smart pigging: lessons learned - aucsc
TRANSCRIPT
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Today’s ILI
Terry Shamblin
AUCSC 2018
May 15, 2018
Today’s ILI
Originally pigs were used for maintenance
service to clean water and crude oil lines. It
is believed that the first devices were
basically balls of barbed wire with burlap
wrapped around them. As they passed
through a line in the product they made a
squealing sound and thus came the name
“PIG”.
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Today’s ILI
• Over the last 50 years the pipeline industry
has seen many advancements in ILI
processes and tools from cleaning pigs to
geometry pigs to smart pigs, tracking
systems and services, data analysis and
reporting, and overall tool and vendor
capabilities.
Cleaning Pigs
• Before starting an ILI program the
subject pipeline needs to be relatively clean
and that is usually accomplished with
cleaning pigs.
• Early cleaning pigs were primarily spheres,
foam pigs and polypigs.
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Spheres
Foam Pigs
• Preferred Inspection Velocity - 4 – 6 mph
• Will traverse bore restrictions up to 25%
of nominal diameter
• Will traverse 1.5D bends
• Multi-Channel Digital Recording
Capability
• Older technology single channel tools still
out there
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Poly Pigs
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Today’s Cleaning Pigs
• All of the mentioned are still utilized with
many more new innovations and tool
types out there today.
• Many configurations with steel mandrels,
urethane cups and discs, brushes, magnets,
studs, and guage plates.
• Rebuildable, can have many
configurations, bi-directional, dual
diameter, tracker cavities, and much more.
Common Inspection Problem
Line not clean enough
• Leads to: jammed odo wheels, clogged
sensors, magnets, or sensor lift-off, adverse
wear on sensors and cups, lodged pig, or
damaged pig.
• Inaccurate geometry or MFL data
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Beast
Brush Cleaning with Guage Plate
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Cleaning Train
Profile Guage Tool
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Dual Diameter Cleaning
Pipeline Cleanng
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Today’s ILI - Geometry
• An important step in an ILI program is to
measure pipeline geometry along the
inspection length of the pipeline to record
dents, mechanical damage, third party
damage and pipeline configuration. It is
also insurance to allow safe passage of the
smart pig.
Early Geometry
Measured distance to feature with Odo wheels
Had 12- 24 sensors all wired to one channel
Recorded to tape or paper rolls with a stylus
Poor capability with clock position, bend
radius and angle of bend
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Today’s Geometry
• Multiple channel standard and high
resolution
• Digital technology, solid state recording
• Very accurate with bore measurement, bend
radius, angle of bend, linear and clock
position
Geometry
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Geometry
Geometry
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Smart Pigs
• The first commercial smart pig was
introduced by Tuboscope in 1964 working
off MFL technology utilized in down hole
inspection. The tool had 6 sensors and only
inspected the bottom ¼ of the pipe. It had
no ODO wheels and recorded to magnetic
reel to reel tape.
Smart Pigs
• First circumferential low resolution MFL
pig in 1966
• First high resolution tool MFL was
introduced in 1978
• First Ultrasonic tool introduced in 1986
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Early Smart Pigs
• Low resolution MFL
• 12 – 24 sensors, did not have 100%
circumferential coverage
• Recorded to reel to reel or DAT tape
• Lower POD level of 60 – 70%
• Data graded to 20% & above wall loss
• No internal external discrimination
Early Smart Pigs
• Clock position was determined from manual
charts
• Casings shielded magnetic signal and data
was poor from them
• Poor bend radius capabilities
• Data presented on large paper rolls with
manual grading off a wheel chart
• Electromagnets – loss of power meant no
MFL
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Today’s Smart Pigs
• High Resolution MFL
• Large array of sensors
• Solid state recording to memory boards
• 80% or greater POD
• Data graded to +/- 5%
• Internal/External discrimination
• Grading Spec. +/- 10% 80% of time
Today’s Smart Pigs
• Full grading through casings and other
structures
• Most all MFL tools can navigate 1.5 D
radius bends
• All data recorded to flash memory
• Clock position for all anomalies
determined by onboard gyros
• Rare earth magnets – full time MFL
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Today’s Available Smart Pigs
• High Resolution Geometry – Utilized to
locate and size dents, buckles, bends, third
party damage and pipe geometry
• High Resolution MFL (Magnetic Flux
Leakage) – Main usage to locate and
measure internal/external corrosion.
HRGeo-HRMFL-UT
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HRMFL
HRMFL
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HRMFL
Today’s Available Smart Pigs
• TFI - Transverse Flux Induction - MFL
magnets are oriented circumferentially to
locate and measure axial cracks.
• Spiral MFL - Magnets and sensors spiraled
around the tool axially and
circumferentially to locate corrosion and
cracks
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TFI
SMFL
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Today’s Available Smart Pigs
• Ultrasonic - Compression wave - Uses
ultrasonic compression waves to locate and
size corrosion. A fluid couplant is required.
• Ultrasonic - Shear wave - Ultrasonic shear
or angled waves utilized to locate and size
axial cracks. A fluid couplant is required.
USWM - UT
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UT
Today’s Available Smart Pigs
• EMAT – Electromagnetic Acoustic
Transducer - Ultrasonics that are induced
into the pipe wall without a fluid coupler
• Dual Diameter MFL - MFL tools with
magnet and sensor setups that can compress
and expand to inspect multiple pipe
diameters
• Coating Tool - Low voltage Eddy current
utilized to locate coating holidays
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EMAT
Dual Diameter
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Dual Diameter
Coating Tool
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Todays Available Smart Pigs
• PGS Tool - To determine pipeline
material grades
• Low Pressure, Low Volume MFL Tool -
To allow inspections to be completed at
lower than normal pressures and flows.
PGS Tool
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Low Pressure, Low Volume MFL
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Today’s Available Smart Pigs
• Speed Control - Many MFL pigs can be
setup with large variable orifices that can be
opened and closed to maintain desired
flows in products.
• INU, IMU, GPS - Inertial Navigation Unit,
Inertial Mapping Unit, GPS - With aid of
an above ground survey this unit will
provide 3D positioning for all pipeline
features
Speed Control
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HRMFL w/Speed Control
Today’s ILI – Smart Pigs
• The trend in today’s inspection world is to
run combo tools for efficiency. The most
common usage is high resolution geometry
combined with high resolution MFL and
INU.
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HRMFL - Combo
Today’s ILI - AGM
• Early AGM’s (Above Ground Markers)
were heavy, bulky and unreliable.
• Some were generators hooked to a large coil
of wire.
• Others were large electromagnets hooked
to a car battery.
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Today’s AGMs
• Today’s AGMs are small, easy to use and
very reliable.
Submit signals to pig and records position
with full GPS.
AGM
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AGM
Today’s ILI – Major Vendors
Baker Hughes
Enduro PLS
GE – PII
NDT
Rosen
TDW
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