digitalisation of inspection for monitoring corrosion risk

Digitalisation of Inspection for Monitoring Corrosion Risk and Impact

NACE Webinar | 27th October, 2020

Dr Jake Davies – Global Product Director, Corrosion and Erosion (UK)Mr. George Varughese – Business Development Manager | MEA (Dubai)Mr. Mansour Aref – Strategic Account Leader | Saudi Aramco (Saudi Arabia)

Topics for Today’s Webinar (75 min)

2

Dr. Jake Davies55min

Destruction from the Inside: The Problem with Corrosion

Understanding Corrosion Risk and Impact on Your Plant – The Missing Pieces of the Puzzle

Digital Transformation of Corrosion Monitoring

Non-Intrusive UT Thickness Monitoring Technology

Refining Case Study

Q&A

George Varughese10min Middle East & Africa Use Cases

Mansour Aref10min Emerson Local presence across Middle East and Africa


3






Refining Case Study

Q&A



Why Does Corrosion Happen and How is it Traditionally Handled?

4

Corrosion is Happening in Your Plant – Is it Understood?

CAUSED BY corrosive components in the process fluid (10s of different corrosion mechanisms!)

DEFINITION: The destruction of materials by chemical and/or electrochemical reaction with their environment

RESULTS IN metal loss from the inside

TYPICALLY CONTROLLED BY choice of metal (CAPEX) and addition of ‘corrosion inhibitor’ (OPEX) to the process fluid, Process parameters

UNDERSTOOD / VALIDATED WITH periodic manual inspection (online or during periodic shutdown), coupons, offline fluid samples

TRA

DIT

ION

AL

APP

RO

AC

HES

Process Industry Pressures Lead to Variable Corrosion Risk and Unknown Impact on the Health of Your Plant – Leading to Major Incidents or Poor Profitability

Variable feedstock quality and “opportunity” crudes

Varying Process Conditions

Longer runs between maintenance shutdowns

Tighter H&S regulations

Tighter CAPEX budgets

Shortage of experienced personnel

Leaks/loss of containment

Conservative operations –poor profitability

Variable (invisible) Corrosion Risk in the Plant

Variable (unknown) Impact on the Asset Health

6

Poll Question 1

Non- intrusiveIntrusive

Your Corrosion Challenges Require A Complete Sensing Portfolio

7Highest sensitivity, quickest response Actual Asset metal thickness and loss

Coupons

• Cannot be instrumented for realtime monitoring

Electrical resistance (ER)

• Any process• After process

changes• Phase changes• Chemical

injection

MONITOR RISK MONITOR IMPACT

Ultrasonic (UT)

• Uniform corrosion impacts

• Permanenet inspection

• Main integrity verification tool

Field Signature Method (FSM)

• Critical locations• Localized attacks• High velocity,

turbulence

Electrochemical (LPR, Galvanic)

• Conductive media(water systems)

• After potential process changes

• In contact with Process Fluid:• Quick response time• Detect process changes• Chemical treatment verification

• Flexible, highly distributable, wall thickness monitoring

• Local area monitoring

• Localized corrosion detection

Adopt innovative sensing technologies that are easy and cost effective to install and maintain

Implement a set of architectures that ensures securityof operational data, and allows secure interaction with IT and cloud applications

Deploy scalable analytics applications to deliver actionable insights and automate manual workflows

Deploy newmonitoring solutions, consulting, andimplementation services ensure operational outcomes

Data AnalyticsEdge, On-Premise, and Cloud

Connectivity Services

Measurements Alone is not Enough: Digital Transformation Gets the Data to the Right People to Make Better Decisions

Continuous, Real Time Corrosion Risk and Asset Health Data Directly to Desk

Easily Installed, Online. Typical Size System Installed in 1- 4 Days

Up to 100 sensors per

gateway

ActionAnalyticsConnectivityData Generation

10Emerson Confidential

Data

AnalyticsEdge, On-Premise,

and Cloud

Connectivity

Services

The Plantweb Digital Ecosystem: Enabling Top Quartile Performance With the Industry’s Broadest Integrated Portfolio of Digital Transformation Solutions

DIGITAL TRANSFORMATION

DIGITAL FOUNDATION

Production Optimization

Operator Performance

Control & Safety Systems

SCADA

Project, Lifecycle, and Educational

Services

ServiceModels

Connected ServicesAsset Expertise and Actionable Insights

Software-as-a-ServiceCloud-Deployed Applications

v4 © 2019

Consulting & Implementation Digital

Strategy & Cybersecurity

Shutdowns, Turnarounds,

& Outages

Upskilling & Change

Management

Industry Expertise

Platforms & Software

Asset Performance PlatformConnect, Analyze, and Collaborate

Device & Machinery DiagnosticsCondition-Based Analytics

Digital TwinPlant & Asset Optimization

Workforce EffectivenessDigitally Enabled People

Asset Health AppsPre-Configured Analytics

PervasiveSensing

Process Equipment People & AssetsEnvironment

Secure Connectivity

CybersecurityEmbedded at All Levels

Secure First MileData Pathways to External Applications and Experts

Data IntegrationArchitectures & Network Design

Intelligent Field Devices

Measurement Instrumentation

Valves & Actuators

MotionControl

Wellhead DX – Sand & Erosion Monitoring – Online Technologies


Monitoring sand production, erosion risk and impact allows Oil & Gas operators to set the optimum choke settings, generating millions of dollars in additional production

Thickness Monitoring• Data: Wall thickness > Quantify Impact• Quantity = 1 to 3 units per Xmas-tree• Location: Closest bend (apex) to Xmas-

tree• Non-intrusive + Battery + Wireless

Sand Production Monitoring• Data: Sand Rate > Quantify Risk • Quantity: 1 per Xmas-tree• Location: After closest bend to Xmas-tree• Non-intrusive + Wired

Fluid Erosivity Monitoring• Data: Fluid Erosivity > Quantify Risk• Quantity: 1 per Xmas-tree• Location: Straight section turbulent flow• Intrusive + Wireless / Wired

Oil & Gas Flow Rate

WT Technology – Unique Ultra-High Temperature Thickness Monitoring

• Unique and patented waveguide transducer– Semi-Permanent installation

• Install anywhere– Temperatures up to 600 C (1100°F), e.g. refinery crude

unit pipework– Intrinsically safe (Class1 Div1 / Zone 0)– Any metal

• Data to desk with no cabling– WirelessHART– 9 year battery life– Remotely adjustable data acquisition rate – Automated temperature and material compensation– Unique and patented processing to eliminate internal

surface roughness effects and detect onset of corrosion activity

ET Technology – Magnetic Mounting, Measure Through Coatings

1st backwall reflection

2nd backwall reflection

Pipe wall (up to 300 C)

External protective coating left in place

Typical recorded ET sensor waveform

EMAT excites ultrasound directly in the metal sample –direct contact is not

required

Subsequent backwall reflections

Time used for thickness

measurement

Magnetic mounting with secondary security strap

Huge Data Quality Enhancement Over Traditional Manual Inspection

• Rosemount Wireless Permasense: measurements every 12 hours within ±25 microns variation; catch onset of corrosion events within days

• Manual UT inspection: years between measurements with ±0.5mm variation; corrosion rate calculation not possible, corrosion events missed

Thickness Monitoring Data for Root Cause Analysis of Corrosion Events and Turnaround Scope and Timing Improvement

Root Cause Analysis Predictive Maintenance

toda

y

Class-Leading Data Visualisation and Analytics Software: Easy to See Where and When the Activity is Occurring

Best-in-Class Data Quality and Frequency

Sens

or lo

catio

n

Time

Return is Driven from Multiple Sources - Refinery Example

17

Business impact model based on a generic 250k bbl/day refinery, and average industry metrics

Monitoring Solution is Configured for Your Application, Leveraging the Best Tools for the Job

Start Small and Easily Expand to Other Applications

MaintenanceSafety Operations

Routine Turn-around

Availability / Utilization

Turn-aroundFrequency

Opportunity Crudes

Serious Incidents

Chemicals /Additives

200 KUSD

1,800kUSD 600

kUSD200

kUSD

3,600kUSD

1,600kUSD

4,100kUSD

Total Annual Margin Improvement

11,640kUSD

5% 3% 3% 10% 1% 0,25% 1%

Refinery Case Study - Crude Unit Overhead Corrosion

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Monitoring

CDU overhead system protected by chemical injection (filmer and neutralising amine)Severe corrosion in the overhead piping system caused leaksExpensive clamps had to be installed to secure operationRisk of damaging the 17 air cooled heat exchangers

Situation

29 Rosemount Wireless Permasense sensors installed to continuously observe the system. Permasense system validated high corrosion rates

120°C

Crude Tower

Overhead Drum

Amine Slipstream17 air cooled heat exchangers

43°C

Using DataTrials done to identify cause of corrosion – reduce flow rate, insulate piping, change filming amine foundationEffects could be immediately seen in dataChemical injection issue identified as the root cause and anime type changedCarry-over reduced, corrosion stopped, damage to ACHEs prevented

Refinery Case Study: Total Estimated Impact $4M Saved

Monitoring system later detected a ‘bad batch’ of crude which lead to tighter desalter controlRefinery expanded their monitoring capability, now using ~300 sensors installed across various process units 19

Maintenance

Controlled Risk: Safe operation without risk of leaks until next planned shutdown

Replacement optimised in time and cost, not compromising the TAR schedule• Costs for unplanned vs. planned and well prepared replacement of piping estimated

at $700k saved• Replacement of piping estimated at $3M avoided• Replacement of one air cooled heat exchanger estimated at approximately $200k

avoided

Long-Term

Unplanned shutdown and loss of profit margin prevented• Loss of profit margin in case of unplanned shutdown: 300k$/d; duration depending

on the necessary actions, min. 4 days. > $1M loss avoided.

Operations

Think Big, Start Small

Digitalisation of Corrosion Monitoring Elevates Performance

Summary

Use the data to better-operate your process plant, ensuring the asset is driven to its maximum capability

21

Corrosion is an ever-present threat to fixed equipment in many process industries

Corrosion risk, and therefore rate of metal loss, varies across the plant and over time

Periodic, rare, manual inspection is not frequent enough to understand asset health or track corrosion rate changes over time

Monitoring of both corrosion risk and corrosion impact on the asset health isessential – using inline probes and non-intrusive thickness monitoring

Leverage Emerson’s WirelessHART® capability to deliver best-in-class data from the sensors in the plant directly to your desk


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Refining Case Study

Question & Answer




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Refining Case Study

Q&A



Proven Results

Predictive AnalyticsProvide actionable information to Inspection engineer

On-line Non-Intrusive corrosion Monitoring on Reactor pipesDigitalizing Inspection rounds with IIoT sensor and Analytics

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Solution

• Enhanced monitoring by adding installing Non intrusive wireless operated Permasense sensors at the monitoring location.

• An operational decision-making tool, to improve plant availability and optimise production

Photo to represent Emerson product...

Region: Middle East Industry: Oil & Gas

CAPEX Optimization Eliminate access fittings, scaffoldings, cabling etc

Reduce risk of containment lossby continuous data monitoring

Proven Result: Share Me

Challenges• Unpredictable and Extremely high corrosion on pipes leading to ruptures and loss of

containment. • Frequent changes of processing liquid quality leading to unpredictive corrosion rates.• Lack of visibility of Asset condition leading to inefficient shutdowns and turnarounds.

Key Emerson Technology• Corrosion immediately detected by

Permasense system and validated

• Corrected inhibitor system and stabilised wall loss based on Permasense data

• Efficient planning of shut down for repair/replacement achieved, maximizing production period.

• Non-Intrusive nature of sensors ensured smooth installation without disrupting production.

Proven Results

Production Optimization Improve confidence on asset by monitoring risk

Implementing Sand Management Strategy in Major Brownfield ProjectAcoustic Non-Intrusive sensor drives Transformation from MSFR to ASR

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Solution• A complete sand monitoring strategy supported by innovative Non-

intrusive acoustic technology and sand monitoring software.• Collaboration between End User Production team, and Emerson

to build and execute Project Specifications for implementation. • Strong installed base of Emerson technology facilitated to drive

confidence in Emerson solutions


Region: Africa| Industry: Oil & Gas

CAPEX Optimization Non-Intrusive Solutions

Eliminate risk of Sand Erosion by real-time monitoring


Challenges• Increased Sand production from offshore wells leading to well shutdowns and workovers. • Fast Track project to recover production loss, as well as prevent potential reservoir damage.• End User corporate directive to change production philosophy related to Sand from MSFR to

ASR.

Key Emerson Technology• Acoustic Sensors for instantaneous

monitoring of sand production• Analytics for calculating sand rates

• Field Optimization of production rates according to allowable sand rates

• Non-Intrusive UT sensors for calculating Impact of sand erosion

Monitor Impact

Monitor Risk

Proven Results

Predictive Analyticsto support reduction in Inhibitor chemical cost

Bringing Asset Integrity visualization of Remote Pipelines to the DesktopFSM Technology Drives Digitization of Remote Assets

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Solution• FSM technology with Fieldwatch corrosion software• Area monitoring of buried sections of pipeline • Data connectivity utilizing existing asset infrastructure• Online visualization of Asset condition at office domain


Region: Middle East | Industry: Oil & Gas

CAPEX Optimization Utilize Wireless Infrastructure

Reduce risk of containment lossfor Underground Pipelines


Challenges• Increased water-cut from onshore wells leading to High corrosion and leaks. • Long distance buried pipelines in Remote locations • Asset integrity data depended on infrequent manual rounds of data collection from the fields.

Key Emerson Technology• Field Signature Monitoring utilizing WiMax,

FO and Fieldbus protocols to deliver data seamlessly to desktops.

• Optimized inhibitor programs based on field data

• Fieldwatch predictive Analytics for calculating corrosion rates and pipe retirement thickness


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Refining Case Study

Q&A



28

Poll Question 2


Emerson Automation SolutionsMiddle East & Africa

Headquarters in Dubai, United Arab Emirates

Diversified manufacturer and technology provider

Approximately 1,900 employees

MAJOR CUSTOMERSARAMCO,ADNOC,SABIC,SOC,ENOC

QP,PDO,SHELL,TOTAL,EXXON,BPSASOL,CHEVRON,NPDC,DOWSONANGOL,SONATRACH,KOC

PETROFAC,ENI,TECHNIP,LUKOIL


Middle East & Africa Presence

Headquartered in Dubai, we have an established presence

in Middle East & Africa with an extensive

network of direct sales offices and dedicated sales

representatives

Oman

Yemen

Lebanon

JordanEgypt

Tunisia

Ivory Coast

Ghana

Kenya

Madagascar

Mozambique

ZimbabweBotswana

NamibiaZambia


Collaboration towards Vision 2030 - Localization Success Stories

Control Valve & Instrumentation Manufacturing – Jubail

Control System & SCADA Manufacturing & Staging – Dammam

COMRES & Appleton Manufacturing – Dammam

Planned manufacturing expansion (50,000sqmplot) at SPARK towards meeting iktva Targets

King Salman Energy Park

Will bring together Emerson’s capabilities around Systems, Devices and Valves under one Roof

60% Saudization, Total Area – 2,650 SQM Manufacturing, Assembly, Testing & Service Valves, Pressure & Temperature Transmitters 3,500 Valves Produced for Sadara project

Production of Condensing Units AC Scroll Compressors Appleton Industrial LED Lighting Appleton Switch racks

• Total Area 1,132 SQM• Major Project Engineering, Design,

Manufacture and Execution• In Collaboration with Prince Sultan Fund for

Women’s Development

Committed toSaudi Arabia’s

Vision 2030


Emerson Automation SolutionsLagos and Port Harcourt, Nigeria

Manufacturing & Assembly• Control system cabinet building facility in Port Harcourt• Systems staging and FAT’s – 7,500m2• Metering skids and Flow Systems complete solutions including local

assembly• Spare Part Management

Lifecycle Services &Training• Training centers in Lagos & Port Harcourt• Instrumentation repair in Port Harcourt• Turnaround services• Full diagnostic capabilities• System support & maintenance• Long-term service agreements • 24 x 7 Global Response System• Site Surveys

Sales, Engineering & Execution• Sales Administration & Management• Proposals, Procurement & PM• 60+ employees in projects and services,

including 60% of local Nigerian engineers• Pre-Project Planning (Pre-FEED / FEED)• System Engineering, configuration and integration• Flow Engineering & Execution group• Valves and Instrumentation Sizing and selection • Technical Support• Local Representative Partner – AOS Orwell

Sales, Service and Assembly100 Employees

(Emerson and AOS)

Nigerian Content Certification

Lagos

Port Harcourt


Emerson Automation SolutionsJohannesburg, South Africa

Manufacturing & AssemblyFinal Control • Valve Operating System and Automated Valve package integration

(2,000 units/annum)• Valve and actuation final assembly and testing

• In-house customer FAT’s (functional, hydro & seat leakage)• In-house machining• Quick ship MRO AVP/VOS capability (same day)• Control systems Staging & FAT

Lifecycle Services & Training• Training facility• System Start up & Commissioning Services

• Turnaround services• Full diagnostic capabilities• Service and retrofit (Valve Operating System, Automated Valve

Packages & Multiport Flow Selector)• Instrumentation remote seal assembly, testing and repair• 24 x 7 Global Response System

Sales, Engineering & Execution• Sales Administration & Management

• Logistics Support

• Engineering capabilities

• Proposals, procurement and Project Management

• Application & Technical support

• Local Representative Partner – A&CS

Sales, Service and Manufacturing

Center40+ Employees

Thank You

[email protected]@[email protected]

digitalisation of inspection for monitoring corrosion risk

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