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
capabilities
Structured
and
integrated
data system
that supports
thickness
monitoring
Stringent
regulatory
compliances
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
CORROSION
MANAGEMENT

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
Copyright © 2017 Accenture All rights reserved.
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
CORROSION
INSPECTION 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 potential
Go 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 management
and 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 SCIENCE
RBI advanced implementation, CUI
digital prediction, corrosion rate forecast
PEOPLE
Acquire skill sets and provide change
management needed to support the
transformation
TECHNOLOGY
Establish environment needed to
enable digital + advanced analytics
execution
ORGANIZATIONAL
TRANSFORMATION
Create 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
ENABLES 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 REPAIRS
ROLE: Inspectors ROLE: Engineering Department Role: 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
• 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
• 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 3
Corrosion 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
nomination
VALUE
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
OUTPUTSMANAGEMENT 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
PROGRAM 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 Bergeron
Corrosion Mgmt. Lead
APAC (Asia Pacific)
Audrey.Bergeron@Accenture.com
Elena Mariotti
Corrosion Mgmt. Lead
EALA (Europe, MiddleEast, Africa, Latin America)
Elena.Mariotti@Accenture.com
Michael Poland
Asset Performance Management Lead
NA (North America)
Michael.E.Poland@Accenture.com

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