Real-Time Corrosion and Erosion Monitoring

The biennial Petrotech conference in New Delhi, India is for oil & gas industry experts to exchange views and share knowledge, expertise and experiences. And given the pricing dynamics and changes in global supply levels and supply chains, there is much to discuss and share.

At the last conference this past December, Emerson’s Rajesh Nogaja presented Online Real-time Corrosion/ Erosion Monitoring Systems Ensure Top Quartile Business Performance. Here is an excerpt from the abstract of this presentation:

Emerson's Rajesh Nogaja


Corrosion and erosion is a major challenge for the Oil and Gas industry, Pipelines, Refineries and Petrochemical plants. Online Realtime Corrosion/Erosion Monitoring Systems helps the customer increase Profitability, Optimise Costs and Enhance Overall safety. Areas of Top Quartile Business Performance Improvements achieved are:

  1. Increased Production rates and margins through Use of High TAN Opportunity Crudes
  2. Sustainability of Infrastructure and Assets for longer periods, delayed Turnarounds
  3. Early detection of Possible Piping and Asset Failures, improving safety and reliability

Rajesh discussed both inline/intrusive monitoring systems and non-intrusive ones. Roxar coupons are installed in pipes and vessels for some time period. Loss rate is determined by the coupon weight loss but can be affected by deposits, bacteria and corrosion. Roxar probes have very high sensitivity and ultrafast responses to provide efficient process corrosion/erosion management through the use of inhibitors and controlling production rates. Continue Reading

Increasing Maintenance Efficiency with Handheld Instrumentation Communicators

Those with smart instrumentation know that installation, configuration and maintenance activities often require the plant technicians to carry multiple tools such as external power supplies or loop simulators in addition to the handheld instrumentation communicator device. Properly functioning instrumentation helps the operations staff and automation system control strategies manage the process more safely, reliably and efficiently.

In this 3:29 YouTube video, AMS Trex: Improving Maintenance, Monsanto’s Joel Holmes describes how Power the Loop technology in the AMS Trex Device Communicator has had a positive impact on their organization’s maintenance practices.

AMS Trex Communicator Power the Loop WhitepaperIn a new whitepaper, Three Ways to Increase Efficiency with Power the Loop Technology, Joel is quoted: Continue Reading

Non-Intrusive Corrosion and Erosion Monitoring

The integrity of process piping is paramount to safe operations. Corrosion and erosion monitoring, especially for processes with challenging fluids, play an important role.

This short 2:10 YouTube video, Permasense ET210 Integrity Monitoring System, shows how piping erosion and corrosion can be monitored with pipe wall thickness measurements with non-intrusive wireless sensors strapped to the pipe. These sensors are yet more building blocks in the Industrial Internet of Things (IIoT) to monitor and provide early warning to improve overall operations. Continue Reading

Under Pressure: New Developments in High-Pressure Chemical Injections

Emerson's Travis Stone


Over in LinkedIn, Emerson’s Travis Stone has posted part 3, Under Pressure: Emerson Announces a New Development in High Pressure Chemical Injections, in our series on improving chemical injection processes.

These posts highlight the issues associated with underinjecting chemicals and the excessive costs associated with over injection. Optimimum rates of injection help assure piping integrity by inhibiting deposits and corrosion.

Here is an excerpt from the opening of his post:

A lot of people have concerns about the future of oil and gas, and about how fossil fuels will contribute to the energy mix in the coming years. Considering the prolonged oil price downturn since 2014, along with budget restrictions on new projects, and the potential for recent political volatility to affect regulations, these concerns seem justified. Continue Reading

Converging Information and Operational Technology Objectives

For brownfield sites, how do you bring in some of the capabilities that the Industrial Internet of Things (IIoT) introduce? At the ARC Industry Forum, ARC’s Craig Resnick led a session, IT/OT Convergence: Linking Legacy to an Industrial Internet of Things World. Emerson’s Phil Niccolls participated on the panel. Here was the description of the session:

We have been hearing a lot about the convergence of information technology and operations technology (IT/OT). This has led to a rapid learning curve for both groups, such as IT learning about what is actually “real time” and OT learning that to leverage the latest technology, 30 year old control systems may need to be upgraded. Connectivity between OT to IT is essential for any business to compete today with the increasing demand for tighter integration and more information and analytics, along with leveraging the Industrial Internet of Things, cloud, and big data. However, the reality is most factories contain multiple generations of systems where 30 year old products need to somehow be part of the convergence story. This session will explore how companies have successfully linked their OT legacy systems to their state-of-the-art OT and IT systems, covering the hurdles and challenges that need to be overcome. Persons wanting to learn about IT/OT convergence, as well as those involved with control systems and/or production management software should attend to gain insight into real world examples of OT and IT convergence success stories involving legacy systems, what lessons were learned, and what were the derived business benefits.​​

Craig opened noting many of the commonalities of requirements between IT and OT. Some of these include: cybersecurity, standards-based solutions, scalable and upgradable, no unscheduled downtime, secure & energy efficient, future proof, measurable ROI, ROA and KPI increases and IIoT deployment. There are of course many unique requirements to each domain that are often a source of friction between organizations.

The path to a digital transformation starts with early engagement and alignment of cross-functional stakeholders, let the use cases define the data requirements, architecture, tools and solutions, and consider the legacy assets to be part of the digital transformation.

Phil described the technologies and services that are bridging the divide between IT and OT organizations. Not all the problems being solved, such as reliability and energy efficiency improvements, need to flow through the control system. One example is wireless instrumentation connected to edge network devices which are collecting historical information. 

This data can flow securely through network devices such as data diodes out to cloud-based analytics applications that provide insights into ways to optimize energy usage and spot problems with mechanical equipment before it fails. The path of the flow of information requires alignment and collaboration between organizations as well as supplier collaboration if remote expertise required.

Phil also highlighted two other types of data–missing data and stranded data. This is data that is valuable to solve business challenges, but is not necessarily a part of the control strategy. Wireless devices can fill in the missing data required to solve business problems. 

Stranded data is the smart information such as diagnostics that is not flowing into the control system. Technologies like WirelessHART THUMs enable this smart information be brought in to help solve business problems that are typically outside the control domain.

Phil shared that the ISA-95 data model is still important but the emerging model that IIoT enables is a more direct path between sensor and expert to solve business problems.

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