inspection of challenging assets - building...
TRANSCRIPT
Take a Walk on the Wild SideInspection of Challenging Assets
Agenda From the Early Days of ILI
The State of the Art Technologies
The Innovations of Tomorrow
From The Early Days of ILI
Overview of Pipeline Inspection Industry Progression
2010 - Today• Robotics• Material Properties• Ultra high resolution
technologies• “Big Data” techniques• EMAT - Cracks in gas
pipelines
TechnologyProliferation• Miniaturization• Combinations of
technologies• Enhanced assessment
techniques• UT Crack detection
Commercial Acceptance• ML/Dent inspections
commonplace• Sizing• Competition• Digitization
60’s/70’s
80’s/90’s
2000’s
Experimental Technology• Limited ranges,
diameters• Quadrant
Inspection• Thing Finders
Progression from Un-piggable to Piggable
Active Speed Control allows for gas velocities up to 12 m/s
Low Flow - Low Pressure Tools become available
Heavy Wall Tools become available
Gas velocities up to 1.5 m/s become possible
Crack Inspection in gas
50 km in a single run becomes possible
Tools become 1.5D capable
Self-Propelled ToolsPressures up to 300 bar possible
Multi-Diameter Tools become available
Dual-Diameter Tools become available
1965
Piggable Un-piggable
Combination Tools
Extreme Inspection Lengths (> 1220km)
2017
Horizontal Storage Tanks Flow Lines
Geometry & Mapping•Detection, identification, and sizing of deformations/ID anomalies and installations
•Optional IMU for accurate mapping of pipelines spatial data - location of anomalies and further integrity assessments
Metal Loss (MFL)•Axial MFL used for detection of circumferential orientated features
•Circumferential MFL used for the detection of axial orientated features
•Tools also available that incorporate both components
•Medium independent•Speed control and combination capable
Metal Loss (UTWM)•Direct & accurate nominal WT measurement; measures echoes from ultrasonic waves induced in pipe wall
•Liquids only•Axial & Circumferential features•Generalized thinning/erosion•Sensitive to debris
Established Technologies
Established Technologies Available in most NPS
Improvements and AdvancementsTool Miniaturization
Analysis software
Wear components
Tool reliability
QA Processes
Data Management
Electronics Reliability
Etc, Etc,…
Sensoric Improvements
ILI Technology Advancements
with Existing Inspection Techniques
Speed Control Capabilities
Component Miniaturization
On Board Data Storage Capabilities
Combination & Dual Diameter Tools
The State of the Art Technologies of Today
Crack Detection (UTCD) Ultrasonic Crack Detection (UTCD)
Available in most nominal pipe sizes (> 4”)
Direct & accurate measurement principle; measures corner and tip echoes from ultrasonic waves reflecting from crack like features
Liquids only
Axial or circumferential crack tools available
Continuous and accurate depth sizing
Crack Detection (EMAT) Electromagnetic Acoustic Transducer (EMAT)
Placing an alternating electric current in a permanent magnetic field producing horizontal shear (SH) waves
Available in most nominal pipe sizes
Continuous and accurate depth sizing
Detects coating type and coating anomalies
Medium independent
Speed control capable
The Innovations of Tomorrow
What Do We Need…?
Hold A lot of people… Go really fast… Be economical…
Have the Best Technology… Be robust…
What Do We Get…?
This is what the Operators are asking for…
This is what the Vendors will build…
MFL Resolution Developments MFL-A Ultra
Ultra high sensor resolution
Detection of the smallest pipeline defects
Advanced imaging methods for defect characterization
Advanced data processing for improved repeatability and reporting accuracy
Provides a realistic evaluation of pipelines current integrity status
Non Conventional ILI Assessments
Leak Detection
Cathodic Protection
System Assessments
Pipeline Strain
Assessments
Material Properties
AssessmentsEngineering Assessments
Feasibility Assessments
Pipe Grade DeterminationPipeline DNA analysis is completed using:• ILI including the Pipe Grade
Sensor (PGS)• Existing pipeline records • Insitu-validation
Feature Type
Feature Length
Location
DiameterWall Thickness
Ultimate Tensile StrengthYield Strength
Pipe Grade
Multi Diameter Tools Began with the
introduction of dual diameter tools
With the emerging regulations for facility / lateral pipeline integrity multi-diameter tools are required to mitigate costly retro-fit expenses
Numerous solutions available for most MFL and caliper inspection NPS and some crack NPS
30”/36” MFL-A Tool - 1.5D w/ SCU
32”/42” MFL-A Tool – 3D w/ SCU
Combination Tools Combination tools
began with the introduction of MFL, IMU, and caliper technologies in one tool
Many technology combinations now available on the market
Plug and play technologies allow for a great number of possibilities for operators
40” combination caliper, UTCD, and UTWM tool with IMU. 400 hr run time & 1.5D compliant (w/ measurement in bends).
34” combination UTCD, EMAT, and UTWM tool. No data reduction and increased sensor spacing.
GEOMETRYMATERIAL
PROPERTIESCRACK & COATINGMETAL LOSS OTHER
RoGeo MDCaliper
RoGeo XtProximity sensor and caliper
RoLeak ACOAcoustic
RoVisual OPDOptical/camera
RoCorr MFL-AAxial Magnetic Flux Leakage
RoCorr MFL-A UltraAxial Magnetic Flux Leakage
RoCorr IECInternal eddy current
RoCorr UTWMUltrasonic wall thickness measurement
RoCorr MFL-CCircumferential Magnetic Flux Leakage
RoGeo XYZInertial measurement unit (IMU)
RoCD EMATElectro-Magnetic Acoustic Transducer
RoMat PGSElectro magnetic
RoCD UTUltrasonic crack
RoMat HSDual field
Speed Control Unit SCUActuator
Pipeline Data Logger PDLAccel, gyro, temp, pres
+ + +RoGeo XtProximity sensor and caliper
Speed Control Unit SCUActuator
RoMat PGSElectro magnetic
Combination Tools
+
RoMat HSDual field
RoCorr MFL-AAxial Magnetic Flux Leakage
Simplified Approach to Challenging Inspections
Standard Tool New ApplicationTailored solutions based
on tool box concept
Questionnaire
Pipeline Modification
Tool Modification
New Development
Challenging DiagnosticsToolbox Approach
PROPULSION ELEMENTS• Medium propelled• Nitrogen / Air• Batching• Robotic / Autonomous• Manual• Tethered
TECHNOLOGY ELEMENTS• MFL-A / MFL-C• Geometry / XYZ • UTWM / UTCD • IEC • EMAT• PMAT• LRUT• Cleaning
ACCESS ELEMENTS• Hot tapping• Tool launch valves• Launchers / Receivers• Spool piece• Single Access• Scaffolding• Rope Access• Insulation• Quick Launch System
MEASUREMENT CARRIERS• Unidirectional• Bidirectional• Low Friction• Ultra Compact• Multi-Diameter• External Scanners (AXUS, CIRC)• Guided Wave• Floor Scanners• Roller Probes
Case StudyBi-directional Inspection Corrosion inspection of 20″ x 1.6
km pipeline
Wall thickness: 7.87 mm / 12.7 mm
Only launching trap available, pipeline ends in a tee
Boundary conditions: Inspection in gas at system
pressure Minimum interference with
operations Full inspection of the system
Case StudyBi-directional InspectionAsymmetric cleaning/gauging tool
Less aggressive on the way in Most of the debris is recovered at the
launching site Amount of debris pushed into the system is
limited
Bi-directional low friction MFL tool Can be pumped in both directions Collects data in both directions Same quality as uni-directional tools Very well controllable since only 5 psi (straight
pipe) -15 psi (bends) dP required
Extended markering/pig tracking To maintain control on the position of the tool Determine position for turn-around accurately
Case StudyGas Storage Laterals Corrosion inspection of 10″ gas
storage laterals
Wall thickness: 7.11 / 12.7 mm
Length: 19.2 – 364 m
Traps: none
Boundary conditions: Data quality - ensure optimum
inspection performance Minimized risk – ensure equipment
comes out
Case StudyGas Storage Laterals The self-propelled RoCorr MFL/BiDi/MTC inspection solution consists
of the following elements: Inspection technology: MFL Carrier: Bi-directional / low friction Propulsion: Crawler Power: Onboard accumulators
Case StudyGas Storage Laterals
Case StudyGas Storage Laterals
Case StudyStorage Tube Inspection Built in: 1985 - 2013
Diameter: 54″ & 48″
Length: 246m to 875m
Bends: None
Wall thickness: 13.21mm/13.7mm & 22.23mm/25.4mm
Cleanliness: Clean
Obstacles: Access not sufficient for ILI tools No flow for ILI tools Older tanks spherical on both ends
Case StudyStorage Tube Inspection
RoHelix BiDi MFL Robotic inspection solution containing the following elements: High Resolution CMFL Technology Bi-directional / Low Friction Yokes Self-propelled Helical Movement
Technology (primary drive) Axial Movement Technology
(contingency drive) Onboard Power Storage Failsafe Tethering Retrieval Unit Visual Monitoring Power Consumption Monitoring 48″-54″ Diameter Range
Case StudyStorage Tube Inspection
Case StudyExtended Length / Multi DiameterParameter Values
Pipeline OD42”/44” (constant ID with valve & tee restrictions)
Pipeline Length 1,173km
Launch Nyhamna , Norway
Receive Easington, England
Run Conditions 16,800 kPA – 12.800 kPA; 2.5 m/s – 3 m/s
Average Tool Speed 2.5 m/s
Tool Run Time 5 days, 7 hours
Pipeline WT 23.3mm – 62mm
Internal coating Epoxy
Bend Radius 5D
Case StudyExtended Length / Multi DiameterLong Distance Challenge & Solution
Challenge: Overcome wear issues while negotiating 42” section first (628 km) then securing sealing
capacity in 44” section Tool differential pressure (resulting from cup friction) greater in smaller section of the p/l
leading also to higher cup friction High WT requires high magnet forces resulting in higher tool P contributing to cup wear
issues Solution:
Front Segment: increased number of PU - collectively forming three sealing planes & reduction of cup wear through tool centralization (magnets & guiding disc).
Rear Segment: wheels to support centralization & run behavior.
Case StudyExtended Length / Multi DiameterHigh Product Flow Challenge & Solution Challenge: Overcome high product density
(@high pressure) & flow with no negative impact on measurement accuracy & p/l capacity
Solution: Speed Control Unit considering
specific boundary conditions affecting capacity (bypass area, tool P, product density etc.).
High velocities & gas densities lead to specific tool design (shorter caliper arms, guiding fins & cups on rear segment) guiding the flow and reducing the load on caliper while ensuring front segment is not pushed.
FEM Calculation
Dent Assessments
Inspection Run
Data Evaluation &
Reporting
Strain Assessment
and/or Stress Screening
Finite Element Analysis (FEA)
Remaining Life Assessment
• ILI using high res caliper or combo tools
• 100% circumferential coverage
• Lift-off compensation through proximity sensor
• Accurate sizing and contour of (sharp) dents, wrinkles, buckles
• Evaluation of Geometry and Metal loss data
• Final Inspection Report
• Strain in accordance with ASME B31.8
• Fatigue screening in accordance with API 579, PDAM or EPRG
• Critical dents identified in previous step or ALL dents
• Automated FEA modelling for plain dents
• Creation of FEA models for dents on welds and/or metal loss
• Calculation of stress concentration factors (SCF)
• Based on SCFs, historic and projected pressure data (cycling) from SCADA
• Rain flow counting and application of API 579 or similar
Bin
ned
cycl
es
∆P
Rain flow Counting
Ultra MFL, AutoSCAN & CGApro
Inspection Run
Data Evaluation &
ReportingAutoSCAN CGApro Corrosion
Consultancy
• Extremely high circumferential resolution
• Fully triaxial & increased sensor focus
• Optimized sensor suspension for smooth girth weld inspection
• Evaluation using automated processing software
• Algorithms based on laser scans & real features
• FR including all features in MFL-A reporting time
• Signal matching using pattern recognition algorithms
• Normalization of the magnetic response
• Accurate depth change estimation
• Applicable for MFL-A and MFL-A Ultra
• Historical CGRs (per feature)
• Segmentation
• Optimized future CGRs (per segment)
• Accurate diagnosis
• Identify & assess symptoms
• Determine corrosion mechanism
• Effective mitigation & prevention
Further advancements to existing technologies (i.e. crack detection)
Further advancements in tool compliance and combination tools
The mother of all tools?...
Continued development of integrity management systems and engineering assessments and further automation of these processes
BIG DATA!...
Thank You!