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Tittel
av Navn
Cost Efficient
Corrosion and
Erosion Monitoring
for Pipeline Integrity
INTSOK Subsea 2015: U.S SPS & SURF Workshop
Trond OlsenPresident, ClampOn , Inc.
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From the start...
WE BUILT A FLOW RIG – BUT THE PLUMBER WANTED 500 USD,
…AND WE DID NOT HAVE THE 500!!!
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Non-Intrusive Ultrasonic Intelligent Sensors
- Sand Monitoring- PIG Detection- Leak Monitoring- Vibration Monitoring- Well Collision Detection- Wall Thickness Monitoring- Corrosion-Erosion Monitoring
- Onshore, topside & Subsea- Service / Support
… into today
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ClampOn – some key figures• Represented in 30+ countries
• We travel 3000+ days/year
• Deliveries to 38 countries in 2012
• Large part of sales to a mix of about
40 companies
• ClampOn supplies products and
services world wide – where there is
oil and gas we are present!
• Start-up in 1994, Houston in 1997
• Employees 115 Bergen, 15 Houston
• More than 15.000 sensors delivered
• More than 2000 subsea sensors
delivered
• Turnover 2014 approx. $35 million.
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The ’Acoustic City’ Bergen
Statoil Christian
Michelsen
Research
(CMR)
Bergen
University
College
campus
Haukeland
University
Hospital
New R&D
park at
Marineholmen
University
of Bergen
Institute of
Marine
Research
Companies:
ClampOn
AADI (Xylem)
KTN
Halfwave
Naxys (GE)
Fluenta
AGR Pipetech
BTC Archer
Xsens
Octio
Kongsberg
Maritime
CGG Veritas
Roxar(Emerson)
Tracerco
METAS
CodaOctopus
Simrad/Simtech
Subsea
Wema
Major local users of acoustic technologies and products; Statoil, Schlumberger, Baker Hughes, Aker Solutions,
FMC Technologies, OneSubsea, DOF Subsea, Royal Norwegian Navy, Haukeland University Hospital
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If you have issues like this …
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… you could be facing
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Your challenge …• Difficult access assets
• Inaccessible sections of pipelines
• Unpiggable pipelines
• Estimation of corrosion/erosion rates for life
management
• Avoid shutting down production to inspect
From random inspection to continuous monitoring
Paradigm shift
License to operate demonstrating safe operations
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CEM Monitoring based on GWT w/tomography
Non-intrusive permanently installed corrosion/erosion monitoring technology providing a cost-efficient solution
What we bring to the table …
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Conventional manual gauge
Limited spot
coverage
Guided wave transducer rings
Full volume coverage
Why guided waves
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• Measures WT between the transducers in “line of sight”• Resolution/sensitivity better then 1% of WT• Signal is Robust and will not break down
• Transducers can be mounted on the outside of coating <1mm /0.04” thickness
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• Measures WT between the transducers in “line of sight”• Resolution/sensitivity better then 1% of WT• Signal is Robust and will not break down
• Transducers can be mounted on the outside of coating <1mm /0.04” thickness
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CEM Coverage Area w/GWT
5 signal paths per transducer –
direct, clockwise and counter clockwise helical and 2 turn helical
Max distance is 5 x OD - Min distance is 20 x WT
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Benefit of modes wrapping around the pipe
Modes up to 2nd order Modes up to 1st order Direct wave paths only
Nominal max depth 2.21 mm
Reconst. max depth 2.24 mm
Error (% wt) 0.39%
Nominal max depth 2.21 mm
Reconst. max depth 2.02 mm
Error (% wt) -2.59%
Nominal max depth 2.21 mm
Reconst. max depth 1.51 mm
Error (% wt) -9.51%
0
5
10
15
20
25
30
100mm
0
5
10
15
20
25
30
100mm
0
5
10
15
20
25
30
100mm
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Comparison with coarse calliper measurements
1 2 3 4 5 6 7 8 9 10 11 120
100
200
300
400
500
600
700
800
900
1000
Defect #
Estim
ate
d m
ax.
depth
(m
m) CorrPrint
Manual gage
Laser scan min
point -0.880mm
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Subsea CEM® configurations
- 3 adifferent models
- CEM® for ROV installation
- CEM® under insulation/coating
- CEM® w/mechanical cover
• Pre Installed - Green field
• ROV Installed - Brown field
• Fully interfaced
• Internal data storage
• Battery or SCM powered
power Consumption
• Wireless Communication
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CEM with Bend Tomography
0 1 2 3 4
Wall loss [% wt]
Available ultimo 2015 – topside and subsea
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CEM® provide
• Continous monitoring for lifeof field
• High resolution 3D tomography of pipe condition
• Sensitivity 1% of wall thickness
• Low power consumption
• SCS or battery power
• SCS communication or localdata storage
• Non-intrusive
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CEM
Field examples
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FPSO Skarv Norwegian Sea
Corrosion-Erosion monitoring
Particle monitoring Vibration monitoring
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Topside CEM at BP Skarv FPSO
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Åsgard/Mikkel/Midgard Compression
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Siakap-NorthMalaysia
Siakap-North
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Pre-installed CEM
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The Corrosion-Erosion Monitoring System
Data Communication via Wave Glider Surfboard
Syst
em in
th
e fi
eld
-S
ub
se
a Brownfield retrofit for GoM project
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Onshore Application Examples
Straight pipes
Up to sixteen transducers mounted on two clamping bands over the selected area.
Bends
Up to sixteen transducers mounted on separate sides of a bend, monitoring the wall thickness loss in the bend.
Reducers
Up to sixteen transducers mounted on selected locations on the reducer. Uneven thickness profile is not a problem.
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Subsea CEM® Technical data
Pipe outer diameter (OD): min 4” (100 mm) Pipe wall thickness (WT): 2 mm to 35 mm (0,08” to 1,38”) Distance between transducers: 0.15 m – 2 m (78”) typical Temperature : -40 to 180 °C (-40 to 356 °F ) Frequency range: 30 to 300 kHz
Sensitivity: (smallest change better than 1% of the pipe wall that can be reliably detected) thickness – typical 0.1%
Repeatability: 0.04%
Power consumption: Avg 6 Watt - Max 10 Watt Sleep Mode: 0,001mA Battery Pack: 5 years with data point weekly Sensor electronics: DSP 66-MIPS, A/D con. 24bit, 25-Years Installation: Vertical & Horizontal Water depth: 3000 Meters Test pressure: 345 BarA
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Operational Data
Operating mode: Active acoustic - Guided Lamb waves Number of transducers: Minimum 2, current 8 – by Q4 32 Transducer type: Electromagnetic Acoustic Transducers
CEMATs can be mounted without any acoustic couplant. Makes the system relocatable – not necessarily a permanent installation. Provides better thermal stability than standard piezoelectric transducers.
Maximum cable length 3000 m, 4 core cable (0.75mm2) Various wireless and battery powered solutions available.
Output data: ModBus, TCP/IP, RS485 Maximum number of sensors/electronic units
per communication line: 12 Maximum temperature for insulation: 130oC (266oF) -Hyperlast etc. Pipe material All metal pipes Calibration Once, on installation Operation life: 220 000 hours
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CEM
Proving the technology
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Defect #1
Defect #12
Tomography Results w/EDMEDM = Electrical Discharge Machining
A copper electrode was machined to pipe surface shape and we
eroded out in 12 different steps with increasing steps of 20um,
40um etc steps
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Circumferential position [mm]
Axia
l positio
n [
mm
]
Maximum Corrosion Depth 0.016 mm
0 100 200 300 400 500 6000
50
100
150
200
250
300
350
400
450
500
Wall
Thic
kness L
oss [
%]
0
1
2
3
4
5
6
7
8
9
10
11
Defect #1R
esu
lt 2
D-v
iew
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Circumferential position [mm]
Axia
l positio
n [
mm
]
Maximum Corrosion Depth 0.049 mm
0 100 200 300 400 500 6000
50
100
150
200
250
300
350
400
450
500
Wall
Thic
kness L
oss [
%]
0
1
2
3
4
5
6
7
8
9
10
11
Defect #2R
esu
lt 2
D-v
iew
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Circumferential position [mm]
Axia
l positio
n [
mm
]
Maximum Corrosion Depth 0.14 mm
0 100 200 300 400 500 6000
50
100
150
200
250
300
350
400
450
500
Wall
Thic
kness L
oss [
%]
0
1
2
3
4
5
6
7
8
9
10
11
Defect #3R
esu
lt 2
D-v
iew
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Circumferential position [mm]
Axia
l positio
n [
mm
]
Maximum Corrosion Depth 0.14 mm
0 100 200 300 400 500 6000
50
100
150
200
250
300
350
400
450
500
Wall
Thic
kness L
oss [
%]
0
1
2
3
4
5
6
7
8
9
10
11
Defect #4R
esu
lt 2
D-v
iew
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Circumferential position [mm]
Axia
l positio
n [
mm
]
Maximum Corrosion Depth 0.17 mm
0 100 200 300 400 500 6000
50
100
150
200
250
300
350
400
450
500
Wall
Thic
kness L
oss [
%]
0
1
2
3
4
5
6
7
8
9
10
11
Defect #5R
esu
lt 2
D-v
iew
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Circumferential position [mm]
Axia
l positio
n [
mm
]
Maximum Corrosion Depth 0.41 mm
0 100 200 300 400 500 6000
50
100
150
200
250
300
350
400
450
500
Wall
Thic
kness L
oss [
%]
0
1
2
3
4
5
6
7
8
9
10
11
Defect #7R
esu
lt 2
D-v
iew
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Circumferential position [mm]
Axia
l positio
n [
mm
]
Maximum Corrosion Depth 0.57 mm
0 100 200 300 400 500 6000
50
100
150
200
250
300
350
400
450
500
Wall
Thic
kness L
oss [
%]
0
1
2
3
4
5
6
7
8
9
10
11
Defect #8R
esu
lt 2
D-v
iew
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Circumferential position [mm]
Axia
l positio
n [
mm
]
Maximum Corrosion Depth 0.67 mm
0 100 200 300 400 500 6000
50
100
150
200
250
300
350
400
450
500
Wall
Thic
kness L
oss [
%]
0
1
2
3
4
5
6
7
8
9
10
11
Defect #9R
esu
lt 2
D-v
iew
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Circumferential position [mm]
Axia
l positio
n [
mm
]
Maximum Corrosion Depth 0.72 mm
0 100 200 300 400 500 6000
50
100
150
200
250
300
350
400
450
500
Wall
Thic
kness L
oss [
%]
0
1
2
3
4
5
6
7
8
9
10
11
Defect #10R
esu
lt 2
D-v
iew
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Circumferential position [mm]
Axia
l positio
n [
mm
]
Maximum Corrosion Depth 0.86 mm
0 100 200 300 400 500 6000
50
100
150
200
250
300
350
400
450
500
Wall
Thic
kness L
oss [
%]
0
1
2
3
4
5
6
7
8
9
10
11
Defect #11R
esu
lt 2
D-v
iew
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Circumferential position [mm]
Axia
l positio
n [
mm
]
Maximum Corrosion Depth 0.95 mm
0 100 200 300 400 500 6000
50
100
150
200
250
300
350
400
450
500
Wall
Thic
kness L
oss [
%]
0
1
2
3
4
5
6
7
8
9
10
11
Defect #12R
esu
lt 2
D-v
iew