WELD ROOT CORROSION MONITORING

WITH A NEW ELECTRICAL FIELD SIGNATURE MAPPING

INSPECTION TOOL

Roy Johnsen, Baard E. Bjornsen

CorrOcean ASA, Teglgaarden, N-7485 Trondheim, Norway

Derek Morton, Dennis Parr, Brian Ridd

CorrOcean Cltd., 430 Clifton Road, Aberdeen AB24 4EJ, Scotland

ABSTRACT

This paper presents a new technology for inspection and monitoring of metallic objects, pipes and
vessels. The system is based on a field proven, non-intrusive, internal corrosion monitoring technique,
which is designed to detect and quantify general metal loss, cracking, or pitting due to corrosion or
erosion.

The inspection tool allows inspection in areas where more conventional inspection techniques
(ultrasonic or intrusive probes) are either costly or difficult to apply.

The significant advantages include the ability to operate in a wide temperature range (- 40 to +
400C); non-intrusive, no operator dependency; measures changes in the actual pipe wall, allows
remote intervention; can be applied to any geometry or wall thickness and maintains a high sensitivity
of one part per thousand of wall thickness for general corrosion.

This paper describes the inspection system and results from a validation test performed to prove the
quality of the measured data for weld root corrosion.
 INTRODUCTION

The techniques and technologies that are currently applied have been utilised in the market for many
years and their potential with respect to sensitivity and inspection life cycle costs would appear to have
been fully exploited. The electric mapping is a sensitive monitoring technique, which has been utilised
since 1991 for monitoring of corrosion/cracking/erosion in vessels and pipework, at more than 90
locations world-wide, both top-side and subsea. Systems are being operated under various
environmental conditions from extreme heat in the desert to extreme cold. Furthermore, systems have
been installed in different hazardous areas: in nuclear power plants and for oil companies in explosive
atmospheres, classified as Ex Zone 1 and 2.

Most the systems delivered are fixed installations where the sensing pins and instrumentation are
permanently attached to the monitored object. The remaining 10% are based on a portable
instrument with clamp on pin holders which have mostly been delivered for laboratory applications.
This design has the same functional specification and has shown that the electrical mapping technique
could be applied for portable NDT instrumentation.

In offshore operations, process plants and refineries, an extensive amount of inspection work is
undertaken, often in the form of key point inspection. Various techniques are used, such as
ultrasonics, radiography and eddy current. It was felt that the mapping technology could be developed
to be a significantly more sensitive, versatile and user friendly inspection tool than the traditional
techniques, and at a competitive cost level. Modification to the technology was however, required for
such a development.

THE ELECTRICAL FIELD SIGNATURE MAPPING PRINCIPLE

The Field Signature Method (FSM)1 is based on feeding a current through a selected section of the
structure to be monitored and sensing the electric field pattern by measuring small potential differences
set up on the surface of the monitored object. The first measurement (signature) is unique to the
geometry of the object. When general or local corrosion occurs the pattern of the electric field will
change and can be compared with the signature. By proper interpretation of the changes in the
potential differences, conclusions can be drawn, e.g. regarding general wall thickness reduction or
localised corrosion.

Figure 1 gives an illustration of the principle: The induced electric current in a pipe, will create a
pattern determined by the geometry of the structure and the conductivity of the metal. This pattern is
represented by current flow lines and equi-potential lines which are normal to the current flow. The
subsequent potential measurements on each pin pair (up to 224 can be applied in a matrix) are
compared to the unique field signature and the changes processed to define the change in pipe wall
over time.

Traditionally the biggest market for internal corrosion monitoring has been related to offshore oil and
gas production and oil refineries. The systems main advantages are :

1
FSM is a trade name
 Monitoring of corrosion is taken directly on the pipe wall, and therefore gives more reliable and
representative information than traditional intrusive probes.
The system can distinguish between different forms of corrosion, e.g. general and pitting corrosion.
The mapping field sensors are non-intrusive and does not introduce any risk for leaks of possible
hot and aggressive fluids (unlike intrusive corrosion probes),
It can be used for locations where access for traditional probes is difficult, and for high
temperatures (over 160C) where the application of probes and UT is limited.
Welds can be monitored directly for eg weld root corrosion.

Until recently this mapping technology has not been widely used in refineries, mainly due to the
operational conditions in such plants which are different from the offshore/pipeline markets. In its
original format, the system was not well suited for such onshore applications with relatively high capital
cost compared to traditional corrosion monitoring techniques.

The project to adapt the technology for refineries and process plants was commenced in 1996, with
financial support from Shell and Elf. The objective was; define, design and construct a new high
sensitive and flexible inspection tool based on the the field signature mapping technique. This paper
offers a brief presentation of the development, testing and operation of the inspection tool; FSM-IT2

DEVELOPMENT OF THE INSPECTION TOOL

The first phase of the development project was to undertake a market survey to determine the needs
of the potential users. A total of 17 representatives from both oil and inspection companies were
contacted who offered the following comments with respect to the concept of the tool.

The tool should be easy to use, and data collected should be independent of the skills of the
operator; i.e. anyone can operate the instrument.
The tool should provide repeatable measurements, i.e. higher reliability compared to competing
techniques, this would be another significant advantage for the concept.
Improved measurement reliability is considered more important than accuracy/sensitivity. However,
improved accuracy/resolution is expected to become a more important requirement in the future.
Sensors that are easily relocated/moved are generally looked upon as advantageous compared to
stationery sensors. An exception may be for detection of crack propagation in welds located under
insulation on tanks/vessels.
Portable instrumentation was requested.
The unit price for the sensor device may be critical to the success of this product, since each user
will likely have a high number of inspection locations. Only one portable meter (instrument and
software) will be needed, thus the unit cost of the meter and software is less important.

Based upon the above industry needs the following product objectives were established;

reliability of readings to be independent of operator

instrument to be small and portable
high quality and repeatability of data required
fast and efficient to utilise
accuracy better than for existing inspection methods (UT)

2
FSM-IT is a trade name
 SYSTEM DESCRIPTION

The inspection system that has been developed is illustrated in Figure 2 and consists of a sensing

matrix, a portable instrument and software.

The Sensing Matrix (SM) is made up of a series of pins stud welded to the area to be inspected. This
fixed pin type matrix provides for a very high degree of repeatability in readings. A Sensing Matrix
Interface (SMI) forms an interface between the SM and the portable instrument and includes a
programmable identification tag for the location as well as noise filtering circuitry. The cabling between
the sensing pins and the instrument connection can vary depending on the application, generally the
instrument connection point is sited at a location which provides safe and convenient access, typically
the cable can be from 3-10 metres. The fixed pin array, can be installed very quickly, and allows
inspection of locations across a wide temperature range (- 40 to + 400 C ). The stud welding
technique is an approved surface weld technique and can be applied at operating temperatures with no
detrimental effect on the pipe. Other methods of attaching the pins are currently being developed e.g.
strap array and conductive strip.

The portable instrument provides the direct current feed and data storage. It is certified for Zone 2
hazardous area operation and comes complete with spare battery, charger and carrying case and
weighs 5kgs (with battery). The instrument is menu driven via an easy to operate touch screen and
can interrogate up to 50 discrete locations (measurements) before the battery requires to be re-
charged/replaced. The stored data is downloaded to a PC which runs the FSMTrend3 software
package, in a safe environment. Typical interrogation period is around 5 minutes from making the
connection to the Sensing Matrix cable connector, taking reading and disconnecting. The instrument
also provides self diagnostic checks and for the Sensing Matrix when connected.

VALIDATION TEST

A programme of intensive testing was conducted to prove all aspects of the new inspection system
thoroughly and to further validate the technique. A validation test using the inspection system was
undertaken in conjunction with Shell Expro. The objectives of the test are described below.

The objectives of the validation test

Demonstrate the technologys ability to detect weld root corrosion in a test pipe (0.25-0.5 mm
depth). The test pipe was a 4OD, T-piece with wall thickness of 17 mm.
Demonstrate accuracy and quantification of defects (groove depth computation)
Demonstrate sensitivity for detection and quantification of pitting corrosion and mesa attack.
Demonstrate the inspection tools operation and technology

The test comprised both the use of computer modelling of the T-pipe for optimising the pin matrix and
current feed points, and measurement with the new portable instrument. Weld root corrosion was
simulated in the T-pipe by machining a groove in the weld. Pitting corrosion was simulated on a plate
by an electrolytic method.

Computer modelling
3
FSMTrend is a trade name
A computer model (NISA FEM Model) of the T-Pipe for simulation of the sensitivity to weld root
corrosion and for optimisation of the pin matrix and current feed points, was used. Computer modelling
was also used for the design of a dedicated algorithm for weld root corrosion which was used in
addition to the general algorithm development previously for such corrosion.

Weld root corrosion in T-Pipe

The T-Pipe was fitted with a pin matrix and current feeding connections. The weld in the T-branch
pipe was monitored along with in a sector at 9 oclock downstream in the same branch. A 4 mm
wide groove was machined in the weld root to number of depths to simulate corrosion. The intention
of machining the groove was to have full control of the dimensions, for testing the accuracy of
quantifying different groove depths (See fig 3 and 4)

Pitting corrosion

A electrolytic method was used on a 19mm steel plate to simulate localised corrosion. The plate was
fitted with a pin matrix on the opposite side. To achieve different shapes of the pits, the plate was
coated and the coating removed according to the desired dimensions. Readings were taken with the
portable instrument each hour. Actual size (depth, width) of attacks were measured with a gauge at
the end of the experiment.

Depth Calculation

Depth of attacks were calculated based on the readings, utilising the designed software and associated
algorithms (See presentation in fig 5).

CONCLUSIONS

The following conclusions were drawn from the test:

The sensitivity for detection of weld root corrosion increases with the depth of the groove. For a
pipe with wall thickness 19 mm, a corrosion attack with an initial depth of 0.25 mm can be
detected. For a groove depth of 12 mm, a depth increase of 0.018 mm will be detected. For deeper
grooves and for smaller wall thickness the sensitivity to detect defect growth will be even higher.

Absolute accuracy for quantification of weld groove depth depends on how exact the width of the
groove is known. The test results showed that when using the correct groove width in the equations
and using a customised equation, the error is approximately 1%, and using the general equation the
error is 2.6%
Using e.g. 20% uncertainly for the groove width, will give an uncertainty of 5% for the depth
calculation. The total error of depth quantification is typically less that 10% for practical
applications. The accuracy in calculation increases with increasing groove depth, and is typically
3.5% for a depth increase of 1mm in a 10mm deep groove. In the test the machined groove was
approx 3.9mm, the electrical field signature mapping computed 3.82mm.

The pit calculation accuracy will in general have a systematic error of 10% to 20% for max. pit
depth calculations. This error is related to the geometry of the defect. Wider pits give better
 accuracy. The test showed an error of 10% for the deepest pit. For the same pit geometry, the
systematic error will always have the same value and not influence the rate calculation.

Pit detection sensitivity showed to be 0.05 mm for the widest pit in a 19 mm thick plate at the start
of the test. The pit had the same length as the pin pair separation distance and a width half of that.
The sensitivity is higher for wider pits.

Fig 1 Electrical Field Signature Mapping Principle.

Weld
Temperature sensor

Fixed pin matrix

Reference plate

Insulation

Current in
Current flow

SMI Ref.
SMI-A
SMI-B

Current out

Laptop PC with
Juntion Box FSMTrend for FSM-
Senser Matrix Interface (SMI) IT
28 Pin Pairs

Instrument
cable

Current cable

Cluster cable
InstrumentUnit

FSM-IT System Modules

 Fig 2 The Inspection Tool System Components.

Pin Current
Current Matrix out
in

Welds

Electrical field
pattern

Fig 3 Test Set-up drawing

Fig 4 Test Set-up

RESULTS OF WELD CORROSION TEST

1. Start of test 2. Defect depth

~ 0.5mm

3. Defect depth 4. Defect depth

~ 1.5mm ~ 2.5mm
Fig 5 Test Results - Weld Root Corrosion