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Permanently Installed Monitoring System for Accurate Wall-Thickness and Corrosion-Rate Measurement
March 9, 2016
Sensor Networks, Inc.Steve StrachanV.P. – Sales North America
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Outline
• Motivation
• Permanently Installed Sensor System
• Power of Data through Continuous Monitoring & Trending
• Typical Applications
• Case Studies
NACE 2016
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Corrosion Damage Accounts for the Cost of one Major Facility Annually
NACE 2016
Refining & Petrochemical $1.7 B
Pipeline , Oil/Gas Production $8 B
* NACE Cost of Corrosion Study
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Data Monitoring Evolution
NACE 2016
1920s -
Manual
monitoring
1990s -
Wireless
2010s - Age
of Internet of
Things (IoT)
1980s -
Digital
Conversion
1960s -
Analog 4-
20mA loop
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Data-to-Desk & The Internet of Things (IoT)
NACE 2016
Remote sensors leverage low-cost & ubiquitous communication infrastructure
Modbus / RS-485
Cellular
Satellite
WiFi
Etc.
24 x 7 asset-health monitoring
Data-to-desk-to-decision instantly
or in minutes
Mobile access by multiple parties
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Why Installed Sensors Today?
Costs ($) associated with manual inspections• Pre-inspection activities:
o T & L – windshield timeo Excavationo Insulation preparationo Surface Preparationo Scaffolding o Rope access
• Access, permitting, approvals• Personnel cost – technicians, equipment, training, etc.• Cost per point is less for applications than manual data collection
Costs (intangibles) • Safety – ropes, ladders, radiation, non-invasive, etc.• Damages – environmental, reputation,• Time/productivity – short- & long-term decision making & planning• Data quality – precision & repeatability
NACE 2016
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Data Quality Enhanced Using Installed Sensor Systems
NACE 2016
Operator variability
Transducer placement variability
Transducer coupling variability
Acoustic velocity uniformity
Measurement Precision
Temperature Compensation
Accurate Corrosion Rates
Data Accessibility
Precision Accuracy Resolution
-150
-100
-50
0
50
100
150
Flank
CrossingZero
Crossing
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Measurement Precision
• Accurate and Precise UT thickness gauging requires a high precision measurement of the arrival time of the ultrasonic pulse
• Measurement principles:
– Depends on the precision of the TOF measurement, not the carrier frequency of the UT signal.
– Choose high slope portion of the waveform (zero crossing) rather than a peak.
– Waveform needs to be sampled at a sufficient speed (Nyquist +)
– Digitizer precision needs to be enhanced: 40MSPS -> 25nS steps -> 0.003” (0.07mm)
– Solution: 8X Upsample using low pass filter. 320MSPS -> 3nS steps -> 0.0004” (0.009mm)
– Interpolate between points yields even greater resolution ~6.1 picosecond resolution.
-150
-100
-50
0
50
100
150
Flank CrossingZero Crossing
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Compensation for Temperature Change
𝐶1 = 𝐶0 1 + 𝑘 𝑇1 − 𝑇0 /100
𝑑1 Temperature corrected thickness
𝐶1 Temperature corrected velocity
𝐶0 Reference or calibration velocity
∆𝑡 Measured, round-trip time of flight
𝑇1 Measurement temperature
𝑇0 Reference or calibration temperature
𝑘 Correction factor in % per °F or °C
• Temperature change can be a significant factor in performing accurate thickness measurement.
• Material velocity AND wall thickness changes, but material velocity effect >10X linear expansion effect.
• Velocity in steel changes by approximately -1% per 100°F (55°F)
• ASTM E790 and API 570 make recommendations for when corrections should be made and how they should be applied.
• Permanently installed monitoring system requires a temperature measurement device such as a RTD or thermocouple to implement the correction
7
7.2
7.4
7.6
7.8
8
0 100 200 300 400 500
Thic
knes
s (m
m)
Temperature (deg C)
Actual vs Measured W.T., 6"SCH40 Pipe
WallThickness
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The Power of Data …
• Sufficient for inspection probably NOT for monitoring– 1/1/2013 inspection = 10.00mm
– 12/30/2013 inspection = 9.79mm
• Gross corrosion rate – cannot calculate, not enough information
9.60
9.65
9.70
9.75
9.80
9.85
9.90
9.95
10.00
10.05
10.10
1/1/2013 1/31/2013 3/2/2013 4/1/2013 5/2/2013 6/1/2013 7/1/2013 8/1/2013 8/31/2013 9/30/2013 10/31/2013 11/30/2013 12/30/2013
W.T
. (m
m)
Wall Thickness Data (1 msmt per year)
NACE 2016
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The Power of Data (ctd) …
• Various corrosion rates evident• Trends evident but still large uncertainty due to measurement precision• Summary – better!
9.60
9.65
9.70
9.75
9.80
9.85
9.90
9.95
10.00
10.05
10.10
1/1/2013 1/31/2013 3/2/2013 4/1/2013 5/2/2013 6/1/2013 7/1/2013 8/1/2013 8/31/2013 9/30/2013 10/31/2013 11/30/2013 12/30/2013
W.T
. (m
m)
Wall Thickness Data (1 msmt per month)
NACE 2016
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The Power of Data (ctd) …
• Various corrosion rates evident
• Regression can be used to obtain accurate corrosion rates over medium time scales.
9.60
9.65
9.70
9.75
9.80
9.85
9.90
9.95
10.00
10.05
10.10
1/1/2013 1/31/2013 3/2/2013 4/1/2013 5/2/2013 6/1/2013 7/1/2013 8/1/2013 8/31/2013 9/30/2013 10/31/2013 11/30/2013 12/30/2013
W.T
. (m
m)
Wall Thickness Data (1 msmt per week)
NACE 2016
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The Power of Data (ctd) …
• Various corrosion rates evident• Regression can be used to remove measurement noise and produce
very accurate corrosion rate data• GREAT!
9.6
9.65
9.7
9.75
9.8
9.85
9.9
9.95
10
10.05
10.1
1/1/2013 1/31/2013 3/2/2013 4/1/2013 5/2/2013 6/1/2013 7/1/2013 8/1/2013 8/31/2013 9/30/2013 10/31/2013 11/30/2013 12/30/2013
W.T
. (m
m)
Wall Thickness Data (1 msmt per day)
NACE 2016
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Corrosion Rate Measurement
• An important by-product of wall thickness measurement and monitoring is the ability to measure corrosion rates.
• Corrosion rate measurements can be used for predictive maintenance as well as for process feedback.
• CR achieved through linear regression.
• Precision is achieved that exceeds the precision of the base measurement.
• Factors:– Standard deviation of the measurement system
– Measurement frequency
– Measurement interval
y = -0.0005x + 10.1039.95
10
10.05
10.1
10.15
0 50 100 150 200
Thic
knes
s (m
m)
Days
Linear Regression of Thickness Data
𝑠𝑚2 =
1
𝑛−2σ𝑖=1𝑛 𝑦𝑖−𝑌(𝑥𝑖)
2
σ𝑖=1𝑛 𝑥𝑖
2−1
𝑛σ𝑖=1𝑛 𝑥𝑖
2
95% 𝐶. 𝐼.≅ 𝑚 ± 2𝑠𝑚 𝑛 − 2 ≥ 6
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Data-to-Desk & The Internet of Things (IoT)
NACE 2016
• Data available across the
organization – remote
viewing for critical decision
making
• Archiving & record
retention simplicity
• Alarms & Warnings
• Saving raw data: RF Signal
• Google Maps & GPS
___
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Typical Applications
NACE 2016
• Replacement of ER probes/ Corrosion Coupons• Baseline of new infrastructure • Crude Unit Overhead w/ chemical Injection and/or Water
Washes• Injection/Mix-point Corrosion• High temperature (900F) real-time monitoring• Gas Spheres / containers• Sand erosion/corrosion in offshore production• Buried Pipelines• General Inspection
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UT Sensor Case Studies – Oil & Gas
NACE 2016
Process Control
• Corrosion RATE monitoring
• Chemical inhibitor injection mgmt.
• Different crude TAN rates require more/less chemical to reduce exposure to wall loss
• Temporary UT wireless sensors placed in misc. areas (1 reading per hour for 3 months)
• Reduction in chemical inhibitor spend varying based on crude slate (in this instance is estimated to be ~$20K/wk.)
Inspection
• Localized corrosion monitoring
• Gas spheres
• “underbelly” pitting/corrosion
• Inspection crews sent bi-weekly to inspect known areas on 4 spheres
• Cost $25K each time
• Manual UT gauges marked “low” spots, tethered UT sensors placed (3 readings per wk. using tablet)
• Saved >$150K in first 3 months of program
Re-Engineering
• TML reduction programs
• Cellular UT sensors in lieu of manual inspection (2 readings per month)
• <1 mil/yr. for +5 yrs.
• 27,000+ TML locations, cost >$3M to inspect 1/3 per year
• Were able to reduce from 27,000 TML points to 13,000 TMLs
• Saving ~$1.7M/yr in manual inspection cost
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UT Sensor Case Studies – Power Gen.
NACE 2016
Transmission
• Regulation driven
• Buried river & road crossings
• UT sensors placed on defined areas -tethered/manual collection
• Junction boxes placed 100’ from road tethered UT sensors installed (1 reading per qtr.)
• Savings in government fines
Storage
• Buried high pressure storage lines
• Installed tethered/manual UT sensors on new (replaced) segments of pipe where corrosion had previously been found (2-3 readings per yr. or as necessary via tablet)
• Savings from avoiding unplanned outages
Inspection
• Ongoing projects & evaluation …
• FAC programs
• Corrosion rate R&D
• MIC programs
• Installed sensors in lieu of manual inspections for known pitting between outages
• High-point vent
• Installed sensors in lieu of manual inspection to detect gas voids
• EHS – avoid radiation areas where possible
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Summary & Q/A
NACE 2016
The world is changing … use technology to your advantage
Installed sensors can be used to optimize safety & asset integrity for inspection as well as monitoring for corrosion/erosion & cracking
The power of data … predictive uptime, real-time asset health monitoring, reduce unplanned outages
Applications for installed sensors exist everywhere, know your short- and long-term goals for any project/program
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NACE 2016