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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® - CH4 Airborne Remote Monitoring
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
Pipeline Operation and Maintenance | 10.4.2014
DVGW G 501
CHARM® - CH4 Airborne Remote Monitoring
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
Pipeline Operation and Maintenance | 10.4.2014
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
Pipeline Operation and Maintenance | 10.4.2014
DVGW G 495 / 497
GasCam® - Remote Gas Detection
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
Pipeline Operation and Maintenance | 10.4.2014
GasCam® - Remote Gas Detection
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
Pipeline Operation and Maintenance | 10.4.2014
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
Pipeline Operation and Maintenance | 10.4.2014
55
Pipeline Operation and Maintenance | 10.4.2014
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
Pipeline Operation and Maintenance | 10.4.2014
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
Pipeline Operation and Maintenance | 10.4.2014
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
Pipeline Operation and Maintenance | 10.4.2014
Component test,
burst pressure: 97,2 bar
Pipeline Operation and Maintenance | 10.4.2014
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
Pipeline Operation and Maintenance | 10.4.2014
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
Pipeline Operation and Maintenance | 10.4.2014
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
Pipeline Operation and Maintenance | 10.4.2014
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
Pipeline Operation and Maintenance | 10.4.2014
Defects at Construction
Dents and Ovalities at Construction (Caliper Pig)
Dents Ovality
Caliper Pigging 66
Pipeline Operation and Maintenance | 10.4.2014
Caliber Pigging
Pipeline Operation and Maintenance | 10.4.2014
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
Pipeline Operation and Maintenance | 10.4.2014
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
IMU - Strain Assessment 69
Pipeline Operation and Maintenance | 10.4.2014
Strain Assessment – Field Verification
Surveyor: 2.09 m
(horizontal displacement) IMU: 2.15 m
IMU - Strain Assessment 70
Pipeline Operation and Maintenance | 10.4.2014
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
Pipeline Operation and Maintenance | 10.4.2014
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
Pipeline Operation and Maintenance | 10.4.2014
72