Maintenance, Test & Measurement, Calibration

Wireless detection of erosion corrosion

6 July 2020 Maintenance, Test & Measurement, Calibration

While many forms of corrosion can be anticipated depending on the presence of corrosion causing factors such as H2S, water injection and oxygen in dry pipelines, erosion caused as a result of sand or solids cannot be directly identified. Since many sudden pipeline leaks and failures can be attributed to this phenomenon, it is a hidden threat to asset integrity.

While the corrosion stops after passive layer formation, solids, especially sand particles, often erode this layer, enhancing the corrosion rate. The sand can travel up to the terminals even with the best downhole completions or sand filters. The effect gets accelerated with high velocity of fluid for wells with high production rates. By detecting the sand at the wellheads, the flow rates can be altered in real time to achieve fluid velocity below critical velocity.

While the problem is complex, combining sand detection with the real-time corrosion monitoring downstream of the choke provides a complete solution. The areas with altered cross-section are subjected to increased velocity of the fluids with accelerated erosion. Devices measuring the change in the cross-section of the flowline provide real-time corrosion monitoring. It is also possible to estimate the life of the flowline with the current corrosion rates.

Emerson’s Sand Monitors, together with Permasense-corrosion monitoring, can be used to detect the erosion corrosion. Both devices are non-intrusive and easy to install and belong to the family of pervasive sensing devices. The combined solution is available in wireless configuration. This provides seamless data transfer of sand and resulting corrosion to the control room. The production engineers may view this data when transmitted to the control room for analysis and decision making. This facilitates real-time production optimisation.

The solution is believed to fetch a 66% ROI for a field with around 500-1000 wells. Software – called Fieldwatch – can provide the sand detection and erosion data for the field with ‘report by exception’ capability. This proves very beneficial for the production team to plan the well interventions and other actions in advance, i.e., a predictive maintenance strategy.

This wireless solution can help avoid manual inspections, which can be misleading due to human errors in observation and interpretation. It also helps through seamless data connectivity to the control room, leveraging predictive maintenance and a step towards digital transformation.

For more information contact Aarti Dange, Emerson Automation Solutions, +97 14 811 9157,,


Share this article:
Share via emailShare via LinkedInPrint this page

Further reading:

Predictive analytics for artificial lifts
September 2020, Emerson Automation Solutions , IT in Manufacturing
Machine learning and artificial intelligence applications in artificial lift systems have seen a growth in importance recently and are no longer a nice to have, but essential tools for well optimisation.

Wireless vibration monitor
September 2020, Emerson Automation Solutions , Industrial Wireless
Emerson’s AMS Wireless Vibration Monitor makes it possible to monitor motors, pumps, fans and other critical plant equipment to reduce downtime and achieve more reliable operations.

Leak detection has never been quicker and easier
September 2020, SKF South Africa , Maintenance, Test & Measurement, Calibration
SKF’s TKSU 10 ultrasonic leak detector is able to identify leakages in compressed air and vacuum systems, delivering substantial savings for end-users by reducing inspection time and minimising energy costs.

Best practices in measurement
September 2020, Yokogawa South Africa , Maintenance, Test & Measurement, Calibration
Operating envelopes are changing and the impact of these changes on instrumentation must not be underestimated. Instrumentation with a design rating of a particular capacity is heavily stressed when the load is increased.

Internal inspection of machinery
September 2020, SKF South Africa , Maintenance, Test & Measurement, Calibration
The TKES 10 Endoscope Series from SKF is designed for fast, easy internal inspection of machinery, delivering significant savings in terms of both time and money to customers and end-users.

Parker releases new software tool
September 2020, Parker Hannifin Sales Company South , Maintenance, Test & Measurement, Calibration
IQANgo enables service technicians or machine owners to connect wirelessly to modules in their machines, allowing them to perform a broad range of actions such as system status checks and troubleshooting errors or alarms.

Condition monitoring solutions from Turck Banner
September 2020, Turck Banner , Maintenance, Test & Measurement, Calibration
Turck Banner’s retrofit solution can be used in industrial plants that do not yet fully support Industry 4.0 sensor-based condition monitoring. Machines can easily be monitored by customised systems, with data transmitted via wireless networks if required.

Detect compressed air, steam, gas and vacuum leaks
September 2020, Comtest , Maintenance, Test & Measurement, Calibration
Comtest has introduced the Fluke ii900, a handheld sonic industrial imager that enables maintenance to quickly locate air, steam, gas and vacuum leaks in compressed air systems. The straightforward, intuitive ...

Emerson publishes 2019 Social Responsibility Report
July 2020, Emerson Automation Solutions , News
Emerson combines industry-leading technology and innovation to make a positive impact on employees, customers and communities around the world.

Digital classroom trains next generation workers
August 2020, Emerson Automation Solutions , News
Emerson has announced the launch of a new 'digital classroom', a virtual training facility that connects students throughout the Middle East and Africa region with Emerson experts who train them on a ...