Combining Corrosion & Erosion Monitoring for Improved Integrity Management

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1 Combining Corrosion & Erosion Monitoring for Improved Integrity Management Ionut Cadar Kjell Wold Heitor Ruschmann Ivan Ruiz Stubelj Emerson Automation Solutions

2 Corrosion Management Why The Increased Focus? Personnel safety Increased plant uptime Increased equipment reliability Process optimization Operational flexibility Environmental impact Each challenge needs a suitable corrosion monitoring and control strategy

3 Quantifying the Value Proposition1)2) Safety Maintenance Operations Serious Incidents Routine Turnaround Chemicals / Availability / Up Additives time Turnaround frequency Opportunity Crudes Total Annual Margin Improvement 4,100 3,600 1,600 11,640 1, KUSD 1)Numbers above are not linked to a specific case, and intended for illustrating approach. Numbers believed to be realistic for an average size refinery. 2)Numbers in 1,000 US Dollars (K USD) A holistic solution approach is needed to maximize value

4 Corrosion & Erosion Monitoring The Toolbox NON-INTRUSIVE INLINE UT WALL THICKNESS ELECTRIC FIELD MAPPING ACOUSTIC SAND- DETECTORS CORROSION/ EROSION PROBES COUPONS Direct metal thickness measurements Measures Impact of Corrosion or Erosion on any location Easy to install No maintenance Deployable anywhere Metal loss measurements across a full area Measures Impact of both general and localised corrosion through a full area coverage No maintenance Immediate warning of solids production (risk of sand erosion) to optimize production rate Easy to install Also available as pig detector Highest sensitivity (nano-meters) and fastest quantification/ response to changed corrosion rates Highly responsive measurement of process changes Direct metal loss measurements Analysis of deposits and bacteria activity Lowest equipment cost ADVANTAGES WIRELESS 4 WIRELESS Each challenge needs a suitable corrosion monitoring and control strategy

5 In-Line Probes The Value of High Sensitivity Plot shows typical ER probe data. Observe: Full scale 7 micrometer Sensitivity low nanometer range Increased corrosion rate detected after fractions of a micrometer metal loss Increased corrosion identified, mitigated (corrosion inhibitors) and mitigation effect verified at total metal loss of 4,1 micrometer and 6 days. Sensitivity and Fast Response

6 Ultrasonic Corrosion and Erosion Monitoring Ultrasonic wall thickness sensors, clamped or stud-welded to any pipe section or asset Extreme Temperature Ranges (-180 to 600 Deg.C) Can be deployed anywhere - Intrinsically Safe and Wireless Compact form factor with Smart Power Pack, 9 years Power Pack Service Life Online Wireless Pipeline Thickness Detection

7 Electric Field Mapping (FSM) Instrument Pipeline temperatures up to 500 oc (932 F) Maximum number of sensing pins: 256 On-line, digital communication Storage capacity: 500 readings Sensitivity: 0,1% of wall thickness for uniform corrosion. Technology An electric current is applied to the pipeline, creating an electric field. The field strength is measured on a large number of positions. A change in field strength is caused by local and general corrosion wall thickness change Information EFM data example showing metal loss versus time plot (above) and distribution of corrosion (below). Observe: EFM measures between sensing pins, hence, total area between sensing pins covered for monitoring localized corrosion. Localized Corrosion Mapping

8 Selecting Monitoring Technologies Criteria Examples Comments Criticality Probability of corrosion damage Consequence Highest focus on locations with high probability of corrosion damage combined with serious consequence of same Also focus on locations where monitoring for diagnostics and process tuning. Purpose Integrity/safety Moderate sensitivity needed preference reliable wall thickness monitoring Process Tuning Fast response to changes required preference in-line probe if suitable for application Corrosion Rate High or low rate expected or accepted Low corrosion rate acceptance preference in-line monitoring. High corrosion expectancy preference wall thickness monitoring Type of Corrosion General corrosion Most methods can monitor uniform corrosion. Preference in-line probes for fast response Enviroment Pressure Temperature Oil/gas/water Localized corrosion Preference wall thickness monitoring area coverage Specialized electrochemical methods an alternative (not Emerson provided) Sour corrosion FeS deposits may disturb in-line probe readings + safety aspect of interventions preference wall thickness monitoring NAC corrosion Preference wall thickness monitoring high temp + localized corrosion High temperature probes option for fast response to changed fluid corrosivity High pressure requires non-intrusive or high pressure access systems Most methods have temperature limitations e.g.for particular refinery applicatons Electrochemical methods may require a conductive electrolyte (water) A Combination of Technologies Often Gives Best Solution

9 Sand Applications Require Different Monitoring Solutions to Provide The Most Value Immediate detection of sand production using acoustic sand monitor Sacrificial sand probe gives you a warning when accumulated erosion reaches critical level In-line, multiple element sand/erosion probes: superior sensitivity and immediate response Non-intrusive UT sensor provides accurate wall thickness change information Non-intrusive, easy installation directly on pipe bend No calibration needed to establish maximum sand free rate and for giving indicative sand production rates Filtering technique to discriminate between sand noise and flow noise. Available also as non-intrusive pig detector Provides alarm on the pressure gauge when accumulated erosion exceeds thickness of probe tube No information received until tube is eroded through Recommended as a back-up safety device only, not for sand and production management. Sensitivity in low nanometer range ensures close to real time information about sand erosion and information about changes in sand production Multiple element design ensures maximum reliability for detecting sand particles for various flow patterns Available in wired and wireless versions Easy installation directly on pipe bend for erosion monitoring Sensitivity in low micrometer range ensures fast information about changes Affordable on-line via wireless communication The technologies can be deployed as stand alone solutions or combined for maximum visibility to sand impact and reservoir performance

10 Real Time Data Delivery Adds Value One user interface for all sensors (not limited to traditional corrosion sensors). Process sensors Traditional corrosion sensors Wireless has made on-line upgrades affordable, allowing better and faster information for the end user

11 Corrosion Monitoring is Part of the Wider Solution Flow meters and blend analysers may also be seen as part of a corrosion management and process optimization program

12 Service and Support Installation and commissioning Support in installation and commissioning phase contributes to successful installation and flawless operation Trouble shooting Training Global support team is needed to support in trouble shooting and problem solving on a 24/7 basis Product and application training is suggested on a regular basis or according to individual client basis Corrosion/sand/erosion monitoring services Offshore services (probe installation/retrieval) System maintenance and drifting Reporting and data management Feedback Operational feedback important for further improvement on technology and support Maximizing the Value of any Monitoring System

13 Summary & Conclusions Corrosion and integrity management play a key role in increased safety, reduced downtime, extended equipment life and operational cost savings. The choice of technology should be based on the information needed and how the information will be used, but also upon how well the specific technology can be adopted for the application in question. In most cases, a combination of monitoring technologies will give the best result. Continuous, on-line monitoring has added information value significantly. Wireless standardization has made on-line upgrades affordable, allowing better and faster information for the end user. Corrosion & Erosion monitoring strategies should be seen as part of a larger process and integrity solution The result will be qualified, accurate and relevant information and knowledge-based decisions for the optimal operation of oil & gas fields and refineries. Thank you for your attention!