Corrosion Under
Insulation Monitoring
using EMGR
Technology
Corrosion Under
Insulation Monitoring
using EMGR
Technology
Dr Prafull Sharma, CorrosionRADAR Ltd www.corrosionradar.com
CorrosionRADAR Ltd. 4
The Story of Rob, Bob and CUI
CorrosionRADAR Ltd. 5
Oil & Gas Chemical Industry
Renewable Energy LNG
Corrosion Under Insulation
ProblemHIDDEN CORROSION
CorrosionRADAR Ltd. 6
Corrosion Under Insulation (CUI)AMONG THE BIGGEST ASSET INTEGRITY THREAT
CUI is #1 asset integrity issue in O&G and Petrochemicals
10% of the overall offshore platforms maintenance cost
60% of all pipeline failures are due to CUI
How CUI happens
Water ingressinto insulation
Unpredictable location Suitable temperature
CorrosionRADAR Ltd. 7
Inspection 4.0 – Mega Trend
Statistics, RBIManual observation,
Leaks
Inspection 1.0 Inspection 3.0Visualisation,
NDT instruments
Inspection 2.0
Manual Automated
Detection Prediction
Reaction
Automated,
Analytics, Prediction
Inspection 4.0
Prevention
CorrosionRADAR Ltd. 8
Predictive Corrosion Management - OpportunityENABLED BY IIOT AND PREDICTIVE ANALYTICS
PERIODICMANUAL
INSPECTION
CURRENT PRACTICE
Reactive
• Labour Intensive
• Unscheduled Shutdowns
• Safety Risk
• High cost
REACTIVE MAINTENANCE
HUMANJUDGEMENT + GUESSED RISK
• Minimal labour effort
• Scheduled Maintenance
• Improved safety
• Reduced cost
PREDICTIVE MAINTENANCE
AUTOMATEDRISK PROFILING
CONTINUOUSMONITORING
FUTURE PRACTICE
Predictive
Sensors
Connectivity
Knowledgebase
Analytics / ML
CorrosionRADAR Ltd. 9
Electro-Magnetic Guided Radar (EMGR)CORE SENSING PRINCIPLE FOR CUI MONITORING
Wave reflection time-of-flight locates the corrosion on sensor
Reflected Wave Travelling
Wave
Pipe
Insulation
DefectInjected
Electromagnetic WaveWaveguide -
Cable
CorrosionRADAR Ltd. 10
Electro-Magnetic Guided Radar (EMGR)CORE SENSING PRINCIPLE FOR CUI MONITORING
Wave reflection time-of-flight locates the corrosion on sensor
CorrosionRADAR Ltd. 11
Electro-Magnetic Guided Radar (EMGR)CORE SENSING PRINCIPLE FOR CUI MONITORING
Wave reflection time-of-flight locates the corrosion on sensor
CorrosionRADAR Ltd. 12
CUI Monitoring SolutionPREDICTIVE CORROSION MANAGEMENT USING IIOT
PREDICTCONNECTDETECT
Distributed Corrosion & Moisture Sensors
Long Range Coverage
Cost Effective Installation
Covering Complex Pipe works
Long-Life Battery Powered
Remote Wireless Communications
Continuous Monitoring
Dashboard for Actionable Intelligence
Predictive Asset Management
Asset life extension
Effective Risk Management
Historical Data & Analytics
CR Moisture
CR Corrosion Wireless Data
CR Digital Twin
CR On-Premises
CR CloudTransmitters
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Helical
Configuration
Line
ConfigurationMesh
Configuration
Embedded
Sensors
Long-range
& Modular (each sensor unit
can cover up to
100 m)
Unaffected
by Complex
Geometries (e.g. vessels, pipe
bends, flanges...)
Cost Effective
for Mass
Deployment
Monitoring
Storage tanks
Monitoring Vessels
Detect - SensorsCORROSION AND MOISTURE SENSORS FOR PREDICTIVE CUI MANAGEMENT
Sensors Type 1) Corrosion 2) Moisture
Sensor Length 1) Up to 100m 2) 50m
Temperature Range -50 to 1) +300 °C 2)+200 °C
Sensors
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Connect - ElectronicsATEX COMPLIANT PRODUCT FOR HAZARDOUS ENVIRONMENT
ATEX/IECEx Certification II 2 GDEx db IIB+H2 T3-T6 GbEx tb IIIC T85°C - T150°C Db
Ingress Protection IP66
Power Source Mains
Temperature Range (°C) - 20 to +60
Communications Wireless: Wifi/Cellular/WirelessHART/LoRaOther options: USB
Approx. Dimensions (mm): 284H X 245W X 169D (Without Antenna)
Approx. Weight 11.2 Kg
Corrosion & Moisture Monitoring System - Electronics
CorrosionRADAR Ltd. 15
Predict - Analytics Platforms
CR Predict Add-on Algorithm Products
CR Predict IIOT Cloud platform CR Predict Digital Twin platformCR Predict On-Prem Software platform
CR Automated Defect Recognition
Module using Machine Learning CUI Prediction Module
enabled by new improved models
CR Analytics Module
CorrosionRADAR Ltd. 16
CR Predict - CUI Prediction ModuleADD-ON ALGORITHM PRODUCT
Time
API 581 is industry guideline for CUI rate estimation CorrosionRADAR moisture
sensors provides critical factor FINF for accurate estimation of CUI rate.
The above plot is an experimental demonstration of CR prediction module
Continued laboratory testing for predictive models Validated to match industry standards
Case Study APRODUCTION COLUMN CORROSION MONITORING (ATEX)
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CorrosionRADAR Ltd. 18
(A) (B)
(C) (D)
Figure (A)
Installation of CR
corrosion sensors on a
3 inch pipe using cable
ties
Figure (C)
Installed CR Nodes
(electronic) driving CR
Moisture and
Corrosion sensors
Figure (B)
Installation of the pre-
fabricated insulation
around the pipe and
the corrosion sensor
Figure (D)
Moisture sensor is
placed inside the pre-
fabricated insulations
and installed at a fixed
distance from the pipe
Case Study BMOISTURE MONITORING SYSTEM
Moisture sensor
Corrosion sensor
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Case Study BMOISTURE MONITORING SYSTEM
Moisture
sensor data
analysis
and
correlation
with historical
weather data
Am
ount of
rain
fall
(mm
)Detected water ingress points
at 22 metres location
CorrosionRADAR Ltd. 20
Installed layout of both CR Corrosion and Moisture monitoring systems
Case Study CINSTALLATION OF CR SYSTEMS
1.0m
1.5m
2.5m
0.5m1.0m
1.0m
Corrosion sensor (10m)
Moisture sensor (10.5m)
Corrosion Bridge Cable (10m)
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Data after 6 months CORROSION AND MOISTURE MONITORING SYSTEMS
No corrosion signal observed
Sensor start
Sensor end
(Baseline)
Sensor start Sensor end(Baseline)
Corrosion Sensor
Moisture Sensor
Water detected
07:14 GMT on 11.06.2019
Moisture Sensor
Corrosion Sensor
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Data after 7 months CORROSION AND MOISTURE MONITORING SYSTEMS
Sensor start
Sensor end
(Baseline)
Sensor start Sensor end(Baseline)
Corrosion Sensor
Moisture Sensor
Moisture Sensor
Corrosion Sensor
Reduced reflection
from sensor end
05.07.19
Minor anomaly
05.07.19
Water detected
08:00 GMT on 05.07.2019
Shift in sensor end
indicates water
presence along the
sensor
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Benefits of CUI Monitoring System
COST RISKESTIMATED
MAINTENANCE
COST SAVINGS:
30-45%
CorrosionRADAR Ltd. 24
CUI Monitoring
(Corrosion & Moisture)
Data Driven RBI
Optimised
Maintenance
Less human
intervention
Reduced assets
Risk
Early Detection
Reduced
unplanned
Shutdowns
Leak
Prevention
Reduced
maintenance cost
CUIPREVENTION
PREDICTIVEMAINTENANCE
Benefits of CUI Monitoring System
HeadingSUB HEADING
Enabling Smarter Assets
CorrosionRADAR Ltd
Future Business Centre
King’s Hedges Road
Cambridge, CB4 2HY
www.corrosionradar.com
HeadingSUB HEADING
Enabling Smarter Assets
CorrosonRADAR Ltd
Future Business Centre
King’s Hedges Road
Cambridge, CB4 2HY
www.corrosionradar.com
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