ROSEN - ROSEN at IPC/IPE 2016

Explore the many facets of ROSEN at booth 512

ROSEN is diverse in many ways. We are a globally operating company, with staff originating from all over the world. We draw on the input of people from the most diverse backgrounds, who themselves display a multitude of different facets. Ninety percent of our employees have a technical education, which equates to over 15,000 years of industry experience; however, their fields of expertise are manifold. They include software development, physics, materials and mechanics, electronics, and many more. For us, diversity means the continuous extension of our pool of in-house know-how and competence.

Our own diversity consistently reminds us that there is always more than one way to look at things. It is exactly what enables us to provide unique solutions for the pipeline industry. Because we comprehend that asset care is much more than the simple inspection of a pipeline. Because we know it is a comprehensive understanding of an asset’s current and predicted condition. Because we realize it is actions that ensure sustainable, safe, efficient, and reliable operation for many years to come.

Ultimately, asset care is the prevention of failures, unnecessary repairs, and interruptions in operation. We understand that asset care has many facets, and we understand how to handle them.

Logos_IPC_IPE_2016

Education Systems and Services

: Zoom; eds_at_ipc; ROSEN Group

During the IPC 2016, ROSEN will introduce Education Systems and Services, which offers learning programs of different intensity levels, certified by an independent qualification panel of recognized industry authorities.

These programs enable professionals in the oil and gas industry to continuously deepen their expertise, while operators who give their employees access to these programs can be sure of a constant increase of certified competence within their company.

For more information, please visit: education.rosen-group.com.

Advanced Pipeline Diagnostics: Take control of cracks

: Zoom; ROSEN Advanced Pipelines Diagnostics with ultrasonic crack detection services.; ROSEN Group; ROSEN Advanced Pipelines Diagnostics with ultrasonic crack detection services.

The ROSEN Group’s specialized “Advanced Pipeline Diagnostics” team addresses cracking in gas and liquid pipelines. In-line inspection technologies like EMAT, UT, and MFL are utilized to locate and accurately size cracking in the base material and in the weld area.

At the IPC 2016, the ROSEN Group will focus on an optimized approach for crack management: a comprehensive service consisting of a framework that begins with appropriate system selection, continues with dedicated data evaluation, and concludes with high quality reporting.

RoCorr MFL-A Ultra Service – Making the invisible visible

: Zoom; ROSEN’s engineers design suitable, high-performance solutions according to the special requirements of each project.; ROSEN Group; ROSEN’s engineers design suitable, high-performance solutions according to the special requirements of each project.

At IPC 2016, ROSEN will introduce its premium inline inspection service RoCorr MFL-A-Ultra. This brand new service makes it possible to detect even the smallest pipeline defects, such as pinholes down to one millimeter (0.04 inches). Furthermore, it is also capable of defining the exact structure of girth weld defects as well as complex corrosion.

Just like an MRI (Magnetic Resonance Imaging) scanner provides lifelike images of the interior of the human body, RoCorr MFL-A Ultra is able to produce lifelike images of a pipe wall’s structure.
For this, RoCorr MFL-A Ultra uses the highly innovative method of Pipeline Imaging™. It is based on the results of ultra-high resolution sensors in combination with machine-learning based AutoData™ algorithms.
RoCorr MFL-A Ultra allows for less conservative integrity assessments that lead to cost reductions in field verification and repair.

Discover more about how this becomes possible by speaking to the experts at the ROSEN booth.

For more information online, please visit: ultra.rosen-group.com.

Papers

Paper 1

Tuesday, September 27, 10:30 - 11 AM

Training & Education – The Great Competence Divide

Phil Hopkins (Phil Hopkins Ltd., UK), Michelle Unger (ROSEN Group, UK)

Abstract

This paper assesses current training in the pipeline industry, and highlights the good points and bad points, and the deficiencies in the learning process, that prevents demonstrable competencies. It then describes how academia has a simple, but rigorous, learning process that allows this demonstration.

Paper 1

All industries need ‘competent’ staff, and competence is now a ‘hot topic’ in the USA: a crude oil pipeline failed in the USA in 2010, with costs above $1 billion to date, and the USA pipeline regulator stated in its report on the failure: ‘... the management of training and competency is particularly critical for an organization [operating pipelines]’.

Competence is a mix of skills, knowledge, and experience, and is obtained from training, mentoring, and experience. Consequently, industry knows how to develop competencies, but how can companies prove their staff are competent? Staff can attend the many training courses on offer, but how can the industry know these courses are the required quality, and that staff have acquired and absorbed the necessary skills/training?

This evidence and demonstration are major problems in the pipeline industry, and need urgent solutions.Fortunately, the industry can learn from academia, who have been providing demonstrable skills for centuries.

Training and Education: The Great Divide…

Most current industry training courses are presented by good trainers, using good materials, through good training providers. Unfortunately, most of these courses/trainers/organizers are not accredited by any reputable organization, the materials are not quality assured, the necessary competence levels are neither specified nor defined, and there is no assessment to demonstrate understanding. This learning process may be good and delivered in good faith, but it is disorganized, unregulated, with no control or benchmarking, and no assessment. This leads to a lack of credibility.

Academia has a simple system to ensure its learning process is credible. It has: courses that are assessed to a specified learning level, with clear objectives, outcomes, and qualification requirements; materials that are independently quality assured; lecturers that are qualified to teach; and, an assessment, qualification, and certification process that demonstrates the student has acquired all the stated skills. This leads to credibility. See above Figure.

The paper ends with a ‘way forward’ for the pipeline industry, in its goal of demonstrating competency in its workforce.

Paper 2

Thursday, September 29, 9:30 - 10 AM

Continuous Depth Sizing of ILI Ultrasonic Crack Detection

Marius Grigat, Abdullahi Atto, Jens Voss (ROSEN Group)

Abstract

This paper describes the development and implementation of a continuous crack depth sizing method and shows its advantages in comparison to the conventional depth classes.

Paper 2

Since the market launch of Ultrasonic crack detection tools, the conventional crack depth sizing is based on four depth classes or buckets. A more differentiated, continuous depth sizing is becoming increasingly relevant for pipeline operators and especially for pipelines with large populations of planar anomalies (SCC colonies, lack-of-fusion in ERW seam-welds, etc.). The ILI industry is introducing a continuous crack depth sizing. Next to the better differentiation and the linearity of the depth reporting, the main advantage of the continuous depth sizing is the direct comparability to the results of field verifications. The continuous depth sizing improves the ability to assess the performance validation of the depth sizing and thus, contributes to a general improvement of the crack depth sizing.

This paper describes the development and implementation of a continuous crack depth sizing method and shows its advantages in comparison to the conventional depth classes. In addition, the paper discusses the extraction of the crack depth profiles from inspection data and shows examples of a direct comparison to field verification data.

Paper 3

Thursday, September 29, 11:30 - 12 PM

Corrosion Growth and Remnant Life Assessment – How to pick the right approach for your pipeline

Michael Smith, Cheryl Argent, Andrew Wilde (ROSEN Group)

Abstract

Paper 3

Accurate modelling of future corrosion growth is critical to long term pipeline integrity. A lot has been published within the industry regarding how to accurately determine corrosion growth rates from repeat in-line inspection data. However, there is limited guidance to support pipeline operators in deciding how to apply corrosion rates in order to support the development of repair plans, and investigate pipeline remaining life. The consequences of significantly under- or over-estimating corrosion growth are high, and getting the balance right between the two is not straightforward.

Accurate modelling of future corrosion activity is difficult due to the vast number of factors that influence corrosion behaviour, including the corrosion mechanism itself, the impact of mitigation activities, changes in factors driving corrosion growth (e.g. product composition changes, further coating degradation, CP system changes). Also, a common phenomenon that is observed is a reduction in the rate of corrosion growth as the depth of the corrosion feature increases. Such behaviour can drastically influence the safe remaining life of a corrosion feature.

The method that is most appropriate for modelling future corrosion growth is also dependent on the purpose of the modelling. For example, if the purpose is to define repair plans and set re-inspection intervals, the corrosion rates applied should be set at a level that conservatively models growth and therefore avoids failures. If, however, the purpose is to predict the remaining life of a pipeline over a long time period, a more realistic estimate of future growth is required.

Paper 4

Thursday, September 29, 11:30 - 12 PM

Detection of Crack Initiation Based on Repeat In-Line Inspection

Michael Palmer, Roland Palmer-Jones, Markus Ginten (ROSEN Group)

Abstract

Paper 4

As Stress Corrosion Cracking and other cracking related issues become a more recognised risk that can be monitored by in-line inspection (ILI), there have been high expectations on the inspection industry to produce a reliable solution for identifying and sizing cracks. The current leading ILI technologies provided for pipeline crack detection are Ultrasonic (UT) and Electromagnetic Acoustic Transducer (EMAT). The introduction of EMAT In-Line Inspection technologies has provided a proven solution for crack detection that can be used in gas pipelines without having to introduce a liquid couplant into the pipeline.

USA Pipeline operators are required by the Office of Pipeline Safety to inspect and assess their pipelines that operate within high consequence areas for integrity issues, such as SCC, and repair or replace affected pipe. The inspection for this includes the use of Inline inspection tools – “smart pigs”. These regulations in combination with the majority of pipeline incidents relating to SCC occurring in gas pipelines has led to a significant increase in the use of EMAT ILI technology in recent years.

With repeat EMAT ILIs now being conducted on some pipelines there is the option to compare data sets to identify any changes between inspections. This technical paper presents a method for identifying initiation of crack growth based on repeat EMAT ILI, using feature matching and comparison of raw EMAT inspection data, supported by a case study of the use of this approach by a responsible operator.

Paper 5

Tuesday, September 27, 1:30 - 2 PM

Pipeline strain and vibration monitoring by smart materials

Dirk Larink, Sascha Pargen, Dorthe Wittje, Nils Reichstein, Tilman Mönster (ROSEN Group)

Abstract

Dielectric elastomer sensors (DESs) are a new class of mechanical sensors and can be used to fabricate unique intelligent elastomeric products with versatile properties.

Paper 5

Dielectric elastomer sensors (DESs) are a new class of mechanical sensors and can be used to fabricate unique intelligent elastomeric products with versatile properties. In this case, a new sensing method was developed to measure strain (intelligent coating) and vibration (intelligent damping pad) of pipelines using a combination of novel polyurea coatings, and high performance polyurethane based elastomers. The structural health monitoring systems described here are suitable to improve safety and maintainability of critical pipeline sections. Such systems can be applied to both steel and to polymeric or composite pipes.

Basically, a DES is a compliant capacitor which consists of an elastomeric film, and highly flexible electrodes. In case of deformation due to tensile or pressure loading, the active sensor area expands while the thickness of the elastomeric film decreases. Both effects result in a measurable increase in capacitance.

Paper 6

Thursday, September 29, 10:30 - 11 AM

Graded EMAT Performance Specification Validated in Blind Test

Toby Fore (Kinder Morgan), Marc Baumeister, Chris Yoxall, Thomas Beuker (ROSEN Group)

Abstract

Paper 6

The management of Stress Corrosion Cracking (SCC) represents one of the challenges for operating companies with potentially SCC susceptible pipelines. In order to further support the management of SCC, a graded performance specification for the high-resolution Electro-Magnetic Acoustical Transducer (EMAT) In-Line Inspection (ILI) technology is required to access higher levels of confidence for anomalies with critical dimensions. This paper gives access to the process to derive a graded performance specification for the EMAT ILI technology with regard to SCC. This validation process covered the Probability of Detection (POD) and Probability of Identification (POI). A blind test is carried out for the derivation and validation of the graded performance specification. A test data set was compiled with relevant anomalies and an additional amount of shallow SCC. These joints have initially been dug based on EMAT ILI data. All of these joints were analyzed with 360 degree Non-Destructive Evaluation (NDE). For each target joint with relevant anomalies to be assessed, two additional joints have been added in random order to generate a realistic density of anomalies. Each individual analysts result was evaluated and utilized to derive the POD and POI values of the graded specification. Anomaly dimensions are derived and are set into relation to the POD and POI values derived. Results of the blind tests will be provided in the paper and discussed in-depth, in comparison to the NDE findings to support interpretation, and comprehensive understanding of the capabilities of EMAT ILI technology for SCC management.

Paper 7

Thursday, September 29, 1:30 - 2 PM

THE USE OF HYDROTESTING AND EMAT INLINE INSPECTION TECH-NOLOGY FOR THE INTEGRITY MA-NAGEMENT OF STRESS CORRO-SION CRACKING IN GAS PIPELINES

Pedro M. Hryciuk, Eduardo Carzoglio, Jose A. Minellono, Leonardo Martinetto (TGN), Pedro M. Guillen, Joerg Grillen-berger (ROSEN Group)

Abstract

This paper describes the activities and stages completed as part of the Integrity Management Program for SCC in the natural gas system of Transportadora de Gas del Norte (TGN-Argentina).

Paper 7

This paper describes the activities and stages completed as part of the Integrity Management Program for SCC in the natural gas system of Transportadora de Gas del Norte (TGN-Argentina) which started in 2000. This document focuses in a pipeline section of the system, which suffered an in-service failure in 2002 due to high pH SCC.

This event triggered a series of activities, and the results are detailed in this paper. These activities involved soil analysis to determine the susceptibility of the pipeline system to develop SCC. For susceptible sections, the program included hydrostatic testing to levels of 100% and 110% of SMYS followed by replacement of degraded coating.

The paper also details the experience in the use of in line inspection tools with high resolution EMAT-C-C technology. The capability of the EMAT-C tool to detect and size SCC defects and the discrimination between SCC colonies that have been recoated and those that may still be active due to degraded coating is discussed. Finally, the severity of SCC cracks detected by in-line inspection is assessed using API 579 methodology, and the feasibility of using these assessment results to determine the critical SCC defect sizes for detection by ILI tools is analyzed.

Paper 8

Tuesday, September 27, 2 - 2:30 PM

Identification of Repair Coatings on Pipelines Using In-Line Inspection Technologies

Joerg Grillenberger (ROSEN Group)

Abstract

One of the major issues in the pipeline industry is coating disbondment. A very large percentage of the external corrosion and SCC is observed under disbonded coatings that shield CP.

Paper 8

One of the major issues in the pipeline industry is coating disbondment. A very large percentage of the external corrosion and SCC is observed under disbonded coatings that shield CP. This has been an ongoing issue with coated and cathodic protected pipelines since the beginning of using these two protection methods. The various coating types and their typical failure scenarios, under various harsh environmental conditions, as well as their compatibility with CP when disbondment occurs, play a major role for re-coating programs.

With the continued development and improvements of the “Electro-Magnetic Acoustic Transducer” (EMAT) technology to locate disbonded coatings, without the need of exposing the pipeline, operators receive economically sound information about their pipeline systems. The “EMAT” technology is also capable of identifying the various coating types and coating condition. In this case study, the challenge was the identification of different coating types used as repairs or for re-coating procedures, within the 60 year history of the inspected pipeline system.

The paper will outline different coating repair methods, as identified by the EMAT tool, and it will describe the associated risks for the pipeline integrity.

Paper 9

Thursday, September 29, 9 - 9:30 AM

Am I Too Rich? - Determining limits for gas composition to ensure crack arrest in an existing pipeline

Robert M. Andrews, Michael Smith (ROSEN Group)

Abstract

Fracture control studies for new gas transmission pipelines usually produce a specified minimum Charpy energy, often including correction factors, which will ensure that a crack will arrest in the body of the pipe.

Paper 9

Fracture control studies for new gas transmission pipelines usually produce a specified minimum Charpy energy, often including “correction factors”, which will ensure that a crack will arrest in the body of the pipe. The basic pipeline parameters such as pressure, pipe grade, diameter and wall thickness will be fixed early in design, and the reservoir and process engineering design will set limits on the extremes of the gas composition. Using these inputs the Charpy energy to ensure crack arrest for the worst case gas composition can be calculated using well accepted methods.

The inverse case, where the gas composition in an existing pipeline is to be changed from the original design basis is more challenging. The impact of variations in gas quality on critical pipeline safety parameters such as crack arrest is not always appreciated. Changes in composition can arise from ageing of the reservoir supplying a pipeline, or opportunities for the operator to generate additional revenue from 3rd party access. Sales gas specification limits for general purpose natural gas transmission often have broad limits, which can be met by a wide range of compositions.

As a wide range of gas compositions can give the same crack driving force, determining the composition limits is a “many to one” problem without a unique solution. This paper describes the derivation of an envelope of richer gas compositions which gave an acceptable probability of crack arrest in an existing pipeline which had been designed for a very lean gas mixture. Hence it was necessary to limit the amount of rich third party gas to ensure that the crack driving force did not increase sufficiently to propagate a long running fracture.

Manufacturing test data for the linepipe were used with the EPRG probabilistic approach to derive a characteristic Charpy energy which would achieve a 95% probability of crack arrest in 5 joints. After “uncorrecting” the high Charpy energy, the value was used with the Battelle Two Curve model to analyse a range of gas compositions and derive an envelope of acceptable compositions. Sensitivity studies were carried out to assess the effects of increasing the temperature and of expanding the limits for nitrogen and carbon dioxide beyond the initial assumptions.

It is concluded that for a specific case it will be possible to solve the inverse problem and produce composition limits which will allow increased flexibility of operation whilst maintaining safety.

Paper 10

Thursday, September 29, 10:30 -11 AM

Under pressure welding on CO2 pipelines - further data

Julian Barnett (National Grid Carbon), Simon Slater, Peter Boothby (ROSEN Group)

Abstract

Paper 10

Whilst There is extensive industry experience of under pressure welding onto live natural gas and liquid pipelines, there is limited experience for Carbon Dioxide (CO2) pipelines, either in the gaseous or dense phases. National Grid has performed a detailed research programme to investigate if existing natural gas industry under pressure welding procedures are applicable to CO2 pipelines, or if new specific guidance is required.

At IPC 2014 a paper was presented (IPC2014-33223) that dealt with the results from one part of a comprehensive trial programme, to define the cooling time from 250 °C to 150 °C (T250-150) in CO2 pipelines and comparing them to the decay times in natural gas pipelines. The results from this part of work identified that maintaining the pre-heat during under pressure welding on dense phase CO2 would be very difficult.

The previous paper gave a brief summary of the effect that cooling time had on the mechanical properties. The aim of this paper is to present the complete findings of the mechanical testing programme and discussion of the critical aspects including the link between weld cooling time and hardness.

Read in conjunction, these two IPC papers will form a comprehensive review of this critical work that is contributing to the development of dense phase carbon dioxide transmission pipelines.

Determine the correlations between the operating parameters of the pipeline, i.e. flow velocity, pressure etc. and the cooling rate after removal of preheat, characterised by the (T250-150) cooling time.
Compare the experimentally determined T250-150 cooling times with the values determined using a simple one dimensional heat transfer model.
Define the implications of heat decay for practical under pressure welding on CO2 pipelines.

Paper 11

Thursday, September 29, 2:30 - 3 PM

Development of Contempo-rary Welding Procedures for Heavy Wall Hot Tap Split Tee Longitudinal Seam Welds

David Teasdale, James Gilliver (National Grid), Mark Atkinson, Simon Slater (ROSEN Group)

Abstract

This paper will present the established procedures for completing the longitudinal welds using and the findings from the qualification of circumferential welds.

Paper 11

Historically, the manual metal arc welding (MMA) process has been used for welding of full encirclement split tees on hot tap connections for gas transmission pipelines. The National Grid high pressure gas transmission network currently consists of pipelines up to and including 1219 mm outside diameter. The large diameter pipes require split tee assemblies up to 80 mm thick. The arc time to complete welding can be considerable and requires multiple welders to complete welding in one continuous operation.

The qualification of a semi mechanised gas shielded flux cored arc welding (GSFCAW) procedure for welding the longitudinal and circumferential welds on large diameter tee connections would realise significant operational and cost benefits over the MMA method. The equipment for mechanised or semi-mechanised field welding is readily available for a large number of applications across many industries. A suitable semi-mechanised procedure has been developed for the longitudinal weld seams of split tee assemblies and is currently being adapted to the circumferential welds.

The first aim of this project was to qualify a semi-mechanised GSFCAW process and procedures in line with the National Grid specification for completing the longitudinal welds. A comprehensive welding and test programme was performed using 50 mm thickness material. Welding was performed using the Firefly welding system in three positions, flat, overhead and horizontal to cover the full range of welding positions required for tee connections with either horizontal or vertical off-take branches.

Based on the mechanical testing and non-destructive examination (NDE) results, the combination of process and consumables used in this project have been qualified in accordance with the National Grid specification.

The travel speeds achieved using the GSFCAW process are up to twice those recorded on a similar size fitting welded using MMA. Even after considering the remedial work, required to rectify quality issues, the overall welding times recorded using the GSFCAW process were lower than those recorded on a similar size fitting welded on site using the MMA process.

The work is currently being progressed to develop the procedures for completing the circumferential welds on split tee assemblies. A critical aspect of these procedures is the welding of the buttering runs and control of the process during this safety critical stage. The circumferential welding procedures will be performed in accordance with the guidance in API 1104 in particular the use of flowing water inside the carrier pipe to simulate the effect of a flowing medium.

This paper will present the established procedures for completing the longitudinal welds using and the findings from the qualification of circumferential welds.

Papers

ROSEN at IPC/IPE 2016

Explore the many facets of ROSEN at booth 512

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Education Systems and Services

Advanced Pipeline Diagnostics: Take control of cracks

RoCorr MFL-A Ultra Service – Making the invisible visible

Papers

Paper 1

Training & Education – The Great Competence Divide

Abstract

Paper 1

Paper 2

Continuous Depth Sizing of ILI Ultrasonic Crack Detection

Abstract

Paper 2

Paper 3

Corrosion Growth and Remnant Life Assessment – How to pick the right approach for your pipeline

Abstract

Paper 3

Paper 4

Detection of Crack Initiation Based on Repeat In-Line Inspection

Abstract

Paper 4

Paper 5

Pipeline strain and vibration monitoring by smart materials

Abstract

Paper 5

Paper 6

Graded EMAT Performance Specification Validated in Blind Test

Abstract

Paper 6

Paper 7

THE USE OF HYDROTESTING AND EMAT INLINE INSPECTION TECH-NOLOGY FOR THE INTEGRITY MA-NAGEMENT OF STRESS CORRO-SION CRACKING IN GAS PIPELINES

Abstract

Paper 7

Paper 8

Identification of Repair Coatings on Pipelines Using In-Line Inspection Technologies

Abstract

Paper 8

Paper 9

Am I Too Rich? - Determining limits for gas composition to ensure crack arrest in an existing pipeline

Abstract

Paper 9

Paper 10

Under pressure welding on CO2 pipelines - further data

Abstract

Paper 10

Paper 11

Development of Contempo-rary Welding Procedures for Heavy Wall Hot Tap Split Tee Longitudinal Seam Welds

Abstract

Paper 11