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Strategic Corrosion Monitoring in Topside Applications

Strategic Corrosion Monitoring in Topside Applications. Tom Swihart GE Measurement & Control Solutions. Introduction. Rightrax products use permanently installed UT transducers to continuously measure wall thickness.

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Strategic Corrosion Monitoring in Topside Applications

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

  2. Introduction 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

  3. 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

  4. Systems Configurations

  5. 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 IECEX • Advantages: • 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 areas • Advantages: • Non-intrusive, easy installation • High resolution point measurement

  6. After Choke Valve Solution: 96 Rightrax M2 sensors on 6 individual platforms M2 sensors wired back to DL2 datalogger and Line Driver (LD) in hazardous area Offshore Riser Monitoring

  7. Offshore Riser Monitoring Sand Erosion Sand 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.

  8. Crude Line Corrosion Monitoring Platforms & FPSOs Crude 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.

  9. Chemical Injection Lines Platforms & FPSOs Chemical 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.

  10. Upstream Case Study 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 thickness Erosion rates can be up to 4 mm / 24 hours Monitoring is required; location is remote Normal operational temperature: 80°C Solution: • 96 Rightrax M2 sensors on 6 individual platforms • M2 sensors wired back to DL2 dataloggerand 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

  11. Recent Upstream Case Studies

  12. Thank you for listening

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