Digitally Monitoring Corrosion and Erosion.

Operators can drive plants to their maximum capability and avoid costly incidents with a fully integrated corrosion and erosion monitoring suite of software and service solutions

A complete corrosion and erosion monitoring portfolio with digital capabilities and full integration with the Plantweb™ digital ecosystem through the new

Rosemount 4390 Transmitter

Rosemount™ 4390 series of corrosion and erosion wireless transmitters and Plantweb Insight Non-Intrusive Corrosion application has been introduced by Emerson. The monitoring portfolio turns existing offline corrosion probes into online tools to monitor for the risk of corrosion or erosion in oil and gas processing.

“Launching these products augments Emerson’s existing corrosion and erosion monitoring capability within our Plantweb ecosystem. Wireless data retrieval enables cost-effective deployment at-scale, class-leading data visualisation and analysis software, and connected services for our clients to fully monitor their corrosion and erosion challenges to drive maximum capability and profitability in their plant assets,” said Jake Davies, global product director for Emerson’s corrosion business.

Combined with Emerson’s class-leading range of non-intrusive Rosemount Wireless Permasense sensors for monitoring metal thickness, which is a major factor in determining the health of piping and other fixed equipment, Emerson now offers a comprehensive solution to monitor both the risk of corrosion or erosion, and the impact of that risk on the health of the plant or asset.

The new Plantweb Insight Non-Intrusive Corrosion application for non-intrusive corrosion monitoring complements the existing suite of Plantweb Insight applications, enabling comprehensive corrosion and erosion analysis at the end-user’s desk.

Plantweb™ Insight Non-Intrusive Corrosion Application

When instrumented with inline probes, changes in corrosion risk can be detected in minutes, enabling sites to take corrective actions before damage occurs. The Rosemount 4390 series of corrosion and erosion transmitters leverage WirelessHART® for reliable and robust data retrieval and work with Emerson’s inline probes that measure the corrosive and erosive nature of the fluid and provide early risk detection for a site. The Plantweb Insight Corrosion applications allow users to access and analyse data from pipe thickness monitoring sensors and inline probes at their desk and gain real-time advanced analytics to assess the risk and impact of corrosion or erosion on the asset or plant.

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Corrosion/erosion monitoring

In the oil and gas industry alone, corrosion- and erosion-related losses total billions of dollars every year through unscheduled plant or pipeline shutdowns, lost production, high repair costs, and imposed fines. In addition, incalculable damage can result from potential employee injuries and the effect of spillage on an organization’s reputation.

In industries where the integrity of piping, vessels, and other fixed assets can be compromised by corrosion or erosion, the consequences of failure can be both serious and costly. Historically, time-based, manual inspection methods have been employed to mitigate these risks; unfortunately, this is a very costly approach, frequently involving excavation, scaffolding, special permits, and other expenses. As a result, the annual maintenance costs for assets relying on manual inspection methods are among the highest in the operation.

GE’s Rightrax® system (from GE Energy) reduces these problems using innovative online technology to end costly, time-based inspections while simultaneously providing better, more timely, and more frequent corro­sion/erosion information that dramatically decreases the risk of asset failure. With ROI for the Rightrax system typically less than a year, the economics of going online are compelling. With support for the Rightrax system now available in GE’s System 1® Software, going online is easier and more powerful.

The system uses non-invasive, ultra­sonic sensing technology that attaches to the outside of the asset and measures wall thickness. Rightrax sensors can be polled periodically, allowing users to assess not only useful life remaining by comparing current values to minimum thickness limits, but to establish historical trends. This ability to trend data sets it apart from even the most frequent manual inspection regimens. The benefits are two-fold:

First, users can understand the rate at which corrosion/erosion is progressing, allowing better maintenance planning. Second, users can correlate Rightrax data with process data, providing powerful insight into cause-effect relationships that can help operators understand and avoid the conditions that accelerate corrosion/erosion rates and corresponding asset degradation.

Second, integration provides Rightrax users with all the powerful capabilities native to System 1 software for displaying, trending, analyzing, plotting, and correlating data. It provides powerful import/export functionality for integration with reporting tools and programs, such as Crystal Reports® and Microsoft® Excel®. What sets the power of the System 1 environment apart is its decision support technology: powerful automa­tion capabilities that can automatically analyze data using sophisticated, user-written rules and embedded knowledge. When specific conditions or anomalies of an unknown origin are detected, the system can send intelligent advisories to appropriate personnel.