The Role of Inspection During the Lifetime of a Pipeline

deadmancrossingraceAI and Robotics

Nov 13, 2013 (3 years and 11 months ago)

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The Role of Inspection During the
Lifetime of a Pipeline

Technical Conference:

7
th

ASIAN PIPELINE CONFERENCE
AND
EXHIBITION,

11
-
12
October 2011

Istana Hotel, Kuala Lumpur,
Malaysia


Jim COSTAIN

Global Leader,

Oil & Gas

GE MEASUREMENT AND CONTROL SOLUTIONS


Industry Drivers

Aging Pipeline Infrastructure

Consequences of Pipeline Failure

Headlines from Pipeline
Failures

Cost of Corrosion

11
to
20
Years

22
%


< 10 Years

14%

New 2%

> 20 Years 62%

Injury & Loss of Life … Environmental Damage

Oil Major
Is Fined $25 Million for ’06 Spills at Pipelines

By
JOHN M. BRODER

Published: May 3, 2011 in the
NYTimes

Gas Major
fined P
24.2
million over pipeline leak

By
ELLALYN B. DE VERA

Published: November
23
,
2010
in the Manila
Buletin

Lost 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

4
x

the

numbers

above

Corrosion Costs in the USA 4% of GDP annually

(Source: USA Department of Transportation)

3

©

2010, General Electric Company

Asset Condition Monitoring


Sensors, monitors and software to monitor asset
integrity

Predictive Maintenance

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

Environmental Monitoring

Radiation detection and emissions measurement for
cleaner operation

Sensors & Measurement


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

Nondestructive Testing

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

Measurement & Control Solutions

High accuracy technologies…

Monitoring assets through the
lifecycle

Ultrasonic

Remote Visual

Inspection

Radiography

Eddy Current

Testing

Machines

Data Management Software

Film, Equipment

and Chemistry

Digital
Radiography

(FS, CR, DR)

X
-
ray Generators




Instruments
and Probes

Automated
Systems

Ultrasonic and X
-
ray

Standard

Customized

Video Borescopes

Borescopes

Fiberscopes

PTZ Cameras

Robotic Crawlers

Inspection
Services

Rentals

Rhythm Acquire

Rhythm Review

Rhythm Archive

Metrology

Non
-
contact

Air Foil System

Flaw Detectors

Thickness Gauges

Hardness Testers

System
Instrumentation

Transducers

Installed Sensors


Inspection Technologies

Pipeline Inspections in the
Manufacturing Process

6

Inspection Technologies During the
Manufacturing Process

Depending 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/annealin
g/sizing
)


Weld


Full body


Tube end

Final acceptance
test (at the
finished product)

Ultrasonic and X
-
Ray testing

in 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 UT

CR for offshore girth welds

GE Proprietary Information

Subject to restrictions on the cover or first page

USM Vision Weld Inspection
Solution

Key Features

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


Meets international codes
& standards


Data analysis, reporting,
and sharing with GEIT
Rhythm

Footer

Inspection

Plan Creation

Data


Acquisition

Data


Analysis


Archive

Rhythm

IPC

Rhythm

Review

Rhythm

Reporting

PA & TOFD

Rhythm

Archive

Probe/Scanner

Cal 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
system

B.
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 system

The smart way to monitor wall thickness

System configurations

1
. 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 Study

Concern:


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, H
2
S, & CO
2
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

M
2
sensors

Natural Gas Pipeline

Subsea Direct Radiography

Development 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

Consistent

Quick 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

Archive

Share

DICONDE

“One standard = One platform”

Common Rhythm Platform