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Agenda

From February 6 to 10, 2023, the Pipeline Pigging and Integrity Management (PPIM) Conference will take place in Houston, Texas, USA, and will promote the exchange and sharing of technical knowledge in the energy pipeline industry.

No matter the challenge ahead, we are ready. We want to ensure you are ready to face any integrity management challenges ahead of you. Drawing from our arsenal of technology, experience, research and development capabilities, and testing and validation facilities, we are able to provide solutions for any asset integrity management need. We look forward to discussing your challenges at our booth #501!

At the conference, we will present twelve papers highlighting a wide range of pipeline integrity and inspection solutions. Please find more information about the topics we will present below. We will once again participate as the Platinum Elite Sponsor and look forward to welcoming all visitors to our on-site booth.

Hydrogen

Future fuels will play an important role in moving the industry forward, including renewable hydrogen as a flexible energy carrier. Existing gas infrastructure offers ideal conditions for storing, transporting, and distributing increasing amounts of hydrogen.

ROSEN’s goal is to encourage the pipeline industry to be ready for hydrogen. By proposing practical processes and approaches for its introduction into the existing grid, we continue to support operators with innovative solutions for a safe and sustainable future.

Learn more:
Hydrogen

Integrity Analytics

Artificial intelligence solutions are driving life extension, the energy transition, and zero-incidents in the pipeline industry. Combining decades of in-line inspection results, metadata for tens of thousands of pipelines worldwide, and a dedicated team of experts, ROSEN’s Integrity Analytics initiative is the future. As partners, we deliver unique insights that enable reliable decision-making for the safety, lifetime, and performance of your assets.

Learn more:
Integrity

NIMA

NIMA is an Integrity Management Software solution that supports dynamic decision-making, providing instant access to inspection and integrity assessment results. It gives clarity in understanding risks and making complex integrity management decisions of any oil and gas asset – be it pipelines, tanks or vessels.

Learn more:
NIMA

Comprehensive Asset Integrity Management

We employ state-of-the-art methods and technologies to obtain precise information on asset condition. Depending on the type of asset, type of threat and operating condition, different technologies and approaches are required.

Learn more:

Hard Spot Detection
Piping Inspection
TOFD Technology

Talent development

At ROSEN, we offer a variety of competency-based learning, assessment and collaboration programs for Pipeline Integrity Management. The offerings include programs at different levels, providing all those involved across the industry the opportunity to continuously develop their expertise, whether they are a student looking to learn or a subject-matter expert keen on exchanging ideas with others.

Learn more:

Talent Development

Agenda

Monday, February 6

08:00 AM

Technical Course: Pigging & In-line Inspection

Chris Yoxall (ROSEN Group)

The use of in-line tools for inspection and cleaning is accepted as essential for the safe and profitable operation of all pipelines. Now, Regulations require internal inspections using geometry pigs for detecting changes in circumference and MFL, ultrasonic pigs and/or EMAT tools for determining wall anomalies, metal loss and flaws in the pipe or the welded segments. To keep the pipelines flowing properly, operators wage a constant battle for flow assurance against paraffin, black powder and, offshore, hydrates and asphaltenes. In this battle pigging technology combined with chemical treatment is their primary weapon.

The Pigging and In-line Inspection Course is designed to provide a comprehensive introduction to all aspects of utility and in-line inspection pigging. Led by four of the most experienced, independent experts in this field today, the course will be conducted as a workshop, and attendees will be actively encouraged to participate. The course content will be fully illustrated, with actual pigs and models being used to aid understanding and help overcome any language difficulties. Comprehensive course notes will be provided, which will form a valuable source of reference afterwards.

Tuesday, February 7

08:00 AM

Technical Course: Pigging & In-line Inspection

Chris Yoxall (ROSEN Group)

Wednesday, February 8

09:00 AM

Evaluating the Suitability of the US Pipeline Network for Hydrogen Service

Simon Slater (ROSEN Group)

In response to the move towards net-zero carbon emissions, operators in the US are considering if and how existing natural gas pipelines can be converted to blended or 100% hydrogen service. Particularly given the cost of, and public opposition to, new pipelines.

This change will bring new challenges in terms of integrity management and at a minimum require a re-evaluation of the way the pipelines are operated. Building new pipelines specifically for hydrogen transportation can clearly mitigate the risk, but it may not be necessary. European operators are envisaging that ~60% of their European Hydrogen Backbone will consist of repurposed pipelines. When considering which pipelines are suitable for repurposing, the first reaction may be to dismiss the use of vintage pipelines, which are assumed to have inferior material properties compared with modern pipelines, and thus increased susceptibility to issues of embrittlement and accelerated fatigue crack growth, and hence higher risk. This may be unduly pessimistic, and we first need to consider the condition of existing lines.

A long history of pipeline inspection means that ROSEN has a significant database, which provides an indicative picture of both the material properties and condition of the US pipeline networks. In this paper some of the questions raised regarding the suitability of the pipeline network for hydrogen service in relation to existing knowledge and code guidance are explored. Specifically, we investigate the extent of existing features, such as crack-like features, dents, hard spots, and significant corrosion that could be a concern in hydrogen service under various scenarios of operating pressures and pressure cycling. In addition, we review the range of material properties and attributes present in the current natural gas transmission system, and how these compare with guidance in standards for hydrogen pipelines and developing industry knowledge.

Finally, we consider how pipeline condition and properties may influence integrity management in the presence of hydrogen. In some cases, converting these vintage lines to hydrogen may offer an opportunity to meet the existing guidelines for conversion and establish a safe operating envelope for hydrogen transportation, without the need for new-build. This paper will discuss the pro’s and con’s for the industry in terms of integrity management of converting existing pipelines to blended or 100% hydrogen service and a best practice approach for selecting candidate pipelines.

03:00 PM

Investigating the Impact of Changes to Formation Strain Predictions on Dent Integrity Management of Gas Pipelines

Morry Bankehsaz (ROSEN Group)

Pipeline Research Council International (PRCI) has recently completed a study funded in part by the Department of Transportation (DOT) and the Pipeline Hazardous Materials Safety Administration (PHMSA) to improve dent/cracking assessment methods for mechanical damage assessment.

Results from the DOT PHMSA project 855 have suggested that the current equations found within Appendix R of ASME B31.8 used to predict dent strain may under-estimate the formation strains, especially for deep and narrow dents or for unconstrained dents. Formation strain is an important characteristic of dents, with critical values potentially inducing the formation of cracks. US DOT regulation 49 CFR 192 requires injurious dents to be remediated while noting that dents where critical strain values are not exceeded may remain in operation as a monitored condition. Accurate prediction of the formation strain for any dent is important in ensuring the structural integrity of the pipeline.

Findings from the DOT PHMSA research program have proposed a modification to the ASME equations in order to better estimate the strain incurred during formation. The new methodology modifies the ASME equations through the adjustment of the axial membrane strain component as well as the incorporation of an additional circumferential membrane strain component. Furthermore, an additional correction for unrestrained dents has been proposed.

Understanding that industry standards and regulations are driven by research performed by PRCI and others, it is essential to understand the impact that these changes to formation strain predictions may have on dent integrity management of US operated gas pipelines. This study investigates the acceptability of dents by comparing strain values, calculated from the current ASME equations, against the methodology proposed in DOT PHMSA project 855. In-service dents for a wide range of pipe geometry and dent shapes from several gas pipelines have been utilized for this study. The current work details the comparison and findings for restrained and unrestrained dents assessed using the dent profiles captured during ILI tool runs. Furthermore, the strain assessment results are compared against critical strain limits to illustrate the impact the proposed methodology will have on gas pipeline systems operating currently. Finally, a discussion as to how these results may be incorporated into the Integrity Management plans of gas pipeline operators is presented.

05:00 PM

Full-Scale Fatigue Testing and Assessment of Dents on Brittle Longitudinal Welds – A Detailed Management Approach for a Liquid Pipeline in Chile

Pedro Guillen (ROSEN Group)

SONACOL owns and operates a 135 km, 6-inch diameter pipeline refined products pipeline located in Chile, which was constructed in 1964 from longitudinally welded (ERW) pipe with thicknesses between 5.16 and 12.7 mm. This pipeline has been inspected on multiple occasions for metal loss, deformations and cracks as part of its Integrity Management Plan. Following the most recent inspection and subsequent integrity assessment, an operational pressure reduction was introduced as some of the reported dents were considered to pose an immediate threat to the pipeline integrity. Of particular concern were dents identified to be associated with brittle longitudinal seam welds.

SONACOL supported by ROSEN have developed a strategy to assure the continuous safe operation of this pipeline. This involved a full scale testing and various levels of assessment increasing in complexity.

The strategy included the selection of critical dents, which were removed from the pipeline and underwent a full-scale fatigue testing, NDT assessment and material characterisation tests. Testing results demonstrated an acceptable level of conservatism in the assessment methods since fatigue growth was found to be overestimated. Dents were prioritised using an initial EPRG fatigue assessment followed by an FEA assessment. Additionally, the API 1183 longitudinal weld interaction was used to determine the likely effect of welds on the fatigue life of dents. The integrity assessment, which incorporated all ILI reported features including crack like anomalies, was used to develop a refined repair plan. This strategy has allowed Sonacol to continue operating the pipeline and demonstrate a suitable safety margin for that.

This paper summarises the different stages through the process of developing the dent management strategy.

Thursday, February 9

08:00 AM

Tolerance of ILI validation inspections, why is it important, and how to reduce it

Tom Oldfield (ROSEN Group)

ILI tools are supplied with a strictly controlled and validated tolerance to apply to integrity calculations in order to make safe engineering decisions. It is a requirement under API 1163 to validate the performance of the ILI tool in the ditch following an ILI campaign with field verification technicians using a range of technologies and procedures. What is the tolerance of the technique being used? And since they are manually applied and dependent on the operator, what is the tolerance associated with the technician?

In contrast to what is commonly assumed, field verifications are not absolute and there can be a significant variation between operators, technologies, and sizing techniques. It is a costly and sometimes complex operation to understand the performance of field verification technicians using a range of technologies, but an important aspect in ensuring compliance and safe operation of pipelines.

This paper discusses the attempts at understanding a universal tolerance by international codes and standards which can be used in conjunction with API 1163, and how these values can be utilized in a validation exercise of ILI tool performance. If these universal values are not suitable then we will discuss how these tolerances can be reduced and measured. We will look at a practical example of this application for inspection of thin walled ERW inspection and the implications of understanding the tolerance of the inspector on the validation process and ultimately the safety of the pipeline network.

10:30 AM

Above and Below: A Holistic Geohazard Monitoring Solution

Daniel Bahrenburg (ROSEN Group)

Geological and hydrological processes continuously reshape the surface of the Earth in ways that are not always predictable or easy to detect. Both cataclysmic and routine weather events are drivers of the geological and sedimentary change that ultimately result in pipeline geohazards. Operators need to consider these processes when constructing new pipelines or managing the integrity of existing assets.

Accounting for the influence of onshore or subsea land movement on structures is the primary goal of any effective geohazard management program. Traditionally, geotechnical monitoring programs are based on distributed point measurements in a defined area of ground movement. Active monitoring of ground movement and pipeline stress states is typically performed with discrete monitoring equipment, such as slope inclinometers or strain gauges. This can provide sufficient information for management of simple pipeline geometries located within basic geological environments and, most importantly, where hazards have already been identified. Frequently, hazards that result in pipeline failures are unmonitored or in areas that do not appear to be problematic, particularly where the surface expression is subtle and not identified by traditional surveillance methods.

To meet the demands placed on operators by advancing regulation and severe weather conditions, more frequent and comprehensive appraisals of pipeline right-of-way corridors will be required. For liquids transmission operators, this occurred in 2019 with 49 CFR 195.414. For gas transmission operators, this will become effective in May 2023 with 49 CFR 192.613.

This paper will demonstrate a holistic and integrated geohazard monitoring solution, which utilizes in-line inertial mapping and electromagnetic stress measurement to assess the condition of the pipeline alongside aerial laser topographical surveys (also known as light detection and ranging, or LiDAR) to evaluate the state of right-of-way at the surface. LiDAR provides invaluable insights into the characteristics of the land surface and whether there are features or anomalies that could represent land instability. Inertial mapping reveals the occurrence of discrete flexural loading and its proximity to performance limits. Additionally, recent case studies have shown the ability of new ILI technologies to accurately measure uniform longitudinal stress resulting from axial loading on pipelines. The integration of these three data collection techniques ultimately results in a high level of confidence when diagnosing and characterizing active geohazard threats.

This approach not only provides the ability to identify geohazards, but also assists with setting appropriate inspection intervals to track changes to pipeline integrity and hazard development. An additional advantage of these complementary technologies is that they provide a robust baseline for any geotechnical program and increased efficacy in the design of site surveys, the selection of monitoring points and guidance toward the most appropriate remediation solution.

01:30 PM

A Novel Concept Addressing Material Properties and Loading Conditions with a Dynamic Micro-Magnetic Sensor

Sebastian Huehn (ROSEN Group)

In 2013/14, an eddy current sensor in a magnetic field for material properties was introduced; together with a population approach that addresses the requirements stated in current U.S. regulations, it determines pipe grade. A novel sensor technology has been developed now, called DMPL (Dynamic Material Properties Loading), which addresses a broader range of material properties, including toughness and, additionally, the axial and circumferential stress condition of a pipeline.

The patent pending technology is a high-resolution non-harmonic micro-magnetic sensor. Essentially, micro-magnetic sensors consist of a magnet yoke, an excitation and a receiving coil to generate and record a hysteresis curve. When testing a component, the generated hysteresis curve contains information about the mechanical properties and the loading conditions of this component. Conventional micro-magnetic sensor applications are mainly used as handheld devices for static local measurements and play a reliable role in quality control of steel plates during manufacturing. To cope with such challenging conditions during in-line inspections as high tool velocities, low power consumption and sensor liftoff, the sensor technology was upgraded and adapted. Using an extensive material database for machine learning is the key factor in this multitalented concept.

This paper provides an introduction of the technology and its suitability in the areas of axial stress condition and material properties demonstrated by laboratory measurements, full-scale tests and first operational experiences. Based on these tests, which comprise a large set of test samples, a first assessment of sizing capabilities is given, and further aspects such as measuring resolution are discussed.

02:30 PM

Making Hard Decisions

Khanh Tran (ROSEN Group)

The definition of a hard spot is introduced in the updated Gas Rule 49 CFR 192 Part 2 as “an area on steel pipe material with a minimum dimension greater than two inches (50.8 mm) in any direction and hardness greater than or equal to Rockwell 35 HRC (Brinell 327 HB or Vickers 345 HV10)”. This update sets an expectation for operators to manage the threat through a combination of assessment, using ILI and in-ditch validation, and an appropriate response.

Over the past two years, Williams Transco has utilized in-line inspection technology capable of detecting, identifying and characterizing hard spots on several transmission pipeline systems. Various types of reported material hardness anomalies have been subsequently verified in a validation campaign, of which a number occurred on not only flash welded A.O. Smith pipes, but also vintage DSAW pipes from a wide range of manufacturers.

This paper will present the results of extensive non-destructive and destructive testing of validated material hardness anomalies, to establish a thorough understanding of the different types of hard spots that can exist, and discuss recommendations for assessing these anomalies and defining appropriate response options.

04:00 PM

Estimating Excavation Damage (Outside Force) 'Hit Rates' Using Machine Learning Models Trained on In-Line Inspection Data and Geographical Information

Steven Carrell (ROSEN Group)

External interference damage is one of the main causes of pipeline failure reported in publicly available industry statistics from agencies such as the United States Pipeline and Hazardous Materials Safety Administration (PHMSA). Thus, failures due to external interference are often the most significant contributors to pipeline probability of failure in risk assessments and can play a significant role in operator decisions regarding risk-control measures, for example when it comes to the installation of additional impact protection, pipeline diversion or pressure restrictions.

The probability of failure due to external interference damage can be estimated by combining the probability that damage occurs (i.e. that the pipeline is hit), the probability that the impact is sufficient to cause instant failure and the probability of degradation to failure, given that damage has occurred. Degradation to failure is assessed using industry standard engineering models (such as the limit state functions given in Annex O of CSA Z662-19 [1]). However, the key challenge is predicting where, when, and with what energy the external interference damage may happen.

The prediction of a “hit-rate,” or impact frequency, is often subjective or based on statistics which may not be applicable to the pipeline under assessment. Top-of-line (TOL) deformation damage (dents) reported by in-line inspection (ILI) are a clear indicator of past external interference, which could have been introduced by third parties, contractors or the operator themselves. In a recent in-house research study ILI data and pipeline parameters from ROSEN’s Integrity Data Warehouse (IDW) – which at the time of writing contains results from over 20,000 inspections – has been combined with geographical information on population density, land use, crossings and socioeconomics, and used to train machine learning models to estimate the frequency of external interference damage (per km-year), or ‘hit-rate’ for pipelines where the route is known but reliable statistics for ‘hit-rate’ are not available.

This paper presents the results of the study describing the extensive dataset used from a selection of pipelines in Europe and Canada, the development of the models and how they were trained and tested, and finally showing the model performance, discussing the capabilities and limitations, and implications for risk assessment studies.

04:00 PM

Development of a Multi-diameter and Low-pressure Compatible Tool to Inspect for Selective Seam Weld Corrosion

John Nonemaker (ROSEN Group)

Enbridge operates a low-pressure multi-diameter natural gas pipeline in the Northeast United States that is susceptible to selective seam weld corrosion (SSWC). The diameter ranges from NPS 24” to NPS 30” with 15 diameter changes over a length of 13.0 miles. SSWC is an environmentally assisted mechanism in which there is increased degree of metal loss in the longitudinal weld in comparison to the surrounding pipe body. Rosen’s RoCorr MFL-C Ultra technology was selected to obtain inspection data in a single in-line inspection for metal loss and long seam features. The multi-diameter and low-pressure operating characteristics of the pipeline presents in-line inspection challenges such as stuck tools, speed excursions and degraded data, particularly when the tool encounters bends and fittings. This paper presents a systematic approach for developing an appropriate in-line inspection tool from the perspective of a natural gas pipeline operator and in-line inspection technology provider, including a description of the in-line inspection execution considerations, in-line inspection tool design and testing process, tool features to mitigated degraded data and field validation results. This case study demonstrates that tool developments for low-pressure and multi-diameter pipelines should be considered as a long-term integrity management strategy.

Friday, February 10

08:00 AM

Axial Flaw and Crack Detection in Multi-diameter Low-Pressure Gas Pipelines

Lance Wethey (ROSEN Group)

Louisville Gas and Electric (LG&E) owns and operates numerous natural gas transmission pipelines in the greater Louisville, KY area. Many were constructed during the 1950’s and therefore present extensive challenges to inline-inspection (ILI) efforts. Multi-diameter pipeline geometry and transient operating conditions combine to create an environment that proves difficult for running in-line inspection tools. LG&E has utilized high resolution geometry and metal loss detection solutions optimized for low-pressure multi-diameter pipelines ILI devices in their integrity management program. There was a desire to expand the technologies deployed to include technologies best capable of detecting axially oriented anomalies and cracking. To address these concerns, circumferentially induced magnetic flux leakage (MFL-C) and electromagnetic acoustic transducer (EMAT) technologies were suggested, however applying these detection methods in low-pressure multi-diameter pipelines was not available.

MFL-C & EMAT-C ILI devices capable of inspecting a pipeline with both 16″ and 20″ diameters in a low-pressure gaseous environment needed to be developed. In addition, traversal of all restrictive features, such as tight radius bends and minimal spacing between fittings, must be achieved with minimal differential pressure to facilitate stable run behavior and allow optimal data capture. ROSEN reviewed all known details regarding the targeted pipelines and compiled a list of challenging fittings to define the required mechanical passage capabilities. The conceptual design, manufacturing, and assembly stages of development resulted with redesigned low-friction ILI tools capable of full circumferential sensor coverage in 16″ – 20″ pipeline diameters. The tools were then pumped with water through a test loop that included the most restrictive features identified in the targeted pipelines. Performance results confirmed mechanical passage and determined the average ∆P’s necessary to pass the included restrictive features. Finally, validation pull tests occurred to confirm data capture functionality within established specifications. After mechanical and data capture performance were verified, the new low pressure multi-diameter 16/20″ MFL-C & EMAT-C were deemed fit for service and deployment.

This technical paper outlines the development process with examples and observations from the testing program. Difficulties related to MFL-C & EMAT-C technologies as related to low-pressure and multi-diameter environments are discussed in further detail. The paper includes real-world operational challenges and inspection results from two successfully inspected pipelines, as well as a discussion of iterative ILI tool improvements.

9:30 AM

Going Above and Below – Material Property Verification Documentation Review

Richard Ingolia (ROSEN Group)

The introduction of regulatory changes by PHMSA in 49 CFR 192, for Traceable, Verifiable and Complete (TVC) pressure test and material property records meant that pipeline operators have had address their systems of record. The challenge is to determine the status of existing documentation for all pipe and components in pipelines, pipeline subsystems, and metering & regulating stations.

Reviewing, aligning, interpreting, and managing the significant amount of data and documentation accumulated over the history of these networks presents a challenge. Processes and specifications have been established to ensure that historical records are treated correctly and consistently in the context of regulatory language. Once extracted, the data is integrated into auditable systems of record, which can be easily visualized to support and facilitate programs for regulatory compliance and Integrity Management.

This paper will present a summary of the processes and applications that a partnership between the operator and engineering consultancy has implemented to surmount these challenges, including document management, Geographical Information Systems (GIS) and geospatial analysis, in-field verification for stations, and quality control methods. Commentary will be provided on the treatment of historical records in the context of the new regulatory requirements, where interpretation is often required. Finally, a discussion on how operators can use these systems and processes to inform and implement strategies for MAOP reconfirmation and material verification will also be provided.

11:30 AM

Enhancing EMAT Crack Detection Services Using State of the Art Deep Learning

Stephan Eule (ROSEN Group)

EMAT crack detection technology is used worldwide by many oil and gas operators to detect and size cracks in liquid and gas pipelines. By collecting data of increasingly higher resolution and quality, it is possible to achieve a more and more accurate representation of the integrity reality of oil and gas structures.

However, the prerequisite for gaining insights from this data is provided by Artificial Intelligence (AI) methods and a corresponding Research-First structure of a company. The AI division at ROSEN Research Center invested significant time and resources to apply powerful machine learning in particular Deep Learning methods to ensure timely and accurate inspection results delivered to operators. These efforts are directed towards building data driven applications to ensure reliability of inspection systems. Supported by a modern data engineering infrastructure, AI-powered data-driven applications can be used to enhance both the quality and efficiency of inspection data analysis.

This paper will provide an insight on how ROSEN uses AI-methods to enhance classification and sizing of metal-loss and crack indications in pipeline inspection data. Particularly, how Deep Learning methods help ensuring the quality of EMAT-Crack detection services.

Navigation

Agenda

Pipeline Pigging and Integrity Management Conference (PPIM) 2023

Hydrogen

Integrity Analytics

NIMA

Comprehensive Asset Integrity Management

Talent development

Agenda

Technical Course: Pigging & In-line Inspection

Technical Course: Pigging & In-line Inspection

Evaluating the Suitability of the US Pipeline Network for Hydrogen Service

Investigating the Impact of Changes to Formation Strain Predictions on Dent Integrity Management of Gas Pipelines

Full-Scale Fatigue Testing and Assessment of Dents on Brittle Longitudinal Welds – A Detailed Management Approach for a Liquid Pipeline in Chile

Tolerance of ILI validation inspections, why is it important, and how to reduce it

Above and Below: A Holistic Geohazard Monitoring Solution

A Novel Concept Addressing Material Properties and Loading Conditions with a Dynamic Micro-Magnetic Sensor

Making Hard Decisions

Estimating Excavation Damage (Outside Force) 'Hit Rates' Using Machine Learning Models Trained on In-Line Inspection Data and Geographical Information

Development of a Multi-diameter and Low-pressure Compatible Tool to Inspect for Selective Seam Weld Corrosion

Axial Flaw and Crack Detection in Multi-diameter Low-Pressure Gas Pipelines

Going Above and Below – Material Property Verification Documentation Review

Enhancing EMAT Crack Detection Services Using State of the Art Deep Learning