corrosion management

CORROSION

Accenture Asset and Operations Services

MANAGEMENT

Copyright © 2017 Accenture All rights reserved.

KEY METRICS

*Source: NACE IMPACT 2016 Report

VALUE DRIVERS

KEY INDUSTRY CHALLENGES

CONSEQUENCES OF POOR ASSET INTEGRITY MANAGEMENT• Leaks and equipment failures

• Corrosion at unexpected locations

• Poor asset integrity performance

• Asset downtime

• HSE incidents

• Cost, lives and reputation at stake

Increased Asset Integrity

Reduced Cost of Inspection

Reduced Cost of Turnarounds

Reduced Production Loss

Reduced Safety and

Environmental Risk

Move towards

proactive/predictive approach

Develop effective &

efficient inspection management practice

Cost of inspections

Gather adequate

asset data

Develop adequate RBI tools

and capabiliti

es

Structured and

integrated data

system that

supports thickness

monitoring

Stringent regulatory complianc

es and norms

Estimated annual cost of

USD $2.5 trillion globally

across all industries*

USD 12 -13 billion across

chemicals industries

3.4% Global GDP (2013)

Nearly 50% of the reports studied

described corrosion incidents as high /

very high consequences

Corrosion failure occurs

predominantly in pipe works,

causing 71% of the accidents

studied

2

CORROSIONMANAGEMENT

http://impact.nace.org/documents/Nace-International-Report.pdf

3

CORROSION Inadequate corrosion and inspection management can result in sudden and hazardous leaks, as well as plant shutdowns

UNCERTAINTY OF ZONES/LINES AT RISK

Currently inspection is often reactive. Cut and remove plugs in the insulation. Visually inspect the surface for immediate signs of corrosion. Ultrasonically test the rest of the pipe, or take equipment offline for internal inspections. This approach is often based on a priority list of perceived risks based on known equipment design parameters and observable equipment condition only. As a result sites of corrosion can easily be missed or equipment over inspected.

If there is sufficient doubt regarding the condition of the surface away from the plugs, large areas of insulation may be removed and equipment taken offline. The issue with this approach is that these larger areas are often targeted unnecessarily, just because of lack of supporting data enabling effective decision-making. For example, CUI is often very localized so unless the plug is positioned in the right spot the sites of corrosion will be missed.

Removing plugs and taking equipment offline is time consuming and costly, particularly if scaffolding is required, and requires significant downtime and/or equipment isolation. Additionally, cutting plugs introduces a fresh source of potential moisture penetration and hence further corrosion.

Personnel need to access hazardous areas and/or work from heights. Additionally some non-destructive techniques require the use of radiation which introduces additional risks and costs for the organization, and undermines reputation.

UNNECESSARY LARGE SCOPE & FREQUENCY OF INSPECTION

TIME CONSUMING AND COSTLY TRADITIONAL TECHNIQUES

SAFETY CONCERNS DUE TO HUMAN INSPECTION

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INSPECTION MANAGEMENT CHALLENGES

Copyright © 2017 Accenture All rights reserved. 4

According to this study published in May 2016 the most advanced non-destructive techniques for Corrosion Under Insulation (CUI) and Vessels Inspection have several limitations, such as:

Overcome CUI & Vessels Corrosion Inspection Challenges by leveraging:

• Limited range of detection due to penetrating power

• Pipeline configurations or insulation types

• Safety concerns due to radiations

• Need for high level of expertise to interpret results

• Presence of water negatively impacting analysis

• Difficulties identifying small pitting

INTERNET OF THINGS (IoT)

DATA VISUALIZATION ADVANCED ANALYTICS

CORROSIONINSPECTION MANAGEMENT CHALLENGES – An Industry View

‘The Asset Integrity Theme Landscaping Study’ – Oil & Gas UK

HOW DIGITAL CAN TRANSLATE

CERTAINTY OF ZONES/LINES AT RISK

REDUCED SCOPE AND FREQUENCY OF INSPECTIONS

REDUCED COSTS, TIME AND DOWNTIME

ENHANCED SAFETY BY LIMITING HUMAN INSPECTION

Advanced analytics are used to predict with high level of accuracy the zones and lines that are most at risk of corrosion. This enables operators to carry out targeted inspections at the right time on the right areas.

Thanks to data-driven decision making, scope and frequency of inspections can be reduced while enhancing asset integrity. Using a richer data set, including multiple data sources it is possible to accurately determine where and when inspection is needed. This allows companies to significantly increase the value to effort ratio, while running down the risk factor more quickly.

Innovative technologies enable identification of potential corrosion without removal of insulation and excessive scaffolding , reducing downtime and costs. For example Image Analytics is used to identify corrosion on a pipe from inspection report pictures, reducing the need for highly skilled personnel.

Beside limiting the number of inspections, additional techniques can be used to enhance worker safety, for example Video Analytics. Using drones or fixed cameras, personnel is no longer required to access hazardous areas or work from heights. This leads to a reduction in the organization’s risk exposure and related costs, helping to enhance their reputation.


INDUSTRY CHALLENGES INTO VALUE DRIVERS

VALUE

Develop superior M&I plans and inhibitors strategies to increase asset integrity while pushing the plant to reach its full potentialGo beyond silos maintenance & inspection activities to achieve optimum asset value. Achieve the right balance between competing objectives, including:

Consider the plant as a connected asset to better and more deeply understand and mitigate or prevent corrosion

Move from reactive to proactive corrosion management for effective and efficient inspection planning

RESULTING IN:

Reduced costs of inspection between 10% and 20%

Increased uptime and productivity by more than 10%

Increased asset integrity, resulting in increased asset life by over 20%

• Cost reduction• Asset integrity• Productivity

• Risk

managementand predictability

• Safety• Skills shortage

6Copyright © 2017 Accenture All rights reserved.

PROPOSITION Digitally enabled corrosion inspection management empowers companies to:

ACCENTURE'S DIGITAL SOLUTIONS ENABLE PREDICTIVE, END-TO-END

ADVANCED ANALYTICS

ENHANCED VISIBILITY AND INTEGRATION

COGNITIVE AUTOMATION

Acquire Monitor Predict Optimize Apply Close Loop

Image & Video Analytics

Combining 3D Model with Accenture

Active Network

Nanotechnology, Ultrasound,

Laser Spectrometry, Optical Non Destructive

Testing

Pipeline Inspection

Using Robotic

Crawlers & Drones

Image & Video Analytics

Advanced Analytics & Deep

Learning

ADAPT - Asset Data Analysis & Processing

Tool

Pipeline Integrity

Management Systems (PIMS)

Asset Integrity Division

Readiness

Risk Based Inspection

Methodology


CORROSION MANAGEMENT

Transformational Journey – Powering physical science by embracing data science

DIGITAL

ELEMENTS OF DIGITAL TRANSFORMATION THROUGH CORROSION MANAGEMENT


CURRENT STATUS STEP CHANGE

• Static documentation• Reduced asset reliability

due to corrosion (Leaks and unplanned outages)

• Long and inefficient shutdown due to unexpected corrosion rate and ineffective monitoring locations

• Stringent regulatory compliances and norms

• Inefficient management of large legacy inspection and corrosion data Paper and monitored data

• Unreliable data• High maintenance and

inspection costs

PROCESS – DATA SCIENCERBI advanced implementation, CUI digital prediction, corrosion rate forecast

PEOPLEAcquire skill sets and provide change management needed to support the transformation

TECHNOLOGYEstablish environment needed to enable digital + advanced analytics execution

ORGANIZATIONAL TRANSFORMATIONCreate data science capabilities

DIGITAL CORROSION MANAGEMENT

• Standardized and streamlined analytical processes• Consistent inspection plans• Risk predicted and mitigated at equipment level

•Operationalized digital workforce•Clear governance model with strong leadership

• Detailed activities from data mining to near real-time automatic inspection recommendations

• Data collected, connected, and modeled in digital platform

• Support customer through transformation • New behavior and ways of working• Optimized inspection costs and enhanced reliability• Optimized inhibitor strategy and extended asset life

CORROSION MANAGEMENTENABLES A STEP-CHANGE IN PLANT OPERATIONS…

… AND CAN LEAD TO SUPERIOR INSPECTION & REPAIR PLANNING AND EXECUTION


ROLE: Engineering Department, Planning

Department

INSPECTION PLANNING

INSPECTION RISK ASSESSMENT REPAIR PLANNING REPAIRSROLE: Inspectors ROLE: Engineering

DepartmentRole: Engineering

Department, Planning Department

Role: Maintenance Department, Turnaround

Department HOW DIGITAL CAN HELP:

• Equipment risk scoring – The additional data help generate statistically significant and accurate risk scores for each piece of equipment thus enhancing the risk scoring overall

• Equipment prioritization –– Inspection scope and

prioritization can be done in 3D

– Can be driven by identified geospatially clustered defects

– Improves risk scoring by helping descope areas with very low risk of corrosion

HOW DIGITAL CAN HELP:• 3D models can be used to

plan and locate inspection points and lines

• Work pack can be checked on field real time using tables to verify inspection priority and scope and to verify inspection location

• Specialized inspection methodologies derived from the likelihood of defects (e.g. general inspection validated with image analytics for low risk zones)

• Inspector can feed inspection and defect findings into the database in real time from the field, and receive real-time recommendations on whether to continue to inspect the current zone or not

• Identify the presence of corrosion using image analytics thus reducing expensive scaffolding, inspector manhours, safety risk

HOW DIGITAL CAN HELP:

• Risk assessment – Output from the analytical model can enrich the corrosion database to enable engineering to carry out more accurate equipment risk assessment

• Faster review of defect-record thanks to real-time upload of inspection findings, which enables prompt and more accurate decision making

• Notifications of mitigation actions automatically include all the information needed to perform the actions efficiently


• 3D model help identify repair scope and determine efficient future repair plans


• Repair data are fed back into the models to provide better insights for improved prioritization of inspection and repair:– Update diagrams and 3D

models in SmartPlant– Update the material data

record (MDR) in real time– All the data are handed over

to operations in an efficient way, ensuring comprehensive and consistent insights

DIGITAL ENABLES A STREAMLINED, MORE EFFECTIVE AND EFFICIENT

Fixed cameras and drones are utilized for data collection. Information is fed into the image analytics model and translated into 3D visualization for inspection engineer to prioritize, e.g. the model displays risk based upon internal and external corrosion.

Inspection engineer creates scope of work. Integration between planning and work-order creation across all activities within the plant.

Inspector inputs result and receives a recommendation for next best action. Results are captured and drone’s routes are programmed with next best action model

Inspection results are captured and recorded in data lake. Defect data is consolidated before repair notifications are generated. Consolidation of repair scope allows for optimization of repairs required and benefits planning.

Repair planner coordinates between work order and integrated planning. Visibility of data and repairs allows repair planner greater visibility of requirements.

Plans are approved, optimized, and allocated. Inspectors will be supported by mobile technology and utilize wearable cameras to support data capture for image analytics. Utilization of advanced technological tools, e.g. voice and robotic arms to perform activities.

The maintenance engineer’s work order will be optimized and scheduled. Information about defects and repair required will be available on the tablets. The engineer will be able to directly locate the defect and repair required through the use of 3D models within the tablets. Engineer will utilize wearables to support data capture for image analytics.


INSPECTION & REPAIR PROCESS

DIGITAL CORROSION A systematic approach to implementing Digital Corrosion Management solutions takes approximately 2 years


PoC 1A 1B 2 3Corrosion Under Insulation PoC

PHASE 1A PHASE 1B PHASE 2

PHASE 3 (Future State)

• Increased prediction accuracy• Informed decision making on

whether scaffolding or expensive removal of insulation is needed

• Reduced frequency & scope of inspection, hence costs

• Model trained on specific assets• Confidence on model accuracy

and reliability

• Run down risk factor quicker through efficient prioritisation• Optimisation of inspection planning, improved visibility of progress• Reduced cost and improved consistency of inspection• Automation of M&I and repair process• Reduced skill set required

• Increased asset integrity and enhanced operations process

• Optimized chemicals costs, streamlined supply chain

• Holistic solution for M&I• Increased asset life and

nominationVALUE

Likelihood of defect

Magnitude of defect: expansion and corrosion rate. Near real-time automatic recommendations on Inspection Strategy

Risk of equipment failure/ loss of containment (likelihood * consequence)

Optimum operations parameters to reduce corrosion rate and inspection costs while increasing asset life

• Robotic inspection to improve detection & measurement of external/internal conditions

• Next Best Action (NBA) Model – Automated and iterative inspection & repair process

• Automatic workpack creation and integration with P6

• Fixed cameras to perform regular inspections on the plant

• Use of tablets for direct inspection data capture and access WO real-time

• Technology connecting inspection engineers on field with remote SMEs to help guide and instruct engineers to take measurements / perform testing

• Analytics to predict the optimum inhibitor dose to extend asset life and streamline supply chain

• Analytics considers the plant as a connected active network, accounting for: similar equipment behaviors, operations parameters of equipment upstream / downstream of the equipment under analysis, vicinity modelling, etc.

• Use a richer data set including multiple environmental factors and geospatial data

• Image/video analytics (e.g. using drones) to increase accuracy

• Field intelligence, data mining on section report to capture engineers knowledge

• Use advanced analytics to demonstrate it is possible to predict the likelihood of corrosion under insulation for every 1 meter pipeline segment

HOW

Change Management

Inspection Planning Optimization:Gain Confidence: Inspection & Repair Planning

Automation:Inspection & Repair Execution Digitization:

Inhibitor Strategy Optimization:

Overall Plant Optimization Strategy:WHAT

OU

TPU

TSMANAGEMENT ROAD MAP (ILLUSTRATIVE)

END-TO-END CAPABILITY FOR IMPLEMENTING A RISK-BASED

Accenture brings an experienced team, supported by well-established processes and a deep understanding of the supporting data and tools required to implement a Risk-Based Corrosion Management program

• Offshore data mining capabilities, leveraging lower cost offshore resources with extensive industry experience (inspections, corrosion, etc.)

• Dedicated teams with industry relevant expertise, readily available• Data processing tool with automated QA/QC controls and web based access

• Support alignment of corporate risk objectives to development and implementation of standard practices for risk management

• Ability to lead site level stakeholder engagement and trainings associated with RBI data, processes, and technology to ensure sustainability

• Repeatable and adaptable processes for data analysis, corrosion loop definition, and degradation mechanism assignment

• Ability to lead client stakeholders through degradation mechanism reviews, risk review workshops, and inspection strategy validation

• Experienced teams with capabilities related to API-580, API-581 and understanding of the data requirements and supporting technologies for each

• Partnerships with risk-based inspection specialists and industry leading corrosions Subject Matter Experts (SMEs) • Ability to assist with IDMS selection and implementation to enable end-state vision

Risk Management

Risk Assessment

Data Processing

Data Collection

Risk Management

Risk Assessment

Data Processing

Data Collection


CORROSION MANAGEMENTPROGRAM LEVERAGING ADVANCED DIGITAL SOLUTIONS

OUR VISION – A FULLY INTEGRATED VALUE CHAIN TO ACHIEVE OPTIMIZED PLANT MANAGEMENT

Market leading companies are making their value chain a strategic differentiator through integration, collaboration, planning, and reliability across the value chain


MAINTENANCE & INSPECTION• Forecasting through predictive and preventative M&I and Operations

identifying early defects• Planned work released with enough time to trigger procurement and

logistics actions• Scheduled routine and high priority work with buffers for unplanned

emergencies• M&I completed and returned to Operations at the agreed time and the

right quality

LOGISTICS & INVENTORY• Min / Max levels set correctly with delivery time buffers• Visibility of M&I activities at the right levels and departments• Inventory turns of high volume, low volume non-critical, and low volume

critical spares tracked• Vendor service levels agreed and monitored• Materials & services in the right quantity, at agreed time and place

through collaboration & quality data• Accurate and maintained list of materials and required spares

OPERATIONS

• Maintenance strategies in place, regularly reviewed, optimised and updated

• Critical equipment, spares, and chemicals clearly identified and visible to Maintenance, Materials Management, and Procurement

• Daily monitoring enables defect and corrosion rate change early identification

• Accurate, complete and maintained data• Coordination through integrated activity planning

PROCUREMENT• Supply / demand requirements captured and planned for (for both

equipment parts and chemicals)• Equipment failure and part use history visible and analysed• Part requirement management with vendors• Asset life-cycle costing and planning• Vendor managed part requirements & lead times• Visibility and activities planned through IAP

PO

KEY CONTACTS

Audrey BergeronCorrosion Mgmt. Lead APAC (Asia Pacific)[email protected]


Elena MariottiCorrosion Mgmt. Lead EALA (Europe, MiddleEast, Africa, Latin America)[email protected]

Michael PolandAsset Performance Management LeadNA (North America)[email protected]

corrosion management

Economy & Finance