latest inspection technologies

Latest Inspection Technologies

for Pipelines

Hiromitsu Saito

Japan Cooperation Center, Petroleum

(JCCP)

http://www.cosmo-oil.co.jp

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1.Crude Oil Pipeline Corrosion

in Refineries and Oil Depots

1-1 Self propelled SLOFEC

1-2 Self propelled Multi UT

1-3 Manual UT

1-4 TOFD UT

1-5 Long range UT

00.5

11.5

22.5

33.5

44.5

0 10 20 30 40

Max.

Corr

osi

n D

epth（ｍ

ｍ）

Duration of Service（Year)

Max. Corrosion Depth of Crude Oil Pipeline

( Report in 2004 )

Refineries & Oil Depots

National Oil Stockpiling Base

Slop Line etc.

Ref. ARef. B

Dep.D

Dep.CDep.E

Dep.A

Dep.F Dep.G Dep.I

Dep.B


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2. Pipeline Inspection Technologies

from the outer surface



2-3 TOFD UT

2-4 Long range UT

2-5 Application for Pipelines


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2-1-1 The Principle of SLOFEC


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2-1-2 Distinction of Defects


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2-1-3 Self propelled Manipulator

ＳＬＯＦＥＣ Manipulator

The SLOFEC manipulator

that reflects the field check.


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Multi UT Manipulator

The Multi UT manipulator

that reflects the field check.


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2-3 TOFD UT

The Principle of TOFD UT

Definition of The Flaw Size measuring

Time of Flight Diffraction for each Wave


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2-4 Long range UT

Applying to Tank annular plate corrosion

Applying to Pipeline corrosion under the patched plate


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2-5 Application for Pipelines

2-5-1 Self propelled SLOFEC

Detection and screening for corrosion

SLOFEC - Saturation Low Frequency Eddy Current -

Whole area of the pipeline etc.

Fast inspection characteristic

- Measuring by SLOFEC Probes mounted

on Manipulator -


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2-5-2 Self propelled Multi UT

Detail inspection for corrosion

Multi UT

- Measuring by Ultrasonic Probes mounted

on Manipulator -

Bottom of the pipeline

Accurate measurement characteristic


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2-5-3 Manual UT

Detail inspection for corrosion by hand

Manual UT

-Measuring by a Hand using Ultrasonic Probe -

・Area where self –propelled inspection techniques are

difficult to implement

・Area where required for check after rough inspection

Accurate measurement characteristic


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2-5-4 TOFD UT

Inspection for defects in the material

TOFD UT -Time of Flight Diffraction -

Bottom part of circumferential weld inside from

the outer surface

Accurate detection characteristic

- Measuring by a couple of Ultrasonic Probes


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1-5 112-5-5 Long range UT Range UT

Inspection for corrosion in a remote area or covered area

Long Range UT

-Measuring by a low frequency Ultrasonic Probe -

Area under patched plate of piping support

system from the outer surface

Far propagation characteristic


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2-5-6 Complete Inspection


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2-5-6 Complete Inspection


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3. Pipeline Inspection Technologies

from the inner surface

3-1 Visual Inspection System inside of

Pipelines

3-2 Magnetic Flux Leakage

Intelligent Pig Inspection System

3-3 Ultrasonic Wave Testing



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3-1 Visual Inspection System inside of

Pipelines

1.Evaluation of Safety

for the Inside Pipeline

2.Pig Washing(special

solvent) & Gas free

3.Visual Inspection for

the Inside Pipeline by

Electric Vehicle

4.Data Collection and

Report

Visual Inspection inside Pipe

by Electric Vehicle


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3-1-1 Inspection Work inside of the

Pipeline

※ Work : 2 Team × 2 Shift


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3-1-2 Inspection Report

0

100

200

300

400

500

2.5～2.9

3.0～3.4

3.5～3.9

4.0～4.4

4.5～4.9

5.0～5.4

5.5～5.9

6.0～

Depth (mm)

Nos.

No. Bead No. Distance from Location Depth Longitudinal Circumferential

Bead (mm) （hr） (mm) (mm) (mm)1 382 890 5 2.5 10φ2 960 5 2.5 10φ3 3300 6 3.0 20 504 4150 6 2.8 20φ5 4770 6 2.5 20φ6 381 0 3～9 0.5-1.0 3～97 120 5 3.0 30 108 1700 7 2.5 170 709 2000 7.5 2.5 20φ

10 2200 7.5 3.0 10φ11 2300 5 2.5 20φ12 2400 7 2.5 20φ13 2450 7.5 3.0 20φ14 2600 6 2.5-3.0 150 50015 380 0 3～6 1.0 3～616 3730 6 3.0 10φ17 379 0 5 1.0-2.0 100φ18 270 6 2.5 30 2019 3100 6 3.0 20φ20 3260 7 2.5 10φ21 3770 5 2.8 10φ22 4010 4.5 2.9 10φ23 4880 6 2.5 10φ24 5250 6 2.9 10φ

Visual Inspection Report

Statistics

Field Photo

Field data


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・Magnetic flux leakage from corroded parts by generating magnetic flux of axial direction is detected by sensor and is measured after magnetizing pipe loc- ally using magnetizing unit equipped with pig

3-2 Magnetic Flux Leakage


Defect Magnetic Circuit

Measurement Principle

Pipe

Wall Brush

Sensor

Magnet


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3-3 UT Intelligent Pig Inspection System

・Pipe thickness and deformation etc. will be measured by ultrasonic probes mounted on pig circumferentially.


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3-4 Comparison of Inspection Method

(1) Visual Inspection Magnetic Flux

Leakage (MFL)

Ultrasonic Wave

Testing (UT)

1.Measurement

Principle

2.Applied Condition

1)Size 26”～56”

（Experience）

5”～50” 6”～56”

2)Length 11km(Experience）～250km ～250km

3)Passing Capability 1.5D(90°Elbow） 1.5D(90°Elbow） 1.5D(90°Elbow）

4)Two Way Capability No Limitation Not Applicable Not Applicable

5)Degree of

Deformation flatness

No Limitation Pipe Dia ±10% Pipe Dia ±10%

6)Applicable Fluid Gas Free Liquid, Gas Liquid only

7)Running Speed 600～3000m/d 0.5～4m/s 0.8～5m/s

Defect Magnetic Circuit

Measurement Principle

Pipe

Wall Brush

Sensor

Magnet


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3-4 Comparison of Inspection Method (2)

Visual Inspection Magnetic Flux

Leakage (MFL)

Ultrasonic Wave

Testing (UT)

3.Pretreatment

1） Cleaning Possible to enter

into pipe

Rough compared to

UT

Clean compared to

MFL

2) Internal

Confirmation

Cleaning

Condition

Gauge Profile Pig Gauge Profile Pig

4.Inspection Accuracy

1)Detection site ( Inner

Surface and Outer

Surface )

Inner Surface only Inner and outer

Surface

Inner and outer

Surface

2)Corrosion Detection

at Welding Part

Available Available Difficult

3)Corrosion Detection

at Elbow

Available Available Available with

Condition

4)Limit of Detection

Depth

1.0mm 0.2 ×thickness 2mm


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3-4 Comparison of Inspection Method (3)

Visual Inspection Magnetic Flux

Leakage (MFL)

Ultrasonic Wave

Testing (UT)

5)Detectable Size 5.0mm (0.4t)× (0.4t) or

7mm×7mm

10mmφ

6)Measurement

Accuracy (Depth)

±0.5mm ±0.1 ×thickness ± 0.5mm

(Location) ±0.1m ±0.2m ±0.2m

5.Inspection Report On-line Reporting Prompt Report only

for Serious Defect

Prompt Report only

for Serious Defect

Analysis Anytime during

Inspection

Approx 40 Days Approx 40 Days

6.Relative

Inspection Cost

100 150 200


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Selection of Inspection Method for Pipelines

・ Inspection Cost ・ Downtime of Operation ・ Capability of Repair Work ・ Other conditions

Selection of Inspection Method


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Selection of Inspection Method

Inspection Work

Execution

Evaluation of Inspection Result & Condition

Long term Planning

PLAN

DO

SEE

ACTION

Selection of Inspection Method for Pipelines


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The End of Slides

Thank you for your attention

Japan Corporation Center Petroleum (JCCP)

latest inspection technologies

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