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Cost Efficient

Corrosion and

Erosion Monitoring

for Pipeline Integrity

INTSOK Subsea 2015: U.S SPS & SURF Workshop

Trond OlsenPresident, ClampOn , Inc.

From the start...

WE BUILT A FLOW RIG – BUT THE PLUMBER WANTED 500 USD,

…AND WE DID NOT HAVE THE 500!!!

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

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.

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

If you have issues like this …

… you could be facing

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

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 …

Conventional manual gauge

Limited spot

coverage

Guided wave transducer rings

Full volume coverage

Why guided waves

• 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

• 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

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

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

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25

30

100mm

0

5

10

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25

30

100mm

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

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

CEM with Bend Tomography

0 1 2 3 4

Wall loss [% wt]

Available ultimo 2015 – topside and subsea

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

CEM

Field examples

FPSO Skarv Norwegian Sea

Corrosion-Erosion monitoring

Particle monitoring Vibration monitoring

Topside CEM at BP Skarv FPSO

Åsgard/Mikkel/Midgard Compression

Siakap-NorthMalaysia

Siakap-North

Pre-installed CEM

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

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.

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

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

CEM

Proving the technology

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

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

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

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2

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4

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6

7

8

9

10

11

Defect #2R

esu

lt 2

D-v

iew

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

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

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

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3

4

5

6

7

8

9

10

11

Defect #5R

esu

lt 2

D-v

iew

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

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

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

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

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

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8

9

10

11

Defect #11R

esu

lt 2

D-v

iew

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

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8

9

10

11

Defect #12R

esu

lt 2

D-v

iew