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 worlds 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 RoCorrUT/Geo

... addressed
in One Run
Mechanical Damage
Strain Mapping
Pipeline Route

42 RoCorrUT/Geo

42 RoCorr
.
Geo
... addressed
in One Run
Mechanical Damage
Strain Mapping
Pipeline Route

42 RoCorrUT/Geo
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 RoCorrMFL/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 RoCorrCMFL/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 RoCorrCMFL/SIC
Reported at once
No misalignment
Single repair campaign

Priority
Target
Anomaly
Type
Query Definition Query Details Repair Condition
H
C
A

C
o
n
d
i
t
i
o
n

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
O
t
h
e
r

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 plentythe 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.

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Combined In-Line Inspection

in the Context of Pipeline Integrity

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