Take a Walk on the Wild SideInspection of Challenging Assets

Agenda From the Early Days of ILI

The State of the Art Technologies

The Innovations of Tomorrow

From The Early Days of ILI

Overview of Pipeline Inspection Industry Progression

2010 - Today• Robotics• Material Properties• Ultra high resolution

technologies• “Big Data” techniques• EMAT - Cracks in gas

pipelines

TechnologyProliferation• Miniaturization• Combinations of

technologies• Enhanced assessment

techniques• UT Crack detection

Commercial Acceptance• ML/Dent inspections

commonplace• Sizing• Competition• Digitization

60’s/70’s

80’s/90’s

2000’s

Experimental Technology• Limited ranges,

diameters• Quadrant

Inspection• Thing Finders

Progression from Un-piggable to Piggable

Active Speed Control allows for gas velocities up to 12 m/s

Low Flow - Low Pressure Tools become available

Heavy Wall Tools become available

Gas velocities up to 1.5 m/s become possible

Crack Inspection in gas

50 km in a single run becomes possible

Tools become 1.5D capable

Self-Propelled ToolsPressures up to 300 bar possible

Multi-Diameter Tools become available

Dual-Diameter Tools become available

1965

Piggable Un-piggable

Combination Tools

Extreme Inspection Lengths (> 1220km)

2017

Horizontal Storage Tanks Flow Lines

Geometry & Mapping•Detection, identification, and sizing of deformations/ID anomalies and installations

•Optional IMU for accurate mapping of pipelines spatial data - location of anomalies and further integrity assessments

Metal Loss (MFL)•Axial MFL used for detection of circumferential orientated features

•Circumferential MFL used for the detection of axial orientated features

•Tools also available that incorporate both components

•Medium independent•Speed control and combination capable

Metal Loss (UTWM)•Direct & accurate nominal WT measurement; measures echoes from ultrasonic waves induced in pipe wall

•Liquids only•Axial & Circumferential features•Generalized thinning/erosion•Sensitive to debris

Established Technologies

Established Technologies Available in most NPS

Improvements and AdvancementsTool Miniaturization

Analysis software

Wear components

Tool reliability

QA Processes

Data Management

Electronics Reliability

Etc, Etc,…

Sensoric Improvements

ILI Technology Advancements

with Existing Inspection Techniques

Speed Control Capabilities

Component Miniaturization

On Board Data Storage Capabilities

Combination & Dual Diameter Tools

The State of the Art Technologies of Today

Crack Detection (UTCD) Ultrasonic Crack Detection (UTCD)

Available in most nominal pipe sizes (> 4”)

Direct & accurate measurement principle; measures corner and tip echoes from ultrasonic waves reflecting from crack like features

Liquids only

Axial or circumferential crack tools available

Continuous and accurate depth sizing

Crack Detection (EMAT) Electromagnetic Acoustic Transducer (EMAT)

Placing an alternating electric current in a permanent magnetic field producing horizontal shear (SH) waves

Available in most nominal pipe sizes

Continuous and accurate depth sizing

Detects coating type and coating anomalies

Medium independent

Speed control capable

The Innovations of Tomorrow

What Do We Need…?

Hold A lot of people… Go really fast… Be economical…

Have the Best Technology… Be robust…

What Do We Get…?

This is what the Operators are asking for…

This is what the Vendors will build…

MFL Resolution Developments MFL-A Ultra

Ultra high sensor resolution

Detection of the smallest pipeline defects

Advanced imaging methods for defect characterization

Advanced data processing for improved repeatability and reporting accuracy

Provides a realistic evaluation of pipelines current integrity status

Non Conventional ILI Assessments

Leak Detection

Cathodic Protection

System Assessments

Pipeline Strain

Assessments

Material Properties

AssessmentsEngineering Assessments

Feasibility Assessments

Pipe Grade DeterminationPipeline DNA analysis is completed using:• ILI including the Pipe Grade

Sensor (PGS)• Existing pipeline records • Insitu-validation

Feature Type

Feature Length

Location

DiameterWall Thickness

Ultimate Tensile StrengthYield Strength

Pipe Grade

Multi Diameter Tools Began with the

introduction of dual diameter tools

With the emerging regulations for facility / lateral pipeline integrity multi-diameter tools are required to mitigate costly retro-fit expenses

Numerous solutions available for most MFL and caliper inspection NPS and some crack NPS

30”/36” MFL-A Tool - 1.5D w/ SCU

32”/42” MFL-A Tool – 3D w/ SCU

Combination Tools Combination tools

began with the introduction of MFL, IMU, and caliper technologies in one tool

Many technology combinations now available on the market

Plug and play technologies allow for a great number of possibilities for operators

40” combination caliper, UTCD, and UTWM tool with IMU. 400 hr run time & 1.5D compliant (w/ measurement in bends).

34” combination UTCD, EMAT, and UTWM tool. No data reduction and increased sensor spacing.

GEOMETRYMATERIAL

PROPERTIESCRACK & COATINGMETAL LOSS OTHER

RoGeo MDCaliper

RoGeo XtProximity sensor and caliper

RoLeak ACOAcoustic

RoVisual OPDOptical/camera

RoCorr MFL-AAxial Magnetic Flux Leakage

RoCorr MFL-A UltraAxial Magnetic Flux Leakage

RoCorr IECInternal eddy current

RoCorr UTWMUltrasonic wall thickness measurement

RoCorr MFL-CCircumferential Magnetic Flux Leakage

RoGeo XYZInertial measurement unit (IMU)

RoCD EMATElectro-Magnetic Acoustic Transducer

RoMat PGSElectro magnetic

RoCD UTUltrasonic crack

RoMat HSDual field

Speed Control Unit SCUActuator

Pipeline Data Logger PDLAccel, gyro, temp, pres

+ + +RoGeo XtProximity sensor and caliper

Speed Control Unit SCUActuator

RoMat PGSElectro magnetic

Combination Tools

+

RoMat HSDual field

RoCorr MFL-AAxial Magnetic Flux Leakage

Simplified Approach to Challenging Inspections

Standard Tool New ApplicationTailored solutions based

on tool box concept

Questionnaire

Pipeline Modification

Tool Modification

New Development

Challenging DiagnosticsToolbox Approach

PROPULSION ELEMENTS• Medium propelled• Nitrogen / Air• Batching• Robotic / Autonomous• Manual• Tethered

TECHNOLOGY ELEMENTS• MFL-A / MFL-C• Geometry / XYZ • UTWM / UTCD • IEC • EMAT• PMAT• LRUT• Cleaning

ACCESS ELEMENTS• Hot tapping• Tool launch valves• Launchers / Receivers• Spool piece• Single Access• Scaffolding• Rope Access• Insulation• Quick Launch System

MEASUREMENT CARRIERS• Unidirectional• Bidirectional• Low Friction• Ultra Compact• Multi-Diameter• External Scanners (AXUS, CIRC)• Guided Wave• Floor Scanners• Roller Probes

Case StudyBi-directional Inspection Corrosion inspection of 20″ x 1.6

km pipeline

Wall thickness: 7.87 mm / 12.7 mm

Only launching trap available, pipeline ends in a tee

Boundary conditions: Inspection in gas at system

pressure Minimum interference with

operations Full inspection of the system

Case StudyBi-directional InspectionAsymmetric cleaning/gauging tool

Less aggressive on the way in Most of the debris is recovered at the

launching site Amount of debris pushed into the system is

limited

Bi-directional low friction MFL tool Can be pumped in both directions Collects data in both directions Same quality as uni-directional tools Very well controllable since only 5 psi (straight

pipe) -15 psi (bends) dP required

Extended markering/pig tracking To maintain control on the position of the tool Determine position for turn-around accurately

Case StudyGas Storage Laterals Corrosion inspection of 10″ gas

storage laterals

Wall thickness: 7.11 / 12.7 mm

Length: 19.2 – 364 m

Traps: none

Boundary conditions: Data quality - ensure optimum

inspection performance Minimized risk – ensure equipment

comes out

Case StudyGas Storage Laterals The self-propelled RoCorr MFL/BiDi/MTC inspection solution consists

of the following elements: Inspection technology: MFL Carrier: Bi-directional / low friction Propulsion: Crawler Power: Onboard accumulators

Case StudyGas Storage Laterals

Case StudyGas Storage Laterals

Case StudyStorage Tube Inspection Built in: 1985 - 2013

Diameter: 54″ & 48″

Length: 246m to 875m

Bends: None

Wall thickness: 13.21mm/13.7mm & 22.23mm/25.4mm

Cleanliness: Clean

Obstacles: Access not sufficient for ILI tools No flow for ILI tools Older tanks spherical on both ends

Case StudyStorage Tube Inspection

RoHelix BiDi MFL Robotic inspection solution containing the following elements: High Resolution CMFL Technology Bi-directional / Low Friction Yokes Self-propelled Helical Movement

Technology (primary drive) Axial Movement Technology

(contingency drive) Onboard Power Storage Failsafe Tethering Retrieval Unit Visual Monitoring Power Consumption Monitoring 48″-54″ Diameter Range

Case StudyStorage Tube Inspection

Case StudyExtended Length / Multi DiameterParameter Values

Pipeline OD42”/44” (constant ID with valve & tee restrictions)

Pipeline Length 1,173km

Launch Nyhamna , Norway

Receive Easington, England

Run Conditions 16,800 kPA – 12.800 kPA; 2.5 m/s – 3 m/s

Average Tool Speed 2.5 m/s

Tool Run Time 5 days, 7 hours

Pipeline WT 23.3mm – 62mm

Internal coating Epoxy

Bend Radius 5D

Case StudyExtended Length / Multi DiameterLong Distance Challenge & Solution

Challenge: Overcome wear issues while negotiating 42” section first (628 km) then securing sealing

capacity in 44” section Tool differential pressure (resulting from cup friction) greater in smaller section of the p/l

leading also to higher cup friction High WT requires high magnet forces resulting in higher tool P contributing to cup wear

issues Solution:

Front Segment: increased number of PU - collectively forming three sealing planes & reduction of cup wear through tool centralization (magnets & guiding disc).

Rear Segment: wheels to support centralization & run behavior.

Case StudyExtended Length / Multi DiameterHigh Product Flow Challenge & Solution Challenge: Overcome high product density

(@high pressure) & flow with no negative impact on measurement accuracy & p/l capacity

Solution: Speed Control Unit considering

specific boundary conditions affecting capacity (bypass area, tool P, product density etc.).

High velocities & gas densities lead to specific tool design (shorter caliper arms, guiding fins & cups on rear segment) guiding the flow and reducing the load on caliper while ensuring front segment is not pushed.

FEM Calculation

Dent Assessments

Inspection Run

Data Evaluation &

Reporting

Strain Assessment

and/or Stress Screening

Finite Element Analysis (FEA)

Remaining Life Assessment

• ILI using high res caliper or combo tools

• 100% circumferential coverage

• Lift-off compensation through proximity sensor

• Accurate sizing and contour of (sharp) dents, wrinkles, buckles

• Evaluation of Geometry and Metal loss data

• Final Inspection Report

• Strain in accordance with ASME B31.8

• Fatigue screening in accordance with API 579, PDAM or EPRG

• Critical dents identified in previous step or ALL dents

• Automated FEA modelling for plain dents

• Creation of FEA models for dents on welds and/or metal loss

• Calculation of stress concentration factors (SCF)

• Based on SCFs, historic and projected pressure data (cycling) from SCADA

• Rain flow counting and application of API 579 or similar

Bin

ned

cycl

es

∆P

Rain flow Counting

Ultra MFL, AutoSCAN & CGApro

Inspection Run

Data Evaluation &

ReportingAutoSCAN CGApro Corrosion

Consultancy

• Extremely high circumferential resolution

• Fully triaxial & increased sensor focus

• Optimized sensor suspension for smooth girth weld inspection

• Evaluation using automated processing software

• Algorithms based on laser scans & real features

• FR including all features in MFL-A reporting time

• Signal matching using pattern recognition algorithms

• Normalization of the magnetic response

• Accurate depth change estimation

• Applicable for MFL-A and MFL-A Ultra

• Historical CGRs (per feature)

• Segmentation

• Optimized future CGRs (per segment)

• Accurate diagnosis

• Identify & assess symptoms

• Determine corrosion mechanism

• Effective mitigation & prevention

Further advancements to existing technologies (i.e. crack detection)

Further advancements in tool compliance and combination tools

The mother of all tools?...

Continued development of integrity management systems and engineering assessments and further automation of these processes

BIG DATA!...

Thank You!