Use of Non-Intrusive Ultrasonic Intelligent

Sensors for Corrosion and Erosion Monitoring

Geir Instanes, Vice President, ClampOn

ClampOn
Ultrasonic Intelligent Sensors
- Sand Monitoring
- PIG Detection
- Leak Monitoring
- Vibration Monitoring
- Condition Monitoring
- Corrosion-Erosion Monitoring

Software/Service
- Sand Management
- Well Collision Detector
- Distributed Monitoring Systems
- Online Erosion Modeling Topside & Subsea
Topside & Subsea

• Non intrusive
• Passive acoustic
• Common hardware
• Digital signal processing
• Noise cancelling
• Superior S/N ratio
Going Subsea means new Challenges
• Subsea Trees
• Subsea Pumps
• Subsea Processing
• Subsea Manifolds
• Subsea Templates
• ROV Tie-in Systems
• Risers
• Pipelines
 Quality / Lifetime
ClampOn’s instruments are manufactured according to the highest
industry standards.

• Sensor electronic is hermetically sealed in titanium body

• MTBF/ Lifetime is more than 30 years
 3 axis vibration monitoring
Upgraded electronic hardware enables us to monitor vibration in all three
axis simultaneously as the instrument is monitoring for other applications

Frequency: 0-1000Hz, Sensitivity: 1mg

0.3 Maximum Vibration [g]

0.25

0.2

0.15

0.1

0.05

0
X Y Z X Y Z X Y Z X Y Z X Y Z X Y Z X Y Z X Y Z X Y Z X Y Z X Y Z X Y Z X Y Z X Y Z X Y Z X Y Z X Y Z X Y Z
0 - 0,25 - 0,5 -1 1 - 2 2 - 8 4 - 8 8 - 16 16 - 32 - 45 - 64 - 90 - 125 - 180 - 250 - 350 - 500 - 700 -
0,25 0,5 Hz Hz Hz Hz Hz Hz 32 Hz 45 Hz 64 Hz 90 Hz 125 180 250 350 500 700 1000
Hz Hz Hz Hz Hz Hz Hz Hz
 Custom Solutions
Portable subsea monitoring system with data
logging
 Custom Solutions
Retrofit sand monitoring, signal integration, one
year power by battery
 The use of Non-Intrusive
Ultrasonic Intelligent
Sensors for Corrosion and
Erosion Monitoring

Cost effective solution for

assessing wall thickness loss in
pipelines - quantitatively - using
Guided Wave technology to
optimize output
 Presentation Layout
ClampOn DSP Corrosion-Erosion Monitor

• Introduction and Background

• System properties
• Selected results
• System layout
• Subsea Installation Options
• Conclusion
 Current State-of-the-Art

• Most pipeline assessment systems are based on

spot measurement technology, involving a large
number of transducers
• The few path-based systems available provide
qualitative rather than quantitative assessment of
damage
• More often than not, intrusive systems are used to
assess the corrosive nature of flow in pipelines
using coupons, etc
 Applications for Corrosion Erosion

o Separators – large tanks

o Pipe lines (Straight pipe sections)
o Pipe bends
o Y-or T-joints
o Risers & splash zone
o Any type of metal
o Can also be combined with monitor particles
o Topside and Subsea
 Applications ClampOn CEM

• Even though the most common application is wall thickness

measurement of pipe wall, the CEM can be used in several other areas:

• Can be mounted on reducers with changing pipe diameter and wall

thickness.
• Thickness characterization on aged boiler tubes
• Analysis of adhesive bonds
• Corrosion monitoring on tanks
• All other metal structures with the need for thickness assessment…

• Flow conditions: water, oil, gas, multiphase, none.

• Large temperature area…
System in the field
System in the field
 Working Principle - Lamb Waves
ClampOn DSP Corrosion-Erosion Monitor

• AGLW = Acoustic Guided Lamb Waves

• Named after Horace Lamb, who discovered the waves in
1916
• Also called Long Range NDT
• The pipe wall will force the transmitted signal into a
given shape and form (mode generation)
• Analytical inversion of acoustic data to obtain relevant
thickness information
• Transducers can be mounted on the outside of coating <1mm /0.04” 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 /0.04” 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 /0.04” 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
What do we measure?

Minimum wall thickness

Average wall 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
• The figure illustrates
the area covered by a
pair of transducers
• Beam divergence
allows the CEM to
„see‟ a large area
• A matrix of
transducers deployed
on a region of pipe
can provide
comprehensive
coverage Transducer 1 Transducer 2
• The larger WT the
larger the coverage
area is
CEM - Coverage Area

• OD pipe – 8”
• Separation 700 mm
• 6 Transducers set-up
Total Coverage:
• ≈ 60%
• Each path width is 70mm
 Pipe Unfolded
Bottom
Pipe / Plate
CEM - Coverage Area

5 4

7 1 Top
line

8 3

Transducers
Bottom
• OD pipe – 8” Total Coverage:
• Separation 700 mm • ≈ 60%
• 6 Transducers set-up • Can be calculated by Software
 Comparison – Coverage Area

COVERAGE AREA –
THE MEASURED AREA THAT THE SYSTEMS ARE COVERING:

a) 2 x CEMAT Transducer separated by 600mm.

Coverage area = 35 000 mm2

b) Alternative 14 spots (el 5mm) each covering 19,5mm2 = 273 mm2

c) Alternative 8 spots (el 12mm) each covering 113mm2 = 904 mm2

OR

d) 8 CEMAT Transducer distributed over the selected surface: <65% of

the surface, which equals to: 187 000 mm2.

= Large coverage with less transducers/equipment

 Detecting average wall thickness

Three separate scenarios:

Transducer
 Highly localized pit

 General erosion

? Localized groove
Transducer

 Highly localized pit exerts a very small (< 1%) effect on average wall
thickness  undetectable

 General erosion exerts a noticeable (> 1%) effect on average wall

thickness  detectable

? A highly localized groove will be detected IF its effect on average wall

thickness is > 1%
The Transducer

• ClampOn have developed their own

transducer, called CEMAT, or
“dry contact” transducers.

• The CEMAT is Ex mb certified for

use in zone 1, for temperatures up
to 200˚C (T3).

• High temperature transducer is

under development for permanent
use up to 400˚C

• Transducers are to be in close

contact with pipe < 2.0 mm lift off
 System properties
CGV mode

• The system measures the wall thickness loss

between pairs of transducers
• The system will have between two and eight
transducers in operation
• The sensitivity for wall thickness assessment is
around 1% of wall thickness (WT) over the full
temperature range
• Can detect small changes as small as 0,1% of WT
• Repeatability is: ± 0,04%
• The system measures wall thickness in REAL time,
at user-definable intervals
Independently observed test
Results from erosion on 12 mm plate
Witnessed by BP, Statoil, Hydro and Shell

• 12mm thick plate eroded

randomly with a power tool
• Test was conducted and
monitored by independent
observers
• Predicted thickness loss on
day of test was later verified
by actual measurements as
seen in the figure
Uniform thickness loss
CEM demonstration – uniform thickness reduction
 Example – Detecting general corrosion
 General corrosion was simulated by grinding on a 1 x 1 m and approximately 22
mm thick plate.
 Corresponded well with results obtained from handheld UT gauge.
 Figure showing 2 grinding runs, showing an average loss of 3.3% and 1.2%.

General corrosion % change

7.0
CEM measurements
6.0

5.0 Run 2

4.0
Run 1
3.0

2.0

1.0

0.0
0 5 10 15 20 25 30 35 40
 Example – Detection ”pitting corrosion”
 Pitting corrosion was simulated by drilling small holes in a 1x1m and
approximately 22mm (0.87”) thick steel plate.
 The ClampOn CEM shows a average loss of about 1%
 UT measurements conducted in a thorough manner at 14 points along the
measurement path showed no corrosion.

3.0
Pitting Corrosion % change
CEM measurements
UT Readings
2.5

2.0

1.5

1.0

0.5

0.0
9:02 9:31 10:00 10:29 10:58 11:26 11:55 12:24 12:53
Sensitivity to groove-like defects
Machined grooves on a plate detected

Machined groove
-10 mm plate
- Measurement method:
- Micrometer
- CEM
Weld-root erosion detection
CEM installed on a pair of welds as shown
Weld-root erosion detection
CEM installed on a pair of welds as shown

 Corroded weld

 OK weld
 Verification of Stability
CEM system tested with heating & cooling

Standard
deviation:

0.02mm

Temp.
range 10 -
170C
 Acid corrosion test
o An acid solution was injected to the pipe to emphasize corrosion.
 PH level was regularly checked to maintain a steady corrosion.
 Temperature cycled to increase/decrease corrosion and check stability.
 Showed good resemblance with UT measurements.

Calculated Corrosion Rate (mm/year)

CEM UT

Bottom 1.77 mm/y 1.63

Top 0.48 mm/y 0.48

Top – Bottom 1 (1 – 2) 0.79 mm/y 1.27

Top – Bottom 2 (1 – 4) 1.01 mm/y 1.11

Top – Bottom 3 (2 – 4) 1.01 mm/y 0.93

ClampOn CEM Subsea
Corrosion-Erosion Monitor
- 3 Models alternatives for CEM -

- CEM for ROV installation

- CEM under insulation/coating

- CEM w/mechanical cover

 CEM Subsea System
Main Parts
Transducers Electronic w/PAC unit Power

4 Transducers

Power

4 Transducers Electronic up to 7 meters from transducers

 Subsea CEM
• Allows CEM system to be
made ROV installable.

• Design based on existing

proven subsea electronic
chambers and ROV funnel
design.

• CEM electronics placed in a

hermetically sealed canister
with up to 16 transducers
connections.

• Are currently being design

and shall be installed on a
BP field
ClampOn CEM
Corrosion-Erosion Monitor
- 3 Models alternatives for CEM -

- CEM for ROV installation

- CEM under insulation/coating

- CEM w/mechanical cover

Fully ROV CEM Subsea configurations

• Pre installed
• ROV installed
• Fully interfaced
• Battery powered
• Internal data storage
• Wireless communication
CEM System in the field
 • Transducers Clamp with up to 4
The CEM ROV System
transducers.

• Main Clamp with CEM electronic

and optional battery
- 2 transducer clamps can be fitted to 1 Main Clamp.

– Cost impacts:
- Material
- Number of transducers and Clamps/location
- Connector type
- Engineering work
- Pipe Size and location
- Battery type and size
- Option Protection cover for falling objects
 • Acoustic communication link to surface.
Communication
Data communication

Subsea acoustic
modem w/battery
ClampOn CEM
Corrosion-Erosion Monitor
- 3 Models alternatives for CEM -

- CEM for ROV installation

- CEM under insulation/coating

- CEM w/mechanical cover

CEM system solution

Transducers located under coating

Interface - Jumper – hose
CEM under insulation/coating
90 Degree bend – 6,625”

Transducers under Novolastic –

(Transparent)

6 Dry Contact transducers

Coverage – approx 50% Bend

area

2 x 12 Pin Wet Bulkhead

connectors

Connectors on top of split box.

Electronic canister have to be

located max 7 meter from
connectors.
CEM under insulation/coating
90 Degree bend – 6,625” – Coverage.

Coverage area

Coverage – approx 50% Bend

area
Coverage of pipe max 35%

6 signal path

Minimum signal path length

400mm

On the inside of the bend we

will apply an acoustic damping
material to allow max path
combinations . Thickness is
approx 10mm
The CEM Insulation System
• 4 Transducer under insulation –
wired back to a split box

• Each split box can handle up to 4

transducers – 12 pin ROV connector

• Funnel
• CEM Electronic located close to
transducers within 7 meters.

– Cost impacts:
- Material
- Connector type
- Engineering work
- Option Protection cover for falling objects
ClampOn CEM
Corrosion-Erosion Monitor
- 3 Models alternatives for CEM -

- CEM for ROV installation

- CEM under insulation/coating

- CEM w/Mechanical cover

CEM installation Subsea
Pipe – 10”

Transducers under mechanical cover

4 or 8 Dry Contact transducers

Coverage – deepening on number of transducers

1 or 2 x 12 Pin
Wet Bulkhead connectors
CEM installation Subsea
Pipe – 10”

Transducers under mechanical

cover – (Transparent)

4 Dry Contact transducers

12 Pin Wet Bulkhead

connectors

CEM Electronic canister have to

be located max 7 meter from
connectors.

Canister ROV mountable

 Coverage - CEM installation Subsea
tba

N.B. O.D. (mm) WT (mm) CA (mm) Transducer - ClampOn CEM coverage

Ring separation (mm) (whole circumference of the pipe)
Different Pipe Sizes

Field name
8” 219,1 12,7 3 840 70%

10” 273,1 14,3 3 380 67%

14” 355,6 19,1 3 540 79%

16” 406,4 20,6 3 590 81%

18” 457,0 22,2 3 635 82%

20” 508,0 23,8 3 725 84%

24” 610,0 28,6 3 825 83%

 • 4 Transducer under cover – wired
The CEM Subsea System
back to a split box – then to a 12
pin ROV connector

• Protection Covers and funnels

• CEM Electronic located close to

transducers within 7 meters.

– Cost impacts:
- Material type
- Pipe size
- Connector type
- Installation method…
- Engineering work
- Option Protection cover for falling objects
Subsea CEM Technical data

 Pipe outer diameter (OD): min 4” (100 mm)

 Pipe wall thickness: 2 mm to 35 mm
 Distance between transducers: 0.15 m – 2 m (78”) typical
 Temperature : -40 to 180 °C (-40 to 356 °F )
 Frequency range: 30 to 300 kHz

 Sensitivity: (smallest change better than 1% of the pipe wall

that can be reliably detected) thickness
 Repeatability: 0.04%

 Power consumption: Avg 6 Watt - Max 10 Watt

 Sleep Mode: 0,001mA
 Battery Pack: 5 years with data point weekly
 Sensor electronics: DSP 66-MIPS, A/D con. 24bit, 25-Years
 Installation: Vertical & Horizontal
 Water depth: 3000 Meters
 Test pressure: 345 BarA
 Conclusion
Clampon DSP Corrosion-Erosion Monitor
• Excellent correlation between measured and actual average
thickness values, for a wide variety of defect types demonstrated
with witness from independent observers (Shell, Statoil, BP, Hydro,
Saudi Aramco, etc)
• Sensitivity of the CEM to changes in wall thickness demonstrated
• Generic defect, groove and pits were machined and detected
• Extremely high unevenness still gave far better results than initially
predicted
• Robust nature of thickness evaluation method illustrated and
monitored over a long time
• Temperature, flow is not affecting the Guided Waves
• Dry contact transducers have been developed to increase flexibility
and stability of the CEM system
• Subsea System under qualification with a BP and have been
demonstrated with ROV installation during SIT
ClampOn High Flexibility
• Non-intrusive, cost-effective installation

• ROV Retrofit

• Designed for down to 3000 meters depth

• Battery pack &/or internal logging

• Multifunctional (Sand, PIG, Vibration, CEM.)

• All data processing in Sensor unit

• Communication Solutions
Thank you for your
attention!

Any questions?
Geir Instanes,
ClampOn

www.clampon.com