Corrosion Under Insulation Monitoring using EMGR Technology
Corrosion Under Insulation Monitoring using EMGR Technology Dr Prafull Sharma, CorrosionRADAR Ltd www.corrosionradar.com
The Story of Rob, Bob and CUI CorrosionRADAR Ltd. 4
Problem H IDDEN C ORROSION Corrosion Under Insulation Oil & Gas Chemical Industry Renewable Energy LNG CorrosionRADAR Ltd. 5
Corrosion Under Insulation (CUI) A MONG THE BIGGEST ASSET INTEGRITY THREAT CUI is #1 asset integrity issue in O&G and Petrochemicals 60% of all pipeline failures are due to CUI 10% of the overall offshore platforms maintenance cost How CUI happens Water ingress Unpredictable location Suitable temperature into insulation CorrosionRADAR Ltd. 6
Inspection 4.0 – Mega Trend Inspection 1.0 Inspection 2.0 Inspection 3.0 Inspection 4.0 Manual observation, Visualisation, Automated, Statistics, RBI Leaks NDT instruments Analytics, Prediction Manual Automated Detection Prediction Reaction Prevention CorrosionRADAR Ltd. 7
Predictive Corrosion Management - Opportunity E NABLED BY IIOT AND P REDICTIVE ANALYTICS Sensors Knowledgebase FUTURE PRACTICE CURRENT PRACTICE Reactive Predictive Connectivity Analytics / ML H UMAN P ERIODIC C ONTINUOUS A UTOMATED JUDGEMENT + M ANUAL M ONITORING RISK PROFILING I NSPECTION GUESSED RISK R EACTIVE M AINTENANCE P REDICTIVE M AINTENANCE Minimal labour effort • Labour Intensive • Scheduled Maintenance • Unscheduled Shutdowns • Improved safety • Safety Risk • Reduced cost • High cost • CorrosionRADAR Ltd. 8
Electro-Magnetic Guided Radar (EMGR) C ORE SENSING P RINCIPLE FOR CUI MONITORING Wave reflection time-of-flight locates the corrosion on sensor Insulation Pipe Injected Defect Waveguide - Electromagnetic Wave Cable Reflected Wave Travelling Wave CorrosionRADAR Ltd. 9
Electro-Magnetic Guided Radar (EMGR) C ORE SENSING P RINCIPLE FOR CUI MONITORING Wave reflection time-of-flight locates the corrosion on sensor CorrosionRADAR Ltd. 10
Electro-Magnetic Guided Radar (EMGR) C ORE SENSING P RINCIPLE FOR CUI MONITORING Wave reflection time-of-flight locates the corrosion on sensor CorrosionRADAR Ltd. 11
CUI Monitoring Solution PREDICTIVE CORROSION MANAGEMENT USING IIOT DETECT CONNECT PREDICT CR Moisture CR Cloud Transmitters Wireless Data CR Corrosion CR On-Premises CR Digital Twin Distributed Corrosion & Moisture Sensors Long-Life Battery Powered Predictive Asset Management Long Range Coverage Remote Wireless Communications Asset life extension Continuous Monitoring Cost Effective Installation Effective Risk Management Dashboard for Actionable Intelligence Covering Complex Pipe works Historical Data & Analytics CorrosionRADAR Ltd. 12
Detect - Sensors C ORROSION AND M OISTURE S ENSORS FOR P REDICTIVE CUI M ANAGEMENT Helical Configuration Monitoring Storage tanks Monitoring Vessels Line Configuration Mesh Configuration Sensors Unaffected Long-range Sensors Type 1) Corrosion 2) Moisture Cost Effective by Complex & Modular Embedded for Mass Geometries Sensor Length 1) Up to 100m 2) 50m (each sensor unit Sensors Deployment can cover up to (e.g. vessels, pipe 100 m) bends, flanges...) Temperature Range -50 to 1) +300 °C 2)+200 °C 13 CorrosionRADAR Ltd. 13
Connect - Electronics ATEX COMPLIANT PRODUCT FOR HAZARDOUS ENVIRONMENT Corrosion & Moisture Monitoring System - Electronics ATEX/IECEx Certification II 2 GD Ex db IIB+H2 T3-T6 Gb Ex tb IIIC T85°C - T150°C Db Ingress Protection IP66 Power Source Mains Temperature Range (°C) - 20 to +60 Communications Wireless: Wifi/Cellular/WirelessHART/LoRa Other options: USB Approx. Dimensions (mm): 284H X 245W X 169D (Without Antenna) Approx. Weight 11.2 Kg CorrosionRADAR Ltd. 14
Predict - Analytics Platforms CR Predict IIOT Cloud platform CR Predict On-Prem Software platform CR Predict Digital Twin platform CR Predict Add-on Algorithm Products CR Automated Defect Recognition CR Analytics Module CUI Prediction Module Module using Machine Learning enabled by new improved models CorrosionRADAR Ltd. 15
CR Predict - CUI Prediction Module A DD -O N A LGORITHM PRODUCT Validated to match industry standards Continued laboratory testing for predictive models Time API 581 is industry guideline for CUI rate estimation CorrosionRADAR moisture sensors provides critical factor F INF for accurate estimation of CUI rate. The above plot is an experimental demonstration of CR prediction module CorrosionRADAR Ltd. 16
Case Study A P RODUCTION COLUMN C ORROSION M ONITORING (ATEX) CorrosionRADAR Ltd. 17
Case Study B M OISTURE M ONITORING S YSTEM (A) Figure (A) (B) Figure (B) Installation of CR Installation of the pre- corrosion sensors on a fabricated insulation 3 inch pipe using cable around the pipe and ties the corrosion sensor (C) (D) Figure (C) Figure (D) Installed CR Nodes Moisture sensor is Corrosion sensor (electronic) driving CR placed inside the pre- Moisture and fabricated insulations Corrosion sensors and installed at a fixed distance from the pipe Moisture sensor CorrosionRADAR Ltd. 18
Case Study B M OISTURE M ONITORING S YSTEM Moisture sensor data analysis and Detected water ingress points at 22 metres location correlation with historical weather data rainfall (mm) Amount of CorrosionRADAR Ltd. 19
Case Study C I NSTALLATION OF CR S YSTEMS Installed layout of both CR Corrosion and Moisture monitoring systems 2.5m 1.0m 1.5m 1.0m 0.5m 1.0m Corrosion sensor (10m) Moisture sensor (10.5m) Corrosion Bridge Cable (10m) CorrosionRADAR Ltd. 20
Data after 6 months C ORROSION AND M OISTURE M ONITORING S YSTEMS (Baseline) Sensor start Corrosion Sensor Sensor end No corrosion signal observed Corrosion Sensor (Baseline) Sensor end Sensor start Moisture Sensor Water detected 07:14 GMT on 11.06.2019 Moisture Sensor CorrosionRADAR Ltd. 21
Data after 7 months C ORROSION AND M OISTURE M ONITORING S YSTEMS (Baseline) Sensor start Corrosion Sensor Sensor end Reduced reflection Minor anomaly from sensor end 05.07.19 05.07.19 Corrosion Sensor (Baseline) Sensor end Sensor start Moisture Sensor Shift in sensor end Water detected indicates water 08:00 GMT on 05.07.2019 presence along the sensor Moisture Sensor CorrosionRADAR Ltd. 22
Benefits of CUI Monitoring System ESTIMATED COST RISK MAINTENANCE COST SAVINGS: 30-45% CorrosionRADAR Ltd. 23
Benefits of CUI Monitoring System Optimised Maintenance Less human intervention Data Driven RBI Reduced assets Risk P REDICTIVE CUI CUI Monitoring M AINTENANCE P REVENTION (Corrosion & Moisture) Reduced unplanned Shutdowns Early Detection Leak Prevention Reduced maintenance cost CorrosionRADAR Ltd. 24
Heading S UB HEADING Enabling Smarter Assets CorrosionRADAR Ltd Future Business Centre King’s Hedges Road Cambridge, CB4 2HY info@corrosionradar.com www.corrosionradar.com
Heading S UB HEADING Enabling Smarter Assets CorrosonRADAR Ltd Future Business Centre King’s Hedges Road Cambridge, CB4 2HY info@corrosionradar.com www.corrosionradar.com
Recommend
More recommend
