Tittel Cost Efficient Corrosion and Erosion Monitoring for Pipeline Integrity av Navn INTSOK Subsea 215: U.S SPS & SURF Workshop Trond Olsen President, ClampOn, Inc.
From the start... WE BUILT A FLOW RIG BUT THE PLUMBER WANTED 5 USD, AND WE DID NOT HAVE THE 5!!!
into today 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
ClampOn some key figures Start-up in 1994, Houston in 1997 Employees 115 Bergen, 15 Houston More than 15. sensors delivered More than 2 subsea sensors delivered Turnover 214 approx. $35 million. Represented in 3+ countries We travel 3+ days/year Deliveries to 38 countries in 212 Large part of sales to a mix of about 4 companies ClampOn supplies products and services world wide where there is oil and gas we are present!
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 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 Institute of Marine Research 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 Paradigm shift From random inspection to continuous monitoring License to operate demonstrating safe operations
What we bring to the table CEM Monitoring based on GWT w/tomography Non-intrusive permanently installed corrosion/erosion monitoring technology providing a cost-efficient solution
Why guided waves Conventional manual gauge Limited spot coverage Guided wave transducer rings Full volume coverage
Transducers can be mounted on the outside of coating <1mm /.4 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 /.4 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
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 2 x WT
Benefit of modes wrapping around the pipe Modes up to 2nd order Modes up to 1st order Direct wave paths only 1mm 3 25 1mm 3 25 1mm 3 25 2 2 2 15 15 15 1 1 1 5 5 5 Nominal max depth 2.21 mm Reconst. max depth 2.24 mm Error (% wt).39% Nominal max depth 2.21 mm Reconst. max depth 2.2 mm Error (% wt) -2.59% Nominal max depth 2.21 mm Reconst. max depth 1.51 mm Error (% wt) -9.51%
Estimated max. depth (mm) Comparison with coarse calliper measurements 1 9 8 7 Manual gage CorrPrint Laser scan min point -.88mm 6 5 4 3 2 1 1 2 3 4 5 6 7 8 9 1 11 12 Defect #
Subsea CEM configurations Pre Installed - Green field ROV Installed - Brown field Fully interfaced Internal data storage Battery or SCM powered power Consumption Wireless Communication - 3 adifferent models - CEM for ROV installation - CEM under insulation/coating - CEM w/mechanical cover
CEM with Bend Tomography Available ultimo 215 topside and subsea Wall loss [% wt] 1 2 3 4
CEM provide Continous monitoring for life of field High resolution 3D tomography of pipe condition Sensitivity 1% of wall thickness Low power consumption SCS or battery power SCS communication or local data 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-North Malaysia Siakap-North
Pre-installed CEM
Data Communication via Wave Glider Surfboard The Corrosion-Erosion Monitoring System System in the field - SubseaBrownfield retrofit for GoM project
Onshore Application Examples Straight pipes Bends Up to sixteen transducers mounted on two clamping bands over the selected area. 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 (1 mm) Pipe wall thickness (WT): 2 mm to 35 mm (,8 to 1,38 ) Distance between transducers:.15 m 2 m (78 ) typical Temperature : -4 to 18 C (-4 to 356 F ) Frequency range: 3 to 3 khz Sensitivity: (smallest change better than 1% of the pipe wall that can be reliably detected) thickness typical.1% Repeatability:.4% Power consumption: Avg 6 Watt - Max 1 Watt Sleep Mode:,1mA Battery Pack: 5 years with data point weekly Sensor electronics: DSP 66-MIPS, A/D con. 24bit, 25-Years Installation: Vertical & Horizontal Water depth: 3 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 3 m, 4 core cable (.75mm 2 ) 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: 13 o C (266 o F) -Hyperlast etc. Pipe material All metal pipes Calibration Once, on installation Operation life: 22 hours
CEM Proving the technology
Tomography Results w/edm Defect #1 EDM = Electrical Discharge Machining A copper electrode was machined to pipe surface shape and we eroded out in 12 different steps with increasing steps of 2um, 4um etc steps Defect #12
Result 2D-view Defect #1 Axial position [mm] 5 45 4 35 3 25 2 15 Maximum Corrosion Depth.16 mm 11 1 9 8 7 6 5 4 3 Wall Thickness Loss [%] 1 5 2 1 1 2 3 4 5 6 Circumferential position [mm]
Result 2D-view Defect #2 Axial position [mm] 5 45 4 35 3 25 2 15 Maximum Corrosion Depth.49 mm 11 1 9 8 7 6 5 4 3 Wall Thickness Loss [%] 1 5 2 1 1 2 3 4 5 6 Circumferential position [mm]
Result 2D-view Defect #3 Axial position [mm] 5 45 4 35 3 25 2 15 Maximum Corrosion Depth.14 mm 11 1 9 8 7 6 5 4 3 Wall Thickness Loss [%] 1 5 2 1 1 2 3 4 5 6 Circumferential position [mm]
Result 2D-view Defect #4 Axial position [mm] 5 45 4 35 3 25 2 15 Maximum Corrosion Depth.14 mm 11 1 9 8 7 6 5 4 3 Wall Thickness Loss [%] 1 5 2 1 1 2 3 4 5 6 Circumferential position [mm]
Result 2D-view Defect #5 Axial position [mm] 5 45 4 35 3 25 2 15 Maximum Corrosion Depth.17 mm 11 1 9 8 7 6 5 4 3 Wall Thickness Loss [%] 1 5 2 1 1 2 3 4 5 6 Circumferential position [mm]
Result 2D-view Defect #7 Axial position [mm] 5 45 4 35 3 25 2 15 Maximum Corrosion Depth.41 mm 11 1 9 8 7 6 5 4 3 Wall Thickness Loss [%] 1 5 2 1 1 2 3 4 5 6 Circumferential position [mm]
Result 2D-view Defect #8 Axial position [mm] 5 45 4 35 3 25 2 15 Maximum Corrosion Depth.57 mm 11 1 9 8 7 6 5 4 3 Wall Thickness Loss [%] 1 5 2 1 1 2 3 4 5 6 Circumferential position [mm]
Result 2D-view Defect #9 Axial position [mm] 5 45 4 35 3 25 2 15 Maximum Corrosion Depth.67 mm 11 1 9 8 7 6 5 4 3 Wall Thickness Loss [%] 1 5 2 1 1 2 3 4 5 6 Circumferential position [mm]
Result 2D-view Defect #1 Axial position [mm] 5 45 4 35 3 25 2 15 Maximum Corrosion Depth.72 mm 11 1 9 8 7 6 5 4 3 Wall Thickness Loss [%] 1 5 2 1 1 2 3 4 5 6 Circumferential position [mm]
Result 2D-view Defect #11 Axial position [mm] 5 45 4 35 3 25 2 15 Maximum Corrosion Depth.86 mm 11 1 9 8 7 6 5 4 3 Wall Thickness Loss [%] 1 5 2 1 1 2 3 4 5 6 Circumferential position [mm]
Result 2D-view Defect #12 Axial position [mm] 5 45 4 35 3 25 2 15 Maximum Corrosion Depth.95 mm 11 1 9 8 7 6 5 4 3 Wall Thickness Loss [%] 1 5 2 1 1 2 3 4 5 6 Circumferential position [mm]