valuable insight into the corrosion status and fitness level of the equipment and components. At the Kuwait Oil Company (KOC), Internal Corrosion Monitoring activities and on stream inspection activities are carried out in all their facilities which consists of 22 Crude Processing Plants (or Gathering Centers), 4 Gas Processing Plants (or Booster Stations); 2 Effluent Water Disposal Plants, Seawater Treatment and Injection Plant, a vast network of pipelines carrying different products, as well as Early Production Facilities.
Internal corrosion monitoring is conducted with online monitoring equipment that include corrosion coupons, corrosion probes, bio probes, hydrogen patch probes etc. installed at key locations. Fluid analyses activities are also carried out for different processes to determine various key parameters such as pH, conductivity, total dissolved solids (TDS), total hardness, dissolved oxygen content, hydrogen sulfide (H2S) and carbon dioxide (CO2) concentrations, corrosion and scale inhibitor residuals, Iron (Fe) content (total and dissolved), bacterial activity, etc.Corrosion data and fluid characteristics are analyzed for trends and appropriate recommendations issued to asset owners for corrective, preventive measures to mitigate corrosion and also to advise Inspection requirements based on findings.
On stream inspection activities include visual inspection and non-destructive testing (NDT) inspections using ultrasonic scanning by Automated Ultra-sonic Test (AUT) method and thickness verification of susceptible portions of piping circuits, equipment and related components in the system.
This paper highlights the significance of integrating the on line corrosion monitoring data and on stream inspection data resulting in proactive inspection intervention, repair and replacement of related piping and piping components in effluent water (EFW) system in one of the crude processing plant. Unscheduled plant shutdown and safety incidents were avoided due to proactive action. Further, it helped the company to initiate MOC process to implement proactive measures in similar piping systems at other facilities also.