Piping CML Optimization,

Design to Reality
Mehdi Samadzadeh
BureauVeritas Angola
[email protected]
 What is Condition Monitoring Location
(CML)?
❖ CMLs are specific areas along the piping circuit where inspections are conducted. The nature of the CML varies

according to its location in the piping system. The allocation of CMLs shall consider the potential for service-

specific damage mechanisms; e.g. localized corrosion, as described in API 574 and API 571. Examples of different

conditions to be monitored at CMLs include wall thickness, stress cracking, CUI and high temperature hydrogen

attack.

❖ Question that occurs to mind for choosing condition monitoring locations:

• How many CMLs?
• Where to place CMLs?
• How to inspect CMLs?
 Performing Data Optimization and Determining
Appropriate CML Coverage

❖ Number of CMLs Before/After Optimization:

O ptimizing Thicknes s Meas urement Locations

Reduction% After Opt Before Opt Platform
46.53% 14342 26825 SP1
35.63% 1512 2349 SPD2
60.75% 2533 6453 SPD3
59.87% 2672 6659 SPD4
65.71% 2471 7207 SPD5
63.35% 2548 6952 SPD6
77.37% 2231 9860 SPD7
78.24% 2234 10266 SPD8
77.68% 2231 9995 SPD9
49.65% 2328 4624 SPD10
51.46% 2179 4489 SPD11
61.04% 37281 95679 Total
Risk Relation with Equipment

4
 Determining Criticality
❖ This entails understanding how the asset is designed, how it operates, its operating conditions
(e.g., temperature and pressure), process fluids, metallurgy, and associated level of risk or other
available measures of severity such as pipe class. Severity should be determined in order to
escalate placement of CMLs on circuits that are more likely to fail by means of degradation, or that
have a greater consequence of failure.
Corrosion model assessment
based on flow regime
 Flow Regime Map
❖Importance of flow regime prediction:
✓ Reliable design
✓ Piping operability
✓ Prediction of corrosion and erosion
✓ Distribution of corrosion, hydrate formation, etc
✓ Inhibitor performance

❖ The key to prediction of the flow regime is to prepare flow regime

map.
❖Flow regime map gives a description of the geometrical
distribution of a multiphase fluid moving through a pipe.
❖Challenge: Flow regime map will change with the change of
✓ Velocity of each phase
✓ Phase fraction
✓ Pipe diameter
✓ Inclination of pipe
 Flow Regime in Horizontal Pipe
❖ Flow regimes in a horizontal pipe for gas-liquid system:
 Flow Regime in Vertical Pipe
✓ Bubble flow
• Continuous liquid phase with dispersed bubbles of
gas
✓ Slug flow
• Large gas bubble (almost the size of pipe
diameter)
• Slug of liquid with small bubbles in between
✓ Churn flow
• Bubbles start to coalesce
• Elongated bubble
✓ Annular flow
• Gas becomes the continuous phase
• Droplets of liquid in the gas phase
Effect of Pipe Diameter on Regime Map
 Effect of Pipe Inclination on Regime Map

❖ Negative Inclination ❖ Positive Inclination

Corrosion Type Based on Flow Regime
Turbulent Flow Through Pipe Fittings
Using Computational Fluid Dynamics
(CFD) Approach
 Velocity Contour for Different Pipe Fittings
❖ Velocity contour for 90⁰ elbow: ❖ Velocity contour for 90⁰ bend:
 Velocity Contour for Different Pipe Fittings
❖ Velocity contour of a tee junction for different inlet/outlet cases :
 Velocity Contour for Different Pipe Fittings
❖ Velocity contour of a reducer :
Flow Accelerated Corrosion in
Elbows
 Flow and Mass Transfer Effect on Flow-Accelerated Corrosion in
Single Elbows
❖Flow and pressure distributions
along a single elbow:
❖ When flow enters the inlet of the elbow, the
axial velocity varies across the elbow cross-
section and is lowest at the extrados and
highest at the intrados.

❖ The extrados of the elbow forces the fluid

around the curved path, causing the fluid to
accelerate. Based on the conservation of
energy, there will be a higher pressure at the
extrados and a lower pressure at the intrados.

❖ The higher pressure at the extrados forces fluid

circumferentially through the wall boundary
toward the elbow intrados.
 Flow and Mass Transfer Effect on Flow-Accelerated Corrosion in
Single Elbows
❖Mass transfer coefficient distributions along a single elbow:

✓ The MTC in the upstream straight pipe is 0.092 mm/s, Intrados after

the entrance MTC = 0.183 mm/s (Region I), Two sides or cheeks of

the intrados near the exit MTC = 0.172 mm/s (Region II), Extrados

just downstream of the exit MTC = 0.156 mm/s (Region III).

✓ The enhanced MTC in Region I and Region II are caused by the

higher velocity gradient and shear stress along the intrados.

✓ The enhanced MTC in Region III is caused by the flow

impingement on the extrados after the elbow exit.

 Flow and Mass Transfer Effect on Flow-Accelerated Corrosion in
Single Elbows

❖Sherwood number distributions along a single elbow:

✓ The numerical results of the Sh distribution along a single elbow are presented in Figurec, with Sh numbers of

6610, 6404, and 5663 in the 3 regions of enhanced MTC, respectively.

✓ The Sh number at the upstream straight pipe section is 3308, so the enhancement ratios are 2.0, 1.9, and 1.7 in

the 3 regions.
 Determine CML placement and allocation

✓ What are the environments present within the asset?

✓ What is the severity of each environment?

✓ What is the damage mechanism morphology?

✓ What is the risk, as determined by RBI assessments or anticipated corrosion rate/susceptibility?

✓ What effect will conditions, e.g. flow, upsets, intermittent operations, etc. have on anticipated

environments?
 Performing Data Optimization and Determining
Appropriate CML Coverage

❖ Number of CMLs Before/After Optimization:

O ptimizing Thicknes s Meas urement Locations
Reduction% After Opt Before Opt Platform
46.53% 14342 26825 SP1
35.63% 1512 2349 SPD2
60.75% 2533 6453 SPD3
59.87% 2672 6659 SPD4
65.71% 2471 7207 SPD5
63.35% 2548 6952 SPD6
77.37% 2231 9860 SPD7
78.24% 2234 10266 SPD8
77.68% 2231 9995 SPD9
49.65% 2328 4624 SPD10
51.46% 2179 4489 SPD11
61.04% 37281 95679 Total
 Sample of Corrosion Rate
0.15
0.14 Before Opt
0.13
0.12 After Opt
0.11
0.1
0.09
CR Rate

0.08
0.07
0.06
0.05
0.04
0.03
0.02
All High Medium Strt Fittings Internal Elbow External Elbow Tee 12 clock 06 clock

Thickness Measurement Locations

Before Opt After Opt

Average Corrosion Rate For All 0.0401 0.0844

Average Corrosion Rate For High 0.0408 0.0863

Average Corrosion Rate For Medium 0.0392 0.0822

Average Corrosion Rate For Strt 0.0391 0.0768

Average Corrosion Rate For Fittings 0.042 0.0963

Average Corrosion Rate For Internal Elbow 0.0489 0.1177

Average Corrosion Rate For External Elbow 0.0363 0.0736

Average Corrosion Rate For Tee 0.042 0.0959

Average Corrosion Rate For 12 clock 0.0392 0.0794

Average Corrosion Rate For 06 clock 0.0392 0.0769

 IDENTIFY PRACTICAL LIMITATIONS
✓ Is scaffolding required?
✓ Does insulation need to be removed? Thickness measurement of an over board line

✓ Is this high-temperature service?

✓ The layout of line (Horizontal or Vertical)
✓ Upper deck of the line
✓ Could an employee be exposed to significant risk?
✓ What is the risk reduction versus cost of inspection?
✓ Complexity
Remained Points

Scaffold 449

OverBoard 1133

Corrosion 431

Insulation 2745
PRACTICAL LIMITATIONS
 Update MI Program Components and
Establish Ever-Greening
✓ Visually identifying new CMLs in the field

✓ Updating inspection isometrics to reflect CML updates

✓ Updating the Inspection Data Management System (IDMS) to reflect CML and Inspection Plan
updates

✓ Verifying a strong Management of Change (MOC) process is in place to ensure the CML
Optimization analysis remains valid and is appropriately reviewed if there are significant changes
in facility design or operations
 Sample of Thickness Measurement Reading
(Inspection History)
5th
1st 1st 2nd 2nd 3rd 4th 5th 6th 7th 8th
3rd 4th Readi 6th 7th 8th
READI READIN READI READING Reding Reading Read Reading Reading Reading
Reding Reading ng Reading Reading Reading
NG G DATE NG DATE Date Date ing Date Date Date
Date
3.6 23/09/2012 4.02 15/04/2015 3.8 02/04/2016 3.71 01/02/2017 3.80 13/01/2019 3.66 15/12/2020
5.4 23/09/2012 3.99 15/04/2015 4.3 02/04/2016 4.27 01/02/2017 4.13 13/01/2019 4.30 15/12/2020
5.6 26/09/2012 3.95 15/04/2015 4.89 15/02/2016 4.52 25/12/2016 4.41 14/01/2019 4.03 17/12/2020
3.9 26/09/2012 4.15 15/04/2015 3.9 15/02/2016 3.91 25/12/2016 3.82 14/01/2019 3.64 17/12/2020
4.1 26/09/2012 4.26 15/04/2015 4.1 15/02/2016 4.08 25/12/2016 3.85 14/01/2019 3.90 17/12/2020
3.8 26/09/2012 4.02 15/04/2015 3.99 15/02/2016 4.1 25/12/2016 3.75 14/01/2019 3.81 17/12/2020
3.8 26/09/2012 3.98 15/04/2015 4.06 15/02/2016 3.94 25/12/2016 3.82 14/01/2019 3.79 17/12/2020
3.9 26/09/2012 3.89 15/04/2015 3.93 15/02/2016 3.85 25/12/2016 3.72 14/01/2019 3.76 17/12/2020
3.8 26/09/2012 3.71 15/04/2015 3.93 15/02/2016 3.94 25/12/2016 3.68 14/01/2019 3.55 17/12/2020
2.9 26/09/2012 3.93 15/04/2015 3.28 15/02/2016 3.63 25/12/2016 3.37 14/01/2019 3.42 17/12/2020
5.2 26/09/2012 4.02 15/04/2015 4.29 15/02/2016 4.1 25/12/2016 3.85 14/01/2019 3.83 17/12/2020
5.1 26/09/2012 5.62 15/04/2015 5.58 15/02/2016 5.27 25/12/2016 5.22 14/01/2019 5.12 17/12/2020
5.2 26/09/2012 5.8 15/04/2015 5.48 15/02/2016 5.63 25/12/2016 5.54 14/01/2019 5.53 17/12/2020
3.5 26/09/2012 4.23 15/04/2015 3.61 15/02/2016 3.66 25/12/2016 3.50 14/01/2019 3.61 17/12/2020
5.3 26/09/2012 4.12 15/04/2015 4.37 15/02/2016 3.96 25/12/2016 3.88 14/01/2019 3.74 17/12/2020
3.4 26/09/2012 4.16 15/04/2015 4.05 15/02/2016 3.79 25/12/2016 3.90 14/01/2019 3.95 17/12/2020
3.9 26/09/2012 4.04 15/04/2015 3.98 15/02/2016 4.03 25/12/2016 3.76 14/01/2019 3.95 17/12/2020
3.4 26/09/2012 3.82 15/04/2015 3.9 15/02/2016 3.92 25/12/2016 3.72 14/01/2019 3.75 17/12/2020
5.1 26/09/2012 4.01 15/04/2015 4.53 15/02/2016 4.1 25/12/2016 3.99 14/01/2019 4.00 17/12/2020
4.1 26/09/2012 3.91 15/04/2015 4.05 15/02/2016 3.96 25/12/2016 3.87 14/01/2019 2.12 17/12/2020
3.8 26/09/2012 4.07 15/04/2015 3.93 15/02/2016 3.82 25/12/2016 3.81 14/01/2019 3.80 17/12/2020
5.3 26/09/2012 5.12 15/04/2015 6.17 15/02/2016 5.7 25/12/2016 5.76 14/01/2019 5.58 17/12/2020
5.2 26/09/2012 4.74 15/04/2015 4.61 15/02/2016 4.52 25/12/2016 4.42 14/01/2019 4.54 17/12/2020
4 26/09/2012 4.23 15/04/2015 3.87 15/02/2016 4.1 25/12/2016 3.86 14/01/2019 4.28 17/12/2020
3.8 26/09/2012 4.26 15/04/2015 3.78 15/02/2016 4.03 25/12/2016 4.21 14/01/2019 3.98 17/12/2020
5.2 26/09/2012 6.12 15/04/2015 6.48 15/02/2016 6.07 25/12/2016 5.94 14/01/2019 5.92 17/12/2020
5.5 26/09/2012 4.21 15/04/2015 5.09 15/02/2016 4.67 25/12/2016 4.74 14/01/2019 4.69 17/12/2020
3.6 26/09/2012 4.11 15/04/2015 3.69 15/02/2016 3.94 25/12/2016 3.93 14/01/2019 3.05 17/12/2020
KPI
 Conclusion

✓ Step 1: Generate Corrosion Model (Or leverage existing if available)

✓ Step 2: Perform Data Optimization and Determine Appropriate CML Coverage

✓ Step 3: Determine CML Placement

✓ Step 4: Identify Practical Limitations (but do not let ease of access drive the locations)

✓ Step 5: Update MI Program Components and Establish Evergreening

Thanks for your
attention