in-line inspection the state of the industry · in-line inspection: the state of the industry ......

12/11/2014

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Bryce BrownCRUG Meeting at SES · Houston, TX · December 10, 2014

IN-LINE INSPECTION:THE STATE OF THE INDUSTRY

Slide 2

• Geometry tools run for passage requirements

• Metal Loss reporting depth (grade), length and width

• Critical Assessment (pressure based) started in the mid-90’s

• Proactive pipeline operators, based on experience gained an understanding and determined the advantages of ILI

LOOKING BACK

ILI: State of the Industry · Bryce Brown · © ROSEN Group · December 10, 2014

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Slide 3ILI: State of the Industry · Bryce Brown · © ROSEN Group · December 10, 2014

HCA Miles2003 – 2005 were actual figures

2006 – 2015 were forecasted figures

LOOKING BACK

Slide 4

INTEGRITY THREATS AND ILI


Prescriptive requirements for addressing threats to integrity.

Multiple runs, multiple technologies, as required.

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Slide 5

GEOMETRY AND INTEGRITY

• Any dent with a stress riser


2 inspection planes

Slide 6

• High Resolution ID mapping, and data integration

• ECA and dent strain, stress concentration factor and remaining life assessment


GEOMETRY AND INTEGRITY

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Slide 7

METAL LOSS

• High Resolution Metal Loss mapping with Magnetic Flux Leakage (MFL)

• Axial1 field, Circumferential2 field MFL

1 2


56” Axial and Circumferential MFL tools

Slide 8

A = wall thickness or 10 mm (0.39"), whichever value is greater

METAL LOSS - COMPLEXITY


Courtesy of European Pipeline Operator Forum, “Specification and Requirements for Intelligent Pig Inspection of Pipelines”, version 2009

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Slide 9

• Axial field MFL


METAL LOSS - COMPLEXITY

Slide 10

LONG, NARROW, AXIAL

• Circumferential field MFL


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Slide 11

LONG, NARROW, AXIAL


Reported - Longitudinal Weld Anomaly / Actual - Lack of Fusion ( 8” Pipeline)

Reported – Longitudinal Weld Anomaly ‘A’ / Actual - Hook Crack (24” & 12” Pipeline)

Slide 12

LONG, NARROW, AXIAL



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Slide 13

LONG, NARROW, AXIAL



Slide 14

CRACKING

Crack Morphologies to Detect and Characterize

� SCC Colonies

� Cracks in Corrosion

� ERW Defects

- At the toe of the ERW weld

- In the center of the ERW

- Hook Cracks

� Single cracks in the pipe body

� Mid wall cracks in the pipe body

� DSAW Defects

- At the toe of the weld

- Non perpendicular to the surface

- In the center of the weld


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Slide 15

CRACKING

• High Resolution inspection for Cracking

• EMAT1 (Electro-Magnetic Acoustic Transducer) and Ultrasonic2 (USCD) Crack inspection

1 2



CRACKING

EMAT (Electro-Magnetic Acoustic Transducer)

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Slide 17

ReceiverSender

Sender

T1Propagation

Transmission

Reflection T2 T3

Transmission

Reflection T4

Transmission

Reflection

Receiver

EMAT Sensor – Sender/Receivers on Magnet Yoke EMAT Sensor – Sender/Receivers on Magnet Yoke

Deeper Cracks:

• Reflect more energy (higher amplitude)

• Reduce transmission energy

Reflection

from a crack Through

transmission


CRACKING

EMAT (Electro-Magnetic Acoustic Transducer)

Slide 18

CRACKING


EMAT - Tool & Service · S.Klein, T.Beuker · © ROSEN Group · 21-Oct-2013

Pipeline Integrity Management Program

Data Analysis

Op

era

tor

ILI

VerificationNDT / DT

Feedback Loop

Preliminary Report Final ReportSecondary Information

RO

SE

N

Result Validation ROSEN NDT Technician Onsite

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CRACKING

Slide 20

Size (inch)

Bendradius

Toolbodies

Speedcontrol

# Tools

12 1.5D 4 + no 1

16 3D 3 no 1

18 1.5D 3 no 1

20/22 1.5D 3 no 1

24/26 1.5D 2 yes 1

24/26* 1.5D 3 + yes 1

28/30 1.5D 2 yes 2

30* 1.5D 3 yes 1

30/32 1.5D 2 yes 2

34/36 1.5D 2 yes 2

36/38 1.5D 2 yes 1

36* 1.5D 3 yes 1

40/42 1.5D 1 yes 1

42* 1.5D 3 yes 2

46/48 1.5D 1 yes 1

19* Wheel design


CRACKING

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Slide 21

CHALLENGING PIPELINES


A “un-piggable” pipeline is defined as one that cannot be inspected with current technologies and procedures.

“Un-piggable” is a function of time and market need Technology & Know-how Level

TODAY

Gas velocities

up to 5 ft/s

become

possible.

30 mi. in a

Single run

becomes

possible.

Tools

become

1.5D

capable.

Dual-Diameter

Tools become

Available.

Active Speed

Control allows

for gas velocities

up to 40 ft/s.

Multi-Diameter

Tools become

Available.Heavy Wall

Tools become

Available.

Pressures

Up to 300 bar

possible.

Temperatures

up to 300˚F

possible.

Self-

Propelled

Tools

Crack

Inspection

in Gas

Extra

Heavy Wall

1965 2015

Slide 22



• Multi-Diameter 14”x20”

30”x36”

• Bi-Directional

• Low Flow / Low Pressure

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Slide 23


• Tailored solutions

• “Tool box”


Slide 24


Pipeline Modification ?

Tool Modification ?

New Development

Questionnaire Time & Effort

Standard Tool

New Application

Tailored solutions based

on tool box concept


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Slide 25


Metal Loss (corrosion) inspection of 6 ea. @ 10” gas storage laterals

Wall thickness: 0.280” / 0.500”Length: 60 ft. to 450 ft. (1275 ft. total)Traps: none

Boundary conditions:Data quality - ensure optimum inspection performanceLean operation - avoid bulky equipment and exposureMinimized risk - ensure equipment will come out


10” ROBOTIC MFL CRAWLER

Slide 26

The self-propelled RoCorr MFL/BiDi/MTC inspection solution consists of the following elements:

Inspection technology: MFLCarrier: Bi-directional / low friction Propulsion: Multi-Trotter Crawler Power: Onboard accumulatorsOperation & control: External via wire lineFail safe: Cable




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Slide 28

Single Tractor & Inspection Unit

• Single body (24” up to 42” currently)• Rotating measurement system based on MFL• Light weight• Easy to handle• Front & rear camera system


ROBOTIC “HELIX” TOOL


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Slide 29

WHAT IS IN THE GROUND?

• Traceable – originating from specific sources containing all information for MAOP calculation.

• Verifiable – confirmed by other complementary, but separate, documentation.

• Complete – finalized and evidenced by signature, date or other appropriate marking.


Slide 30


• Step 6 – ECA consists of material documentation, assessment, and analysis to establish material condition of pipeline and MAOP, commensurate with segment-specific issues and documentation shortcomings.

Assessment could include, as appropriate: ILI Program, CIS, Coating Survey, Interference Survey Remaining Life Fatigue Analysis, etc.


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Slide 31


• Step 11 – of the IVP, “Detail of Material Documentation Process” requires the operator to review design and material documents that address chemical and mechanical properties.


The program to test pipe samples to establish material properties using a “long term statistical sampling program” has great uncertainty, because every joint in between the sampling remains unknown.

Alone a statistical sampling program presents fundamental challenges that can immediately be mitigated using an ILI solution.

Slide 32


• Existing Data

• ILI Solution


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Slide 33


• ILI Solution


Color Scan

Line plot

Slide 34

100

150

200

250

300

350

400

450

500

550

600

0 10,000 20,000 30,000 40,000 50,000 60,000 70,000

YS

[M

Pa]

LogDist [ft]

OPERATORS INCOMPLETE RECORDS

Avg. YS per section (ILI)

SMYS acc. to operator records



X60

X52

X42

X24

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100

150

200

250

300

350

400

450

500

550

600

0 10,000 20,000 30,000 40,000 50,000 60,000 70,000

YS

[M

Pa]

LogDist [ft]

Avg. YS per section (ILI)

SMYS acc. to operator records

X42

X52

X60

X24


PIPE GRADE DATA, RECORDS CONFIRMED AND SUPPLEMENTED

Slide 36

INDUSTRY CONSENSUS STANDARDS


NACE Standard SP0102-2010

Recommended Practice: In-Line Inspection of Pipelines

ASNT ILI_PQ-2005

In-line Inspection PersonnelQualification and Certification

ILI System = Tool(s) + Personnel + Process

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Slide 37

ESTABLISHING CONFIDENCE

• Duty of care requires full capability for development and testing

• Process driven, guided by ISO and API 1163


Slide 38

INDUSTRY PARTICIPATION AND CONTRIBUTION


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www.rosen-group.com

THANK YOU FOR JOINING THIS PRESENTATION.

in-line inspection the state of the industry · in-line inspection: the state of the industry ......

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