Lloyd Pirtle Technical Representative August 12 , 2015 www ...

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® Registered trademarks of T.D. Williamson, Inc. in the United States and in foreign countries. © Copyright 2013

In-Line Inspection & MoreLloyd Pirtle

Technical RepresentativeAugust 12th, 2015

Contents

• Preparing for In-Line Inspections� Assessment Regulations & Standards� Pipeline Design� Pipeline Cleaning

• Threat Identification• Dents, Metal Loss, Planer Features, Cracks, Strain, Unknown Materials,

Combined Anomalies

• In-Line Inspection Technologies• Multiple Data-Sets• Low Drag Solutions for Low Pressure Low Flow• After the “Smart Pig”

• NDE & PMI (Positive Material Identification)

• Conclusion

Regulations & Standards

Integrity Regs & Standards

� Pigging Regulation – all transmission lines must be piggable - 1994

� 195 – Hydrocarbon Liquid Pipeline Integrity Regulations - 2000

� 192 – Natural Gas Transmission Pipeline Integrity Regulation – 2002

� ASME B31.8S – Managing System Integrity - NGT Pipelines - 2010

� API 1160 – Managing System Integrity – Haz. Liquid Pipelines - 2013

� POF – Pipeline Operators Forum - ILI Inspection of Pipelines 2009

� NACE Int. Pub – 35100 - 2000

� NACE SP0102-2010 – ILI Tool Standard Practice – 2010

� API 1163 – An In Line Inspection System Qualification Standard - 2005

� ASNT – ILI PQ 2005 – Personnel Qualification & Certification – 2005

� PRCI – Pipeline Research Council International – Various Projects

Introduction

Technology & Limitations

API 1160 also has a similar table

Pipeline Design

Pipeline Dimensions - Length, WT, Pipe ID’s

Pipeline Materials - Coatings, 70’s ERW, Seamless

Bends - Miters, LR, wt, Back to back, Factory / Field

Reducers – Concentric / Eccentric

Tees - Positioning, Diameter, WT, Flows, Bars & Bar design

Stopple Fittings/Tees - Piggable Fittings / Pig bars installed

Valves - Design, Bore, Position Indicators

Launchers/Receivers - Design, PIG-SIG®

Drips, Coupons, Multi Diameter, etc

Pipeline Piggability

Pigging Tools and Accessories

PiggingRelated Tools

There are many of options and variations with regard to pigging products in the market place. Each tool is designed and configured to perform a particular function. Just like any other tools, it’s important to use the right tool for the specific job you intend to perform

Pigs

Can either be off the shelf or Engineered to Order. Pig designs have certain fundamental characteristics, but can be customized for your specific needs

Typical Launcher & Receiver Designs

Differences ?

Why it matters

Equipment RentalTemporary Traps –

Drop-down Reducing Spools(Pressure and size)

ValvesTemp Pipe & FittingsTracking Equipment

(1 Transmitter / 2 Receivers)

Non-Intrusive Pig-SigsGeophones

Specialty Pigs – (bodies)Filters & Separators

Pipeline Cleaning

Will reduce the intensity of the magnetic signal id entified and will effect data quality. It’s a fundamental mistake to cut the clea ning program short.

MFL tools are the best most effective cleaning tool s in the industry

No One wants an MFL Tool to be a Cleaning Pig!

Sensor “Lift Off”

Your Choice…..ILI Tool Motivation Options

There are various options to meet your needs whether Pumping, Slugging, Pushing or Pulling

Threats

Natural Gas Transmission Failure Causes

Significant Incident Cause Breakdown 20 Year Average (1995 -2014)System Type: GAS TRANSMISSION State: ALL Offshore: ALL

Inline Inspection Technologies

What’s it called ?

aka – “Geo Pig”aka – “ILI”aka – “Smart Pig”aka – “Intelligent Pig”aka – “MFL”aka – “Metal Loss Pig”aka – “UT”aka – “Wall Thickness tool”aka – “Crack Tool”

ILI Technology

LGT (GEO)

KALIPER® 360

Deformation

MFL (SM)

GMFL (FM)

SpirALL

RMFL / LFMFL

XYZ

MDS

SPC

LD GMFL

EMAT

(Light Geometry Tool) 6 - 14”

(Geometry Inspection - NC) 16 - 48”

(Hi Res Geometry Inspection) 4 - 48”

(Axial Magnetic Flux Leakage) 4 - 20”

(Gas Magnetic Flux Leakage) 8 - 48”

(Spiral Magnetic Flux Leakage) 6 - 24”

(Residual / Low Field MFL) 8 - 30”

(IMU – GPS Mapping) 6 - 48”

(DEF/GMFL/SMFL/RMFL/IMU) 6 - 30”

Speed Control (24,26,36,42,48”)

Low Drag Air-coupled Axial MFL

Electro-Magnetic Acoustic Trans 12/16”

(GEO)

(ML)

Versatile

Newest

App Specific

Geometry Inspection

Basic Tool Design (Def Tool)

FRONT TO REAR OF TOOL

• Drive Section

• Magnet Section to trip AGM’s (tools use next size smaller MFL mag section without brushes)

• Deformation Section – includes Sensor Arms and CPU

• Battery Pack

• Odometers

ILI Tool Specs

• Arms ride directly on the pipe wall for greater sensitivity to ID changes

• Circumferential arm spacing approx. 0.25” (6.35mm) when collapsed in ID

• High resolution offers strain capability

Deformation

Deformation

DEF: Expansion

Cross Section at Nominal

Cross Section at Increased ID

DEF: Expansion

Metal Loss Technologies

MFL Tools

• MFL sizes from 4” – 24”

• GMFL sizes from 8” – 48”

10” GMFL

4” MFL

24” GMFL

Axial MFL - Principle

Brushes

Magnet

Pipe Wall Section

SNSensor

SNSensor

Brushes

Magnet

Pipe Wall Section

Magnet FluxLeakage

Metal Loss Defect

Chapter HeaderChapter HeaderChapter HeaderChapter Header

Combination Tools

Combination Deformation and MFL IDOD Tool• Combined high resolution

technology• Geometry survey• Metal loss inspection survey• All the data required to assess

a pipelines structural integrity in a single pass.

• Cost effective, saving time and money.

Combination Tools –MFL and Geometry

More Technologies

DEF

LFMSMFL

EMAT

• Axial grooving & cracking• Axial ID & OD connected

Laminations• Mill anomalies• Coating disbondment• SCC

MFL w/IDOD

• Bore Changes• Measure Dents

• Dent w/ Residual Stress

• Permeability Anomalies (i.e. HardSpots)

• Pipe Grade Changes• Mechanical Strain

• Axial gouging,grooving andslotting with re-rounding or cyclingof dents

• Axial metal loss• Selective seam corrosion• Seam anomalies• Seam variations• Volumetric metal loss• Mill anomalies• Metal loss in girth welds

• Dents w/ Metal Loss

• Volumetric Anomalies• Detect Mill Anomalies• Extra Metal• Internal/External Discrimination• Detect Dents

• Dents w/ Metal Loss• Re-rounding of Dents• Cycling of Dents

• Prediction of Hard Spot• Gouging• Discriminate Mill Anomalies

• Cracking associated withvolumetric metal loss

• Discrimination ofcracks, axial groovingand slotting, corrosionand mill anomalies

• Discriminate axial groovingfrom cracking

• Identify laminations• Discriminate mill anomalies

Combined Technologies

• Dents w/ Cracks

• Crack w/ volumetric metal loss,rerounded/cycled dent, dent, axialmetal loss

• Crack w/ re-rounding orcycling ofdents

• XYZ Mapping

0 1 2 3 4 5 6 7 80

1

2

3

4

5

6

7

8

Normalized Defect Length, L/A

Nor

mal

ized

Def

ect

Wid

th,

W/A

Axial Slotting

Axial GroovingPitting

General

Pinhole

Circ

umfe

rent

ial S

lott

ing

Circ

umfe

rent

ial G

roov

ing

Axial MFL

SpirALL® MFL Technology

Overlap = Enhanced Characterization

Axial MFL + SMFL

Threat: SSC

MFL SMFL

Anomaly 1

longitudinal seam weld

MFL SMFL

longitudinal seam weld

Anomaly 2

MFL SMFL

longitudinal seam weld

Anomaly 3

# Descr. ILI % Field %

ILI Length(in.)

Field Length (in.)

ILI Width (in.)

Field Width (in.)

1 Planar 37 39 2.22 2.18 0.04 0.01

2 Planar 35 36 1.92 1.22 0.03 0.01

3 Planar 28 35 1.88 2.00 0.06 0.01

Planar / Crack-like Anomalies

Threat: Crack-Like

Metal Loss

Planar Defect –Nothing in MFL

SMFLMFL

MFL SMFL

CharacterizationMetal Loss crossing and within a girth weld

Low Field MFL - Steel Microstructure

Weld Low Carbon

High Carbon Hard Spot

MFL

Residual Field

Threat: Pipe Properties

Threat: Pipe Properties0.188” WT

Re-rounded versus Cycled Dents

Threat: Mech Damage

Re-rounded dent

signature

Cycled dent signature,

notice the strong

“halo” effect

Re-rounded versus Cycled Dents

Threat: Mech Damage

6”

20”

24”

12”

16”

10”8”

30”

Unique Technologies

• Survey / Site Documentation- Centerline

- Depth of Cover

• AGM Selection

• Anomaly Locating

• GPS Mapping

AGM’s“aka” Above Ground Markers

NOTE: If you’re interested in finding anomalies / d efects… this is important

XYZ Mapping (XYZ)

• Inertial Measurement Unit (IMU) senses motion using a combination of accelerometers and gyroscopes

• ILI vehicle attitude and position is calculated

− Calculations are tied to geographic location

XYZ Mapping

Output from high resolution mapping

6” Low Drag Def + MFL Combo

Low Drag, Compact, LightweightUnder 4 feet long

Wheel Mounted Geo Module

Air-CoupledMagnetizer

Centering Brushes

Tool Drive Module ODO’s

Electromagnetic Acoustic Transducer (EMAT)/Ultrason ic Transducer (UT)

EMAT concept

Main Pulse

Wave Propagation

EMAT (Electro Magnetic Acoustic Transducer) UT technology functions by :

• Inducing an ultrasonic wave in a structure through the inter action of a magnetic fieldand an eddy current induced by coil circuit

• Different mechanism from Piezo UT— EMAT does not require cou plant to pipe wall

Piezoelectric UT EMATUT

EMAT Coil Circuit

Ultrasonic WaveUltrasonic Wave

Eddy Currents

LorentzForce

Magnetic Field

Couplant

CrystalMagnet

EMAT UT and Piezoelectric UTtechnology

Piezo-UT

UT angled beam sensors (crack detection scheme)—signals generated at angle

Angled UT sensor heads for crack detection

Angled beam successfullydetecting crack—UT beambounces off crack andreturns to UT sensor

= crack/feature of interest

Couplant—to allow signal topenetrate inspected material

Inspected material

*TDW proprietary sensor arrangement—self-calibrating due to R1 measuring how muchEMAT signal was imparted to the inspected material (signal “ heartbeat”)

Anomalies/cracks causesignal return regardless ofthe alignment

Sensing area

• EMAT transmitters induce signals that travel through the en tire thickness ofinspected material without the need for couplant or angular signals

EMAT signals generated through entire thickness of inspected material—guided shear wave

Xmit Rec1

No couplant required

Inspectedmaterial

Reflected signals

EMAT Overview

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NDE & Positive Material Identification

Equipment

Thickness Meters�Krautkramer DMS 2

�Pipeline, tubes, vessels, tanks in the Oil / Gas and Chemical industries� A Scan and B scan displays

Mag-Particle�Parker AC Portable Yoke

�Wet and Dry Mag-Particle

Dye-Penetrant�Wet water washable dye

�Aerosol developer

Pit Depth Gauges�Farwest Digitial Gauges

�Bridging Bar, Notched feet and Ceramic Magnets hold the unit in place toallow for quick accurate measurements

Multi-Meters�Fluke

�Pipe to Soil�PH Readings

EquipmentPocket UT�C-Scan Data Acquisition

�Quickly detects and assesses the depth, shape and orientation of cracks, flaws,corrosion/erosion, delaminations, and internal anomalies

Flaw Detectors�Epoch LTC flaw detector�Avenger EZ�Sonatest D10

�Ultrasonic flaw detection (Shear Wave) is widely used for locating and sizing hidden cracks, voids,disbonds and similar discontinuities in welds, forgings, billets, axles, shafts and pressurevessels, turbines, pipelines, and structural components.

AUT

Semi-Automated Fully-Automated

Material Preparation Mechanical Properties Assessment

Optical Emissions Spectrometry Magnetic Particle

Proof: NDE (PMI)

Conclusion

• Individual Technologies can be effective when identifying simple features

• Individual technologies have limitations when used independently as defined by NACE SP0102-2010 and API 1160

• Multiple DataSets, is proven to enhance characterization and sizing for complex integrity threats and…• Overcomes limitations of individual technologies• Is better suited for characterization of complex defects• Provides clarity of anomalies, which translates into greater

accuracy• More effectively detects and characterizes crack-like and

metal loss anomalies whether seam or pipe body• Provides comprehensive mechanical damage assessment• Offers foundation for in-situ pipe properties documentation

Questions ?