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The Role of Inspection During the Lifetime of a Pipeline . Technical Conference: 7 th ASIAN PIPELINE CONFERENCE AND EXHIBITION, 11-12 October 2011 Istana Hotel, Kuala Lumpur, Malaysia Jim COSTAIN Global Leader, Oil & Gas GE MEASUREMENT AND CONTROL SOLUTIONS. Industry Drivers.

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the role of inspection during the lifetime of a pipeline

The Role of Inspection During the Lifetime of a Pipeline

Technical Conference:

7th ASIAN PIPELINE CONFERENCE AND EXHIBITION,

11-12 October 2011

Istana Hotel, Kuala Lumpur, Malaysia

Jim COSTAIN

Global Leader,

Oil & Gas

GE MEASUREMENT AND CONTROL SOLUTIONS

industry drivers
Industry Drivers

Aging Pipeline Infrastructure

Consequences of Pipeline Failure

> 20 Years 62%

11 to 20 Years

22 %

Injury & Loss of Life … Environmental Damage

< 10 Years14%

New 2%

Headlines from Pipeline Failures

Cost of Corrosion

  • Cost of Corrosion (US, 1998) was estimated at a total of $276 billion per year.
  • Corrosion experts estimate that a net of 20 to 25% of that annual cost can be saved by applying currently available corrosion control technologies
  • Global estimates at least 4x the numbers above

Oil Major Is Fined $25 Million for ’06 Spills at Pipelines

By JOHN M. BRODER

Published: May 3, 2011 in the NYTimes

Gas Major fined P24.2 million over pipeline leak

By ELLALYN B. DE VERA

Published: November 23, 2010 in the Manila Buletin

Lost Production.. Repair Costs.. Damaged Public Image

Corrosion Costs in the USA 4% of GDP annually

(Source: USA Department of Transportation)

measurement control solutions high accuracy technologies
Measurement & Control SolutionsHigh accuracy technologies…

Nondestructive Testing

Cutting edge inspection solutions to smartly monitor plant asset health without major disruption

Monitoring assets through the lifecycle

Asset Condition MonitoringSensors, monitors and software to monitor asset integrity

Predictive Maintenance

Software and predictive maintenance strategies & solutions for safe, more efficient operation

Environmental Monitoring

Radiation detection and emissions measurement for cleaner operation

Sensors & Measurement

Instrumentation and systems for validating critical processes and applications in high growth industries

inspection technologies
Inspection Technologies

Remote VisualInspection

Testing Machines

Ultrasonic

Radiography

Eddy Current

Film, Equipment and Chemistry

Digital Radiography(FS, CR, DR)

X-ray Generators

Instruments and Probes

Automated Systems

Video Borescopes

Borescopes

Fiberscopes

PTZ Cameras

Robotic Crawlers

Inspection Services

Rentals

Ultrasonic and X-ray

Standard

Customized

Flaw Detectors

Thickness Gauges

Hardness Testers

System Instrumentation

Transducers

Installed Sensors

Metrology

Data Management Software

Non-contact

Air Foil System

Rhythm Acquire

Rhythm Review

Rhythm Archive

inspection technologies during the manufacturing process
Inspection Technologies During the Manufacturing Process

Depending on the manufacturing process (ERW, SAW) and on the subsequent use of the tube, there are several options where in the process and to what extent non-destructive testing can be applied.

Testing machines are typically operated inline with the manufacturing process and need to be designed according to individual requirements based on flaw detectability and test speed.

Ultrasonic and X-Ray testing

in the SAW process

Ultrasonic testing in the ERW process

saw ultrasonic testing machines
SAW - Ultrasonic testing machines

Weld testing on SAW longitudinally welded tubes(linear transported tubes)

saw ultrasonic testing machines8
SAW – Ultrasonic testing machines

Spirally welded tubes

Strip testing (body and edge) with stationary probes

saw x ray testing machines
SAW - X-Ray testing machines

Weld testing of SAW longitudinally welded tubes

slide11
Weld quality is a critical part of any project in the O&G market whether a new refinery, offshore platform or cross country or subsea pipeline.

GE S&I has a comprehensive portfolio of solutions from the pipe mill to the field. Using state of the art UT and RT technology, GE can provide fit for purpose tools to suit all types of weld examinations.

Weld Inspection

Automated UT

CR for offshore girth welds

usm vision weld inspection solution
USM Vision Weld Inspection Solution

Key Features

Menu guided set-up and inspection to optimize time of inspector capabilities

Meets international codes & standards

Data analysis, reporting, and sharing with GEIT Rhythm

slide14

USM Vision Weld Inspection Solution

Level I or II UT or RT inspector performs inspection

Administrator inputs data

Level III reviews plan

Adminstratorgenerates report and archives data

Level II/III reviews data

Inspection

Plan Creation

Data

Acquisition

Data

Analysis

Reporting

Archive

Rhythm

IPC

PA & TOFD

Rhythm

Reporting

Rhythm

Review

Rhythm

Archive

Probe/Scanner

Cal Blocks

usm vision guided inspection workflow
USM Vision Guided Inspection Workflow

Inspection preparation

UT Expert

Non UT Specialist

Non UT Specialist

UT Inspector

UT Expert (Remote)

slide17

The GE Rightrax systemThe smart way to monitor wall thickness

  • Rightrax Applications in Oil & Gas
  • Upstream, Exploration and Production
    • Offshore Installations
    • Unmanned Offshore Installations
    • FPSO
  • Midstream, Transportation
    • Cross-country pipe lines
  • Downstream, Processing and Refining
    • Refineries
    • Petrochemicals
  • Rightrax is a system that can measure wall thickness continuously by using permanently installed UT transducers.
  • Rightrax consists of two product versions.
    • A low temperature -40°C <120°C / -40°F < 248°Fsystem
    • A high temperature version -20°C<500°C / -4°F < 932°F system
  • Both systems are non intrusive and can be installed on live pipelines
  • Both system installed versions have hazardous area certification
  • Installed without any welding
  • Data can be easily read by Asset Integrity and easily transferable to existing RBI program
system configurations
System configurations
  • 1. PORTABLE
  • For both LT and HT systems
  • Manually operated
  • Data collection in the field
  • Data download to PC or laptop
  • Manual assessment of data
  • ADVANTAGE
  • Lower system cost
  • Flexibility of system use
  • 2. INSTALLED
  • For both LT and HT systems
  • Automatically operated
  • Fixed interval measurements
  • Data storage
  • Manual data collection
  • Manual assessment of data
  • ADVANTAGE
  • System is certified for HAZ use
  • No human intervention for measurements
  • Monitor process related events
  • 3. INTEGRATED
  • For both LT and HT systems
  • Automatically operated
  • Fixed interval measurements
  • Data storage
  • Automatic data analyses
  • Integration with third party systems with data and alarming
  • ADVANTAGE
  • System is certified for HAZ use
  • No human intervention required
  • Monitor process related events
  • System alarming on special events and conditions
upstream case study
Upstream Case Study
  • Concern:
  • Unmanned offshore installations require frequent wall thickness monitoring due to unpredictable sand erosion.
  • 6” & 8” Lines: 6-8mm wall thickness
  • Erosion rates can be up to 4mm / 24 hours
  • Monitoring is required and location is remote
  • Normal Operational Temperature is 80°C
  • Solution:
  • Total of 96 Rightrax M2 sensors on 6 individual platforms
  • M2 sensors wired back to DL2 Datalogger and LD2 in hazardous area
  • LD2 line driver connected to RTU using Modbus interface and VFC contacts
  • Configuration:
  • Measurements made every 8 hours
  • Data analysed on the LD2 line driver
  • Measure to 5mm thickness with VFC dry contact alarm if threshold thickness value is violated
  • Data sent to Onshore Control Room to analyse and monitor riser wall thickness
  • Data by Modbus Via RTU – HMI - PCS
  • Value and cost saving:
  • No bi-weekly mobilization of personnel
  • Monitoring critical process and preventing incidents
  • More operational control (pressure and flow)
  • Less downtime

offshore

onshore

midstream case study
Midstream Case Study
  • Concern:
  • Measure Water, H2S, & CO2 Corrosion on Underground Natural Gas Allocation, Transmission & Distribution Lines
  • Monitor reduction of pipe wall thickness at top, sides, and bottom locations along the pipes
  • Solution:
  • Initially Twelve (12) Measurement Locations
  • Four (4) M2 Sensors per TML
  • 18 Mtr Extension Cable wired back to Data collection post
  • Manual DL2 Datalogger
  • Configuration:
  • Measurements made manually as per customer’s required time frames
  • Data stored on DL2
  • Data analyzed via downloading DL2 to customer’s PC w/ supplied software
  • Value and cost saving:
  • Covered known & suspected corrosion locations
  • Long Design/Performance Life
  • Inexpensive: Met Customer’s Needs
  • Met Political & Regulatory issues/concerns

M2 sensors

Natural Gas Pipeline

slide21

Subsea Direct Radiography

Development Project

subsea direct radiography project
Subsea Direct Radiography Project
  • Corrosion/Erosion
  • ROV or diver deployed
  • Now rated to 1800ft (600m)
  • Planned 9000ft (3000m)
  • All trials completed
  • First inspection Oct 2011
rhythm turning information into intelligence
Rhythm - Turning information into intelligence

Capture, share, analyze, report, and archive digital inspection information

Consistent

Quick Reports

Remote Review

& Analysis

Data Storage &

Enables Trending

Rhythm CR

Rhythm Report

Rhythm Review

Rhythm Archive

Rhythm DR

LAN

LAN

Rhythm Visual

Rhythm UT

Multi-Modality Platform

common rhythm platform
Common Rhythm Platform

Review

DICONDE

“One standard = One platform”

Inspect

Report

Share

Archive