PIPE GRADE DETERMINATION AND MAOP VALIDATION ?· PIPE GRADE DETERMINATION AND MAOP VALIDATION USING…

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  • PIPE GRADE DETERMINATION AND MAOP VALIDATION

    USING SOPHISTICATED SCRAPER TECHNOLOGY

    Thomas Eiken, Werner Thale, Mohammed Jaarah

    7th MENDT Conference Bahrain 09/15/2015

  • Slide 2

    CONTENT

    1. Pipe Grade in the Context of PIM

    2. RoMat PGS - Development of an ILI

    Solution for Pipe Grade

    Determination

    3. RoMat PGS - Field Experience with

    the Sophisticated Technology

    4. RoMat PGS The Data Evaluation

    Process

    5. Process of MAOP Reconfirmation

    6. Key Benefits and Conclusion

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 3

    0.0%

    10.0%

    20.0%

    30.0%

    40.0%

    50.0%

    60.0%

    70.0%

    80.0%

    90.0%

    100.0%

    0.0%

    5.0%

    10.0%

    15.0%

    20.0%

    25.0%

    30.0%

    Inst

    alle

    d b

    y D

    eca

    de

    Cu

    mu

    lati

    ve (

    red

    lin

    e)

    Inst

    alle

    db

    yD

    eca

    de

    (blu

    eco

    lum

    s)

    Percentage of gas transmission pipeline mileage installed in

    the USA [1]

    Ageing pipelines:

    E.G. approx. 50% of all

    pipelines installed

    between 1950 and 1970

    in the US..

    PIPE GRADE IN CONTEXT OF PIM

    1) J. F. Kiefner, M. J. Rosenfeld, The Role of Pipeline Age in Pipeline Safety, Final Report

    No. 2012.03, INGAA Foundation, October 2012

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 4

    PIPE GRADE IN CONTEXT OF PIM

    Effective integrity management requires holistically pipeline data.

    The pipe grade is a critical input for defining allowable operating pressure.

    Pipe grade is also needed for the accurate assessment of anomalies found

    in pipelines.

    Pipe grade is uncertain for some pipelines due perhaps to changes in

    ownership or the accidental destruction of records.

    Historical emergency repairs or diversions may have resulted in pipe of

    unknown grade being introduced.

    The complete and accurate determination of pipe grade will allow effective

    integrity management in line with industry best practice.

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 5

    Resulting Diagnostic Challenges:

    Validated In Situ NDT delivers no holistic survey.

    Until now, no economic, holistic method to measure yield strength of an

    entire pipeline section has been available.

    Holistically inline inspection solutions are needed for decoding the pipeline

    design of pipeline sections with insufficient records to reconfirm MAOP/MOP.

    PIPE GRADE IN CONTEXT OF PIM

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 6

    Proportional limit stress

    Yield Strength (YS)

    Fracture

    (Ultimate Strain)

    Ultimate Tensile

    Stress (UTS)

    xx x

    Barlow Equation

    MAOP: Maximum Allowable Operating Pressure

    t: Nominal Wall Thickness

    PY: Specified Minimum Yield Strength (SMYS)

    D: Outer Pipe Diameter

    SF: Safety Factor

    Including according to ASME B 31.8 :

    - Design Factor

    - Joint Factor

    - Temperature Derating

    Factor

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

    PIPE GRADE IN CONTEXT OF PIM

  • Slide 7

    CONTENT

    1. Pipe Grade in the Context of PIM

    2. RoMat PGS - Development of an

    ILI Solution for Pipe Grade

    Determination

    3. RoMat PGS - Field Experience with

    the Sophisticated Technology

    4. RoMat PGS The Data Evaluation

    Process

    5. Process of MAOP Reconfirmation

    6. Key Benefits and Conclusion

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 8

    ROMAT PGS - DEVELOPMENT OF AN ILI

    SOLUTION FOR PIPE GRADE DETERMINATION

    Destructive testing

    Our calibration data set are supported by destructive testing and mill test reports

    As of today we used 23 vintage pipe sample with unknown properties for destructive testing

    The properties of five modern grades are supported by mill test reports

    Tensile Testing (ASTM A 370)

    Charpy Testing (ASTM A 370)

    Micro-sections

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 9

    ROMAT PGS - DEVELOPMENT OF AN ILI

    SOLUTION FOR PIPE GRADE DETERMINATION

    100

    150

    200

    250

    300

    350

    400

    450

    500

    350 400 450 500 550 600 650

    Measu

    rem

    en

    t [a

    .u.]

    Ultimate tensile strength [MPa, N/mm2]

    st37, S235JR+AR

    A516_Grade70

    ST52, S355MC

    X65, API 5L X65 PSL2

    X70, SAWL 485 IFD

    Results

    Coefficient of determination:

    UTS: r2 = 0.92

    Laboratory tests:

    Conjunction between mechanical

    and electro-magnetic steel

    properties

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 10

    a.b

    .

    Schematic view

    WT measurement

    from MFL

    Color scan of the

    PGS response

    PGS response

    clearly

    independent

    from WTMedian in

    circumferential

    direction of

    PGS response

    Conducting performance pull tests at the

    ROSEN Technology and Research

    Center test field, Lingen/Germany

    ROMAT PGS - DEVELOPMENT OF AN ILI

    SOLUTION FOR PIPE GRADE DETERMINATION

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 11

    Color scans of pull tests with varying velocities

    PGS response

    independent

    from tool velocity

    ROMAT PGS - DEVELOPMENT OF AN ILI

    SOLUTION FOR PIPE GRADE DETERMINATION

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 12

    Color scan of the PGS response

    ROMAT PGS - DEVELOPMENT OF AN ILI

    SOLUTION FOR PIPE GRADE DETERMINATION

    Unity plot of performance pull tests is within the tool performance

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 13

    Development conclusion:

    Pipe Grade Sensor (PGS): Electro-Magnetic sensor technology

    High resolution approach, high circumferential resolution

    Vintage UTS and YS value are based on destructive testing according to

    ASTM A 370

    Laboratory and full-scale testing proved the capabilities to quantify UTS and

    YS values

    ROMAT PGS - DEVELOPMENT OF AN ILI

    SOLUTION FOR PIPE GRADE DETERMINATION

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 14

    CONTENT

    1. Pipe Grade in the Context of PIM

    2. RoMat PGS - Development of an ILI

    Solution for Pipe Grade

    Determination

    3. RoMat PGS - Field Experience

    with the Sophisticated

    Technology

    4. RoMat PGS The Data Evaluation

    Process

    5. Process of MAOP Reconfirmation

    6. Key Benefits and Conclusion

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 15

    Pipeline data:

    Natural gas transmission pipeline

    16 pipeline, 70,000 ft.

    Nominal wall thickness 0.250

    Pipe line was constructed and partial replaced with

    new and used (refurnished) pipes

    Known pipe grades: X42, X52, X60

    Unknown pipe grades: X24 according to 49 CFR

    1583 pipe segments and fittings

    ROMAT PGS FIELD EXPERIENCE WITH THE

    SOPHISTICATED TECHNOLOGY

    Performance test of the tool in the field

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 16

    The ILI survey was executed in January 2014

    11 Inspection System Results verifications were carried out in fall 2014

    Validation Digs and NDE program has been completed in Q4 2014.

    Data comparison with mill test reports of known pipe properties were carried

    out.

    Discrepancy analysis and case studies confirmed the technology.

    ROMAT PGS FIELD EXPERIENCE WITH THE

    SOPHISTICATED TECHNOLOGY

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 17

    CONTENT

    1. Pipe Grade in the Context of PIM

    2. RoMat PGS - Development of an ILI

    Solution for Pipe Grade

    Determination

    3. RoMat PGS - Field Experience with

    the Sophisticated Technology

    4. RoMat PGS The Data Evaluation

    Process

    5. Process of MAOP Reconfirmation

    6. Key Benefits and Conclusion

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 18

    0

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    72

    80

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    600

    0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000

    Yie

    ld S

    tre

    ng

    th [k

    si]

    Yie

    ld S

    tren

    gth

    [M

    PA

    ]

    Log Distance

    Determination per pipe joint

    Sections with unknown grade

    Sections with unknown grades 165 MPa (X 24) in accordance with 49 CFR

    ROMAT PGS THE DATA EVALUATION PROCESS

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 19

    Co

    un

    ts [

    a.u

    .]

    [ft]

    ROMAT PGS THE DATA EVALUATION PROCESS

    Color scan of the PGS response for 1583 pipe segments47 P

    ipe S

    egm

    ents

    282 P

    ipe S

    egm

    ents

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 20

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    600.00

    0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000

    Yie

    ld S

    tren

    gth

    [k

    si]

    Yie

    ld S

    tren

    gth

    [M

    PA

    ]

    Log Distance

    Determination per pipe joint

    Yield strength per joint (ILI) Sections with unknown grade

    RoMat PGS determines yield strength values

    ROMAT PGS THE DATA EVALUATION PROCESS

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 21

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    0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000

    Yie

    ld S

    tre

    ng

    th [k

    si]

    Yie

    ld S

    tren

    gth

    [M

    PA

    ]

    Log Distance

    Determination per pipe joint

    Yield strength per joint (ILI) yield strength per joint (hardness testing) Sections with unknown grade

    RoMat PGS determined yield strength values are compared with Inspection

    System Results verification

    ROMAT PGS THE DATA EVALUATION PROCESS

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 22

    Inspection System Result verification according to API 1163 - by the use of mobile

    hardness testing

    Unity plot: UTS determined by ILI versus UTS determined mobile hardness testing

    ROMAT PGS THE DATA EVALUATION PROCESS

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 23

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    500.00

    600.00

    0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000

    Yie

    ld S

    tren

    gth

    [k

    si]

    Yie

    ld S

    tren

    gth

    [M

    PA

    ]

    Log Distance

    Determination per pipe joint

    Yield strength per joint (ILI) yield strength per joint (hardness testing)

    Sections with pipeline records Sections with unknown grade

    RoMat PGS determined Yield strength values are compared with existing pipeline

    records

    ROMAT PGS THE DATA EVALUATION PROCESS

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 24

    0

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    600.00

    0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000

    Yie

    ld S

    tre

    ng

    th [k

    si]

    Yie

    ld S

    tren

    gth

    [M

    PA

    ]

    Log Distance

    Determination per pipe joint

    Yield strength per joint (ILI) Sections with pipeline records Sections with unknown grade RoMat determined Pipe Grade

    Yield strength values (ILI) complemented with determined SMYS (Pipe Grade)

    Closing the gap in the pipelines DNA

    ROMAT PGS THE DATA EVALUATION PROCESS

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 25

    0

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    600.00

    0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000

    Yie

    ld S

    tre

    ng

    th [k

    si]

    Yie

    ld S

    tren

    gth

    [M

    PA

    ]

    Log Distance

    Determination per pipe joint

    Sections with pipeline records Sections with unknown grade RoMat determined Pipe Grade

    Pipeline DNA is complemented with pipe grade

    ROMAT PGS THE DATA EVALUATION PROCESS

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 26

    0

    8

    16

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    600.00

    0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000

    Yie

    ld S

    tre

    ng

    th [k

    si]

    Yie

    ld S

    tren

    gth

    [M

    PA

    ]

    Log Distance

    Determination per pipe joint

    Sections with pipeline records RoMat determined Pipe Grade

    Pipeline DNA is completed => process MAOP validation is starting

    ROMAT PGS THE DATA EVALUATION PROCESS

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 27

    CONTENT

    1. Pipe Grade in the Context of PIM

    2. RoMat PGS - Development of an ILI

    Solution for Pipe Grade

    Determination

    3. RoMat PGS - Field Experience with

    the Sophisticated Technology

    4. RoMat PGS The Data Evaluation

    Process

    5. Process of MAOP Reconfirmation

    6. Key Benefits and Conclusion

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 28

    PROCESS OF MAOP RECONFIRMATION

    COMPLETION OF RECORDS

    Incomplete

    pipe tally (PT)

    Pro

    gre

    ss

    ILI

    Segmentation

    based on

    measured YS

    Determination

    of outliers in

    YS

    Preliminary

    data analysis YS per joint

    Determination of

    YS equivalent

    SMYS

    Final

    data analysis

    YS per joint

    Completed

    pipe tally

    Determination

    of verification

    locations

    Integrate YS

    from mill

    certificate

    Field

    verification

    using NDE

    Tensile tests

    on pipe

    samples

    Mill

    report?

    no

    yes

    ILI & Data Analysis Data Integration Verification Testing

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 29

    known

    SF

    WT

    OD

    MAOP

    SMYS (RoMat)

    SMYS (before) Partially unknown > As low as 24 ksi (as per CFR)

    >=42>=46>=42known

    Resulting MAOP segments further used for integrity assessments such as

    FFP/FFS Analysis

    Risk Assessments

    Pressure Uprating

    PROCESS OF MAOP RECONFIRMATION

    COMPLETION OF RECORDS

    known known

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 30

    CONTENT

    1. Pipe Grade in the Context of PIM

    2. RoMat PGS - Development of an ILI

    Solution for Pipe Grade

    Determination

    3. RoMat PGS - Field Experience with

    the Sophisticated Technology

    4. RoMat PGS The Data Evaluation

    Process

    5. Process of MAOP Reconfirmation

    6. Key Benefits and Conclusion

    Pipe Grade Determination and MAOP validation using sophisticated scraper technology ROSEN Group 09/15/2015

  • Slide 31

    KEY BENEFITS

    Deliverable is a holistically view of the pipeline design. All potential rogue pipes will be

    located and part of a replacement program

    High availability and a wide range of proven tool configurations addressing

    individual operational pipeline requirements

    RoMat PGS is the solution for pipe grade determination without costly excavations to

    fulfil regulatory long or short term statistical material sampling programs

    A holistically ILI-service for pipe grade determination is a first step i...

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