Corrosion Monitoring Data Integrity

January 23 - 25, 2024 | Henry B. Gonzales Center | San Antonio, TX

 • Philip Ramos
• Valero
• Sr. Reliability Inspector
• 8 years of experience
• Field of Expertise: Risk Based Inspection, Field Inspection, Data Analysis

API INSPECTION & MECHANICAL INTEGRITY SUMMIT

 Corrosion Monitoring Data Integrity

Presentation Foundation Recommended Program Program Expansion and

and Focus Prerequisites Growth

API INSPECTION & MECHANICAL INTEGRITY SUMMIT

 Corrosion Monitoring Life Cycle
Planning
Define Scope and Objective
Identify Assets/Components to be Monitored
Determine Corrosion Monitoring Technique
Establish Frequency of Monitoring
Planning
Periodic Evaluation & Review
Conduct Periodic Validations of Corrosion Monitoring Effectiveness Data
Review and Update Plan Based on Findings Periodic Data Collection & Baseline Assessment
Evaluation & Collection &
Collect Baseline Data
Review Baseline Establish Predicted Corrosion Rate
Assessment

Life Cycle

Maintenance & Mitigation Maintenance Ongoing

Implement Maintenance/Mitigation Strategies Based on & Mitigation
Ongoing Monitoring
Corrosion Monitoring Results Monitoring Conduct Regular Monitoring Based on Established Frequency
Track Implemented Strategies through Subsequent Monitoring

Data Analysis
& Reporting

Data Analysis & Reporting

Analyze and Collected Data
Compare Data against Established Criteria/Industry Standards
Identify any Arears of Concern or Potential Risks
API INSPECTION & MECHANICAL INTEGRITY SUMMIT Report Findings and Recommendations for Further Evaluation
 Key Challenges in the Corrosion Monitoring Life Cycle
• Program Complexity
Planning
• Manpower

Data Collection & • Inaccurate & Conflicting Documentation

Baseline Assessment • Unverified Baselines

• Unvalidated Incoming Data

Ongoing Monitoring
• Unjustified Scope Reduction

Data Analysis &

• Inaccurate Interpretation
Reporting

Maintenance & • Maintenance Schedule Conflicts

Mitigation • Failed Mitigation Strategies

Periodic Evaluation & • Lack of Participation

Review • Review oversights

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 Data Integrity Program Establishment

Procedure Tool Identification Baseline Program

Development & Utilization Establishment Execution

x
• Scope • Tool Capabilities • Strategic
• Historical Data Implementation
• Application • Data Collection Analysis
• Implementation
• Program Parameters & • Data Entry • Historical Data Constraint
Variables • Visualization Anomaly Corrective Identification &
• Anomaly Resolution Action Corrective Action
• Automation
Strategies • Adaptive Program
• Data Analysis
Workflow

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 Incoming Data Validation

FIELD COLLECTION REPORT RESULT

GENERATION INTERPERTATION DATA ENTRY DATA ANALYSIS DECISION

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 Incoming Data Validation

Common Limitations
• Uncalibrated Equipment
• Inconsistent Location
FIELD COLLECTION • Technician Qualification
• Data Recording Errors

Corrective Actions
• Consistent Calibration
• Location Identifier
• Certification Program
• Improved Communication & Attention to Detail

API INSPECTION & MECHANICAL INTEGRITY SUMMIT

 Incoming Data Validation

Common Limitations
• Inaccurate Data Transfer
• Inconsistent Report Quality
REPORT GENERATION
• Inexperienced User

Corrective Actions
• Attention to Detail
• Report Expectations
• User Training and Procedure Implementation

API INSPECTION & MECHANICAL INTEGRITY SUMMIT

 Incoming Data Validation

Common Limitations
• No Interpretation
RESULT INTERPERTATION • Baseline Error
• Role Qualification

Corrective Actions
• Task Implementation
• Data Availability
• Role Expectations

API INSPECTION & MECHANICAL INTEGRITY SUMMIT

 Incoming Data Validation

Common Limitations
• Human Error
DATA ENTRY • Task Expectations
• Inexperienced User
• Data Translation

Corrective Actions
• Automated Data Entry
• Automated Anomaly Detection
• Task Prioritization & Allocation
• Comprehensive Training Program
• Procedural Nomenclature and Data Standards

API INSPECTION & MECHANICAL INTEGRITY SUMMIT

 Incoming Data Validation

Common Limitations
• Data Quality
• Outliers
DATA ANALYSIS
• Limited Sample Set
• Subjective Interpretation

Corrective Actions
• Automated Anomaly Detection
• Standardization
• Data Auditing
• Source Verification
• Qualitative Expertise
• Procedural Interpretation

API INSPECTION & MECHANICAL INTEGRITY SUMMIT

 Incoming Data Validation

Common Limitations
• Inaccurate Data
• Inaccurate Planning
DECISION
• Decision Delay
• False Confidence

Corrective Actions
• Systematic Data Validation
• Structure Planning Deviations
• Weighted Determination Factors

API INSPECTION & MECHANICAL INTEGRITY SUMMIT

 Data Utilization

Increased
Inspection
Efficiency

Increased
Cost Optimization Inspection
Effectiveness

Predictive Analysis

Corrosion Rate
Based Inspection
Intervals

API INSPECTION & MECHANICAL INTEGRITY SUMMIT

 Conclusion
People spend a lot of time improving the pump but never the well
-William Makepeace Thackeray

Program Establishment Data Validation Data Utilization

API INSPECTION & MECHANICAL INTEGRITY SUMMIT