role of inspection during the lifetime of a pipeline (1)

7/30/2019 Role of Inspection During the Lifetime of a Pipeline (1)

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The Role of Inspection During theLifetime of a PipelineTechnical Conference:7th ASIAN PIPELINE CONFERENCE AND EXHIBITION,11-12 October 2011Istana Hotel, Kuala Lumpur, Malaysia

Jim COSTAINGlobal Leader,

Oil & GasGE MEASUREMENT AND CONTROL SOLUTIONS


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Industry DriversAging Pipeline Infrastructure Consequences of Pipeline Failure

Headlines from PipelineFailures

Cost of Corrosion

11 to 20 Years22 %

< 10 Years14%

New 2%

> 20 Years 62%

Injury & Loss of Life Environmental Damage

Oil MajorIs Fined $25 Million for 06 Spills at PipelinesBy JOHN M. BRODERPublished: May 3, 2011 in the NYTimes

Gas Major fined P24.2 million over pipeline leakBy ELLALYN B. DE VERAPublished: 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 4x the numbers above

Corrosion Costs in the USA 4% of GDP annually(Source: USA Department of Transportation)


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3

2010, General Electric Company

Asset Condition MonitoringSensors, monitors and software to monitor assetintegrity

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

Environmental Monitoring

Radiation detection and emissions measurement forcleaner operation

Sensors & MeasurementInstrumentation and systems for validating critical

processes and applications in high growth industries

Nondestructive TestingCutting edge inspection solutions to smartly monitor

plant asset health without major disruption

Measurement & Control SolutionsHigh accuracy technologies

Monitoring assets through the

lifecycle


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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 CamerasRobotic Crawlers

Inspection

Services

Rentals

Rhythm Acquire

Rhythm Review

Rhythm Archive

MetrologyNon-contact

Air Foil System

Flaw Detectors

Thickness Gauges

Hardness Testers

SystemInstrumentation

Transducers

Installed Sensors

Inspection Technologies


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Pipeline Inspections in theManufacturing Process


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6

Inspection Technologies During theManufacturing ProcessDepending 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 requirementsbased on flaw detectability and test speed.

Ultrasonic testing in the ERWprocess

Strip body

Edge

Strip testing(at the inlet of the

welding line,

before forming)

Weld

Scarf monitoring

Heat-affected zone

Inline weldtesting (after

welding/annealing/sizing)

Weld

Full body

Tube end

Final acceptancetest (at the

finished product)

Ultrasonic and X-Ray testingin the SAW process

Plate

Online weld UT Final acceptance test UT

Final acceptance test X-Ray

Longitudinallywelded

Strip

Online weld UT

Final acceptance test UT

Final acceptance test X-Ray

Spirally welded


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SAW - Ultrasonic testing machines

Weld testing on SAW longitudinally welded tubes

(linear transported tubes)


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SAW Ultrasonic testing machines

Spirally welded tubes

Strip testing (body and edge) with stationary probes


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Weld testing of SAW longitudinally welded tubes

SAW - X-Ray testing machines


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Pipeline Inspections during PipelineConstruction


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Weld quality is a critical part of any

project in the O&G market whether anew refinery, offshore platform or crosscountry or subsea pipeline.

GE S&I has a comprehensive portfolioof solutions from the pipe mill to thefield. Using state of the art UT and RTtechnology, GE can provide fit for

purpose tools to suit all types of weldexaminations.

Weld Inspection

Automated UTCR for offshore girth welds


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GE Proprietary InformationSubject to restrictions on the cover or first page

USM Vision Weld InspectionSolution

Key FeaturesMenu guided set-up andinspection to optimize timeof inspector capabilities

Meets international codes& standards

Data analysis, reporting,and sharing with GEITRhythm


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Footer


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Inspection

Plan Creation

Data

Acquisition

Data

AnalysisArchive

Rhythm

IPC

Rhythm

Review

Rhythm

Reporting

PA & TOFDRhythm

Archive

Probe/ScannerCal Blocks

Administrator

inputs dataLevel III reviews

plan

Level I or II UT orRT inspector

performs inspectionLevel II/IIIreviews

data

Adminstrator generatesreport and archives data

USM Vision Weld Inspection Solution

Reporting


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USM Vision Guided InspectionWorkflow

UT Inspector

Non UT Specialist

UT Expert (Remote)

Inspection preparation

Non UTSpecialist

UTExpert


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In-Service Pipeline Inspections


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1. Rightrax is a system that can measure wall thickness

continuously by using permanently installed UTtransducers.

2. Rightrax consists oftwo product versions.

A. A low temperature -40C


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System configurations1. PORTABLE

For both LT and HT systems

Manually operatedData collection in the field

Data download to PC or laptop

Manual assessment of data

ADVANTAGE

Lower system cost

Flexibility of system

use

2. INSTALLED


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


Automatically operated

Fixed interval measurements

Data storage

Automatic data analyses

Integration with third party systems withdata and alarming


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Upstream Case StudyConcern:

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 80C

Solution:

Total of 96 Rightrax M2 sensors on 6 individual

platforms

M2 sensors wired back to DL2 Datalogger and LD2in 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


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Midstream Case StudyConcern:

Measure Water, H2S, & CO2 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 TML18 Mtr Extension Cable wired back to Data collection

post

Manual DL2 Datalogger

Configuration:

Measurements made manually as per customersrequired time frames

Data stored on DL2

Data analyzed via downloading DL2 to customers

PC w/ supplied software

Value and cost saving:

Covered known & suspected corrosion locations

Long Design/Performance Life

Inexpensive: Met Customers Needs

Met Political & Regulatory issues/concerns

M2 sensors

Natural Gas Pipeline


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Subsea Direct RadiographyDevelopment Project


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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


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The Power of Digital Data


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Rhythm - Turning information into intelligence

Rhythm Report RhythmArchive

LAN

Consistent

Quick Reports

LAN

Capture, share, analyze, report, and archive

digital inspection information

Data Storage &

Enables Trending

RhythmReview

Remote Review

& AnalysisRhythm CR

Rhythm UT

Rhythm Visual

Rhythm DR

Multi-Modality Platform


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Sharing RT and UT Images inRhythm


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Inspect

Review

Report

ArchiveShare

DICONDEOne standard = One platform

Common Rhythm Platform


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role of inspection during the lifetime of a pipeline (1)

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