practical solutions for un-scrapeable pipeline … · tee fittings could result in a tool becoming...

Frank J. Mueller

7th MENDT· Manama Bahrain · September 16th, 2015

PRACTICAL SOLUTIONS FOR UN-SCRAPEABLE

PIPELINE INSPECTIONS

CONTENTS

Introduction

Managing Complexity

Preparation

Practical Solutions

Low Flow Low Pressure

Multi Diameter

Bi-Di Application

Loading Lines

Flow Lines with 3 way valve

Conclusion

Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN

INTRODUCTION

Some pipelines deteriorate slowly, and in certain cases pipeline life has been

reliably targeted at 70 years or more. Other pipelines have been built which

have exhausted their useful life after 1 year of operation.

The industry has identified suitable ways to inspect most trunk and main lines

and to a certain extent some non-piggable pipelines. However, a large

number of pipelines remain a challenge and often cannot be inspected in its

entirety.


INTRODUCTION

Standard Inline Inspection activities are applied such as:

MFL

UT

EMAT

To identify the integrity of the pipeline. Although the technologies would be suitable

for non standard and challenging lines the tools and set up is often not suitable.

AFD

SIC / ECD

GEO


EVOLUTION OF ILI

Active Speed Control

for high gas velocities

Low Flow - Low Pressure Tools

become available

Heavy Wall Tools

become available.Gas velocities up to

1.5 m/s become possible.Extreme inspection length

(1173 km in a single run)

50 km in a single run

becomes possible.

Tools become

1.5D capable.Ultra compact MFL tools

for bi-directional operation

Self-Propelled MFL tool

Pressures up to

300 bar possible.

Multi-Diameter Tools

become available.

Dual-Diameter Tools

become available.

1965

Un-piggable?

“Unpiggable” - a function of time and market need

2014

Piggable

Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015

Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN

CONSTRAINTS

Constraint Description

Tight radius Bends

Tight radius bends could result in a tool becoming lodged.

While specifications vary significantly by tool type and service provider (vendor) not all service providers have high

resolution tools that can safely negotiate bends < 3D.

Unbarred Tees

Tee fittings could result in a tool becoming wedged in a pipeline if the intersecting line is of sufficient diameter –

especially, if product exists in the main pipeline at that point.

While specifications vary significantly by tool type, unbarred tees in the 6 o‟clock position are of particular concern, as

are off-takes that are greater than 50% of the main pipeline diameter.

Diameter Restrictions /

Transitions

Any restriction in the diameter of the pipeline could result in a scraper becoming lodged, or significantly damaged.

Diameter restrictions can be a result of both planned and unplanned. Planned items can include dual diameter

pipelines, heavy-wall pipe sections. Unplanned items can range from simple temperature/pressure probes left in the

pipe prior to a scraper run all the way to pipeline deformation, such as buckling, which is an integrity concern in itself.

Eccentric reducers at launch/receive can cause tool damage depending on orientation and the abruptness of the

transition.

Lack of Launch/ Receive

Facilities

Launch and receive facilities are necessary for launching scraper to ensure that an appropriate means for access into a

high(er) pressure line is available.

In some cases “temporary” (i.e., moveable) facilities can be used – although this becomes increasingly difficult as pipe

diameters increase.

In some cases, factors such as line configuration or lack of physical space can limit an operator‟s ability to install

launchers/receiver.

Valves

Full-bore valves are crucial for safe passage of inspection tools as valves with restrictions (e.g., plug valves) can

damage tools, or in some cases trap a tool.

Typically, full-bore ball valves are best suited for scraping operations, but other valves types and configurations may

also be acceptable depending on the specifics of the tool.

Inability to Control

Process condition

Smart inspection tools must operate within a specific speed envelope in order to acquire good quality data. The ability

to control the speed of the flow is critical for the entire length of the inspection.

Debris / Residual

Deposits

Internal surface condition and surface preparation are playing a key role in the success or failure of a ILI survey.

Particularly UT tools are very much affected by debris and residual deposits in a pipeline


CONSTRAINS

Main Reasons for Challenging Pipelines:

• Pipeline Access

• Mechanical Pipeline Design

• Pipeline Operating Conditions

Main Challenges are:

• Access

• Inspection

• Cleanliness

• Information

A pipeline is generally defined “Unscrapable, or Challenging” if inspection

applying current Technologies and Procedures is considered not feasible.


WISH LIST

Even the best engineering approach is unlikely able to invent a

multi purpose tool which could address all challenging pipelines

A toolbox considering individual applications is more likely to succeed


MANAGING COMPLEXITY

Pipeline

Modification ?

Tool

Modification ?

New

Development

Questionnaire

Standard Tool

New Application

Tailored solutions based

on tool box concept

Time & Effort


THE BROADER CHALLENGE

• Approximately 40% of the worlds pipelines is currently unpiggable

• One of the most significant challenges with difficult to inspect pipelines is the

unique combination of the specific factors that make each of the pipelines an

inspection challenge

• Every challenging pipeline is a challenge on its own

• Building a new tool for every pipeline is not feasible

• So therefore many commercial technology developers hesitate to invest in

developing solutions

• At ROSEN – independent of investors banks and share holders - we look

ahead and develop solutions based on a tool box approach


CONSIDERATIONS

External

Internal

Gas

LiquidDent

SCC

Corrosion

The highest resolution should be applied inspecting the line, it is critical to select

an accurate measurement technology that provides the most accurate

information

Influences

Boundary conditions

Operational conditions

Medium Expected threats


CONSIDERATIONS

• Uni-directional

• Bi-directional

• Low friction

• Ultra compact

• Multi – diameter

• Robotic


CONSIDERATIONS


• Medium propelled

• Nitrogen/ Air

• Batching

• Crawlers

• Cable operated

CONSIDERATIONS

• Hot tapping

• Pig launch valves

• Temporary or permanent launcher

• Spool piece

• Only from one end


PIPELINE PREPARATION


As with conventional pipeline inspection, a sufficiently clean pipeline is a pre-

requisite for a successful inspection of a challenging pipeline. Being classified as

„challenging‟ often means that also no maintenance scraping has been carried out

and the cleanliness of the pipeline is unknown.

Cleaning

• Review

• Analyze

• Compare

• Identify

• Monitor

• Establish



Progressive approach: At any given time the integrity of the operation must take precedence over the

desire to complete the program in a period as short as possible. The only way to achieve this is by

applying a progressive approach. The program is split into well-defined stages and only after a

cleaning scraper achieves an agreed result the next level commences.

Redundancy: For each cleaning phase a sufficient number of cleaning tools must be available. The

cost for mobilizing and then not using a cleaning tool is marginal in comparison to cost of standby and

delays caused by mobilization of additional equipment.

Knowledge: The more historical information on the pipeline, the operational conditions and previous

cleaning and inspection runs, the more appropriate the selection of the cleaning scrapers. For the vast

majority of today's pipeline this information is readily available, but it must be submitted to and

sufficiently considered by the operator.

Experience: A good understanding on the cleaning capabilities of each type of scraper within any

given environment is absolutely essential in order to define critical acceptance criteria for each phase

of the cleaning program.

Communication: The acceptance criteria for each phase must be defined in a way that the entire

cleaning program can be safely executed by even lesser experienced operators. The flow of

information must be designed in a way that a continuous operation can be guaranteed in a 24/7

environment. At the same time all critical decisions must be discussed and agreed on senior level.

Reliability: The cleaning tools must be manufactured to high standard to achieve the best possible

results within the given time frame.

Considerations



Monitoring

Time based recording of differential pressure for two consecutive runs

• Temperature

• Pressure

• Differential Pressure

• Acceleration (x,y,z)

• Inclination

• Rotation

PRACTICAL SOLUTIONS


LOW FLOW - LOW PRESSURE LINES


Reason for Tool-Stop & Speed Excursions

• Wall Thickness Changes

• Weld Penetration

• Debris (Dust, Condensate)

• Bends

• Rough internal surface

• Dents

Influencing factors

• Length

• Diameter

• Pressure and flow

Pressure



Typical ILI run behavior of MFL ILI in LFLP gas linesTool S

pee

d [m

/s]

5 m/s

1 m/s

Distance [km]

17.2 m/s


0

5

10

15

20

25

30

35

40

0

100

200

300

400

500

600

8 10 12 14 16 18 20 22 24

Pre

ssu

e [

ba

r]

Pre

ssu

re [

psi

]

Diameter [inch]


Tool selection guideline for gas pipelines

Operating condition in low flow and low pressure pipelines especially so in gas

lines has always been a challenge to run ILI tools. Larger diameter can operate in

lower pressure then small diameter tools



Requirements

• Minimized and constant Friction

To minimize differential pressure because of

reduced absolute pressure

Constant friction reduces speed variations

• Minimized Difference Static/Dynamic Friction

To reduce the acceleration after tool stops

• Optimized Sealing

Zero bypass

Focus on tool design

• Cup design / configuration

• Magnetizer

• Length & weight12” LFLP MFL ILI



5 m/s

1 m/s

3.25 m/s

Improving ILI run behavior of MFL ILI in LFLP gas linesTool S

pee

d [m

/s]

Distance [km]

Sample:

10” gas line 10.5km long pressure 9 bar

MULTI DIAMETER PIPELINES


• Dual-diameter (i.e. 8/10”)

• Multi-diameter pipelines (i.e. 18-20-24”)

• Multiple internal changes

• Aged Lines

• Limited or no maintenance scraping

• Ineffective scraping

Pump test loop for 32"/42" multi-diameter tools

Multi Diameter pipelines are difficult to inspect because of their significant variations

in internal diameter.



Over the past years a number multi-diameter tools have been developed, built

and successfully deployed in a multitude of projects.

Sample MFL 14/18” ILI:

ID min passage 11.22” (285 mm)

Bend Capability 14” 3D (11.6”) (295 mm)

18” 1.5D

Operational Range: 11.25” – 18” (286 mm – 457mm)

37.4 % ID Reduction

Magnetic Saturation

Max wt (18”) 0.94” (24 mm)

Max wt (14”) 1.38” (35 mm)

(min ID) / OD = 0.63



Pump test



Pump test

simulated Valve Bore

simulated Valve Bore

Barred Tee

(10” offtake)

Barred Tee

(12” offtake)

simulated Flex Joint

Check Valve

simulated

Valve Bore

Reducer (18” to 14”)

Wye (18”)simulated Connector

Reducer (20” to 14”)

Reducer

(24” to 18”)

18”14”

BI-DIRECTIONAL APPLICATION


Inspection of pipelines with only access from one end of the line can be

addressed using Bi-Di tools. Loading lines are an good example as they from the

onshore facility, such as a tank farm, to an offshore buoy or to a pipeline end

manifold.

24" BiDi MFL tool

Before the run After the run



Most loading lines cannot be addressed with a conventional pigging approach.

Typical challenges:

• Single access

• No traps

• Subsea end

• Sedimentation of heavy components (paraffin, asphaltine) due to stagnant flow

• No cleaning/ inspection history

Storage

& pump

SPM

PLEM

Flexible

hoses



Pig valves are 3 way ball valves that are used in flow lines that require frequent

maintenance pigging. Inspection in such flow lines is a significant challenge.



Tool equipped with electronics and

battery inside magnetizer body

High resolution MFL sensor - no

compromise in inspection performance

Back 2 back

bend passage

Bend capability 1.5 D

Single body set up for

Pig valve applications

Symmetrical design for

Bi-Directional operation



wellhead

dunes

Launcher

Valve

Receiver

valve

H

e

a

d

e

r

ROBOTIC SOLUTIONS


Addressing pipelines with no flow, limited access mostly require self-propelled

inspection solution. Elements to consider:

Inspection technology: MFL / UT / EC / EMAT

Carrier: Bi-directional / low friction

Propulsion: Multi Trotter Crawler

Power: Onboard accumulators

ROBOTIC SOLUTIONS


Robotic Survey System (RRS)

Passage of high ID reduction

Tight bend passing capacity

Multi-diameter capacity

Vertical climb

Self-adapting tractor drive and sensor unit in one body

Intelligent and redundant on-board mission control

Single entry to the pipeline

Capable of safely negotiating 1.5D bends

Bi-directional operation

Autonomic (only batteries) or tethered (external cable with communication)

operation possible

Reliable in various media (water, gas, crude oil and dual-phase products)

Stand-alone sensor carriers (Eddy Current, UT, EMAT, etc.)

CONCLUSION


The inspection of challenging pipelines must be seen in the

context of integrity management programs. The risk

(cost/safety) balanced selection of an inspection and

rehabilitation method allows optimization of economic aspects

without compromising safety concerns.

The evolutional improvement and extension of in-line inspection

methods is reducing the number of un-scrapable pipelines

world-wide. The great variety of the different inspection options

can be structured and managed by risk based selection

approach and the corresponding modules in integrity software

packages like ROAIMS.

The technology for robotic inspection tools has been advanced.

However, the necessity for access-points and a status of

cleanliness in combination with the high operational cost

require a well prepared cost benefit analysis. Once identified,

robotic inspection help to reduce significantly the probability of

failure of a subsection in accordance with the term to

strengthen the weakest link of a chain.

www.rosen-group.com

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practical solutions for un-scrapeable pipeline … · tee fittings could result in a tool becoming...

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