12
Results you can work with! Reporting, Data Visualization, Integrity Services
Results you can work with!
Reporting, Data Visualization, Integrity Services
K.038-en.v0
209/2
012
LineExplorer
A short introduction
High pressure pipelines constitute a highly efficient and safe means to transport large quantities of oil, product or gas over large dis-tances. Although designed, constructed and operated with greatest care, pipelines and their integrity are constantly under threat external and internal damage can occur. In-line inspection has proven itself to be an effective and efficient instrument within the overall mainte-nance process in ensuring pipeline integrity, operational efficiency, protection of the environment and statutory compliance.The LineExplorer range of advanced in-line inspection tools designed and operated by NDT Systems & Services GmbH & Co. KG applies the precision of ultrasound technology in order to detect, size and locate metal loss and crack features in the pipe wall with unsurpassed accuracy and reliability.Major advantages of ultrasound technology are: directquantitativewallthicknessmeasurementhighestlevelofaccuracyhighestlevelofconfidencecapableofdetectingandsizingmetallossandcrackfeaturesdataqualityideallysuitedforintegrityassessmentandfitness-for- purpose studies
The LineExplorer range of inspection tools is based on a modular design philosophy, including the easy mechanical adaptation to all required pipeline diameters, currently ranging from 6 to 56 for metal loss and crack inspection. This modular approach is also applied to the electronic design of the tools, allowing basic mod-ules to be specifically configured for individual inspection tasks. The enclosed tables provide an overview of the available configura-tions. Further information regarding this advanced range of inspec-tion tools can be found in the LineExplorer brochure.
2
LineExplorer
A short introduction
LineE
xplo
rer U
M
LineE
xplo
rer U
C
LineE
xplo
rer U
CM
LineE
xplo
rer
Spec
ial C
onfig
urat
ions
Mission/Task
Available Configurations
Quantitativewall thickness measurement
Metal loss
Laminations and mid-wall flaws
Narrow axiallyextended corrosion
Enhanced resolution or pitting inspection
Cracks, stress corrosion cracking (SCC):axial orientation
Cracks, stress corrosion cracking (SCC):circumferential orientation
Crack inspection,spirally welded pipe
High temperature
High pressure
Bi-directional mode
Non-piggable
Dual- and multi-diameter
Task Configuration
Combined metal loss A configuration of the LineExplorer tool isand crack inspection available which combines metal loss and crack inspection capabilities. This tool provides major advantages from an operational point of view: single mob/demob for both inspection types and single run for a given section.
Enhanced resolution Special configuration utilizing a sensor carrier or pitting inspection design optimized for housing an optimum sensor arrangement with higher resolution or for pitting corrosion detection and sizing.
Bi-directional Special tool configuration which allows to apply the LineExplorer tool in a bi-directional mode, for instance for the inspection of loading lines.
High pressure/ Special configurations of the LineExplorer toolsHigh temperature optimized for application in a high pressure and/ or high temperature environment.
Circumferential Special sensor carrier design for the detection crack detection and sizing of cracks and crack-like flaws with a circumferential orientation.
Spiral crack detection Special sensor carrier design for the crack inspection of spirally welded pipe.
Baseline survey Special setting regarding sensitivity and threshold to fingerprint a pipeline. Used as reference to be correlated with repeated inspections during operational life.
3
Information QualityData collected by in-line inspection tools is not gathered for its own sake, but for further use. Data has to be of a certain standard and quality in order to become useful information. Information manage-ment is defined as the conscious process by which information is gathered and used to assist in decision-making. But to be useful in decision-making, the information provided must be the right informa-tion of the right quality. The quality of information can be defined in terms of three main dimensions. Information must be:Relevant: Information is relevant if it can be used by the recipient to perform more effectively than would be possible without it.Reliable: Reliable information is timely, accurate and verifiable. Robust: Information must stand up to the rigors of time, system fail-ures and organizational changes.
With regard to pipeline inspection and integrity, achieving the first two dimensions is strongly dependent on the quality of the data provided by the in-line inspection tool and the analysis performed by the service company. Providing all relevant and necessary infor-mation is part of the reporting process whilst the issues of reliability also address tool and defect specifications. Verification includes the issue of confidence levels regarding detection and reporting.
Purpose of InspectionThe major purpose of performing a pipeline inspection is to obtain good quality data regarding any flaws and anomalies present in the pipe wall. Accurate, reliable and reproducible data are re-quired for integrity assessment and fitness-for-purpose studies. Rel-evant data collected during an in-line inspection includes:remainingwallthickness,flawgeometriesandtopologies,flawlocations.
The full picture, however, will also need to include data from exter-nal surveys, information about pipeline materials and operations as well as any active or passive pipeline protection measures.In-line inspection tools apply non-destructive testing techniques in order to detect, size and locate anomalies in the pipe wall.
Reporting
Figure 1: List of Reported Features
4
Pipe Wall,e.g. Steel
Coupling Medium,e.g. Oil
Internal Metal Loss External Metal Loss
WallThickness
Stand-off
100 200 300 400 500 600 700 800 900 1000 1100
2015105
Length, mm
Length, mm
Stand-off
100 200 300 400 500 600 700 800 900 1000 1100
2015
3025
105
Wall Thickness
Stan
d-of
f, m
mW
all T
hick
ness
, mm
USProbe
USProbe
t1
t2
t1
t2
Pipe Wall, e.g. Steel
Coupling Medium,e.g. Oil
Incident Wave
Reflected Wave
Internal Crack EchoExternal Crack Echo
Time-of-flight
External Crack
Refracted Wave
Internal Crack
Am
plitu
de
USProbe
45
Surface Entry Echo
Information ProcessThe process from inspecting the pipeline to providing an inspection report to the operator consists of several distinct steps. They can be summarized into: Data Gathering Data Analysis Reporting Use of Information
Data GatheringThe in-line inspection tool collects data during an inspection run. This data is stored in a solid state memory and retrieved after the inspection has been completed. Prior to saving the data on perma-nent storage it is checked for quality and completeness. In prepara-tion for an inspection, the tool used is specifically configured for the given inspection task. This implies a configuration, e.g. setting, of the tool itself and also the use of a specific sensor carrier. Depend-ing on the inspection tasks, different sensor carrier designs and sensor alignments are used. Figures 2 and 3 depict the testing principles applied for metal loss/wall thickness measurement and crack inspection.
Figure 2: Wall thickness measurement principle
A Word on ResolutionThere is no clear-cut definition in the pipeline inspection industry on what the term resolution or high resolution really means. A further complication is the fact that resolution is a three-dimensional phenomenon, e.g. the respective resolutions in the radial, axial and circumferential directions of the pipe. So which resolution do general statements regarding a high resolution in-line inspection tool refer to and how does this link to accuracy? At NDT Systems & Services GmbH & Co. KG we use the following definitions and approach:Radial Resolution: This value refers to the resolution or refinement with which the depth of a feature can be measured and is linked to the electronic capabilities of a tool. Strictly speaking this refers to the sampling rate with which the analog ultrasonic signal data is digitized. The LineExplorer tools can achieve a radial resolution of 0.06 mm.Axial Resolution: This value refers to the resolution or refinement with which features can be measured in the axial direction of the pipe. The actual resolution is linked to the electronics of the tool utilized. If more pulses of the ultrasound probes can be triggered per time interval, more readings can be taken for a given travel distance. With other words, the distance from axial reading to axial reading decreases and the resolution increases. The LineExplorer tools can be configured for an axial resolution of up to 0.75 mm.Circumferential Resolution: This value refers to the resolution a tool can achieve across its circumference and depends on the number of probes or sensors placed around the circumference of the pipe. The width resolution depends also on the size of the individual ultra-sound transducers. In simple terms it can be stated that the more sensors are placed around the sensor carrier the higher the circum-ferential resolution. A special pitting sensor carrier is available achieving a circumferential resolution of approx. 4.0 mm, whilst the standard is 8.0 mm.Accuracy: In general it can be said that the maximum accuracy an inspection technique can provide is limited by the resolution that can be achieved. The accuracy that is usually achievable under practical considerations is influenced by additional parameters such as surface roughness, variations in ultrasonic velocity etc.
5
Figure 3: Crack detection testing principle
6ReportingThe next step in the analysis process is the compilation of an Inspec-tion Report including a detailed description of the features identi-fied. Quality assurance involves a four step checking procedure involving the data analysts, team leaders, departmental heads as well as the documentation department. NDT Systems & Services GmbH & Co. KG sees itself as a partner for its customers and a high-quality service provider. The product provided is the service of pipeline inspection, the results of which are documented in the Inspection Report handed over to the client. The pipeline inspection data collected and analyzed becomes valuable information regarding integrity assessment, fitness-for-pur-pose studies and decision-making within the maintenance process. This information needs to be presented in such a way as to effec-tively assist the operator or any third party using it.Inspection Reports are not automatically generated or standardized at NDT Systems & Services, but individually compiled to meet cus-tomer requirements. The initial structure of the reports is based on the companys experience, making use of the intensive and effective interaction between NDT Systems & Services and its customers.
Data AnalysisThe first step in the data analysis process is the creation of a pipe tally. Specialized software is used for identifying girth welds and using this information for the pipe tally. Any deviations from cus-tomer pipe tallies are investigated and corrected if required. Dis-tance correlation of any features found depends on the information provided by the odometer wheels and additional benchmarking operations. Automated analysis routines using pre-determined threshold settings are used for identifying locations within the in-spection data indicating relevant features or anomalies. The output created is utilized by experienced data analysts for the preparation of an optional Preliminary Report. The next step entails the detailed classification and sizing of all relevant features based on the defect specifications of the in-line inspection tool applied and the customer requirements. Rigorous quality management procedures ensure data quality and relevance. At this stage metal loss inspection data will be used for performing Maximum Allowable Operating Pressure (MAOP) calculations in order to provide an initial ranking of the severity of anomalies identified.
Verification of inspection data a lamination with contact to the surface
Verification of inspection data crack field (SCC colony)
7Appendices to the Inspection Report include the inspection tool and defect specifications, a description of the data evaluation proce-dure, background information on the application of ultrasound technology and the integrity assessment procedures applied.
Formats and LanguagesThe Inspection Report is available in hard copy and/or in a digital format. Feature related information can be made available in a number of formats including MS Excel, MS Access and other data-base specifications. Moreover, data supplied can be formatted as input for GIS systems or SQL databases.
By default, the Inspection Report is prepared in either German or English. French, Italian and other language versions are optionally available.
The Inspection Report is then refined according to the scope of reporting agreed upon with the customer.A typical layout and content can be viewed in the Sample Final Reports which are available from NDT Systems & Services GmbH & Co. KG upon request.A typical Inspection Report will include:anExecutive Summary highlighting the major findings of the inspection,Operational Details of the Inspection, such as speed, tempera ture, pressure and pendulum profiles,aSummary of Results including the reporting threshold applied, and feature statistics shown in tables and histograms,anMAOP calculation based on the chosen assessment code for metal loss surveys and visualized through pressure sentenced plots,anoptional Crack Assessment utilizing deterministic or probabi- listic assessment routines,aList of Reference Points consisting of time-based markers and natural markers (valves, T-pieces etc.) to easily locate features,acomprehensivePipe Tally that lists all pipe joints.Figure 1 on page 4 shows a typical List of Reported Features.InspectionReportsalsoincludeDetailed Feature Descriptions (dig sheets) as well as printouts of the C-scan and B-scan of anoma-lies chosen by the customer.
Verification of inspection data crack
Verification of inspection data external metal loss
8Visualizing Information with NDTs Inspection Data Management SoftwareThe most convenient way to handle the data gathered in an NDT inspection run is using NDTs state-of-the-art inspection data manage-ment software suite LineExplorer PixusC. As part of the LineExplorer family of tools, this software, like its hardware counterparts, has a modular design and can be easily adapted to the need of each user. Different software modules offer varied functionalities, provid-ing highest flexibility in the choice of the software product that is best equipped for the tasks at hand.
LineExplorer PixusC:Advanced visualization software
Visualization of a circumferential fatigue crackC-scans of crack inspection data (top) as well as wall thickness data (bottom) are shown on the left hand side. A reliable classification of the indications is ensured by using the B-scans displayed on the right hand side.
Innovative Functionalities, Advanced ErgonomicsOur software designers put special care in making the handling of LineExplorer PixusC as convenient as possible. Users can therefore change the appearance of the software according to their indi-vidual requirements. Different views can be arranged as hovering windows or within the frame of the software desktop for maximum overview. Various functions are available for the intuitive interaction with the inspection data. The examples on this page show a small fraction of the different software modules available and examples of existing software functions.
C- and B-scans can be freely arranged on the workspace for easy data comparison
Feature list placed below the B-scan in order to optimally use the available workspace
Shows distance, time-of-flight, and amplitude information of the reflected signal at the mouse pointer position
9Basic Version C-scan and B-scan view with measuring ability (distance, box dimensions) Profile view (speed, pressure, etc.) List view (box, weld, marker with select and filter functionality)
A-scan Module* A-scan with measuring ability Overlap C-scan Sensor mode C-scan
Assessment Module* Assessment methods that can be implemented: B31G,modifiedB31G, RSTRENG,SHELL92, DNVRPF101,MAOPusing river bottom profile, based on RSTRENG,DNVcomplex shape Otherstandardsonrequest
Run Comparison Module* Run comparison functionality (viewing only) One workspace hosting two C-scans and two list views of two different runs
Run Data Export Module* Run data export to CSV files
3D View Module* 3Dview
* requires basic version
Amplitude C-scan showing a crack field (SCC colony)The crack inspection data is displayed in the top window. A C-scan of the corresponding wall thickness data is displayed in the small window thereunder.
C-scan representation of an external metal lossThe metal loss indication is visible in the top window. In the lower window a cross section (B-scan) of the wall thickness data and the standoff data is displayed for a selected orienta-tion. The B-scans are used for precise depth sizing of metal loss indications.
Right-clicking the mouse shows a tool tip with odometer distance and circumferential position as well as other inspection infor-mation at the position of the mouse pointer
Feature list arranged next to the C-scan for most comfort-able navigation
Measurement units can be preset to either metric or imperial system
Dimensioning tool: gives the dimensions of a measuring rectangle which has been drawn up with the mouse
10
The integrity of a pipeline must be assured at all times. Maintenance procedures must ensure the safety, availability and regulatory com-pliance of a pipeline, storage facility or whole network. In addition a pipeline constitutes a major investment, an asset that must be protected. In-line inspection tools provide the necessary information regarding the geometries and locations of anomalies or flaws in the pipe steel. This information, together with external data, mate-rial specifications and operational parameters, is used in order to assess whether a given line is fit for purpose (FFP assessment).
Pipeline integrity assessment involves all aspects of:design,operation,inspection,FFPassessment,riskassessment,maintenanceandmanagementofapipeline.
NDT Systems & Services GmbH & Co. KG offers a range of integ-rity services complementing the in-line inspection services, with a
The effect of crack-like features on the pipeline integrity is evaluated with the Failure Assessment Diagram (FAD) method of the industry standard API Recommended Practice 579 (Fitness for service).
focus on ma king the special expertise and experience relating to in-line inspection data available to its customers. A summary of services provided is included in this brochure. Detailed information is available upon request.
Integrity Assessment and Fitness-For-PurposeA fitness-for-purpose investigation is defined as a quantitative engineering evaluation to demonstrate the structural integrity of an in-service pipeline containing a flaw or damage. Two main types of assessment can be distinguished:
Immediate Integrity AssessmentThis implies the assessment of all features detected in relation to their significance to the integrity of the pipeline at the time of inspection, the as is situation. NDT Systems & Services offers a range of assessment procedures, based on published codes. Below is an overview of typical codes or procedures used.
Future Integrity AssessmentThis applies to the issue of assessing the significance of corrosion features in relation to the future integrity of a pipeline. The evalua-
Integrity services
Software for the run comparison and corrosion growth analysis of consecu-tive inspection runs. The river bottom profile or the individual sensor signals of the corrosion defects can be compared in detail.
11
tion investigates how external and internal corrosion growth affects the long-term integrity of a pipeline and what rehabilitation activities are required.
The depths of corrosion defects are extrapolated into the future using growth rates, ideally calculated from an inspection run com-parison. An assessment according to an advanced method is per-formed in order to determine repair dates, repair priorities and an optimized re-inspection interval.
Run Comparisons/Corrosion Growth AssessmentFor the planning of a cost-efficient maintenance and operating strat-egy of a pipeline, it is important to understand how the pipeline condition will deteriorate. Accurate and highly confident corrosion growth rates are essential inputs into any future integrity assessment and corrosion management.
NDT compares in-line inspection data from consecutive runs in or-der to determine any changes in depth and to identify new corro-sion sites or other new features such as dents caused by third party damage. A corrosion growth study is performed to investigate the
external and internal corrosion growth behaviour. Statistical methods can be included to consider, for example, the effect of tool tolerances.
Fatigue AssessmentCracks and laminations may grow by fatigue in service. For instance, pipelines that transport batched products are susceptible to fatigue failure as pressure cycling can occur due to changes in daily de-mand. This pressure cycling may result in loading conditions initiat-ing fatigue, which needs to be assessed.
The aim of the assessment is the calculation of the remaining fatigue life of the pipe affected by the reported crack-like defects.
Remaining Life AssessmentThis assessment determines the remaining life for a pipeline based on in-line inspection data and known loading conditions. The data available can also be used for the determination of service intervals.
NDT Systems & Services GmbH & Co. KG offers a wide range of integrity services. Further advanced integrity assessment services can be offered in cooperation with strategic partners.
Assessment of corrosion defects according to RSTRENG. The RSTRENG method is an advanced method for calculating the safe operating pressure of a defective pipe. The real contour of the corrosion defect, not just the overall length and depth, is used as input for the assessment. When conducting an RSTRENG assessment, an effective depth and an effective length based on the defect river bottom profile is determined. These effective dimensions can be compared to the assessment curve (ERF = 1) in order to decide whether repair is required or not.
Type of Anomaly Applicable Code
MetalLoss ASMEB31G,ModifiedB31G,RSTRENG,DNVRP
F-101,API579etc.
Cracks API579,BS7910
Laminations API579,BS7910
Dents ASMEB31.4,ASMEB31.8
K.038-en.v0
209/2
012
Corporate Headquarters
NDT Systems & Services GmbH & Co. KG
Friedrich-List-Str.1D-76297StutenseeGermany
Phone: +49(0)72447415-0Fax: +49(0)72447415-97Internet: www.ndt-global.com
Copyright2009-2012,NDTSystems&Services.TheNDTlogoandLineExplorerareregisteredtrademarksofNDTSystems&ServicesGmbH&Co.KG.
Operating Companies
Germany/EMAANDT Systems & Services GmbH & Co. KG
Friedrich-List-Str.1D-76297StutenseeGermany
Phone: +49(0)72447415-0Fax: +49(0)72447415-97E-mail: [email protected]
USA/AmericasNDT Systems & Services LLC
2835HolmesRoadHouston,Texas77051USA
Phone: +17137995430Fax: +17137995406E-mail: [email protected]
Middle EastNDT Middle East FZE
POBox261651ZH-01,R/A13Jebel Ali Free Zone, DubaiUnited Arab Emirates
Phone: +97148837741Fax: +97148837762E-mail: [email protected]
CanadaNDT Systems & Services (Canada) Inc.
604-19thAvenueNisku,Alberta,T9E7W1Canada
Phone: +17809558611Fax: +17809558615E-mail: [email protected]
MexicoNDT Systems & Services de Mxico, S.A. de C.V.
BaltimoreNo.92Col. NochebuenaC.P.03720Mxico,D.F.
Phone: +525555631920Fax: +525556153492E-mail: [email protected]
