The Role of Inspection During the Lifetime of a Pipeline Technical Conference:7th ASIAN PIPELINE CONFERENCE AND EXHIBITION,11-12 October 2011Istana Hotel, Kuala Lumpur, Malaysia

Jim COSTAINGlobal Leader,Oil & Gas GE MEASUREMENT AND CONTROL SOLUTIONS

Industry DriversAging Pipeline Infrastructure

Consequences of Pipeline Failure

Headlines from Pipeline Failures

Cost of Corrosion

11 to 20 Years22 %

< 10 Years14%

New 2%

> 20 Years 62%

Injury & Loss of Life … Environmental Damage

Oil Major Is Fined $25 Million for ’06 Spills at PipelinesBy JOHN M. BRODERPublished: May 3, 2011 in the NYTimesGas Major fined P24.2 million over pipeline leakBy ELLALYN B. DE VERAPublished: November 23, 2010 in the Manila BuletinLost Production.. Repair Costs.. Damaged Public Image

• Cost of Corrosion (US, 1998) was estimated at a total of $276 billion per year.

• Corrosion experts estimate that a net of 20 to 25% of that annual cost can be saved by applying currently available corrosion control technologies

• Global estimates at least 4x the numbers above

Corrosion Costs in the USA 4% of GDP annually (Source: USA Department of Transportation)

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© 2010, General Electric Company

Asset Condition Monitoring Sensors, monitors and software to monitor asset integrity

Predictive MaintenanceSoftware and predictive maintenance strategies & solutions for safe, more efficient operation

Environmental MonitoringRadiation detection and emissions measurement for cleaner operation

Sensors & Measurement Instrumentation and systems for validating critical processes and applications in high growth industries

Nondestructive TestingCutting edge inspection solutions to smartly monitor plant asset health without major disruption

Measurement & Control SolutionsHigh accuracy technologies…

Monitoring assets through the lifecycle

UltrasonicRemote Visual

Inspection

Radiography Eddy CurrentTesting

Machines

Data Management Software

Film, Equipment and ChemistryDigital Radiography(FS, CR, DR)X-ray Generators

Instruments and ProbesAutomated Systems

Ultrasonic and X-rayStandardCustomized

Video BorescopesBorescopesFiberscopesPTZ CamerasRobotic CrawlersInspection ServicesRentals

Rhythm Acquire

Rhythm Review

Rhythm Archive

Metrology

Non-contact

Air Foil System

Flaw DetectorsThickness GaugesHardness TestersSystem InstrumentationTransducersInstalled Sensors

Inspection Technologies

Pipeline Inspections in the Manufacturing Process

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Inspection Technologies During the Manufacturing ProcessDepending on the manufacturing process (ERW, SAW) and on the subsequent use of the tube, there are several options where in the process and to what extent non-destructive testing can be applied.

Testing machines are typically operated inline with the manufacturing process and need to be designed according to individual requirements based on flaw detectability and test speed.Ultrasonic testing in the ERW

process• Strip body• Edge

Strip testing (at the inlet of

the welding line, before

forming)

• Weld• Scarf monitoring• Heat-affected zone

Inline weld testing (after

welding/annealing/sizing)

• Weld • Full body• Tube end

Final acceptance test (at the

finished product)

Ultrasonic and X-Ray testingin the SAW process

• Plate• Online weld UT• Final acceptance test UT• Final acceptance test X-

Ray

Longitudinally welded

• Strip• Online weld UT• Final acceptance test UT• Final acceptance test X-

Ray

Spirally welded

SAW - Ultrasonic testing machines

Weld testing on SAW longitudinally welded tubes

(linear transported tubes)

SAW – Ultrasonic testing machines

Spirally welded tubes

Strip testing (body and edge) with stationary probes

Weld testing of SAW longitudinally welded tubes

SAW - X-Ray testing machines

Pipeline Inspections during Pipeline Construction

Weld quality is a critical part of any project in the O&G market whether a new refinery, offshore platform or cross country or subsea pipeline. GE S&I has a comprehensive portfolio of solutions from the pipe mill to the field. Using state of the art UT and RT technology, GE can provide fit for purpose tools to suit all types of weld examinations.

Weld Inspection

Automated UTCR for offshore girth welds

GE Proprietary Information Subject to restrictions on the cover or first

page

USM Vision Weld Inspection Solution

Key FeaturesMenu guided set-up and inspection to optimize time of inspector capabilities

Meets international codes & standards

Data analysis, reporting, and sharing with GEIT Rhythm

Footer

InspectionPlan Creation

Data Acquisition

Data Analysis

Archive

RhythmIPC Rhythm

ReviewRhythm

Reporting

PA & TOFDRhythmArchive

Probe/ScannerCal Blocks

Administrator inputs data

Level III reviews plan

Level I or II UT or RT inspector

performs inspection

Level II/III reviews

data

Adminstrator generates report and archives data

USM Vision Weld Inspection Solution

Reporting

USM Vision Guided Inspection Workflow

UT Inspector

Non UT Specialist

UT Expert (Remote)

Inspection preparation

Non UT Specialist

UT Expert

In-Service Pipeline Inspections

1. Rightrax is a system that can measure wall thickness continuously by using permanently installed UT transducers.

2. Rightrax consists of two product versions. A. A low temperature -40°C <120°C / -40°F

< 248°F systemB. A high temperature version -20°C<500°C /

-4°F < 932°F system

3. Both systems are non intrusive and can be installed on live pipelines

4. Both system installed versions have hazardous area certification

5. Installed without any welding

6. Data can be easily read by Asset Integrity and easily transferable to existing RBI program

Rightrax Applications in Oil & Gas• Upstream,

Exploration and Production

• Offshore Installations

• Unmanned Offshore Installations

• FPSO

• Midstream, Transportation

• Cross-country pipe lines

• Downstream, Processing and Refining

• Refineries

• Petrochemicals

The GE Rightrax systemThe smart way to monitor wall thickness

System configurations1. PORTABLE

• For both LT and HT systems• Manually operated• Data collection in the field• Data download to PC or laptop• Manual assessment of data

ADVANTAGE

• Lower system cost

• Flexibility of system use

2. INSTALLED

• For both LT and HT systems• Automatically operated• Fixed interval measurements• Data storage• Manual data collection• Manual assessment of data

ADVANTAGE

• System is certified for HAZ use

• No human intervention for measurements

• Monitor process related events

ADVANTAGE

• System is certified for HAZ use

• No human intervention required

• Monitor process related events

• System alarming on special events and conditions

3. INTEGRATED

• For both LT and HT systems• Automatically operated• Fixed interval measurements• Data storage• Automatic data analyses• Integration with third party

systems with data and alarming

Upstream Case StudyConcern: • Unmanned offshore installations require

frequent wall thickness monitoring due to unpredictable sand erosion.

• 6” & 8” Lines: 6-8mm wall thickness

• Erosion rates can be up to 4mm / 24 hours

• Monitoring is required and location is remote

• Normal Operational Temperature is 80°C

Solution:• Total of 96 Rightrax M2 sensors on 6

individual platforms

• M2 sensors wired back to DL2 Datalogger and LD2 in hazardous area

• LD2 line driver connected to RTU using Modbus interface and VFC contacts

Configuration: • Measurements made every 8 hours

• Data analysed on the LD2 line driver

• Measure to 5mm thickness with VFC dry contact alarm if threshold thickness value is violated

• Data sent to Onshore Control Room to analyse and monitor riser wall thickness

• Data by Modbus Via RTU – HMI - PCS

Value and cost saving: • No bi-weekly mobilization of personnel

• Monitoring critical process and preventing incidents

• More operational control (pressure and flow)

• Less downtime

offshore onshore

Midstream Case Study Concern: • Measure Water, H2S, & CO2 Corrosion on

Underground Natural Gas Allocation, Transmission & Distribution Lines

• Monitor reduction of pipe wall thickness at top, sides, and bottom locations along the pipes

Solution:• Initially Twelve (12) Measurement Locations

• Four (4) M2 Sensors per TML

• 18 Mtr Extension Cable wired back to Data collection post

• Manual DL2 Datalogger

Configuration: • Measurements made manually as per

customer’s required time frames

• Data stored on DL2

• Data analyzed via downloading DL2 to customer’s PC w/ supplied software

Value and cost saving: • Covered known & suspected corrosion

locations

• Long Design/Performance Life

• Inexpensive: Met Customer’s Needs

• Met Political & Regulatory issues/concerns

M2 sensors

Natural Gas Pipeline

Subsea Direct RadiographyDevelopment Project

Subsea Direct Radiography Project

• Corrosion/Erosion• ROV or diver deployed• Now rated to 1800ft

(600m)• Planned 9000ft

(3000m)• All trials completed• First inspection Oct

2011

The Power of Digital Data

Rhythm - Turning information into intelligence

Rhythm Report

Rhythm Archive

LAN

ConsistentQuick Reports

LAN

Capture, share, analyze, report, and archive digital inspection information

Data Storage &Enables Trending

Rhythm Review

Remote Review & Analysis Rhythm

CR

Rhythm UT

Rhythm Visual

Rhythm DR

Multi-Modality Platform

GE Proprietary Information Subject to restrictions on the cover or first

page

Sharing RT and UT Images in Rhythm

GE Proprietary Information Subject to restrictions on the cover or first

page

Inspect

Review

Report

ArchiveShare

DICONDE“One standard = One platform”

Common Rhythm Platform