1

Remote Diagnostics of Underground, Underwater,

Aboveground Pipelines Using Controlled Unmanned Systems

Dr. Michael Getmansky1

, Prof. Efim Lyublinski2

, Eng. Boris Verbitsky3,

Dr. Ilya Silvokon1

1“Intercor, Inc.” USA, intercor@comcast.net;

2 “COR/SCI”, USA, elyublinski@gmail.com;

3”

AMT-Asmos LLC”, Russia, asmos08@mail.ru

Abstract

The typical approaches for the corrosion protection of pipelines (coatings, cathodic

protection and their combination) often fail due to unpredictable environmental and application

conditions. Presented controlled unmanned systems and technologies that allow predicting

corrosion conditions and other possible damages of Oil, Gas and Water pipelines. The

technology was developed based on modern innovative methods of non-destructive testing to

ensure the operational safety of the pipelines. Presented statistical data from that allows

interpreting information with a high degree of certainty. This new technology can significantly

reduce the risks of accidents and provide recommendations on carrying out maintenance work on

the most weakened sections of pipeline transmission, which ultimately leads to significant

financial savings.

Keywords: pipeline, fire, explosion, contamination, diagnostic

INTRODUCTION

Corrosion of pipelines (pipes, flanges, valves and welded joints) is a major world-wide

problem in many industries, including Oil and Gas Exploration and Production, Petroleum

Refining, Mining, Chemical Process, Petrochemical, Water and Gas Distribution Systems in all

cities, etc. [1-3]. More than half of the pipelines are at least 50 years old. Operators use a risk-

based system to maintain their pipelines – instead of treating all pipelines equally, they focus

safety efforts on the lines deemed riskiest, and those that would cause the most harm if they

failed. The form of corrosion, corrosion rate and accordingly the useful service life of pipelines

(that can be from 1 to 50 years) are unpredictable in the unpredictable environmental and

application conditions. There are well-known examples of oil and gas pipelines that have become

a source of environmental contamination, fire and/or explosion after only 5-10 years of service

as the result of leakage from pitting, crevice and stress cracking corrosion. The frequency of

inspections is increased if the pipeline passes close to High Consequence Areas (Drinking Water

Unusually Sensitive Area, Ecological Unusually Sensitive Area, Highly Populated area,

Commercially Navigable Waterway, etc.). According to NACE, the estimated corrosion cost in

USA increased from $276 billion in 1998 to about $1 trillion in 2013-2015. Corrosion of onshore

gas and liquid transmission pipelines only in USA represents more than $7 billion per year in

1998 and accordingly can be predicted above $28 billion in 2013-2015. The operations and

maintenance costs comprise approximately half of the total costs associated with corrosion.

The management-related cost of corrosion control and service include:

– Corrosion-related inspection and maintenance

– Repairs those are required due to corrosion

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– Replacement of corroded parts that are found during inspections or operation

– Inventory and maintenance of backup components

– Rehabilitation and refurbishment

– Loss of productive time for operations

-- Leakage, fire, explosions and contamination of the environment.

In most cases the corrosion attacks occur on the external and internal surfaces of pipelines

(Figure 1).

Figure 1 – Examples of pipeline external and internal surface corrosion

The recent and rapid collapse of oil prices has created a challenging environment for all

companies in the energy sector. We expect that industry will be entirely dedicated to search and

determining the most economical and cost-effective solutions for pipeline operators to ensure

that risks to asset integrity arising from ageing and life extension are adequately controlled

through innovative technologies.

In many cases the danger of pipeline application increases due to corrosion of the

pipeline connections – welded joints, flange faces, as well as on flange bolts and nuts. The

severity in many cases mainly depends on the external environment and operating conditions

(Figure 2).

Due to this situation in many countries the biggest problem is the leakage of oil and gas

pipelines, fire and explosion, contamination of environment, etc.

In different publications presented information about accidents in different countries and

some of the following results (Table 1): length and type of pipelines, number of leaks, released

volume of product (oil, gasoline), cost of the damages. As example on the Fig. 3 presented

number of accidents in USA.

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Figure 2 – Examples of pipeline connections corrosion

In different publications presented information about accidents in different countries and

some of the following results: length (Table 1) and type of pipelines, number of leaks, released

volume of product (oil, gasoline), cost of the damages. As example on the Fig. 3 presented

number of accidents in USA.

From 1994 through 2013, the U.S. had:

> 745 serious incidents with gas distribution, causing 278 fatalities and 1059 injuries, with

$110,658,083 in property damage;

> additional 110 serious incidents with gas transmission, resulting in 41 fatalities, 195

injuries, and $448,900,333 in property damage.[

> additional 941 serious incidents with gas all system type, resulting in 363 fatalities, 1392

injuries, and $823,970,000 in property damage.

Examples of explosions in some countries presented on Fig. 4.

Existing corrosion protection systems [4-16] of external surface of aboveground,

underground and underwater pipelines is typically a high efficient coating and/or insulating

systems. For corrosion protection of underground and underwater pipelines in addition to coating

recommended impressed current or galvanic cathodic protection systems (CPS). The entire

described problems happened because in most cases the pipeline systems and their location

(Fig.5) does not allow to check the corrosion condition of pipelines, provide maintenance and

replace the protection systems before pipelines start leak.

The described problems can be solved only by frequency diagnostic the corrosion

condition through all length of pipelines and replacing the:

> corrosion protection systems only in areas where they have some defects;

> parts of the pipelines where the corrosion condition became critical.

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Table 1. List of main countries by total length of pipelines (TLP)

( Based on the Central Intelligence Agency accessed in November 2015)

TLP (km) Gas LPG Oil

Refined

products

Argentina 39,850 29,930 41 6,248 3,631

Australia 34,612 30,054 240 3,609 72

Brazil 27,468 17,312 352 4,831 4,722

Canada 100,000 74,980 23,564

China 86,921 48,502 23,072 15,298

France 23,345 15,322 2,939 5,084

Germany 34,335 26,985 2,826 4,479

India 35,676 13,581 2,054 8,943 11,069

Indonesia 21,704 11,702 119 7,767 728

Iran 38,906 20,794 570 8,625 7,937

Kazakhstan 26,963 12,432 11,313 1,095

Mexico 37,008 18,074 2,102 8,775 7,565

Nigeria 12,714 4,045 164 4,441 3,940

Russia 259,913 163,872 1,378 80,820 13,658

Ukraine 45,597 36,720 4,514 4,363

United Kingdom 39,778 28,603 59 5,256 4,919

United States 2,225,032 1,984,321 240,711

LPG - Liquefied petroleum gas

0

10

2000

40

30

20

20152005 2010

50

Num

ber o

f acc

iden

ts

Years Figure 3 -The pipeline accidents in the United States

in the 21st century

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Existing corrosion protection systems [4-15] of external surface of aboveground,

underground and underwater pipelines is typically a high efficient coating and/or insulating

systems. For corrosion protection of underground and underwater pipelines in addition to coating

recommended impressed current or galvanic cathodic protection systems (CPS). The entire

described problems happened because in most cases the pipeline systems and their location

(Fig.5) does not allow to check the corrosion condition of pipelines, provide maintenance and

replace the protection systems before pipelines start leak.

Figure 4 - Examples of pipeline explosions.

Figure-5. Some examples of aboveground pipeline installation in the field

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The described problems can be solved only by frequency diagnostic the corrosion

condition through all length of pipelines and replacing the:

> corrosion protection systems only in areas where they have some defects;

> parts of the pipelines where the corrosion condition became critical.

Development of this solution important for all countries. But the most critical it became

for 120 countries of the world that in 2014 had a total of slightly less than 3.5 million km. length

of pipelines. The most important it is for the three countries thus had 75% of all pipeline - United

States (65%), Russia (8%), and Canada had (3%).

To solve the described problems, the following were taken into consideration:

1. To ensure long-term, cost-effective and safe operation of pipelines for the transportation of oil,

gas and water, necessary to conduct systematic diagnostic work - scanning the entire length of all

piping and components.

2. Provide identification of all kinds of defects that change the initial state of the pipeline, including

the change in the form of pipelines, properties of the coating and the nature and level of

corrosion deterioration of the external and surfaces of pipes.

In this paper presented general information of the innovative approach to check pipeline

condition from based on the AAMMTT--AASSMMOOSS TTEECCHHNNOOLLOOGGYY

To achieve the Pipeline Integrity Management requirements, the following methodology was

taken into consideration:

Diagnostic the condition (all type of defects and threats) on all length and part of pipeline

Find out the exact plan for reliability maintenance by using, for example the following

technologies/equipment-«Smart pigs», «Wavemaker» or «Roxar Field Signature Method»

Sustainable difference of AAMMTT--AASSMMOOSS TTEECCHHNNOOLLOOGGYY::

> An innovative and multidisciplinary approach to check pipeline integrity from the air (“Jump

tech” – from 6 up to 20 foots height)

The objective is achieved by setting up a system consisting of a manned helicopter and/or

UAV/Drone operating on low altitude:

>> Optimal monitoring and detection of pipeline integrity in all types of terrain.

> Adoption of new generation of remote sensing devices using appropriate measurement

methodology based on:

- Magnetometer measurement of stress and strain

- Deciphering aerial photography

- 3D imaging based on GPS, induction instrumentation and photogrammetry

- Hydraulic and stress and strain calculations

- Risk Assessment and Prioritization

- Integration of dataflow from a number of remote sensing technologies in a single database

- Non invasive and non intrusive

- High profile persons available

- Successful practice in place

- Substantial evidence rev swamp costs

AMT-ASMOS/Intercor Technology has the broadest anomalies identification (Table 2)

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Table 2. Main inspected parameters

Listing of anomalies Inspection type by provider/technology

Ultrasound Inner tube AMT-Asmos

External corrosion √ √ √

Internal corrosion √ √ √ Fatigue cracks and stress

deformation conditions √ √ √

Manufacturing damage √ √ √ Insulation damage - - √

Landslides, dunes - - √

Oil leakages detection - - √ (on board sniffer)

Unauthorized cut-in - - √

Gas leakages detection - - √ (on board sniffer)

Underground soil drift - - √ (use 3D imaging)

AMT-Asmos technology advantages:

• The only system which allow for very long pipeline inspection in a very short time

(inspection throughput of more than 100 km/day).

• Use the same technology for land, swamp, shallow and deep waters

• Diagnosing of areas that are inaccessible to all other methods (swamp and deep

water)

• Avoid security problems to inspecting teams faced when walking on the ground or

using boat.

• Does not require preparation of the pipeline, stop it, or change its operating

mode/status.

• Very effective inspection by automatic tracking of the actual pipeline route and

positioning it on topographic map of the area.

• Emergency and 3-year management planning of pipeline integrity based on more than

20 years of experience of Intercor.

The report on the pipeline and about what to do with it, rather than a list of dangerous or not

defects (Inspection report content) include the following:

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1. Common information -Technical data:

Pipeline history of operations including repairs, leaks, etc.

Hydraulic calculation and operational specifications.

2. Results of magneto-metric inspection:

Probability of defects at each point of pipeline length.

List and position of detectable defects and/or anomalies.

3. Air photography analysis:

Oil spills.

Illiegal Bunkering/cut-ins.

Environment of pipeline segments and its Ecological significance

3D presentation of Pipeline profile.

4. Risk assessment:

Evaluation of leaks’ probability and its consequences - determine the level of risk on one

of 5 levels and its place on risk matrix);

Evaluation of priority of a current pipeline as compared with another one.

5. Optional verification of detected anomalies and/or defects:

Ranking of defects according to 4 or 5 data sources (magnetic/land

decryption/calculations/case history/risk assessment).

Creation of the final verified list.

6. Emergency and 3-year management planning of pipeline integrity:

Repair/replacement additional section.

Maintenance, corrosion protection and monitoring.

Risk prioritisation ranking justification.

Description of detailed activities of integrity management.

7. Conclusions - must include:

Final decision on pipeline resource vs its operational deadline;

Proposal of prospective activities dedicated to integrity management at mid and long

terms.

Tools used for reports generation:

• Big data approach.

• Software for pipeline hydraulic, risk and corrosion calculation

• Special software for calculation of mechanical stress and strain deterioration (the

know-how of Tyumen State University and based on West Siberia oil field pipelines

operation experience).

• Risk assessment (GDP 3.1-0001 Evaluation, prioritization and risk management).

• Risk-based inspection (API RP 580. Risk-Based Inspection. Recommended Practice,

2000. API RP 581. Risk-Based Inspection. Base Resource Document, 2000).

The report must contain information that will be taken into consideration for

maintenance of pipelines:

• The Integrity management actions are planning on the basing on hazard evaluation

of all type of Defects and anomaly which use the appropriate measurement

methodology (Magnetometer measurement of stress and strain, deciphering aerial

photography, 3D imaging based on GPS, induction instrumentation and

photogrammetry, hydraulic, stress and strain calculations and Risk Assessment and

Prioritization).

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• Planning the integrity actions (inhibition/repair/replacement/inspection/maintenance)

strictly for high priority pipelines with verified defects and operation data.

• The increase of safety, compliance and decrease of leaks is possible without

additional cost.

• Some examples of the AAMMTT--AASSMMOOSS TTEECCHHNNOOLLOOGGYY OOPPEERRAATTIINNGG

BBUUIILLDDIINNGG BBLLOOKKSS presented on Fig. 6.

Remotely piloted long range UAV

equipped with different types of

subsystems/sensors

Video wireless communication

from the air vehicle to the

control center for operation, a

data collection and analysis

bHelicopters (inland and offshore

models)

Figure 6. Operation parts of AMT operation building.

This system operation must be used first of all for inventory of the whole pipeline network

through aerial inspection. including:

Topographic imaging: a digital terrain map is created for a 200 m wide strip including the

pipeline

3D imaging: a 3D map of the pipeline is created with its exact positions using the inductive

system.

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These systems allow very fast to check the corrosion condition of pipelines and find out the areas

where it is critical and must be fixed (Fig.7).

Figure 7. The Magnetogram,

Illustrated corrosion condition of

the pipe operated during 20 years.

The loss of metal – over 50%

Similar measurements must be provided on all pipelines

In addition, the new ASMOS technology allows to check and prevent oil spill and fire

protection.

For this case:

> developed technology for automatic

detection of fire and unauthorized discharges through

the monitoring of atmosphere layer

and sea surface,

> method of passive remote sensing attached to

UAV helicopter.

The developed technology is an alternative pipeline inspection, diagnostic and monitoring

technology.

The integrated system’s tools consist of the following components:

1. Digital topographical map of 0.2 km wide area along the length of the tested pipeline.

2. Precise digital orthophotographic map with uniform (Digital Terrain Map).

3. 3D digital model of the pipeline, both above and below the earth's surface using special

equipment measuring inductive phenomena to locate metal pipes and other objects.

4. Command and Control Center that includes proprietary software for characterization and

analysis of pipeline network integrity in real time.

5. Carrying special sensors on a low altitude above the pipeline axial which collect data for

the pipeline dynamic stress-state calculation.

Monitoring of the described system can be performed periodically across the pipeline

network as well as for examining specific parts of the pipeline in all types of terrain. This data

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characterizes sections of the pipeline that don’t have any changes compared with the original

deployment, as well as those segments which are under mechanical stress, and thus likely to

suffer from initial corrosion or other damage, and also parts that require immediate direct

inspection & maintenance because of high probability of leaks and ruptures. The focus must on

preventing leaks and ruptures in the first place. This new technology generates a database of the

critical parameters of pipelines and contains tools that facilitates an effective decision making

process of monitoring, maintenance and protection of pipelines.

CONCLUSIONS

1. Leakage and explosion of oil and gas underground, underwater, aboveground pipelines due to

unexpected external and/or internal corrosion, loss of products, contamination of environment

well-known problems in most of countries

2. Developed an alternative pipeline inspection, diagnostic and monitoring technology that can

solve the worldwide problem.

3. The integrated system’s tools consist of the following components:

> Digital topographical map of 0.2 km wide area along the length of the tested pipeline.

> Precise digital orthophotographic map with uniform (Digital Terrain Map).

> 3D digital model of the pipeline, both above and below the earth's surface using special

equipment measuring inductive phenomena to locate metal pipes and other objects.

> Command and Control Center that includes proprietary software for characterization and

analysis of pipeline network integrity in real time.

4. Monitoring can be performed periodically across the pipeline network as well as for

examining specific parts of the pipeline in all types of terrain. This technology focus on

preventing leaks and ruptures in the first place, generates a database of the critical parameters of

pipelines and contains tools that facilitates an effective decision making process of monitoring,

maintenance and protection of pipelines.

5. The described technology applicable in most cases, exclude the environment contamination,

can significantly decrease the cost of application, maintenance and increase the service life of

pipelines.

References

1. Peabody's Control of Pipeline Corrosion, 2nd Ed., 2001, NACE International.

2. Beckmann, Schwenck & Prinz, Handbook of Cathodic Corrosion Protection, 3rd Edition

1997.

3. Roberge, Pierre R, Handbook of Corrosion Engineering, 1999, NACE International

4. Requirements for Corrosion Control - Transportation of natural and other gas by pipeline:

minimum federal safety standards - 49 CFR 192.112.

5. EN 12068:1999 - Cathodic protection. External organic coatings for the corrosion protection of

buried or immersed steel pipelines used in conjunction with cathodic protection.

6. EN 12474:2001 - Cathodic protection for submarine pipelines NACE.

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7. SP0169:2007 - Control of External Corrosion on Underground or Submerged Metallic Piping

Systems

8. NACE TM 0497 - Measurement Techniques Related to Criteria for Cathodic Protection on

Underground or Submerged Metallic Piping Systems.

9. Corrosion control in petroleum production, NACE International, Houston, 1999.

10. NACE International TM0497-2002, Measurement Techniques Related to Criteria for Cathodic

Protection on Underground or Submerged Metallic Piping Systems.

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