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Specialist tank & pipe inspection services. January 2009 by Alan Ashton. An introduction to a comprehensive storage tank and pipe work inspection service for the Middle East region using technology driven equipment. A unique service using Silverwing MFL and UT expertise as both a

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Presentation Transcript
slide2

An introduction to a comprehensive storage tank and pipe work inspection service for the Middle East regionusing technology driven equipment

slide3
A unique service using Silverwing

MFL and UT expertise as both a

supplier of equipment

and

provider of specialist corrosion

inspection services

for

Storage tanks and associated pipe work

slide7

The Cost Of Corrosion

The American Petroleum Institute calculated that between 1990 and 1996 the annual average remediation and spill costs for 14 petroleum companies was

1.171 BILLION US DOLLARS

slide8

Therefore the API survey shows that the indirect cost of CORROSION for these 14 petroleum companies between 1990 and 1996 was……..1.171 BILLION US DOLLARS per year

The Cost Of Corrosion

storage tanks and corrosion
Storage Tanks and Corrosion

A leaking Storage Can Damage:

  • The Environment
  • PublicHealth
  • Plant Profit Margins
slide10

Corrosion sources

  • Atmospheric
  • Vapour Phase
  • Interface
  • Product side
  • Under insulation or coating
  • Under floor( soil side)
slide12

Vapour Space Corrosion

Occurs in the vapour space of tanks above the level of liquid. Caused by moisture condensing on the inner surfaces due totemperature changes

occurs at the interface between the liquid product and gas in the vapour space
Occurs at the interface between the liquidproduct and gas in the vapour space

Interface Corrosion

Usually only a problem if liquid levels remain the same over long periods of time

slide15

Corrosion Under Insulation

Caused by water trapped under insulation

or coating

slide16

Under floor Corrosion

  • Occurs at under (soil) side of tank floors
  • Usually associated with moisture contact.
  • Sub soil characteristics
  • Impossible to detect visually
slide18

Classification of Corrosion types

  • Pitting
  • Conical
  • Pipe
  • Lake
  • Crevice
  • Galvanic
  • Biological
  • Preferential
  • Stray( interference) current
slide19

Example Lake & Pit type corrosion

Classification of Corrosion types

Underside of floor cut-outs showing Under floor corrosion

Enlarged view lake type

slide20

Example Biological corrosion

Classification of Corrosion types

Underside of floor cut-outs showing Under floor corrosion

slide21

WHAT DO WE DO ?

Silverwing offers a comprehensive

tank and pipe inspection service

utilising our highly experienced

service team covering both in service

and out of service inspection.

in service inspection
IN SERVICE INSPECTION
  • In service Acoustic Emission screening to

identify potential defects and prioritise the order

in which tanks should be taken out of service for

a detailed Maintenance inspection

  • Thermography
  • API 653 surveys
  • Tank shell and roof corrosion measurement
  • Laser alignment
in service inspection1
IN SERVICE INSPECTION

Acoustic Emission - Signal

slide24

IN SERVICE INSPECTION

  • Technique based on detection of high frequency vibrations (AE signals)
  • Signals detected by AE sensors (50 kHz -1MHz)
  • High speed data-acquisition unit collects data
slide25

IN SERVICE INSPECTION

  • Data-analysis for characterising
  • Corrosion / cracks / leaks
  • Extremely sensitive technique:0.5 mm pencil point break detectable at 70 m from sensor

Acoustic Emission – Basic theory

slide26

IN SERVICE INSPECTION

  • Sensors are placed on tank wall
  • Approx. 1 metre above bottom
  • No. of sensors controlled by tank diameter normally one or two rows

Acoustic Emission – Basic theory

slide27

IN SERVICE INSPECTION

Acoustic Emission - Instrumentation

Sensors

Data-acquisition unit

slide28

IN SERVICE INSPECTION

Examples of acoustic emission report on Storage tank floor plates

slide29

IN SERVICE INSPECTION

Thermography Theory

Spectral range

slide30

e

T

b

T

s

camera

IN SERVICE INSPECTION

Thermography Theory

What is detected by the camera?

T

- object temperature

s

T

- backgroundtemperature

b

e

- emission factor

slide31

IN SERVICE INSPECTION

  • Thermography Comparisons
slide32

20.6

18.6

16.6

14.6

12.6

10.6

8.6

Temperature °C

6.6

4.6

2.6

0

5

10

15

20

25

0.6

Distance

[Metres]

IN SERVICE INSPECTION

  • Thermography sensitivity

Temperature profile along side wall

slide33

OUT OF SERVICE INSPECTION

Out of service MFL floor scanning

using the latest generation

FloormapVS2i mapping system

and

HandScan unit for inaccessible areas

slide34

FloormapVS2i

OUT OF SERVICE INSPECTION

Computerized MFL tank floor inspection

Corrosion detection and sizing with advanced reporting software

FloormapVS2i

slide35

FloormapVS2i

OUT OF SERVICE INSPECTION

The new FloormapVS2i

is the most operator friendly, comprehensive tank floor inspection system in the world.

slide36

OUT OF SERVICE INSPECTION

  • Hall effect sensors are used to detect the flux leakage path to ensure that the MFL unit secures precise data rather than averaging data when using electro magnetic

Unique User Benefits of the Floormap VS2i

FloormapVS Mark 2

slide37

OUT OF SERVICE INSPECTION

  • Eliminate the variable scanning speed of manually operated equipment which can result in different amplitude signal strength for the same discontinuity depending on the speed by utilising a fixed speed DC motor as well as eliminate the requirements contained in Appendix G of API 653.

Unique User Benefits of the Floormap VS2i

FloormapVS Mark 2

slide38

OUT OF SERVICE INSPECTION

  • Permanent sintered neodymium iron boron magnets which:
    • Eliminate the need to have a 110 v supply for MFL scanning inside the tank
    • Eliminates any heavy duty power cables
    • Reduced time to complete inspection by as much as 25%
    • guarantee uniform strength across the magnet
    • are mechanically the strongest

Unique User Benefits of the Floormap VS2i

FloormapVS Mark 2

slide39

OUT OF SERVICE INSPECTION

  • Improved defect detection and sizing over previous designs being able to detect any discontinuity within 3 mm on an 8 m long plate.
  • Annular plate scanning capability on certain tank designs.

Unique User Benefits of the Floormap VS2i

FloormapVS Mark 2

slide40

OUT OF SERVICE INSPECTION

  • Automatic CAD drawing of tank floor which ensures that:
    • there is a patch plate design capability including bill of material schedule with total Material requirements - a MAJOR time and overhead saving for any organisation.

Unique User Benefits of the Floormap VS2i

FloormapVS Mark 2

slide41

OUT OF SERVICE INSPECTION

  • the operator and client has a very clear report on which areas where not automatically scanned due to being inaccessible
  • reduces shutdown cost by eliminating the need to deploy a third party inspector to witness the scanning.

Unique User Benefits of the Floormap VS2i

FloormapVS Mark 2

slide42

OUT OF SERVICE INSPECTION

  • Real time as well as quicker dataacquisition and analysis giving the MFL operator immediate access to plate and track data as well as the ability to repeat selected scans which may be suspect.

Unique User Benefits of the Floormap VS2i

FloormapVS Mark 2

slide43

OUT OF SERVICE INSPECTION

  • Combined defect profiling and amplitude analysis using a bespoke software programme to automatically cross check the data by using amplitude analysis to refine the data and ensure that

the final reported data is easily identifiable as being either pipe, conical or lake type by the trained operator and more accurate than that secured by manual UT.

Unique User Benefits of the Floormap VS2i

FloormapVS Mark 2

slide44

OUT OF SERVICE INSPECTION

Unique User Benefits of the Floormap VS2i

  • Full finger print reporting by data addition
  • to support trend management and including:
  • MFL HandScan results
  • Digital photos
  • Visual comments
  • Manual pit gauge and UT reports comments
  • Auto UT C scan reports , if performed by Silverwing
  • Vacuum box reports, if performed by Silverwing
  • MPI inspection report. if performed by Silverwing
  • USB port for data transfer to facilitate 24 hour working if required.

FloormapVS Mark 2

slide45

OUT OF SERVICE INSPECTION

Unique User Benefits of the Floormap VS 2i

  • Multiple license capability for read only version users such that the data maybe be shared and viewed at various local and worldwide locations within a terminal operator organisation.
  • Base line data acquisition comparison reports to assist with future asset life assessment by being able to superimpose previously collected FM data for the same tank and identify the change in the tank floor between the different inspection dates.
  • Multi Language capability.

FloormapVS Mark 2

slide46

FloormapVS2i

OUT OF SERVICE INSPECTION

All new data acquisition and analysis

software has been developed for the FloormapVS2i on-board computer.

slide47

FloormapVS2i

OUT OF SERVICE INSPECTION

The New FloormapVS2i contains

significant improvements in terms

of defect positioning, defect sizing and

ease of use.

slide48

FloormapVS2i

OUT OF SERVICE INSPECTION

A new encoder system has been

developed which is electronically

calibrated to each individual scanner,

giving accuracy to within 30mm

on an 8 metre track length.

slide49

FloormapVS2i

OUT OF SERVICE INSPECTION

The ruggedized on-board SM 1000 data acquisition computer uses touch screen technology for ease of use within the hostile storage tank environment

slide50

FloormapVS2i

OUT OF SERVICE INSPECTION

Latest generation rare

earth magnets achieve localised magnetic

saturation of the

mild steel tank

floor plates

floormapvs2i
FloormapVS2i

OUT OF SERVICE INSPECTION

Magnetic saturation comparisons

FM 2000 - 1.40 Telsa

FVMVS2i - 1.90 Telsa

An increase in 35%

floormapvs2i1
FloormapVS2i

OUT OF SERVICE INSPECTION

  • Improved top surface detection such that defects not identified

by UT

slide53

FloormapVS2i

OUT OF SERVICE INSPECTION

slide54

FloormapVS2i

OUT OF SERVICE INSPECTION

Our custom designed data acquisition software not only captures all the MFL signals but analyses and displays the location and severity of the corrosion in real time

slide55

FloormapVS2i

OUT OF SERVICE INSPECTION

The off-line reporting software automatically produces a CAD drawing of the tank floor with the discontinuities being positioned to within 30mm accuracy.

slide56

FloormapVS2i

OUT OF SERVICE INSPECTION

Individual dis-continuities view

slide57

FloormapVS2i

OUT OF SERVICE INSPECTION

Maximum dis-continuity per track

slide58

FloormapVS2i

OUT OF SERVICE INSPECTION

Appurtenances and notes can be added

slide59

FloormapVS2i

OUT OF SERVICE INSPECTION

Plate view showing discontinuities

slide60

FloormapVS2i

OUT OF SERVICE INSPECTION

Link digital images to plate

slide61

FloormapVS2i

OUT OF SERVICE INSPECTION

Add patch plates and automatically generate of full bill of material

slide62

FloormapVS2i

OUT OF SERVICE INSPECTION

Tank Plate statistics of dis-continuities

floormapvs2i2
FloormapVS2i

OUT OF SERVICE INSPECTION

Summary of plate discontinuities

slide64

FloormapVS2i

OUT OF SERVICE INSPECTION

Easy to use, customizable report configuration

slide65

FloormapVS2i

OUT OF SERVICE INSPECTION

Produce a hard copy of the report

slide66

FloormapVS2i

OUT OF SERVICE INSPECTION

Produce a hard copy of the report

slide67

FloormapVS2i

OUT OF SERVICE INSPECTION

Produce a hard copy of the report

slide68

MFL HandScan unit

OUT OF SERVICE INSPECTION

To ensure that the tank floor inspection can be optimised in the areas where the Floormap unit cannot access Silverwing always utilises the Hand scan unit in lieu of spot thickness checking

Handscan

slide69

AUTO UT CRAWLER units

IN & OUT OF SERVICE INSPECTION

Remote access UTcorrosion surveys on tank walls using the Scorpion B scan UT remote access crawler, or ScanmapVS or the RMS C-scan imaging system for inspection of large surface areasand vessels

slide70

Tank floor weld Leak testing by 20in Hg vacuum

box technique

OUT OF SERVICE INSPECTION

The vacuum box leak detection system is used for effective weld integrity evaluation and results can be added to the FloormapVS reporting software

Vacuum Box

laser alignment
Laser alignment

IN & OUT OF SERVICE INSPECTION

  • To ensure that we are able to provides a complete tank inspection services to the client Silverwing also provide a laser alignment service using Sokia 530 unit to cover
    • Vertical( plumbness) alignment
    • Circumferential concentricity
    • Tank settlement
labour hire training

Consultancy

Labour hire & training
  • API 653 tank recertification
  • Training & familiarisation
  • courses

Hire of specialist API

and UT engineers

consultancy
Consultancy

- Typical Tank Inspection Strategy

slide74
We are convinced that our

experienced engineers coupled

with highly accurate, advanced

equipment and software makes

the Silverwing Tank Inspection

service unbeatable value for money in the gaol to minimise the risk form unforeseen environmental catastrophes

slide75
In addition we also offer to supply:
  • Silverwing Middle East also supplies tank floor and tank wall inspection equipment and vacuum box testing systems for direct purchase
  • Calibration and recertification of Silverwing equipment to meet ISO 9000
  • Silverwing ME offers a full after sales service
  • Training and familiarisation courses for all current
  • Silverwing equipment
slide76

MFL Manual PipeScan

IN & OUT OF SERVICE INSPECTION

PipeScan is an easy to use, cost effective, portable, magnetic flux leakage inspection system for the

detection of random internal as well as PIT type corrosion in non insulated pipe work systems

Pipescan

slide77
Fixed, Adjustable and Circumferential scan heads

MFL Manual PipeScan

IN & OUT OF SERVICE INSPECTION

Pipescan

slide78

MFL Manual PipeScan

IN & OUT OF SERVICE INSPECTION

Both in service and out of service surveys can be carried out since MFL is not affected by product flowing through the pipe

slide79

MFL Manual PipeScan

IN & OUT OF SERVICE INSPECTION

Corrosion is easily detected above

predetermined levels normally requested by the

Client or plant operator and is automatically

displayed as both a visual and audible alarm

Electronic Module

Pipescan

slide80

MFL Manual PipeScan

Pipescan Electronic module

1On/off switch

2 Battery state indicator

3 Alarm threshold control

4 Visual warning indicators

5 Audible alarm

6 Audible alarm/ Remote earphone switch

7 Plate thickness selector switch

8 Sensor cable input sockets

9 Remote earphone socket

slide81

MFL Manual PipeScan

MFL PipeScan is both a user friendly as well as cost effective system for determining the plant integrity when combined with A-scan or B –Scan or C scan Ultrasonic monitoring of corrosion techniques

slide82

MFL Manual PipeScan

TECHNICAL CHARACTERISTICS

  • Magnetic flux leakage measurements
  • via18 hall effect sensors
  • Pipe sizes Nominal bore 48 mm to 2400
  • mm diameter with wall thicknesses up to
  • 19 mm including bonded coating of up to
  • 6 mm.
  • Manually operated, typically at speeds of
  • 0.5m/second.
slide83

MFL Manual PipeScan

TECHNICAL CHARACTERISTICS

  • Battery charge life normally 10 hours
  • continuous working
  • Restricted space limit of 120 mm
  • Operating weight including 12v battery of electronic module -18 kg
slide84

MFL Manual PipeScan

TECHNICAL CHARACTERISTICS

  • Sensitivity may be adjusted to suit a particular operator criteria
    • Pitting 30% for pipe systems 6 mm wall

thickness

    • Pitting 40% for pipe systems 12 mm wall

thickness

    • Pitting 50% for pipe systems 19 mm wall thickness
slide85

MFL Manual PipeScan

TECHNICAL CHARACTERISTICS – PS 100B

PS100B SCANNING HEAD

Specifications

Type Fixed Longitudinal

Pipe Diameter 48mm-54mm

Sensor Gap 2mm (4 shims)

slide86

MFL Manual PipeScan

TECHNICAL CHARACTERISTICS-PS 100F

PS100F Scanning Head

Specifications

Type Fixed Longitudinal

Pipe Diameter 63mm-75mm

Sensor Gap 1mm (2 shims)

slide87

MFL Manual PipeScan

TECHNICAL CHARACTERISTICS- PS 100C

PS100C SCANNING HEAD

Specifications

Type Fixed Longitudinal

Pipe Diameter 75mm-90mm

Sensor Gap 1mm (2 shims)

slide88

MFL Manual PipeScan

TECHNICAL CHARACTERISTICS - PS 500

PS500 SCANNING HEAD

Specifications

Type Adjustable Longitudinal

Pipe Diameter 100mm-200mm

Sensor Gap 1mm (2 shims)

slide89

MFL Manual PipeScan

TECHNICAL CHARACTERISTICS- PS 200

PS200 SCANNING HEAD

Specifications

Type Adjustable Longitudinal

Pipe Diameter 150mm-300mm

Sensor Gap 1mm (2 shims)

slide90

MFL Manual PipeScan

TECHNICAL CHARACTERISTICS – PS 1200

PS1200 SCANNING HEAD

Specifications

Type Adjustable Longitudinal

Pipe Diameter 300mm-2400mm

Sensor Gap 1mm (2 shims)

slide91

MFL Manual PipeScan

TECHNICAL CHARACTERISTICS - PS 300

PS300 SCANNING HEAD

Specifications

Type Fixed Circumferential

Pipe Diameter 300mm - 2400mm

Sensor Gap 1mm (2 shims)

slide92

MFL Manual PipeScan

TECHNICAL CHARACTERISTICS- PS 400

PS400 SCANNING HEAD

Specifications

Type Fixed Circumferential

Pipe Diameter 150mm-300mm

Sensor Gap 1mm (2 shims)

slide93

MFL Manual PipeScan

TYPICAL APPLICATIONS

  • Overhead pipe work
  • corridors
  • Offshore flow lines and
  • jetty lines
slide94

MFL Manual PipeScan

TYPICAL APPLICATIONS

  • Pipe line corridors
  • Crossed pipe work
slide95

MFL Manual PipeScan

TYPICAL APPLICATIONS

  • Transfer pipe work systems
slide96

Alternative Pipe Scanning or Screening

Long range ultrasonic screening of

Pipe work using the latest generation

G3 system from Guided Ultrasonic Limited

slide97

THE FUTURE

Why not plan a visit to our stand at the StocExpo 09 Exhibition in Hyatt Regency on 20th and 21st January 2009 where you will be able to see the equipment operational