Corrosion Monitoring
System
YESTERDAY’S EXPERIENCE…
TODAY’S TECHNOLOGY
Today's Outline
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Who is TXINS
Corrosion Market Drivers
General Corrosion
Corrosion & Corrosion-Assisted Cracking
Hydrogen Damage
Corrosion Inhibitors
How TXINS’s Monitor Works
Overview of the TXINS System
Applications
Installation
Data Acquisition & Reporting
Benefits, Limitations & Costs
Common Questions Asked
Who is TXINS?
TXINS :
• Corrosion Monitors
• NACE Inspectons
• Industrial Coating Specifications
TXINS is a group of individuals dedicated to the
Corrosion Protection Industry with well over 100
years of experience. TXINS takes years of
experience coupled with today’s technology and
produces accurate, real-time, cost savings for
their clients.
What’s Driving the Market
Approach to Corrosion Monitoring?
• Corrosion expenditures increasing
• Major drivers:
– Aging infrastructure
– Higher pressures and temperatures
– Higher concentrations of acid gases (e.g., CO2, H2S, Cl-)
– Environmental costs associated with leaks or spills
and lost production & commodity
What’s Driving the Market
Approach to Corrosion Monitoring?
(cont.)
• Drilling in environmentally sensitive areas under
stringent regulations & environmental impact
legislation.
• Integrity management programs costs
$2.8 – $4.6 billion annually, about 10 – 15% of
company’s maintenance expenditures.
Internal Corrosion is #1 Issue for
Production Pipelines
AEUB Statistics 2007 Leaks and Ruptures Only
2%
3%
3%
2%
2%
Internal Corrosion
5%
External Corrosion
Damage By Others
Weld
5%
Construction Damage
3%
5%
57.7%
Over Pressure
Pipe
Joint
12%
Earth Movement
Value/Fitting
Other
Total # of Releases 12191, Pipeline Releases by Cause for all years combined
What’s Driving the Market to
Change its Approach to
Corrosion Monitoring?
• Current corrosion detection methods employed are
reactive
– High-resolution “smart pigging”, measures wall loss,
“REACTIVE”
– Hydrostatic testing, integrity of the pipe wall “PRO-ACTIVE”
– Direct assessments, visual inspection, “REACTIVE”
– Corrosion Coupons, weight loss, “REACTIVE”
– FSM-IT inspection, again wall loss, “REACTIVE”
– Liquid and Gas sampling, “PRO-ACTIVE, but limited to sampling
areas is an intrusive technology”
– TXINS Monitoring, “PRO-ACTIVE”, monitors the change in the
production of hydrogen directly proportional to the corrosion
rate.
Corrosion Monitor Comparison
Coupons
ER Probes
LPR
ElectroChemical
Noise
Ultrasonic Scan
FSM-IT
TXINS Monitoring
System
Corrosion over
time
Electrical signal
Polarization
resistance
Fluctuation
in current
and voltage
noise
Wall thickness
Wall loss
Hydrogen
production
Detects Corrosion
Yes
Yes
Yes
Yes
No
No
Yes
Multi-phase Corrosion
Monitoring
No
No
No
No
No
No
Yes
Detects Pits or Wall Loss
No
No
No
No
Yes
Yes
No
Inhibitor Monitoring
No
No
Yes
No
No
No
Yes
Reactive
Proactive with
real-time
communication
Proactive with
real-time
communication
Reactive
Reactive
Proactive
Intrusive
Yes
Yes
Yes
Yes
No
No
No
Shut Down to Install
Yes
Yes
Yes
Yes
No, except for
safety reasons
No, except for
safety reasons
No
Retrieval Limitation
Shut Down /
pressure
Shut Down /
pressure
Shut Down /
pressure
Shut Down /
pressure
None
None
None
Feature
Data Read
Proactive or Reactive
Can be Used in High
Temperature
Environments
Limited
Limited
Limited
Limited
Limited
Yes
Yes
(320F/ 160C)
Or weld
attachment
Can be Used in High
Pressure Environments
Limited
Limited
Limited
Limited
Yes
Yes
Yes
Corrosion Monitor Comparison
Coupons
ER Probes
LPR
ElectroChemical Noise
Ultrasonic Scan
FSM-IT
TXINS Monitoring
System
Service Environments
All
All
Conductive
Aqueous
Conductive
Aqueous
All
All
All except high O2
environments
Presence of Electrolyte
No
No
Yes
Yes
No
No
No
Point
Point
Point
Point
Point/Section
Point/Section
Section
Pigging Compatible
No
No
No
No
Yes
Yes
Yes
Continuous Monitoring
No
Yes
Yes
Yes
No
Yes
Yes
Satellite Communication
No
No
No
No
No
Yes
Yes
Cost to Production from
Shutdowns
High
High
High
High
Minimal
Minimal
None
Cost of Equipment
Low
Medium
Medium
High
High
High
Medium
Labor Cost to Install
Low
Medium
Medium
Medium
High
High
Medium
Labor Cost to Repeat
High
High
High
High
High
Low
Low
Feature
Area of Coverage
General Corrosion
• This term is reserved for straightforward dissolution
of a metal in corrosive water
• Example: dissolution of steel in HCl. Simple systems
like this serve to demonstrate the electrochemical
basis of corrosion reactions, e.g.:
anodic reaction: Fe ----> Fe++ + 2 e- (e = electron)
cathodic reaction: 2 H+ + 2 e- ----> H2 (hydrogen gas)
Corrosion and Corrosion-Assisted
Cracking
• Depending on the reservoir composition,
– carbon dioxide (CO2)
– hydrogen sulfide (H2S), or a combination of both
can be present in hydrocarbons.
• The terms "sweet" and "sour" are used in the oil and
gas industry to identify hydrocarbons that contain
CO2 and H2S, respectively.
Corrosion and Corrosion-Assisted
Cracking
• In the oil and gas industry, water is the catalyst for
corrosion. When water is combined with CO2 or H2S
the environments form the following reactions:
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• H2CO3 Reaction:
Fe+H2CO3->FeCO3+H2
• H2S Reaction:
Fe+H2S+H2O->FeS+2H
• Or combination if both gases are present
Hydrogen Damage
• Hydrogen may enter a metal surface by the cathodic
reduction of hydrogen or water:
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2H+ + 2e- → 2H Absorbed (acidic waters)
2H2O + 2e- → 2H Absorbed + 2OH- (neutral
waters)
• Normally, the absorbed hydrogen at the surface
recombines to form hydrogen gas:
• 2H Absorbed → H2
• Sulfide (S2-), prevents Hydrogen gas from forming.
Hydrogen Damage
Hydrogen Induced Cracking (HCI), or Blisters.
H2
Outside
Metal Surface
H
Inside
Metal Surface
Corrosive
Environment
H
Hydrogen Damage
• Hydrogen may enter a metal surface by the cathodic
reduction of hydrogen or water:
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2H+ + 2e- → 2H absorbed (acidic waters)
2H2O + 2e- → 2H absorbed + 2OH- (neutral
waters)
• Normally, the absorbed hydrogen at the surface
recombines to form hydrogen gas:
• 2HAbsorbed → H2
• Sulfide (S2-), prevents Hydrogen gas from forming.
Corrosion Inhibitors
d
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How TXINS’s Monitor Works
Satellite Monitoring
equipment, above
ground level
Liquid Epoxy
TXINS Monitoring Systems Vessel - Cap under vacuum
Adhesive
External
Pipe wall
Pipe
H0
H0
H2
H0
H0
Cathode Area
e-
OH-
Environment
H
H0
Cathode Area
H0
e- e-
OHFe ++
0
H0
H0
e-
e-
H2
Anodic Area
Wall
Internal
gas/liquid
H0
H0
OHFe ++
Fe(OH)2
Fe ++
H0
H0
H0
H2
H0
Inhibitor film
H0
Permeation Rates of
H0 VS Carbon Steel Thickness
Table of Corrosion Scenarios
Hydrogen Permeability of Steels
TXINS T-1 or T-2 System
Remote
Communications
Via Satellite
TXINS’s
T-1 or T-2
Monitor
Non Intrusive
Hydrogen monitoring
Cap
ATOMIC HYDROGEN FROM CORROSION
Applications
Any metal substrate where hydrogen is being produced as a result of the
corrosion process.
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Pipelines (Sour)
• Pipelines (Natural Gas)
Pipeline (Sweet)
• Pipelines (Condensate)
Gas Plants
• Treaters
Water Disposal
• Vessels
Petrochemical
• Amine Towers
Water Floods
• Refinery
Closed or Sealed Rolling Stock (rail cars or tanker
trucks)
Applications
Gas and Oil Production (H2S)
• Oil/Gas Gathering and Transmission Lines
• Oil/Gas Well Heads
• Sour Water Flood Lines
• Underground Gas Storage Facilities
Applications
Gas-Oil Separation Plants and Gas
Plants (H2S)
• Amine Units – Inlets,
Outlets, transfer lines
• Contactors
• Absorbers
• Flash Drums
• Wash Columns and
Drums
• Blow down Drums
• Flare Lines
• Sour Water Strippers
• Sour Gas Gathering
Lines
• Fractionators
• Catalytic Cracker –
overhead recovery
system
• Hot Wells
• High and Low
pressure sour gas
separators
Applications
Refinery HF Alkylation Units
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Acid Settler Tanks
Accumulators
Condensors
Depropanisers
Transfer Lines
Recontactors
Installation of the
Equipment
• Site preparation – hand tool only to white metal
• Bonding the vessel to the pipe - Liquid epoxy
• Mechanically clamp the vessel to the pipe
• Mount monitoring equipment to a pole above
ground or to secured area on the rolling stock
Reporting
• Graphical representation of corrosive activity
• Programming alarms can be set by Client
• All client information is password protected for
their use only
Graph Showing 2 Corrosion Events
ABC Co.
2nd Event
1st Event
7/17/2007
7/18/2007
7/19/2007
7/20/2007
7/21/2007
7/22/2007
7/23/2007
7/24/2007
7/25/2007
7/26/2007
7/27/2007
7/28/2007
7/29/2007
7/30/2007
7/31/2007
8/1/2007
8/2/2007
8/3/2007
8/4/2007
8/5/2007
8/7/2007
8/16/2007
8/17/2007
8/18/2007
8/19/2007
8/20/2007
8/21/2007
8/22/2007
8/23/2007
8/24/2007
8/25/2007
8/26/2007
8/27/2007
8/28/2007
8/29/2007
8/30/2007
8/31/2007
9/1/2007
9/2/2007
9/3/2007
9/4/2007
9/5/2007
9/5/2007
9/5/2007
9/6/2007
9/7/2007
9/8/2007
9/9/2007
9/10/2007
9/11/2007
9/12/2007
9/13/2007
9/14/2007
9/15/2007
9/16/2007
9/17/2007
9/18/2007
9/19/2007
9/20/2007
9/21/2007
9/22/2007
9/23/2007
9/24/2007
Pressure
Customer #2
FIGURE 3 - Pressure Readings from 7/16/07 to 9/24/07
0
Re-evacuate
-10
Re-evacuate
-30
Daily Readings
Re-evacuate
-20
Re-evacuate
Re-evacuate
-40
Re-evacuate
-50
-60
-70
-80
Customer #2
TABLE 3 - Average Vacuum Loss Over Time
25
Average Change in Pressure
20
15
10
5
0
July 23 - 29
July 30 - Aug 5
Aug 16 - 22
Aug 24 - 28
Aug 29 - Sept 5
Sept 6 - 18
Sept 19 - 21
Sept 22 - 24
Benefits
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Real time data
Records
Non-intrusive
Low maintenance
Remote capability
Coordinates corrosion programs
Cost effective
Benefits (cont.)
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No down time
Works in Conjunction with other Technologies
Early Corrosion Detection
High Risk Remote Areas Can be Monitored
Low Installation and Operating Costs
High Temperature Installations (200˚C)
“Can be placed on higher temperature if welded”
Limitations of the Technology
• No correlation of TXINS data to intrusive probes or
corrosion coupons
• Does not work in fully oxygenated water systems or
ponds
• Each system has to be looked at individually, no
comparison
Costs
• Standard Satellite Unit costs will vary dependent on
how many transducers are included
• Remote Satellite data collection and download of
data at competitive rates $75-100/month/unit
• Remote Cellular data collection and download of
data at competitive rates
• Installation costs will vary as a result of location
and number of units to be installed
Commonly Asked Questions and
Answers
Q1: Does your Hydrogen Vessel work in Sweet and
Sour Gas Systems?
A1: Yes
Commonly Asked
Questions and Answers
Q2: Does the internal process pressure affect the
hydrogen flux process?
A2: No
Q3: Does temperature influence the monitor’s
accuracy?
A3: No and yes
Commonly Asked
Question and Answers
Q4: Can the TXINS monitor environments containing
bacterial corrosion or iron sulfide deposits?
A4: Yes
Q5: Does the formation of Hydrogen polarization
film caused by cathodic protection on the
external of the pipe affect the TXINS
monitor?
A5: No
Commonly Asked
Questions and Answers
Q6: Is the TXINS monitoring system capable of
monitoring internal environments that have
been internally coated?
A6: Yes
Q7: Where do you typically install the TXINS
caps?
A7: Each application will be different
Commonly Asked
Questions and Answers
Q8: Can the TXINS monitor help in evaluating the
effectiveness of my corrosion inhibitors?
A8: Yes
Q9: Can the results of the TXINS monitor give
me a metal loss per year (“MPY”) value?
A9: Yes and No
Commonly Asked
Questions and Answers
Q10: Will the TXINS monitor work in all my corrosive
environments?
A10: No
Q11: Will the TXINS monitor work in a high ph
environment?
A11: Yes
Conclusion
• TXINS Monitor is:
– Non-intrusive
– Pro-active corrosion monitor
– Cost effective
– Remote communication and installations
– TXINS gives the flexibility required to meet all
our customers, corrosion monitoring needs.
Thank you for your time.
If you require any further information,
please contact:
Corrosion Monitors
USA/ Intl.-877.378.2377
Canada- 403.250.3382
Email- khavran@txins1.com