Accenture Asset and

Operations Services

CORROSION
MANAGEMENT
CORROSION
MANAGEMENT
KEY METRICS KEY INDUSTRY CHALLENGES

Estimated annual USD 12 -13 3.4% Global Nearly 50% of the Corrosion failure Move Develop Develop Structured Cost of Stringent Gather
cost of USD $2.5 billion across GDP (2013) reports studied occurs towards adequate effective & and inspections regulatory adequate
trillion globally chemicals described corrosion predominantly in proactive/ RBI tools efficient integrated compliances asset data
across all industries incidents as high / very pipe works, predictive and inspection data system and norms
industries* high consequences causing 71% of approach capabilities management that supports
the accidents practice thickness
studied monitoring

VALUE DRIVERS CONSEQUENCES OF POOR

ASSET INTEGRITY MANAGEMENT
• Leaks and equipment failures

• Corrosion at unexpected locations

Increased Asset Reduced Cost of Reduced Cost of Reduced Reduced • Poor asset integrity performance
Integrity Inspection Turnarounds Production Loss Safety and
Environmental • Asset downtime
Risk
• HSE incidents

• Cost, lives and reputation at stake

*Source: NACE IMPACT 2016 Report

Copyright © 2017 Accenture All rights reserved. 2

CORROSION Inadequate corrosion and inspection management can result in
sudden and hazardous leaks, as well as plant shutdowns
INSPECTION MANAGEMENT CHALLENGES

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.

UNNECESSARY LARGE
SCOPE & FREQUENCY
OF INSPECTION
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.

TIME CONSUMING AND Removing plugs and taking equipment offline is time consuming and costly, particularly if scaffolding is
COSTLY TRADITIONAL required, and requires significant downtime and/or equipment isolation. Additionally, cutting plugs
TECHNIQUES introduces a fresh source of potential moisture penetration and hence further corrosion.

SAFETY CONCERNS Personnel need to access hazardous areas and/or work from heights. Additionally some non-destructive
DUE TO HUMAN techniques require the use of radiation which introduces additional risks and costs for the organization, and
INSPECTION undermines reputation.

Copyright © 2017 Accenture All rights reserved. 3

CORROSION ‘The Asset Integrity Theme Landscaping Study’ –
INSPECTION MANAGEMENT CHALLENGES – Oil & Gas UK
An Industry View

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:

• Limited range of detection due to penetrating • Need for high level of expertise to interpret results
power
• Presence of water negatively impacting analysis
• Pipeline configurations or insulation types
• Difficulties identifying small pitting
• Safety concerns due to radiations

Overcome CUI & Vessels Corrosion Inspection Challenges by leveraging:

INTERNET OF THINGS (IoT) DATA VISUALIZATION ADVANCED ANALYTICS

Copyright © 2017 Accenture All rights reserved. 4

HOW DIGITAL CAN TRANSLATE

INDUSTRY CHALLENGES
INTO VALUE DRIVERS

CERTAINTY OF Advanced analytics are used to predict with high level of accuracy the zones and lines that are most at risk of
ZONES/LINES AT RISK corrosion. This enables operators to carry out targeted inspections at the right time on the right areas.

REDUCED SCOPE 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
AND FREQUENCY OF when inspection is needed. This allows companies to significantly increase the value to effort ratio, while running
INSPECTIONS down the risk factor more quickly.

Innovative technologies enable identification of potential corrosion without removal of insulation and excessive
REDUCED COSTS,
scaffolding , reducing downtime and costs. For example Image Analytics is used to identify corrosion on a pipe from
TIME AND DOWNTIME inspection report pictures, reducing the need for highly skilled personnel.

ENHANCED SAFETY 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
BY LIMITING HUMAN from heights. This leads to a reduction in the organization’s risk exposure and related costs, helping to enhance their
INSPECTION reputation.

Copyright © 2017 Accenture All rights reserved. 5

VALUE Digitally enabled corrosion inspection management empowers
PROPOSITION companies to:

Develop superior M&I plans and inhibitors strategies to RESULTING IN:

increase asset integrity while pushing the plant to reach its
full potential

Go beyond silos maintenance & inspection activities to Reduced costs of inspection between
achieve optimum asset value. Achieve the right balance 10% and 20%
between competing objectives, including:
• Cost reduction • Risk management
• Asset integrity and predictability Increased uptime and productivity by
• Productivity • Safety
• Skills shortage
more than 10%

Move from reactive to proactive corrosion management for

effective and efficient inspection planning Increased asset integrity, resulting in
increased asset life by over 20%
Consider the plant as a connected asset to better and more
deeply understand and mitigate or prevent corrosion

Copyright © 2017 Accenture All rights reserved. 6

ACCENTURE'S DIGITAL SOLUTIONS ENABLE PREDICTIVE, END-TO-END
CORROSION MANAGEMENT
ENHANCED VISIBILITY ADVANCED COGNITIVE
AND INTEGRATION ANALYTICS AUTOMATION

Acquire Monitor Predict Optimize Apply Close Loop

Risk Based Asset Pipeline ADAPT - Image & Video Advanced Image & Video Pipeline Nanotechnology,
Inspection Integrity Integrity Asset Data Analytics Analytics & Deep Analytics Inspection Ultrasound,
Methodology Division Management Analysis & Learning Combining 3D Using Laser
Readiness Systems Processing Model with Robotic Spectrometry,
(PIMS) Tool Accenture Crawlers & Optical Non
Active Drones Destructive
Network Testing

Copyright © 2017 Accenture All rights reserved. 7

DIGITAL
Transformational Journey – Powering physical
CORROSION MANAGEMENT science by embracing data science
ENABLES A STEP-CHANGE IN PLANT OPERATIONS…

ELEMENTS OF DIGITAL TRANSFORMATION THROUGH CORROSION

MANAGEMENT

CURRENT STATUS STEP CHANGE DIGITAL CORROSION MANAGEMENT

PROCESS – DATA SCIENCE • Standardized and streamlined analytical processes

• 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
RBI advanced implementation, CUI • Consistent inspection plans
digital prediction, corrosion rate forecast • Risk predicted and mitigated at equipment level
PEOPLE
Acquire skill sets and provide change • Operationalized digital workforce
management needed to support the • Clear governance model with strong leadership
transformation
TECHNOLOGY
• Detailed activities from data mining to near real-time
Establish environment needed to
automatic inspection recommendations
enable digital + advanced analytics
• Data collected, connected, and modeled in digital platform
execution
• Support customer through transformation
ORGANIZATIONAL
• New behavior and ways of working
TRANSFORMATION • Optimized inspection costs and enhanced reliability
Create data science capabilities
• Optimized inhibitor strategy and extended asset life

Copyright © 2017 Accenture All rights reserved. 8

… AND CAN LEAD TO SUPERIOR INSPECTION & REPAIR PLANNING AND EXECUTION
INSPECTION PLANNING
ROLE: Engineering Department,
Planning 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
Copyright © 2017 Accenture All rights reserved.
INSPECTION
ROLE: Inspectors
HOW DIGITAL CAN HELP:
• 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
ROLE: Engineering Department
HOW DIGITAL CAN HELP:
• 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
REPAIR PLANNING
Role: Engineering Department,
Planning Department
HOW DIGITAL CAN HELP:
• 3D model help identify repair
scope and determine efficient
future repair plans
REPAIRS
Role: Maintenance Department,
Turnaround Department
HOW DIGITAL CAN HELP:
• 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
9
DIGITAL ENABLES A STREAMLINED, MORE EFFECTIVE AND EFFICIENT
INSPECTION & REPAIR PROCESS

Fixed cameras and Inspection Plans are Inspector inputs The maintenance Repair planner Inspection results
drones are utilized engineer creates approved, result and receives engineer’s work order coordinates are captured and
for data collection. scope of work. optimized, and a recommendation will be optimized and between work order recorded in data
Information is fed Integration allocated. for next best action. scheduled. and integrated lake. Defect data is
into the image between planning Inspectors will be Results are Information about planning. Visibility consolidated
analytics model and work-order supported by captured and defects and repair of data and repairs before repair
and translated into creation across all mobile technology drone’s routes are required will be allows repair notifications are
3D visualization for activities within and utilize wearable programmed with available on the planner greater generated.
inspection engineer the plant. cameras to support next best action tablets. The engineer visibility of Consolidation of
to prioritize, e.g. the data capture for model will be able to directly requirements. repair scope allows
model displays risk image analytics. locate the defect and for optimization of
based upon Utilization of repair required through repairs required
internal and advanced the use of 3D models and benefits
external corrosion. technological tools, within the tablets. planning.
e.g. voice and Engineer will utilize
robotic arms to wearables to support
perform activities. data capture for image
analytics.

Copyright © 2017 Accenture All rights reserved. 10

DIGITAL CORROSION A systematic approach to implementing Digital Corrosion
Management solutions takes approximately 2 years
MANAGEMENT ROAD MAP (ILLUSTRATIVE)

Corrosion Under PHASE 3

PoC Insulation PoC 1A PHASE 1A 1B PHASE 1B 2 PHASE 2 3 (Future State)

WHAT Gain Confidence:
• Use advanced analytics to
demonstrate it is possible to
predict the likelihood of
corrosion under insulation
for every 1 meter pipeline
segment
HOW
Inspection Planning
Optimization:
• 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
Inspection & Repair Planning
Automation:
• 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
Change Management
Inspection & Repair
Execution Digitization:
• 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
Inhibitor Strategy
Optimization:
• Analytics to predict the
optimum inhibitor dose to
extend asset life and
streamline supply chain
Overall Plant Optimization
Strategy:
• 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.

Likelihood of defect
OUTPUTS

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

• Model trained on specific assets
• Confidence on model accuracy
and reliability
VALUE
• Increased prediction accuracy
• Informed decision making on
whether scaffolding or expensive
removal of insulation is needed
• Reduced frequency & scope of
inspection, hence costs
• Run down risk factor quicker through efficient prioritisation • Increased asset integrity and • Holistic solution for M&I
• Optimisation of inspection planning, improved visibility of progress enhanced operations process • Increased asset life and
• Reduced cost and improved consistency of inspection • Optimized chemicals costs, nomination
• Automation of M&I and repair process streamlined supply chain
• Reduced skill set required

Copyright © 2017 Accenture All rights reserved. 11

END-TO-END CAPABILITY FOR IMPLEMENTING A RISK-BASED Accenture brings an experienced team,
supported by well-established processes and a
CORROSION MANAGEMENT deep understanding of the supporting data and
PROGRAM LEVERAGING ADVANCED DIGITAL SOLUTIONS tools required to implement a Risk-Based
Corrosion Management program

• Offshore data mining capabilities, leveraging lower cost offshore resources with extensive industry experience (inspections,
Data
Data Collection
corrosion, etc.)
Collection • Dedicated teams with industry relevant expertise, readily available
• Data processing tool with automated QA/QC controls and web based access

• Experienced teams with capabilities related to API-580, API-581 and understanding of the data requirements and
Data
Data Processing
supporting technologies for each
Processing • 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

• Repeatable and adaptable processes for data analysis, corrosion loop definition, and degradation
mechanism assignment
Risk Assessment
Risk Assessment • Ability to lead client stakeholders through degradation mechanism reviews, risk review workshops, and
inspection strategy validation

• Support alignment of corporate risk objectives to development and implementation of

Risk
Risk Management
standard practices for risk management
Management • Ability to lead site level stakeholder engagement and trainings associated with RBI data,
processes, and technology to ensure sustainability

Copyright © 2017 Accenture All rights reserved. 12

OUR VISION – A FULLY
INTEGRATED VALUE CHAIN TO ACHIEVE
OPTIMIZED PLANT MANAGEMENT
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
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
Copyright © 2017 Accenture All rights reserved.
Market leading companies are making their value chain a strategic
differentiator through integration, collaboration, planning, and reliability
across the value chain
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
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
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KEY CONTACTS

Audrey Bergeron Elena Mariotti

Corrosion Mgmt. Lead Corrosion Mgmt. Lead
APAC (Asia Pacific) EALA (Europe, MiddleEast, Africa, Latin America)
Audrey.Bergeron@Accenture.com Elena.Mariotti@Accenture.com

Michael Poland
Asset Performance Management Lead
NA (North America)
Michael.E.Poland@Accenture.com

Copyright © 2017 Accenture All rights reserved. 14