UPGRADING OF REFINERY\u27S CORROSION MANAGEMENT SYSTEM

Beside purchasing crude oil maintenance cost is the second major element of refinery operational expenditures and hence its influence on refinery profit margins is very high. According to a comprehensive US survey it is estimated that about 40% of refinery maintenance costs are in association with corrosion caused failures. It is also indicated that 10 – 40% of the corrosion costs (according to the type of industry) can be avoided with operating appropriate corrosion management systems. Moreover indirect costs of corrosion (Loss of Gross Margin – LGM) due to unscheduled unit shutdowns and environmental pollution can be even one magnitude higher then direct costs. Corrosion failures not only increase direct maintenance costs and indirect costs but are associated with high risk of accidents the frequency and severity of which has an increasing tendency worldwide. It was realized that the ambitious profit goals of MOL Group Refining cannot be accomplished without maintaining high asset availability by focusing on prevention and significantly reducing the frequency of corrosion failures. Refining management launched the 3A (Anti-corrosion Application and Actions) initiative and a Corrosion Team was established with the following tasks: 1. Setting up effective corrosion management organizational structure for all MOL Group refineries. 2. Supporting work of Maintenance by unified corrosion failure reporting, compiling central corrosion database and applying advanced corrosion monitoring and inspection techniques. 3. Elaborating methodology for calculation of valid costs of corrosion prevention and mitigation. 4. Dissemination of corrosion information and refinery best practices, raising knowledge level and commitment of employees by regular training and education. The above strategic goals have been broken down in short and medium term action plans and development projects according to the actual corrosion management status of each refinery. It is expected that after successful execution of the above projects corrosion caused failures as well as associated maintenance costs and risk of accidents could be minimized with increase in profitability of refining