Projects

Innovative wall thickness monitoring system can save industry >85% over traditional methods

A field trial of the Permasense (now Emerson Rosemount) wireless wall thickness measurement system was undertaken on the Chevron Alba Northern Platform. The technology consists of a non-intrusive, wireless sensor which provides continuous measurement of pipework wall thickness, with metal loss detection, for managing asset integrity. Each sensor can route the data it collects back to the gateway and has a battery life of up to nine years, which minimises maintenance requirements.

The trial focussed on the water injection system and consisted of eight ET210 sensors installed on a number of key bends (at the 6 o'clock position) and at straight sections of pipework, recording over a period of six months.

Industry Value

The Permasense wireless wall thickness monitoring system has the potential to save the industry >85% over traditional wall thickness measuring methods. The overall cost saving per annum for one single monitoring location would be in the region of £3,500, with an annual cost saving to the UKCS of £1 million.

Sensors can be fitted on insulated and uninsulated equipment. When insulated, the sensors are fitted underneath insulation, which has the potential to significantly reduce costs: insulation does not require to be stripped and reapplied every time an inspection is required; plus the sensors are low power with up to nine years battery life, minimising maintenance throughout operations.

Technology Organisation

Emerson

Emerson concentrates on the most complex and profound challenges facing the world in the process, industrial, commercial and residential markets. We refocused our business portfolio to deliver solutions that bring greater value to our customers.

ProjectEmerson - Erosion Sensors

Challenge

Asset Integrity

Vision

Transform Tomorrow

Entry TRL

8

Field Trial

Completed

Technology

Erosion Sensors

Type

Develop

Achieved TRL

9

Technology Organisation

Emerson

Emerson concentrates on the most complex and profound challenges facing the world in the process, industrial, commercial and residential markets. We refocused our business portfolio to deliver solutions that bring greater value to our customers.

Key Results

The sensors recorded good quality ultrasonic waveforms, giving stable and reliable thickness trends for the duration of the six month trial.

Information provided from the real-time monitoring system could be advantageous for chemical treatment programmes to establish sweet spots, problematic areas, reducing overall chemical dosage rates. This not only saves money, it also has the potential to reduce environmental impact.

Lessons Learned

The trial was successful and the lessons learnt, along with the capabilities of the technology, could be used to optimise the chemical dosing and non-intrusive inspection programmes for aging plants.

Next Steps

The Permasense (Emerson) system proved to be extremely robust in the environment of the North Sea and has been deployed to several North Sea assets, producing a long-term cost saving. Chevron are currently reviewing the use of Permasense technology for use on other applications.