Integrityfocused, riskbased, external corrosion management'

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ECM Metacor painting by numbers!

• Integrity-focused, risk-based, external corrosion
  management.

NACE Corporate Member
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Which would you paint first?
Primary Structural Member
Primary Escape Route
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Our Role

• Documented scheme for control and management of
  external corrosion risks.
• Integrated external corrosion management and
  integrity.
• Prioritised coatings, insulation and PFP
  maintenance scopes.
• Packaged information necessary for informed
  decision making and budget justification.
• Add on to integrity / work management system.

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Key features

• Integrity Focused
• Affordable (phased, low cost start-up and
  maintenance)
• Auditable line of sight from Safety Case to
  activity
• Justifiable, clear, costed plans
• Flexible (what ifs)
• Optimised strategy and budget costs

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METHOD - Focus on risk (from external corrosion)
Criticality
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Worksite information
Design specification Dimensions Pressures U Value
Element type and Duty Purpose (sets consequence
of failure)
Corrosivity Zone Corrosion rate
Probability of failure information Remaining
Corrosion allowance Required life
Reference Reports and photos
Loss to Date From condition information.
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Criticality Processing

• Probability of failure is related to the
  elements tolerance to external corrosion related
  to required life
• Consequence of failure in terms harm (persons or
  environment) and cost
• Combined in a simple matrix to give the
  Criticality rating

The matrix is weighted in favour of the
Consequence .
N.B. In this context, Failure is taken to be loss
of Fitness for Purpose (i.e. the potential for
failure).
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Condition

• Paint
• Corrosion Severity
• Wall Thickness
• Pit Depth
• Anomaly / Observation
• Penetrations
• Seals

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Planning (settings and choices)
Plan settings

• Least cost
• Least interventions
• Least metal loss
• Most coating life
• Appearance critical (e.g. for attracting 3rd
  party customers)

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Stage 1- Choosing Strategy

• Set Criticality criteria (Client or Metacor)
• Set Integrity Criteria (i.e. Corrosion Allowance,
  Corrosion Allowance diminution allowed)
• Produce alternatives (e.g. Little and often, big
  hit etc.)
• Review and make / take decision on strategic
  approach to maintenance

or
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Stage 2 Optimising Strategy

• Establish extent of maintenance required
• Optimise chosen strategy
• Build budget
• Produce listing and graphs for review.
• Present plans for review and approval.

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Stage 3 Executing Strategy

• Final optimisation (e.g. opportunistic access
  availability etc.)
• Package into Detailed Work Scope Packs - logical
  work chunks for effective communication,
  management control.
• Define execution and quality specifications

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Integrating Internal and External Corrosion
Predictions

• Client data
• Internal corrosion monitoring and prediction.
• Metacor data
• External corrosion monitoring and prediction.
• Example
• 3nb Pipe, 3mm CA, 2.4mm Internal CA, 0.6mm
  allocated to External CA.
• Existing loss to date (internal) recorded.
• Predicted internal corrosion rate recorded.
• Existing external loss to date recorded.
• Metacor predicts external corrosion rate.
• Internal and external LTD and predicted corrosion
  rates combined to give predicted retiral (loss of
  fitness for purpose) date.

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Integrating Internal and External Corrosion
Predictions

• Current wall thickness / loss to date details
  recorded in condition form.
• Internal corrosion rates integrated within Metacor

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Integrating Internal and External Corrosion
Predictions
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Systems connectivity

• Metacor link to Management and other systems.
• Exchange box used to match other system data
  fields to Metacor and vice versa.
• User is informed that update available, and can
  review before accepting.
• Process ensures information transfer is secure
  and neither other system data nor Metacor
  database can become corrupt.

System (e.g. SAP) Asset List and Management
Reporting
Metacor Coatings Condition / Coatings Maintenance
Plan
Metacor exchange box
SAP data
Metacor accepts SAP data
Metacor update
SAP accepts Metacor update
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Stage 4 Managing Strategy

• Load to MetacorWeb for
• Progress reporting / record as work completed
  versus planned.
• Remote access (onsite and contractor)
• Upload of quality and inspection documents /
  photos.
• Anomaly and condition reports

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Benefits

• Safety
• Less corrosion-related failures
• Less offshore ad-hoc labour
• Knowledge of risks to asset, environment and
  personnel

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Benefits

• Cost reduction
• Less wasted painting costs clear focused scope
• Less administration clear management / scope
  development and budgeting
• Less logistics focused deployment not
  scattered.
• Less engineering assessment demonstrate
  knowledge of condition
• Less corrosion related repairs

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Track Record - Majors

• Shell (All UK Dutch) coatings / corrosion
  survey, alternatives, budget scope, detailed
  scope, QA, ITP Co-ordinator, annual plans,
  MetacorWeb.
• Talisman (All UK Norway) coatings / corrosion
  survey, alternatives, budget scope, detailed
  scope, QA, ITP Co-ordinator, annual plans,
  MetacorWeb.
• Nexen Inc. pfp and coatings / corrosion survey,
  alternatives, budget scope, detailed scope,
  annual plans, MetacorWeb.
• Hess - coatings / corrosion survey, alternatives,
  budget scope, detailed scope, bid process, QA,
  ITP Co-ordinator, annual plans, MetacorWeb.
• bp TT - coatings / corrosion survey,
  alternatives, budget scope, detailed scope, QA,
  ITP Co-ordinator, annual plans.

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Services

• NACE Certified Inspector / Surveyors
• ECM has the most NACE Certified / Qualified
  Inspectors in Europe (currently 18, continuously
  adding).
• Trained in Piping, Structural and static
  equipment coatings and corrosion surveys.
• Understanding of Piping / Structural systems and
  process issues.
• Systematic survey methodology.

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Services

• Painting Project Managers
• ECM supplies Project Managers and Coordinators
  for major painting programs.
• One Stop Shop
• ECM supplies a one stop shop for the management
  of painting maintenance, from producing the
  scope, through prequalification and selection of
  materials and contractor, to managing the project
  through to completion on time and budget.
• Specifications, Consultancy and Verification
• ECM writes corporate Painting Specifications,
  advises on specific external corrosion problems
  and can verify specific external corrosion
  control systems to ensure they meet the Clients
  needs.

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Track Record ex Oil and Gas

• Vosper Thornicroft
• Network Rail
• MoD
• BP Tankers

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Discussion

• Thank you for your time, over to you
• Corrosion Issues?
• Budget Issues?
• Scope Issues?
• Management Issues?
• Life extension?
• Knowing where to start?