Corrosion

Corrosion is the main cause of damage or destruction of the infrastructures, industrial equipment, surface and sea transportation facility, etc. It results in huge financial loss and many other serious consequences, e.g., loss of production and a health, safety, environmental hazard (fire, explosion and toxic release, etc.), in case of sudden failure of an equipment or pipeline, etc.

In recent/ future oil and gas-, petroleum refinery- and petrochemical- industries, the control and mitigation of corrosion is becoming more challenging than earlier ones due to enhanced aggressiveness of the produced/ transported/ processed fluid because of increased amount of acidic gases, salts, solids, temperature, pressure, velocity, etc. in the new oil or gas field.

Corrosion engineering and management is the key driver of all asset-integrity/ risk management programs at all phases of asset’s life-cycle which include concept and feasibility, design, engineering, construction, operation, etc.

We are committed to combat corrosion and catastrophic failure events and ensure integrity of the facility through different services to our valuable clients in safe, reliable, cost effective and timely manner, using our vast experience, expertise, qualified human resource, competent partners. Our service aspects generally include - Corrosion Assessment and Material Selection, Materials Engineering and Specification, Corrosion Control and Prevention, Corrosion.

Major Services

Corrosion Assessment & Material Selection

Selection of the construction material, for a service component (equipment, pipeline, machinery, etc.), is of highest importance to ensure its integrity, reliability and safety, throughout the designed life-cycle. We recommend most appropriate and cost effective material, with or without a corrosion control/ mitigation measure, after thorough assessment of corrosion-rate and damage mechanisms in the intended application.

Corrosion Control & Protection

Based on qualitative and quantitative assessment of potential corrosion risks, we recommend most economically viable corrosion-control strategy, including corrosion allowance, proper design, coating, cathodic protection, corrosion inhibitor and chemical treatment, corrosion monitoring, etc.

Condition Assessment & Corrosion Audit

Condition assessment is done for individual equipment or pipeline, while corrosion audit is done for the whole facility. Steps include - site visit and inspection; collection of technical data, records and history; interaction with plant personnel; review and analysis; etc., followed by report with preventive/corrective actions or remedial measures.

Failure Investigation & Root Cause

This is carried out for individual equipment (or piping) of the operating facility, and involves activities are - component inspection; sample accumulation; collection of technical records and history; feedback from plant personnel; lab testing and characterization; analysis and review; etc., followed by report with identified cause of trouble and future remedies.

Review of Design, EPC and Maintenance Documents

Peer review of concept, FEED, engineering, construction, licensor and major maintenance (or modification) documentation to ensure adequacy and suitability of used material and metallurgy, corrosion-control strategies and technologies, corrosion/risk- assessment and management, etc., and adherence to companies standards, practices and specific requirements.

Risk & Integrity Management Support

For new or existing assets, corrosion risk assessment may be carried out with identification of potential corrosion threats (damage mechanisms) and severity estimation, followed by recommending a suitable risk management strategy.

Details Of Services

Material selection & corrosion-control for engineering projects & operating plant (or facility) of oil & gas, petroleum refinery, petrochemical, chemical, utility, pulp & paper, etc. industries, after thorough assessment of fluid corrosivity, corrosion rates, properties of material (MOC), prevalent damage mechanisms, site requirement, etc.

To develop material selection & corrosion control report; material selection diagrams (MSD); material & corrosion standards, etc. for EPC projects or facility. Also, to update the same, where requested.

Development of standard specification for the selection & application of protective coatings & linings for the facility (equipment, piping, pipelines, etc.).

Evaluation, optimization and recommendation of corrosion inhibitors and chemical treatment, to mitigate corrosion at an operation and transport facility. Also, to assist in conducting lab testing and qualification of such products, where requested. Selection of a cathodic protection (CP) system for an equipment or piping and development of standard specification. Also, “Scope of Work for a CP System Package” may be prepared, where requested.

Evaluation and recommendation of corrosion monitoring requirement, type of system (technology), installation guidelines, etc. for equipment/pipeline in a corrosive service. Peer review of above documents, submitted by an EPC contractor, unit licensor and service provider, to ensure overall suitability and compliance to company’s standards, strategies and change instructions; codes; best practices, etc. Our design review also takes care of operational, safety and environmental concerns.

Review of drawings, datasheets and P&ID; vendor procedures; vendor packages; etc. of a project, to ensure use of correct material & metallurgy and compliance to corrosion/risk mitigation philosophy.

Corrosion risk assessment with identification of potential corrosion threats and severity, with estimation of consequence and probability of failure, followed by recommendations (strategy) of risk management.

Resolution of technical issues and vendor deviations regarding material, metallurgy, a corrosion control measure, testing, inspection, component-integrity, etc., for projects.

Develop or review of corrosion management manual for a new or existing facility involving design details of major components; identified threats or damage mechanisms; damage severity; control/mitigation measures undertake; need, type and schedule of monitoring/inspection; standards and practices; criteria of reporting, etc.

Evaluation of new products & technologies for upgrade or improvement at the operating facilities, e.g., metals & non-metals, corrosion monitoring tools & techniques, protective coatings, corrosion inhibitors & chemical treatments, design, etc.

Provide support for data analysis & result’s interpretation of corrosion monitoring program at an operating facility, and give recommendations for its effectiveness and future corrective actions.

Review of CP system’s monitoring & survey data, results, report, etc., followed by identifying problems & anomalies, and recommend appropriate remedial solutions. Corrosion audit and survey for production facility, and recommendation for current and future program of inspection, maintenance, modification, investigation, etc.

Conduct failure investigation and root cause analysis for ‘in-service’ failed equipment and suggest remedies to avoid recurrence of such failures.

Condition assessment of an equipment or pipeline and recommend its remaining service life and future preventive measures.

To provide support for conducting corrosion testing and investigation (in lab, pilot plant, field, etc.) on different metals & alloys, to study their performance (thinning rate or susceptibility to critical damage mechanisms) in complex fluid streams or to qualify a material in standard fluids (i.e., sour service), where required.

Provide support to implement risk (RBI or RBA), reliability (RCM & similar), and integrity management programs for the operating facility. Also, to assist in development/ updating of asset Corrosion Management Strategy (CMS) based on the RBA outcomes. Moreover, performance assessment may be conducted for existing corrosion/ risk/ integrity management programs.

Assist in establishing a corrosion testing & investigation laboratory at a facility.

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Team Corrosion & Materials

Our Corrosion Team is led by Corrosion & Material SME (Subject Matter Expert), who is doctorate (Corrosion Engineering field) from India’s premier technical institute (Indian Institute of Technology or IIT) and bears 30 years of subject exposure. He has played a leading role in number of projects and operating facilities pertaining to oil & gas, petroleum, petrochemical, chemical, pulp and paper, etc. industries.

He has worked with world’s most prestigious groups in India & abroad including Reliance Industries Limited (RIL) [India], Saudi Arabian Basic Industries Corporation (SABIC) [Saudi Arabia], Fluor Corpn. (India Office), Worley Parsons (UAE), etc. The major projects include KGD6 and associated offshore fields (RIL, India), Al-Zour & other refinery (KNPC, Kuwait), Green Diesel refinery (ADNOC, UAE), KOC Pipeline (Kuwait), etc., and operating facilities include Ar-Razi (SABIC, Saudi Arabia), RIL (Kakinada, India), Gharda Chemicals (India), etc.

His contributions got constant recognition from NACE International, SABIC (KSA), Saudi Aramco (KSA), Fleming-Gulf (UAE), Elsevier Publications (USA), National Metallurgical Lab. (India), etc.

He has published/presented about 45 papers, internationally, e.g., in Corrosion-NACE (USA), Corrosion Science (UK), British Corrosion J., Werkstoffe U. Korrosion (Germany), Materials & Techniques (France), Mechanics & Industry (France), Anti-Corrosion Methods & Materials (UK), Tappi J (USA), Appita J. (Australia), NACE Conferences, etc.

He is well aware of most of the world’s standards, codes, practices, softwares, technologies used in field of corrosion engineering & management as well as risk/integrity management at plant/ facility. Besides, he has experience in establishing corrosion/material testing & investigation laboratories. Moreover, he has conducted over 35 failure investigations for the damaged plant components or corrosion-control technologies.