Ultrasonic Corrosion Surveys

Presented by
Harold Hadley

Inspection Consultant and Contract Chief Inspector for

Provident Energy
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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.

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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?

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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?

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Consider a Typical Inlet System
Insulation
Kit

Insulation
Kit

Insulation
Kit

Insulation
Kit

To inlet separator To Inlet separator

To test separator
To test separator

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Typical Inlet System

Where would the corrosion be?

Insulation
Kit
2

Ground level

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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

352
351

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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.
2 1
3
4
What about horizontal elbows?
5 • Start the data collection in the
6 same area (be sure you are
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7
measuring on the bottom).
6 • In the case of high velocity all
5 measurements should be on
4
3
the outside of the elbow.
2 1

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A Second Look at the Inlet

350
Insulation
Kit
2

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 : .087

4 .298*
5 .307 How is Critical Determined?

Where exactly are these points?

How is life expectancy calculated?

Life Expectancy (Years)

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The Next Surveys

Dec May Apr

Total Avg. Period
2002 2004 2006
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
PSV to Flare or Tank Gas

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

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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.

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Tall Columns

Mist Pad

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Consider a 3-Phase Separator

PSV to flare or tank Gas 7

Inlet Deflector
Mist Eliminator
4 Weir or Baffle

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Water Liquid Off Liquid Hydrocarbon
Level Points
6

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Where would the corrosion be?
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Three Phase Locations

There is little difference when choosing

locations for inspection on horizontal or
vertical vessels.
Mist Pad

(Lay vessel on it’s side, remove some hardware, and

alter internal configurations).
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Inlet Reciprocal Compressor
Suction Bottles Discharge Bottle

1st Stage
Cooling

1st Stage
Scrubber 10
4
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5 11
7 4th Stage
1st Stage 31
Compression Compression 20
3rd Stage
8 9 32 33 Scrubber 2nd Stage
Cooling
Inlet 21 19
1 Scrubber
To Plant or
2 39
Process
3rd Stage
27 Cooling
15 4th Stage
3

6 Scrubber 36 37
16 17 24 25
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13 28 4th Stage
2nd Stage 3rd Stage Compressor
Cooling
Compression Compression Discharge
35 Scrubber
18
14 2nd Stage
Scrubber 12
26
34
30

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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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 Pipeline Failure
Pipeline Failure

A line failed at a Y junction. Junction is under a road. Junction had been worked on.
Line PSV’s 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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