Paper 1
Pipeline Inspection Report Validation with Field Measurements
Rafael Almeida, Fabio Fernandes, Simon Gall (ROSEN Group)
Abstract
A very common and well accepted technique for performing non-destructive examinations on pipelines is an inline inspection (ILI) with intelligent tools. There is a vast amount of inspection tools on the market that able to assess different threats to pipelines, such as...
Paper 1
A very common and well accepted technique for performing non-destructive examinations on pipelines is an inline inspection (ILI) with intelligent tools. There is a vast amount of inspection tools on the market that able to assess different threats to pipelines, such as metal loss, internal diameter changes, and/or cracks. Each inspection tool has its own performance specifications, i.e. each tool can detect certain types of threats within specified accuracy ranges. Field measurements are often taken to verify if an ILI inspection report is accurate according to the inspection tool performance specifications. However, prior to any comparison with the reported data, the measurements from the field should be validated. Aspects like measurement technique, modifications on the pipeline environment, and operational conditions can influence the obtained results, thus creating unrealistic deviations which may wrongly invalidate an inspection report. The goal of this paper is to identify factors that could affect the quality of the results obtained in the field verification and consequently affect the quality of their comparison with an ILI inspection report.
Often, clients lack knowledge on tool performance specifications and field measurement good practices. Several cases were observed, such as incomplete information from field, comparison of anomalies out of the POI of the inspection tool, pipeline environment modification before the measurement of ID anomalies, etc. The paper will provide guidance on what information is required from a data evaluation perspective and make recommendations on when it makes sense to compare the field data with the inspection report. It will also discuss the limitations and potentials of comparing inline inspection reports and field verification reports and propose a more appropriate workflow with clearer guidance.
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Paper 2
Flow Modelling: A Key Element in Identification of Causal Factors for Wear in Slurry Pipelines
Ashwin Pinto, Charles Ofosu, Gareth Smith, Jozef Soltis (ROSEN Group)
Abstract
Internal degradation of long-distance slurry pipelines is inevitable, given the nature of transported product(s). This degradation is attributed to erosion, corrosion or a combination of both, i.e. erosion-corrosion. From an asset-operation perspective, the goal is to ...
Paper 2
Internal degradation of long-distance slurry pipelines is inevitable, given the nature of transported product(s). This degradation is attributed to erosion, corrosion or a combination of both, i.e. erosion-corrosion. From an asset-operation perspective, the goal is to be able to identify active damage mechanisms and associated causal factors so that process variables and slurry characteristic parameters can be optimized to maintain the integrity and prolong the life span of a given slurry pipeline system. In general, wear in slurry pipelines is affected by slurry particle properties and their interaction with the pipeline wall, slurry chemical properties and rheology, as well as the pipeline design and its operation. Accordingly, a pipeline can be subject to different flow regimes, and the detrimental effects of stationary and sliding (moving) beds on wear are now well known. In order to understand the effects of such parameters on flow dynamics and wear in slurry pipelines, a systematic and holistic approach is needed. Our concept is based on: (i) analysis of slurry rheology, particle properties, and the internal conditions of the pipeline; (ii) hydraulic calculations to determine the viscous transitional limits; (iii) single point calculations to develop mechanistic two-layer models to simulate the deposition behavior of solids, and (iv) multiphase flow modelling (integrated with particle tracking) to establish the critical deposition velocity and identify pipeline locations susceptible to stationary and/or sliding bed formation.
In this paper, we present the above-mentioned concept through a case study. We emphasize the importance of combining flow modelling with solid particle deposition calculations in order to gain key insights and identify primary causal factors for slurry pipeline wear mechanisms.
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Paper 3
An approach to understanding and managing large landslide loads on pipelines
Andy Young, Pedro Guillen (ROSEN Group)
Abstract
Pipelines are at risk of damage or failure when subjected to ground movements from large landslides. A management process must be established to ensure that the pipeline is protected from excessive loading in areas where large landslides may occur during...
Paper 3
Pipelines are at risk of damage or failure when subjected to ground movements from large landslides. A management process must be established to ensure that the pipeline is protected from excessive loading in areas where large landslides may occur during pipeline operation. The action to be taken will depend on the threat the landslide presents to the pipeline. It includes a combination of monitoring, load reduction, stabilization, or re-routing. Monitoring ground movement or the pipeline’s response to displacements is an essential element of the management process; however, it is important that this is linked to appropriate performance limits.
In this paper, we present a management process for pipelines during large landslides. The method involves identification and characterization of the threat, evaluation of the pipeline condition and how these factors can be predicted in the future as further movement takes place. This provides an effective framework for making decisions and deploying resources for the mitigation works to be implemented and for scheduling when these activities should take place. The approach is illustrated using a case study.
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Paper 4
Pipeline Integrity Management Program: How to operate a new pipeline system where crack-like milling features may represent a critical threat?
Pedro Guillen (ROSEN Group)
Abstract
The current practices for manufacturing of carbon steel have seen a considerable improvement, since the modern-day steel line-pipes produced in the early 1800s. These improvements, notably superior steel properties and quality, have led to ...
Paper 4
The current practices for manufacturing of carbon steel have seen a considerable improvement, since the modern-day steel line-pipes produced in the early 1800s. These improvements, notably superior steel properties and quality, have led to the reduction of line-pipe manufacturing anomalies. Consequently, it is expected that new line-pipes, manufactured to the relevant industry standards, come without features that may be deemed as defects. Nevertheless, despite all the improvements, line-pipe manufactured today can still contain anomalies (e.g. seam-weld imperfections such as lack of fusion, toe cracks, etc.), which – if present with critical dimensions – can pose a significant threat and inherent risk to the integrity of a given pipeline system. As one of the operators of gas pipelines in Mexico, IEnova acknowledge existence of such a risk.
In our current work, we present a case study that deals with integrity management of a 48-inch onshore gas pipeline that contains inherent manufacturing anomalies. More specifically, the pipeline was constructed in 2014 from longitudinally welded line-pipes and experienced two seam weld failures during commissioning hydro testing. We demonstrate that a well-defined pipeline integrity management program based on (i) threat identification, (ii) inspections, (iii) defect and anomaly assessment, (iv) interventions, and (v) reviews can be successfully used for a safe operation of pipelines with similar inherent predispositions.
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Paper 5
Always be prepared – The pipeline-specific critical crack identification and assessment manual
Brian Kerrigan, Andrew Wynne, Toby Fletcher (ROSEN Group)
Abstract
Managing the threat of cracking is a complex issue and, depending on the severity, may require a significant number of in-field digs. Once an ILI tool is run and data is available, the features are typically assessed, and locations are prioritized for...
Paper 5
Managing the threat of cracking is a complex issue and, depending on the severity, may require a significant number of in-field digs. Once an ILI tool is run and data is available, the features are typically assessed, and locations are prioritized for excavation depending on the severity and risk they impose. After excavation, all features require an assessment based on the feature type identified in the ditch, which may be different from that indicated by the in-line inspection system. The dimensions given by in-the-ditch measurements which may also be different from those indicated by ILI, requiring the recalibration of the ILI tool in some cases. This assessment will then determine the need for a structural repair and, of course, has to be completed quickly and safely.
This paper offers an overview of the need for and the advantages of a critical defect response manual, which has been successfully deployed to help manage cracking found in-field in Brazil. This manual considers all credible features and uses pipeline-specific properties and loads to enable an adequately conservative and quick assessment of features found in-situ, improving dig campaign efficiency and ensuring safety for staff involved in excavation and non-destructive examination.
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Paper 6
Developing a robust SCC Management Plan for Safe Operation
Brian Kerrigan, Roland Palmer-Jones(ROSEN Group)
Abstract
SCC has been described as the pipeline threat that is the most difficult to deal with due to the uncertainties of location, identification, measurement, and growth rate prediction. Managing SCC is a challenging at the best of times. However, it is ...
Paper 6
SCC has been described as the pipeline threat that is the most difficult to deal with due to the uncertainties of location, identification, measurement, and growth rate prediction. Managing SCC is a challenging at the best of times. However, it is particularly challenging if cracking is present across multiple pipeline systems and if the cracking is both axially and circumferentially orientated.
This paper describes the development of a robust plan combining in-line inspection, direct assessment, hydro testing, and risk assessment to manage both axial and circumferential stress corrosion cracking across an extensive gas pipeline network. Key considerations in the development of the SCC management plan are discussed, and an approach that could be used to put together similar plans is recommended based on the lessons learned.
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Paper 7
Data-driven best practice in pipeline corrosion management
Michael Smith, Erika Santana, Matthew Capewell, Konstantinos Pesinis, Jonathan Martin (ROSEN Group)
Abstract
Mechanistic modelling of pipeline corrosion can be an extremely challenging task. Firstly, a number of different corrosion mechanisms can occur. Secondly, the governing variables of these mechanisms can fluctuate greatly over time, leading to an ...
Paper 7
Mechanistic modelling of pipeline corrosion can be an extremely challenging task. Firstly, a number of different corrosion mechanisms can occur. Secondly, the governing variables of these mechanisms can fluctuate greatly over time, leading to an unpredictable ‘stochastic’ behavior. Finally, the situation is complicated by inaccurate and incomplete input data. The most popular alternative to mechanistic modelling is the use of inline inspection (ILI) data to estimate corrosion growth rates (CGRs) and simulate future integrity scenarios. These post ILI techniques are largely empirical in nature (trading theoretical rigor for completeness) but if used competently, they can provide good heuristics to support managerial decision making. The problem lies in understanding what ‘competence’ in this regard actually means. There remains a clear need for more formalized best practice in this area. The ongoing digitalization of the pipeline industry has allowed alignment of multiple ILI datasets – and subsequent matching of corrosion defects – to be executed quickly and accurately. This provides a wealth of information on metal loss damage progression along individual pipelines at minimal computational cost. Our ‘data lakes’ are flooded, but we have barely rippled the surface when it comes to extracting knowledge from these data. The current paper breaks new ground by using data analytics techniques to elicit parametric relationships between CGR distributions and pipeline characteristics and service history. At this early stage, the ILI datasets (and metadata) for a population of over 1,000 pipelines have been assessed. It is expected that this number could increase tenfold in the relatively near future. The results are envisioned to be used in a number of ways, including the determination of re-inspection intervals and refinement of direct assessment programs for individual pipelines. The wider goal, however, is the development of data driven best practice for the pipeline industry as a whole.
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Paper 8
Combined inspection (MFL-A/MFL-C/IEC) of an oil transmission pipeline system for an operator in Brazil
Vincent Brughuis, Rafael Almeida (ROSEN Group)
Abstract
Pipeline integrity is negatively affected by a multitude of anomalies, flaws and threats, which sometimes may even interact. Trying to assess multiple threats with only a single inspection technology often falls short, as each technology has its...
Paper 8
Pipeline integrity is negatively affected by a multitude of anomalies, flaws and threats, which sometimes may even interact. Trying to assess multiple threats with only a single inspection technology often falls short, as each technology has its distinct strengths.
To increase the reliability of integrity assessments, combining the evaluation of two or more different in-line inspection (ILI) data sets is possible. While these data sets may stem from consecutive runs with different ILI tools, there is also the ability to merge together different inspection technologies on one in-line inspection tool. Performing several inspection tasks in one ILI run significantly reduces the risks and efforts involved.
This paper describes a failure of one pipeline by an operator in Brazil caused by the above-mentioned combination of complex anomalies, which could not be detected by one single inspection technology alone. It describes the failure cause, ROSEN-proposed combined technology to ensure threats affecting the safe operation of the pipeline are being detected and reported, the findings of the combined inspection, and the benefit of implementing integrity solutions in such a critical asset.
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Paper 9
The role of inspection in the integrity management of flexible risers, flowlines and pipelines
Andrew Burton, Manuel Quack, Roland Palmer-Jones (ROSEN Group)
Abstract
Flexible pipes are increasingly popular in the oil and gas industry for the development of deep-water fields, for example offshore Brazil, and small fields in mature regions such as the North Sea. Flexibles are complex structures, and the options for...
Paper 9
Flexible pipes are increasingly popular in the oil and gas industry for the development of deep-water fields, for example offshore Brazil, and small fields in mature regions such as the North Sea. Flexibles are complex structures, and the options for inspection to confirm their integrity as they age are limited but developing. As inspection technology – internal and external – advances in capability, the focus will transfer to the integrity assessment and detailed analysis of the data through generation of models and methodologies. In parallel with inspection technology development, we are also developing methodologies to utilize the data collected and link the results with the risk assessments, integrity management strategy and remaining life evaluation activities that all operators need to complete. The combination of failure mode knowledge and inspection data will allow ROSEN to perform complementary analysis for verification against the as-designed concept, enabling the identification of potential life extension and enhancing risk management.
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Paper 10
Computing 3D Metal Loss from MFL ILI Data for Reliable Safe Pressure Prediction
Andrey Danilov, Johannes Palmer (ROSEN Group)
Abstract
Today, phenomenological MFL data parameterization is simplifying complex metal loss structures and often results in a reduced accuracy. Notwithstanding this inherent reduced accuracy, the established maximum depth boxes do not...
Paper 10
Today, phenomenological MFL data parameterization is simplifying complex metal loss structures and often results in a reduced accuracy. Notwithstanding this inherent reduced accuracy, the established maximum depth boxes do not necessarily prevent cases where MFL data interpretation is insufficiently conservative - resulting in underestimation of risks.
This paper presents a groundbreaking MFL data evaluation technique: Directly calculating an accurate 3D pipe and metal loss geometry instead of typical data interpretation techniques currently practiced. The granularity of the innovative result marks a new dimension for MFL. Auxiliary components of the typical MFL indirect interpretation approach lose importance with this new methodological system. Experience based practices using human expertise, artificial intelligence or elaborate sizing models play a role still, but the final accuracy of the calculated metal loss profile becomes significantly independent from the variability of these experience based practices. This innovative technique makes possible focusing directly on safe burst pressure calculations of even the most complex metal loss structures and hence opens a new realistic prospect of MFL ILI.
The paper will detail concrete case examples. These examples are derived from challenging locations selected by the operator and compared after blind testing with high quality laser maps. The paper will show the new approach in comparison to the traditional MFL evaluation. Performance and reliability analyses help contrast and rationalize this principally novel method compared to typical conventional findings. Ultimately, the paper will demonstrate that the new technique will materially contribute to more reliable management of metal loss threats.
As part of describing this new evaluation technique, this paper will discuss the theoretical and practical advantages of combining axial and transverse MFL measurements in detecting and sizing metal loss defects.
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Paper 11
Ultimate high-precision combo loading line inspection
Luciano Baptista, Johannes Keuter, Guenter Sundag, Udo Ruehle, Carlos Alfredo Cruz (ROSEN Group)
Abstract
Loading lines provide a vital link from producer to consumer. They are located in high-consequence subsea environments where repair or replacement is difficult and costly. These are critical assets that...
Paper 11
Loading lines provide a vital link from producer to consumer. They are located in high-consequence subsea environments where repair or replacement is difficult and costly. These are critical assets that, with the increase in the need of either importation or exportation of refined or crude production, represent an important portion of companies’ revenues while being associated with a high environmental risk if not handled properly.
Another key element for loading line inspection is the fact that they have no standard pigging receiver but a PLEM, so a bi-directional approach is required. The safe and reliable operation of a loading line is therefore key, making reliable and accurate assessment essential. Pipeline operators, meanwhile, are challenged to maintain its premises in a position that ensures safe and reliable operation. Pig inspections have proven economically and technically viable, and inspection companies are trigged to conduct intensive research and develop inspection tools able to provide the best possible and accurate diagnosis regarding pipeline integrity, which means using the correct technology/methodology to precisely find, size and report each feature, no matter its origin, shape or position.
A combination of the highest-precision technologies was applied to a loading line in the Caribbean sea, including MFL-A Ultra – developed to not only detect even the smallest pipeline defects but also to define the exact structure of defect groups and complex corrosion, extended high resolution geometry and XYZ inspection with subsea georeferencing accuracies of less than one meter.
Our aim is to demonstrate how such a complex project was successfully executed as well as show the achieved results compared to previous inspections using different technologies.
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Paper 12
Implementing an internal cleaning strategy for the gas pilot pipeline: Tulua- Cali which is property of TGI SA ESP
Vincent Brughuis, Bibiana Silva, Leonardo Mendoza Sanchez, Diego Castro, John Jordan Valderrama, Rafael Afanador (ROSEN Group)
Abstract
Transportadora de Gas Internacional S.A ESP (TGI), aiming to preserve the integrity of its infrastructure, people and environment, started a project to maintain its pipelines 'reliability and availability levels. Internal corrosion is one of the ...
Paper 12
Transportadora de Gas Internacional S.A ESP (TGI), aiming to preserve the integrity of its infrastructure, people and environment, started a project to maintain its pipelines 'reliability and availability levels.
Internal corrosion is one of the main threats to which the TGI infrastructure is exposed. TGI mitigates the risks associated with this threat, through a preventive maintenance strategy which includes: monitoring gas quality and corrosion coupons, measurement of pipe wall thickness and internal cleaning through pigging.
As part of TGI's internal cleaning strategy, the following four (4) activities were identified and implemented, in a continuous improvement cycle:
- Cleaning tool selection, assembly, and diagnostic feedback by qualified personnel;
- Characterization of the products removed during the cleaning process;
- Tool tracking and data collection;
- Pigging strategy optimization for each pipeline section.
The Troncal Tulua- Cali gas pilot pipeline was selected as baseline, using the following evaluation variables:
- Cleaning tool configurations;
- Pigging duration and frequency;
- Debris physical, chemical, and microbiological characterization, searching for corrosion products;
- Operational conditions during pigging;
- System geometry of pipes, among others.
The above attributes will be analyzed to assess the cost-effectiveness strategy. Understanding the transportation medium, types of debris to be removed, and debris loading and distribution, will also be considered to define an improvement plan to maximize the life cycle of TGI's assets.
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PAPER 13
Application of descriptive analytics for benchmarking of cracked pipelines
Michael Smith, Erika Santana, Konstantinos Pesinis, Brian Kerrigan (ROSEN Group)
Abstract
Crack management procedures aim to help pipeline operators understand the significance of cracks, and support with decisions on rehabilitation and future monitoring. Such procedures have developed significantly over recent years, but...
PAPER 13
Crack management procedures aim to help pipeline operators understand the significance of cracks, and support with decisions on rehabilitation and future monitoring. Such procedures have developed significantly over recent years, but crack management remains a notoriously challenging area of engineering. It is data intensive, uncertain, and relies heavily on the judgement of experts.
Under these difficult conditions, it is worth exploring the value of data analytics techniques. In this paper we use descriptive analytics for the purpose of ‘crack benchmarking’. This is accomplished by automatically calculating simple metrics (such as the number of features per kilometre) across a large population of pipelines. This information can be very pertinent to operators, as it can help them understand the severity of their issues compared to others around the world. It is also possible to identify best crack management practices, by looking at differences in the condition of pipelines with a similar age or environment.
To accomplish the above, in line inspection (ILI), operational and environmental data for hundreds of pipelines have been collated and explored. It is shown that the data can quickly provide insight into the nature of cracked pipelines, and provide some real empirical weight to our expert judgement.
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