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UPSTREAM
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
• Conservative Operations
• Lower Conversion Margins
• Process Information and • Expansion of production
Optimization into more demanding
4
environments
Driving Operation Excellence with Corrosion & Erosion Monitoring
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
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
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
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
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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
Emerson Confidential 14
Dealing with internal surface roughness or pitting
Roughness scattering
affects all ultrasound-based
technologies
No clear peak
0.05 mm 2 mils
Temperature compensated data – easier to understand
and interpret
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
Data recently Remaining wall thickness to Rate calculated with confidence bound
received retirement
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
Emerson Confidential
Production Maximization via Continuous Solid Free Flow Production
Emerson Confidential
Production Maximization – Managing Preferential Weld Corrosion (PWC)
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
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
Emerson Confidential
Production Maximization via Extended Equipment Life Span
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).
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.
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
Emerson Confidential 33
Confidence to increase offshore gas platform production rate
▪ Caribbean Sea.
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
Emerson Confidential 35
Wet gas corrosion detection and control on mature asset
▪ Corrosion immediately detected by
Permasense system and validated
0.25 mm 10 mils
Emerson Confidential 39
Thank You!
Emerson Automation Solutions