Rosen.pdf

Combined In-Line Inspection

in the Context of Pipeline Integrity

Markus Brors & Thomas Beuker

22-September-2011

Content

• Introduction by Business Review

• The ROSEN Group

• Pipeline Anomalies

• Combined Inspection Technologies

• Asset Integrity Management

• Conclusion

Content

The ROSEN Group

With our motivated staff we want to create

ultimate value for our customers by providing

advanced products and integrity service

solutions as the world’s undisputed leading

supplier – most reliable, competitive and

flexible.

Since 30 years ROSEN develops and

manufactures equipment, software and

methods for the inspection and diagnosis

of engineering structures.

ROSEN Worldwide Coverage

Dubai

Kuala Lumpur

Oldenzaal

Houston

Calgary

Veracruz

Bogota

Buenos Aires

Rio de Janeiro

Moscow

Kiev

Newcastle

Dammam

Perth

SLO

Lingen Stans

Technology and Research Center in 4 different

countries. More than 2000 employees

Worldwide Coverage in more than 100

countries with 14 major operating companies

and branch offices

Pipeline Anomalies can be Complex !

Introduction

“Single Threat“

“MultipleThreat“

Rules can be Complex !

Introduction

“Straightforward Rules“

“Decision Tree“

e.g. B31G; RStreng

calculation of safe

maximum pressure

based on dimensions

of corrosion

e.g. cfr 49 – 192 or 195

complex decision tree with

different consequences

(remediation schedule)

understanding of multiple

threads and environmental

factors (HCA)

What is Combined In-Line Inspection ?

1. Two or more Data Sets are used for a Combined Evaluation Data could be obtained from different runs at different times with

different tools; combined evaluation conducted by data analysis

department; combined reporting mandatory

AND / OR

2. Two or more In-Line Inspection Technologies are integrated

on a single Combined Tool Data are obtained at the same time with one tool; operational

synergies; combined evaluation or reporting not mandatory



dist

sync



Combined Tools – All Technologies in One Run

Effective Operation & Data Gathering

1. Main Motivation improved Cost and Safety

i. scheduling and planning

ii. onsite operation launching - receiving

iii. public transportation of personnel and equipment

iv. tool tracking

v. cleaning program

2. Improved Integrity Process and Timing

i. syncronized data sets

ii. alteration of pipeline between runs can be excluded

iii. snapshot of time dependent threads

iv. run condition identical for all technologies



UT – ultrasonic wallthickness

MFL – magnetic flux leakage

Complementary technologies for corrosion assessment,

high resolution geometry survey and inertial measurement

brought together in single inspection tools ...

Geo – extended geometry service

XYZ – IMU mapping of pipe route

42” RoCorr.Geo

... addressed

in One Run • Corrosion / Metal Loss

• Mill Related Anomalies

• Mechanical Damage

• Dents and Stress Riser

• Ovality / ID Reduction

• Strain Mapping

• Pipeline Route

42” RoCorr·UT/Geo









... addressed






• Strain Mapping

• Pipeline Route










42” RoCorr.Geo

... addressed






• Strain Mapping

• Pipeline Route


• debris on the pipe wall can

affect UT measurements

• deep external feature

require minimum wall

thickness for UT

False Calls Echo Loss

Multiple Technologies for Metal Loss

• MFL more forgiving with

regards to debris

• MFL not affected by non-

ferromagnetic material

• MFL support plausibility

check for sizing accuracy

and POD

defect

dimension

signal

dimension


UT MFL


b

d

Corrosion Mapping with

Shallow Internal Corrosion Sensor

Corrosion Mapping with MFL

Strain in Bends and Dents

XYZ

MFL

GEO

SIC

Bending Strain

with XYZ Mapping

Dent Strain with

High-Res Geo Mapping

24” RoCorr·MFL/SIC


SIC Sensor SIC Sensor (schematic)

Sensor over full pipewall Sensor over metal loss

Amplitude change

Phase movement

Pipe wall


Seamless Pipe or Longseam Integrity

Longseam

• LOF

• Dents

• Gouges

• Corrosion

Seamless

• low noise

• accurate sizing

• ID/OD discrimination

HighRes

XYZ GEO

corrosion – pitting – axial anomalies – ID/OD – deformation – IMU

HighRes

CMFL

HighRes

CMFL

16” RoCorr·CMFL/SIC


Heavy Seamless Pipe (+/- 15%*t)

MFL RAW Data – Adaptive Noise Filter Required

Solution

High Resolution CMFL technology

magnetization perpendicular(!) to pipe axis and

parallel to seamless pattern

High Fidelity Raw Data

allow Accurate Analysis

CMFL RAW Data – Principal Noise Cancellation

seamless variation affect MFL path. MFL Raw

data require adaptive noise filter to reduce

influence of seamless

pattern. Filter Method

typically sufficient for

smaller wt-tolerances


Overview

Corrosion Growth FFP Assessment Diagnosis of

Threats

Risk Assessment

Consequence Assessment

Inspection Data (ILI, CP, …)

Integrity Management Plan

Rehabilitation

Threat Assessment

Risk-based Prioritization

Preventive Measures

Inspection Interval

Repair Schedule

Data Gathering, Review & Integration

• Practical Prioritization

Methods and

Prerequisites to perform

those

• From Data Integration to

Integrity Assessment

• The Final Task: Record

Keeping to demonstrating

Compliance

Baseline Risk Assessment

• Develop baseline inspection

plan based on Risk

Assessment

• Decide on inspection

technique based on threat

characteristics

?

1) Isolated ILI considerations

• ILI Defect parameters

• Operating Conditions

• No influence of environmental

factors or inspection history

Basic screening identifying

immediate repairs utilizing ILI

Vendors Reporting Software.

Practical Prioritization Methods

2) ILI and Environmental Factors


• Operating Conditions

• Influencing Geographical Factors

More consequence-driven prioritization requiring spatial data

integration and analysis tools.


3) Inspection History, Threat Interaction &

Environmental Factors


• Inspection History

• External Events / Threats

• Influencing Geographical Factors

Accurate and focused process

requiring stringent data

collection and integration

processes and sophisticated

integrity assessment / query tools.


Advanced process following ILI evaluation:

• GIS Processing: All non-ILI features have to be processed along

the pipeline route to allow for interpretation and intersection

• PIMS Processing: ILI data is intersected with (linear) features to

calculate critical defect parameters and to apply queries

From Data Integration to Integrity Assessment

GIS Processing

PIMS Processing

Parameter depend on Prioritization Rules

Sample Prioritization Query Implementation:


HighRes

XYZ GEO

corrosion – pitting – axial anomalies – ID/OD – deformation – IMU

HighRes

CMFL

HighRes

CMFL

16” RoCorr·CMFL/SIC

• Reported “at once”

• No misalignment

• Single repair campaign

Priority

Target

Anomaly

Type

Query Definition Query Details Repair Condition

HC

A C

on

dit

ion

1 Metal Loss Metal Loss > 70 % Depth >70% and

HCA = YES Immediate Repair

2 Dent

Top Side Dent within 5ft of any

metal loss, cracking or a stress

riser

o'clock ≥08:00 and ≥04:00 and

event DENT-DWML, DENT-

DWGC, IDAN-DWML, IDAN-

DWGC and

HCA=YES and STR=YES

Immediate Repair

3 Dent Top Side Dent with a Depth > 6

%

o'clock ≥08:00 and ≥04:00 and

event IDAN-DENT and

ID-Reduction >6% and

HCA=YES

Immediate Repair

Oth

er

14 Gouge/

Groove Gouge or Groove > 12.5% NWT

Depth >12.5 % and

event MELO-MEDA or MELO-

GOUG

Scheduled

16 Crack Potential crack event like *CRACK* Scheduled

20 Metal Loss

Metal Loss within 100 ft from a

CP

reading that is ≥ -850 mV

event like '*MELO*' and

CP_UP=YES Scheduled


Assessment results are interactively presented and can

directly be related to any external feature for optimal

judgement on rehabilitation activities ...

Joint decision

platform incorporating:

• ALL environmental

input parameters

• ALL types of defects

• External Inspections

Record Keeping and Demonstrating Compliance

Field activities should be tracked in their

entirety...

• What was the

input information?

• What was the

decision tree?

• Who decided for

the action?

• Which task was

assigned?

• Who executed it?

• What was the

outcome?

Record Keeping and Demonstrating Compliance

Thinking about Accuracy for Immediate

and Future Decisions...

• Utilization of Field Verifications for immediate run

accuracy / acceptance checks

• Application of accuracy buffers for future Corrosion

Growth Studies

Reflection / Implementation Options

Cloud Services available for

Advanced Reporting...

• Operator decides to implement

system or to request services via

hosted services

• Utilization of latest IT Technologies to

allow for centralized and enterprise

availablability of ILI data and analysis

capabilities

Conclusion

Combined Inspections provide you with synchronized,

reliable and more accurate records not only assessing the

isolated corrosion threat...

…besides the far greater detail on information the Economical

Factor is obvious.

To optimally utilize the valuable inspection results, a

Combined Analysis with surrounding factors is

advantegous and allows for well-founded decisions…

The possible combinations are plenty…the Advantages are

leveraged if Integrity Tools are used in the planning stage.

Integrity Tools and Services around this process are

offered by ROSEN allowing for an accurate picture

alongside the inspection campaign.

Thank you for joining this presentation.

Documents

Rosen.pdf