LlogSA Symposium, 19 August, Mexico City Conditions 3% 1% Reliable detection 9% 5% Long range Short range ion try Contents l gths Gas bonded paint d epoxy / s ing d …

Copyright © Plant Integrity Ltd 2015

Guiding the wave of innovation

Agata Surowiec

Guided Waves Applications LlogSA Symposium, 19thAugust, Mexico City

About TWI and Plant Integrity Ltd

Guided Waves on

Pipelines

Pipeline Advances

Structural HealthMonitoring


Outline to Presentation

Plant Integrity Ltd

• Long Range Ultrasonic Testing

• Guided wave ultrasonics• Involved in all aspects of

Teletest Manufacturing Sales Service R&D and bespoke

solutions Training

• Wholly owned subsidiary of TWI


What is TWI?

• Research & Technology Organisation

• Membership based • Non-profit distributing• Effectively owned and

run by representatives from Member CompaniesTWI Council (appoints the Executive Board)Research Board


Key Figures

1000 staff£80M/$120M Turnover in 2014Five UK locations and 13 international officesOn-going £4.5M/$7M Research & Innovation Programme£20M/$30M On-going Collaborative ProgrammesMore than 700 Members in 4500 locations worldwideSIRFTM/NSIRC - £150m Initiative ($225m)


Regulators

Governments

Standards bodies

Certification bodies

Engineering, R&D, technical specialist

divisions of oil majors

Research & Technology

organisations

Training bodies

Operators:

International (IOC)

National (NOC)

2nd tier

Independent

Contractors:

Inspection

Integrity management

Engineering

Design

Fabricators

OEMs

Hardware & equipment suppliers

Over 700 organisations, e.g.

HSE (UK) Petroleum Safety

Authority (Norway) ABS Lloyd’s Register DNV GL Bureau Veritas

Chevron ExxonMobil ConocoPhillips Shell BP BG Group Statoil ENI Maersk

Transocean SBM Offshore MODEC Technip Subsea 7

Tenaris Cameron Onesubsea Schlumberger GE Oil & Gas

ADMA-OPCO Saudi Aramco

Petrobras KPO (Kazakhstan)

Oil and Gas Industrial MembersOil & Gas Supply Chain


Laser and sheet processes, incl. laser welding and cutting

Friction and forge processes, incl. linear friction and friction stir welding

Electron beam welding

Adhesives and composites

Ceramics Brazing R&D developing

new technologies

Key Technologies and Expertise

Fitness-for-service assessment (FFS)

Risk-based inspection (RBI)

Advanced & specialist NDT/inspection

Fatigue & fracture testing & assessment

Testing in critical environments, e.g. sour (H2S), sweet (CO2), HTHP, H2

Software tools

Specialist training

Materials and failure mode characterisation

Materials/joints performance and degradation testing

Materials performance improvement for demanding service

Surface engineering

Welding engineering and fabrication

JOINING

ENGINEERING

MATERIALS


Guided Waves on Pipelines

Low frequency Ultrasound (20-100kHz)• Developed for Corrosion Under Insulation• First introduced into the market in 1997• Established method for screening pipelines• Inspection of inaccessible areas


Rapid screening for in-servicedegradation

Reduction in costs of gainingaccess

Avoidance of removal/reinstatement of insulationor coating, except at locationof transducer tool

Ability to inspect inaccessible areas

i.e. clamps and cased or buried pipes


Guided waves offer

Conventional UT versus LRUT


Longitudinal

Torsional

Flexural

Wave Modes in Pipes


How GWT is Performed


Test Data – A-scans

Source: BS 9690-2


Limitations

• Large volume of material examined from a

single point limits sensitivity and resolution

• Pipe conditions (particularly coatings) and geometry influence test performance

• Currently no means of providing flaw sizing from GWT which can be used to determine fitness-for-service (R&D)

Currently a screening technique


Detection of internal or external metal loss Sensitivity

Both Algorithms available in the WaveScansoftware.

Discrimination between flaws and pipe features; welds, bends, supports, etc.

Longitudinal accuracy better than 100mm

Detection


Cross Section Loss Algorithm

Best Fit Curve Linear Extrapolation

Ideal Conditions 3% 1%

Reliable detection 9% 5%

Long

range

Short

range

Surface condition Geometry Contents

Bare metal Straight lengths Gas

Smooth well bonded

paint

Fusion bonded epoxy Attachments/

Brackets

Liquid Light pitting

Heavy pitting

Plastic, e.g. PVC Branches

Buried (earth or sand)

Bitumen coated Multiple bends High

viscosity

Concrete coated Flanges

Performance Summary



Applications

• Road and river crossings

• Power plant tubing

• Risers

• Caissons

• Offshore topsides pipework

• Jetty lines

• Refinery pipework

• Chemical plant pipework

• Tank farm link lines

• Sphere legs

• Pipe bridges

• Spiral welded pipe

• Austenitic stainless steel

• Nuclear Boiler spines

Copy1r0ight © Plant Integrity Ltd 2015

Practical – User friendly unit and collar design for fast inspection

Multimode – Longitudinal and torsional wave modes on one tool

3 Ring Torsional –Extra ring for further penetration

Focusing – Simple identification of defect distribution around pipe circumference (secondary phase focusing)

Wi-Fi data collection

On-site report capability

Teletest Focus+ State of the Art

Teletest Features

Diameters – 1.5" to 48" with

capabilities to inspect up to 72"

100% Coverage

Test Range• Typical ±30m (100ft)

• Ideal conditions ±180m (590ft)

Productivity• Data collection in minutes

• On-site reporting

• Typical 10 locations per day

• Under ideal conditions 3km has been achieved

Standard Service Temperature up to +120°C (248°F)

High Temperature Equipment up to +240°C (464°F)


3 Ring torsional only modules

3rd Ring Provides 50% greater sound energy

5 transducers at 2 spacings

30mm

45mm

Specifically for lines unsuitable forLongitudinal

Liquid filled lines

Thick pipes

Buried pipes

Proven better penetration over 2-ring

Only Teletest can do this

Torsional Only Modules


1

0

frequency, kHz

2

3

7

6

5

4

am

plitu

de

,a

rbit

rary

un

its

3 ring, 30mm

3 ring, 45mm

2 ring, 30mm

2 ring, 45mm


5-Ring Torsional

Also called synthetic focussing

Single wave mode transmitted

Pipe features cause mode conversion

The collection of reflected modes is analysed

The inferred location and extent of featuresis presented on a map

C-Scan to Complement A-scans


Secondary Focusing

Focusing allows the energy to be concentrated where the defect is, increasing sensitivity andgiving position and size information

Sound energy concentrated in one region

Focus results link directly to Report Manager

Rotation 8 times around pipe

4 times greater sensitivity

Multi defect focus capability

Both wavemodes used for

focusing


Information about the circumferential extents

Focusing


Advanced Applications


Buried Lines

60m Inspection using

3 Ring Torsional


Additional 50% of

energy for better

penetration

Capable of all functions of Teletest Focus

Inspection up to 240C (464°F)

Separate HT modules and transducers

Special HT Tool Lead

Uses current collar with an insulating adapter

Available for rent orpurchase

Teletest Focus HT


Inspection of Furnace Tubes

Difficult to inspect using conventionaltechniques

Expensive in cost and time

Access is difficult for conventional tooling

Access: Cut the U-bends off or an internal tool

Guided Waves can screenpipes quickly during shut-down'Reproduced courtesy of Petro-Tech Heaters Ltd'


What Wavemode?

Torsional

Longitudinal

Longitudinal capabilities identified the both, the pipe end and the defect.


Special tool developed for access

Test loop built

Tool developed

Low profile

Modified spacing

Longitudinal

Clam shell design for easy application

All connections on the side

Only 3” (76mm) space needed between first fin and bend weld


Teletest provides information about a condition of caissons, risers, deck penetration, Bestobell seals and piping

Splash zone and below can be inspected from the top side

Teletest can be used as monitoring tool (Permamount)

Offshore


Example of data


TL02

Internal Tool for drill riser inspection

Current inspectiontechnique – spots check

Teletest offers 100%inspection

Quicker and cost effective technique compared to current best practise


All capabilities and benefits of Teletest Focus

IP68 rated, IEC standard for ingress protection –dust tight and protection against complete and continuous immersion in water.

Easy Installation

Excellent Data Stability &Repeatability

Teletest Permamount


Easy Data Collection

On-site analysis or remoteanalysis by CSWIP trainedoperators.

Wide Temperature Range from -40°C(-40°F) to +80°C (+176°F)

Internal temperature monitoring tool

Pipe Size Range: ASMESchedule 2” to 48”.

Unique Serial Numbered Tool Heads for traceability and control.

Teletest Permamount


10 15 20 25 30 35 40180

190

200

210

220

230

240

250

260

270

280

Temperature C

Am

plit

ude (

mV

)

The Effect of Temperature on Far End Amplitude

m = y/x = 3.3mV per C

Temperature v Amplitude


0 100 200 300 400 500 600140

160

180

200

220

240

260

280

Amplitude Distrubution Over the duration of the Test (27kHz)The Non-Linear Trend is Due to Seasonal Temperature Variation

(619 Tests in Total)

Number of Tests

Am

plitu

de

(m

V)

Amplitude Variation


0 100 200 300 400 500 6000

50

100

150

200

250

300

350

400

Normalised Amplitude of the Far End (W.R.T. Temperature) at 27kHz Showing the Effect of Defect Growth on Feature Amplitude

Number of Tests

No

rma

lise

d A

mp

litu

de

W.R

.T.

Te

mp

era

ture

1.1% CSA Defect Added




Normalised Amplitude w.r.t. Temperature


GWT testing began in 2004Change in signal Sept 2013Immediate part power operation475mm fully penetrating crack detected in July 14.Weld supports the weight of the Boiler and reheater.

Case Study - Nuclear


Design


Access


• Teletest Inspection of Boiler spines since 2005• One Boiler spine changed signal in Sept 2013 at Weld

LRUT for complicated components

Weld


Teletest result – June 2010


Teletest result - Sept 2013


• Size the defect (6 months and cost £ millions)InaccessibleContaminated area

• Reason? – Thermal Fatigue• Inspect the other spines – Teletest and remote

visual• Reduce Operating temperature – 80% power• Introduce cooling modifications• Spine catchers• More frequent inspection and monitoring

Actions


Teletest HT Permamount


Tool design complies with nuclear industry standards

Tool developed for high temperature monitoring

240°C operation

Continuous monitoring

Online monitoring available

High Temperature Monitoring


Testing transducer collar array at 250°C


Automated Data Collection


Summary

• 32 Permanently Installed monitoring system on site

• Continuous collection of data every 15 min

• Analysis of data off-site• Aim to get back to 100% power


Copyright © Plant Integrity Ltd 2015A TWI Group Company

Guided Waves forTank Floors

Industrial Need

• Current ‘interval-based’ inspection regimes for assessment of storage tank floor integrity do not wholly meet the needs of industry:• Internal examinations are expensive and

incur substantial preparation costs,• Time-based decisions on when to inspect

tanks do not always prevent leaks or, in some cases, failures of tanks.


Tank Monitor system concept

Multiplexer

Communications

• Tomography technique

• Automatic data collection

• Remote signal analysis

• Time-dependent

assessment of floor

condition

• Instrumentation based on

successful pipeline

inspection system

Transducers and arrays

Teletest Focus+

Electronics


Image generation: Tomography

Technique Concept


Tank 4m with 3 defects(70mm, 70mm, 20mm)


Teletest Electronics

Due to extensive data collection more than one MK4 unit required

Current status: Successful daisy chaining of 2 Mk4

Connector box for each Mk4 has been developed.

Future: 4 Mk4 to be daisy chained around the tank


Tank T1358 29m


T20809 installation

Protective

conduitConnector

Sensors

Protective resin &

Paint over sensors


Good signal propagation through the 29m and18.5m (with sump).

We are now installing systems on industrial sides of Vopak, ConocoPhillips, Petrobras,Chevron and Shell

We are looking for more tanks!!!


Conclusion

Structure monitoring reduces risk of failure, increases personal and environmental safety and saves huge amount of money.

Permamount increases sensitivity, reduces humanerrors and an impact of external factors on a quality of data.

Sensor design has to be carefully chosen for both the correct ultrasonic parameters and for longevity.

Frequent gathering and trending of data allows to reduce an impact of any variables (temperature)

Detection performance for corrosion and crackingis within industrial requirements.


Summary

CSWIP Independent Certification

http://www.cswip.com/verification/

Level 1 (80hrs),2(40hrs) and 3

Compliance with ISO 9712(1)

Meets Requirements of EN 473(2)

Management and Technician LRUT Training

GWT Training and Certification


http://www.cswip.com/verification/

Pi Office in Houston

Training and rental equipment available in US

Rental equipment available in UK, SEA

Training – CSWIP Certified Level 1, 2, 3

UK, SEA and North America

Attentive customer support

Technician support available for overspill work,report review and mentoring

Technical experts for specialist applications


Summary – Plant Integrity support


Contact Us

Plant Integrity Limited

Telephone:

+44 (0)1223 893994

TWI North America

Telephone:

+1 281-680-2000

Address:

12243 C FM 529 Road

Houston

E-mail:[email protected]

www.teletestfocus.com

mailto:[email protected]

http://www.teletestfocus.com/

Documents

LlogSA Symposium, 19 August, Mexico City Conditions 3% 1% Reliable detection 9% 5% Long range Short range ion try Contents l gths Gas bonded paint d epoxy / s ing d …