APPLICATION AND

MAINTENANCE OF INTRUSIVE
CORROSION MONITORING
CORROSION MONITORING FITTINGS REVIEW
I) INTRODUCTION

A) PURPOSE OF THE GUIDELINE :

• Intrusive monitoring with access fittings is one of many asset integrity management activities with the purpose of
collecting data instrumental for corrosion management as part of the asset Corrosion Management Framework
• The online retrieval of these access fittings is an activity that carries significant HSSE risk.
• The number of incidents or near misses (reported or not) associated with these types of activities in Shell operated
and non-operated assets over the years is significant, and, although the root causes for these incidents may differ
from case to case (i.e. lack of competence, procedural, maintenance, etc.), there is an imminent need to reduce
exposures and minimize the risk to ALARP while still maintaining robust asset integrity management programs.
• Two recent serious incidents, one of which resulted in a fatality, have triggered the need for Shell to rethink the
current philosophy and challenge the need and application of intrusive monitoring that requires retrieval of access
fittings under pressurized conditions.
1) INTRODUCTION
Steps to be followed for the reduction or elimination of
intrusive monitoring tools that require online retrieval :
• Challenging the need for continuous monitoring
• Challenging the need to retain intrusive
monitoring tools that require online retrieval
• Identifying safer retrieval and servicing practices
• Determining a safer retrieval frequency to
minimize HSSE exposure
A planned phased approach will need to be
developed by the assets, with the following
milestones in mind :
• Charter established for each asset for a clear definition of
action items and relevant focal points for subsequent
traceability
• Complete inventory of access fittings
• Demonstrated challenge exercise to reduce the number of
existing intrusive coupons and/probes
• Demonstrated re-evaluation of the frequency of retrieval
• Justification, risk assessment and mitigation strategies in
place for continuation of online intrusive retrieval
I) INTRODUCTION

B) SCOPE : C) BACKGROUND :
This approach focuses on intrusive access
Effective corrosion management consists of three
fittings, such as :
• Corrosion weight loss coupons main elements:
• Corrosion monitoring probes (ER, HR-ER, LPR, • Review and identification of relevant corrosion threats
galvanic probes)
• Definition and implementation of suitable corrosion
• Chemical injection points engineered to be retrieved
barriers to mitigate the identified threats
online
• Coupons or bio probes monitoring for MIC
• Verification of barrier effectiveness
(Microbiologically Induced Corrosion) • Monitoring of the internal/external corrosion rates
• Others such as polymer coupons to monitor the
deterioration of the thermoplastic carcass in flexibles
 1) INTRODUCTION

D) RECOMMENDED PHILOSOPHY FOR ASSETS :

P&T recommends to all assets to follow this guidance in order to
succeed in the rationalization and use of intrusive access fittings.

Figure 1: Guidance for rationalization and use of

intrusive access fittings
II) CHALLENGING EXISTING PRACTICE

A) RISK ASSESSMENT METHODOLOGIES

In order to do a proper risk assessment of all fittings, the Responsible Engineer from the Operating Unit (Materials and Corrosion Engineer, Asset
Integrity Engineer, Production Chemist or equivalent discipline) should make an inventory of all access fittings in the field

a) Live inventory for access fittings :

• Required information (non-optional): • Recommended information :
II) CHALLENGING EXISTING PRACTICE
b) Peer to peer challenge sessions :
It is recommended to set-up peer to peer challenge sessions to rationalize the use of each
intrusive access fitting.
• The presence of the following functions is required in order
to have comprehensive challenge sessions:
 Materials and Corrosion Engineer
 Production Chemist or Chemical Engineer
 Pipeline Integrity Engineer
 Operations Representative
 M&C TA1, M&C TA1 delegate or external peer with
relevant expertise
 Inspection Engineer (optional)
• The aim of these sessions is to agree what data are needed
(i.e., corrosion and chemicals performance), verify the
relevance of data provided by the corrosion coupons/probes
and to eventually reduce their number to a minimum. These
challenge sessions should be organized by the Responsible
Engineer.
• In order to rationalize the need for the access fittings, it is
recommended to follow a “Decision Tree” and respective
guidelines provided to challenge each intrusive access
fitting.
 II) CHALLENGING EXISTING PRACTICE

• With the use of this Decision Tree

and guideline, the team should be
able to:
 Assess the need for intrusive access
fittings and;
 Evaluate feasibility of an
alternative technique (i.e., switch to
continuous online corrosion rate
monitoring where possible)

Figure 2: Guidance for the challenge sessions regarding the need of

access fittings : Decision Tree
II) CHALLENGING EXISTING PRACTICE

c) Challenge the need for the data :

• Assess corrosivity of the service where the fitting is located

• If the data are needed for other monitoring purposes (i.e., chemicals performance), assess the criticality

• A Risk Assessment Matrix approach is suggested as an additional tool to assist during the challenge session to determine the criticality
of the corrosion monitoring location, and the need for continuous corrosion monitoring at this location

• Category locations of the Risk Assessment Matrix approach :

 E and H category locations : Frequent continuous corrosion monitoring is critical for proper corrosion management
 M category locations : Corrosion monitoring is required but frequency can potentially be extended. For these cases, it is
recommended to reassess the frequency and/or evaluate alternative ways to manage the risk with Non-Intrusive Inspection
(NII) using appropriate inspection techniques (i.e. UT, RT) at intervals defined by RBI
 L and N categories locations : Service is deemed as not corrosive or the corrosion rate is known to be low
(< 0.1 mm/ or 4 mpy), in which case frequent corrosion monitoring is not required. For these locations, it is recommended to
abandon the coupons/probes and manage the risk with NII and RBI.
II) CHALLENGING EXISTING PRACTICE

• This matrix is adapted from a matrix

developed in the Gulf of Mexico
platforms following the 2012 LFI to
challenge the need for corrosion
coupons/ probes.
• As an example, this matrix was applied
to rationalize the number of coupons for
the Perdido platform which resulted in a
decrease from 79 to 22 with the use of
this matrix

Figure 3: Example of a risk assessment matrix for corrosion monitoring locations (CMLs)
II) CHALLENGING EXISTING PRACTICE

B) OTHER STEPS TO BE ADOPTED FOR CHALLENGING EXISTING

PRACTICE :

• Consider the relative HSSE risk of the retrieval activity with respect to the corrosion risk that the data is intended to
mitigate

• Challenge whether the coupons/probes are placed at a corrosion monitoring location (CML) that is representative of the
expected corrosion degradation mechanism

• Challenge if the right corrosion monitoring technique is being used

• Critically validate the quality of the data received

 III) FREQUENCY AND SCHEDULING OF
RETRIEVALS

• Frequency of the weight loss coupon retrievals

or probe replacements is determined by the
Responsible Engineer in the asset. There are
mainly two different approaches to determine Figure 3: Overall approach to be adopted
when considering corrosion monitoring
the period between two retrievals: schedule
 Opportunity based (i.e., adjusting the activities

frequency of retrievals to coincide with

planned shutdowns or activities that require
full depressurization)
 Risk based approach
III) FREQUENCY AND SCHEDULING OF
RETRIEVALS
• Demonstration of ALARP for pressurized • Some parameters considered in the
retrievals : demonstration of ALARP :
 The intent to maintain and continue pressurized
 H2S
retrievals must be accompanied with a risk
assessment for each fitting or group of fittings on  Level of fouling
the same line (such as a pair of probe/coupon  History of the asset
fittings)
 The need to carry out a risk assessment to that detail
 Corrosion rate
is required due to variability in fouling risk,  Dryness of the service
orientation of fittings, difficulty of access, fitting
 Flowing medium (HC, water, etc.)
clearance, escape routes, galling, etc., all of which
could preclude safe and reliable retrieval activity
IV) RECOMMENDED PATH FORWARD FOR THE
ASSETS
• It is recognized that the previous recommendations will require a planned phased
approach to be developed by the assets, with the following milestones in mind as already
discussed above :
 Charter established for each asset for a clear definition of action items and relevant focal points for
subsequent traceability
 Complete inventory of access fittings
 Demonstrated challenge exercise to reduce the number of existing intrusive coupons/probes
 Demonstrated re-evaluation of the frequency of retrieval
 Justification, risk assessment and mitigation strategies in place for continuation of online intrusive
retrieval with the approval of the local M&C TA1
ROLES AND RESPONSIBILITIES CHART FROM
UIE