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Corrosion Awareness Day -
Corrosion Monitoring
1
Corrosion Monitoring
INTRUSIVE MONITORING
(A Specialized Area of
Corrosion Monitoring)
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
2
Corrosion Monitoring
The RBI / CRA Process…..
• Requires Constant Feedback /
Updating from all Available
Sources.
• Inspection Frequencies Require
Regular Review.
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
3
Corrosion Monitoring
KEY RISKS
(Water and Dissolved Gases)
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
4
Corrosion Monitoring
Steve Tate – (Stork)
Generally the higher the concentration of dissolved gases in
solution the higher the corrosion tendency.
Oxygen most Aggressive.
Gases
Corrosion Awareness Day -
Corrosion Monitoring
5
Corrosion Monitoring
Steve Tate – (Stork)
Effect of Water Cut on Oil Line Corrosion Rate
0.0
1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
0 10 20 30 40 50 60 70 80 90
Water Cut (%)
Corrosion Rate, mm/yr
Water
Corrosion Awareness Day -
Corrosion Monitoring
6
Corrosion Monitoring
Steve Tate – (Stork)
FLOWLINE CO2 CORROSION and EROSION
Subsequent Erosion / Scale Undercutting in Direction of Flow
FLOW
DIRECTION
Corrosion and Erosion Damage
Corrosion Awareness Day -
Corrosion Monitoring
7
Corrosion Monitoring
Corrosion Monitoring…..
• Applications and Benefits (as Part
of an Overall CRA / RBI Process)
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
8
Corrosion Monitoring
Steve Tate – (Stork)
Corrosion MonitoringCorrosion Monitoring
Sand MonitoringSand Monitoring
MultiMulti--probeprobe
(Sand/Corrosion)/ (Sand/Corrosion)/
Pressure TemperaturePressure Temperature
FSMFSM
Flexible Pipe MonitoringFlexible Pipe Monitoring
and Riser/ Caisson inspectionand Riser/ Caisson inspection
Inspection, IntegrityInspection, Integrity
Management.Management.
CP DesignCP Design
FSMFSM
Plant RBI,Plant RBI,Plant RBI,Plant RBI,Plant RBI,Plant RBI,Plant RBI,Plant RBI,FSM (Refinery)FSM (Refinery)FSM (Refinery)FSM (Refinery)FSM (Refinery)FSM (Refinery)FSM (Refinery)FSM (Refinery)Ports & Harbours: Ports & Harbours: Ports & Harbours: Ports & Harbours: Ports & Harbours: Ports & Harbours: Ports & Harbours: Ports & Harbours: Asset Management, Asset Management, Asset Management, Asset Management, Asset Management, Asset Management, Asset Management, Asset Management, Corrosion ManagementCorrosion ManagementCorrosion ManagementCorrosion ManagementCorrosion ManagementCorrosion ManagementCorrosion ManagementCorrosion ManagementWell Well TestingTesting
CP SurveyCP Survey
Topsides StructuresTopsides StructuresTopsides StructuresTopsides Structures RBI, Plant RBI, RBI, Plant RBI, RBI, Plant RBI, RBI, Plant RBI, PSV RBI, Integrity Management, FSM, PSV RBI, Integrity Management, FSM, PSV RBI, Integrity Management, FSM, PSV RBI, Integrity Management, FSM, Well Testing / Solids Monitoring Risk Well Testing / Solids Monitoring Risk Well Testing / Solids Monitoring Risk Well Testing / Solids Monitoring Risk Based Maintenance, Vessel InspectionBased Maintenance, Vessel InspectionBased Maintenance, Vessel InspectionBased Maintenance, Vessel Inspection
Pipeline RBI,Pipeline RBI,Pipeline RBI,Pipeline RBI, Integrity Integrity Integrity Integrity Management, CP Survey, Management, CP Survey, Management, CP Survey, Management, CP Survey, FSM, CP Engineering FSM, CP Engineering FSM, CP Engineering FSM, CP Engineering ER and Sand probesER and Sand probesER and Sand probesER and Sand probesJacket Risk Based InspectionJacket Risk Based InspectionJacket Risk Based InspectionJacket Risk Based Inspection, Integrity , Integrity , Integrity , Integrity Management, Caisson / Riser Integrity, Management, Caisson / Riser Integrity, Management, Caisson / Riser Integrity, Management, Caisson / Riser Integrity, Caisson / Riser Inspection, CP SurveyCaisson / Riser Inspection, CP SurveyCaisson / Riser Inspection, CP SurveyCaisson / Riser Inspection, CP Survey
FPSO Integrity ManagementFPSO Integrity ManagementFPSO Integrity ManagementFPSO Integrity Management, , , , Corrosion Management, Corrosion Management, Corrosion Management, Corrosion Management, ProcessesProcessesProcessesProcessesIntegrity Management
Corrosion Awareness Day -
Corrosion Monitoring
9
Corrosion Monitoring
Reasons For Monitoring…..
• To help identify the location, rate,
and underlying causes of
corrosion and erosion.
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
10
Corrosion Monitoring
Types of Monitoring…..
1.Intrusive
2.Non-Intrusive
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
11
Corrosion Monitoring
Intrusive…..
• Test Coupons (of Same Material as
Pipe.
• Corrosion Probes – Electrical
Resistance, Galvanic, Weld etc.
• Erosion (Sand Monitoring) Probes.
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
12
Corrosion Monitoring
Non-Intrusive…..(NDT)
• Electro-magnetic
• Radiographic
• Ultrasonic
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
13
Corrosion Monitoring
What Monitoring Gives Us
• Corrosion Coupons – Pitting + Microbial + Corrosion Product Analysis.
• Corrosion Probes – Alarms For Process Trends / Corrosion Trends / Upsets / Loss of Inhibition.
• UT Parent Metal Scan at Probe / Coupon Sites – More Accurate Determination of WT Losses / Regular WT Trending, (Monthly Preferred at Main Complexes).
• TOFD – Additional Weld Monitoring (where Appropriate), e.g. Manifold Tees.
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
14
1. A Coupon is not a direct measurement of wall
loss but remains a useful guide to process
trends and process ‘corrosivity.
2. An insulating washer separates the test
coupon from the coupon holder and the pipe
wall itself.
3. Coupons should be pulled at least annually for
Examination / Weight Loss Measurement /
Micro Swabbing.
Corrosion Monitoring
The Corrosion Coupon
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
15Steve Tate – ConocoPhillips (Stork)
1. Electrical Resistance probes (when used for Corrosion
Monitoring), monitor material loss directly* and do not
require a continuous conductive path. Therefore the
ER technique can be used to monitor corrosion in
areas where water wetting is not continuous or under
deposits where conductive may be limited.
1. The replacement interval for electrical resistance
probes is dependant on probe sensitivity and the
corrosion rate. Readings from ER probes will be
obtained manually or automatically via an offline or
online logging system (PI).
Corrosion Monitoring
The Corrosion ER Probe
Corrosion Awareness Day -
Corrosion Monitoring
16
1. ER probes of stainless steel, with similar
mechanical properties as for the pipe that is the
subject for monitoring. Hence the erosion sensors
will not corrode and all material loss and can then
be attributed to erosion.
1. Often there is little general evidence of solids
posing a serious problem, other than very
locally at Choke Valves / Sudden Geometry
Changes.
Corrosion Monitoring
The Erosion ER Probe
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
17
Corrosion Monitoring
POSITIONING
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
18
Corrosion Monitoring
TOL
12 O’Clock
Watch Future Maintenance / Accessibility !
Steve Tate – (Stork)
Positioning
Corrosion Awareness Day -
Corrosion Monitoring
19
Corrosion Monitoring
Watch Orientation
TOL
12 O’Clock
BOL
5 O’Clock
Better Than 6 O’clock
For Liquids
(Less Debris)
O.K For
Wet Gas
(Orientation
Less
Critical)
Steve Tate – (Stork)
Positioning
Corrosion Awareness Day -
Corrosion Monitoring
20
Corrosion Monitoring
MAIN PROBE TYPES
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
21
Corrosion Monitoring
Steve Tate – (Stork)
ER Electrical Resistance Probe – is used to track rates of metal loss.
The probe directly measures the increase in resistance of a metal
as its cross-sectional area is reduced by corrosion. At suitable times, after
probe bedded-in readings can be converted into corrosion rates
ER Probe
Electrical resistance probes can be
used in conductive systems, as well
as non-conductive environments
such as oil, gas, and atmosphere.
Corrosion Awareness Day -
Corrosion Monitoring
22
Corrosion Monitoring
Steve Tate – (Stork)
Verifying Metal Loss
Culmulative
Metal Loss v.
Reference
Electrodes
Corrosion Awareness Day -
Corrosion Monitoring
23
Corrosion Monitoring
Steve Tate – (Stork)
Combined Sand/Erosion and
Corrosion Probe
Erosion Elements
Corrosion Element at Rear of Probe
Combination Probe
Corrosion Awareness Day -
Corrosion Monitoring
24
Corrosion Monitoring
Steve Tate – (Stork)
Galvanic Probe - operates by measuring the galvanic current in the circuit between
a steel and a brass electrode and is particularly sensitive to
the amount of oxygen in the water. Although the galvanic current, within certain
restrictions, is proportional to the oxygen concentration in a system.
It is not intended to replace an oxygen sensor (Orbisphere).
Galvanic Probe
Corrosion Awareness Day -
Corrosion Monitoring
25
Corrosion Monitoring
Steve Tate – (Stork)
Weld Probe Counter (Electrochemical Noise Measurement)
Reference Electrode
Weld Metal
Parent Metal
WELD PROBE LAYOUT
Weld Probe
Weld probes - are
fabricated to
simulate Weld Composition
but are not widely used.
Corrosion Awareness Day -
Corrosion Monitoring
26
Corrosion Monitoring
Steve Tate – (Stork)
LPR Probe – LAB Use
LPR probes - are used in
conductive environments
such as water or any
electrolyte. The operating
principle is based on
measuring the flow of
current between
multiple electrodes.
Corrosion Awareness Day -
Corrosion Monitoring
27
Corrosion Monitoring
MORE EQUIPMENT DETAILS
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
28
Corrosion Monitoring
Steve Tate – (Stork)
Types of Access Fitting
Corrosion Awareness Day -
Corrosion Monitoring
29
Corrosion Monitoring
Steve Tate – (Stork)
2” Mechanical System Components
Thread
Cap
Flareweld
Fitting
Plug
Assembly
Mechanical to
Hydraulic Fitting
Adapter
Pressure
Retaining Cover
Mechanical System
Corrosion Awareness Day -
Corrosion Monitoring
30
Corrosion Monitoring
Steve Tate – (Stork)
Mechanical to Hydraulic Conversion
2” Mechanical access
fitting 2” Mechanical fitting
converted to hydraulic
system with adaptor
Modern Conversion
Corrosion Awareness Day -
Corrosion Monitoring
31
Corrosion Monitoring
Steve Tate – (Stork)
Service ValvesDouble Isolating
Single Isolating
Safety Valves
Corrosion Awareness Day -
Corrosion Monitoring
32
Corrosion Monitoring
Steve Tate – (Stork)
Safety
Valve
Retrieval
Tool
Pressure
Equalisation
(Fitting
Retrieval
Process)
Valve
Closed
Retriever
Removed
(With
Fitting)
Retrieval Process
Corrosion Awareness Day -
Corrosion Monitoring
33
Heavy Duty Cap with Gauge –
Secondary Pressure Containment
Corrosion Monitoring
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
34
Corrosion Monitoring
DATA TRANSMISSION
(REAL-TIME LOGGING)
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
35
Corrosion Monitoring
Steve Tate – (Stork)
Logger Logger (or Wireless
Transmitter)
Field BusSand/Erosion
Probe
Corrosion
Probe
Data
PC/Software
Logger Logger (or Wireless
Transmitter)
Field BusSand/Erosion
Probe
Corrosion
Probe
Data
PC/Software
Corrosion Awareness Day -
Corrosion Monitoring
36
Corrosion Monitoring
Steve Tate – (Stork)
Gas Import – BOL Transmitter (White) / ER Probe and HD Cap (Blue)
Corrosion Awareness Day -
Corrosion Monitoring
37
Corrosion Monitoring
PROBE INFORMATION
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
38Steve Tate – (Stork)
Corrosion Monitoring
Probe Retrieval
Corrosion Awareness Day -
Corrosion Monitoring
39
Corrosion Monitoring
Steve Tate – (Stork)
ER probe metal loss results with the introduction of
corrosion inhibitor at maximum production
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
11/11 21/11 01/12 11/12 21/12 31/12 10/01 20/01 30/01 09/02 19/02
Date
Metal loss/ um
E
FGE - Inhibitor injected for 1 day only
F - Inhibitor injection for 5 days
G - Inhibitor injection stopped
H - Inhibitor injection resumed
H
Corrosion rate increasing
from 0.2 to 0.8mm/yr
Corrosion rate
reduced to
approx
0.04mm/yr
Tracking Inhibitors
Corrosion Awareness Day -
Corrosion Monitoring
40
Corrosion Monitoring
Steve Tate – (Stork)
-10
0
10
20
30
40
Jun Jul Aug Sep Oct Nov Dec Jan Feb
µm
16/05/2007 to 01/02/2008
MultiTrend for Windows © 2002 CorrOcean ASA
CE3720 Metal Loss (µm)
Gas KO Drum
Inhibited Operations
Un-inhibited Operations
From Start-Up (Approx 5
Months)
Platform
Shutdown
Corrosion Inhibitor
Commenced
Probe Failure
Metal Loss
Prevented
Previous Trend
Tracking Inhibitors
Corrosion Awareness Day -
Corrosion Monitoring
41
Corrosion Monitoring
Steve Tate – (Stork)
250
260
270
280
290
300
310
Jun Jul Aug
µm
21.05.2001 to 23.08.2001
17.2
17.4
17.6
17.8
18.0
18.2
18.4
18.6
18.8
19.0
19.2
19.4
19.6
µm
MultiTrend for Windows © 2001 CorrOcean ASA
GA-09S ER Metal Loss (µm) GA-09S Metal Loss (µm)
Data from Combined Sand/ER Probe
Sand elementCorrosion element (0.25 mm)
Twin Trace
Corrosion Awareness Day -
Corrosion Monitoring
42
Corrosion Monitoring
MONITORING EXAMPLES
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
43
Corrosion Monitoring
Steve Tate – (Stork)
• ER Corrosion Probe Data – early warning for
loss of inhibition measured at tree.
• Sand / Erosion Probe Data - early warning of
sand production and extent of erosion damage.
Corrosion Awareness Day -
Corrosion Monitoring
44
Effect of Corrosion Inhibitor Outage
Corrosion Monitoring
Steve Tate – (Stork)
Excursions
Corrosion Awareness Day -
Corrosion Monitoring
45
Effect of Corrosion Inhibitor Outage
Corrosion Monitoring
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
46
Effect of Well Openings
Corrosion Monitoring
Steve Tate – (Stork)
Excursions
Corrosion Awareness Day -
Corrosion Monitoring
47
Effect of Well Openings
Corrosion Monitoring
Steve Tate – (Stork)
Excursions
Corrosion Awareness Day -
Corrosion Monitoring
48
Corrosion Monitoring
The larger spikes in the middle of the
plot are when production was halted
then restarted and the choke stepped open.
Further Choke Change
Acoustic Monitoring
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
49
Corrosion Monitoring
COUPON INFORMATION
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
50
Corrosion Monitoring
Steve Tate – (Stork)
Gas System Coupons –
Low Corrosion Rates
Corrosion Awareness Day -
Corrosion Monitoring
51
Corrosion Monitoring
Steve Tate – (Stork)
Heavy Weight Loss
and Microbial Attack
Water Injection Coupons – High
Corrosion Rates
Before Cleaning
Corrosion Awareness Day -
Corrosion Monitoring
52
Corrosion Monitoring
Steve Tate – (Stork)
PIPER / TWEEDSMUIR GAS / OIL SYSTEMS
Results of iiCorr Corrosion Coupon Retrieval Analysis - January 2008
Note. Unable to Retrieve Coupons From Amine Sweetening Plant Area This Trip.
0.042 0.045
0.003
0.069
0.168
0.024
0.000
0.050
0.100
0.150
0.200
0.250
0.300
CP 2230 - D/S C2230 -
Piper Cond. KO Drum
CP 2302 - D/S C-2300 -
Tweedsmuir
Separator
CP 2652 - D/S AP-2652
- Pre MOL Export
CP 3230 - D/S E-3230 -
2nd Stage Aftercooler
CP 3720 - U/S C-3720 -
Dehyd In Gas KO
Drum
CP 3722 - D/S C-3720 -
Dehyd In Gas KO
Drum
Estimated Annual Corrosion Rate mm/yr (based on Coupon Findings)
Estimated Annual Corrosion Rate (mm/yr) -Typically 3 x Measured Rate
NACE Low Corrosion Limit (< 0.025 mm/yr)
NACE Moderate Corrosion Limit (<0.126mm/yr)
NACE High Corrosion Limit (<0.254 mm/yr)
EXAMPLE GAS SYSTEM CORROSION RATES
Highest Rates on Dehydration Unit
NACE High
NACE Moderate
NACE Low
Corrosion Awareness Day -
Corrosion Monitoring
53
Coupon Trending
Corrosion Monitoring
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
54
International Codes
Corrosion Monitoring
Typical Standard is 0.100 mm/yr,
(for 30 yr life).
i.e. NACE Medium Rate
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
55
Corrosion Monitoring
MAINTENANCE
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
56Steve Tate – ConocoPhillips (Stork)
Corrosion Monitoring
Logging
Control
System
Export
Riser Acoustic
All Acoustic
All Intrusive
PI / Experion Control
Corrosion Awareness Day -
Corrosion Monitoring
57
Management Codes
Corrosion Monitoring
Probe malfunction - Known Reason
Probe malfunction - Reason Unknown
Alarm malfunction - Known Reason Action Implemented or Underway
Action Implemented or Underway
Action Required
Probe Status Indication Codes
OK No Action Required
Coupon changed out
Coupon change out visit due
Coupon not changed out
B/D Below Detection No Action Required
Action Implemented or Underway
Action Required
Coupon Status Indication Codes
No Action Required
Steve Tate – (Stork)
Corrosion Awareness Day -
Corrosion Monitoring
58
Corrosion Monitoring
QUESTIONS ?
Steve Tate – (Stork)