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Key Components for an Effective Corrosion Control Program

Published: November 10, 2023

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Author: Inspector/Analyst José G. López M, November 9, 2023.

Introduction

A comprehensive program of corrosion control should include the evaluation of applicable mechanisms for control, the selection and application of prevention and mitigation measures, monitoring of equipment and conditions, expanded professional competence, integration within an organizational management system, management policy for this phenomenon and periodic audit.

Periodic monitoring of equipment and conditions is necessary to evaluate the effectiveness of the control measures implemented and determine if additional adjustments or improvements are required.

Corrosion management professionals ¹ must acquire additional skills and knowledge in business tools, financial decision making, risk assessment and management systems, to support strategic and informed decision making.

Therefore, a clear policy must be established that defines the principles and requirements used to manage the threat of corrosion throughout the life cycle of the assets.

Corrosion control program

An effective corrosion management program should include the following components:

The program must include a thorough evaluation of the corrosion mechanisms that may affect the assets, identifying the associated potential risks and vulnerabilities.
Select and apply appropriate prevention and mitigation measures to prevent or reduce the occurrence of asset failures.
Regular monitoring of equipment and conditions is necessary to evaluate the effectiveness of the control measures implemented and determine if additional adjustments or improvements are required.
Corrosion management professionals must acquire additional skills and knowledge in business tools, financial decision making, risk assessment and management systems, to support informed and strategic decision making.
Decisions and practices related to corrosion management must be coherently integrated into the organization’s overall management system, ensuring effective communication and alignment of organizational processes, objectives and strategies.
Establish a clear corrosion management policy that defines the principles and requirements used to manage this threat throughout the life cycle of the assets.
Carry out periodic audits of work plans and processes related to corrosion control to ensure compliance, their continued effectiveness, and their alignment with the organization’s management strategy and objectives.

In the initial phases of development, it is essential to compile a comprehensive inventory of all potential corrosion threats.

From this report, each threat is subjected to an evaluation considering the conditions of the process, the accumulated prior knowledge, industry standards and, to the extent possible, the use of simulation models.

How to develop a reliable corrosion control system?

Control practices for this phenomenon are widely known and applied in various industries that face different corrosion degradation mechanisms. These practices focus on several essential technical activities, including ² :

Assess relevant burnout threat mechanisms to determine associated risks.
Select and apply appropriate prevention and mitigation measures to control corrosion.
Continuously monitor equipment and conditions to determine the effectiveness of control measures and make adjustments if necessary.

Steps to establish a corrosion control system

A Corrosion Management System (QMS) is an essential component in the industry, especially in critical sectors such as oil and gas. Effective corrosion management is essential to ensure asset integrity, operational safety and long-term sustainability. To achieve successful corrosion management, it is necessary to consider several key elements that make up a Corrosion Management System.

1. Risk assessment: This involves identifying and understanding the potential corrosive threats to which assets are exposed, as well as evaluating the impact of these threats. Risk assessment provides critical information to make informed decisions about how to effectively address corrosion.

2. Design and material selection: Choosing appropriate materials to resist corrosion includes the use of resistant alloys, protective coatings, and design methods that minimize exposure to corrosive environments. Choosing appropriate materials and designs is key to extending the useful life of assets.

3. Inspection and monitoring: Using inspection methods such as Non-Destructive Testing (NDT) and real-time monitoring technologies allows structural failures or weaknesses to be identified in time. This makes it easier to take preventive measures before they become costly problems.

4. Maintenance Planning: It is important to schedule inspections, repairs and replacements in a timely manner. This ensures that assets continue to operate safely and efficiently. Proper maintenance reduces the risk of failure and increases the useful life of assets.

5. Training and education: Personnel involved in corrosion management must receive adequate training. Understanding corrosive processes, inspection techniques and best maintenance practices is crucial to QMS success.

6. Documentation and registration: It is necessary to have inspection reports, maintenance records and documentation on the selection of materials, which provides a database for decision making and regulatory compliance. A regular flow of information and data is needed to make the best and most profitable technical and integrity decisions. This requires a consistent, organized and transparent reporting system to facilitate existing or future corrosion assessments, planning and mitigation activities ³ .

A Corrosion Management System integrates these elements to ensure assets remain safe and operational in corrosive environments. Effective corrosion management is an essential component to sustainability, safety and efficiency in the industry, and these elements are the key to achieving that success.

An inevitable phenomenon or a challenge for technology?

What used to be considered an inevitable phenomenon is now conceived as a challenge that can and, indeed, should be managed proactively. However, even the most advanced mitigation and inspection techniques cannot completely eliminate the significant global threat that corrosion poses to pipelines, tanks and other metal structures.

When it comes to critical infrastructure, even cutting-edge mitigation technologies are not enough on their own. To make optimal technical, integrity and financial decisions, a continuous flow of accurate information and data is essential.

This involves implementing a consistent, well-organized and transparent reporting system that facilitates corrosion assessments, planning and mitigation activities, both now and in the future. Lack of this information can have negative repercussions on the integrity of the system and may result in unnecessarily high costs.

Therefore, it is essential to have a robust system that provides the necessary information to make the most appropriate decisions, thus avoiding possible failures and deterioration of assets.

Conclusion

The implementation of an effective corrosion control program is necessary to safeguard the integrity of assets and ensure safe and efficient operation in various industries. Key components such as risk assessment, selection of appropriate materials, regular inspection, maintenance planning, personnel training, and robust documentation are important in mitigating the effects of corrosion.

A well-designed program not only reduces the risk of costly and potentially dangerous failures, but also contributes to extended asset life and long-term operational sustainability. Proper corrosion management is a critical factor in ensuring infrastructure reliability and environmental protection. Corrosion control is an investment in the safety, efficiency and sustainability of the industry.