IOSR Journal of Mechanical and Civil Engineering (IOSR-JMCE) e-ISSN: 2278-1684,p-ISSN: 2320-334X, Volume 15, Issue 4 Ver. IV (Jul. - Aug. 2018), PP 06-11 www.iosrjournals.org DOI: 10.9790/1684-1504040611 www.iosrjournals.org 6 | Page Corrosion Management and Control in the Petroleum Industry-A Case Study of Kaduna Refinery T.N. Guma And Ajayi Eunice Olukemi Department of Mechanical Engineering Nigerian, Defence Academy, Kaduna Corresponding author: T.N. Guma Abstract: Corrosion is preponderant in the petroleum environment because most known factors that can cause to extreme various types of corrosion of a wide range of materials are abundantly present in the physicochemical composition of crudes. Every crude oil has about the same kinds of constituent chemical types but in different proportions, so different types of crudes coupled with their processing, transportation and storage conditions can have different corrosivities to materials in different refineries. Kaduna refinery uses Nigerian crudes sometimes blended with foreign crudes to produce some fuels and chemical industrial raw feedstock. The refinery has however been experiencing maintenance problems over its years of existence. This paper is a report of field and literature surveys that attempted to lay bare the basis of the problems. The study found that the entire refinery structures or systems were well designed with corrosion consideration, and corrosion management and control institutionalized therein. Corrosion is managed and controlled in the refinery through many methods including corrosion monitoring and inspections, corrosion audit, and maintenances of all designed controls. The study nevertheless found that corrosion had been a serious problem in the refinery by contributing greatly to its costly maintenance needs, shutdowns and downtime, low production and profitability, and time to time non-availability of its products to the public. Shoddy and lack of proactive corrosion management and control of the refinery have been attributed to its maintenance needs at expensive costs. Possible ways of improving corrosion management and control in the refinery are suggested for enhancing its productivity, profitability and service delivery. Key words: Refinery products, daily needs, low production, non-availability, maintenance costs, corrosion, and ways out . --------------------------------------------------------------------------------------------------------------------------------------- Date of Submission: 27-07-2018 Date of acceptance: 13-08-2018 --------------------------------------------------------------------------------------------------------------------------------------- I. Introduction Back ground to the Study: Corrosion is a destructive attack on an engineering material especially metal as a result of either chemical or electrochemical reaction between the material and its environment [1]. Material corrosion can result to serious impediments of economic and industrial developments and safety depending on how it is controlled. Not all environments are equally corrosive; some are far more corrosive than others. Also, not all materials have the same rate of corrosion deterioration in the same environment; some deteriorate at far greater rates than others [2]. Corrosion generally occurs at a greater degree in the petroleum and water environments than most other types of environments, because most factors that are known to cause different types of corrosion of a wide range of materials to extreme are abundantly present in the two environments. The total global cost of corrosion in the petroleum sector alone is huge and estimated at 3.5% of the Gross Global Domestic Product [3]. A refinery is the type of industry that uses petroleum to produce fuels and wide range of chemical raw materials for the public and other different types of industries. Like all petroleum industries corrosion in refineries is very common and can be very serious with its resultant effects depending on how it is managed and controlled. The level of corrosion in refineries stems from the corrosive nature of crude oils coupled with their processing conditions involving heating to high temperatures and cooling to ambient temperature under various pressures [3, 4]. The combination of all these and other factors influences corrosion in different ways at the preparation, transportation, storage and processing stages of crude oils in refineries. Corrosion in refineries is therefore a serious problem and must be managerially and economically technologically controlled to avert its consequences. Corrosion management is that part of the overall management system which is concerned with the development, implementation, review and maintenance of the corrosion policy. The corrosion policy provides a structured framework for identification of risks associated with corrosion, and the development and operation of suitable risk control measure. Effective management of corrosion will contribute towards achieving statutory or corporate compliance with safety and health and environmental policies, reduction in leaks, increased plant availability, reduction in unplanned maintenance and deferment costs. Management activities such as corrosion monitoring, inspection etc. are utilized to support