Polyinform_pipelines inspection_english

Address: Ligovsky pr., 254, St. Petersburg, Russia, 196084E‐mail: info@polyinform.comURL: http://www.polyinform.com

Tel. (+7‐812) 458‐ 85‐73Tel. (+7‐812) 458‐85‐74Fax. (+7‐812) 485‐85‐76

THE TECHNOLOGIES OF FUTURE THE TECHNOLOGIES OF FUTURE IN YOUR HANDS TODAY IN YOUR HANDS TODAY

UNIQUEUNIQUE METHOD OF METHOD OF THE CONTACTLESS THE CONTACTLESS

PIPELINES PIPELINES INSPECTION INSPECTION

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PROBLEM

Pipelines have significant tear-and-wear, lifetime of most pipelines is over 20 years:

More than 10% of Russian pipelines are impassible for the traditional (in-tube and contact) diagnostics methods due to the technical limits (underwater crossings etc)

Existing NDT methods are costly, labour-intensive, time consuming, require considerable customers resources to attract, multiple runs of the pig, stop and / or changing the mode of transportation of product, which leads to owners significant associated losses

Providing industrial safety of oil and gas pipelines by implementing qualitative and moderate diagnostics is the issue not only environment protection but the factor providing economic stability of the pipelines operating enterprises

47%

23%

30%

40%

8%26%

15% 11%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

Нефтепроводы Газопроводы

менее 10 лет

от 10 до 20 лет

от 20 до 30 лет

более 30 лет

Oil pipelines Gas pipelines

More then 30 yearsFrom 20 to 30 yearsFrom 10 to 20 yearsLess then 10 years

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The principally new approach to pipelines technical inspection by contactless magnetometric diagnostic method using high-tech system KMD-01M

The contactless magnetometric diagnostic system KMD-01M consists of:

SOLUTION – KMD-01M

3-component magnetometers unit Data saving and visualization unit

Additionalequipment

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PHYSICAL PRINCIPLES of KMD-01M OPERATING

The systems work is based on the Villari effect (magneto-elasticity effect ) which means the changing of the magnet magnetization under the influence of mechanical deformations and stresses in the pipes metal

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NOVELTY

The device KMD-01M is based on the thin-film magneto-resistive transducer, which measures full magnetic induction vector in the four points

One of the main factors determining the high sensitivity of KMD-01M and diagnostics selectivity is applying of magnetic nano-films having the range of advantages

Nano-films key advantages:

• High magnetic sensitivity• Wide range of operating frequencies• Low hysteresis• Low voltage bias• Low temperature drift• Low temperature coefficient of

sensitivity

The magnetogram of anomalies received in real time mode

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NANOTECHNOLOGY COMPONENT

ТМРС

- 10

нм

SiO

2 - 0

,8 мкм

S i, 4 5 0 м км

Principles of the contactless diagnostics require applying high sensitive sensors able to register extremely weak magnetic fields at the distance from a pipeline

The main sensitive element of the magnetic field sensors is ferrite made as the nano-film on the silicone plate

The ferrites size and its composition defines the sensitivity, selectivity and speed of the sensors

The best characteristics have the magnetic films we use - based on FeNi alloy and FeNiCo permalloy with a thickness from 10 nm to 30 nm and the thickness of separation layer to 5 nm (Ta or Ti)

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SCIENCE AND TECHNICAL FEASIBILITY AND APPROVING

New design, technological solutions and software developed for the measuring equipment are protected by patents

In 2010 the project received a positive conclusion of the Scientific‐Technical Council of State Corporation "Russian Corporation of Nanotechnologies", signed by three active members of the Russian Academy of Sciences

In 2011 the project has passed the technical expertise of 10 independent experts of the Skolkovo Found for receiving the status of the innovation project. The company became a participant of Skolkovo Found 

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Remote discovering the areas of the pipelines with the defects of metal from the earth or water surface (without digging out of pipelines, while the normal mode)

Remote contactless defining the technical state of the underwater areas of pipelines

Determine the degree of injury risk

Detection of the pipeline defects in "on-line" mode

Automatic tracing of the pipeline with the following marking the trace at the topography map

Creating the electronic maps of the defects localization with linking them to GPS coordinates

PROBLEMS SOLVED BY KMD-01M:

At the pipeline ofOAO «Lukoil - West

Siberia», 2010

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Stress-deformed condition

Bundles of metal

Defects in welds

Corrosion fatigue

Local damage (pitting, loss of metal etc)

Changing the pipelines geometry

TYPES OF DEFINABLE DEFECTS:

Stress-deformed area

Local corrosion Pitting area Weld defect

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The distance between the magnetometers block and the pipeline

Up to 10 pipes diameters depends on operating pressure

The diameters of inspected pipelines from 159 mm

The instrumental error of current coordinate defining

± 0,5 m

The degree of metal lose from 20 % of the pipes wall thickness

Memory sizeEnough for non-stop writing of information about 500 km of pipeline

ProductivityUp to 50 km daily per the shift (2 persons)

Temperature range From - 55 °C up to + 55 °C

SPECIFICATION OF KMD-01M

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KMD-01M ADVANTAGES*

Does not require preliminary preparation of pipeline, stopping or changing the operating mode

High adequacy of the received data (up to 93%)

High productivity (up to 50 km daily per 1 shift)

Wide specter of the detected defects and highest accuracy

Inspection of the areas, not reachable for in-tube an contact defectoscopy methods

Automatic tracing

Preliminary data processing for magnetic anomalies indicating in on-line mode, ability to out on markers, link it with the voice information as well as photo and video-files

Low cost of the service

The test inspection of the pipeline made for OAO "Lukoil West Siberia" Oil Company showed 93% accuracy for the critical defects

* Direct analogues of the system DOES NOT EXIST

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METHODIC OF MEASURING WITH KMD-01M

Complex is operated by two operators: :

The first operator locates the pipeline with the pipeline finderas well as links the route with the GPS receiver to the reference points

The second operator measures the fluctuations of the constantmagnetic field with the magnetometers.

Based on the received data the areas of stress concentration due to the corrosion teat-and-wear, stressed-deformed condition, pipelines geometry failure, and other defects are defined

While measuring the system automatically records the GPS-geographical coordinates.

The processing and interpretation of the received data take place after the measuring.

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I stage Collecting all necessary information and preparing the measuringequipment.

II stage Field inspection with КМD-01М – magnetometric contactless measuring with the simultaneous data visualization. At the same time detecting of GPS - coordinates is made. While working the received data can be transferred to the Data Processing Centre through Internet.

III stage The processing and interpretation of the received data is held. By the customers request the opening of the pipeline can be made with the NDT - additional control by non-destructive methods (measuring of thickness and hardness).

IV stage The analysis of the received information is executed, the electronic maps of the discovered anomalies are designed and then the final objects technical condition conclusion is made.

THE TECHNIQUE OF PIPELINES COMPLEX DIAGNOSTICS

The complex diagnostics of oil & gas pipelines technical conditions is carried out in four stages:

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VISUALIZATION EXAMPLE

Supercritical stress-deformed condition at the top and bottom forming of the pipeline

Magnetogram of the supercritical level anomalies

Supercritical stress-deformed state

Critical fatigue-and-corrosive stress state

Critical fatigue-and-corrosive stress state

Critical local defect

The pipe on the ground surface

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ELECTRONIC MAP OF THE SUPERCRITICAL LEVEL ANOMALIES

Electronic map showing

the binding of supercritical

levels defects requiring

additional defectoscopy

control at the field pipeline

with the definition of

geographical coordinates

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PLANNED DESTINATIONS AND DEVELOPMENT

Purpose: increasing the productivity up to 75 km daily per a team (depending on the route).

Placing the device at a all-terrain car

Placing the device at a submersible

Purpose: inspection of underwater pipeline passages

Placing the device at a pilotless aircrafts

Purpose: increasing the productivity and extending the areas available for inspection (deserts, swamps and taiga).

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EXPERIENCE The diagnostics using the system KMD-01M was carried out on the pipelines of different types, destinations and level of readiness for operatingООО «Kazmunajgas», Kazakhstan

- main gas pipeline «Central Asia - Center», ø 1220 mm.ОАО «Lukoil - West Siberia», Russia

- gas collecting pipeline TPP «Yamalneftegaz», ø 260-400 mm- field oil pipelines TPP «Kogalymneftegaz», «Pokachineftegaz», «Langepasneftegaz», «Urajneftegas» -ø 159-400 mm

ОАО «ТNК-ВР», Russia- gas- and oil gathering pipelines near Njagan , ø 159 - 400 mm

OAO «Bashneft», Russia- field pipeline, ø 159-420 mm

ОАО «Oil Company «Rosneft», Russia- field pipeline «RN-Uganskneftegas», ø 530 mm

ООО «LUKOIL-Komi», Russia- field pipeline, ø 530 mm

ОАО «GAZPROM», СУ «Lenorgenergogaz», Russia- gas pumping stations - КС «Rhevskaya», КС «Smolenskaya», КС «Volhovskaya», ø 1020 mm

«Saudi Aramco», Saudi Arabia- main pipeline, ø 31”

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OBJECT: main gas pipeline (ø1020 mm) АО "IntergasCentral Asia" (Kazakhstan) Scope of work: Inspection of the pipeline with the system of magnetometric diagnostics KMD-01M Duration: 19.07.2010 –23.07.2010

OBJECT: gas- and oil gathering pipelines near Njagan , ø 159 -400 mm (OAO "TNK-BP") Scope of work: Inspection of the pipeline with the system of magnetometric diagnostics KMD-01M Duration: 18.03.2011 –28.03.2011

OBJECT: field and gas gathering pipelines (ø 159 -600 mm) of Oil Company «Lukoil - West Siberia»Scope of work: inspection of pipelines via NDT (nondestructive testing) methods with the help of magnetometric device KMD-01M Duration: 18.08.2010 –08.10.2010

OBJECT: gas pumping stations near towns Rzhev, Smolensk, Volhov (ø 1020 mm), OAO"Gazprom"Scope of work: Diagnostics of input and output gas compressor stations pipelines with the system of magnetometric diagnostics KMD-01M Duration: 14.06.2011 –17.06.2011

EXPERIENCE

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The system is certified by State Standard of Russia as a measuring tool. The inspection method and the system are patented in the State Register of the Useful Models of Russia (9 patents). The company processes the License on the activity on executing of expertise of industrial safety.

PATENT PROTECTION

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International Oil CompanyMain oil pipeline

- Diameter 24”

- Walls thickness 0,250 inch

- Type of pipes steel X52

- Operating pressure 400 psi

- Type of pipeline buried

EXPERIENCE IN ILLUSTRATIONS

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The operator of KMD-01M system is following the pipeline

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Open pit made at the place where high level of stressed-deformed state had been detected

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Magnetogram of the part of pipeline with the stressed-deformed state of the high critical level

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Measuring of stressed-deformed state after removing the load

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Magnetogram of the same section of the pipeline after the removal of the load.

No stressed-deformed state

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Changing the pipes geometry causing stressed-deformed state of supercritical level

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The sand dune with the height of more than 10 m where the pipeline could not been inspected (the distance is more than 10 diameters of the pipe)

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Magnetogram of the pipeline under the sand dune. The high level of stressed-deformed state is detected at points of entering and exiting

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Detailing of the magnetic anomaly connected with the corrosive defects

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Zone of the corrosion defects marked as the result of the contactless inspection with KMD-01M. The coincidence of the measured coordinates of the anomaly with fact is well seen (0,5-1,0 m)

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Local defect of scuff type

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Pit corrosion with the loss of metal 22%

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Detailing the anomaly in the open pit, the anomaly is related with the local corrosion damage

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Corrosion damage at the specified area of the bottom surface, with the losses of the metal up to 30%

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The scuff

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Russian Oil Company

Field pipelines, diameters 259-426 mm

Pressure 1,0-2,2 mPa

Transported products: oil, oil-gas-water emulsion

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Inspection of the pipeline on the skies

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Using of the snowmobile for diagnostics of the field pipeline. The speed - 20 km/h

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The optimal vehicle for operator while winter is non-magnetic Nenets sledge (pulk)

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Using of a snowmobile with the pulkallows working in the dark

41Additional diagnostics control in the test pit

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Ultrasonic thickness measuring in the frames of additional diagnostics control

OUR SOLUTION FOR EXPERTISE OF INDUSTRIAL SAFETY

Address: Ligovsky pr., 254, St. Petersburg, Russia, 196084E‐mail: info@polyinform.comURL: http://www.polyinform.com

Tel. (+7‐812) 458‐ 85‐73Tel. (+7‐812) 458‐85‐74Fax. (+7‐812) 485‐85‐76