Digitalisation of Inspection for Monitoring Corrosion Risk and Impact
NACE Webinar | 27th October, 2020
Dr Jake Davies – Global Product Director, Corrosion and Erosion (UK)Mr. George Varughese – Business Development Manager | MEA (Dubai)Mr. Mansour Aref – Strategic Account Leader | Saudi Aramco (Saudi Arabia)
Topics for Today’s Webinar (75 min)
2
Dr. Jake Davies55min
Destruction from the Inside: The Problem with Corrosion
Understanding Corrosion Risk and Impact on Your Plant – The Missing Pieces of the Puzzle
Digital Transformation of Corrosion Monitoring
Non-Intrusive UT Thickness Monitoring Technology
Refining Case Study
Q&A
George Varughese10min Middle East & Africa Use Cases
Mansour Aref10min Emerson Local presence across Middle East and Africa
Topics for Today’s Webinar (75 min)
3
Dr. Jake Davies55min
Destruction from the Inside: The Problem with Corrosion
Understanding Corrosion Risk and Impact on Your Plant – The Missing Pieces of the Puzzle
Digital Transformation of Corrosion Monitoring
Non-Intrusive UT Thickness Monitoring Technology
Refining Case Study
Q&A
George Varughese10min Middle East & Africa Use Cases
Mansour Aref10min Emerson Local presence across Middle East and Africa
Why Does Corrosion Happen and How is it Traditionally Handled?
4
Corrosion is Happening in Your Plant – Is it Understood?
CAUSED BY corrosive components in the process fluid (10s of different corrosion mechanisms!)
DEFINITION: The destruction of materials by chemical and/or electrochemical reaction with their environment
RESULTS IN metal loss from the inside
TYPICALLY CONTROLLED BY choice of metal (CAPEX) and addition of ‘corrosion inhibitor’ (OPEX) to the process fluid, Process parameters
UNDERSTOOD / VALIDATED WITH periodic manual inspection (online or during periodic shutdown), coupons, offline fluid samples
TRA
DIT
ION
AL
APP
RO
AC
HES
Process Industry Pressures Lead to Variable Corrosion Risk and Unknown Impact on the Health of Your Plant – Leading to Major Incidents or Poor Profitability
Variable feedstock quality and “opportunity” crudes
Varying Process Conditions
Longer runs between maintenance shutdowns
Tighter H&S regulations
Tighter CAPEX budgets
Shortage of experienced personnel
Leaks/loss of containment
Conservative operations –poor profitability
Variable (invisible) Corrosion Risk in the Plant
Variable (unknown) Impact on the Asset Health
6
Poll Question 1
Non- intrusiveIntrusive
Your Corrosion Challenges Require A Complete Sensing Portfolio
7Highest sensitivity, quickest response Actual Asset metal thickness and loss
Coupons
• Cannot be instrumented for realtime monitoring
Electrical resistance (ER)
• Any process• After process
changes• Phase changes• Chemical
injection
MONITOR RISK MONITOR IMPACT
Ultrasonic (UT)
• Uniform corrosion impacts
• Permanenet inspection
• Main integrity verification tool
Field Signature Method (FSM)
• Critical locations• Localized attacks• High velocity,
turbulence
Electrochemical (LPR, Galvanic)
• Conductive media(water systems)
• After potential process changes
• In contact with Process Fluid:• Quick response time• Detect process changes• Chemical treatment verification
• Flexible, highly distributable, wall thickness monitoring
• Local area monitoring
• Localized corrosion detection
Adopt innovative sensing technologies that are easy and cost effective to install and maintain
Implement a set of architectures that ensures securityof operational data, and allows secure interaction with IT and cloud applications
Deploy scalable analytics applications to deliver actionable insights and automate manual workflows
Deploy newmonitoring solutions, consulting, andimplementation services ensure operational outcomes
Data AnalyticsEdge, On-Premise, and Cloud
Connectivity Services
Measurements Alone is not Enough: Digital Transformation Gets the Data to the Right People to Make Better Decisions
Continuous, Real Time Corrosion Risk and Asset Health Data Directly to Desk
Easily Installed, Online. Typical Size System Installed in 1- 4 Days
Up to 100 sensors per
gateway
ActionAnalyticsConnectivityData Generation
10Emerson Confidential
Data
AnalyticsEdge, On-Premise,
and Cloud
Connectivity
Services
The Plantweb Digital Ecosystem: Enabling Top Quartile Performance With the Industry’s Broadest Integrated Portfolio of Digital Transformation Solutions
DIGITAL TRANSFORMATION
DIGITAL FOUNDATION
Production Optimization
Operator Performance
Control & Safety Systems
SCADA
Project, Lifecycle, and Educational
Services
ServiceModels
Connected ServicesAsset Expertise and Actionable Insights
Software-as-a-ServiceCloud-Deployed Applications
v4 © 2019
Consulting & Implementation Digital
Strategy & Cybersecurity
Shutdowns, Turnarounds,
& Outages
Upskilling & Change
Management
Industry Expertise
Platforms & Software
Asset Performance PlatformConnect, Analyze, and Collaborate
Device & Machinery DiagnosticsCondition-Based Analytics
Digital TwinPlant & Asset Optimization
Workforce EffectivenessDigitally Enabled People
Asset Health AppsPre-Configured Analytics
PervasiveSensing
Process Equipment People & AssetsEnvironment
Secure Connectivity
CybersecurityEmbedded at All Levels
Secure First MileData Pathways to External Applications and Experts
Data IntegrationArchitectures & Network Design
Intelligent Field Devices
Measurement Instrumentation
Valves & Actuators
MotionControl
Wellhead DX – Sand & Erosion Monitoring – Online Technologies
11Emerson Confidential
Monitoring sand production, erosion risk and impact allows Oil & Gas operators to set the optimum choke settings, generating millions of dollars in additional production
Thickness Monitoring• Data: Wall thickness > Quantify Impact• Quantity = 1 to 3 units per Xmas-tree• Location: Closest bend (apex) to Xmas-
tree• Non-intrusive + Battery + Wireless
Sand Production Monitoring• Data: Sand Rate > Quantify Risk • Quantity: 1 per Xmas-tree• Location: After closest bend to Xmas-tree• Non-intrusive + Wired
Fluid Erosivity Monitoring• Data: Fluid Erosivity > Quantify Risk• Quantity: 1 per Xmas-tree• Location: Straight section turbulent flow• Intrusive + Wireless / Wired
Oil & Gas Flow Rate
WT Technology – Unique Ultra-High Temperature Thickness Monitoring
• Unique and patented waveguide transducer– Semi-Permanent installation
• Install anywhere– Temperatures up to 600 C (1100°F), e.g. refinery crude
unit pipework– Intrinsically safe (Class1 Div1 / Zone 0)– Any metal
• Data to desk with no cabling– WirelessHART– 9 year battery life– Remotely adjustable data acquisition rate – Automated temperature and material compensation– Unique and patented processing to eliminate internal
surface roughness effects and detect onset of corrosion activity
ET Technology – Magnetic Mounting, Measure Through Coatings
1st backwall reflection
2nd backwall reflection
Pipe wall (up to 300 C)
External protective coating left in place
Typical recorded ET sensor waveform
EMAT excites ultrasound directly in the metal sample –direct contact is not
required
Subsequent backwall reflections
Time used for thickness
measurement
Magnetic mounting with secondary security strap
Huge Data Quality Enhancement Over Traditional Manual Inspection
• Rosemount Wireless Permasense: measurements every 12 hours within ±25 microns variation; catch onset of corrosion events within days
• Manual UT inspection: years between measurements with ±0.5mm variation; corrosion rate calculation not possible, corrosion events missed
Thickness Monitoring Data for Root Cause Analysis of Corrosion Events and Turnaround Scope and Timing Improvement
Root Cause Analysis Predictive Maintenance
toda
y
Class-Leading Data Visualisation and Analytics Software: Easy to See Where and When the Activity is Occurring
Best-in-Class Data Quality and Frequency
Sens
or lo
catio
n
Time
Return is Driven from Multiple Sources - Refinery Example
17
Business impact model based on a generic 250k bbl/day refinery, and average industry metrics
Monitoring Solution is Configured for Your Application, Leveraging the Best Tools for the Job
Start Small and Easily Expand to Other Applications
MaintenanceSafety Operations
Routine Turn-around
Availability / Utilization
Turn-aroundFrequency
Opportunity Crudes
Serious Incidents
Chemicals /Additives
200 KUSD
1,800kUSD 600
kUSD200
kUSD
3,600kUSD
1,600kUSD
4,100kUSD
Total Annual Margin Improvement
11,640kUSD
5% 3% 3% 10% 1% 0,25% 1%
Refinery Case Study - Crude Unit Overhead Corrosion
18
Monitoring
CDU overhead system protected by chemical injection (filmer and neutralising amine)Severe corrosion in the overhead piping system caused leaksExpensive clamps had to be installed to secure operationRisk of damaging the 17 air cooled heat exchangers
Situation
29 Rosemount Wireless Permasense sensors installed to continuously observe the system. Permasense system validated high corrosion rates
120°C
Crude Tower
Overhead Drum
Amine Slipstream17 air cooled heat exchangers
43°C
Using DataTrials done to identify cause of corrosion – reduce flow rate, insulate piping, change filming amine foundationEffects could be immediately seen in dataChemical injection issue identified as the root cause and anime type changedCarry-over reduced, corrosion stopped, damage to ACHEs prevented
Refinery Case Study: Total Estimated Impact $4M Saved
Monitoring system later detected a ‘bad batch’ of crude which lead to tighter desalter controlRefinery expanded their monitoring capability, now using ~300 sensors installed across various process units 19
Maintenance
Controlled Risk: Safe operation without risk of leaks until next planned shutdown
Replacement optimised in time and cost, not compromising the TAR schedule• Costs for unplanned vs. planned and well prepared replacement of piping estimated
at $700k saved• Replacement of piping estimated at $3M avoided• Replacement of one air cooled heat exchanger estimated at approximately $200k
avoided
Long-Term
Unplanned shutdown and loss of profit margin prevented• Loss of profit margin in case of unplanned shutdown: 300k$/d; duration depending
on the necessary actions, min. 4 days. > $1M loss avoided.
Operations
Think Big, Start Small
Digitalisation of Corrosion Monitoring Elevates Performance
Summary
Use the data to better-operate your process plant, ensuring the asset is driven to its maximum capability
21
Corrosion is an ever-present threat to fixed equipment in many process industries
Corrosion risk, and therefore rate of metal loss, varies across the plant and over time
Periodic, rare, manual inspection is not frequent enough to understand asset health or track corrosion rate changes over time
Monitoring of both corrosion risk and corrosion impact on the asset health isessential – using inline probes and non-intrusive thickness monitoring
Leverage Emerson’s WirelessHART® capability to deliver best-in-class data from the sensors in the plant directly to your desk
Topics for Today’s Webinar (75 min)
22
Dr. Jake Davies55min
Destruction from the Inside: The Problem with Corrosion
Understanding Corrosion Risk and Impact on Your Plant – The Missing Pieces of the Puzzle
Digital Transformation of Corrosion Monitoring
Non-Intrusive UT Thickness Monitoring Technology
Refining Case Study
Question & Answer
George Varughese10min Middle East & Africa Use Cases
Mansour Aref10min Emerson Local presence across Middle East and Africa
Topics for Today’s Webinar (75 min)
23
Dr. Jake Davies55min
Destruction from the Inside: The Problem with Corrosion
Understanding Corrosion Risk and Impact on Your Plant – The Missing Pieces of the Puzzle
Digital Transformation of Corrosion Monitoring
Non-Intrusive UT Thickness Monitoring Technology
Refining Case Study
Q&A
George Varughese10min Middle East & Africa Use Cases
Mansour Aref10min Emerson Local presence across Middle East and Africa
Proven Results
Predictive AnalyticsProvide actionable information to Inspection engineer
On-line Non-Intrusive corrosion Monitoring on Reactor pipesDigitalizing Inspection rounds with IIoT sensor and Analytics
24
Solution
• Enhanced monitoring by adding installing Non intrusive wireless operated Permasense sensors at the monitoring location.
• An operational decision-making tool, to improve plant availability and optimise production
Photo to represent Emerson product...
Region: Middle East Industry: Oil & Gas
CAPEX Optimization Eliminate access fittings, scaffoldings, cabling etc
Reduce risk of containment lossby continuous data monitoring
Proven Result: Share Me
Challenges• Unpredictable and Extremely high corrosion on pipes leading to ruptures and loss of
containment. • Frequent changes of processing liquid quality leading to unpredictive corrosion rates.• Lack of visibility of Asset condition leading to inefficient shutdowns and turnarounds.
Key Emerson Technology• Corrosion immediately detected by
Permasense system and validated
• Corrected inhibitor system and stabilised wall loss based on Permasense data
• Efficient planning of shut down for repair/replacement achieved, maximizing production period.
• Non-Intrusive nature of sensors ensured smooth installation without disrupting production.
Proven Results
Production Optimization Improve confidence on asset by monitoring risk
Implementing Sand Management Strategy in Major Brownfield ProjectAcoustic Non-Intrusive sensor drives Transformation from MSFR to ASR
25
Solution• A complete sand monitoring strategy supported by innovative Non-
intrusive acoustic technology and sand monitoring software.• Collaboration between End User Production team, and Emerson
to build and execute Project Specifications for implementation. • Strong installed base of Emerson technology facilitated to drive
confidence in Emerson solutions
Photo to represent Emerson product...
Region: Africa| Industry: Oil & Gas
CAPEX Optimization Non-Intrusive Solutions
Eliminate risk of Sand Erosion by real-time monitoring
Proven Result: Share Me
Challenges• Increased Sand production from offshore wells leading to well shutdowns and workovers. • Fast Track project to recover production loss, as well as prevent potential reservoir damage.• End User corporate directive to change production philosophy related to Sand from MSFR to
ASR.
Key Emerson Technology• Acoustic Sensors for instantaneous
monitoring of sand production• Analytics for calculating sand rates
• Field Optimization of production rates according to allowable sand rates
• Non-Intrusive UT sensors for calculating Impact of sand erosion
Monitor Impact
Monitor Risk
Proven Results
Predictive Analyticsto support reduction in Inhibitor chemical cost
Bringing Asset Integrity visualization of Remote Pipelines to the DesktopFSM Technology Drives Digitization of Remote Assets
26
Solution• FSM technology with Fieldwatch corrosion software• Area monitoring of buried sections of pipeline • Data connectivity utilizing existing asset infrastructure• Online visualization of Asset condition at office domain
Photo to represent Emerson product...
Region: Middle East | Industry: Oil & Gas
CAPEX Optimization Utilize Wireless Infrastructure
Reduce risk of containment lossfor Underground Pipelines
Proven Result: Share Me
Challenges• Increased water-cut from onshore wells leading to High corrosion and leaks. • Long distance buried pipelines in Remote locations • Asset integrity data depended on infrequent manual rounds of data collection from the fields.
Key Emerson Technology• Field Signature Monitoring utilizing WiMax,
FO and Fieldbus protocols to deliver data seamlessly to desktops.
• Optimized inhibitor programs based on field data
• Fieldwatch predictive Analytics for calculating corrosion rates and pipe retirement thickness
Topics for Today’s Webinar (75 min)
27
Dr. Jake Davies55min
Destruction from the Inside: The Problem with Corrosion
Understanding Corrosion Risk and Impact on Your Plant – The Missing Pieces of the Puzzle
Digital Transformation of Corrosion Monitoring
Non-Intrusive UT Thickness Monitoring Technology
Refining Case Study
Q&A
George Varughese10min Middle East & Africa Use Cases
Mansour Aref10min Emerson Local presence across Middle East and Africa
28
Poll Question 2
29Emerson Confidential
Emerson Automation SolutionsMiddle East & Africa
Headquarters in Dubai, United Arab Emirates
Diversified manufacturer and technology provider
Approximately 1,900 employees
MAJOR CUSTOMERSARAMCO,ADNOC,SABIC,SOC,ENOC
QP,PDO,SHELL,TOTAL,EXXON,BPSASOL,CHEVRON,NPDC,DOWSONANGOL,SONATRACH,KOC
PETROFAC,ENI,TECHNIP,LUKOIL
30Emerson Confidential
Middle East & Africa Presence
Headquartered in Dubai, we have an established presence
in Middle East & Africa with an extensive
network of direct sales offices and dedicated sales
representatives
Oman
Yemen
Lebanon
JordanEgypt
Tunisia
Ivory Coast
Ghana
Kenya
Madagascar
Mozambique
ZimbabweBotswana
NamibiaZambia
31Emerson Confidential
Collaboration towards Vision 2030 - Localization Success Stories
Control Valve & Instrumentation Manufacturing – Jubail
Control System & SCADA Manufacturing & Staging – Dammam
COMRES & Appleton Manufacturing – Dammam
Planned manufacturing expansion (50,000sqmplot) at SPARK towards meeting iktva Targets
King Salman Energy Park
Will bring together Emerson’s capabilities around Systems, Devices and Valves under one Roof
60% Saudization, Total Area – 2,650 SQM Manufacturing, Assembly, Testing & Service Valves, Pressure & Temperature Transmitters 3,500 Valves Produced for Sadara project
Production of Condensing Units AC Scroll Compressors Appleton Industrial LED Lighting Appleton Switch racks
• Total Area 1,132 SQM• Major Project Engineering, Design,
Manufacture and Execution• In Collaboration with Prince Sultan Fund for
Women’s Development
Committed toSaudi Arabia’s
Vision 2030
32Emerson Confidential
Emerson Automation SolutionsLagos and Port Harcourt, Nigeria
Manufacturing & Assembly• Control system cabinet building facility in Port Harcourt• Systems staging and FAT’s – 7,500m2• Metering skids and Flow Systems complete solutions including local
assembly• Spare Part Management
Lifecycle Services &Training• Training centers in Lagos & Port Harcourt• Instrumentation repair in Port Harcourt• Turnaround services• Full diagnostic capabilities• System support & maintenance• Long-term service agreements • 24 x 7 Global Response System• Site Surveys
Sales, Engineering & Execution• Sales Administration & Management• Proposals, Procurement & PM• 60+ employees in projects and services,
including 60% of local Nigerian engineers• Pre-Project Planning (Pre-FEED / FEED)• System Engineering, configuration and integration• Flow Engineering & Execution group• Valves and Instrumentation Sizing and selection • Technical Support• Local Representative Partner – AOS Orwell
Sales, Service and Assembly100 Employees
(Emerson and AOS)
Nigerian Content Certification
Lagos
Port Harcourt
33Emerson Confidential
Emerson Automation SolutionsJohannesburg, South Africa
Manufacturing & AssemblyFinal Control • Valve Operating System and Automated Valve package integration
(2,000 units/annum)• Valve and actuation final assembly and testing
• In-house customer FAT’s (functional, hydro & seat leakage)• In-house machining• Quick ship MRO AVP/VOS capability (same day)• Control systems Staging & FAT
Lifecycle Services & Training• Training facility• System Start up & Commissioning Services
• Turnaround services• Full diagnostic capabilities• Service and retrofit (Valve Operating System, Automated Valve
Packages & Multiport Flow Selector)• Instrumentation remote seal assembly, testing and repair• 24 x 7 Global Response System
Sales, Engineering & Execution• Sales Administration & Management
• Logistics Support
• Engineering capabilities
• Proposals, procurement and Project Management
• Application & Technical support
• Local Representative Partner – A&CS
Sales, Service and Manufacturing
Center40+ Employees
Thank You