Digitalization of Corrosion Management Program – Leveraging Industrial Revolution 4.0 towards Asset Integrity

Abstract Regenerative amine systems are a crucial part of gas processing plants, responsible for removing impurities and contaminants from natural gas. However, their operation also poses significant corrosion risks to carbon and stainless steel materials, leading to potential equipment failure, production losses, and environmental hazards. This paper presents a case study on the development and deployment of a Digitalized Corrosion Management (DCM) system in a gas processing facility. By leveraging digitalization, the system integrates real-time monitoring of critical parameters, such as rich amine loading, velocity, and amine degradation products using soft sensors technology. On-Stream Inspection (OSI) data validates the accuracy of predictions, while Integrity Operating Windows (IOWs) define acceptable operating conditions.1 A customized real-time corrosion dashboard provides real-time alerts when corrosion thresholds are exceeded, enabling operators to take corrective actions to prevent unplanned outages. Advanced analytics allow for analyzing historical trends and prediction of future corrosion behavior, facilitating proactive optimization of plant performance and extension of equipment lifespan. The DCM system has been successfully implemented in a gas processing facility, demonstrating improved corrosion control and enhanced overall efficiency. This paper shares key learnings, highlighting the benefits of digitalization in corrosion management, and providing insights into the design, implementation, and operation of the system. It aims to inspire similar initiatives in other industries and applications, showcasing the transformative impact of digitalization on asset integrity.