Corrosion Monitoring System
- Sensorlink Ultramonit™
Pipeline Corrosion Monitoring System - Sensorlink Ultramonit™
High accuracy pipeline corrosion monitoring and wall thickness measurement
UltraMonit® is a system that effectively monitors internal corrosion and erosion rates in pipelines using ultrasound technology to provide highly accurate measurements. The system is a “clamp-on” tool, meaning that the installation and utilization of the equipment does not interfere with the operation of the pipeline in any way. It is ideal for new and existing pipelines.
An advantage of the system is that customers can optimize their use of corrosion inhibitors or can predict the remaining lifetime of a pipeline. The UltraMonit® system can also be used for the verification and calibration of inspection pig data at selected locations and provide information about critical areas between inspection surveys.The technical implementation of the UltraMonit® tool for subsea pipelines is as an instrumented clamp which can be installed on pipelines by diver or ROV. As the tool can be retrofitted at any time, it can be moved between different locations.
The UltraMonit® system is based on the well-established ultrasonic pulse-echo method (A-scan). Special processing methods have been developed for such instrumentation that is fixed to the pipeline. This gives high resolution and accuracy measurements for monitoring wall loss.
Key Advantages:
•Non-intrusive, meaning no threat to pipeline integrity
•Flexible number and placement of sensors in the UltraMonit tool
•Immediate feedback on the effectiveness of corrosion inhibitors
•Online or remote operation
•Real-time data readout
•Automated measurement, logging and analysis
•Flexible reading intervals determined by operator
•Direct access to results from via secure web interface
Subsea Installation
The Ultramonit™ equipment can be installed and operated without interfering with the operation of the pipeline. It can also be removed and reinstalled in another location if the client desires. In the case of subsea pipelines, the equipment is deployed through use of an instrumented clamp which can be installed on new or existing pipelines by diver or ROV.
Data Communication
The UltraMonit® system communicates wirelessly via acoustic modem or alternatively via cable or optical link, as well as satellite or radio link from surface to the UltraMonit® server.
Alternatively, a cable to a surface communication buoy or platform can be installed, and if not viable, data stored in the UltraMonit® controller can be retrieved by an ROV or diver. The controller is designed for long-term data storage due to its internal long-life battery.
Technical Specification
Pipe size: 3" - 34"
Wall thickness: 3 – 200 mm
Relative accuracy: < 0.1 mm
Inclinometer: ± 2° (angular)
Temperature sensor: ± 1°C
UltraMonit® In Situ
The UltraMonit® InSitu is an ultrasonic erosion and corrosion monitoring toolproviding real-time and online wall thickness data on subsea spools and
pipelines.
The UltraMonit® InSitu system uses an array of ultrasound transducers providing reliable high precision ultrasonic wall thickness measurements at selected locations. It is based on the well-established ultrasonic pulse-echo method. The UltraMonit® system integrates with the subsea control system providing the operators with live wall thickness data.
Some key advantages are:
• Reduces or eliminates the need for intelligent pigging
• Real-time monitoring of the effectiveness of corrosion inhibitors
(feedback on corrosion inhibitor programmes)
• Benchmarking of intelligent pigging
• Improved pipeline integrity management on non-piggable pipelines
• Life extension and improved safety margins for late life pipelines
• Monitor weld/HAZ on pipe to show variation in corrosion rates
How does it work?
The ultrasound transducers measure wall thickness as a function of time and provide high resolution data on material wall loss. The sensors are installed directly on the pipe outer wall, or on top of the weld seam, before the pipeline or pipe spool is installed. The figure to the right shows a subsea layout where the UltraMonit® typically can be installed. The ultrasound transducers are mounted in PEEK sensor housings, which are fixed to the pipe. Wall thickness is detected by pulse-echo ultrasound measurements, with the transducers immersed in a coupling liquid in front of the pipe wall.
A short ultrasound pulse is generated by the transducer, and echoes from different interfaces are recorded by the same transducer. The UltraMonit® consists of multiple ultrasound sensor module spread around the pipe, and each contains several ultrasound transducers mounted together with a multiplexer card and a temperature sensor. The transducer assembly is moulded into the same insulating material as the rest of the pipeline.
Network and interfaces
All data is processed by the UltraMonit® subsea unit. In addition, raw data can be transferred to topside. The data is communicated through the subsea control system via RS 485 or Ethernet using transparent link, OPC or Modbus protocols. As shown in the figure to the right 2 the corrosion data can be presented in a simple table or a sector map in the platform control room. The UltraMonit® In Situ gets its power from an external power supply (9-36 V), or alternatively from a battery pack.
How do you install it?
The UltraMonit® In-Situ is pre-installed on the actual pipe joint or spool prior to pipe lay or subsea spool installation. The UltraMonit® may be insulated to avoid cold spots. A ROV connects the UltraMonit® to the subsea control system using a wet mateable jumper cable. All external cabling and electronics are ROV replaceable. The UltraMonit® sensors can be installed on top of FBE, 3LPP or other solid homogenous insulation materials.
UltraMonit® Retrofit
The UltraMonit® Retrofit is an ultrasonic subsea erosion and corrosion monitoring tool providing high resolution online pipe wall thickness data. It is non-intrusive and can be installed on new and existing pipe spools and pipelines.
The UltraMonit® system uses an array of pulse-echo ultrasound transducers providing reliable high precision wall thickness measurements at selected locations.
Some key advantages are:
Non-Intrusive direct wall thickness measurement
• Can be installed post pipe lay (no rotation issues)
• Online and real-time feedback on corrosion inhibitor effectiveness
• Reduces or eliminates the need for intelligent pigging
• Selection of less expensive pipe material through increased monitoring
• Can discriminate corrosion rates between weld, pipe wall and HAZ corrosion
• Battery powered or powered by cable
• Works through solid external coatings (PE, 3LPP, FBE, etc.)
• Improved pipeline integrity management
• Life extension and improved safety margins for late life pipelines
• Removable, movable and replaceable throughout the lifetime of the tool
How does it work?
The UltraMonit® technology is the best on the market with respect to precision, accuracy and speed of detection for non-intrusive wall thickness monitoring, corrosion rate estimation and corrosion profile estimation.
The UltraMonit® consists of a matrix of pulse-echo ultrasound transducers that are clamped to the outer pipe wall. The transducers measure wall thickness over time and provide high resolution data on material wall loss. Fixed sensors combined with advanced signal processing make the UltraMonit® detect wall loss of less than 0.1 mills (2.5 micrometres). The sensor matrix is optimized to suit the expected corrosion/erosion phenomena and can be configured according to user requirements.
The UltraMonit® data logger is retrievable. It stores the raw signals, and the raw signals can be collected and post processed for detailed and advanced analysis (i.e. evaluation of pitting growth).
Installation
The UltraMonit® Retrofit is ROV and diver installable. The smaller sizes can be made “neutral” in water (< 50 kg). Larger units need additional buoyancy or require a heave compensated crane during installation. There is no need for calibration during the installation; the sensors are fixed to the pipe wall, the speed of sound in steel is known, and time of flight is measured using the ultrasound transducer. The performance of the single element transducers is not influenced by the wall thickness, nor to solid external pipe coatings. This allow installation without compromising the pipe integrity, and allow a very easy marine operation.
Upon completed installation the ROV will activate the data logger and the data logger will commission the UltraMonit® and confirm successful installation.
Operation
The UltraMonit® Retrofit can be made fully autonomous by fitting a battery package. An acoustic communication package can be added enabling any surface vessel or nearby platform to collect data via an acoustic modem without the assistance from a diver or ROV. If there is access to a subsea control system, the Retrofit can also be integrated into this, and be powered from the control system. Typical communication of data is via RS485, Ethernet (SIIS level 3), Modbus, Can bus (SIIS level 2) or just about any know protocol.
All data will be processed locally and the calculated wall thickness, pipe wall temperature and battery status (if applicable) is communicated through the available interface. The data can be fed into the clients control system or can be viewed using the PipeView® software.
Product Brochure In-Situ
Product Brochure Retrofit
