High Resolution Corrosion/Erosion Monitoring

High Resolution Corrosion/Erosion Monitoring

Rohrback Cosasco Systems, Inc.

Project Field: Major Offshore Development Five remote wellhead platforms, a floating production, storage

and offloading (FPSO) vessel, and riser utility platform (RUP) Production: 190,000 bpd of oil and 510,000 bpd total fluids

Background

Problem:Corrosion and Erosion caused by corrosive factors (i.e chemical) and erosive factors (i.e. sand) in oil and produced liquids

Solution:Continuous, on-line corrosion/erosion monitoring system including transmitters, probes, coupons, access & retrieval equipment, communication equipment, corrosion server and software

System Configuration

Online System consists of 142 monitoring points– A combination of 95 Quicksand™ and Microcor® Transmitters with corrosion probes/biological probes– 47 Coupons (weight-loss) monitoring points, including coupon holders

Cosasco® Access System containing RSL Retrievers, access fitting assemblies, and service valve kits.

ICMS3™, data retrieval and management system, corrosion server and software

With Quicksand Transmitters in exactly the same configuration as a Microcor Transmitter, a comprehensive corrosion/erosion monitoring solution is established.

Advantages of Continuous, On-line Corrosion/Erosion System

High resolution monitoring Rapid response Immediate alerts to process upsets Real-time data A single cable can connect up to 32 transmitters with

a single cable run Integrated corrosion/erosion system measures rates

from both corrosive and erosive factors Delivery of information enables corrosion/erosion

rates to be integrated and used as process parameters

Sand Erosion

The probability of sand erosion has increased with advances in horizontal well drilling

Velocities can exceed over 100 ft/sec causing an increase in the occurrence of sand erosion

Sand at high velocities produces a “sandpaper” effect, scraping away layers of protective coatings and metal

Elbows and bends are more vulnerable Former methods of erosion monitoring (i.e.

coupons, ultrasonics) were inadequate because of the lack of distinction between erosion and erosion-corrosion

Quicksand™

High sensitivity transmitters and sand probes for real time monitoring

Seamlessly integrates with Microcor

online and data-logging system

Two probe types Cylindrical – suitable for severe flow or

high temperature applications Angled – exposed to the flow at a 45°

angle

S4500 Probe Rugged, all welded cylindrical element Specially designed element support shield,

suitable for severe flow or high temperature applications

S4700 Probe 45° element simulates change in

direction in pipe Maximum temperature is 400°F Recommended for flow rates less

than 25 ft/sec

Quicksand™ offers real time detection of sand erosion

Detection Time Vs. Erosion Rate

0.0

2.0

4.0

6.0

8.0

10.0

12.0

14.0

16.0

18.0

20.0

22.0

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26.0

28.0

0 20 40 60 80 100 120 140 160 180 200

Erosion Rate (MPY)

De

tec

tio

n T

ime

(M

inu

tes

)

EFFECTIVE SENSING ELEMENT THICKNESS = 10 MILS

Erosion Rate (MPY)

Det

ecti

on

Tim

e (M

inu

tes)

Detection Time Vs. Erosion Rate

-0.20

-0.15

-0.10

-0.05

0.00

1 MonSep 2003

8 Mon 15 Mon 22 Mon 1 Wed

Metal Loss

Mark 1:-0.188 Mark 2:-0.018 Slope: 6.28 mpy

mils

-0.188 9/17/2003 1:35:17 PM

Actual Data Showing a Corrosion Upset

How the Quicksand System Works

A sand probe is positioned middle-of-the-line

where velocity of flowing sand is greatest

Summary RCS provides a comprehensive erosion/corrosion

monitoring system using the latest technology

Advantages of Erosion/Corrosion Monitoring System Real time data and immediate alerts to process upsets so that

proper action can be taken to prevent further damage

Measures rates from both erosive and corrosive factors

Rugged design allows for use in severe flow and high temperature environments

Rapid detection of low erosion/corrosion in systems with little or no corrosion allowance

Saves you money by saving you time