CORROSION failure caused a major operator from the Gulf of Mexico geomarket to shut in an offshore production pipeline. An investigation of the failure found that, while the operator was on a chemical corrosion inhibition programme, there was no definitive way to confirm that the treatment was effective or even if the pumping systems were operating.
Manually monitoring the volume of chemical being injected on remote, unmanned platforms can be challenging and problematic. In this case, the operator added seven chemical injection skids to the existing systems to protect against additional corrosion problems. Adding the injection points cost more than $127,000 each month and increased chemical consumption by more than 7,000 gal (26,500 litres).
“The operator wanted a permanent solution that was cost effective, simple, and would help prevent future failures,” says Jim MacLeod, chemical automation applications engineer for Baker Hughes.
Baker Hughes field chemicals personnel suggested the use of Sentrynet FLX wireless tank monitors. The remote monitoring system would not only alert the operator’s staff to over- or under-treatment events, it would also verify the chemicals were actually being injected and would help manage the chemical inventory.
The Sentrynet technology transmits chemical tank data via satellite communications to a secure, Web-based, Baker Hughes data platform. “The service compares the onsite data to target injection rates and can send an alarm when out-of-parameter situations occur,” adds MacLeod. “This prompts the operators to quickly respond and correct the problem.”
The operator installed Sentrynet FLX tank monitors at 19 corrosion injection sites to qualify as a permanent solution. The Baker Hughes Chemical Automation team worked with operations personnel to install the correct tank monitor sensor technology and assure that accurate data was being collected and aggregated at all the locations.
When the monitors were in place and the website set up, the Sentrynet solution: Verified chemical injection and usage; enabled fieldwide, remote observation of chemical activities; identified injection locations with erratic injection behaviour and alerted the operator; provided the operator custom web viewing and reporting as well as the status of the available chemical inventories; streamlined the chemical provision process and reduced customer risk and unnecessary field expense.
“The Sentrynet service delivered on all levels,” MacLeod says. “The reliability of the data assured the operator that the production facilities were protected by a proper, effective and verifiable chemical corrosion inhibition programme. The operator removed the additional injection systems, saving more than $1.7 million annually. In addition, the customer made the Sentrynet tank monitors a recommended best practices process for the company.”
According to the company, Baker Hughes Sentrynet tank monitoring services enhance production chemical programme while reducing risk and exposure.
“The wide range of level sensors and wireless communications technologies send data to the secure Baker Hughes website, so companies can monitor their entire field and determine their production and chemical status,” says the company .
“With Sentrynet remote access, your people have field-wide visibility. They will be able to concentrate on the most critical and urgent needs, rather than spending unproductive windshield time randomly searching for problems. Reliable, automated tank monitoring reduces labour costs and health safety and environment (HSE) risks by minimising employee travel,” it explains.
Wireless tank monitors help to maintain the integrity of well and protect investment in chemicals and equipment. Sentrynet tank monitors verify well sites get the required chemical treatment by verifying the chemical usage and providing data on tank levels for inventory management, it says.
“The system automatically alerts firms when they’re over-injecting or underinjecting chemical, while at the same time prompting them when they need to refill the tank. Sentrynet secure, web-based monitoring can also produce historical data analysis to support planning and budgeting activities,” it adds.
Web-based monitoring using standardised communication platforms delivers more data for analysis and action and ensures a more efficient and productive operation because they have the information to make better decisions.
Sentrynet tank monitoring services extend the capability of Baker Hughes Upstream Chemicals product line. This value-added technology helps us help companies by enhancing our ability to manage and react to their chemical servicing needs.
