Ultrasonic Corrosion Surveys

Presented by

Harold Hadley
Inspection Consultant and Contract Chief Inspector for
Provident Energy
1

Where to Look

Where to look is the first question when

planning a UT corrosion survey. You must
have an understanding of:

The corrosion potential of the location.

Corrosion mechanisms.

Where the corrosion will occur.

To

understand where the corrosion will occur some

understanding of the process is required.

How to look
How

is the data collected?

Collect

as data points?
Collected as scan information?
Are the data points to be repeated in the
future?

How to look
How is the data reported?
Has

information already been collected from

this site?
Are there previous reports to refer to?
Did the previous inspection take into
account the above comments?

Consider a Typical Inlet System

To inlet separator
To test separator
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Typical Inlet System

Where would the corrosion be?

Ground level

How to Collect the Data

Operation

of the Ultrasonic instrument is

straightforward, however challenges emerge
in obtaining answers to the following:
Where

do we put the probe?

Should we scan the area? Use single point?
How can we make it repeatable?
Could we find an anomaly again if we looked
in 6 months? 2 years?
Could someone else find the anomaly?
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Consider the Data Collection

We need reference points.
350

Insulation Kit
2
3
1

351

352

Base Line Location Elbows

For elbows start at the first weld and follow the
direction of the flow taking a data point every 1.5
inches or 4 cm.
What about horizontal elbows?
7
6
5
4
3

Start the data collection in the

same area (be sure you are
measuring on the bottom).
In the case of high velocity all
measurements should be on
the outside of the elbow.

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A Second Look at the Inlet

350

351

352

For data points that are on the bottom of the line use the
same considerations (352).
Start the data from a reference point and collect data in the
direction or flow.
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Base Line Information Elbows

Critical

4
5

.298*
.307

.087

How is Critical Determined?

Where exactly are these points?
How is life expectancy calculated?

Life Expectancy (Years)

12

The Next Surveys

Dec May Apr
2002 2004 2006

Total Avg. Period

Loss Loss Loss
(Mils) MPY MPY

Look at the data calculations.

Are we comparing the base line data to current data?

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Consider a 2-Phase Separator

Gas

PSV to Flare or Tank

Mist Pad

Typical Liquid Level

Float Column
Liquid
Inlet Separator (Two Phase)

Where would the corrosion be?

Where would damage be?
What type of corrosion or damage can be expected?
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Where to Look on a Vertical Vessel

410
415

Mist Pad
Typical Liquid Level

Inlet Separator (Two Phase)

420

Float Column
Liquid

425
430

15

Location Explanations
Why

did we look at those locations?

Because it is the most likely place that corrosion

damage will occur in a vertical vessel.

Top head:

Condensation corrosion and under-deposit corrosion.

Shell:
Across the mist pad,
Interface between the gas and liquid,
Liquid phase,
There should be at least one band on each segment.

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Location Explanations
Bottom

Head

Liquid

phase corrosion,
Under-deposit corrosion.
Bottom

Elbow

Stagnant

liquid corrosion potential,

Flow induced corrosion.

17

Tall Columns

Mist Pad

18

Consider a 3-Phase Separator

Gas

PSV to flare or tank

Inlet Deflector
4

7
Mist Eliminator

Weir or Baffle

3
Water
Level

Liquid Off
Points

Liquid Hydrocarbon
6
5

Where would the corrosion be?

19

Three Phase Locations

Mist Pad

There is little difference when choosing

locations for inspection on horizontal or
vertical vessels.

(Lay vessel on its side, remove some hardware, and alter

internal configurations).
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Inlet Reciprocal Compressor

Where would the corrosion be?

Is corrosion the only damage that could occur?
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The Locations
Look

at all the locations and consider the

numerous areas where damage can
occur.
Rotating

Equipment introduces damage due

to the Vibration Factor.
The

corrosion survey on compressors must

include an inspection for cracking.

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 The

following are examples of

interesting failures and damage.

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25

26

27

28

29

Pipeline Failure

Pipeline Failure

A line failed at a Y junction. Junction is under a road. Junction had been worked on.
Line PSVs were being tested prior to Start-up.

Line failed at a Y junction under a road during PSV testing prior to start-up.
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Remember the Following Rules

RUST NEVER SLEEPS

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Remember the Following Rules

CORROSION OCCURS IN
LOCATIONS THAT ARE THE:
COLDEST
WETTEST
MOST INCONVENIENT

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Remember the Following Rules

Your job
(should you choose to accept it)
is to find that location!

(This is not Mission Impossible).

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