28

Corrosion monitoring using the field signature

method inspection tool (FSM-IT)
N G U Y E N N. B I C H, P. Eng,
Pangea Solutions Inc, Canada

28.1 Introduction
An effective corrosion control program for a pipeline should contain the
following four components1:
• Understand the corrosion mechanisms prevailing during various phases
of operations including startup, steady-state operations, shut-in, etc.
• Formulate and implement mitigation measures according to the appro-
priate corrosion mechanisms.
• Validate the effectiveness of the corrosion mitigation measures by mon-
itoring corrosion at strategic locations.
• Verify the physical integrity of the pipeline by suitable inspection
activities.
This chapter describes several case studies where the use of the field sig-
nature method inspection tool has led to early warnings of the lack of
performance of the mitigation measures which, if left unchecked, could
result in more severe corrosion and eventually, failure.

28.1.1 Field signature method inspection tool (FSM-IT)

The FSM-IT technology is a non-intrusive corrosion monitoring tool con-
sisting of a geometric matrix of sensing pins (3 mm diameter) that are per-
manently attached to the outer pipe wall by spot welding (Figures 28.1 and
28.2). During measurements, by passing a controlled current through the
sensing matrix, an electrical field signature is established. The first signature
is unique to the geometry of the object. With the occurrence of internal
corrosion or erosion, the electrical field is changed. This change is detected
by the FSM-IT as a ‘potential drop’ across the matrix. Computer software
then compares new measurements against the original signature to produce
the metal loss value. The software can trend the metal loss over time, cal-
culate corrosion rates and create three-dimensional plots to illustrate accu-
mulated wall loss over the whole matrix.

658
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 Corrosion monitoring using the FSM-IT 659

28.1 Pin matrix layout.

28.2 An FSM-IT installation with protective cover.

To compensate for the effects of temperature on the conductivity of the

steel, the pin matrix measurements are compared to parallel readings taken
on a reference plate. This plate is made from the same material as the
pipeline and is thermally coupled to the external surface. By comparing the
reference plate and matrix readings, it is determined whether actual metal
loss or just a change due to temperature or both causes the detected shift
in electrical potential.
In terms of operating principles, FSM-IT is analogous to ER as FSM-IT
uses the structure as the sensing element. For that reason, this method
should be referred to as Electrical Resistance Matrix (ERM). FSM-IT

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660 Techniques for corrosion monitoring

monitors internal corrosion over a large area and can differentiate between
general corrosion and isolated pitting thanks to the matrix design where
general corrosion affects all pin pair responses and pitting corrosion only
affects nearby pin pairs.

28.1.2 Typical challenges for wet sour gas pipeline

corrosion monitoring
The most common form of corrosion encountered in wet sour gas is pitting.
The pitting growth, in many cases, starts with small or insignificant rate for
a prolonged period of time, then suddenly due to various reasons, unexpect-
edly jumps to a very high value leading to failures. Pitting rates in the order
of 50 mm/y have been reported in several wet sour gas pipelines. In many
cases, the pits are very isolated. It is quite common to find pit depths of
several millimeters and the pits are separated meters away from each other.
In between, the pipeline surface is covered with protective iron sulfide
scales and suffers no corrosion. A single point device such as a corrosion
coupon or an electrical resistance (ER) probe (see Chapter 11) will have
to be placed in a precise location to detect such isolated pits. Quite often,
the coupon or ER probe shows very little or no corrosion, but a leak can
develop just centimeters away. Due to the high toxicity of H2S, non-intru-
sive devices are preferred. In the author’s experience, FSM-IT is most
suitable and efficient for sour gas pipeline corrosion monitoring.

28.2 Case studies

Six case studies2–8 where the results from corrosion monitoring by FSM-IT
have been beneficial to maintaining pipeline integrity and timely in prevent-
ing failure are presented in this chapter. FSM-IT data acquisition covers all
pin pairs but in most applications, typical reports show the deepest metal
loss readings and the most active pin pairs. Positions of the pits can be
identified by the corresponding pin pair numbers.

28.2.1 Case study 1: 6 inch sour gas pipeline

The pipeline configuration and conditions are:
(a) pipeline particulars: 6 in (168.3 mm) in diameter and 12 km long
(b) fluid effluents: 15% H2S, 2% CO2, 100 000 ppm Cl− and elemental
sulfur deposition
(c) corrosion mechanisms: wet sour gas. Corrosion morphology: isolated
pits mainly at the 6:00 o’clock position
(d) mitigation: continuous injection as there was no launcher/receiver
facility.

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 Corrosion monitoring using the FSM-IT 661

28.3 An FSM-IT installation before earth filling.

K-3 12˝ FSM-IT accumulated wall loss trends and corrosion rates
7.0
Pitted area #1 -Accumulated NEW wall loss detected
6.5 in ADDITION to the original 2.0 mm pit depth
Pitted area #2 -Accumulated NEW wall loss detected
6.0
in ADDITION to the original 3.76 mm pit depth
5.5 Pitted area #1 Corrosion rate

5.0 Pitted area #2 Corrosion rate

4.5
Metal loss (mm)

4.0

3.5

3.0

2.5 35
FSM-IT readings (mm/yr)
Corrosion rate between

2.0 30
25
1.5 20
1.0 15
10
0.5
5
0.0 0
Sep 14
Sep 16
Sep 18
Sep 20
Sep 22
Sep 24
Sep 26
Sep 28
Sep 30
Oct 02
Oct 04
Oct 06
Oct 08

Oct 20
Oct 22
Oct 24
Oct 26
Oct 28
Oct 30

Nov 03
Nov 05
Nov 07
Nov 09
Oct 12
Oct 14
Oct 16
Oct 18
Oct 10

Nov 13
Nov 15
Nov 17
Nov 19
Nov 01

Nov 11

28.4 Case study 1: corrosion monitoring responses.

The line was shut down and FSM-IT device was installed ‘over’ existing pits.
The monitoring was started in September 2004.

Results
Figure 28.4 shows the monitoring results. Area 1 had an original pit depth
of 2.0 mm and was growing at a maximum rate of over 25 mm/y as detected
by FSM-IT. Area 2 had an original pit depth of 3.8 mm and was growing at

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662 Techniques for corrosion monitoring

a maximum rate of 28 mm/y as detected by FSM-IT. Up to 70% wall loss

was detected.

Benefits
Because of the timely detection of high corrosion rate by the FSM-IT
device, action was taken to cut out the section of the corroded pipe. In
adjacent areas not covered by the device, corrosion rate as high as 75 mm/y
was observed at the deepest pits. It was learned that it was difficult to miti-
gate deep pits with continuous-injection inhibitors. This FSM-IT monitoring
program effectively prevented sour gas leak under river.

28.2.2 Case study 2: 4 inch sour gas pipeline

The pipeline configuration and conditions are:
(a) pipeline particulars: 4 in (114.3 mm) in diameter and 4 km long
(b) fluid effluents: 24% H2S, 9% CO2, 42 000 ppm Cl− and elemental sulfur
deposition
(c) corrosion mechanisms: wet sour gas. Corrosion morphology: isolated
pits mainly at the 6:00 o’clock position
(d) mitigation: continuous injection and pigging/batching.
The previously corroded line was cut out and FSM-IT device was installed.
The monitoring was started in January 2001.

Results
Figure 28.5 shows the monitoring results. Significant corrosion was detected
from June 2002 with indicated wall loss of 87% as of January 2003.

Benefits
Because of the timely detection of high corrosion rate by the FSM-IT
device, action was taken to cut out the section of the corroded pipe (Figure
28.6). It was learned that changing operations (plunger lift) resulted in more
severe corrosivity/fluid flows. Actual wall loss was 44% and actual corrosion
rate of 5 mm/y allowed re-calibration of software. The second sour gas leak
was prevented.

28.2.3 Case study 3: 30 inch process water line

The pipeline configuration and conditions are:
(a) pipeline particulars: 30 in (762 mm) in diameter and 30 km long
(b) fluid effluents: process water

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 Corrosion monitoring using the FSM-IT 663

4˝ Sour gas pipeline – FSM-IT detection of isolated pit defect initiation and growth
3.5

3.0

2.5
Wall loss (mm)

2.0

1.5

1.0

0.5

0.0
Jan 01,01
Feb 01,01
Mar 01,01
Apr 01,01
May 01,01
Jun 01,01
Jul 01,01
Aug 01,01
Sep 01,01
Oct 01,01
Nov 01,01
Dec 01,01
Jan 01,02
Feb 01,02
Mar 01,02
Apr 01,02
May 01,02
Jun 01,02
Jul 01,02
Aug 01,02
Sep 01,02
Oct 01,02
Nov 01,02
Dec 01,02
Jan 01,03
28.5 Case study 2: corrosion monitoring responses.

28.6 Case study 2: actual cut-out from monitored area.

(c) corrosion mechanisms: oxygen corrosion. Corrosion morphology:

numerous pits occurring around the entire circumference of the pipe
(d) mitigation: continuous injection and pigging.
The line was shut down and one section was replaced with new pipe adja-
cent to an old section with 35% wall loss left in place. Two FSM-IT’s were

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664 Techniques for corrosion monitoring

28.7 Case study 3: two FSM-IT matrices installed on adjacent new/old

pipes.

installed on the two adjacent old/new pipes (Fig. 28.7) and another one on
one elbow. Corrosion monitoring was started in June 2002.

Results
Figures 28.8 and 28.9 show the monitoring results: 70% wall loss on old
pipe, 52% on new one as of November 2002. On-going corrosion rate was
in good trending agreement with LPR and ER (located in the plant further
upstream) probe readings.

Benefits
Because of the timely detection of high corrosion rate by the FSM-IT
devices, action was taken to cut out both new/old sections of the corroded
pipe (Figure 28.10). It was learned that there was a slight difference in
new/old pipe corrosion. The data was useful in evaluating further mitigation
strategy.

28.2.4 Case study 4: 6 inch sour gas pipeline

The pipeline configuration and conditions are:
(a) pipeline particulars: 6 in (168.3 mm) in diameter and 15 km long
(b) fluid effluents: 18% H2S, 5% CO2, 30 000 ppm Cl−
(c) corrosion mechanisms: wet sour gas. Corrosion morphology: isolated
pits mainly at the 6:00 o’clock position
(d) mitigation: continuous-injection and pigging/batching.

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 Corrosion monitoring using the FSM-IT 665

FSM-IT accumulated GENERAL CORROSION wall loss trends and corrator ER probes
8.5

8.0 Downstream "New Pipe" FSM-IT (long term corrosion rate: 22 mpy)
7.5 Aurora ER probe metal loss at FSM reading dates (long term corrosion rate: 14.7 mpy)
7.0 Upstream (Old Pipe) FSM-IT (long term corrosion rate: 15.5 mpy)
6.5
3D Bend FSM-IT (long term corrosion rate: 11.3 mpy)
6.0
Base Plant ER probe metal loss at FSM reading dates (long term corrosion rate: 6.2 mpy)
5.5
Metal loss (mils)

5.0

4.5

4.0

3.5

3.0

2.5

2.0

1.5 Brush
launched
1.0 then
Seven
Three day double
0.5 One day Brush
day outage dose of
outage pig chemical
0.0 outage
Sep 02, 02
Sep 05, 02
Sep 08, 02
Sep 11, 02
Sep 14, 02
Sep 17, 02
Sep 20, 02
Sep 23, 02
Sep 26, 02
Sep 29, 02
Aug 03, 02
Aug 06, 02
Aug 09, 02
Aug 12, 02
Aug 15, 02
Aug 18, 02
Aug 21, 02
Aug 24, 02
Aug 27, 02
Aug 30, 02

Nov 01, 02
Jun 25, 02
Jun 28, 02
Jul 01, 02
Jul 04, 02
Jul 07, 02
Jul 10, 02
Jul 13, 02
Jul 16, 02
Jul 19, 02
Jul 22, 02
Jul 25, 02
Jul 28, 02
Jul 31, 02

Oct 02, 02
Oct 05, 02
Oct 08, 02
Oct 11, 02
Oct 14, 02
Oct 17, 02
Oct 20, 02
Oct 23, 02
Oct 26, 02
Oct 29, 02
28.8 Case study 3: corrosion monitoring responses from FSM-IT and
ER probes.

Accumulated wall loss trends for PITTING corrosion; FSM-IT and LPR
32
31
30
29 LPR @ Base Plant, Accumulated wall loss at FSM reading dates (long term corr rate: 80 mpy)
28
27 Downstream "New Pipe" FSM-IT (long term corrosion rate: 65 mpy)
26
25
3D Bend FSM-IT (long term corrosion rate: 58 mpy)
24
23
22 Upstream "Old Pipe" FSM-IT (long term corrosion rate: 45 mpy)
21
20
19
Metal loss (mils)

18
17
16
15
14
13
12
11
10
9
8
7
6 Brush
5 Seven
launched
4 day
then
3 Three outage
Brush double
2 One day day
pig dose of
1 outage outage
chemical
0
Jun 25, 02
Jun 28, 02
Jul 01, 02
Jul 04, 02
Jul 07, 02
Jul 10, 02
Jul 13, 02
Jul 16, 02
Jul 19, 02
Jul 22, 02
Jul 25, 02
Jul 28, 02
Jul 31, 02
Aug 03, 02
Aug 06, 02
Aug 09, 02
Aug 12, 02
Aug 15, 02
Aug 18, 02
Aug 21, 02
Aug 24, 02
Aug 27, 02
Aug 30, 02
Sep 02, 02
Sep 05, 02
Sep 08, 02
Sep 11, 02
Sep 14, 02
Sep 17, 02
Sep 20, 02
Sep 23, 02
Sep 26, 02
Sep 29, 02
Oct 02, 02
Oct 05, 02
Oct 08, 02
Oct 11, 02
Oct 14, 02
Oct 17, 02
Oct 20, 02
Oct 23, 02
Oct 26, 02
Oct 29, 02
Nov 01, 02

28.9 Case study 3: corrosion monitoring responses from FSM-IT and

LPR probes.

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666 Techniques for corrosion monitoring

28.10 Case study 3: actual cut-out from the monitored old/new

pipe section.

The previously corroded line was cut out and FSM-IT device was installed.
The monitoring was started in October 2002.

Results
Figure 28.11 shows the monitoring results: an alarm of 66% wall loss and
19 mm/y corrosion rate.

Benefits
Because of the timely detection of high corrosion rate by the FSM-IT
device, action was taken to shut down the pipeline, cut out the corroded
pipe (Fig. 28.12) and in-line inspection of the remaining line. Actual wall
loss was measured at 41%. The current inhibition program was not effective.
A sour gas leak was prevented.

28.2.5 Case study 5: 48 inch oil transmission pipeline

The pipeline configuration and conditions are:
(a) pipeline particulars: 48 in (1220 mm) in diameter and 40 km long
(b) fluid effluents: low water-cut crude containing less than 1% H2S, 5%
CO2, and sand deposits
(c) corrosion mechanisms: sour water corrosion. Corrosion morphology:
pits at 6:00 o’clock where water drops out
(d) mitigation: batching.

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 Corrosion monitoring using the FSM-IT 667

6˝ Sour Gas Pipeline – FSM-IT PinPairs detecting isolated pit defect initiation and growth
2.500
Date: 31-Mar-03
0:00
2.250
Wall loss Fsm matrix area surface plot
(mm) 64 65 66 67 68 69 70 71 72 73 74 4:30
2.000
1.80–2.00
53 54 55 56 57 58 59 60 61 62 63 5:00
1.60–1.80
1.750 1.40–1.60
38 39 40 41 42 43 44 45 46 47 48 5:30
Wall loss (mm)

1.20–1.40
PinPair 20
1.00–1.20 27 28 29 30 31 32 33 34 35 36 37 6:30
1.500
0.80–1.00
0.60–0.80 12 13 14 15 16 17 18 19 20 21 22 7:00
1.250 0.40–0.60
0.20–0.40 1 2 3 4 5 6 7 8 9 10 11 7:30

0.00–0.20
1.000 0.00
0

17.5

52.5

87.5

122.5

157.5

192.5

227.5

262.5

297.5

332.5

367.5

mm
0.750 PinPair 21
0.500
PinPairs 9, 19, 35

0.250

0.000
Oct 18, 02
Oct 22, 02
Oct 26, 02
Oct 30, 02
Nov 03, 02
Nov 07, 02
Nov 11, 02
Nov 15, 02
Nov 19, 02
Nov 23, 02
Nov 27, 02
Dec 01, 02
Dec 05, 02
Dec 09, 02
Dec 13, 02
Dec 17, 02
Dec 21, 02
Dec 25, 02
Dec 29, 02
Jan 02, 03
Jan 06, 03
Jan 10, 03
Jan 14, 03
Jan 18, 03
Jan 22, 03
Jan 26, 03
Jan 30, 03
Feb 03, 03
Feb 07, 03
Feb 11, 03
Feb 15, 03
Feb 19, 03
Feb 23, 03
Feb 27, 03
Mar 03, 03
Mar 07, 03
Mar 11, 03
Mar 15, 03
Mar 19, 03
Mar 23, 03
Mar 27, 03
Mar 31, 03
28.11 Case study 4: corrosion monitoring responses.

28.12 Case study 4: actual cut-out (rectangular area was covered by

FSM-IT on the external side).

An FSM-IT was installed at a location where a previous in-line inspection

indicated significant metal loss.

Results
Figure 28.13 shows the monitoring results. A maximum corrosion rate of
3.5 mm/y was indicated. The monitoring results will be validated in future
in-line or UT inspection.

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668 Techniques for corrosion monitoring

48˝ Oil Transmission Pipeline – corrosion activity detected by FSM-IT vs. batch inhibitor treatments
6.0
5.5 Peak corrosion rates
detected by the most
5.0 Batch inhibition active PinPairs
Corrosion rate (mm/yr)

treatment dates Corrosion rates of

4.5 deepest defect
4.0 (PinPair #48)

3.5
3.0
2.5
2.0
1.5
1.0
0.5
0.0
Jan 18, 03

Feb 07, 03

Feb 27, 03

Mar 19, 03

Apr 08, 03

Apr 28, 03

May 18, 03

Jun 07, 03

Jun 27, 03

Jul 17, 03

Aug 06, 03

Aug 26, 03

Sep 15, 03

Oct 05, 03

Oct 25, 03

Nov 14, 03

Dec 04, 03

Dec 24, 03

Jan 13, 04

Feb 02, 04
28.13 Case study 5: corrosion monitoring responses.

Benefits
Batching activities were found to be correlated to corrosion readings and
hence could be optimized using FSM-IT results. The line will continue to
operate until an alarm level is reached.

28.2.6 Case study 6: 8 inch sour gas process piping

The pipeline configuration and conditions are:
(a) pipeline particulars: 8 in (219.08 mm) and 300 m long
(b) fluid effluents: high-velocity gas containing 0.53% H2S, 21% CO2,
115 000 ppm Cl− at 90°C and 19 000 kPa
(c) corrosion mechanisms: mixed H2S/CO2 corrosion/erosion. Corrosion
morphology: general wall loss around whole circumference
(d) mitigation: continuous injection inhibition.
An FSM-IT was installed on a new pipe and the monitoring was started in
October 2001.

Results
Figure 28.14 shows monitoring results. From October 2001 to June 2002,
average corrosion of 2 mm/y (80 mpy) was detected. After October 2002,
average corrosion of 5 mm/y (200 mpy) was detected.

Benefits
Because of the timely detection of high corrosion rate by FSM-IT, the line
was shut down and a weld overlay was installed as the inhibition was not

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 Corrosion monitoring using the FSM-IT 669

FSM-IT accumulated wall loss trend at Pin-Pair #1

(area of the pin matrix with the most significant corrosion – 12:00 Position
at the upstream end)
120
110
100
90
80
Metal loss (mils)

70
60 80 mpy average corrosion rate
50
40
Corrosion rate
30 Increase to over
20 200 mpy
10
0
–10
Oct Nov Dec Jan Feb Mar Apr May Jun Jul Aug Sep
28/09/2001 to 12/09/2002

28.14 Case study 6: corrosion monitoring responses.

effective for the given high velocity/turbulent operating conditions. A sour

gas leak was prevented.

28.2.7 Summary
In the six case studies, FSM-IT as a corrosion monitoring tool has been
successfully used in monitoring the mitigation effectiveness and has been
found beneficial in preventing sour gas leaks in four cases, and in providing
useful data for further evaluation in the other two.

28.3 Acknowledgments
The sharing of corrosion experience and monitoring information by Ray
Goodfellow and Jason Thomas of Chevron Texaco Canada, Harley Fear
of Shell Canada, Ben Kitt and Dave Webster on behalf of Syncrude, Mike
Johnson of Talisman and Tanis Elm and Joe Boivin of/on behalf of Enbridge
is acknowledged and greatly appreciated.

28.4 References
1 Nguyen N. Bich, ‘An Approach to Corrosion Mitigation for Wet Gas Pipelines’,
4th International Pipeline Conference, 29 September–3 October 2002, Calgary,
Canada, Paper IPC02-27417.

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670 Techniques for corrosion monitoring

2 Nguyen N. Bich and Eric Kubian, ‘Corrosion Monitoring as an Integral Compo-

nent of an Effective Corrosion Management Program’, 5th International Pipeline
Conference, 4–8 October 2004, Calgary, Canada, Paper IPC04-0582.
3 Daryl Baxandall, Eric Kubian and Ray Goodfellow, ‘Corrosion Assessment using
Alternate Monitoring Tools for High Pressure and High Temperature Gas Wells’,
NACE Northern Area Western Conference, 3–6 February 2003, Calgary,
Canada.
4 Jason Thomas, ‘Corrosion Monitoring Using the Field Signature Method Inspec-
tion Tool’, Upstream Pipeline Integrity Management Association, FSM-IT Work-
shop, 24 February 2004, Calgary, Canada.
5 Harley Fear, ‘FSM Corrosion Monitoring Experiences on a 4-in Sour Gas
Pipeline’, Upstream Pipeline Integrity Management Association, FSM-IT
Workshop, 24 February 2004, Calgary, Canada.
6 Ben Kitt, Dave Webster and Eric Kubian, ‘Corrosion Monitoring Experiences on
a 30-in Process Water Pipeline’, Upstream Pipeline Integrity Management Asso-
ciation, FSM-IT Workshop, 24 February 2004, Calgary, Canada.
7 Mike Johnson and Eric Kubian, ‘FSM Corrosion Monitoring Experiences on a 6-
in Sour Gas Pipeline’, Upstream Pipeline Integrity Management Association,
FSM-IT Workshop, 24 February 2004, Calgary, Canada.
8 Tanis Elm, Joe Boivin and Eric Kubian, ‘Summary of Initial Corrosion Monitoring
Experiences on a 48-in Oil Transmission Pipeline’, Upstream Pipeline Integrity
Management Association, FSM-IT Workshop, 24 February 2004, Calgary,
Canada.

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