Continuous condition monitoring of pipelines and risers · 2014. 11. 17. · of pipelines and risers. ICT 2 The SmartPipe vision An on-line system reporting the technical condition

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Ole Øystein Knudsen, SINTEF

www.smartpipe.com

Continuous condition monitoring of pipelines and risers

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The SmartPipe vision

An on-line system reporting the technical condition of the pipeline through a combination of sensors, degradation models, and analysis tools

Self-contained, distributed sensors packages with locally produced power and wireless communication

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General system requirements

No interference with laying operations Non intrusive sensors Low cost, simple, robust Lifetime >20 years Interfacing to existing sensor technology Low power consumption Local processing to reduce needed communication

capacity

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Key parts

• Technical condition• Warnings• Simulations• Visualisation

Data interpretation

• Materials degradation• Analysis tools• Database

• Sensors• Communication• Power

Decision making

Data collection

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Lithiumbatteries

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SmartPipe

Sensors Ultrasound wall thickness

measurement Strain gauges for measuring

deflection and internal pressure Thermistor for temperature Accelerometer for measuring

vibrations and inclination

Communication Wireless electromagnetic signal

in coating

Power A package of conventional

Lithium batteries Thermoelectric generator

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Battery packing

Four cells in series insertedin steel tubes 300 mm length Space available for charge

balancing electronics Hermetically sealed to

prevent water intrusion Five 14.4 V battery packs

encased in exterior bracelet 40 cells in total (120%

capacity) Close contact to cold sea

water beneficial for batterylifetime

Exterior bracelet can be partially embedded in PP-insulation.

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For pipes exposed to seawaterthe thermoelectric generator is capable to generate enoughpower.

The communication system willbe operational only when thereis a hot flow in the pipe No data during installation

phase No data in shut-down period

For trenched pipes an energystorage must be used to getenough power when theelectronics is active (super capacitor)

70 mW12 mW70 °C

35 mW6 mW50 °C

Not buried50 % of ΔTover Peltier

Buried20 % of ΔTover Peltier

tot ΔT

The preliminary conservative estimatesfor a single Peltier element module

Thermoelectric generator

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Communication

Electromagnetic wave in the coating

Inter node distance: 24 m Redundancy distance: 72 m

(three nodes) Carrier frequency: 5 MHz Propagation loss: 0.5 dB/meter

Patent application submitted

Antenna

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Global analysis:• Installation simulation• Free-span analysis • Fatigue (stress range/SN based)• Global buckling• Upheavals/snaking• On-bottom stability

Corrosion analysis:• Corrosion rates• Wall thickness reduction• Safe operation windows

Local analysis:• Fracture• Fatigue (fracture mech.)• Local buckling• Plastic collapse• Burst

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SmartPipe data management

Fibre modem or powerlinemodem

Host machine

Data collecionsystem

Fibre modem or powerlinemodem

Cab

leor

opt

ical

fibre

Data base

Sub-sea

Fibre modem or powerlinemodem

Pick-upantenna onoutside ofpipe

Cable or optical fibre

Degrada-tion

analysis

Visuali-sation tools

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Mounting concept

Mounting in field-joint is the most feasible solution

Belt with hardware fixed to FBE coating with adhesive and strap.

Molded into the PP coating

Standard coating procedure

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Demonstrator 24 meter long 10” pipe with 70 mm PP insulation 4 sensor belts with communication units distributed along

the pipe. In addition one anode pad Belts mounted in field-joints on top of FBE coating Produced in February 2009 Tested in May 2009

Technip spool base

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CAnode

24 m

0.8 m

A B

Communication

Sensor data

Demonstrator

Summer 2009

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”Reeling” test at Bredero Shaw 090625

4 cycles bending to radius of8,225 m and straightening

No cracks or fractures in PP coating

No problems in any of theinstalled sensors occurredduring the test

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”Reeling” test – strain gauges

Belt C: no sign of reduced contact with steel surface after 3 ”reeling” cycles

Measured strain during bend-test

-1500

-1000

-500

0

500

1000

1500

0 100 200 300 400 500 600 700 800

Time [Seconds]

Mic

rost

rain

S1S2S3S4S5S6

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Reeling test - Ultrasound

4 ultrasound transducers tested

No signs of reducedcontact with steelsurface

No signs of reducedenergy in reflectedsignal

US-6 before bending

-5,00E+10

0,00E+00

5,00E+10

1,00E+11

1,50E+11

2,00E+11

2,50E+11

3,00E+11

-5,00 0,00 5,00 10,00 15,00 20,00 25,00 30,00 35,00 40,00

Time (microseconds)

Sign

al

US-6

US-6 after bending

-5,00E+10

0,00E+00

5,00E+10

1,00E+11

1,50E+11

2,00E+11

2,50E+11

3,00E+11

-5,00 0,00 5,00 10,00 15,00 20,00 25,00 30,00 35,00 40,00

Time (microseconds)

Sig

nal

US-6

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Temperature test at SINTEF 090914

Heated oil circulated in closed test pipe

Test temperature 20-140 oC No functional problems

discovered with sensor system or interfaces

Strain gauges will relaxwhen Tg of glue is passed

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SUMMARY Sensors and electronics survives field joint moulding and reeling

Less than 2 minutes required to install the sensor hardware on the pipe.

Antennas are successfully installed.

The electromagnetic waves were successfully transmitted in the coating, and signal loss was as previously modeled.

Transition to an industrialized production and mounting procedure seems feasible.

• Alternative glue must be used for operating temperatures over Tg of PP adhesive

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Where are we today?

Phase 1 Phase 2

Generaldevelopmentof the system andverification

Design andtesting of pilot

2006-2009 2010-2012

Application for Phase 2 to be submitted autumn 2009 More companies are welcome to join in Phase 2

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The consortium