inspection of refinery piping and vessels from the … beijing2013.pdf · inspection of refinery...
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Inspection of Refinery Piping and Vesselsfrom the Outside for External
and Internal CorrosionNeil Goldfine, Todd Dunford, Scott Denenberg, Yanko Sheiretov, Andrew Washabaugh, Shayan Haque
JENTEK Sensors, Inc., 110-1 Clematis Avenue, Waltham, MA 02453-7013Tel: 781-642-9666; Email: [email protected]
web: jenteksensors.com
API Beijing, China9‐13 September 2013
Primary Session: Downstream
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NDT & SHM Applications for MWM-Arrays, a flexible eddy current sensor technology
DeepwaterPipelines (CUI)
DeepwaterRisers(CUI)
In‐Ditch Pipeline
(Mechanical Damage)
In‐Ditch Pipeline
(SCC) Pipeline ILI (Corrosion, Cracks, & Stress)
Aero TurbineBlade (Cracks)
Refinery Piping(CUI)
Land‐Based Turbine Blades(Cracks)
“Common Box”
“Common Electronics”
Full‐Scale Test Stress & Damage Monitoring
“Smart” Washers for Cracks
Buried Pipe Stress & Damage Monitoring
NDT SHMNondestructive
TestingStructural Health
Monitoring
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Decay rate determined by skin depth at high frequency and sensor dimensions at low frequency
Large dimensions needed for thick coatings/insulation
Low frequencies needed to penetrate through steel pipe wall
MWM-Array Sensor Selection
VWA001 MWM‐Array*
Depth of Penetration = 1/Re(n)
*Note: Other MWM winding designs provide better performance
Stainless Steel
AluminumCarbon Steel
1 inch = 25.4 mm
Skin depth:1f
22n /2j/n2
Low Frequency Limit =
3
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HyperLattices & Multivariate Inverse Method (MIM) Hyperlattices are Precomputed Sensor Response Databases
Rapid means for converting multiple frequency MR-MWM-Array data into material and geometric properties
Grids (two-unknown databases), Lattices (3-unknowns), Hyperlattices (4+ unknowns) are generated and stored in advance
Rapid search through database for solution
Example Lattices
Wall thickness
MIM
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Corrosion Under Insulation (CUI) Inspection
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MWM-Array Inspection for CUIProblem Definition
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Wall loss imaging for internal and external corrosion through insulation and
weather jacket
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MWM-Array Inspection for CUIPre-Alpha System Performance
(Wall Thickness Image)
Improved Resolution with Alpha System(Wall Thickness Image)
(in.)
(in.)
(in.)
(in.)
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Problem Definition
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Low cost ILI Cleaning Tool
PIG-IT: Pipeline Inspection Gage, with integrated IT
Internal and external corrosion imaging from inside the pipe
Corrosion Under Insulation
Oil & Gas Application ExamplesIn-Line Inspection
Stress Corrosion Cracking Mechanical DamageMD
• Mapping of SCC clusters• Developing depth
screening capability• MPI replacement
SCC
Riser Inspection
ILICUI
Magnetic profilometry Crack Detection in Dents Developing residual stress
mapping
MWM-Array Sensor
NDT without coating/insulation removal CUI detection through ~2 in.
insulation and weather jacketPhased Array UT replacement
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Perm
eabi
lity
Lift-
off
Defect
Perm
eabi
lity
Lift-
off
Defect
0.5 in. coating 1.0 in. coating
Previous MWM-Array Results
Distance Measured From Weld at Flange Neck Ground Supports –
Limited Access
Inlet
Riser section of interest
0.5 in. 1 in.
Defect
Defect
Using VWA001 MWM-Array
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In-Line Inspection (ILI) Tools
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JENTEK ILI Development and DemonstrationsGeneration 1 – 2010 (Completed)
Preliminary capability demonstration, December 2010 Small MWM-Array mounted on a tool and pulled through straight sections High freq. test to help understand issues for integrating sensors into an ILI tool
Enhanced capability demonstration, September 2011 Large MWM-Arrays to accommodate larger lift-offs (e.g., 0.25-1.00 in.) Integrated electronics with only power supply tether (24v)
Generation 2 - 2011 (Completed)
Generation 3 – 2012/2013 (Ongoing PRCI Program)Increase channel count and data rate – Q3 2013 Increased number of channels to provide complete coverage Higher data throughput per channel to increase the maximum speed of the tool
through the pipe Include on-board power onto tool Improved durability and hardening of the instrument, including isolation from
the environment.
Generation 4 – 2013/2014 OptionsIntegrated Capability Development and Demonstration Improved durability and hardening of the instrument, including sealing for
environmental protection in oil and gas environments and shock protection Reduce power consumption for battery operation of instrumentation Reduce the size of the electronics to consolidate the tool into one module Team with an ILI tool vendor to support testing in a flow line Perform first flow line test
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Generation 2 Technology: Pull Test ResultsMWM-Array 2Pull Speed ~0.36 mph
Per
mea
bilit
yLi
ft-O
ff
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NDT
Cracks
SHM
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Representative data on flat plate
specimen with EDM notches
Crack Detection Multiple-Channel MWM-Array Crack
Depth Measurement C-Scan Imaging on Flat and Curved
Surfaces, using Conformable MWM-Arrays and MR-MWM-Arrays
Crack Imaging & Depth Measurement Capability
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36-in. long, 8-in. diameter pipes Axial EDM notches located at various positions around each pipe Scanned with FA24 (medium size) MWM-Array Wider array and sense elements compared to FA26
Schedule 80 Sample
EDM Notch Pipe Samples
Schedule 40 Sample
0.250”
0.160”
0.080”
0.020”
0.040”
11.0-in. 2.0-in. 2.0-in. 11.0-in. 10.0-in.
0.200”
0.120”
1.0-in.
1.0-in.
0.25-in. gap
0.12-in. gap
0.06-in. gap1.0-in.
1.0-in. 0.12-in. gap
0.06-in. gap
0º
-90º
-180º
180º
-90º
1.0-in.
0.200”
0.160”
0.120”
0.080”
0.040”
11.0-in. 2.0-in. 12.0-in. 10.0-in.
Depth of notch is indicated
0.160”
0.120”
Pairs of notches, either 0.5-in. or 1.0-in. long, each notch being 0.080” deep (sched. 80) or 0.040” deep (schedule 40). The vertical spacing is indicated.
1.0-in.
1.0-in.
0.25-in. gap
0.12-in. gap
0.06-in. gap1.0-in.
1.0-in. 0.12-in. gap
0.06-in. gap
0º
-90º
-180º
180º
-90º
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FA24 MWM-Array Scan of EDM Notch Pipe SampleBaseline & Post-EDM Fabrication Data on Schedule 80 Sample
Lift‐OffPermeability
Baselin
ePo
st‐EDM
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Representative FA24 data at 100 kHz Notches clearly indicated as increase in permeability Pairs of notches show resolution capability
Schedule 80 Sample
Permeability
Post
-ED
M
1.0 in.
1.0 in.
1.0 in.
0.5 in.
0.5 in.
20 22 24
Crack Imaging & Depth Measurement Capability
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Reasonable measurement correlation between depth and effective permeability change
Pairs of notches show increased response as notches are closer together Sensitive to notch depth over this range
160
140
120
100
80
60
40
20
00.250.200.150.100.050.00
EDM Notch Depth ( in.)
Schedule 40 and 80, FA24, 100 kHzlength (in.):
2.0 [single] 1.0 [single] fit: p = 627.2 d - 15.1, R2=0.950
160
140
120
100
80
60
40
20
00.250.200.150.100.050.00
EDM Notch Depth ( in.)
0.250.12
0.060.250.12
0.06
0.120.06
0.12
0.06
Schedule 40 and 80, FA24, 100 kHzlength (in.):
1.0 [pairs] 0.5 [pairs] fit: p = 627.2 d - 15.1, R2=0.950
Increasing interaction.smaller spacing (in.)
Single Crack Crack Pairs
Res
pons
e C
hang
e at
flaw
cen
ter
Res
pons
e C
hang
e at
flaw
cen
ter
Crack Imaging & Depth Measurement Capability
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FA28 MWM-Array Imaging of SCCPipeline Sample Provided by
Applus/RTD
Paper to simulate coating
Conductivity Images Lift-Off Images
FA28
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FA28 Imaging of Stress Corrosion Cracking
Lift‐Off Scan ‐ Through Coating
Close‐Up of Conductivity Scan Conductivity Scan
Close‐Up of Lift‐Off Scan
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(RTD p/n NPS34 #1)
MWM‐Array Threshold Image
MWM‐Array Spectrum Color Image
MWM-Array Imaging of SCC in Pipeline SampleScans of Pipe Section with Identified SCC (FA28 sensor)
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Full-Scale Fatigue Test at Mechanical Damage Site
under DOT and PRCI funding with GDF Suez
4-pt static load testing of coupon
Dynamic pipeline pressure testing
Damage Monitoring Stress Monitoring
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Weld Imaging
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MWM-Array Residual Stress ImagingFor Post-weld heat treatment (PWHT)
Effect of Thermal Stress Relief on Weld in Witness Coupon, Pressure Vessel Steel
Permeability/stress scanning across the weld
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