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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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