Engineering Principles & Cost-Effective Solutions for Corrosion Control

Abstract Corrosion is a major problem in the oil & gas industry. A huge expenditure is spent every year on corrosion damages. Based on international studies, the cost of corrosion ranges from 4 – 6% of the gross national product of some countries. Several corrosion control techniques are used to maintain the integrity of equipment. Corrosion control techniques either increase the corrosion resistance of materials or reduce the corrosivity of the environment. Selection of a suitable corrosion control method requires technical and economical evaluation of the applicable options in order to have a cost-effective solution. This work introduces the engineering of some cost-effective solutions that enhance integrity and corrosion control with measurable cost savings & avoidance. Some of the solutions done within the refinery or using corporate resources. Minor changes in operations were found to be very effective in increasing the service life of equipment, eliminating the cost of continuous chemical injection, and reducing the flaring. Representative methodologies used for equipment health checks reduced the maintenance and replacement cost. Engineered Composite repair restored operating unit timely and saved cost of outage and maintenance. The aim of the work is to provide corrosion engineering principles and examples that economically enhance plant reliability.