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 Erosion Rate (MPY) Detection Time (Minutes) Detection Time Vs. Erosion Rate
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