charm® - ch airborne remote monitoring · the measurement method of charm® is based on the...

Evolution of pipeline monitoring

CHARM® - CH4 Airborne Remote Monitoring

For several years OGE has been inspected

its pipelines with old and new, unconventional

and efficient method of gas detection

OGE has developed a new technology to

detect natural gas via a helicopter-based

system

CHARM® is based on an infrared laser

system that is capable of precisely detecting

even gas layers with very low methane

concentrations

49

Pipeline Operation and Maintenance | 10.4.2014

DVGW G 501


CHARM® can be used for inspecting

pipelines both in open country as well as in

urban areas

The measurement method of CHARM® is

based on the absorption of specific infrared

light wavelengths by methane, the main

constituent of natural gas

= Differential Absorption Lidar (DIAL)

The measurement beam can be targeted at

the pipeline corridor automatically and

extremely precisely (CHARM® Auto Tracking,

CAT)

50


DVGW G 501


Automatical alignment of the mesurement

beam

Accurate geographic positioning of

measurement beam with CHARM® Auto

Tracking (CAT) < 0,5 m

Authorisations

DVGW authorisation (inspecting)

LBA- und EASA authorisation (aviation)

CHARM® is state of the art of inspecting natural gas transmission systems and is

based on a high-performance combination of innovative technologies.

Accuracy of measurement

Area-wide inspection of pipeline route

High methane sensitivity of system

(operational detection limit < 25

ppm·m)

Automated documentation of pipeline

inspection and real-time reporting of

incidents

High patrol speed (50 – 90 km/h)

High detection resolution (100 double

pulse measurements per second)

51


DVGW G 501

GasCam® - Remote Gas Detection

The CasCam® is based on Infrared Radio

Spectrometry and allows real-time gas

detection of gas clouds against real

backgrounds

Developed to monitor and inspect facilities,

pipeline networks and constructions

measures on gas-carrying systems of natural

gas

The analyzing software provides

comprehensive documentation material

(measurements, video recordings, pictures)

52


DVGW G 495 / 497


Key Benefits

Rapid detection of gas releases and precise localisation of

leakages

In-situ valuation via real time visualisation

Improved safety level

Significant reduced inspection time of gas facilities

Avoidance of emissions economise on resources

Audit compliant documentation

High detection sensitivity also at far distances

All-purpose for gas-carrying facilities

The system was developed jointly by OGE and project partners from the gas

industry.

53



OGE offers the service of inspecting and evaluating facilities, pipeline networks

and constructions measures on gas-carryings systems.

Application

Recurrent tightness checks at gas carrying

facilities Safety Approval

Monitoring of gas releases

Definition of safety zones

Detection of emission sources

Quality Inspections in the course of constructing

and re-constructing facilities

54


Contents

OGE at a Glance, OGE Pipelines in Germany

Integrated Management System

Pipeline Design & Safety Philosophy

Pipeline Integrity Management System

Corrosion Control

Hydrostatic and Tightness Testing

Inline Inspection Techniques

Defect and Failure Investigation

Troubleshooting & Repair-Techniques

Conclusions


55


56

Defects are reliably detected by ILI

MFL-Pigging EMAT-Pigging US-Pigging IMU

Displacement

Bending

Additional Strain

(Mapping)

Coating

disbondment

Cracks Loss of wall

thickness

(corrosion,

grinding)

Milling defects

(inclusions)

Mechanical

damage

Weld anomalies

Calliber Pigging

Expansions

Dents

Ovalities

TFI-MFL-Pigg.

Axial grooving

Standard method

Optional method


57

1996 2003 2009

ILI leads to pipeline safety and increasing level of information

US-Pigging

EMAT-Pigging

RunCom

IMU/Strain Assessment

MFL-Pigging HR-MFL-Pigging

Dummy-Pig

(Multi-Channel) Calliber Pig

2008

„Learning curve“

0

100

200

300

400

500

600

700

800

900

1.000

1.100

1.200

19

96

19

97

19

98

19

99

20

00

20

01

20

02

20

03

20

04

20

05

20

06

20

07

20

08

20

09

20

10

20

11

km

/Jah

r

IST PLAN

Inspection of approx. 8.100 km until

2011 (incl. reinspection)

approx. 6.500 km inpected at last

once

DVGW G 466-1, G 450


58

Defect Assessment – Example

ILI Assessment Excavation and NDT Standard repair (if needed)

Gauging Modelling and FE-

Calculation

Assessment, Certified

experts statement and

documentation

Repair (if needed)

RN 210-001

Corrosion Damage, Example

Detected by pig Excavated defect Measured (OPTO-CAM)

FEA model

Calculation of stress,

burst pressure: 100,5 bar

Direct (Defect) Assessment Methods 59


Component test,

burst pressure: 97,2 bar


60

Det Norske Veritas

ASME/ASTM

Length [mm]

De

pth

[%

of

Wa

llth

ick

ne

ss

]

to be repaired

safe

Direct Defect Assessment Methods – DNV or ASME

RN 210-001

0

10

20

30

40

50

60

70

80

90

0 50 100 150 200 250 300 350 400

Length [mm]

Dep

th [

% o

f W

all

th

ickn

ess]

DNV (S=1,8)

ASME

external metal loss

external MFG

internal MFG

external metal loss (SN)

excavation

Test: Bursting at 199 bar Sreal = 3.2

DNV: Just safe enough with S = 1.8

FEA: Bursting at 193 bar Sreal = 3.1

Calculation is Conservative

compared to real Pipe Behaviour

External Metal Loss

Pig 52%, 137 mm long, 5:10

Excavation 69%, 150 mm long, 5:30

Verification of Calculation

Model

61


0

10

20

30

40

50

60

70

80

90

100

0 100 200 300 400 500 600 700 800

Length [mm]

De

pth

[%

of

Wa

ll t

hic

kn

es

s]

DNV (S=1,8)

ASME

external metal loss

external VFF

internal VFF

external metal loss (SN)

internal VFF (SN)

excavation

DNV: to repair with S = 1.25

FEA: Bursting at 121 bar Sreal = 1.79

Calculation is Conservative

compared to real Pipe Behaviour

Test: Bursting at 122 bar Sreal = 1.80 Pig 90%, 71 mm long

Excavation 92%, 83 mm long

Verification of Calculation

Model

62


Loss of wall thickness

Usage factor

Calculated usage factor at time of ILI

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1,6

0% 20% 40% 60% 80% 100%

reduction of wall thickness

usa

ge fact

or Safety against failure = 1.8

0,0

0,2

0,4

0,6

0,8

1,0

1,2

1,4

1,6

0% 20% 40% 60% 80% 100%

reduction of wall thickness

usa

ge fact

or

action recommended

Calculated usage factor at e.g.

20 years (with corrosion growth)

short term measure recommended

Evaluation ILI Data Inteligently – Corrosion Growth

Loss of wall thickness

Usage factor

Sheduling of next ILI is condition based

63


DIN 50929-3

Typical Corrosion Rates

Type of corrosion Typical corrosion rate DIN 50929-3

max. metal loss rate (100 a)

max. penetration rate L,max (30 a)

General corrosion (aeration cell) 0,1 – 0,2 mm/a 0,005 – 0,06 mm/a 0,03 – 0,4 mm/a

Corrosion by contact element up to 0,5 mm/a 0,01 – 0,2 mm/a 0,05 – 1 mm/a

Stray current corrosion bis zu 1 mm/a --- ---

AC corrosion commonly 0,1 – 0,2 mm/a up

to 1 mm/a --- ---

TGL

W, 64

DIN 50929-3

Determining Corrosion rates by ILI Run Comparison

+5% accuracy (reproducability)

-5% accuracy (reproducability)

Depth (% of wall thickness), 2001

Deve

lop

ment o

f fe

atu

re d

epth

(%

WT

)

external features with significant growth

65


Defects at Construction

Dents and Ovalities at Construction (Caliper Pig)

Dents Ovality

Caliper Pigging 66


Caliber Pigging


67

Assessment of

Dents

Ovalities

Expansions

Assessment criteria approved by TÜV

Up to 4% increase in diameter

after stress testing because of

wrong material selection

Expansion

Expansio

n (

%)

Expansio

n (

%)

Profile measured by pig Measured profile

IMU - Strain Assessment 68


Identification of areas with environmentally

induced pipeline deformations, for example due

to landslides, thermal load, frost heave, sea bed

movement, ships dragging their anchors

Accuracy to be expected within one tenth of a

centimeter or +/-0.01% strain

Strain Assessment



Strain Assessment – Field Verification

Surveyor: 2.09 m

(horizontal displacement) IMU: 2.15 m



Vergleich Messwerte GE PII und PLEdoc

0

10

20

30

40

50

60

70

80

90

0 10 20 30 40 50 60 70 80 90

ERGEBNIS MOLCH [%]

ME

SS

UN

G F

RE

ILE

GU

NG

[%

] .

Wanddickenminderung von MFL

Linie 1:1

+/-10%

0

30

60

90

120

150

180

210

240

270

0 30 60 90 120 150 180 210 240 270

Result IMU [mm]

Resu

lt E

xcavati

on

[m

m]

.Lageverschiebung aus IMUDisplacement measured by IMU

Results fro

m e

xcavation [%

]

Results from MFL - ILI [%]

Wall thickness reduction, MFL

MFL versus IMU 71


Contents

OGE at a Glance, OGE Pipelines in Germany

Integrated Management System

Pipeline Design & Safety Philosophy

Pipeline Integrity Management System

Corrosion Control

Hydrostatic and Tightness Testing

Inline Inspection Techniques

Defect and Failure Investigation

Troubleshooting & Repair-Techniques

Conclusions


72

charm® - ch airborne remote monitoring · the measurement method of charm® is based on the...

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