Corrosion Under Technology - Institute of Corrosion...Dr Prafull Sharma, CorrosionRADAR Ltd . CorrosionRADAR Ltd. 4 The Story of Rob, Bob and CUI. CorrosionRADAR Ltd. 5 Oil & Gas Chemical

Corrosion Under

Insulation Monitoring

using EMGR

Technology

Corrosion Under

Insulation Monitoring

using EMGR

Technology

Dr Prafull Sharma, CorrosionRADAR Ltd www.corrosionradar.com

CorrosionRADAR Ltd. 4

The Story of Rob, Bob and CUI


Oil & Gas Chemical Industry

Renewable Energy LNG

Corrosion Under Insulation

ProblemHIDDEN CORROSION


Corrosion Under Insulation (CUI)AMONG THE BIGGEST ASSET INTEGRITY THREAT

CUI is #1 asset integrity issue in O&G and Petrochemicals

10% of the overall offshore platforms maintenance cost

60% of all pipeline failures are due to CUI

How CUI happens

Water ingressinto insulation

Unpredictable location Suitable temperature


Inspection 4.0 – Mega Trend

Statistics, RBIManual observation,

Leaks

Inspection 1.0 Inspection 3.0Visualisation,

NDT instruments

Inspection 2.0

Manual Automated

Detection Prediction

Reaction

Automated,

Analytics, Prediction

Inspection 4.0

Prevention


Predictive Corrosion Management - OpportunityENABLED BY IIOT AND PREDICTIVE ANALYTICS

PERIODICMANUAL

INSPECTION

CURRENT PRACTICE

Reactive

• Labour Intensive

• Unscheduled Shutdowns

• Safety Risk

• High cost

REACTIVE MAINTENANCE

HUMANJUDGEMENT + GUESSED RISK

• Minimal labour effort

• Scheduled Maintenance

• Improved safety

• Reduced cost

PREDICTIVE MAINTENANCE

AUTOMATEDRISK PROFILING

CONTINUOUSMONITORING

FUTURE PRACTICE

Predictive

Sensors

Connectivity

Knowledgebase

Analytics / ML


Electro-Magnetic Guided Radar (EMGR)CORE SENSING PRINCIPLE FOR CUI MONITORING

Wave reflection time-of-flight locates the corrosion on sensor

Reflected Wave Travelling

Wave

Pipe

Insulation

DefectInjected

Electromagnetic WaveWaveguide -

Cable








CUI Monitoring SolutionPREDICTIVE CORROSION MANAGEMENT USING IIOT

PREDICTCONNECTDETECT

Distributed Corrosion & Moisture Sensors

Long Range Coverage

Cost Effective Installation

Covering Complex Pipe works

Long-Life Battery Powered

Remote Wireless Communications

Continuous Monitoring

Dashboard for Actionable Intelligence

Predictive Asset Management

Asset life extension

Effective Risk Management

Historical Data & Analytics

CR Moisture

CR Corrosion Wireless Data

CR Digital Twin

CR On-Premises

CR CloudTransmitters

CorrosionRADAR Ltd. 13 13

Helical

Configuration

Line

ConfigurationMesh

Configuration

Embedded

Sensors

Long-range

& Modular (each sensor unit

can cover up to

100 m)

Unaffected

by Complex

Geometries (e.g. vessels, pipe

bends, flanges...)

Cost Effective

for Mass

Deployment

Monitoring

Storage tanks

Monitoring Vessels

Detect - SensorsCORROSION AND MOISTURE SENSORS FOR PREDICTIVE CUI MANAGEMENT

Sensors Type 1) Corrosion 2) Moisture

Sensor Length 1) Up to 100m 2) 50m

Temperature Range -50 to 1) +300 °C 2)+200 °C

Sensors


Connect - ElectronicsATEX COMPLIANT PRODUCT FOR HAZARDOUS ENVIRONMENT

ATEX/IECEx Certification II 2 GDEx db IIB+H2 T3-T6 GbEx tb IIIC T85°C - T150°C Db

Ingress Protection IP66

Power Source Mains

Temperature Range (°C) - 20 to +60

Communications Wireless: Wifi/Cellular/WirelessHART/LoRaOther options: USB

Approx. Dimensions (mm): 284H X 245W X 169D (Without Antenna)

Approx. Weight 11.2 Kg

Corrosion & Moisture Monitoring System - Electronics


Predict - Analytics Platforms

CR Predict Add-on Algorithm Products

CR Predict IIOT Cloud platform CR Predict Digital Twin platformCR Predict On-Prem Software platform

CR Automated Defect Recognition

Module using Machine Learning CUI Prediction Module

enabled by new improved models

CR Analytics Module


CR Predict - CUI Prediction ModuleADD-ON ALGORITHM PRODUCT

Time

API 581 is industry guideline for CUI rate estimation CorrosionRADAR moisture

sensors provides critical factor FINF for accurate estimation of CUI rate.

The above plot is an experimental demonstration of CR prediction module

Continued laboratory testing for predictive models Validated to match industry standards

Case Study APRODUCTION COLUMN CORROSION MONITORING (ATEX)



(A) (B)

(C) (D)

Figure (A)

Installation of CR

corrosion sensors on a

3 inch pipe using cable

ties

Figure (C)

Installed CR Nodes

(electronic) driving CR

Moisture and

Corrosion sensors

Figure (B)

Installation of the pre-

fabricated insulation

around the pipe and

the corrosion sensor

Figure (D)

Moisture sensor is

placed inside the pre-

fabricated insulations

and installed at a fixed

distance from the pipe

Case Study BMOISTURE MONITORING SYSTEM

Moisture sensor

Corrosion sensor


Case Study BMOISTURE MONITORING SYSTEM

Moisture

sensor data

analysis

and

correlation

with historical

weather data

Am

ount of

rain

fall

(mm

)Detected water ingress points

at 22 metres location


Installed layout of both CR Corrosion and Moisture monitoring systems

Case Study CINSTALLATION OF CR SYSTEMS

1.0m

1.5m

2.5m

0.5m1.0m

1.0m

Corrosion sensor (10m)

Moisture sensor (10.5m)

Corrosion Bridge Cable (10m)


Data after 6 months CORROSION AND MOISTURE MONITORING SYSTEMS

No corrosion signal observed

Sensor start

Sensor end

(Baseline)

Sensor start Sensor end(Baseline)

Corrosion Sensor

Moisture Sensor

Water detected

07:14 GMT on 11.06.2019

Moisture Sensor

Corrosion Sensor


Data after 7 months CORROSION AND MOISTURE MONITORING SYSTEMS

Sensor start

Sensor end

(Baseline)

Sensor start Sensor end(Baseline)

Corrosion Sensor

Moisture Sensor

Moisture Sensor

Corrosion Sensor

Reduced reflection

from sensor end

05.07.19

Minor anomaly

05.07.19

Water detected

08:00 GMT on 05.07.2019

Shift in sensor end

indicates water

presence along the

sensor


Benefits of CUI Monitoring System

COST RISKESTIMATED

MAINTENANCE

COST SAVINGS:

30-45%


CUI Monitoring

(Corrosion & Moisture)

Data Driven RBI

Optimised

Maintenance

Less human

intervention

Reduced assets

Risk

Early Detection

Reduced

unplanned

Shutdowns

Leak

Prevention

Reduced

maintenance cost

CUIPREVENTION

PREDICTIVEMAINTENANCE

Benefits of CUI Monitoring System

HeadingSUB HEADING

Enabling Smarter Assets

CorrosionRADAR Ltd

Future Business Centre

King’s Hedges Road

Cambridge, CB4 2HY

[email protected]

www.corrosionradar.com

HeadingSUB HEADING

Enabling Smarter Assets

CorrosonRADAR Ltd

Future Business Centre

King’s Hedges Road

Cambridge, CB4 2HY

[email protected]

www.corrosionradar.com

Documents

Corrosion Under Technology - Institute of Corrosion...Dr Prafull Sharma, CorrosionRADAR Ltd . CorrosionRADAR Ltd. 4 The Story of Rob, Bob and CUI. CorrosionRADAR Ltd. 5 Oil & Gas Chemical