Strategic Corrosion Monitoring in Topside Applications Tom Swihart

Report
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.
• 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
Where & Why Rightrax is Used
In hard to access areas
Processes
• With scaffolding, rope access,
under insulation
• Where changing crude oils
cause corrosion
• Where sand causes erosion in
riser and
re-injection lines
Hazardous areas
• Chemicals, heat, height,
explosive contents
Aged assets
Remote locations
• Offshore platforms,
manned/unmanned,
FPSOs
• 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
• For both LT and HT systems
• For both LT and HT systems
• Manually operated
• Automatically operated
• Automatically operated
• Data collection in the field
• Fixed interval measurements
• Fixed interval measurements
• Data download to PC or
laptop
• Data storage
• Data storage
• Automatic data analyses
• Manual data assessment
• Manual data
collection/assessment
Advantages:
Advantages:
• Integration with 3rd party systems
with data and alarming
• Lower cost
• Certified for HAZ use
Advantages:
• Flexibility of use
• No human intervention for
measurements
• Same Advantages as Installed
Configurations with . . .
• Monitor process-related events
• System alarming on special events
and conditions
Product Versions
Flexible Array (LT)
High Temperature (HT)
• 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
•
•
•
•
•
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
Offshore Riser Monitoring
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
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.
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.
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.
Upstream Case Study
Concern:
Solution:
• Unmanned installations off the coast of Indonesia
require frequent wall thickness monitoring due to
unpredictable sand erosion
• 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
•
•
•
•
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
Configuration:
Value and cost saving:
• 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
• 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
FPSO
West 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 Platforms
Central Asia
Erosion monitoring on flow
lines on offshore barges
Online monitoring system
12 sensors fully automated
system on pig launchers flow
line
Thank you for listening

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