What is Corrosion Management Program (CMP) ?
CMP is something which if implemented in its true spirit can save not only CAPEX and OPEX but also can ensure all safety risks at ALARP. CMP defines all protocols which a facility needs in order to ensure smooth operation till its design life and sometimes beyond that. It identifies, categorizes and quantifies risks associated with each individual component of a plant or facility and accordingly recommends appropriate inspection methodology and risk mitigation measures.
CMP should be implemented right at concept select stage for green field projects and all the way through operations. Nevertheless, it can be implemented at any stage. For brown field projects or plants already in operations CMP becomes very important specially if there is no prior material selection or corrosion study. CMP gives confidence to higher management that plant will keep operating without any safety related or production related incidents.
What are main components of a CMP ?
- Introduction and Background of Project / plant / facility.
- Key components listing Names/tags (Wellhead, piping, flowlines, trunklines, export pipelines, manifolds, pressure vessels, tanks and sumps, etc).
- Listing and analysis of process parameters and fluid composition.
- Corrosion rate calculations (for carbon steel piping/pipelines) to know how much material will corrode per annum – using appropriate corrosion rate modelling.
- Corrosion risk assessment – external and internal (qualitative and semi quantitative).
- Identify and listing of applicable corrosion damage mechanisms (API 571 and reputed operators standard practices like Aramco, Adnoc, Shell).
- Prepare corrosion loops (segregate equipment subjected to similar corrosive conditions) in the form of color coded diagrams (Process Flow Diagrams / Material Selection Diagrams / Process and Instrument Diagrams.
- Fully Quantitative Risk Based Inspection using E2G API RBI software.
- Material selection for new facilities or material selection validation/review for existing facilities based on latest process parameters and fluid composition.
- Corrosion mitigation or control techniques for all applicable corrosion damage mechanisms.
- Recommendations about material substitution, painting, coating, chemical injection, cathodic protection and inspection.
- Corrosion Inspection and monitoring requirements with recommended KPIs and inspection frequency (covered in more detail under OSI section).
- Plant integrity operating windows (IOW) – this is a window of operating conditions which have an effect on degradation when outside of a defined range and can be influenced by operation.
- OSI – On Stream Inspection methodology and requirement with listing of equipment and piping/pipeline. Inspection points are marked on isometric level for pipeline and data sheets for equipments with type and frequency of inspection.
Why do I need to implement CMP ?
- To establish a base line data – if no baseline data and design study exists, inspection requirements cannot be established and implemented. It is possible that an equipment is being inspected with less inspection interval whereas it is actually required to be inspected less often (a cost saver). Similarly, it is possible that an equipment is being ignored for inspection which should otherwise be inspected frequently (a safety threat or production loss threat).
- Extended life of facility.
- No production losses or safety threats.
- CMP provides a detailed record archive which helps in audits.
Cormat has extensive experience in providing Concept Select, FEED and EPC solutions to its Clients. Our experts have required qualifications, trainings, certifications, skills and experiences to support our Clients for all stages of a project i.e. Concept select, FEED and EPC.