Corrosion Monitoring System

YESTERDAY’S EXPERIENCE…YESTERDAY’S EXPERIENCE…TODAY’S TECHNOLOGYTODAY’S TECHNOLOGY

Today's Outline• Who is TXINS• Corrosion Market Drivers • General Corrosion• Corrosion & Corrosion-Assisted Cracking• Hydrogen Damage• Corrosion Inhibitors• How TXINS’s Monitor Works• Overview of the TXINS System • Applications• Installation• Data Acquisition & Reporting• Benefits, Limitations & Costs• Common Questions Asked

Who is TXINS?

TXINS :• Corrosion Monitors

• NACE Inspectons

• Industrial Coating Specifications

TXINS is a group of individuals dedicated to the Corrosion Protection Industry with well over 100 years of experience. TXINS takes years of experience coupled with today’s technology and produces accurate, real-time, cost savings for their clients.

What’s Driving the Market Approach to Corrosion Monitoring?

• Corrosion expenditures increasing• Major drivers:

– Aging infrastructure– Higher pressures and temperatures– Higher concentrations of acid gases (e.g., CO2, H2S, Cl-)

– Environmental costs associated with leaks or spills and lost production & commodity

What’s Driving the Market Approach to Corrosion Monitoring?

(cont.)

• Drilling in environmentally sensitive areas under stringent regulations & environmental impact

legislation.

• Integrity management programs costs $2.8 – $4.6 billion annually, about 10 – 15% of company’s maintenance expenditures.

Internal Corrosion is #1 Issue for Production Pipelines

12%

5%

3%

5%

2%3%

3% 2%2%5%

AEUB Statistics 2007 Leaks and Ruptures Only

Internal Corrosion

External Corrosion

Damage By Others

Weld

Construction Damage

Over Pressure

Pipe

Joint

Earth Movement

Value/Fitting

Other

Total # of Releases 12191, Pipeline Releases by Cause for all years combined

57.7%

What’s Driving the Market to Change its Approach to Corrosion Monitoring?

• Current corrosion detection methods employed are reactive– High-resolution “smart pigging”, measures wall loss,

“REACTIVE”– Hydrostatic testing, integrity of the pipe wall “PRO-ACTIVE”– Direct assessments, visual inspection, “REACTIVE”– Corrosion Coupons, weight loss, “REACTIVE”– FSM-IT inspection, again wall loss, “REACTIVE”– Liquid and Gas sampling, “PRO-ACTIVE, but limited to sampling

areas is an intrusive technology”– TXINS Monitoring, “PRO-ACTIVE”, monitors the change in the

production of hydrogen directly proportional to the corrosion rate.

Corrosion Monitor ComparisonFeature Coupons ER Probes LPR

Electro-Chemical

Noise

Ultrasonic Scan

FSM-ITTXINS

Monitoring System

Data ReadCorrosion over time

Electrical signal

Polarization resistance

Fluctuation in

current and

voltage noise

Wall thickness

Wall lossHydrogen production

Detects Corrosion Yes Yes Yes Yes No No Yes

Multi-phase Corrosion Monitoring

No No No No No No Yes

Detects Pits or Wall Loss

No No No No Yes Yes No

Inhibitor Monitoring No No Yes No No No Yes

Proactive or Reactive ReactiveProactive with

real-time communication

Proactive with real-time

communicationReactive Reactive Proactive

Intrusive Yes Yes Yes Yes No No No

Shut Down to Install Yes Yes Yes YesNo, except for

safety reasons

No, except for safety

reasonsNo

Retrieval LimitationShut Down /

pressureShut Down /

pressureShut Down /

pressureShut Down / pressure

None None None

Can be Used in High Temperature Environments

Limited Limited Limited Limited Limited Yes

Yes (320F/ 160C)

Or weld attachment

Can be Used in High Pressure Environments

Limited Limited Limited Limited Yes Yes Yes

Corrosion Monitor Comparison

Feature Coupons ER Probes LPRElectro-

Chemical Noise

Ultrasonic Scan

FSM-ITTXINS

Monitoring System

Service Environments

All AllConductive

AqueousConductive

AqueousAll All

All except high O2 environments

Presence of Electrolyte

No No Yes Yes No No No

Area of Coverage Point Point Point Point Point/Section Point/Section Section

Pigging Compatible No No No No Yes Yes Yes

Continuous Monitoring

No Yes Yes Yes No Yes Yes

Satellite Communication

No No No No No Yes Yes

Cost to Production from Shutdowns

High High High High Minimal Minimal None

Cost of Equipment Low Medium Medium High High High Medium

Labor Cost to Install Low Medium Medium Medium High High Medium

Labor Cost to Repeat High High High High High Low Low

General Corrosion

• This term is reserved for straightforward dissolution of a metal in corrosive water

• Example: dissolution of steel in HCl. Simple systems like this serve to demonstrate the electrochemical basis of corrosion reactions, e.g.:

anodic reaction: Fe ----> Fe++ + 2 e- (e = electron)

cathodic reaction: 2 H+ + 2 e- ----> H2 (hydrogen gas)

Corrosion and Corrosion-Assisted Cracking

• Depending on the reservoir composition, – carbon dioxide (CO2)– hydrogen sulfide (H2S), or a combination of both

can be present in hydrocarbons. • The terms "sweet" and "sour" are used in the oil and

gas industry to identify hydrocarbons that contain CO2 and H2S, respectively.

Corrosion and Corrosion-Assisted Cracking

• In the oil and gas industry, water is the catalyst for corrosion. When water is combined with CO2 or H2S the environments form the following reactions:

• • H2CO3 Reaction:

Fe+H2CO3->FeCO3+H2

• H2S Reaction:Fe+H2S+H2O->FeS+2H

• Or combination if both gases are present

Hydrogen Damage

• Hydrogen may enter a metal surface by the cathodic reduction of hydrogen or water:

• 2H+ + 2e- → 2H Absorbed (acidic waters)

2H2O + 2e- → 2H Absorbed + 2OH- (neutral waters)

• Normally, the absorbed hydrogen at the surface recombines to form hydrogen gas: • 2H Absorbed → H2 • Sulfide (S2-), prevents Hydrogen gas from forming.

Hydrogen Damage

Hydrogen Induced Cracking (HCI), or Blisters.

H H

H2Outside

Metal Surface

Inside

Metal Surface

Corrosive Environment

Hydrogen Damage

• Hydrogen may enter a metal surface by the cathodic reduction of hydrogen or water:

• 2H+ + 2e- → 2H absorbed (acidic waters)

2H2O + 2e- → 2H absorbed + 2OH- (neutral waters)

• Normally, the absorbed hydrogen at the surface recombines to form hydrogen gas: • 2HAbsorbed → H2 • Sulfide (S2-), prevents Hydrogen gas from forming.

Corrosion Inhibitors

?

d

How TXINS’s Monitor Works

Anodic Area Cathode AreaCathode AreaPipe

Wall

OH-

Fe ++ H 0

Fe(OH)2

e-

H 0

H 0 H 0H 0

H 0

H 0

H 0

H 0

H 0

H 0

H 0

Fe ++ Fe ++OH-OH-

H 0

H 0

H 0H 0

e-e-

e- e-

H2 H2

H2

TXINS Monitoring Systems Vessel - Cap under vacuum

Satellite Monitoring equipment, above ground level

Liquid Epoxy

Adhesive

Internal gas/liquid

Environment

External Pipe wall

Inhibitor film

Permeation Rates of H0 VS Carbon Steel Thickness

Table of Corrosion Scenarios Hydrogen Permeability of Steels

ATOMIC HYDROGEN FROM CORROSION

Non Intrusive Hydrogen monitoring

Cap

TXINS’s

T-1 or T-2

Monitor

Remote

Communications

Via Satellite

TXINS T-1 or T-2 System

Applications

• Pipelines (Natural Gas)• Pipelines (Condensate)• Treaters• Vessels• Amine Towers• Refinery

• Pipelines (Sour)• Pipeline (Sweet)• Gas Plants• Water Disposal• Petrochemical• Water Floods• Closed or Sealed Rolling Stock (rail cars or tanker

trucks)

Any metal substrate where hydrogen is being produced as a result of the corrosion process.

ApplicationsGas and Oil Production (H2S)

• Oil/Gas Gathering and Transmission Lines

• Oil/Gas Well Heads

• Sour Water Flood Lines

• Underground Gas Storage Facilities

ApplicationsGas-Oil Separation Plants and Gas

Plants (H2S)• Amine Units – Inlets,

Outlets, transfer lines• Contactors• Absorbers• Flash Drums• Wash Columns and

Drums• Blow down Drums• Flare Lines• Sour Water Strippers

• Sour Gas Gathering Lines

• Fractionators• Catalytic Cracker –

overhead recovery system

• Hot Wells• High and Low

pressure sour gas separators

ApplicationsRefinery HF Alkylation Units

• Acid Settler Tanks• Accumulators• Condensors• Depropanisers• Transfer Lines• Recontactors

Installation of the Equipment

• Site preparation – hand tool only to white metal

• Bonding the vessel to the pipe - Liquid epoxy

• Mechanically clamp the vessel to the pipe

• Mount monitoring equipment to a pole above ground or to secured area on the rolling stock

Reporting

• Graphical representation of corrosive activity

• Programming alarms can be set by Client

• All client information is password protected for their use only

Graph Showing 2 Corrosion Events

ABC Co.

1st Event

2nd Event

Customer #2FIGURE 3 - Pressure Readings from 7/16/07 to 9/24/07

-80

-70

-60

-50

-40

-30

-20

-10

0

7/1

7/2

007

7/1

8/2

007

7/1

9/2

007

7/2

0/2

007

7/2

1/2

007

7/2

2/2

007

7/2

3/2

007

7/2

4/2

007

7/2

5/2

007

7/2

6/2

007

7/2

7/2

007

7/2

8/2

007

7/2

9/2

007

7/3

0/2

007

7/3

1/2

007

8/1

/2007

8/2

/2007

8/3

/2007

8/4

/2007

8/5

/2007

8/7

/2007

8/1

6/2

007

8/1

7/2

007

8/1

8/2

007

8/1

9/2

007

8/2

0/2

007

8/2

1/2

007

8/2

2/2

007

8/2

3/2

007

8/2

4/2

007

8/2

5/2

007

8/2

6/2

007

8/2

7/2

007

8/2

8/2

007

8/2

9/2

007

8/3

0/2

007

8/3

1/2

007

9/1

/2007

9/2

/2007

9/3

/2007

9/4

/2007

9/5

/2007

9/5

/2007

9/5

/2007

9/6

/2007

9/7

/2007

9/8

/2007

9/9

/2007

9/1

0/2

007

9/1

1/2

007

9/1

2/2

007

9/1

3/2

007

9/1

4/2

007

9/1

5/2

007

9/1

6/2

007

9/1

7/2

007

9/1

8/2

007

9/1

9/2

007

9/2

0/2

007

9/2

1/2

007

9/2

2/2

007

9/2

3/2

007

9/2

4/2

007

Daily Readings

Pre

ssu

re

Re-evacuateRe-evacuate

Re-evacuate

Re-evacuate

Re-evacuate

Re-evacuate

Customer #2

TABLE 3 - Average Vacuum Loss Over Time

0

5

10

15

20

25

July 23 - 29 July 30 - Aug 5 Aug 16 - 22 Aug 24 - 28 Aug 29 - Sept 5 Sept 6 - 18 Sept 19 - 21 Sept 22 - 24

Aver

age C

han

ge

in P

ressu

re

Benefits

• Real time data• Records • Non-intrusive • Low maintenance• Remote capability • Coordinates corrosion programs• Cost effective

Benefits (cont.)

• No down time• Works in Conjunction with other Technologies• Early Corrosion Detection• High Risk Remote Areas Can be Monitored• Low Installation and Operating Costs• High Temperature Installations (200˚C) “Can be placed on higher temperature if welded”

Limitations of the Technology

• No correlation of TXINS data to intrusive probes or corrosion coupons

• Does not work in fully oxygenated water systems or ponds

• Each system has to be looked at individually, no comparison

Costs

• Standard Satellite Unit costs will vary dependent on how many transducers are included

• Remote Satellite data collection and download of data at competitive rates $75-100/month/unit

• Remote Cellular data collection and download of data at competitive rates

• Installation costs will vary as a result of location and number of units to be installed

Commonly Asked Questions and Answers

Q1: Does your Hydrogen Vessel work in Sweet and Sour Gas Systems?

A1: Yes

Commonly Asked Questions and Answers

Q2: Does the internal process pressure affect the hydrogen flux process?

A2: No

Q3: Does temperature influence the monitor’s accuracy?

A3: No and yes

Commonly Asked Question and Answers

Q4: Can the TXINS monitor environments containing bacterial corrosion or iron sulfide deposits?

A4: Yes

Q5: Does the formation of Hydrogen polarization film caused by cathodic protection on the external of the pipe affect the TXINS monitor?

A5: No

Commonly Asked Questions and Answers

Q6: Is the TXINS monitoring system capable of monitoring internal environments that have been internally coated?

A6: Yes

Q7: Where do you typically install the TXINS caps?

A7: Each application will be different

Commonly Asked Questions and Answers

Q8: Can the TXINS monitor help in evaluating the effectiveness of my corrosion inhibitors?

A8: Yes

Q9: Can the results of the TXINS monitor give me a metal loss per year (“MPY”) value? A9: Yes and No

Commonly Asked Questions and Answers

Q10: Will the TXINS monitor work in all my corrosive environments?

A10: No

Q11: Will the TXINS monitor work in a high ph environment?

A11: Yes

Conclusion

• TXINS Monitor is:– Non-intrusive– Pro-active corrosion monitor– Cost effective – Remote communication and installations– TXINS gives the flexibility required to meet all

our customers, corrosion monitoring needs.

Thank you for your time. If you require any further information,

please contact:

Corrosion MonitorsCorrosion Monitors USA/ Intl.-877.378.2377

Canada- 403.250.3382Email- khavran@txins1.com