Asset Integrity Management

Pipeline Asset Integrity

Three Dimensions of Shapes
Fourth Dimension of Time

Martin Fingerhut- Applus RTD , Manager of Asset Integrity Engineering Services, USA
Richard McNealy- Applus RTD
Mark Piazza- PRCI, Program Manager

Draft ver 0.1

Content

Introduction of Speakers
Applus RTD
Martin Fingerhut, Manager AIES USA
Richard McNealy, Principal Engineer
Pipeline Research Council International, PRCI
Mark Piazza, Program Manager
Asset Integrity Management Principles
Operational Phase
Pipeline Integrity Management
Role of Technology
Measurement
Integrity Evaluation
Data Management
Emerging
Applications Research Community
PRCI Roadmaps and Pipeline Operator Involvement
Questions
Global Presence, Ability to Deliver

ApplusRTD: Leading provider of Asset Integrity

Management, Inspection and specialist NDT
services
Over 70 years at the forefront of
technological development.
80 offices in 29 countries

Employs around 3000 personnel with experience spanning materials,

inspection engineering and integrity management, pre or in-service
inspection; advanced and conventional NDT.
Supplies own specialist equipment world-wide
Member of PRCI

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PRCI

Pipeline Research Council International

Provides global leadership in collaboratively funded energy
pipeline research that provides safe, reliable, environmentally
conscious, and efficient means of energy delivery.
PIPELINE RESEARCH
Natural Gas Knowledge
Crude Oil & Petroleum Products Technology
Biofuels Deployment & Transfer
CO2 Innovation
Related Facilities

COUNCIL INTERNATIONAL
Forum for Ideas & Opportunities North America
Peer-based Europe
Industry-driven South America
Source of Research Inventory Middle East
Asia
Australia
 PAS 55 Asset Management System Life
Cycle Phases

Focus of Pipeline
Integrity

Design Construction Commissioning Operation Decommissioning

plan engineering tender welder procedure vendor inspection inspection engineering disposal engineering
consulting qualification risk assessment risk assessment
risk analysis
do design for inspection new construction NDT hydro testing (witness) maintenaince phase NDT decom. phase NDT
FEED participation heat treatment leak testing NDT process management check waste composition
radiation protection radiation protection radiation protection radiation protection
data management initiation Filling consultancy
check design review ECA, PLA baseline measurement FFS, plant life assesment enviromental reporting
act review of process prepare written practice comissioning consultancy RBI communication to gov.
SEVESO documentation CBM
RCM
all (process) work package prep. project management work package prep. turnaround management project management
work package prep. as built documentation work package prep. work package prep.
PED certification

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Operation Phase Asset Integrity
Management
Asset Integrity
Is the ability of an asset to perform its required
function effectively and efficiently providing value
through optimum return on capital investment,
whilst safeguarding life and the environment
Piper Alpha - July 1988

Asset Integrity Management

The related management activities ensure that
the people, systems, processes and resources
which deliver integrity, are in place, in use and fit
for purpose over the whole lifecycle of the asset.

Without Asset Integrity plant failure Longford - September 1998

may result in events which affect:
Safety
Environment
Business
Company reputation
BP Texas - 2005
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Scope of AIM Inspection Services

Applus RTD Services:

Engineering Services:
Risk based inspection (RBI)
assessment,
Fitness for service (FFS)
Plant life assessment (PLA)
Materials and corrosion engineering
Development of inspection
strategies
In-Service Inspection
Advanced NDT & Conventional NDT
New Construction, incl. Automated
UT of LNG and other tanks and
Offshore & Onshore Scope
pipelines Vessels and piping
In-service NDT Tanks
Non-intrusive inspection (NII) Pipelines
Subsea equipment
Asset Management System
Certification
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Pipelines and Related Facilities

Issues Unique to Pipelines

Multiple Threats
Visible and Invisible
Corrosion
Environmental Cracking
3rd Party Damage
Loss of Ground Support
Time Dependent Threats
Justify the Future
High Consequence
Public and Environment
Pipeline Integrity Process

DMAIC Cycle
Define
Measure Risk and Threat

Analyze
Define
Improve
Improve
Control Mitigate, Establish
Hydro or
In-line Inspect
Decisions Re-Assess Interval

Improve
Chance being wrong
Measure
Timing ILI
Analyze Predictions
Cost of being right
Resources Integrate & Discovery of
Evaluate:
Goal Decisions Conditions

Failures are Rare ILI Predictions +

Validation= True Performance NDE
Validations
Transmission Pipeline Integrity Elements
Advanced-
Risk Based

Reactive-
Threat Response

Prescription
Levels

Threat and Risk

Evaluate Assessment
Risk Reduction and
Program Effectiveness
& Monitor
Technical Support Market

ILI Vendor Runcom

& Corrective Action

Inspection Market
Return to Service

Hydro Test
CGA: half life or
Crack Sure

Integrity
Justify Six Sigma Assessment
Re-Inspection DMAIC
Intervals
Analyze

Remediation
Mitigation

Applus RTD
NDE Measurements

Applus Kiefner Products

Asset Integrity Management
Transmission Pipeline Application
Applus Kiefner Services

Rehabilitation Market
Common Pipeline Inspection
Technologies

In-Line Inspection (ILI)

Electromagnetic (MFL)
Ultrasonic
Caliper
Direct Examination
Response to ILI
Hydrostatic Test
Addressing ILI Performance

Dig ILI Indications

But recoats vs
repairs cost
resources
cost of
business?
Failures very, very
rare
Improve Adjust
What is left in
ground ? No
Confidence?
Yes
Re-inspection Confidently
Accept ILI

Failures have
Indications,
No Integrity

happened: rare ILI Performance

Threat?

- Exceptional conditions
Repair? Or Recoat?
NDE Considerations

Recoat vs Repair Decisions

In-Ditch; speed is the issue
Laser can be 10X faster than manual RSTRENG grid
Accuracy and Precision
Adequate safety for wide range of accuracy
ILI Validation
Accuracy is important: Consequences
Measurement
Feature Matching for MFL technologies
Because boxes dont always match to metal loss
Because with low filter thresholds boxes might not be
metal loss
ILI Validation Issues

Sample Size
Technologies to gather large, significant samples
In-Ditch NDE Performance (all the errors)
Nil error beneficial
Reveals True ILI error
Digital data allows for accurate correlation
Matching complex corrosion
Sorting out false call metal loss
Managing ILI filters
ILI Response Management
Acceptance of log based on large scale tests
Log rejection; rejection of ILI performance (should be rare)
Is Tool in-spec for what it is designed to see?
Calibration of response based on true ILI tool error
Considers the actual metal loss
Advanced NDE- Addresses the Issues

Minimizes In-Ditch Measurement Errors

Laser Profilometry (LPIT)
AUT Scanners
Better than +/- 2%wt
Digital Source of Large Samples !
Laser Profile Inspection Tool

LPIT
PRCI and EWI
Sponsorship

Launch
Handyscan 3D External Corrosion

Benefits of Handyscan Application for

Corrosion
The hand-held 3D laser scanner--- Handyscan, integrated with Applus RTD Remaining Strength Analysis
software---CorroPro, for in-the-ditch use, and real time burst pressure determination.

The only truly portable, light weight 3D scanner for external corrosion
mapping on pipelines (diameters >/= 4)
Fast and accurate in-the-ditch assessment of external corrosion
ILI Verification, Correlation & Permanent Reference Pieces for Subsequent
ILI Runs- External Corrosion AND Mechanical Damage

Launch
Effect of ML shape on Flux Leakage

Location and Measurement

Error
ILI boxes may not locate or
measure actual ML shape
ILI boxes may not be actual
ML
Magnetic false calls
Matching ILI to In-Ditch Data

Sometimes a better level of understanding is required

ILI location conventions; top-bottom-or center of clusters?
Make up of ILI boxes could help?
Here is where pattern matching can increase understanding.

Why MFL and Corrosion may not

correlate ?
Laser Sure

Depth Correlation
80

70

60
ILI Depth, (%wt)

50

40
Burst Pressure Correlation
30 10000

20 8000
ILI EAA Rstreng, (kPa)

10 6000

0 4000
0 10 20 30 40 50 60 70 80
2000
Laser Validation Depth, (%wt)
0
0 2000 4000 6000 8000 10000

Laser Validation RSTRENG Pburst, (kPa)

Conservatism and Accuracy

Reduced Conservatism associated with more accuracy

does not imply reduced safety
Requires reliable estimates of defect size and corrosion
growth rates
If performance cant support safety
- Adjust the dig response
- Adjust the ILI

* M Rosenfeld PHMSA
Public Meeting June 2009
When Things Are As-Expected

Both ILI Tool and Corrosion; in-spec

Depth: Accept 80% +/- 10% wt, no bias
Nil NDE and Nil Correlation Error (Laser Sure)
Decreased variance in Pburst error
No Need for More Conservative Dig Response
Repair rate will be as good as RSTRENG allows
Pburst Unity
14000

12000

10000
ILI EAA Pburst, kPa

8000
1.25 MAOP

6000
MAOP

4000

1.25 MAOP
MAOP
2000

0
0 2000 4000 6000 8000 10000 12000 14000

Laser Validated RSTRENG Pburst, kPa

So What?...

Effect of True Tool Error on POE (MAOP)

D=20 in, t=.219 in, SMYS=52000 psi, MAOP=820 psi
Higher accuracy ILI assessment sensitive to ILI error
Example of adjustment to response based on error
Understanding of bias and variance basis for action
Maintain Safety
Minimize ILI response cost
Digging and NDE

POE vs ILI Tool Depth Tolerance, Nil Length

Error
ILI Tool Depth Tolerance, +/- %wt
5 10 15 20 25
1.0E+00
1.0E-01
1.0E-02
1.0E-03
1.0E-04
1.0E-05 B31G
1.0E-06
ModB31G
1.0E-07
POE

1.0E-08 RSTRENG
1.0E-09
1.0E-10
1.0E-11
1.0E-12
1.0E-13
1.0E-14
1.0E-15
1.0E-16
Handyscan 3D Mechanical Damage

Handyscan
The Handyscan technology has also
been adapted to characterize
mechanical damage
Dents
Gouges
Handyscan 3D Mechanical Damage

Laser Solution for Deformations and Coincident Damage

Mechanical Damage (MD)
Standard Field Measurements
Strain Analysis based on ASME B31G Appendix R
Data used in ILI performance evaluations
Optimum response schedules
MD solution, with Handyscan 3D

3D comparison in Polyworks
MD solution, with Handyscan 3D

Strain Analysis
For comparison with ILI predicted strain
Most effective ILI response
Dig only where it is needed
Displacement Profile
Strain (Peak strain at 4.65%)

Application qualified under PRCI project MD-1-4 Dent Apex 1.68m

Peak Strain
SCC: Where and When ?????

Predicting the future is hard, especially if it hasnt

happened yet
ILI not perfect, hydro not always possible..
Integrated Data Approach
Applus RTD direct exam technology provides
understanding to ILI or Direct Assessment methods
Applus RTD provides consulting to develop predictive
models based on multiple data streams
SCC Application Research

Application of established NDE technologies

Develop Integrated Technology for Reliable Prediction of Failure
Pressure Due to Stress Corrosion Cracking (SCC)
Prior research demonstrated physical limitations to application of piezo based Time
of Flight Diffraction (ToFD) and other deployable UT techniques for crack sizing
within colonies
Potential for Laser ToFD technology demonstrated by prior research
Facilities Integrity

Risk and Threat Assessment

Defines the correct technology
Pulsed Eddy Current X-ray
Source
Digital
Media

Radiography Digital
X-Ray Detector X-Ray
Tube

Corroded
Area

DR Sensing X-ray Digital

X-rays Media Source Media

Pipe
Corroded Area

INCO Test Pulsed Eddy Current

Pipe
Radiograph

Inspection for Corrosion Corroded

Application on Concrete
Covered Pipe Structure

Under Insulation Area

Digital Radiography
DR Sensing
X-rays Media
Transmitter
Current

Pipe
Receiver Magnetic
Amplifier
Field Corroded Area
Pipe
Radiograph
Analysis of Transmitter
Eddy Current Signal
Sensor
Coils
Receiver

Wall Thickness
Measurements
Sheeting

Insulation

Eddy Current
Steel Wall
UnPiggable Technologies

Deck penetration Inspection of externally Piping through road

piping on offshore insulated pipeline crossings
facility

Long Range UT

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Un-piggable Pigs

Pipeline Inspection Tool

PIT
Tractor Driven
Ultrasonic Tech
Asset Integrity Data Management

More than just inspection data

Asset Data
Risk Based Planning
Quantify Reduction in Risk and Costs
Quantify Economics

Applus RTD Pipeline Integrity Algorithms

Value Proposition

Over Investment Under Investment

Total Cost
COST OR FINANCIAL LOSS

Potential to Potential to
Save Costs Reduce
Consequential
Loss Cost of Failure

Cost of Maintenance

RISK
OPTIMUM
Research Roadmap Example
PRCI Integrated Program for Technology Development
Key:
Red font = US DOT funded
PRCI In-Line Inspection Projects
SCC/cracking

Mechanical Damage Stress Corrosion Cracking

Dual Field MFL (1-1) Mechanical
SCC 3-4
Current Tool Performance Damage
SCC 3-7
(MD 1-2) SCC 3-12
MFL Signal Analysis (MD1-3)
NDE

Weld Fatigue Cracking

Fatigue Cracks on Heavy Wall
Input to Models
Integrated Cleaning &
Gas Risers and Pipeline (SPIM
Inspection Tool (NDE 1-3 )
1-2)

Improved Repair
and Decision
Test Samples for Program PRCI Sample Repository
Making
Create Dent
Detection, Sizing and
+Gouge (MD 4-7) Characterization of SCC and PRCI related in-ditch projects
Other Cracks in Dents in Liquid
Pipelines (SCC 3-4)
SCC 2-8/3-6
SCC 3-5 JENTEK MWM
Create Cracks in Technologies to Detect Fatigue Application of In-the- SCC 3-10 MD 1-4
Dents (SES MD 4-2) Cracks in Heavy Wall SCRs Ditch Tools (NDE-2-2) JENTEK MWM MD 1-5
(SPIM 1-2) MD 1-6
NDE 2-1 Crack
Monitoring IOS SBIR
Opportunities Leveraging PRCI Programs

Leak Detection
Damage Prevention old and new systems (reverse thinking)
Reliability-Based Integrity Management
New materials and construction methods
New Technology for Inspection and Integrity Assurance
Pipeline and Facility Design Abandonment & Cradle to Grave
Emission control and GHG reductions
Measurement and Analytical Improvements

BECOME A MEMBER OF PRCI

PRCI - Some Useful Information

Annual PRCI Research Exchange Meeting

February 7-9, 2012, Phoenix, AZ (USA)
Detailed information and presentations on PRCI
Research Projects
Generating Research Ideas
Open process
Submit ideas through PRCI web site
http://prci.org/index.php/site/idea_submit
2012 Ballot
May 2012 Technical Committee Meeting in Barcelona, Spain
Hosted by Applus RTD
Opportunity for New Member Forum
Summary

Applus RTD have extensive experience in:

Development AIM inspection solutions
Application of integrity management and optimized inspection
strategies.
Providing inspection solutions through provision of effective and
efficient inspection engineering, advanced & conventional NDT &
inspection services
R&D of advanced NDT technologies.
Focus on minimizing inspection on-cost due to plant shutdown,
access, cleaning etc and optimized frequencies
Development of long term alliance relationships with clients
Commitment to research
Local and global resources to provide support
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Call to Action

For more information

Jason Gray- Business Development Applus RTD
USA 832-295-5017
jason.gray@applusrtd.com
Tim Kruger- Business Line Manager- Gmbh
tim.kruger@applusrtd.com
Mark Piazza- PRCI, Inc
USA 678-339-3645
mpiazza@prci.org
Thank You

Questions