PRACTICAL SOLUTIONS FOR UN-SCRAPEABLE PIPELINE … · Tee fittings could result in a tool becoming...
Transcript of PRACTICAL SOLUTIONS FOR UN-SCRAPEABLE PIPELINE … · Tee fittings could result in a tool becoming...
Frank J. Mueller
7th MENDT· Manama Bahrain · September 16th, 2015
PRACTICAL SOLUTIONS FOR UN-SCRAPEABLE
PIPELINE INSPECTIONS
Slide 2
CONTENTS
Introduction
Managing Complexity
Preparation
Practical Solutions
Low Flow Low Pressure
Multi Diameter
Bi-Di Application
Loading Lines
Flow Lines with 3 way valve
Conclusion
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Slide 3
INTRODUCTION
Some pipelines deteriorate slowly, and in certain cases pipeline life has been
reliably targeted at 70 years or more. Other pipelines have been built which
have exhausted their useful life after 1 year of operation.
The industry has identified suitable ways to inspect most trunk and main lines
and to a certain extent some non-piggable pipelines. However, a large
number of pipelines remain a challenge and often cannot be inspected in its
entirety.
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Slide 4
INTRODUCTION
Standard Inline Inspection activities are applied such as:
MFL
UT
EMAT
To identify the integrity of the pipeline. Although the technologies would be suitable
for non standard and challenging lines the tools and set up is often not suitable.
AFD
SIC / ECD
GEO
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Slide 5
EVOLUTION OF ILI
Active Speed Control
for high gas velocities
Low Flow - Low Pressure Tools
become available
Heavy Wall Tools
become available.Gas velocities up to
1.5 m/s become possible.Extreme inspection length
(1173 km in a single run)
50 km in a single run
becomes possible.
Tools become
1.5D capable.Ultra compact MFL tools
for bi-directional operation
Self-Propelled MFL tool
Pressures up to
300 bar possible.
Multi-Diameter Tools
become available.
Dual-Diameter Tools
become available.
1965
Un-piggable?
“Unpiggable” - a function of time and market need
2014
Piggable
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015
Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Slide 6
CONSTRAINTS
Constraint Description
Tight radius Bends
Tight radius bends could result in a tool becoming lodged.
While specifications vary significantly by tool type and service provider (vendor) not all service providers have high
resolution tools that can safely negotiate bends < 3D.
Unbarred Tees
Tee fittings could result in a tool becoming wedged in a pipeline if the intersecting line is of sufficient diameter –
especially, if product exists in the main pipeline at that point.
While specifications vary significantly by tool type, unbarred tees in the 6 o‟clock position are of particular concern, as
are off-takes that are greater than 50% of the main pipeline diameter.
Diameter Restrictions /
Transitions
Any restriction in the diameter of the pipeline could result in a scraper becoming lodged, or significantly damaged.
Diameter restrictions can be a result of both planned and unplanned. Planned items can include dual diameter
pipelines, heavy-wall pipe sections. Unplanned items can range from simple temperature/pressure probes left in the
pipe prior to a scraper run all the way to pipeline deformation, such as buckling, which is an integrity concern in itself.
Eccentric reducers at launch/receive can cause tool damage depending on orientation and the abruptness of the
transition.
Lack of Launch/ Receive
Facilities
Launch and receive facilities are necessary for launching scraper to ensure that an appropriate means for access into a
high(er) pressure line is available.
In some cases “temporary” (i.e., moveable) facilities can be used – although this becomes increasingly difficult as pipe
diameters increase.
In some cases, factors such as line configuration or lack of physical space can limit an operator‟s ability to install
launchers/receiver.
Valves
Full-bore valves are crucial for safe passage of inspection tools as valves with restrictions (e.g., plug valves) can
damage tools, or in some cases trap a tool.
Typically, full-bore ball valves are best suited for scraping operations, but other valves types and configurations may
also be acceptable depending on the specifics of the tool.
Inability to Control
Process condition
Smart inspection tools must operate within a specific speed envelope in order to acquire good quality data. The ability
to control the speed of the flow is critical for the entire length of the inspection.
Debris / Residual
Deposits
Internal surface condition and surface preparation are playing a key role in the success or failure of a ILI survey.
Particularly UT tools are very much affected by debris and residual deposits in a pipeline
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Slide 7
CONSTRAINS
Main Reasons for Challenging Pipelines:
• Pipeline Access
• Mechanical Pipeline Design
• Pipeline Operating Conditions
Main Challenges are:
• Access
• Inspection
• Cleanliness
• Information
A pipeline is generally defined “Unscrapable, or Challenging” if inspection
applying current Technologies and Procedures is considered not feasible.
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Slide 8
WISH LIST
Even the best engineering approach is unlikely able to invent a
multi purpose tool which could address all challenging pipelines
A toolbox considering individual applications is more likely to succeed
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Slide 9
MANAGING COMPLEXITY
Pipeline
Modification ?
Tool
Modification ?
New
Development
Questionnaire
Standard Tool
New Application
Tailored solutions based
on tool box concept
Time & Effort
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Slide 10
THE BROADER CHALLENGE
• Approximately 40% of the worlds pipelines is currently unpiggable
• One of the most significant challenges with difficult to inspect pipelines is the
unique combination of the specific factors that make each of the pipelines an
inspection challenge
• Every challenging pipeline is a challenge on its own
• Building a new tool for every pipeline is not feasible
• So therefore many commercial technology developers hesitate to invest in
developing solutions
• At ROSEN – independent of investors banks and share holders - we look
ahead and develop solutions based on a tool box approach
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Slide 11
CONSIDERATIONS
External
Internal
Gas
LiquidDent
SCC
Corrosion
The highest resolution should be applied inspecting the line, it is critical to select
an accurate measurement technology that provides the most accurate
information
Influences
Boundary conditions
Operational conditions
Medium Expected threats
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Slide 12
CONSIDERATIONS
• Uni-directional
• Bi-directional
• Low friction
• Ultra compact
• Multi – diameter
• Robotic
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Slide 13
CONSIDERATIONS
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
• Medium propelled
• Nitrogen/ Air
• Batching
• Crawlers
• Cable operated
Slide 14
CONSIDERATIONS
• Hot tapping
• Pig launch valves
• Temporary or permanent launcher
• Spool piece
• Only from one end
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Slide 15
PIPELINE PREPARATION
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
As with conventional pipeline inspection, a sufficiently clean pipeline is a pre-
requisite for a successful inspection of a challenging pipeline. Being classified as
„challenging‟ often means that also no maintenance scraping has been carried out
and the cleanliness of the pipeline is unknown.
Cleaning
• Review
• Analyze
• Compare
• Identify
• Monitor
• Establish
Slide 16
PIPELINE PREPARATION
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Progressive approach: At any given time the integrity of the operation must take precedence over the
desire to complete the program in a period as short as possible. The only way to achieve this is by
applying a progressive approach. The program is split into well-defined stages and only after a
cleaning scraper achieves an agreed result the next level commences.
Redundancy: For each cleaning phase a sufficient number of cleaning tools must be available. The
cost for mobilizing and then not using a cleaning tool is marginal in comparison to cost of standby and
delays caused by mobilization of additional equipment.
Knowledge: The more historical information on the pipeline, the operational conditions and previous
cleaning and inspection runs, the more appropriate the selection of the cleaning scrapers. For the vast
majority of today's pipeline this information is readily available, but it must be submitted to and
sufficiently considered by the operator.
Experience: A good understanding on the cleaning capabilities of each type of scraper within any
given environment is absolutely essential in order to define critical acceptance criteria for each phase
of the cleaning program.
Communication: The acceptance criteria for each phase must be defined in a way that the entire
cleaning program can be safely executed by even lesser experienced operators. The flow of
information must be designed in a way that a continuous operation can be guaranteed in a 24/7
environment. At the same time all critical decisions must be discussed and agreed on senior level.
Reliability: The cleaning tools must be manufactured to high standard to achieve the best possible
results within the given time frame.
Considerations
Slide 17
PIPELINE PREPARATION
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Monitoring
Time based recording of differential pressure for two consecutive runs
• Temperature
• Pressure
• Differential Pressure
• Acceleration (x,y,z)
• Inclination
• Rotation
Slide 18
PRACTICAL SOLUTIONS
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Slide 19
LOW FLOW - LOW PRESSURE LINES
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Reason for Tool-Stop & Speed Excursions
• Wall Thickness Changes
• Weld Penetration
• Debris (Dust, Condensate)
• Bends
• Rough internal surface
• Dents
Influencing factors
• Length
• Diameter
• Pressure and flow
Pressure
Slide 20
LOW FLOW - LOW PRESSURE LINES
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Typical ILI run behavior of MFL ILI in LFLP gas linesTool S
pee
d [m
/s]
5 m/s
1 m/s
Distance [km]
17.2 m/s
Slide 21
LOW FLOW - LOW PRESSURE LINES
0
5
10
15
20
25
30
35
40
0
100
200
300
400
500
600
8 10 12 14 16 18 20 22 24
Pre
ssu
e [
ba
r]
Pre
ssu
re [
psi
]
Diameter [inch]
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Tool selection guideline for gas pipelines
Operating condition in low flow and low pressure pipelines especially so in gas
lines has always been a challenge to run ILI tools. Larger diameter can operate in
lower pressure then small diameter tools
Slide 22
LOW FLOW - LOW PRESSURE LINES
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Requirements
• Minimized and constant Friction
To minimize differential pressure because of
reduced absolute pressure
Constant friction reduces speed variations
• Minimized Difference Static/Dynamic Friction
To reduce the acceleration after tool stops
• Optimized Sealing
Zero bypass
Focus on tool design
• Cup design / configuration
• Magnetizer
• Length & weight12” LFLP MFL ILI
Slide 23
LOW FLOW - LOW PRESSURE LINES
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
5 m/s
1 m/s
3.25 m/s
Improving ILI run behavior of MFL ILI in LFLP gas linesTool S
pee
d [m
/s]
Distance [km]
Sample:
10” gas line 10.5km long pressure 9 bar
Slide 24
MULTI DIAMETER PIPELINES
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
• Dual-diameter (i.e. 8/10”)
• Multi-diameter pipelines (i.e. 18-20-24”)
• Multiple internal changes
• Aged Lines
• Limited or no maintenance scraping
• Ineffective scraping
Pump test loop for 32"/42" multi-diameter tools
Multi Diameter pipelines are difficult to inspect because of their significant variations
in internal diameter.
Slide 25
MULTI DIAMETER PIPELINES
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Over the past years a number multi-diameter tools have been developed, built
and successfully deployed in a multitude of projects.
Sample MFL 14/18” ILI:
ID min passage 11.22” (285 mm)
Bend Capability 14” 3D (11.6”) (295 mm)
18” 1.5D
Operational Range: 11.25” – 18” (286 mm – 457mm)
37.4 % ID Reduction
Magnetic Saturation
Max wt (18”) 0.94” (24 mm)
Max wt (14”) 1.38” (35 mm)
(min ID) / OD = 0.63
Slide 26
MULTI DIAMETER PIPELINES
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Pump test
Slide 27
MULTI DIAMETER PIPELINES
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Pump test
simulated Valve Bore
simulated Valve Bore
Barred Tee
(10” offtake)
Barred Tee
(12” offtake)
simulated Flex Joint
Check Valve
simulated
Valve Bore
Reducer (18” to 14”)
Wye (18”)simulated Connector
Reducer (20” to 14”)
Reducer
(24” to 18”)
18”14”
Slide 28
BI-DIRECTIONAL APPLICATION
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Inspection of pipelines with only access from one end of the line can be
addressed using Bi-Di tools. Loading lines are an good example as they from the
onshore facility, such as a tank farm, to an offshore buoy or to a pipeline end
manifold.
24" BiDi MFL tool
Before the run After the run
Slide 29
BI-DIRECTIONAL APPLICATION
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Most loading lines cannot be addressed with a conventional pigging approach.
Typical challenges:
• Single access
• No traps
• Subsea end
• Sedimentation of heavy components (paraffin, asphaltine) due to stagnant flow
• No cleaning/ inspection history
Storage
& pump
SPM
PLEM
Flexible
hoses
Slide 30
BI-DIRECTIONAL APPLICATION
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Pig valves are 3 way ball valves that are used in flow lines that require frequent
maintenance pigging. Inspection in such flow lines is a significant challenge.
Slide 31
BI-DIRECTIONAL APPLICATION
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Tool equipped with electronics and
battery inside magnetizer body
High resolution MFL sensor - no
compromise in inspection performance
Back 2 back
bend passage
Bend capability 1.5 D
Single body set up for
Pig valve applications
Symmetrical design for
Bi-Directional operation
Slide 32
BI-DIRECTIONAL APPLICATION
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
wellhead
dunes
Launcher
Valve
Receiver
valve
H
e
a
d
e
r
Slide 33
ROBOTIC SOLUTIONS
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Addressing pipelines with no flow, limited access mostly require self-propelled
inspection solution. Elements to consider:
Inspection technology: MFL / UT / EC / EMAT
Carrier: Bi-directional / low friction
Propulsion: Multi Trotter Crawler
Power: Onboard accumulators
Slide 34
ROBOTIC SOLUTIONS
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
Robotic Survey System (RRS)
Passage of high ID reduction
Tight bend passing capacity
Multi-diameter capacity
Vertical climb
Self-adapting tractor drive and sensor unit in one body
Intelligent and redundant on-board mission control
Single entry to the pipeline
Capable of safely negotiating 1.5D bends
Bi-directional operation
Autonomic (only batteries) or tethered (external cable with communication)
operation possible
Reliable in various media (water, gas, crude oil and dual-phase products)
Stand-alone sensor carriers (Eddy Current, UT, EMAT, etc.)
Slide 35
CONCLUSION
Practical Solutions for un-scrapable pipeline inspection - Frank J. Mueller © ROSEN Group · 12-Sep-2015Copyright © ROSEN Group 2015 - No part of this document may be reproduced or disclosed to any other party without the prior permission of ROSEN
The inspection of challenging pipelines must be seen in the
context of integrity management programs. The risk
(cost/safety) balanced selection of an inspection and
rehabilitation method allows optimization of economic aspects
without compromising safety concerns.
The evolutional improvement and extension of in-line inspection
methods is reducing the number of un-scrapable pipelines
world-wide. The great variety of the different inspection options
can be structured and managed by risk based selection
approach and the corresponding modules in integrity software
packages like ROAIMS.
The technology for robotic inspection tools has been advanced.
However, the necessity for access-points and a status of
cleanliness in combination with the high operational cost
require a well prepared cost benefit analysis. Once identified,
robotic inspection help to reduce significantly the probability of
failure of a subsection in accordance with the term to
strengthen the weakest link of a chain.
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