The unfortunate thing about corrosion is its autocatalytic nature, once corrosion commences, and then that is it. In practice, the best way to prevent the spread of corrosion is to prevent it from starting at all! Given the cost of engineering, procurement and construction of process installations, the ultimate successful facility is one that remains in the intended service for as long as possible.Corrosion and integrity management is a systematic approach to protect assets from material degradation, ensuring their safe, long-lasting, and reliable operation. It involves developing and implementing a Corrosion Management Plan (CMP) that includes procedures, risk assessments, and performance metrics, all within an organization's overall management system. The goal is to minimize life cycle costs, meet safety and environmental goals, and prolong the life of critical assets like pipelines and storage tanks.The key components of a Corrosion Management Plan are:Objectives and policies: Establishes the overall goals and framework for corrosion control.Procedures and practices: Outlines the specific working methods for managing corrosion.Risk assessment: Uses techniques like Risk-Based Inspection (RBI) to identify and quantify potential threats and prioritize mitigation efforts.Performance metrics: Defines Key Performance Indicators (KPIs) to track the effectiveness of the management system.Implementation: Puts the plan into action through activities like monitoring, inspection, and maintenance.Continuous improvement: Uses a “Plan-Do-Check-Act” cycle to review performance and make necessary updates to the strategy.Why it CMP so important?Safety: Prevents failures and leaks that could lead to accidents.Reliability: Ensures that critical infrastructure can operate without interruption.Cost reduction: Minimizes the costs associated with asset replacement, repairs, and downtime over the asset's life cycle.Environmental protection: Prevents spills and releases of hazardous materials.Compliance: Helps organizations meet regulatory requirements and industry standards.Look at asset integrity management as a value enablerCorrosion costs definitely more than what the management thinks it does, and that's what corrosion mitigation professionals would agree. “It's high time we look at asset integrity management as a value enabler, rather than a compliance tool,” said Mr Rahul Kejriwal, CEO, Senosco, a global Software as a Service (SaaS) leader in asset integrity management.<img src="https://cdn.magzter.com/1640066610/1763442819/articles/9TfcCIR1B1763445948781/3966377396.jpg" alt="image">He, along with the others were speaking at the Technical Interactive Forum on Corrosion Monitoring and Integrity Management at the CORCON 2025 held in Jaipur recently.“First, it is important to start with the challenge. Once we know that, we can more on to the opportunity. So, what is the challenge? I have spoken to inspection teams, integrity teams, etc., at most of the major assets around the world and in India, and one always hears aging assets, rising risk, and in many parts of the world very tight margins. It's always about pressures of the work, pressures of the job and always running behind the curve.The company Senosco, which Mr Kejriwal heads, has developed software that gets data to do more than just documentation, but use data to unlock insights and eventually return on investment (ROI), he said. “This software enables a multidisciplinary digital-first asset integrity platform. It's about turning data into decisions. If you don't have a strong platform, a technology backbone that is interoperable, that is comprehensive, that not only covers your integrity inspection workflows, but also covers reliability, functional safety and integrates into your Systems, Applications, and Products in Data Processing (SAP).“Let me share a few data points with you. Number one, over 50% of the aging assets around the world are running beyond their original design life cycle. Next, 3X is the number of a reactive maintenance over a predictive maintenance action. In other words, it is 3X more expensive to fix something proactively than reactively,” said Mr Kejriwal.They have been using this software the last 20 years, so they have the data, he said. One of the asset, he said, that within 12 months of rolling out a proper program, they were generating almost nine times their investment in the program, i.e they were generating nine times ROI. By year five, that had risen to 15 times ROI on a yearly basis, and by the 10th year of proper processing, capturing data, analysing data and investing in a proper program, they were generating almost 20 times ROI.<img src="https://cdn.magzter.com/1640066610/1763442819/articles/9TfcCIR1B1763445948781/4993367536.jpg" alt="image">AI/ML transforming corrosion management“People have done a lot of work on Artificial Intelligence (AI) and Machine Learning (ML) technologies,” said Mr Amish Gandhi, a chemical engineer and consultant specializing in corrosion monitoring and management, with expertise in both traditional and advanced techniques like AI/ML integration. He has worked with companies like Honeywell Automation India Limited and is currently a consultant for Metal Samples Co., focusing on using high-frequency sensor data and artificial intelligence to predict corrosion and transforming corrosion management through predictive maintenance, real-time monitoring, and automated inspection.According to him, these technologies use AI to analyze data from sensors and images to predict corrosion, identify it earlier and more accurately than traditional methods, and recommend preventative actions. This leads to more efficient, proactive, and cost-effective corrosion control strategies.AI models can analyze historical and real-time data to predict where and when corrosion is likely to occur, enabling proactive maintenance and preventing costly failures. By integrating with sensors and IoT devices, AI systems can continuously monitor conditions that lead to corrosion, providing instant alerts when risk levels increase. Computer vision and deep learning models can automatically analyze images from cameras and drones to detect and map corrosion with high accuracy, even for patterns invisible to the human eye. These systems can identify corrosion severity (e.g., light, moderate, severe) and automatically create work orders for repairs.AI can process large, complex datasets from various sources (e.g., electrochemical noise, material properties, environmental conditions) to provide deeper insights into corrosion behavior and material selection. Al can assist in developing more effective corrosion inhibitors and selecting the right materials for specific environments, improving overall protection.Al can detect corrosion with a higher level of accuracy and consistency. Automation reduces the time and manual effort required for inspections. Shift from reactive repairs to proactive prevention, minimizing downtime and costs. Early detection in inaccessible or harsh environments can prevent catastrophic failures.Of course, there are challenges too. For example, obtaining high-quality, comprehensive data for training models can be difficult. At times, understanding why a model makes a certain prediction can be challenging. Besides, integrating Al systems with existing infrastructure and workflows requires careful planning.Importance of designing an assetThe design of an asset and material selection are one of the most critical phases in the life of the asset. Major operational plant issues if envisaged at the time of the design are easier to execute when the need arises.<img src="https://cdn.magzter.com/1640066610/1763442819/articles/9TfcCIR1B1763445948781/3445935617.jpg" alt="image">Most people think asset management and corrosion control measures are largely implemented at the in-service stage. Contrarily, these phenomenal are best controlled at the asset conception and material selection stage. The material has to be selected in view of the process that the asset would support. Before commencement of construction, the steel Mill Test Certificate (MTC) and factory quality documents has to be checked and confirmed that the steel materials supplied meets project specifications. Cleanliness and uniformity of supplied material are also essential.Design and material selection are crucial in corrosion management because they are fundamental to preventing or minimizing corrosion from the initial stages of a project. A good design minimizes corrosion-prone areas, facilitates drainage, and isolates dissimilar metals, while material selection ensures the component can withstand the specific corrosive environment and stresses, leading to greater safety, reliability, and longevity.Designs can avoid sharp corners, crevices, and areas where debris can accumulate, as these are prone to pitting and crevice corrosion. Designs should incorporate features like drainage holes to prevent moisture from collecting on surfaces. By avoiding direct electrical contact between dissimilar metals or using insulating gaskets, galvanic corrosion can be prevented. Proper design helps minimize mechanical stresses, which can lead to stress corrosion cracking.<img src="https://cdn.magzter.com/1640066610/1763442819/articles/9TfcCIR1B1763445948781/6554953536.jpg" alt="image">Importance of material selectionSelecting materials with adequate chemical and corrosion resistance prevents premature failure and accidents. The right material choice is critical for achieving a long service life and avoiding operational failures caused by corrosion. Materials are selected based on their ability to perform under specific conditions, such as heat transfer, pressure resistance, and mechanical strength. While some high-performance materials may have a higher initial cost, they can lead to significant savings by reducing maintenance, downtime, and replacement costs over time. Choosing sustainable or circular materials can reduce a project's environmental footprint throughout its lifecycle. Selecting materials based on performance data and experience minimizes the risk of failure in challenging environments like those in the oil and gas industry.Creating and setting standards"So that one may select the right design and material, there has to be some standards to follow," said Mr Amit Jani, Vice President, Corrosion Engineering and Static Reliability at Reliance Industries Ltd.Standards in design and material selection involve adhering to industry-wide requirements and best practices to ensure a product is functional, reliable, and safe. This process requires identifying design needs (performance, reliability, cost, manufacturing), defining material criteria, researching potential materials, and evaluating them against the set standards and requirements before making a final selection.<img src="https://cdn.magzter.com/1640066610/1763442819/articles/9TfcCIR1B1763445948781/4676171357.jpg" alt="image">“Without standards, it may be difficult to really do a proper design that confirms to the requirements of the industry one may be working in,” said Mr Jani. “This would also help the Engineering, Procurement and Construction (EPC) contractors that they are doing a project to the right standards that has been set and the asset has been built according to it.”The best forum to address these standard specifications would be associations like the AMPP, he said. “Associations would have no kind of commercial interest that will benefit them one way or the other. Business would be willing to share data with associations, which can be gathered and used for the common good.”Importance of training and certificationsBut all this would be of no use if the people are not well acquainted or aware about what they are supposed to do. are not trained. “My advice to the operators is to invest in your people, train them, and build a culture of innovation and technology. You can have all the technology, but you need to have trained people who need to put in the data, analyse the data, and work on that data. If you feed garbage, it’s simply garbage in, garbage out,” said Mr Gasem Fallatah, Advisor for HRH the Saudi Energy Minister, and Vice President, Strategic Geographies - AMPP.Training and certification are crucial for corrosion management as they equip professionals with the necessary skills to prevent failures, ensure safety, and extend asset life, ultimately reducing the high financial and environmental costs associated with corrosion. These programs provide the technical knowledge for identifying, assessing, and mitigating corrosion through methods like material selection, protective coatings, and inhibitors, and result in a globally recognized qualification.<img src="https://cdn.magzter.com/1640066610/1763442819/articles/9TfcCIR1B1763445948781/4134597313.jpg" alt="image">Certified professionals implement programs that prevent equipment failure, reduce accidents, and ensure assets are maintained in a safe and reliable condition. Proper corrosion management significantly lowers the direct costs of repairs and replacement and the indirect costs like lost opportunity and environmental damage. Training provides the knowledge to minimize corrosion, which extends the functional life of equipment and infrastructure, making it more cost-effective over time. By mitigating corrosion, training helps prevent operational disruptions that can arise from equipment failures, leading to greater efficiency. Training upgrades professionals to experts by providing in-depth knowledge on corrosion science, monitoring, and control technologies. Certification demonstrates a commitment to industry standards and ensures that corrosion management practices are integrated into an organization’s management system. A certification is often a globally recognized qualification that validates a professional’s skills and knowledge to employers.<img src="https://cdn.magzter.com/1640066610/1763442819/articles/9TfcCIR1B1763445948781/7134437431.jpg" alt="image">Training provides hands-on knowledge in areas such as material selection, protective coatings, corrosion monitoring, and inhibitor application. Certification emphasizes the importance of a comprehensive corrosion management system, which integrates technical practices into an organization’s overall management. It is highly beneficial for both new graduates, providing them with a solid foundation, and experienced professionals, upgrading their expertise.“You have to keep yourself updated. You cannot use old techniques and old technology for addressing present day transitions. It’s training and certifications that will make a measurable difference,” exclaimed Mr Fallatah.

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