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How Do We (Actually) Know Our Quality Is Improving?
Justin R. Papp, William H. Forbes, Matthew A. R. Yarmuch
Proc. ASME. IPC2018, Volume 2: Pipeline Safety Management Systems; Project Management, Design, Construction, and Environmental Issues; Strain Based Design; Risk and Reliability; Northern Offshore and Production Pipelines, V002T01A006, September 24–28, 2018
Paper No: IPC2018-78407
DOI: https://doi.org/10.1115/IPC2018-78407
We have all dealt with performance metrics in the pipeline industry. How do we measure operational excellence? Are we prioritizing the right corrective actions? Are our existing metrics fair and driving the right behaviors? Will they recognize success and actually show us and our clients that we are improving? This paper describes how Enbridge Major Projects measures and knows our Quality is improving; how we prioritize, focus, and monitor Quality improvement. Using our roadmap, your organization can transform existing data streams from anecdotal to well established facts that produce actionable results and drive business objectives. To reach this outcome, Enbridge Major Projects quickly matured our Quality Culture by leveraging our strong Safety Culture and habits. On our journey to meaningful overall Quality metrics, Enbridge built a foundation through non-punitive incident reporting using incident resolution tools and a Cost of Quality model. Cost of Quality models can be designed and executed in a variety of ways. This paper will focus on applying a model specifically suited for pipeline construction and operational activities. Key topics to be addressed include: • basic common principles of an overall Cost of Quality model, • various data collection methods to suit the model's design, and • how a Documented Defects Quality cost model allows Enbridge to identify, prioritize, and monitor Quality improvements focused on preventing recurrence and occurrence of Quality issues. Examples will be provided for common pipeline applications, including valves, pipe, and other commodities and services. This approach has enabled Enbridge Major Projects to prioritize improvement actions and meet business objectives. Applying a Cost of Quality model will enhance your operational excellence and greater adoption would provide the foundation for industry-wide Quality performance metrics that will recognize success and validate that Quality is improving in the pipeline industry.
Topics: Corrective actions, Data collection, Design, Performance, Pipeline construction, Pipelines, Pipes, Resolution (Optics), Safety, Valves
EMAT As a Basis for a Comprehensive System Wide Crack Management Program
David Katz, Steve Potts, Thomas Beuker, Jörg Grillenberger, Ralf Weber
Proc. ASME. IPC2018, Volume 1: Pipeline and Facilities Integrity, V001T03A009, September 24–28, 2018
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 introduced over the last decade, which is based on an electromagnetic acoustic transducer (EMAT). Meanwhile, a high resolution implementation of the technology has been utilized on in-line inspection (ILI) tools from 10″ to 48″ in diameter. Williams Gas Pipelines have utilized this inspection technology successfully on several pipelines, therefore an overview will be given about this experience. Secondly a case study will be presented, in which a post hydrostatic test ILI service was used to gain additional relevant safety and integrity information from the ILI inspection and to better understand the actual capabilities of a hydrostatic test. The approach taken is in accordance with API 1163 and in consideration of API 1176. As part of this approach the performance of the ILI tool was confirmed based on a set of full scale tests conducted at the PRCI ILI test facility. The results were used to increase the statistical confidence in the capabilities of the technology.
Topics: Acoustics, American Petroleum Institute, Cracking (Materials), Fracture (Materials), Fracture (Process), Hydrostatic testing, Inspection, Pipelines, Resolution (Optics), Safety
Threshold Geometrical Dimensions of Stage II Cracks Versus Required Resolution of Crack-Detection Techniques
Weixing Chen, Jiaxi Zhao, Karina Chevil, Erwin Gamboa, Bersi Alvarado
Environmental-assisted cracks in pipeline steels usually undergo the following three sequential stages prior to the failure: • Stage 1 – crack initiation and early stage crack growth, in which cracks initiate at imperfections but grow slowly depth-wise with time. Crack length may be seen to increase either because of merging with new small cracks in the vicinity of an existing crack or faster crack growth at the crack tip. Some cracks pose little threat to pipeline steel integrity if they remain dormant. • Stage 2 – Increased crack growth rate where crack growth can be dictated by mechanical driving forces and crack growth rate increases with time. • Stage 3 – The final stage of crack growth where crack growth rate is very high. Typical crack management programs mitigate cracks prior to entering Stage III. It is of great importance that pipeline steels with Stage II cracks are detected, monitored, and managed to ensure operational pipeline integrity. Although a range of crack in-line inspection and detection techniques with varied detection limits are available, it is not clear how their detection limits match the threshold geometrical dimensions of Stage 2-cracks. This investigation is aimed to define critical geometrical dimensions of cracks that are considered to be Stage 2 cracks. The determination of critical geometrical dimensions of Stage 2 cracks was made with a consideration of a wide range of situations including pipeline operating conditions, susceptible environments for crack growth, metallurgical, fabrication and construction conditions of pipeline steels. A comparison of the threshold geometrical dimensions of Stage 2 cracks with the crack detection limits of modern crack inspection and detection techniques are made at the end of the paper.
Topics: Crack detection, Dimensions, Fracture (Materials), Resolution (Optics), Pipelines, Steel, Inspection, Construction, Failure, Manufacturing
Do You Have Wrinkles? A Strain- and Stress-Based Approach for the Assessment of Wrinkles Reported by In-Line Inspection
Chris Holliday, Dominic Wynne, Alasdair Clyne, Andrew Wilde
Improvements in in-line inspection (ILI) technology have led to an increase in the probability of detection and ability to characterize geometric features such as wrinkles, the assessment of which was introduced into CSA Z662, "Oil & Gas Pipeline Systems", in the 2015 version. The CSA wrinkle acceptance limits are based predominantly on fatigue assessment criteria; part of the assessment procedure is confirmation that wrinkles are free from associated cracking. In practice, this often restricts the assessment to wrinkles that have already been investigated in-field and where the absence of cracking has been confirmed by non-destructive examination (NDE). This paper describes the assessment of a series of wrinkles that exceeded the CSA height criteria, reported by ILI within field bends in an insulated liquid pipeline. Strain-based assessment, supported by in-field investigations, was used to investigate the likelihood of associated cracking. Utilizing the high resolution caliper ILI tool data, three-dimensional profiles of the wrinkles were generated. Previous work that compared "tool-measured" with "field-measured" profiles identified that caliper tool measurements can underestimate the true depth and profile of wrinkles, this effect is more pronounced for particularly sharp wrinkles. The wrinkle profiles were therefore adjusted based on the historical field-tool correlation. Strain profiles were then calculated using the guidance within ASME B31.8 Appendix R. It was identified that the majority of the wrinkles exceeded the 6% strain limit commonly applied to dents. One field bend containing multiple wrinkles was subsequently excavated in order to gather detailed profile information and to inspect for cracking. Upon excavation, the wrinkles were not visually apparent, but their presence was confirmed following removal of the insulating coating. Profile information was subsequently recorded using laser scanning technology. In addition, NDE confirmed the absence of cracking, despite the fact that the majority of wrinkles were associated with strain levels that exceeded the CSA limiting value, 6%. The laser scan data were then compared with the adjusted "tool-measured" profiles. It was observed that the adjusted measurements based on the ILI tool data were conservative, and in some cases excessively so. The caliper measurements were optimized by identifying a factor that could be systematically applied to the "tool-measured" wrinkle profiles, which provided consistency with the profiles measured by the laser scan, thereby improving the accuracy of the dimensions and strain estimation of the remaining (non-excavated) wrinkles. Finally, a S-N based fatigue assessment was performed using operational cyclic pressure data and estimates of the stress concentration factors associated with the wrinkles. The calculated fatigue lives exceeded the expected operational life of the pipeline.
Topics: Inspection, Stress, Cracking (Materials), Fracture (Process), Fatigue, Lasers, Nondestructive evaluation, Pipelines, Coating processes, Coatings
An Authoritative Comparison of Remaining Life Assessments for Pipeline Dents
Rhett Dotson, Chris Holliday, Luis Torres, Damien Hagan
A significant amount of effort has been expended in the area of advancing pipeline dent remaining life assessment methods beginning in the late 1980s and extending to the current day. Initial research efforts were primarily empirical in nature while more recent research efforts have incorporated finite element modelling. Coupled with advancements in assessment techniques, the capabilities of advanced in-line inspection (ILI) tools have increased to a point where they can provide consistent, reliable information that is suitable for dent assessments. As a result of these advancements in assessment models and ILI tools, operators can now perform remaining life assessments using ILI data, and a multitude of remaining life assessment models are available, including solutions from the European Pipeline Research Group (EPRG), Pipeline Research Council International (PRCI), American Petroleum Institute (API), and finite-element based approaches. In addition to these remaining life assessments, many operators routinely perform strain-based assessments based on guidance from ASME B31.8. To date, there have been few studies comparing the various assessment methods on large numbers of dents, and as a result, significant questions persist as to the conservatism inherent in each method. In addition, the EPRG and PRCI methods are largely based on full-scale testing and finite-element models performed with idealized indenter shapes while actual pipeline dents typically exhibit complex shapes and interactions between multiple dents. Each model also has limitations and advantages that are discussed in this paper, such as ease of use and how pipeline geometry and weld association are considered. This paper provides a robust comparison of selected dent assessment methodologies on 220 actual dents from a 24-inch pipeline with depths ranging from 0.6–4.5% OD, and 32 dents from a 30-inch line with depths ranging from 1–2.5% OD. The assessment includes both top and bottom of line dents and investigates the influence of restraint on remaining life. The results presented in the paper are based on high-resolution ILI caliper data collected during two in-line inspections. Furthermore, the paper provides statistical comparisons between strain and remaining life methodologies and also between the various remaining life assessments. The paper also provides a comparison of the restraint parameter from the PRCI model with calculated stress concentration factors from finite-element models. The paper provides a first of its kind comparison of the various methods and discusses how the work may be extended to other pipe diameters and wall thicknesses.
Topics: Pipelines, Remaining life assessment, American Petroleum Institute, Finite element analysis, Finite element model, Inspection, Shapes, Geometry, Modeling, Pipes
In-Line Inspection in Lieu of Hydrostatic Testing for Low Frequency Electric Resistance Welded Pipe
Matt Krieg, J. Bruce Nestleroth, Thomas Hennig, Harvey Haines
Hydrostatic testing is a costly, operationally-impactful method of verifying seam integrity in low frequency electric resistance welded (LF-ERW) line pipe. Pipeline operators seek an alternative seam assessment method that provides a sufficiently conservative integrity assessment without the potentially negative impacts of hydrostatic testing. As in-line inspection (ILI) and field nondestructive evaluation (NDE) improve, pipelines that have been historically hydrostatic tested can now use ILI to ensure operational integrity. The improved ILI technology assessed in this work is an enhanced ultrasonic crack ILI tool with higher circumferential resolution and finer axial sample intervals. Magnetic ILI data from previous assessments is used to assist in anomaly identification. In addition to utilizing NDE technologies such as phased array, the emerging full matrix capture (FMC) imaging method that quantifies the size, position, and orientation of seam weld anomalies was examined. This paper discusses the work performed to ensure the efficacy of the improved ILI and NDE methods to accurately detect and quantify all anomalies that could possibly fail a hydrostatic test. An early step in the process was removing three sections of pipe from service for technology calibration and assessment. Each spool was examined with ILI technology in a pump-through facility, inspected using many NDE methods and then destructively tested. These results were communicated to ILI analysts and used to calibrate and improve the interpretation of the inspection results. Then the pipeline was inspected as part of the scheduled integrity assessment. Using field evaluation of anomalies detected by ILI, pipes were selected for removal from service to examine destructively. This paper presents the inspection and destructive testing results in addition to prognosis for the use of the ILI in lieu of hydrostatic testing for LF-ERW pipe.
Topics: Electrical resistance, Hydrostatic testing, Inspection, Pipes, Nondestructive evaluation, Pipelines, Calibration, Fracture (Materials), Hydrostatics, Imaging
An ILI Based Program That Prevents Reoccurrence of Post ILI Failures Seen in Industry
Terry Huang, Shahani Kariyawasam
The pipeline industry has been using Inline Inspection (ILI) since the 1970s. High resolution tools have been available for inspecting corrosion from about the 1980s and related ILI-based programs have been evolving. In this study incident rate data from the last 30 to 40 years of experience was examined and trended. Corrosion related incident rates have reduced where ILI programs have been implemented. Significant changes in programs have shown related incident reductions or positive trends. Throughout this time there have been a few post-ILI incidents and by taking a closer look at these incidents and learning from the findings the ILI-based assessments and programs were further improved. In this study, all of the post-ILI corrosion related ruptures on the TransCanada system have been closely examined and trended. The effects of program changes and related changes to performance indicators have been examined. Some significant industry failures, where data is publicly available, have also been examined. These failures have been analyzed and trended to understand significant commonalities between these failures. Data was analyzed with the intention of learning from them and applying this learning to avoid similar failures in the future. By understanding the uncertainties, technology limitations, and limits of applicability as well as the types of programs used and where these have not identified probable failures practical solutions were derived. All of the failures have been examined (as allowed by the data available) to find approaches which would have proactively identified these events, so that similar events can be avoided in the future. ILI tools generate a wealth of information and appropriate use of this information has shown to be effective in managing pipelines. However, it is also important to understand the limitations of technologies, learn from the failures, and acknowledge uncertainties so that undesirable events can be avoided.
Topics: Failure, Corrosion, Pipelines, Uncertainty, Inspection, Resolution (Optics), Rupture
Use of Advanced Processing Techniques of High Density LiDAR in Place of Survey for Cost and Schedule Reductions on Early Phase Pipeline Projects: Capital Project Results
Joseph T. Hlady, David Parker
Proc. ASME. IPC2016, Volume 2: Pipeline Safety Management Systems; Project Management, Design, Construction and Environmental Issues; Strain Based Design; Risk and Reliability; Northern Offshore and Production Pipelines, V002T02A013, September 26–30, 2016
In the early phases of a pipeline project, the lack of data available for routing results in multiple routes being considered and interactions with land owners with only a general route. As a consequence, multiple survey programs are undertaken only to collect data that often is not being used, or site revisits are required to collect additional survey data. Repeated visits by survey crews to the field results in considerable cost and schedule delay to the project. A project was undertaken to reduce these costs and schedule impacts by replacing the need for survey work during FEED by utilizing remote sensing data and Artificial Intelligence (AI). This paper outlines the methods for collection of High Density (HD) LiDAR and high resolution imagery and then using AI to automatically identify all above ground features. This technique has proven to provide data of sufficient accuracy and completeness to conduct Pre-FEED and FEED level routing and engineering of a pipeline project. When survey is required, it is only to collect below ground features and to collect or verify data in very specific detail. Additionally, when required for legal or engineering reasons, survey work can be conducted more efficiently by providing the crews with a field database of the features already captured and means for updating the database with the data they collect or verify.
Topics: Density, Pipelines, Databases, Artificial intelligence, Delays, Resolution (Optics)
Enhancing Pipeline Project Management With Refined Rock Excavation Forecasting
Jeffrey R. Keaton, Luther H. Boudra, Eleanor L. Huggins
Accurate rock-excavation forecasting is one of the geotechnical risk factors that challenge successful management of cross-country pipeline projects. Pipeline construction personnel with local experience typically estimate rock excavation requirements for economic feasibility, permitting, and contracts. Where the excavation is paid on a "classified" basis, construction bid and contract documents typically call for excavation of "ditch" rock to be paid per lineal foot, whereas "area" or right-of-way (ROW) grading rock is paid per cubic yard. This paper briefly reviews the desktop procedure for estimating rock excavation quantities presented at IPC2012 and describes refinements to the procedure that expand its utility for pipeline project managers and planners. Input for the desktop study consists of digital GIS files of topography, geology, soil survey, pipeline alignment, and construction ROW layout and width. Publically available topographic data commonly has a horizontal resolution of 10-m; therefore, the pipeline centerline is subdivided into 10-m-long segments, the endpoints of which are used to summarize the data and perform calculations. Profiles of elevation, maximum ground slope, apparent ground slope across the ROW perpendicular to segment alignment (sidehill slope), and the relative sidehill slope direction are plotted for visual reference. A virtual geologic field reconnaissance along the alignment is performed using Google Earth Pro to supplement digital geology and soil survey data. Bedrock type is interpreted for general ease of excavation (granite versus shale) and soil survey map units are used to identify shallow cemented zones or bedrock that form the basis for an overall rock excavation index factor, which is expressed in terms of estimated mean and standard deviation of depth to rock and rock-like material. Rock factors vary based on the range of pipe size and ground conditions for a particular pipeline project or segment. Rock Factor 0 on a recent project corresponded to a mean-minus-one standard deviation (−1σ) depth to rock that was below pipeline depth, whereas Rock Factor 3 corresponded to a −1σ rock depth that was above pipeline depth. Refined rock excavation calculations consider equipment parameters (boom reach, track offset), trench configuration parameters (working pad width, bench offset, two-tone geometry), centerline distance to adjacent pipelines, and direction of lay, as well as pipe diameter and minimum cover depth. Desktop rock excavation results can be further refined by field examination and seismic refraction surveys to check depth to blast rock in trench excavations which is interpreted to be seismic velocities >1,220 to 1,370 m/s. Construction records of actual blasting details are needed to further improve the rock excavation model.
Topics: Pipelines, Project management, Rocks, Construction, Soil, Blasting, Ditches, Geometry, Geotechnical risk, Pipe sizes
Pipeline Integrity Reliability Analysis Levels
Sherif Hassanien, Len Leblanc, Javier Cuervo, Karmun Cheng
Reliability engineering science is a mature discipline that has been used extensively in industries such as aviation, nuclear energy, automobiles, and structures. The application of reliability principles (especially structural reliability) in oil and gas transmission pipelines is still an active area of development. The advent of high resolution in-line inspections tools (ILI) facilitates a formal application/utilization of reliability methods in pipeline integrity in order to safely manage deformation, metal loss, and crack threats. At the same time, the massive amount of ILI data, their associated uncertainties, and the availability/accuracy of failure prediction models present a challenge for operators to effectively implement the use of reliability analysis to check the safety of integrity programs within available timeframes. On the other hand, approximate reliability techniques may affect the analysis in terms of both accuracy and precision. In this paper, a Pipeline Integrity Reliability Analysis (PIRA) approach is presented where the sophistication of the reliability analysis is staged into three levels: PIRA levels I, II and III. The three PIRA levels correspond to different representations of integrity uncertainties, uses of available validated/calibrated data, uses of statistical models for operating pressure and resistance random variables, implementation of reliability methods, and consideration of failure modes. Moreover, PIRA levels allow for improved integration of reliability analysis with the existing timelines/stages of traditional integrity programs, such that integrity data are updated as the integrity program progresses. The proposed integrity reliability approach allows for the delivery of safety checks leveraging all types of information available at any given point in time. In addition, the approach provides a full understanding of the strengths and weaknesses of each PIRA level. Pipeline corrosion case studies are provided herein to illustrate how the PIRA Levels can be applied to integrity programs.
Topics: Event history analysis, Pipeline integrity, Reliability, Pipelines, Safety, Uncertainty, Accuracy and precision, Automobiles, Aviation, Corrosion
Failure Along Spiral Welds in Gas Pipeline
Saleh Al-Sulaiman, Shabbir Safri, Abdul Salam, Chi Lee
Proc. ASME. IPC2016, Volume 1: Pipelines and Facilities Integrity, V001T03A001, September 26–30, 2016
A 16 km. long, 18" Gas pipeline (HP055) was in service to transport High Pressure Gas from an oil gathering center in West Kuwait (WK) area since 2001. The Pipeline carried wet sour gas. It was inspected in 2008 using high resolution MFL-ILI tool. No significant corrosion was found. In late 2012, a leak developed in the pipeline. The leak was due to a crack along a spiral weld on the bottom. Inspection during repairs revealed severe internal pitting on the bottom. The pipeline continued to leak several times in the next year, eventually resulting in decommissioning of the pipeline. Another ILI could not be carried out due to operational constraints and frequent leaks. The Pipeline was critical in the operation of the oil gathering center, and the loss of it severally affected the gas/oil export target and the flaring reduction commitment. An internal failure investigation was inconclusive, though indicating possibility of sulfide stress cracking. The failure investigation work was then entrusted to TWI, UK. A failed section of the pipeline was sent to their facilities and various tests including Chemical analysis, tensile test, residual stress measurement, SSC/HIC test, microstructure analysis, and analysis of corrosion products were carried out. The outcome of the tests and conclusion was very surprising. This paper describes in detail the leaks, inspection of leak locations, and the failure investigation findings and conclusions.
Topics: Failure, Pipelines, Welded joints, Leakage, Corrosion, Inspection, Stress, Cracking (Materials), Fracture (Materials), Fracture (Process)
Graded EMAT Performance Specification Validated in Blind Test
Munendra Tomar, Toby Fore, Marc Baumeister, Chris Yoxall, Thomas Beuker
The management of Stress Corrosion Cracking (SCC) represents one of the challenges for pipeline operating companies with pipelines potentially susceptible to SCC. In order to help better support the management of SCC, a graded performance specification for the high-resolution Electro-Magnetic Acoustical Transducer (EMAT) In-Line Inspection (ILI) technology is derived which provides higher levels of confidence for detection of crack-field anomalies with critical dimensions. This paper presents the process used to derive the graded performance values for the EMAT ILI technology with regard to SCC. The process covers the Probability of Detection (POD) and Probability of Identification (POI). A blind test was carried out to derive the graded performance specification. Test data set was compiled comprising EMAT data for several joints containing relevant anomalies and neighboring joints, some containing additional shallow SCC. These joints had been dug based on EMAT ILI data and all of the joints were evaluated with 360 degree Non-Destructive Examination (NDE) followed by destructive testing. For each target joint with relevant anomalies to be assessed, four additional joints were added in random order to generate a realistic density and distribution of anomalies. Furthermore, pipe joints with non-crack like anomalies, as well as pipe joints with mixed populations were included in the blind test data set to ensure a realistic feature population and to assess POI without side effects of a weighed feature population inside set of composed ILI data. The data set was then evaluated by multiple analysts and result from each analyst were evaluated and utilized to derive the POD and POI values for the graded specification. In addition, the full process of data analysis including team lead review was carried out for one of the analysts for comparison to the individual analyst results. Anomaly dimensions were compared against the true population to derive the POD and POI values. Furthermore, length and depth sizing performance was assessed.
Topics: Acoustics, Density, Dimensions, Fracture (Materials), Inspection, Nondestructive evaluation, Pipe joints, Pipelines, Probability, Resolution (Optics)
A Different Approach to High Resolution CP Evaluation
Len J. Krissa, David M. Williams, Dennis C. Janda
Assessing the effectiveness of Cathodic Protection (CP) in multiple pipeline corridors can be challenging. Close interval potential (CIS or CIPS) above ground CP surveys rely on interruption of all current sources that affect a particular pipeline and can be especially problematic in multi-pipe corridors involving several operators. Multi-pipe corridors can be very congested and complicated with numerous pipeline crossings and bonds. These circumstances can lead to difficulties in locating and ensuring the above ground survey is being conducted over the pipeline of interest. Inappropriate decisions surrounding the actual integrity of a particular pipeline have been made based on conventional pipe to soil surveys. The use of inline cathodic protection current measurement tools can eliminate a number of errors associated with above ground potential assessment techniques in multiple pipeline corridors and provide more accurate integrity data. CP ILI inspections can conclusively identify undocumented electrical connections to other structures on pipelines in such congested corridors. Active, unbeknownst bonds/connections will cause significant errors in CIS/CIPS data if not properly addressed during data acquisition. Additionally, information collected through the CIS technique is generalized since it is the average gradient being measured from all influencing adjacent lines. Information from an inline cathodic protection current measurement tool is specific to only the pipeline being inspected and therefore eliminates this uncertainty. This paper outlines an alternative approach to above ground close interval survey for assessing CP performance using inline inspection technology.
Topics: Cathodic protection, Data acquisition, Errors, Inspection, Pipelines, Pipes, Resolution (Optics), Soil, Uncertainty
Detection of Crack-Related Features Within Dented Pipe Using Electromagnetic Acoustic Transduction (EMAT) Technology
Luis Torres, Geoff Vignal, Kaitlyn Korol, Jeffrey Sutherland, Stephan Tappert
Mechanical damage has been identified as a significant integrity threat within the Oil & Gas pipeline industry. In addition to deformation, associated secondary pipeline damage may also consist of coating removal, metal removal and cold working of the underlying metal that may result in cracking within the dented area. Detection of cracks within dented areas of the pipe using conventional Ultrasonic Technology (UT) and Magnetic Flux Leakage (MFL) In-line Inspection (ILI) technologies has been of limited success due to the variety of possible feature expressions, sensor design and arrangements, and the related complexity within the underlying physics for detection and characterization. Previous studies have shown the feasibility of Electro Magnetic Acoustic Transduction (EMAT) technology for detecting and characterizing crack related indications within dents on liquid pipelines. This study expands upon experimental investigations using pull through ILI tests on manufactured dents where machined linear indications (notches) were introduced into the dents. In this paper, the performance of EMAT technology for detection and characterization of crack related features in liquids pipelines under real operating conditions is presented. EMAT data were combined with high resolution caliper data, ultrasonic crack inspection data and dent strain assessment data, to demonstrate the EMAT capabilities to enhance pipeline integrity management of dents. Results of field non-destructive examinations are compared to EMAT predicted values to assess the performance of this technology. This study presents a supplementary method of detecting and mitigating coincidental crack related features with dents on liquids pipelines, further enhancing the safety and improving the integrity management of pipelines.
Topics: Acoustics, Fracture (Materials), Pipes, Pipelines, Damage, Inspection, Coating processes, Coatings, Crack detection, Cracking (Materials)
Evaluating Dents With Metal Loss Using Finite Element Analysis
Justin Gossard, Joseph Bratton, David Kemp, Shane Finneran, Steven J. Polasik
Dents created by third party mechanical damage are a severe integrity threat to onshore and offshore transmission pipelines. This type of damage is often associated with metal loss, which can be introduced during the initiation of a dent or develop as a result of the presence of a dent and associated coating damage. Once a dent has been found to be associated with metal loss through excavation, there is little guidance to determine the serviceability of the anomaly. In this study, dents with associated metal loss due to corrosion examined in the field are evaluated to determine the contribution of the interacting dent and metal loss features to the associated burst pressure of the feature. Twenty dents with metal loss flaws were identified through an ILI survey while in service to capture dimensions of the dent and metal loss features. Each site was excavated and measured using a laser scanner. The laser scanner produced 3D imaging with sufficient resolution of both the dent and metal loss areas as a 3D surface mesh. The 3D surface mesh was transformed into a 3D solid mesh and analyzed using a finite element analysis software package in order to determine a predicted internal pressure that would cause failure. A subsequent statistical assessment was performed to analyze the relationship between the ILI measurements and the predicted burst pressure resulting from finite element analysis of each dent with metal loss feature. Statistical analyses were used to evaluate the prediction capabilities of burst pressures of dent with metal loss features identified through ILI, prior to excavation and direct examination.
Topics: Finite element analysis, Metals, Damage, Pressure, Lasers, Coating processes, Coatings, Computer software, Corrosion, Dimensions
Pipeline Operator Perspective in Use of Hydrostatic Testing as an Integrity Management Tool
M. M. Hilger, B. C. Mittelstadt, M. Piazza, P. H. Vieth
Regulation in the United States mandating the use of pressure testing as an assessment tool for the construction and commissioning of pipelines was initiated in 1970. Prior to regulation, however, pressure testing was being applied within the pipeline industry to provide confidence in the operational integrity of pipeline systems. Additional assessment technologies and processes including high resolution in-line inspection continue to be developed and further enhanced; however pressure testing remains a valuable and acceptable tool in the management of pipeline integrity. Current applications include quality verification of original construction practices, integrity assessment of existing pipelines, and verification of material yield strength when key records may be missing or incomplete. It is recognized that extensive hydrostatic testing knowledge exists today in the form of API Recommended Practices, ASME code documents, the body of work of industry consultants, regulatory language and other resources. A key element to implementing the current industry standards is a pipeline operator perspective in practical application on selection of hydrostatic testing as an assessment tool and the subsequent technical design of a hydrostatic test program in order to achieve integrity management goals. This paper discusses hydrostatic testing in the context of selection as an integrity management tool, development of risk-balanced objectives for a hydrostatic test program, and understanding the limitations and potential detrimental effects of hydrostatic testing. This paper summarizes key considerations in guidelines published in 2016 that were developed through a Pipeline Research Council International (PRCI) project. While written to be applicable to all hydrostatic testing, this work is a key element of the multi-year PRCI Electric Resistance Welded (ERW) and Longitudinal Seam Pipe Program which began in 2011 and was formed to comprehensively study and develop strategies for management of factors that contribute to seam failures.
Topics: Hydrostatic testing, Pipelines, Pressure testing, Construction, American Petroleum Institute, ASME Standards, Design, Electrical resistance, Engineering standards, Failure
Integrated Process- and Quality Control to Secure the Production of Slabs for Plates for Line Pipe Application
Matthias Weinberg, Heike Meuser
Proc. ASME. IPC2016, Volume 3: Operations, Monitoring and Maintenance; Materials and Joining, V003T05A019, September 26–30, 2016
For safety reasons, the demands made on line pipe steels have been continuously increasing in recent years. The focus is on the steels' mechanical, weldability and toughness properties, in particular. In addition to this typical pattern of increasing demands, it is also observable that customers increasingly require an integrated process and quality control system, from the steel-making process right through to ultimate plate production. Awareness of the potentials available in the production of the steel and of the plate, and their interaction in process improvement, is an essential factor in the meeting of such demands for comprehensive process control. Both steelmaking plant and rolling-mill processes are increasingly being automated via the incorporation of sophisticated control and instrumentation technology. This creates optimum conditions for precise adjustment of these processes on the criteria of product quality. The methods of process adjustment using the latest quality-evaluation tools, such as SILENOS ( S teel I nclusion L evel E valuation by N umerical O ptical S ystems) and THEMiS ( T esting for He terogeneous Mi croinclusions and S egregation) are examined here. SILENOS is a new procedure for the assessment of steel cleanliness in which particle diameters of above 20 micron are analysed using computer-tomographic images. A special CNC milling machine, a high-resolution scanner and a laser spectrometer examine the layers of metal by removing a large number of 10 μm layers in order to obtain a statistically correct evaluation. An automated procedure determines the concentration, size, geometry and chemical composition of the particles. THEMiS was developed for assessment of the quality of the centre zone of slabs. Centre segregation in slabs is monitored and non-metallic inclusions evaluated simultaneously. A large number of spark-spectrometric analyses are performed perpendicular to the centreline segregation for this purpose. The classical spectrometric analyses and individual sparks are evaluated. This permits precise description of centre segregation by measurement, and also assessment of non-metallic inclusions of between 1 and 10 μm in the centre zone. The cleanliness and quality of the centre zone can then be described with very great accuracy and a new confidence level. These specific measuring instruments are used for control of the steel-making processes at HKM (Hüttenwerke Krupp Mannnesmann) and at SMGB (Salzgitter Mannesmann Grobblech) in order to accommodate end-customers' requirements and are directly correlated to production data and can be used for a product improvement. This paper's topic is the evaluation of an integrated improvement and quality assurance process extending from the very start of steel production, and including the interlinking of the properties of the cast slabs and the ultimate outcome in the form of the final plate. The benefits for the end customer and milestones along this evaluation route are examined and discussed.
Topics: Pipes, Plates (structures), Quality control, Slabs, Steel, Iron and steel making, Particulate matter, Computers, Fracture toughness, Geometry
Oil Pipeline Standoff Leak Detection: A Novel Approach for Airborne Remote Detection of Small Leaks
Jean-François Gravel, Martin Allard, François Babin, François Chateauneuf, Eric Bergeron
While natural gas pipelines already benefit from airborne, remote detection of leaks [1, 2], oil pipeline leak detection has been for a long time reliant on SCADA systems limited in their capability to detect very small leaks, and/or visual inspection of the right of way (line flyers, pipeline employees or members of the public). This paper presents a novel and complementary way of detecting small leaks (i.e. sensitivity of 0.1 L/minute, 1 barrel/day) of oil (crude or refined products) using an optical detection system mounted on an airborne platform (UAV, plane or helicopter). The scope of this paper is based on the requirements provided by TransCanada, namely sensitivity (herein referred as LOD — Limit of Detection) and accuracy (herein referred as spatial resolution) as similar to their description in API 1130, while the topic of reliability is addressed in our noted concerns on the false alarms that may be generated in Infrared-DiAL based systems due to soil reflectivity. Robustness, as described in API 1130, was out of scope. Keeping in mind the requirement of airborne operation, three different approaches for the detection of leaks along long pipeline ROWs were studied. Infrared Differential Absorption lidar (IR-DiAL), UltraViolet Raman lidar (UV-Raman lidar) and UltraViolet Laser-Induced Fluorescence lidar (UV-LIF lidar) have been tested in realistic conditions. In the first round of tests, laboratory spectral measurements of vapors in a closed cell were performed. In the second round of tests, the breadboards were placed in a mobile laboratory and the light beams aimed at a large open at 40 to 50 meters and reflected off a sand target. Finally, the mobile laboratory with the breadboards was installed at ∼40 meters from a leak simulator. The leak simulator was made by using a large sand container in which petroleum products were leaked. Intermediate scale leak simulator tests showed that it is clearly a challenge to correlate a measured concentration to an actual leak size. Tests have also shown that there is a strong concentration gradient in the air above a leak. This indicates that a better overall detection performance should be obtained with a measurement using the air next to the ground, and that it is feasible to detect a leak of less than 1 barrel/day. UV-Raman tests performed in the outdoors suggested a Limit Of Detection (LOD) of the system below 1 500 ppm-m when detecting all hydrocarbons. Because of the hardware that would be needed to lower this detection limit, results suggest abandoning the Raman technique for remote leak detection from an airborne platform. IR-DiAL showed the best sensitivity for the detection of hydrocarbons (< 1 ppm-m of LOD). However the effective LOD will be reduced because of the soil spectral reflectance variations that may lead to a high false alarm rate for concentrations of hydrocarbons lower than 235 ppm-m. The UV-absorption approach was also briefly tested, suggesting a LOD for benzene of between 1.5 and 2.5 ppm-m. The UV absorption of benzene is not affected by ground spectral reflectance variations. This is an approach that will be investigated further.
Topics: Leakage, Pipelines, Ultraviolet radiation, Absorption, Reflectance, American Petroleum Institute, Benzene, Sands, Soil, Containers
Integrating Geophysical and Geotechnical Engineering Methods for Assessment of Pipeline Geohazards
Alastair McClymont, Erin Ernst, Paul Bauman, Nicholas Payne
Because pipelines can cover extensive distances through diverse terrain, they are subject to various geohazards, including slope failure and earthquake damage, which can have costly environmental and monetary impacts over their designed operational lifetime. Here, we show how geophysical investigative techniques can be used to complement other geotechnical investigation methods to provide a detailed understanding of site geology to best inform geohazard assessments. We pay particular attention to how multiple geophysical methods can be used to obtain spatially continuous measurements of subsurface physical properties, and layer and structural geometries. The geophysical data can then be used to either interpolate or extrapolate geotechnical engineering properties between and away from boreholes and excavations, or optimize the locations of subsequent boreholes or excavations. To demonstrate the utility of our integrated approach of incorporating geophysical methods to geohazard assessments, two case studies are presented. The first case study shows how electrical resistivity tomography (ERT), seismic refraction tomography (SRT) and multichannel analysis of surface wave (MASW) datasets are used to constrain the thickness and extent of potentially sensitive glaciomarine clay layers that are subject to slope instability and structural failure along a proposed pipeline route near Kitimat, British Columbia (BC). A second case study describes how high-resolution ground-penetrating radar (GPR) and seismic reflection surveys are used to locate and characterize fault strands that may cause future ground deformation at a proposed pipeline crossing of the Tintina/Rocky Mountain Trench fault in northeastern BC.
Topics: Geotechnology, Pipelines, Damage, Deformation, Earthquakes, Electrical resistivity, Failure, Radar, Resolution (Optics), Seismic reflection surveying
Application of Higher-Order TVD Resolution for Investigation of Transients Problems in Natural Gas Pipelines
Sarafa O. Ibraheem, Michael A. Adewumi
Proc. ASME. IPC1996, Volume 2: Design, Construction, and Operation Innovations; Compression and Pump Technology; SCADA, Automation, and Measurement; System Simulation; Geotechnical and Environmental, 1167-1173, June 9–13, 1996
Paper No: IPC1996-1928
DOI: https://doi.org/10.1115/IPC1996-1928
A higher-order numerical procedure is applied to simulate typical transient phenomena in natural gas transportation. Reliable modeling and prediction of transients features in transmission pipelines are desirable for optimal control of gas deliverability, design and implementation of active controls, and modeling of operational behavior of network peripheral equipment (e.g., chokes, valves, compressors, etc.). As an alternative to the Method of Characteristics (MOC) that is widely used presently, a higher-order Total Variation Diminishing (TVD) method is used to model some transient problems. This, class of methods has the capability to capture fine-scale phenomena and provides a better resolution of frontal discontinuities. In this study, the TVD method is utilized in conjunction with upwind methods. Also, in order to ensure a stable time-stepping scheme over a wide range of Courant-Friedrich-Lewy (CFL) number, a special Runge-Kutta method is employed as the base solution algorithm to integrate the highly non-linear, hyperbolic equations which govern the transportation of natural gas in pipelines. The overall procedure is stable, robust and accurate when applied to solve practical problems with simulated pressure waves.
Topics: Natural gas distribution, Resolution (Optics), Transients (Dynamics), Modeling, Natural gas, Pipelines, Transportation systems, Algorithms, Compressors, Design