Corrosion Management Activities in India

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INDIA
Corrosion Management
New Hope
Challenges
Opportunities
New Directions
Prepared by: M Valliappan
Jan 2009
Corrosion Management Services
PSG-Science and Technology Entrepreneurial Park, Coimbatore-641004, India
Email: corrosion.management@gmail.com; visalvalli@rediffmail.com

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Contents
Key Economic Indicators .............................................................................3
Country Profile .......................................................................................3
Cost of Corrosion in India ...........................................................................4
Overview of Industries in India .....................................................................5
Oil and Gas ............................................................................................... 5
Chemicals ................................................................................................. 6
Petrochemicals ....................................................................................... 6
Inorganic Chemicals ................................................................................. 6
Organic Chemicals ................................................................................... 6
Fine and Speciality Chemicals ..................................................................... 7
Bulk Drugs ............................................................................................. 7
Agrochemicals ........................................................................................ 7
1
Key Players – Operating Companies .................................................................8
ONGC ..................................................................................................... 8
Cairn India ............................................................................................... 9
Reliance Industries..................................................................................... 9
IOCL ..................................................................................................... 11
BPCL ...................................................................................................... 13
HPCL...................................................................................................... 14
Key Players - Corrosion Awareness in India ..................................................... 15
Key Factors for Corrosion Management .......................................................... 15

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Analysis Criteria and Reporting Levels ........................................................... 16
Corrosion Management Activities in India ........................................................ 16
Overview................................................................................................. 16
Corrosion Management Functional Areas ......................................................... 17
Market Research Analysis Criteria ................................................................ 17
Present Trend Vs Future Growth .................................................................. 18
Index of Production – Industries in India ..................................................... 18
Production Growth .................................................................................. 19
Comparative Analysis ............................................................................... 19
India, Malaysia, Singapore, Indonesia and Middle East........................................ 19
Market Research – Qualitative Assessment – India Vs Other Countries .................. 20
Industry specific Analysis ......................................................................... 21
Oil and Gas .............................................................................................. 21
Chemicals and Power .................................................................................. 22
What I Can Do? .................................................................................... 23
Corrosion Management Services .................................................................. 23 2
Testimonies ......................................................................................... 25
Corrosion Software Development ................................................................. 25
Corrosion Awareness in India...................................................................... 25
NACE India Section Award - 2003 ............................................................. 25
Press Clipping ........................................................................................ 26
Technical Publications.............................................................................. 27
CV Summary ........................................................................................ 28
Current Development ............................................................................... 29

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Key Economic Indicators
C
GDP: $804 billion (2006 est.)
Growth: Estimated 8 percent or higher in 2006-07; 7 percent in 2004-05
Breakdown: Services equal 54 percent of the GDP; industry and agriculture equal 46 percent
Ranking: 10th largest economy in the world and one of its fastest growing; fourth largest in
purchasing -power parity terms.
Per capita income: $720 in 2005 -06, (double the figure of two decades ago). Of the 1.1 billion
people, 39 percent live on less than $1 per day.
Purchasing power: In 2006, approximately 180 -200 million people had growing purchasing power,
thus creating a growing middle-class consumer population.
Youth Power: Over 58 percent of the Indian population is under the age of 20. That is over 564
million people, nearly twice the total population of the United States.
Source: BUYUSA.GOV -- U.S. Commercial Service –India
Country Profile
3
Source: Doing Business in South Asia in 2007

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Cost of Corrosion in India
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Cost of Corrosion in India
2007
2005
2003
0 20,000 40,000 60,000 80,000 100,000 120,000 140,000 160,000
Total Loss in Crores
Source: CORCON conference – NACE India Section- Press Clippings
Cost of Corrosion in India - Sectorwise
Infrastructure
4
15%
Others
28%
Utility Services
32%
Defence and
Nuclear
13%
Production and
Manufacturing
12%

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Overview of Industries in India
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Oil and Gas
India, in 2004-2005, met 75 %of its crude oil demand through imports. The domestic production of crude oil
has been in the range of 30-34 Million Metric Tons from 2001-2005. About 60 % of its crude import is from
Middle East.
The consumption of natural gas grew at a CAGR of 2.7 % in the period 1999-2005, supported by rise in
availability through domestic and imported sources of gas.
Oil comprises 36 % of India’s primary energy consumption in 2005, and is expected to grow both in absolute
and percentage terms driven by overall economic growth. Growth in demand is expected to catapult the overall
demand to 196 Million Metric Tons in 2011-2012 and 250 Million Metric Tons in 2024-25.
Demand for oil is expected to grow from 119 Million Tons Oil Equivalent (MTOE), from 2004, to 250 MTOE,
during 2025, at an annual growth of 3.6%. During the same period domestic production from existing developed
reserves is expected to grow at approximately 2.5 %.
Natural gas comprises 9 % of India’s primary energy consumption at present and it will be 14% of energy mix
by 2010. Demand for natural gas is also likely to increase at an annual growth rate of 7.3%.
Source: http://www.researchandmarkets.com/reports/338112/
5
Source: ONGC, OIL and DGHA, Ministry of Petroleum, Govt. of India.

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Chemicals
Contributes to 13% of GDP.
One of the fastest growing sectors of Indian economy.
Chemical Industry in India is fragmented and dispersed - multi product and multi faceted.
Chemicals sold directly to large customers and through distribution channels. Distribution channels mostly 6
consist of stockists and dealers spread all over India addressing small segments and retail market.
Petrochemicals
The major category in the chemicals. One of the fastest sectors at 13% p.a.
Basic chemicals like Ethylene, Propylene, Benzene and Xylene.
Intermediates like MEG, PAN and LAB.
Synthetic fibres like Nylon, PSF and PFY.
Polymers like LDPE/HDPE, PVC, Polyester and PET.
Synthetic rubber like SBR, PBR.
Major players are Reliance, IPCL, NOCIL, Haldia and GAIL.
Inorganic Chemicals
US$ 2.5 Billion industry.
Covers basic products like Caustic, Chlorine, Sulphuric Acid etc.
Inorganic chemicals mostly used in detergents, glass, soap, fertiliser, alkalies etc.
Competition from imports are on the rise.
Organic Chemicals
1 Billion Dollar industry.
Covers a wide range of chemicals.
Units concentrated mostly in the Western India.

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M Fine and Speciality Chemicals
Low volume, high price/margin chemicals.
C Fragmented with large number of players.
Major Players - Domestic: ION Exchange, Balmer Lawrie, Dai Ichi Karkaria: MNC: Ciba, Hoechst, Foseco, Nalco
Chemicals, Clariant, ICI: Many small Indian companies.
Market around US$ 80 million p.a.
Major end user segments - Textile, Leather, paper, detergent, rubber, paints, polyester, oil and gas etc.
Growing very fast.
Bulk Drugs
Large market due to large population
Large exports (US$600-800 million) which is around 6-8% of global drugs market. Total market is US$3 Billion
/ pa.
Out of 475 drugs used, 425 are locally produced.
Over 350 units in the organised sector and many more in the unorganised sector.
Bulk drug units concentrated around three areas: Bombay – Ankleshwar; Hyderabad – Madras; Chandigarh.
India very strong in reverse Engineering, molecular chemistry and because patents not on products but on
process.
Major players: Ranbaxy, Shasun, Cipla, Dr. Reddy's, Cheminor, Lupin, IPCA, Sun, Cadilla, Wockhardt, Aurobindo,
Kopran etc.
Most of the bulk drug companies are Indian companies, whereas some of the major pharmaceutical formulation
companies are MNCs.
Agrochemicals
India is a large agricultural economy which is the major user. Average Indian consumption is very low (1/20th
of world average).
Market size 100,000 MT (in terms of technical grade).
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US$ 800 million and Growth at 10% pa.
Consumption varies depending on crop and region
Cash crops like sugarcane, tobacco etc. are the major consumers of pesticides (above 60%).
Two types of producers -Technical – 40; Formulators - above 500.
Major players: Domestic-United Phosphorus, Rallis and Excel; MNCs: Hoechst Agrevo, Novartis and Bayer
Significant exports.
Source: http://www.indianchemicalportal.com
Source: KPMG Report – The Indian Chemical Industry

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Key Players – Operating Companies
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ONGC
Discovered 6 of the 7 producing basins in India: Cambay Basin (1958); Rajasthan Basin (1967); A & AA FB
(1973); Mumbai Offshore (1974); KG Basin (1980); Cauvery Basin (1985).
Established over 6.4 of the 8.5 billion metric tonnes of In-place hydrocarbon reserves discovered so far in
India.
Produces over 1 million barrels of Oil Equivalent per day. Contributes around 80% of domestic oil and gas
production.
Strategic Goals – 2020:
Double Oil and Gas In-place reserves to 12 billion tones.
Augment global recovery factor from existing 28% to 40%.
Obtain 20 million tonnes per annum equity Oil from abroad.
100% QHSE (Quality, Health, Safety)
Infrastructure: ONGC owns and operates through: 70 onland drilling rigs, 29 offshore drilling rigs and 74
onland work-over rigs; 147 well platforms and 32 process platforms; 55 Offshore Support Vessels (OSVs) and
2 Multipurpose Support Vessels (MSVs), one seismic survey vessel and 2 for stimulation services; More than
15,000 kilometers of pipelines, the biggest pipelines in network in India, including more than 4,500 kilometers
of sub-sea pipelines; Five Virtual Reality centres to augment accuracy in its exploration efforts.
8
ONGC, in its endeavor to empower its regional work centers and to bring more accountability, had undertaken a
corporate restructuring exercise by which the regional locations and departments have been categorized
under Assets (Producing centres), Basins (Exploring centres), Plants (Processing centres) and Services. Apart
from this ten R&D and Management Institutes are there. There are ten (10) Assets, three (3) in Offshore and
seven (7) in Onshore.
Offshore Assets: Mumbai High, Neelam & Heera and Bassein & Satellite.
Onshore Assets: Ahmedabad, Ankleshwar, Mehsana, Rajahmundry, Cauvery, Assam and Tripura.
There are seven (7) Basins, one (1) in Offshore and six (6) in Onshore:
Offshore: Western offshore.
Onshore: Western Onshore (Cambay and Jodhpur), Assam & Assam Arakan, Krishna Godavari, Cauvery,
Bengal-Purnea-Mahanadi and Frontier
There are four (4) Plants producing Value Added Products: Uran (Maharashtra), Hazira (Gujarat), Gandhar
(Gujarat) and Tatipaka (Andhra Pradesh-Mini Refinery). Another is coming up at Karaikal, Tamilnadu.
Source: http://wwww.ongcindia.com

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Cairn India
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Cairn India was listed on 9 January 2007 on the Bombay and National Stock Exchanges. The Initial Public Offering
(IPO) of Cairn India was the largest IPO to date in the Indian primary equity markets and Cairn India currently has a
market capitalisation in excess of $5 billion, ranking as the fourth largest oil and gas company in India.
Operations
The Company operates the largest producing oil field in the Indian private sector and has pioneered the use of cutting-
edge technology to extend production life. Today, we have a world-class resource base, with an interest in 15 blocks in
India.
A Decade of Achievement
Exploration
More than 30 Hydrocarbon discoveries:
Onshore
Shallow Offshore
Deep Offshore
Development
Fast-track development
Lakshmi gas field discovery in May 2000 and first gas by October 2002.
Ravva developed from a 3,700 bopd field to 35,000 bopd field in 26 months, now producing over 50000 bopd.
Mangala FDP approved within 30 months from discovery 9
Production
Operates the largest producing field in Indian Private Sector.
Combined field direct opex of Ravva and Cambay is $1/boe.
Pioneered use of cutting-edge technologies to extend production life
Source: http://wwww.cairnindia.com
Reliance Industries
RIL is the largest Oil & Gas acreage holder among the Private sector companies in India with 34 domestic exploration
blocks covering an area of about 331,000 sq. km. This is in addition to its interest in one exploration block each in
Yemen and Oman RIL also has 5 coal bed methane (CBM) blocks covering an area of about 4,000 sq. km.
RIL is India's first private sector company in the Exploration and Production (E&P) sector to have discovered large gas
reserves. The E&P strategy of RIL is aimed at further enhancing the level of vertical integration in its energy business,
and realising value across the entire energy chain, while fulfilling important national priorities.

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M In the years to come, RIL is well positioned to be amongst the largest value creators in the upstream oil and gas sector.
RIL's portfolio of E&P assets, gives it the potential to create value across entire value chain from wellhead to burner
C tip. Accretion of new reserves through exploration, development of existing oil and gas reserves and development of
related downstream infrastructure facilities would result in significant value creation for RIL in future. RIL has
achieved a high success rate of 74 % in terms of discoveries made from the wells drilled thus far, excluding wells
under evaluation.
Reliance Petroleum
Reliance Petroleum Limited ("RPL" or the "Company"), was set up to harness an emerging value creation opportunity in
the global refining sector by Reliance Industries Limited (RIL), one of India's largest private sector company with a
significant presence across the entire energy chain and a global leadership across key product segments. Currently, RPL
is 75% owned subsidiary of RIL. RPL also benefits from a strategic alliance with Chevron India Holdings Pte Limited,
Singapore, a wholly owned subsidiary of Chevron Corporation USA (Chevron), which currently holds a 5% equity stake.
RPL was formed to set up a greenfield petroleum refinery and polypropylene plant in the Special Economic Zone (SEZ)
at Jamnagar in Gujarat. This global sized, highly complex refinery is being located adjacent to RIL's existing refinery
and petrochemicals complex, which is amongst the largest and most efficient in the world, thus offering significant
synergies.
With an annual crude processing capacity of 580,000 barrels per stream day (BPSD), RPL will be the sixth largest 10
refinery in the world. It will have a complexity of 14.0, using the Nelson Complexity Index, ranking it amongst the
highest in the sector. The polypropylene plant will have a capacity to produce 0.9 million metric tonnes per annum.
The refinery project is being implemented at a capital cost of Rs 27,000 crore being funded through a mix of equity
and debt. This represents a capital cost of less than US $10,000 per barrel per day and compares very favourably with
the average capital cost of new refineries announced in recent years. The International Energy Agency (IEA) estimates
the average capital cost of new refinery in the OECD nations to be in the region of US $15,000 to 20,000 per barrel
per day. The low capital cost of RPL becomes even more attractive when adjusted for high complexity of the refinery.
RPL's low capital cost is a result of the benefits of 'intelligent repeat' of design and engineering aspects of RIL's
existing refinery, proactive procurement strategy and faster implementation of the refinery project. This is expected
to provide sustainable competitive advantage in the market place and enable RPL to deliver superior value in the coming
years.
RPL has embarked on an aggressive implementation plan and is targeting to complete the project within a short span of
3 years by 'intelligently replicating' the existing refinery of RIL, through repeat efforts on the engineering,
procurement and construction fronts, with the same team, viz. Bechtel, UOP, Foster Wheeler that created the existing
refinery of RIL at Jamnagar - considered to be a modern temple of resurgent India.
Source: http://wwww.ril.com

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IOCL
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Refineries
Indian Oil Corporation Ltd. is currently India's largest company by sales with a turnover of Rs. 220,779 crore (US $51
billion), the highest-ever for an Indian company, and profits of Rs. 7499 crore (US $1.73 billion) for fiscal 2006.
IndianOil is also the highest ranked Indian company in the prestigious Fortune 'Global 500' listing, having moved up 18
places to the 135th position this year based on fiscal 2006 performance. It is also the 20th largest petroleum company
in the world.
IndianOil controls 10 of India’s 19 refineries. The group refining capacity is 60.2 million metric tonnes per annum
(MMTPA) or 1.2 million barrels per day -the largest share among refining companies in India. It accounts for 40.4%
share of national refining capacity.
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M Pipelines
C IndianOil’s cross-country pipelines network is nearly 9,300 km in length and 61.72 million metric tonnes per annum
(MMTPA) in capacity. Pipelines being the safest, cost-effective, environment-friendly and energy-efficient mode of
transportation, have been continuously adding to the efficiency and productivity of IndianOil's refineries and
marketing set-up. IndianOil's oldest pipeline, the Guwahati-Siliguri Pipeline commissioned way back in 1964, is still being
operated at designed pressure and capacity. All IndianOil pipelines are certified to ISO 14001:1996 environment
management system and ISO 9001:2000 quality management system while giving paramount importance to safety too.
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Source: http://wwww.iocl.com

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BPCL
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BPCL Refineries - a Transformed Organisation
BPCL, a Fortune 500 Company with an equity base of Rs.300 crore, is a leading player in the Petroleum Sector in the
country. BPCL currently have Refineries at Mumbai and Kochi with a capacity of 12 Million Metric Tonnes (MMT) and
7.5 MMTPA respectively for refining crude oil. BPC's subsidiary at Numaligarh has a capacity of 3 MMT.
Mumbai Refinery
Future Plans: Specific areas in which R&D is being carried out by the Company
Catalytic processes
Clean Fuel Technology
Residue Upgradation
Detailed crude evaluations
Value added products
Modelling and simulation of Refinery processes
Corrosion and fouling
Analytical methods development
Alternate fuels 13
High performance Diesel Engine Oil
Kochi Refinery
Future Plans
In view of the declining market for furnace oil with high sulphur content and reducing availability / increasing prices of
light and low sulphur crudes, a suitable residue upgradation facility has been found essential for Kochi Refinery. The
proposed capacity expansion of the refinery by the year 2010 will result in generation of additional quantities of high
sulphur heavy residue. Delayed coking has been identified as an option for upgradation of refinery residue to value
added distillate products. A detailed feasibility study for refinery bottoms upgradation is being carried out with the
help of a consultant. The possibility of transporting and processing some short residue from BPCL-Mumbai Refinery is
also being studied.
Numaligarh Refinery
Future Plans
In order to increase value addition to the surplus naphtha currently available at the refinery, NRL proposes a new
project within the existing refinery premises to produce Motor Spirit (MS), which also conforms to Euro-III quality
specifications. This is mainly by taking into consideration the Auto Fuel Policy in India on future automobile fuel quality
specifications as a mater of environmental concern. Major process units to set up are:
Naphtha Hydrotreating Unit (NHTU) with splitter section, Semi-Regenerative Catalytic Reformer Unit (CRU),
Isomerisation Unit with Deisohexanizer Section (ISOM). M/s Toyo Engineering (I) Ltd, Mumbai has been engaged as

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M Project Monitoring Consultant. M/s AXENS, France is the Process Licensor for the project. The total plant capacity
would be 225 TMTPA.
C
Addition of superior quality MS in product line will give better market flexibility to NRL and also increased production
of LPG from the MS Project would generate additional revenue. It will ensure availability of hydrogen for meeting
future needs for HSD upgradation
Source: http://wwww.bharatpetroleum.com
HPCL
HPCL is a Fortune 500 company, with an annual turnover of over Rs 1,03,837 Crores ($ 25,142 Millions) during FY 2007-
08, 16% Refining & Marketing share in India and a strong market infrastructure. Corresponding figures for FY 2006-07
are: Rs 91,448 crores ($20,892 Million).
The Corporation operates 2 major refineries producing a wide variety of petroleum fuels & specialties, one in Mumbai
(West Coast) of 5.5 MMTPA capacity and the other in Vishakapatnam, (East Coast) with a capacity of 7.5 MMTPA.
HPCL holds an equity stake of 16.95% in Mangalore Refinery & Petrochemicals Limited, a state-of-the-art refinery at
Mangalore with a capacity of 9 MMTPA. In addition, HPCL is progressing towards setting up of a refinery in the state
of Punjab in the joint sector.
HPCL also owns and operates the largest Lube Refinery in the country producing Lube Base Oils of international 14
standards. This Lube Refinery accounts for over 40% of the India's total Lube Base Oil production.
HPCL has successfully integrated Information Technology in its activities at different levels. The Enterprise Resource
Planning (ERP) system is now operational on J.D.Edwards, an Oracle product, across the Company.
Source: http://wwww.hindustanpetroleum.com

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Key Players - Corrosion Awareness in India
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Source: http://wwww.naceindia.org
Key Factors for Corrosion Management
Corrosion Awareness
Cost of corrosion
HSE Awareness
Environmental and Safety Regulations
Industry type
Industry management
Attitude towards implementing new technical solutions
Corrosion monitoring and management

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M Corrosion data management and analysis
Corrosion expertise available – in-house, external-domestic and external-overseas
C
Corrosion research programs
Corrosion education
Corrosion conferences – national and international levels
Information technology development
Knowledge process outsourcing
Analysis Criteria and Reporting Levels
Following levels are used in all tables throughout this report for qualitative representation of opportunities available
for corrosion management in India. Similar approach is also employed to focus on the opportunities, challenges and new
directions for corrosion management in Malaysia, Singapore, Indonesia and Middle East presented in this market
analysis report.
Level Colour Coding Representation
0 No colour Activity/development is yet to be noticed
1 Activity has been initiated
2 Activities are growing; Improvements are there
3 Significant developments 16
Corrosion Management Activities in India
Overview

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C Corrosion Management Functional Areas
Functional areas covered in this report are given in the following table.
Corrosion Management Area Component
Coupons
Probes
Data Loggers
Corrosion Monitoring Instruments Portable Monitors
Data Transmitters
Retrieval Tools
Impressed Current Systems
Soil Analysis
Pipeline Survey – CIPS/DCVG
CP Evaluation and Maintenance
Corrosion Monitoring Services Internal Corrosion Monitoring
Chemical Treatment Optimization
Laboratory Corrosion Testing
Field Trials
Cathodic Protection
Chemical Injection
Corrosion Management (CM)
Design
Field Trials-CM
CM Component of Risk Based Inspection (RBI)
CM Component of Integrity Management (IM)
Corrosion Management Manual
Corrosion Standards and SOPs
Corrosion Data Management 17
Information Management Corrosion Software Development
Integration with Other Systems
Material Selection
Corrosion Training
Market Research Analysis Criteria
Factors taken into consideration for analyzing the corrosion management business opportunities are:
Index of production
Industries growth rate
Corrosion losses reported in the public domain through media and conferences
Corrosion awareness programs in place
HSE awareness programs
Corrosion analysis focus
Corrosion control implementation
Operational corrosion monitoring facilities
Corrosion management expertise
Information management systems

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Present Trend Vs Future Growth
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18
Index of Production – Industries in India
Index of Production-Industries in India
250
200
150
100
50
0
1993-1994 2000-2001 2001-2002 2002-2003 2003-2004 2004-2005 2005-2006
Source: Ministry of Petroleum, Govt. of India

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M Production Growth
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Source: Confederation of Indian Industries
Comparative Analysis
India, Malaysia, Singapore, Indonesia and Middle East 19

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Market Research – Qualitative Assessment – India Vs Other Countries
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20

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Industry specific Analysis
C
Oil and Gas
21

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Chemicals and Power
C
22

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What I Can Do?
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Corrosion Management Services
Corrosion Management Services (CMS) has been started in 1998 under the Science and
Technology Entrepreneurial Scheme of Department of Science and Technology (DST), Govt. of
India. CMS is functioning from PSG-Science and Technology Entrepreneurial Park, Coimbatore,
India. CMS specializes in the development of technology software solutions for multiplex CM and
provides technical consultancy services for CM.
Corrosion Management Technical Services
Design, develop, implement and maintain Corrosion Management (CM) system.
Conduct Corrosion Management audit.
Review P&I diagrams for corrosion monitoring, chemical injection and stream sampling
locations.
Identify corrosion management requirements – FEED package; plant and laboratory; regular
operational corrosion monitoring (OCM) and field trials;
Prepare corrosion management manual; Define and use Key Performance Indicators (KPIs) –
corrosion monitoring and control activities. 23
Develop ranking methodology to screen chemicals for corrosion inhibition, scale control,
oxygen scavenging and microbial control.
Identify International standards and develop in-house Standard Operating Procedures
(SOPs) for efficient operation.
Provide training to personnel for executing corrosion management operation.
Gather HAZOP, HSE and Integrity Management information for CM activities; Create
awareness for the leak free environment through corrosion management activities.
Apply information management for planning, scheduling, reporting and integrating CM.
Corrosion Risk Assessment
Provide corrosion management inputs (expert corrosion rate, damage mechanism, corrosion
circuits, consequence of failures and online/offline monitoring/corrosion control factors) to
Risk Based Inspection, Integrity Assessment and Life Cycle Costing (LCC).

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M Prepare Corrosion Management technical reports and develop mappings for material
selection, corrosion monitoring and corrosion control based on actual plant data.
C
Analyze corrosion management data (process data, materials of construction, equipment
types, fluid composition, corrosion monitoring, corrosion control, equipment visual inspection,
NDT, ILI-Intelligent Pigging, downhole tubular corrosion log and specialized inspection) in
the entire process network for asset integrity report.
Identify critical locations for close monitoring and risk assessment.
Corrosion Management Software
Develop corrosion management software solutions.
Develop interface tools for linking multitude functions.
Build expert system for consequence of failures and risk management.
Develop simulation models for corrosion.
Ability to work with various modules of plant information management – process, laboratory,
inspection, maintenance and enterprise resource planning to develop relational corrosion
prediction and management systems.
24
Corrosion Research and Development
Provide technical support for evaluating new technologies proposed by Research and
Technology division of industrial establishments.
Amalgamation of corrosion research with asset corrosion management.
Write technical articles on corrosion management.
Ability to transform industrial experience into commercially viable and technically
challenging corrosion management solutions.

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Testimonies
C
Corrosion Software Development
Developed integrated corrosion management software
solution for Cairn Energy India Ltd., (CEIL) – S Yanam
oilfield (50,000BOPD) - onshore (water injection and
crude/gas processing) and offshore (seven
platforms);
Corrosion Awareness in India 25
NACE India Section Award - 2003
Corrosion Management Services, India
Recipient of Corrosion Awareness Award-2003-
Individual Engineer Category for introducing quality
management systems for corrosion.

27. S
M Press Clipping
C http://www.thehindu.com/thehindu/lf/2004/11/28/stories/2004112801870200.htm
Date:28/11/2004 URL:
http://www.thehindu.com/thehindu/lf/2004/11/28/stories/2004112801870200.htm
Back Life Bangalore Chennai Coimbatore Hyderabad Kochi Madurai
Thiruvananthapuram
`There is no maintenance culture in India'
"When there is a breakdown or a failure there is no attempt to analyse the causes of
failure. Immediate replacement is done, but the data is not used to minimise
corrosion"
26
Cost reduction is an important issue facing the industry. While many systems have been
implemented to control costs such as total quality management, total preventive maintenance and
ISO standards, more needs to be done to address specific issues which tend to escape the purview
of such general systems. Material corrosion is considered to be the number one life-limiting
factor in production, manufacturing and infrastructure. India loses Rs. 36,000 crores in corrosion
costs annually.
Manickam Valliappan has researched and worked with the problems of industrial corrosion and
has found some answers. In conversation with Puja S Navin, he discusses how he views the issue.
"I began my career as a research fellow in the corrosion department of the Central
Electrochemical Research Institute (CECRI), Karaikudi, in 1987. During my Chemical
Engineering course, I learnt about industrial corrosion and developed an interest in it. It was also
during this time CECRI was coming up and I joined it."
From 1987 to 1995, he worked on various industrial projects with oil, gas and refining sector. It

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M Technical Publications
Number of Publications: Seventeen
C Partial List:
1. Computerized Multiplex Corrosion Management System, Materials Performance, April 2005, NACE
International, USA, pp40-43. (peer reviewed - ISSN: 0094 -1492)
2. Corrosion Management for Quality Control and Assurance, Paper No. 05059, Corrosion 2005 Annual
Conference, NACE International, USA.
3. Corrosion Management in Cooling Water Systems, Materials Performance, Feb 2002, NACE
International, USA. (peer reviewed - ISSN: 0094 -1492)
4. Software Analysis of Cooling Water Treatment Problems - eCorr 2000 - Internet Conference -
http://www.corrosionsource.com/CS2000/session8 - Applications of Computers and Internet for
Corrosion Control.
5. Influence of MIC on the Pitting Resistance of Stainless Steels in Sea Water - Intercorr 96 - The first
Global Internet Corrosion Conference - Session 5 - Industry focus - http://www.intercorr.com
6. Selection of Biocides for Oil fields - Review and Laboratory Assessment - 15th World Petroleum 27
Congress, Forum 15, China.
7. Pitting Corrosion of Stainless Steels in Acidified Chloride Medium - 13th International Corrosion
Congress, November '96, Australia, Paper No. 380.
8. Electrochemical Dissolution of Cu-Ni alloys in Acidic Chloride Medium - 13th International Corrosion
Congress, November '96, Australia, Paper N0. 129.
9. Concern over the Selection of Biocides for Oil fields and Power plants - Second Arabian Corrosion
Congress, October '96, Kuwait - Oil field Corrosion Session.
10. Pitting Corrosion of Stainless Steels in Acidified Chloride Medium - STAINLESS STEELS Conference,
June '96, Germany.

29. S
M
CV Summary
C
A Corrosion Management Consultant who has demonstrated the ability to work independently and lead
diverse teams of engineering professionals from the asset owners and service contractors to achieve
maximum efficiency of corrosion management functions. Proven ability to analyze an organization's
corrosion management requirements, resource planning, develop innovative and cost-effective solutions for
corrosion analysis, increasing life of equipments, and improving asset integrity for safe and reliable
operation.
Academic Qualification and Professional Certifications
B.Tech., (Chemical Engineering); Graduated from Coimbatore Institute of Technology, Bharathiyar
University, India (1982-’86).
1. NACE International certified 'Chemical Treatment Specialist' (Certification No.4949 issued on
01 May 1998).
2. NACE International certified ‘Senior Corrosion Technologist'.
Award: Recipient of NACE International-India section award for excellence in corrosion for introducing
quality management systems in the year 2003.
Experience Since Jan 1987
Corrosion Consultant Kuwait Oil Company (KOC), Kuwait Jan 2007-Present
Specialized Corrosion Engineer Kuwait Oil Company (KOC), Kuwait Feb 2005-Dec 2006
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Self-employed Consultant Corrosion Management Services, India Jun 1998-Present
Corrosion Engineer Kuwait National Petroleum Co., Kuwait Mar 1997-May 1998
Research Engineer Corrosion Lab, Kuwait University, Kuwait Feb 1995-Feb 1997
Research Fellow Central Electrochemical Research Institute, India Jan 1987 – Jan 1995
Recent Accomplishments
Kuwait Oil Company, Kuwait
KOC produces 2.6 MMBOPD Oil (Varied composition – API Gravity, CO2, H2S, Salt Content and Water Cut - South & East–1500 MBOPD; West-
500; North-600) and 1,348 MMCFPD Associated Gas from 20 Gathering Centers (process oil from more than 500 wells), 4 Booster Stations,
and 2 Water Injection systems.
Successfully developed in-house laboratory procedures for fluid analyses relevant for corrosion
management.
Prepared specifications for corrosion monitoring and control activities; Developed the first-of-
its kind sampling and data management matrices for internal corrosion monitoring activities;
produced corrosion mappings for the entire process network.
Application of technology software solutions for corrosion management, corrosion prediction,
operations information management, inspection management, risk based inspection and integrity
management.

30. S
M Provided CM inputs to Risk-based Inspection (RBI) system and gather inputs from RBI for
correlating corrosion management data with risk assessment; Reviewed corrosion circuits,
C expert corrosion rate and damage mechanism information provided by RBI group.
Explore CM inputs for Integrity Management to identify internal/external threats and
consequences.
Integration of Production Operation Information, ILI Survey (Intelligent Pigging) and Corrosion
Log, and Risk Based Inspection with Corrosion Management.
Identified requirements for the design and development of interface tools for integrated
analysis of corrosion management with process management, risk based inspection and integrity
management.
Corrosion Management Services, India
Recipient of NACE India section award in 2003 for introducing quality management system
for corrosion management.
Initiated indigenous software solution development in India for corrosion management under
Science and Technology Entrepreneurial Scheme of Department of Science and Technology
(DST), Government of India; successfully implemented the integrated management system with
Cairn Energy India Ltd.
Continuing the state-of-the-art multiplex corrosion management software development.
Executed B-O-T type corrosion management contract in Cairn Energy.
Proficiency in Technical Software Solutions
1. Integrated Corrosion Management built on MS Access for process-corrosion mapping; Corrosion
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Data Management using Amulet V 6.0.
2. FINDER-Version.9.2.2 – E & P data management system developed by Schlumberger.
3. Business Process Explorer-Version.2.6.0.404 – POIS developed by ASPEN Technology.
4. Orbit Plus and Orbit Onshore developed by DNV.
5. Linaview PRO – Pipeline Integrity Management Suite developed by Tuboscope.
6. ArcGIS 9.2 – Geographic Information System developed by ESRI
7. Downholesat for scale prediction.
8. PREDICT and NORSOK M-506 for expert corrosion rate calculation.
9. Data acquisition system for corrosion monitoring probes.
10. MS Office applications including MS Project.
Current Development
Development of corrosion management for risk based inspection. Concept