ROSEN - Rio Pipeline Conference & Exhibition 2017

The Rio Pipeline Conference & Exhibition is just around the corner, and we are delighted to announce that the ROSEN Group will once again play an active role as a Platinum Elite Sponsor. The 11th edition of the biennial event will take place from 24 to 26 October, 2017, at Riocentro – Convention & Event Center in Rio de Janeiro, Brazil.

With more than 2,000 professionals in attendance, from both technical and managerial levels, Rio Pipeline is among the leading events in its sector. Themed “Connecting the Future: Trends and Challenges,” the conference and exhibition will focus on the latest technologies and new developments supporting sustainable energy strategies worldwide.

Visit us at booth #J13, where we will showcase our solutions in the fields of Offshore Asset Care and Crack Management. Get to know our experts and learn how our innovative solutions can apply to your unique asset.

Focus_Topics-PPIM2017

Additionally, we would like to invite you to the following activities:

• 24 October, 2:00–4:00 p.m., Panel discussion on the “Technological Challenges and Innovation in the Pipeline Segment,” with participation by Michael Rapp, Global Business Line Manager of Proficient Pipeline Diagnostics, together with other industry experts

• On 24 October, from 5:00 to 7:00 p.m, a special toast and tablet raffle at our booth #J13

• 25 October, 3:00 p.m: Presentation about the offerings of our business line Education Systems and Services by Eduardo Soria, member of ROSEN Regional Management in South America, on the occasion of the Arena do Conhecimento (Knowledge Arena)

Papers

Special Session

Tuesday, October 24, 10:40 - 12:00 PM

Developing a tailored integrity management approach for high-temperature pipelines

Pedro Guillen (ROSEN Group)

Abstract

Special Session

Pipelines that operate at high temperatures, such as heated crude oil lines, present a number of challenges for integrity management. In particular high operating temperatures can accelerate the aging of the coating, and where the coating is damaged and corrosion does occur, the corrosion rates can be high. High failure rates of high-temperature insulated crude oil transport pipelines in Western Europe in the 1980’s resulted in most of the systems being modified such that operations were reduced to ambient temperatures. However, there are still many high-temperature systems in operation and modification to allow lower temperature operation is not practical in all cases. For these pipelines, corrosion under insulation (CUI) continues to be a critical issue. Whilst some guidance on damage mechanisms, design considerations and inspection and maintenance can be found in NACE SP0198-2010 standard practice, the document is intended primarily on addressing this phenomenon in refineries, and gas and chemical plants.

In order to address this situation and allow long-term safe operation, a specifically tailored integrity management approach was developed for a system of high-temperature pipelines in Brazil. This approach uses the results of multiple in-line inspection (ILI) runs to identify sections of pipelines that have different corrosion activity and specifically sections affected by CUI. For each section representative corrosion growth rates are estimated. The representative corrosion rates are then used to predict a future growth) of identified corrosion features, thus defining pipeline integrity operating limits associated with CUI damage. The most critical features are then subject to a River Bottom Profile analysis, where the focus is on (i) reducing conservatism and (ii) developing an optimal repair and inspection plan for a given pipeline. The Integrity Management approach developed for this network has now been applied to a number of pipelines which are susceptible to CUI and which were subject to multiple ILIs.

In the current work, we present representative results from such inspections and integrity assessments, and discuss the key outcomes and implications for the overall pipeline integrity management and corrosion control. Additionally, possible improvements to the process are critically reviewed.

Paper 1

Tuesday, October 24, 11:20 - 11:40 AM

Risk management of stress corrosion cracking

Pedro Guillen (ROSEN Group)

Abstract

Paper 1

Many pipeline operators’ first significant experience of Stress Corrosion Cracking (SCC) is dealing with the aftermath of an unexpected failure. At this point, the operator’s priority is to repair/replace the affected section and return the pipeline to full service. However, experience shows that SCC rarely occurs in isolation, which places substantial uncertainty upon the feasibility of continued safe operation. In some cases, this uncertainty has resulted in operators having to accept significant reductions in operating pressure for extended periods and even permanently.

A return to full service is contingent upon the operator being able to demonstrate that the pipeline is fit for service and that any residual risk is within tolerable limits. To define a robust risk-based management plan for future operation, a collaborative approach is required that formally incorporates consideration of susceptibility to cracking, critical defect dimensions, a thorough understanding of the cause of the failure, appropriate inspection technology, rehabilitation actions, and risk assessment. This can be visualized as a framework of interconnected elements.

This paper will present and discuss the risk-based elements of the framework. Parametric susceptibility analyses are used to aid inspection data analyses, focussing on those locations of highest susceptibility and overall risk, which then evolve into risk analyses used to select appropriate rehabilitation, prevention, and mitigation measures. The paper will explore in detail how influential parameters are used as diagnostic assumptions and subsequently tested and refined iteratively through in-line and subsequent infield inspections.

Paper 2

Tuesday, October 24, 12:00 - 12:20 PM

Customized cleaning program to improve sensor coverage on UT runs

Allan Browne (ROSEN Group)

Abstract

Paper 2

First-run success for UT tools is often compromised by the presence of heavy paraffin wax debris, which interferes with UT sensors and UT beam transmission and reception. This typically results in an incomplete data set even though there is 360-degree coverage from the sensors. This impacts the quality of the data, analysis capability, and ultimately the accuracy of the final report conclusions.

Most of the time, pipeline cleaning operations are controlled and performed directly by the pipeline operator. This typically includes the selection of the cleaning tools. After their successful run through the system, the operator declares the pipeline clean and ready for the ILI inspection.

The objective of this paper is to illustrate the importance of cleaning on the basis of a case history. Here, first-run success was assured for a UT inspection in a pipeline which had a history of heavy paraffin wax deposition.

The heavy wax tends to build up on top of the UT sensors, causing data loss. Having access to the right selection of tools, measuring the amounts of debris after the runs, and evaluating the results in light of appropriate cleaning acceptance criteria is one way to achieve the required cleanliness of a pipeline prior the ILI UT.

The case demonstrated in this document identifies the use of two different heavy-duty/aggressive cleaning tool configurations. Three cleaning runs in total were performed prior the UT run. The amount of waxy debris was reduced significantly after each cleaning run. The UT ILI tool run had 100% sensor coverage and 0% data loss.

100% sensor coverage will also contribute to a first-run success.

Paper 3

Wednesday, October 25, 10:00 - 10:20 AM

Managing the threat of circumferential Stress Corrosion Cracking

Roland Palmer-Jones (ROSEN Group)

Abstract

Paper 3

In recent years there have been a number of pipeline failures attributed to circumferential cracking, and cases where circumferential stress corrosion cracking has been found in field. These failures remain rare but are often unexpected (a hazard not previously identified or included in any risk assessment) and can create a major incident with significant disruption to pipeline operations.

Failure investigations of circumferential cracking have identified tensile axial strain and a corrosive environment as contributing to the development of stress corrosion cracking (SCC). Most cases of SCC result in axial cracking, often linked to stress raisers such as dents, areas of corrosion, and welds. The industry has developed tools capable of detecting these axial crack, in-line inspection tools for detecting circumferential cracks are now available, in particular tools utilizing liquid coupled piezo electric ultrasonic sensors. Sensor technology for ILI of gas pipelines is being developed.
In this paper a process for identifying pipelines potentially susceptible to circumferential SCC, picking out specific high risk sites, and developing appropriate inspection and mitigation plans is proposed. The process has been developed in response to the authors experiences with a number of operators who have experienced circumferential SCC and is based on industry guidance and readily-available information on pipeline design, construction, and route, publically available spatial information including terrain models, soil data and rainfall records, combined with proven in-line inspection technologies for coating disbondment detection, deformation, bending strain estimation, and the identification of high strains generated at tie-in points. Inspection technologies that are available and in development are also discussed.

Following this system will provide a justifiable basis for decisions on managing the threat of circumferential SCC such as running specially configured circumferential crack detection tools, and completing site investigations.

Paper 4

Wednesday, October 25, 03:10 - 03:30 PM

The future of managing complex corrosion threats using ultra-high-resolution in-line inspection technology

Pedro Guillen (ROSEN Group)

Abstract

Paper 4

Unusual corrosion processes – such as corrosion under insulation, microbially induced corrosion (MIC), and preferential girth weld corrosion – result in complex metal loss features that may include pinholes. Features like this are notoriously difficult to reliably size using MFL-based inline inspection technology. Improvements in the understanding of magnetic flux leakage based on detailed finite element simulations and advances in computer and sensor technology have allowed the development of an ultra-high-resolution MFL system that supplies a resolution similar to that of 3D optical scanning.
In order to provide reliable inspection results using an ultra-high resolution MFL measurement system, a series of challenges had to be overcome:

Sensors must be very close together to prevent any circumferential gaps in the data recorded. This calls for accurate mechanical design to ensure each sensor stays exactly in its track, especially when passing welds.
There can be a significant impact on the recorded data quality due to sensor placement on the yoke in relation to the magnetic field. Specific normalization efforts are required to ensure a uniform appearance of data for subsequent evaluation.
The huge volume of inspection data generated requires the use of machine-learning based algorithms in data evaluation, reducing the ‘human factor’ impact.

In addition to presenting solutions for the technical challenges listed above, this paper will provide some real-life examples that demonstrate the advantages for cost effective integrity management of improved detection capability and measurement accuracy of complex corrosion defects combined with expert corrosion diagnosis and defect assessment. The advantages are considered in terms of focusing short term efforts on the genuine critical defects, and optimizing mid-term excavation and re-inspection planning accounting for potential corrosion growth.

Paper 5

Wednesday, October 25, 03:10 - 03:30 PM

Multiphase Pipeline Operational Pigging, Flow Assurance Study Comparison to Real Operation and Model Validation

Roland Palmer-Jones (ROSEN Group)

Abstract

Paper 5

It is now widely accepted that operational pigging is a key operational and maintenance activity for maintaining production efficiency in pipelines. Although the removal of excess liquids from a pipeline is necessary, this in turn creates operational issues. The management of these unwanted liquids is a critical stalling point at many receiving and processing facilities, and understanding the chain of events leading up to the receipt of the cleaning pig is crucial.

In one recently reviewed project, it was expected that during pigging of a 36” 120 km offshore trunk line, large liquid volumes would be accumulated in front of the tool. If this liquid were allowed to flow without restriction, the liquid would arrive onshore at a rate that would overload the slug catcher, resulting in production deferment due to protective measures. A flow assurance study was required to estimate the amount of liquid expected at the slug catcher during pigging in order to ensure a continuous gas supply to downstream users. The analysis was carried out using a detailed OLGA™ flow model integrated with onshore slug catcher, on selected sensitivity studies based on flowrate, venting control at pig receiver, pig properties e.g. bypass, frictional forces etc. to recommend the desired pigging procedure and ensure a successful pigging run.

In the current work, the modelling predictions generated by the OLGA™ multiphase flow model were compared with actual field data upon receipt of the cleaning pig. Additional advanced 3D modelling for flow behavior around the bypass tool will be carried out using CFD to address the bypass modelling limitations of most 1D simulators. CFD modelling, along with the field data from the pig tool onboard data loggers, will add to the validation of parameters considered in the OLGA™ flow model for better modelling accuracy.

Paper 6

Wednesday, October 25, 03:30 - 03:50 PM

In-line Inspection Technology for crack detection in gas pipelines

Thomas Beuker (ROSEN Group)

Abstract

Paper 6

The integrity of aging assets like gas pipelines are managed by a variety of inspection and validation methods. In the particular case of gas pipelines and their susceptibility to cracking, an ultrasonic inspection methodology has been developed by ROSEN, which is based on an electromagnetic acoustic transducer (EMAT). Meanwhile, a high resolution implementation of the technology has been utilized on in-line inspection tools from 10” to 48” tool size. The utilization of ultrasonic shear horizontal wave and a corresponding spectral analysis of the wave modes of higher order allows an accurate depth sizing and identification of crack anomalies present in pipelines. The high resolution approach provides redundancy in gathering reflection signals from individual cracks and crack colonies. Beside the reflection signal a so called transmission signal is recorded as well. This signal is used to normalize the ultrasonic crack response with regards to spurious artefacts. The fundamental measurement principles and the results from the inspection programs conducted so far will be discussed and re-viewed in this paper. Williams Gas Pipelines have utilized this inspection technology successfully on several pipelines. An overview of the experience gained so far will be given. Secondly a case study will be presented, in which a post hydrostatic test ILI service was used to gain additional safety and integrity relevant information from the ILI inspection and to better understand the actual capabilities of a hydrostatic test.

Paper 7

Wednesday, October 25, 03:30 - 03:50 PM

Longer – colder – deeper: Engineered Pipeline Maintenance Cleaning Solutions

Eduardo Soria (ROSEN Group)

Abstract

Safe and reliable operation of subsea pipeline systems is key to assuring targeted results in a challenging production environment. Optimized maintenance processes assure...

Paper 7

Safe and reliable operation of subsea pipeline systems is key to assuring targeted results in a challenging production environment.

Optimized maintenance processes assure sustainable asset operation even beyond the scheduled system life time. State-of-the-art subsea pipeline systems require not only innovative but also sustainable solutions.
Today, assets like subsea pipeline systems are often more remote, meaning that access to system key components becomes more sophisticated and costly.

To reliably remain on top of maintenance efforts and manageable risks, subsea maintenance campaigns must be well coordinated. The use of valuable data can directly influence present activities and lead to continuous regular future improvements.

An integrated pipeline cleaning concept can improve pipeline maintenance strategies significantly by considering the overall context and evaluating documented system information gained during regular maintenance activities, pipeline inspections, pipeline modifications and repair campaigns.

Data-based engineered solutions provide a systematic, continuous, and proactive approach involving individual and customized tool and component designs as an alternative to reactive execution of single campaigns.

This paper focusses on a smart use of existing data about transported products, operational parameters and ancillary information gained over time. It explains how documented experience can support key decisions in pipeline operation and how preparation leads to cost efficient run frequencies, selection of cleaning tools and subsequently an optimized production environment.

Paper 8

Wednesday 03:30 - 03:50 PM

Intelligent internal protection of steel pipes - field weldable elastomer coated pipes with integrated wear monitoring

Tomas Cruz (ROSEN Group)

Abstract

Paper 8

Internal pipe coatings made from High-performance polyurethane elastomers have proven to extend design life of slurry pipelines by factors in the range of 10-fold. With more than half a decade of experience in oil sands coarse tailings lines and other slurry hydrotransport applications, operators are valuing this type of erosion and erosion-corrosion protection for large savings of maintenance cost and down time.
A simple and highly efficient proprietary field-welding system allows welding of internally coated steel pipes in the field. By employing this method, there is no need for joint area re-coating nor for cooling or other expensive measures to maintain coating integrity. This method, tested up to 250 bar / 3000 PSI, makes these internal high-performance polyurethane elastomers even more economical, much more so than other (e.g., metallic or ceramic) wear protection
systems.
Since April of 2015, a continuous wear monitoring system for polymeric internal pipe coatings is available in the market. This system allows monitoring from outside the pipe without the need for shutdowns. There is no need for wire access to the pipe interior, i.e., no need for a hole through the pipe wall. From field experience in Canadian oil sands, operators calculated maintenance cost reduction in the range of 25-35% thanks to more exact shutdown scheduling and
rotation schedules made possible by this wear monitoring system.
Field experience with intelligent internal coatings made from high-performance polyurethane elastomers will be
summarized in this presentation.

Paper 9

Wednesday, October 25, 03:50 - 04:10 PM

A framework to develop effective crack management strategies for gas transmission pipelines

Brian Kerrigan (ROSEN Group)

Abstract

Paper 9

A basic structure to guide the decision-making process is vital for creating optimized in-line inspection programs. The Crack Management Framework presented in this paper is intended to ensure structured decision-making based on the hazards present and the activities to be completed by all parties involved with the objective of obtaining optimum results when using in-line inspection systems and other related services. This approach must not only take into account system selection and the actual in-line inspection, but also reporting, prioritization, as well as field verification, repair, and post-ILI assessments.

Instead of a typical sequentially oriented program, an integrated framework is proposed where the settings of each sub-process are adjusted based on feedback of other process elements. Full scale testing (pull-testing), the integration of historical data, and field verification results increase the statistical confidence in the inspection results as outlined in API 1163, for example. The combination of different inspection technologies and the utilization of an adapted/staged performance specification results in an improved probability of identification (POI) for crack-like anomalies. The paper will discuss the probabilistic process to balance the feature distribution of false-positives and false-negatives for critical and sub-critical stress corrosion cracking including the corresponding plausibility validation.

A case study of a practical application of the framework to a gas transportation pipeline is discussed. The above-mentioned elements were applied integrating the results from an in-line inspection campaign using different ILI technologies including electromagnetic acoustic testing (EMAT).

Paper 10

Wednesday, October 25, 03:50 - 04:10 PM

Development of an integrity management plan for a slurry pipeline system considering repeat in-line inspection results

Ricardo Nebias (ROSEN Group)

Abstract

Paper 10

Slurry pipelines, and pipeline systems in general, are susceptible to a range of integrity threats which need to be considered in the development of an effective integrity management plan (IMP). Given the nature and composition of conveyed fluids, one of the main and common integrity threats for slurry pipeline systems are erosion and erosion-corrosion, which typically result in localized metal loss and general wall thinning. Consequently, the effect of these two mechanisms should be considered an intrinsic part of any IMP, especially when the primary focus is on modeling and predicting future behavior of such pipeline systems.

It is well established that in-line inspection (ILI) represents a reliable method for detection and identification of pipeline defects and anomalies. It allows for an integrity assessment of any inspected pipeline system. In the case of pipeline systems subject to multiple ILI runs, a comparison of ILI results facilitates the identification of changes in the pipeline condition; e.g. corrosion and erosion rates can be estimated. Such assessments provide valuable feedback on the effectiveness of implemented corrosion control and mitigation activities and support the development of a repair plan conducive to the combined effect of metal loss and wall thinning.

In this paper, we describe the current approach to corrosion-erosion control that – as part of the larger IMP system – is employed by HYDRO to maintain integrity of a 243-kilometer bauxite slurry pipeline that suffers from the previously mentioned integrity threats and was subject to two ILIs. In addition, we discuss likely operating scenarios and their impact on the integrity of the pipeline. We will then recommend control and mitigation measures.

Paper 11

Thursday, October 26, 11:00 - 11:20 AM

Technical challenges of in-line inspection on offshore unbonded flexible pipes

Roland Palmer-Jones (ROSEN Group)

Abstract

Paper 11

Unbonded flexible pipes have been widely used in offshore oil and gas developments as an alternative to traditional steel pipes due to their technical advantages and financial benefits particularly for high pressure and high temperature (HPHT) conditions and deep-water applications. In-line inspection (ILI) has been widely adopted as a key source of data for the integrity management of traditional steel pipelines. However, to date limited progress has been made in developing an efficient in-line inspection method suitable for unbonded flexible pipes due to the complexity of their structural characteristics, i.e. multiple layers of different materials and constructions.

The development of ILI technologies that can inspect all layers of unbonded flexible pipes would provide the industry with a step towards change in the integrity management of this asset type. With its specialist experience in design, analysis, manufacturing and operations of offshore unbonded flexible pipes around the world, combined with very strong technical capabilities in pipeline in-line inspection, ROSEN is now developing in-line inspection solutions and associated condition assessment methods to enhance the integrity management of flexible pipes. As a first stage in this development, we have been exploring what value, in terms of integrity management, can be extracted from data collected as ILI tools pass through flexibles.

This paper presents the initial findings from expert review of ILI data collected during normal ILI runs (targeted at the rigid steel pipeline) where the tool passes through an unbonded flexible pipe. It is apparent that by combining knowledge in ILI technology (limits of detection) and unbonded flexible pipes (structure/failure mechanisms), valuable data is available, and therefore certain assessments can be completed.

The primary information obtained was related to the end-fitting to flexible pipe-layer transition, carcass pitching and internal surface condition. The potential defects and relevant risks from the data can be assessed effectively, for example, in terms of irregular distances for the carcass pitching and spacing between the interlocked wraps, geometric anomalies of the inner diameter (ovalities, dents, etc.) with reference to relevant locations. The data can reveal very important information related to local carcass stress, etc., and can further help identify the possible root causes of damage from external loadings. Examples of external loading are gross tension, bending, torsion, external pressure collapse, or abnormal loadings due to external crushing and impact damage. In addition, depending on available data and the type of technology, we may also be able to assess the transition through the end fitting, the location of external structural features e.g. Mid Water Arch (MWA) clamp, the location of the bend stiffener, etc.

This paper will discuss the development of assessment processes that will allow operators to maximize the value of data collected by existing tools. Furthermore, it will investigate tool and sensor technologies, which – when combined with appropriate assessment methods – will provide more data to help with risk-based integrity management of unbonded flexible pipe.

Paper 12

Thursday, October 26, 12:00 - 12:20 PM

Pipeline inspection data cross-check and tool inspection findings comparison

Rafael Almeida (ROSEN Group)

Abstract

Currently there is no single pipeline inspection technology that can detect and size all possible kinds of anomalies and installations found on a pipeline system by itself.

Paper 12

Currently there is no single pipeline inspection technology that can detect and size all possible kinds of anomalies and installations found on a pipeline system by itself.

Carrying out several inspection campaigns, not only with the same inspection tool but also with different inspection technologies and in regular time intervals, is one of the most efficient ways to ensure that all possible threats to a pipeline are properly detected and reported. Simultaneous evaluation of different data sets in order to provide combined reports is one of the keys to achieving this goal. In addition, historical data sets can be used to enhance the quality of a more recent inspection run. Reports offer insight into upgrades and improvements of several factors, such as tool setup, pipeline distance system, anomaly typing, and sizing.

The aim of this paper is to highlight the benefits of pipeline inspection data cross-check and inspection findings comparison.

Papers

Rio Pipeline Conference & Exhibition 2017

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Papers

Special Session

Developing a tailored integrity management approach for high-temperature pipelines

Abstract

Special Session

Paper 1

Risk management of stress corrosion cracking

Abstract

Paper 1

Paper 2

Customized cleaning program to improve sensor coverage on UT runs

Abstract

Paper 2

Paper 3

Managing the threat of circumferential Stress Corrosion Cracking

Abstract

Paper 3

Paper 4

The future of managing complex corrosion threats using ultra-high-resolution in-line inspection technology

Abstract

Paper 4

Paper 5

Multiphase Pipeline Operational Pigging, Flow Assurance Study Comparison to Real Operation and Model Validation

Abstract

Paper 5

Paper 6

In-line Inspection Technology for crack detection in gas pipelines

Abstract

Paper 6

Paper 7

Longer – colder – deeper: Engineered Pipeline Maintenance Cleaning Solutions

Abstract

Paper 7

Paper 8

Intelligent internal protection of steel pipes - field weldable elastomer coated pipes with integrated wear monitoring

Abstract

Paper 8

Paper 9

A framework to develop effective crack management strategies for gas transmission pipelines

Abstract

Paper 9

Paper 10

Development of an integrity management plan for a slurry pipeline system considering repeat in-line inspection results

Abstract

Paper 10

Paper 11

Technical challenges of in-line inspection on offshore unbonded flexible pipes

Abstract

Paper 11

Paper 12

Pipeline inspection data cross-check and tool inspection findings comparison

Abstract

Paper 12