Optimizing Plant Integrity Through

Continuous Wall Thickness Monitoring

Non-Intrusive Erosion and Corrosion Monitoring Solution.

Emerson Automation Solutions.

 The Cost of Corrosion

1,400,000,000 $ annual cost of corrosion

UPSTREAM

14,000,000,000 $ annual cost of corrosion

MIDSTREAM

3,700,000,000 $ annual cost of corrosion

DOWNSTREAM

10,000,000,000 $ annual cost of corrosion

GENERAL Source: The United States Cost of Corrosion Study – DOT & NACE
 Industry Benchmarks Reveal Significant Business Improvement
Opportunities from Average to Top Quartile Business Performers
Safety Reliability
Recordables Maintenance
3X fewer 4% higher Availability
availability
recordables Process
Incidents
and process
incidents Approximately Half the
maintenance
4th Quartiles 1st
ONE TRILLION costs 4th Quartiles 1st

Production
DOLLARS Emissions
in company value is
Operating Costs lost every year to CO2 Emissions
20% lower Utilization suboptimal operating 30% lower
performance emissions
operating costs Energy Use

30% less
10% higher energy use
Utilization Rate 4th Quartiles 1st 4th Quartiles 1st

Sources: Refining and Petrochemical Benchmarks,

API, Solomon, OSHA, IHS Market and Company Reports
3
Industry Key Concern & Challenges

Sustainable Business Higher Availability

• Tighter HSE Regulations • Unplanned Shutdowns

• Leaks/ Loss Containment • Metallurgy Selections
• Manual Integrity Assurance • Treatment Optimization
• Ageing infrastructure Increased Profitability • Loss of production
• Environmental cost • Corrosion sizeable portion
associated with leaks or of maintenance
spills • Variable Feedstock Quality expenditure

• Conservative Operations
• Lower Conversion Margins
• Process Information and • Expansion of production
Optimization into more demanding
4
environments
Driving Operation Excellence with Corrosion & Erosion Monitoring

Sustainable Business Higher Availability

Protect 10%
Operational Risk
Safety
Management

Personal Availability Improvement

Enhanced Decision Making
Process Integrity Assurance

Increased Profitability Personnel Effectiveness

5% Material Selection

Improved Profitability Equipment Life Management

Process Optimisation Shutdown Planning

Treatment Optimisation Production Maximisation

5
Key Notes from NACE
Technological advancements have provided many new ways to prevent
corrosion, better corrosion management can be achieved using
preventive strategies :

• Increase awareness of significant corrosion cost and potential cost savings.

• Change the misconception that nothing can be done about corrosion.

• Change policies, regulations, standards, and management practices to

increase corrosion cost savings through sound corrosion management.

• Improve education and training of staff in the recognition of corrosion

control.

• Implement advanced design practices for better corrosion management.

• Develop advanced life-prediction and performance-assessment methods.

• Improve corrosion technology through research, development, and

implementation.

6
Online Monitoring Enables Knowledge-Based Decisions
• Provide early warning of asset health degradation
and integrity issues
– Spare equipment can be planned/installed in time to
prevent an upset

• Detect and understand process conditions that

may be creating equipment fault or integrity risk
– Adjust and optimize process to avoid fault

• Accurately determine when service is necessary

– No expensive “run-to-failure” or wasted service efforts
– Measurements through different technologies provides
better and wider assessment

• Determine root cause of failure

– More measurements provide higher probability to
identify cause of problem

• Asset monitoring visibility into the control room

– Eliminate unnecessary trips to the field, possibly in
hazardous areas
Permasense Applications – Upstream

Damage Mechanisms
• Erosion
• CO2 / H2S Corrosion
• MIC
• Pitting
• PWC

Applications
• CRI
• Well Testing
• HPHT
• Corrosion Inhibitor Monitoring
• Inspection planning / verification
• Difficult to access pipework / vessels
• Insulated pipework / vessels
• Personnel Safety Issues

Emerson Confidential
 Emerson’s Total Corrosion & Erosion Monitoring Solution

Online Corrosion Monitoring System aligned to

The PlantWeb Digital Ecosystem a comprehensive Industrial IOT Platform
Connect to Anything
A simple, lightweight, web-based analytics platform
Web Visualization

Azure
)))

Host Systems
& Historians

HART IP

Web UI

HART IP
Plantweb Healt Advisor
Database Server
Secure With Local Mobile
First Mile Visualization

Deploy Anywhere
Sense Everything Visualize Anywhere 9
Technology Overview – Data Transmission Offshore

Emerson Confidential
 Emerson’s Total Corrosion & Erosion Monitoring Solution
NON-INTRUSIVE INLINE

On-line Ultrasound FSM (Field Signature ACOUSTIC PROBES

COUPONS
(EMAT / Waveguide) Method) (Sand / Pig) (ER / LPR)
• Direct metal thickness • Metal loss • Immediate warning of • Highest sensitivity • Direct metal loss
measurements measurements across solids production (risk (nano-meters) and measurements
• Measures Impact of a local area of sand erosion) to fastest quantification/ • Analysis of deposits
• Measures Impact of
ADVANTAGES

and bacteria activity

ADVANTAGES
Corrosion or Erosion on optimize production response to changed
any location both general and rate corrosion rates • Lowest equipment
• Easy to install localised corrosion • Easy to install • Highly responsive cost
• No maintenance through a full area • Also available as pig measurement of
• Deployable anywhere coverage detector process changes
• No maintenance

11
Sensors for any location, operating at any temperature
ET410 WT210
ET310

ET210

Temperature range
ET210 - Up to 120oC (248oF) Up to 300oC (572oF) Up to 600oC (1100oF)
ET310 - Up to 200oC (392oF)
Measurement technique
Ultrasound - EMAT Ultrasound - Waveguide
Sharing WirelessHART infrastructure - All data viewed in Data Manager, at desk

Emerson Confidential 12
Permasense Non Intrusive Corrosion and Erosion Monitoring
• The WT210 are Waveguide type Ultrasonic Wall thickness • The ET’s are Magnetically coupled Ultrasonic Wall
sensors, clamped or stud-welded to any pipe section or asset thickness sensor, that is able to work through protective pipe
coating. EMAT technology.
• Extreme Temperature Ranges (-180 to 600 °C)
• Temperature range is from -50 to 200 °C.
• Deploy anywhere - Intrinsically Safe and WirelessHART
• No clamping or Stud Welding Required
• Compact form factor with Smart Power Pack, 9 years Power
Pack Service Life • Deploy anywhere - Intrinsically Safe and WirelessHART
• Compact form factor with Smart Power Pack, 9years Power
Pack Service Life
 Advanced signal processing
Standard processing
• Adaptive Cross Correlation, AXC
– Correlation where signal matches previous backwall
signal most closely
– Roughness scattering effect is overcome
• Permasense Shape Indicator, PSI
– Correlation to previous backwall signal introduces AXC
backwall reflection and morphology change indicator
– Early warning of the onset of localised corrosion

Permasense Shape Indicator, PSI Adaptive Cross Correlation, AXC

Total sulphur content, (wt. %)
PSI scale

Emerson Confidential 14
Dealing with internal surface roughness or pitting
Roughness scattering
affects all ultrasound-based
technologies

No clear peak

Unique to Permasense technology

Emerson Confidential 15
Temperature compensation simplifies data interpretation
uncompensated data

0.05 mm 2 mils
Temperature compensated data – easier to understand
and interpret

Oct Nov Dec Jan Feb

Metal temperature measurements

Emerson Confidential 16
 Enhancement in data quality and frequency
• Permasense: measurements every 12 hours within +/- 10 microns variation; catch onset of corrosion
events within days
• Manual UT Inspection: years between measurements with +/- 0.5-1.0 mm variation; corrosion rate
calculation not possible, corrosion events missed

1 mm 40 mils
1mm

Permasense measurements

Emerson Confidential 17
Data Visualization and Analytics:
easy to see where the activity is occurring
Classification for each Click here to see all 26 test points Click here to see all 15 test
address exhibiting linear wall loss points at this address

Click here to see all 52 location

User defined address structure graphs at this address
Emerson Confidential
Data Visualization and Analytics:
easy to see where the activity is occurring
User defined test point Classification of activity at
each test point Click here to view graph of measurements
ID and name

Data recently Remaining wall thickness to Rate calculated with confidence bound
received retirement

NB: Users can switch between Metric and Imperial units

Emerson Confidential
 Data Visualisation and Analytics: easy to see where the activity
is occurring
Local high corrosion rates detected by multiple Local high corrosion rate detected by a single
sensors at the same address sensor at a particular address

A
Little to no corrosion
B detected by sensors at
this address

Corrosion
activity spikes D
after
shutdown E
F
G

H
2013 2014 2015

Constantly high corrosion rates detected across multiple sensors at Unique to Permasense technology
the same address (Naphtha/Reflux)

Emerson Confidential 20
DataManager – Turnaround planning - Trending

Emerson Confidential
Upstream Application
Production Maximization via Sand Management

• Sand screen, gravel packing & sand agglomerates

ultimately has only one goal – to restrict free flow fine
sand particle with no reduction in permeability resulting in
Maximum Sand Free Rate (MSFR)

• Inevitably, there will still be some level of fine sand lifting,

causing erosion & solid accumulation on top side. Solid
management is mandatory on top side

• Sand probe with rough estimation of sand loading

quantity can be installed to decide sand accumulation

• Permasense can be installed to monitor the impact of

sand erosion and corrosion on real time online basis.

Emerson Confidential
Production Maximization via Continuous Solid Free Flow Production

• Risks associated with solid are

traditionally controlled by
choking production resulted in
solid built-up, wells shut-ins &
costly coil tubing interventions.

• Effective solid management

enables continuous solid free
flow enhance production
performance & significantly
lower cost per barrel
production.

Permasense further ensures the performance of

production, monitoring on real time basis, the asset
integrity of the system confidently.

Emerson Confidential
Production Maximization – Managing Preferential Weld Corrosion (PWC)

• Welds in many instances, have much higher corrosion /

erosion rate compared to the parent material

• Root cause of PCW are numerous starting from

method of welding, microstructure of weld, composition
of filler etc.

• PCW can be a result fluid chemistry, sand content, flow

rate, temperature, pressure, pipe geometry etc.

Permasense technology can be deployed directly on

top of weldment to monitor internal degradation
whether the cause of wall thinning is from corrosion
or erosion. Efficient planning of shut down for
repair/replacement can be achieved, maximizing
production period.

Wall thickness of welds is reliably measurable at any stage of weld root corrosion with EMAT ET’s sensors
Emerson Confidential
Production Maximization via Monitoring Choke Valve

• Choke valve outlet and first elbow of Choke

valve
flowlines are often found susceptible Flow
erosion. Production is often limited by
unreliable sand loading information. 1 2

Sensor
6 sensors are required.
• Given necessary action taken with sand 3 4
management downhole & solid removal on
topside, monitoring minimum thickness
allowable on choke valve is critical to
maximize production. Flow

Permasense is deployed to accomplish

this monitoring, to unlock the potential of
maximum production.

Emerson Confidential
Production Maximization via Extended Equipment Life Span

• Standard plate thickness & manufacturing tolerances give rise to extra

thickness available for corrosion allowance.
• Subject to internal safety policy, system pressure can be managed &
controlled in order to continuously produce without compromising safety
despite reaching the alert & high critical alert.
Permasense to provide accurate real time thickness data integrated to
Plant Information (PI) system for effective decision making

Emerson Confidential
Effectiveness of Corrosion Inhibitor – Real Time Online Feedback
• The level of corrosion inhibitor is determined by
measuring the presence of micelles; microscopic
groups of corrosion inhibitor molecules. These
micelles form when the dose of corrosion inhibitor
reaches the ‘critical micelle concentration’ (CMC).

• Depending on the characteristic of reservoir fluids

which changes from time to time, corrosion
behaviour varies over time.

The adoption of Permasense technology enables

scrutiny of the effectiveness of the corrosion
inhibitor as and when process condition changes.

Emerson Confidential
Effectiveness of Corrosion Inhibitor – Liquid Shear Stress
• High pressure reservoir system or low pressure system
where compressor or ejector is used to boost downhole
pressure typically produce high liquid shear stress.

• Computerized Fluid Dynamic (CFD) can clearly show the

corrosion/erosion ‘hot spots’ as illustrated.

• With such a flow regime. No corrosion inhibitor can work

effectively.

• Permasense is an ideal system to adopt to ensure

real time online thickness monitoring

Emerson Confidential
 Effectiveness of Corrosion Inhibitor vs. Flow Pattern
• It is a phenomenon that subject to • Contours of velocity distribution also
different oil to water ratio, process results in different magnitude of fluid
fluids form different flow pattern flow in the pipeline different section
which affect the effectiveness of of the pipeline.
corrosion inhibitor
• Permasense technology is
the perfect solution to
deploy to monitor
corrosion ‘hot spots’ where
protective film of corrosion
inhibitor cannot be
effectively established

Emerson Confidential
Case Studies
Global Experience to-date

>20,000 sensors in >250 facilities in >40 countries

>18 million wall thickness measurements delivered to desk, >170 million operating hours
Real Time UT wall thickness monitoring

Emerson Confidential 33
Confidence to increase offshore gas platform production rate
▪ Caribbean Sea.

▪ Well operation constrained on throughput: fear of sand erosion

▪ Insufficient confidence in acoustic sand detector and intrusive

ER measurement

▪ Now monitoring with Permasense system downstream of choke

Downstream of cushioned tee and blind tee

▪ Permasense data verified erosion rates had not increased

▪ Payback on Permasense system in days

Downstream of choke

Emerson Confidential
12% production rate enhancement 34
 Wet gas corrosion detection and control on mature asset
▪ UK Sector, Southern North Sea – Major Oil Company

▪ Original plan was to install 25-30 intrusive probes.

▪ Permasense system selected because:

▪ Lower cost, non-intrusive; ability to be installed on-line

▪ Deliver real-time, reliable, accurate data to shore

▪ A few intrusive probes were installed at the injection points

to provide feedback loop

▪ On start-up, inhibitor system set to design condition

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Wet gas corrosion detection and control on mature asset
▪ Corrosion immediately detected by
Permasense system and validated
0.25 mm 10 mils

▪ Asset Integrity Manager acted on the

Permasense data, corrected inhibitor system
and stabilised wall loss
▪ Reduced risk and operational/inspection
manpower requirements
0.25 mm 10 mils
▪ Assured ongoing operations

Sensor offshore – part

of 30 sensor system

Corrosion detected, measured, actioned, controlled, control

validated in service
Emerson Confidential 36
 Corrosion monitoring through extended run length
▪ Permasense sensors already installed in 20 “known damage” locations
▪ Have successfully extended runs between planned maintenance from 3
to 5 years
▪ Intrusive electrical resistance probe tips need replacement after
maximum 3.5 – 4 years, but cannot be retracted online for safety
reasons
▪ Operator is left ‘blind’ for the most critical last year of the cycle
▪ Enhancing monitoring by adding Permasense sensors at the 120 ER
probe locations across the facility

▪ Significant potential risk reduction

and cost savings from reducing
use of intrusive probes on
offshore production facilities

Permasense sensors are maintenance-free over 7-9 year period

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 Optimized Inspection Costs
▪ Permasense sensors installed in 12 “known damage”
locations – UKCS Major Oil Company
▪ Permasense data is being reviewed remotely by corrosion
specialists onshore.
▪ On-site inspection (frequency, locations) is being optimised
to account for level of wall thickness loss activity
▪ Longer-term aim is to focus on-site inspection activities to
reduce helicopter costs from transporting specialists to
platform

High quality, reliable remote monitoring for safer

and more cost effective operations
Emerson Confidential 38
Summary

• Improved Safety and reliability

• Cost-effective monitoring with low installation costs
• Non-intrusive, intrinsically safe, easy to deploy, on-line
• Continuous monitoring at many, widely distributed locations
• Reduced exposure for personnel to hazardous inspection
monitoring/maintenance activities
• Allows more efficient and effective use of inspection personnel
• An operational decision making tool, to improve plant availability and optimise
production
• Very short payback time

Emerson Confidential 39
Thank You!
Emerson Automation Solutions

For more information please contact:

Tran Van Tu (Mr.)
Deputy Director of Oilfield Services Company Limited
Mobile: +84 979993600
Email: [email protected]