Strategic Corrosion Monitoring in Topside Applications Tom Swihart GE Measurement & Control Solutions.

Strategic Corrosion Monitoring in Topside ApplicationsTom SwihartGE Measurement & Control Solutions

Rightrax products use permanently installed UT transducers to continuously measure wall thickness.• Erosion, general and localized corrosion are detectable and measurable• Rightrax is available in 3 versions:

- Low temperature (-40°C to 120°C / -40°F to 248°F) - High temperature (-20°C to 350°C /-4°F to 662°F) - Ultra-high temperature to be released soon (500°C /

932°F) • All systems are non-intrusive• All installed versions have hazardous area certification• High return on investment possible < 1 year

Introduction

Where & Why Rightrax is Used

In hard to access areas• With scaffolding, rope

access, under insulation

Hazardous areas• Chemicals, heat, height,

explosive contents

Remote locations• Offshore platforms,

manned/unmanned, FPSOs

Processes• Where changing crude oils

cause corrosion• Where sand causes erosion

in riser and re-injection lines

Aged assets• Where inspections are

costly, to increase safety or retain integrity, to reduce loss of production

Systems Configurations

Portable Installed Integrated

• For both LT and HT systems

• Manually operated

• Data collection in the field

• Data download to PC or laptop

• Manual data assessment

Advantages:

• Lower cost

• Flexibility of use

• For both LT and HT systems

• Automatically operated

• Fixed interval measurements

• Data storage

• Manual data collection/assessment

Advantages:

• Certified for HAZ use

• No human intervention for measurements

• Monitor process-related events

• For both LT and HT systems

• Automatically operated

• Fixed interval measurements

• Data storage

• Automatic data analyses

• Integration with 3rd party systems with data and alarming

Advantages:

• Same Advantages as Installed Configurations with . . .

• System alarming on special events and conditions

Product Versions

Flexible Array (LT)• Manual and integrated versions• Flexible array with 14 individual

transducer elements• Glued to the object• Repeatability up to ±0.1 mm /

±0.004"• Wall thickness 5 mm to 100 mm / 0.2"

to 3.9"• Pipe sizes of 6" and over, and flat

surfaces• Operational temperature up to 120°C /

248°F• Certified for ATEX zone 2 and IECEXAdvantages:• Non-intrusive, easy installation• Array coverage of effected area

High Temperature (HT)• Manual and integrated versions• Single-point transducer with delay line• Clamped to the object• Repeatability up to ±0.0025 mm /

0.001"• Wall thickness 3 mm to 16 mm / 0.12"

to 0.6"• Pipe sizes of 3" to 42"• Surface temperature up to 350°C /

662°F(500°C / 932°F for ultra-HT version)

• Certified IS for use in zone 1 areasAdvantages:• Non-intrusive, easy installation• High resolution point measurement

After Choke ValveSolution:96 Rightrax M2 sensors on

6 individual platformsM2 sensors wired back to DL2

datalogger and Line Driver (LD) in hazardous area

Offshore Riser Monitoring

Sand ErosionSand erosion can occur at direction/diameter

changes in offshore production risers due to solids ingestion. Erosion is typically a smooth surface with a sand-dune pattern.

Riser locations where sand erosion may occur are difficult to access and inspect with conventional UT or RT.

Permanently mounted UT array sensors can be applied to suspect areas for accurate monitoring without the need for manual access.

Offshore Riser Monitoring

Platforms & FPSOsCrude lines with chemical injection and/or water

washes are subject to periodic inspections per API 570.

Many overhead lines have no platform access, making these inspections difficult and costly.

UT and RT can provide useful inspection data, but costly to obtain based on access equipment.

Corrosion monitors can be permanently installed and accessed on a continuous basis to improve operational knowledge.

Crude Line Corrosion Monitoring

Platforms & FPSOsChemical injection (MEG, etc.) and mixing

points have potential for extreme corrosion failures.

API, UL, CSA-US and NACE provide specific process guidelines to minimize injection point damage.

Installed strategic corrosion monitoring M2 strips can provide dynamic monitoring of suspected injection point damage locations without repeated access.

Chemical Injection Lines

Concern:Unmanned installations off the coast of Indonesia

require frequent wall thickness monitoring due to unpredictable sand erosion

6" & 8" lines with 6-8 mm wall thicknessErosion rates can be up to 4 mm / 24 hoursMonitoring is required; location is remoteNormal operational temperature: 80°C

Upstream Case StudySolution:• 96 Rightrax M2 sensors on 6 individual

platforms• M2 sensors wired back to DL2 datalogger and

LD in hazardous area• LD connected to RTU using Modbus interface

Configuration:• Measurements made every 8 hours• Data analyzed on the LD • Measure to 5 mm thickness with VFC dry

contact alarm if threshold thickness value is violated

• Data sent to onshore control room to analyze and monitor riser wall thickness

Value and cost saving:• Large European IOC total project value $1.3M

for 6 platforms fully integrated system

• No bi-weekly mobilization of personnel• Monitoring critical process and preventing

incidents• More operational control (pressure and flow)• Less downtime

Recent Upstream Case Studies

Project Concern Solution Configuration

FPSOWest Africa

Sand erosion of first elbow after the choke valve

Continuous monitoring on flow lines with data integration to RTU

4 sensor LT Rightrax, ATMS Data Logger system, Line driver cabinet and Software

Offshore Platform North Sea

Flow line sand erosion Manual monitoring of flow lines

5 M2 sensors and a DL2 datalogger

Offshore Platform Australia

Flow line sand erosion Manual monitoring of flow lines

8 M2 sensors on riser spool

Offshore Platform North Sea

Flow line sand erosion Continuous monitoring on flow lines with data integration to onshore

8 sensors on riser modification pipework

Offshore PlatformsCentral Asia

Erosion monitoring on flow lines on offshore barges

Online monitoring system

12 sensors fully automated system on pig launchers flow line

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