ASSET INTEGRITY THEME LANDSCAPING STUDYFINAL REPORT
OIL & GAS UK
TECHNOLOGY LEADERSHIP BOARD
May 2016
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FOREWORD Welcome to the Asset Integrity Theme Landscaping Study, which Oil & Gas UK has commissioned from Lockheed Martin on behalf of the Maximising Economic Recovery from the UK Continental Shelf (MER UK) Technology Leadership Board. The study’s aim is to provide the most current and comprehensive update both on technologies with the potential to deliver efficiency improvements for inspecting pressurised systems including process vessels, and those effective in managing corrosion under insulation (CUI) of structures used in onshore and offshore environments.
The development of technology and its implementation play a key role in efforts to maximise economic recovery from the UK Continental Shelf where billions of barrels of oil and gas remain to be recovered. Techniques that help the industry to improve asset integrity and safely extend the operating lives of oil and gas fields can significantly contribute to the sector’s drive to increase the production efficiency of existing fields.
In a technology landscape that could be perceived as complex and multi-faceted, it makes sense from a cost and efficiency point of view for Oil & Gas UK, on behalf of the industry, to co-ordinate the wealth of research and development the sector has undertaken to address the key priority of asset integrity, one of four key areas identified by the Technology Leadership Board (TLB). Included in the study are advanced technologies which have helped drive efficiency in other high performing sectors including the medical, space exploration and nuclear industries.
This study looks at technological advances for carrying out internal process vessel inspections which could significantly reduce production downtime during a shutdown and minimise the time required for personnel to enter the inspection area. Alternative methods for improving the detection and management of corrosion under insulation in order to reduce costs are also explored.
The TLB is focused on ensuring that technology development is collaborative, focused on priority areas and suitable for multi-field application. This study is a clear demonstration of collaborative working in action; operators, prime contractors, government and research councils, innovation centres, joint industry bodies and academia have all provided input.
I would like to thank everyone for their much valued contribution to this study, which I believe will play an important role in helping to secure a safe and enduring future for the UK Continental Shelf.
Paul White, industry co-chair of the MER UK Technology Leadership Board
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CONTENTSSECTION 1 5Acknowledgements
SECTION 2 6Executive Summary2.1 INTRODUCTION 72.2 BACKGROUND 72.3 BUSINESS DRIVERS AND CONSTRAINTS 72.4 STAKEHOLDERS 72.5 CURRENT SITUATION 92.6 SCOPE AND OBJECTIVES 102.7 METHODOLOGY 112.8 SUMMARY OF RESULTS 122.9 MANAGEMENT AND CULTURAL IMPEDIMENTS 172.10 TECHNOLOGY GAPS 172.11 CONCLUSIONS AND RECOMMENDATIONS 172.12 NEXT STEPS 20
SECTION 3 21Data Collection and Analysis3.1 APPROACH 223.2 LIMITATION 223.3 ANALYSIS METHODOLOGY 223.4 RESULTS 26
SECTION 4 30Vessel Inspection4.1 LOW FREQUENCY ELECTROMAGNETIC TECHNIQUE 314.2 PHASED ARRAY ULTRASONIC 334.3 DIGITAL IMAGE CORRELATION 364.4 GUIDED WAVE ULTRASONIC 404.5 ACOUSTIC RESONANCE 434.6 AUTONOMOUS INSPECTION 454.7 FULL MATRIX CAPTURE 484.8 REMOTE MOBILE INSPECTION 514.9 3D LASER SCANNING 544.10 UNMANNED AERIAL VEHICLE 574.11 ENVIRONMENT AND HEALTH MONITORING SYSTEM 604.12 WIDEBANDSONARBEAM-STEERING 634.13 ELECTROMAGNETIC INDUCTANCE DEGRADATION 654.14 TERAHERTZ SPECTRAL IMAGING 67
SECTION 5 69CUI Detection5.1 GUIDED WAVE ULTRASONIC TESTING 705.2 RADIOGRAPHIC-DIGITALDETECTORARRAY 735.3 RADIOGRAPHIC–OPENVISION 765.4 SNIFFER DOGS 78
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CONTENTS CONTINUED5.5 PULSED EDDY CURRENT 825.6 MICROWAVE SENSING 855.7 MICROWAVE DETECTION OF WATER WITHIN INSULATION 895.8 VAPOUR PHASE CORROSION INHIBITOR 925.9 LATERAL WAVE LFET 955.10 CORROSION RADAR 975.11 ACOUSTIC RESONANCE 1005.12 SACRIFICIAL WIRE 1025.13 ELECTROMAGNETIC INDUCTANCE 1055.14 ELECTROCHEMICAL IMPEDANCE SPECTROSCOPY 1075.15 ULTRASONIC SURVEYS 1095.16 TERAHERTZ SPECTRAL IMAGING 1115.17 ACOUSTIC EMISSION 1135.18 ULTRASOUND TOMOGRAPHY 116
SECTION 6 120Management and Cultural Impediments
SECTION 7 122Technology Gaps7.1 TECHNOLOGY GAPS 123
SECTION 8 124Conclusions and Recommendations8.1 GENERAL CONCLUSIONS AND RECOMMENDATIONS 1258.2 TLB ASSET INTEGRITY THEME WORKSHOPS 1258.3 VESSEL INSPECTION 1258.4 CUI DETECTION 1258.5 FURTHER RESEARCH 1258.6 INDUSTRY COLLABORATION 127
APPENDIX A 128Organisations Contacted
APPENDIX B 132Survey QuestionnaireB.1 INITIALQUESTIONS(ALLRESPONDENTS) 133B.2 OIL & GAS OPERATOR QUESTIONS 133B.3 SOLUTION PROVIDER QUESTIONS 133B.4 CONTRACTOR QUESTIONS 133B.5 RESEARCHER/ACADEMIC QUESTIONS 134B.6 CUI AND VESSEL INSPECTION QUESTIONS (ALLRESPONDENTS) 134
APPENDIX C 135Glossary
APPENDIX D 139References
SECTION 1
ACKNOWLEDGEMENTSThis work has come about through the efforts and contribution of many to whom Lockheed Martin is most grateful.
Thanks, in no particular order, are extended to the following for their:
Financial contribution for sponsoring the study
Oil & Gas UK
Input to the theme in its entirety
Jeremy Cutler, Total
Andy Ewens, AMEC Foster Wheeler
Taiwo Olaoya, Oil & Gas UK
Ernie Lamza, OGIC
Ian McCabe, ITF
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6
SECTION 2
EXECUTIVE SUMMARY
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2.1 IntroductionThisreporthasbeenproducedattherequestoftheOilandGasTechnologyLeadershipBoard(TLB)which isworking in partnershipwithOil&GasUK (OGUK),Oil&Gas Authority (OGA),Oil&GasInnovationCentre(OGIC)andIndustryTechnologyFacilitator(ITF).
In response to Sir Ian Wood’s final report on Maximising Economic Recovery (MER) for the UKContinentalShelf(UKCS)–the“WoodReport”hereafter–theTLBidentifiedthreemainthemesforfurtherinvestigation,namelySmallPoolDevelopment,AssetIntegrityandWellConstruction.
In November 2015 LockheedMartinwas contracted by OGUK on behalf of the TLB to conduct atechnologylandscapingstudyaddressingthefirstelementoftheAssetIntegrityThemewhichisledbyTotalE&PUKandAmecFosterWheelerwithsupportfromOGICandITF.
The study targets advances in process vessel inspection andmanaging corrosion under insulation(CUI)fortheonshore,offshoreandsubseaareas.IfsuccessfultheTLBbelievethiscouldcontributetounlocking£1billionofrevenuethroughimprovedproductionefficiencyandcostreductionfortheoilandgasindustryintheUKCS.
2.2 BackgroundOverthelast10yearstheaverageUKCSproductionefficiencyhasfallenfrom80%to60%.Processvessel inspection isasignificantcontributor toproductiondowntimeduringashutdownandofteninvolvespersonnelentryintoconfinedspaces,thusposingamajorsafetyrisk.Thisstudyexploresnewandexistingtechniquesandtechnologieswiththepotentialforsignificantlyreducingprocessvesselinspectiontimesandeliminating(oratleastminimising)theneedforpersonnelentryintovessels.
CUIisdifficulttodetectbecauseoftheinsulationcoverthatmasksthecorrosionproblem,sometimesuntilitistoolate.Itisexpensivetoremovetheinsulation,particularlyifasbestosisinvolved.Historically,industrydatasuggeststhat60%ofpipeleaksarecausedbyCUIandaddasignificantsafetyissueinhydrocarbonservice.FurthermoreitisestimatedthatCUIincurs40–60%ofpipemaintenancecosts.ThisstudythereforealsoexploresmethodsforimprovingdetectionandmanagementofCUIwithoutfirsthavingtoremovetheinsulation,andconsidersportable/mobileorpermanentlyinstalleddevicestoallowinspectionofprocesspipeworkwithminimalrequirementforscaffolding.
2.3 Business Drivers and ConstraintsTheprimarybusinessdriversinupstreamoilandgasproductionaremaximisingproductionefficiency(definedasactualannualproductionasapercentageofmaximumpotentialyieldorotherpotential),andminimising cost (CAPEX andOPEX). Avoiding harm to people and the environment (includingreputational damage e.g., resulting from a serious safety or environmental incident) is also animportantconsideration.
Some of the constraints are: safety, the environment, availability of skilled personnel, regulations,offshorelogistics(e.g.,helicopterandbedplaces)and,inaneraoflowoilprices,availabilityofandwillingnesstocommitcapital.
2.4 StakeholdersThe major stakeholders on the technology user side are the oil and gas producer companies,their operational andmaintenance contractors and, through taxation, theUKgovernment.On thetechnologysuppliersidearespecialistcontractorsandvendors,technologyandproductdevelopersandresearchbodieswithinuniversitiesandelsewhere.
Basedonourresearchtherelationshipbetweenorganisationsinthelandscapeiscomplexandmulti-facetedasshowninthediagrambelow.Withnosingleleadingorganisationactivelycoordinatingtheoil andgas industry’s researchanddevelopment for vessel inspectionsorCUIdetection there is adangerthatorganisationsduplicateresearch,oralternativelyfailtotargetresearchnotspecificallyintheirareaofexpertise.
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There are several different funding routes for research and development, ultimately however thefundingcomesfromthreelocations:theoperatorsandprincipalcontractors,government(UK,Scottish,EuropeanUnion)andfromtechnologyvendors.
Muchoftheresearchthatdevelopsintoproductsiscarriedoutdirectlybythetechnologyvendors,withvaryingdegreesofexposuretothewiderindustry.
The research does not indicate that there are any preferences given tomeeting set standards forqualityorinter-operabilityofdevelopedsolutions,thusadvancesinultrasonicdetectionmaynotbeeasilyadaptedtoworkwithnewsolutionsinremotemobileinspectionforexample,ortomakebestuseofexistingdatahistoriantechnologyandothercommonlyusedITinfrastructure.
Government Statutory Authorities, Initiatives, Research Councils Joint Industry Bodies
Facilitation &Innovation Centres Academia,
R&D bodies
Technology Vendors /Developers
Operators & PrimeContractors
NEW TECH, DEVELOPMENT& DEPLOYMENT
STEER,FUNDING
STEER, FUNDING& RESULTS
STEER,FUNDING
FUNDING
STEER, FUNDING & RESULTS STEER, FUNDING& RESULTS
STEER, FUNDING& RESULTS
STEER, FUNDING& RESULTS
RESEARCH &
COLLABORATION
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Operators & Prime ContractorsThisincludesthemainoperatorsintheoilandgasindustryandtheprimeengineeringcontractors.Theorganisationsthathavecontributedtothisstudyinclude:
Operators• BP; • NexenPetroleumUKLtd;• Shell;• StatoilTechnologyInvest(STI);• Total.
Prime Contractors• AmecFosterWheeler;• BilfingerSalamis;• DetNorskeVeritas;• DoosanBabcock;• ForsysSubseaLtd;• Sonomatic;• Stork;• Technip.
Government Statutory Authorities, Initiatives and Research Councils• UKGovernment;• ScottishGovernment;• EuropeanUnion;• OilandGasAuthority;• HSE;• NERC.
Facilitation and Innovation Centres• ITF;• OGIC;• HighValueManufacturingCatapult.
Joint Industry Bodies• Oil&GasUK,andtheTLB;• TWI;• HOIS;• InstituteofCorrosion;• NationalBoardofBoiler&PressureVessel Inspectors.
Academia, Research & Development Bodies• Heriot-WattUniversity;• ImperialCollegeLondon;• RobertGordonUniversity;• UniversityofAberdeen;• UniversityofCambridge;• UniversityofManchester;• UniversityofStrathclyde;• HighValueManufacturingCatapult;• NationalPhysicalLaboratory(NPL);• SINTEF(Norway);• TNO, Science and Industry, Business Unit:
OilandGas(Netherlands).
2.5 Current SituationGeneralNon-destructive testing (NDT) techniques widely used in the inspection of oil and gas plant andequipmentinclude:• ultrasonictesting;• magneticparticleinspection;• dyepenetrantinspection;• visualinspection;• radiography.
Eachcanbehighlyeffectivebuttherateofcoverageisoftenslow.Inspectionmayalsorequireextensivepreparation, including the removal of insulation to allow external inspection.Deployment is oftencomplicatedbythenatureofthephysicalenvironment.
Alternative, lesssensitiveNDTtechniquescanbeusedina large-scalescreeningprocess,providingameansof inspectingareas thatwouldotherwisebe impossible toaccess.The idea is topinpointproblemareas, and then follow thisupwithdetailed inspectionsat targeted locationsusingmoresensitivetechniques.
Adetailedevaluationof20screeningmethods isprovided intheHealth&SafetyExecutive’s (HSE)
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researchreportRR659,“Evaluationoftheeffectivenessofnon-destructivetestingscreeningmethodsforin-serviceinspection,2009”.Theseinclude:
• profileradiography;• smallcontrolledarearadiography;• thermographicimaging;• X-raydigitalfluoroscopy;• neutronbackscatter;• electromagneticinductance.
Vessel inspectionTheusualtechniqueforinspectingtheinternalsofprocessvesselsinvolvesfullandsecureisolation,gas-freeingandothersafetyprecautionsbeforeatechniciancanentertocarryoutavisualinspection,takephotographsandpossiblyuseinstrumentstomakeothermeasurements.
Althoughitispossibletoobtainathoroughanddetailedassessmentofthevessel’sinternalconditioninthisway, thenecessaryprecautionsaretime-consumingandevenwiththemostrigoroussafetymeasures,entrytoconfinedspacesisinherentlyhazardous.
Consequently,oil andgasoperators tend tominimise the frequencyof internal inspections,whichobviously increases the risk of corrosion or internal mechanical damage going undetected. Anytechniquethatallowsvesselinternalconditiontobeinspectedorotherwiseassessedwithoutrequiringanyonetoenterhasclearadvantageswithrespecttoreduceddowntime,morefrequentassessmentandimprovedsafety.
CUI DetectionThemost common and straightforwardway to inspect for CUI is to cut and remove plugs in theinsulation,visually inspectthesurfacefor immediatesignsofcorrosion,thenultrasonicallytesttherestofthevesselorpipe.
ThemainproblemwiththistechniqueisthatCUItendstobelocalised,andunlesstheinspectionplugisaccuratelypositioned,sitesofcorrosioncanbemissed. If there is sufficientdoubt regarding theconditionofthemetalawayfromtheplugs,largeareasofinsulationmayneedtoberemoved.
Furthermore, cuttingplugs introducesa fresh sourceofpotentialmoisturepenetrationandhencefurther corrosion. Removing plugs is not particularly hazardous (unless the insulation containsasbestos)butitmaybetimeconsumingandcostly,particularlyifscaffoldingisrequired.
Removal(andreinstatement)oflargeareasofinsulationismessyandmaydisruptnormaloperationsas well as being expensive and time-consuming. Inspection techniques that preserve the laggingthereforehavesignificantadvantages.
2.6 Scope and ObjectivesThe objective of the TLB Asset Integrity Theme is to facilitate the introduction of products and services, potentially from outside the oil and gas industry, that allow vessel inspection and CUI detection to be carried out at lower cost, with reduced impact on production efficiency, without introducing additional safety risks and potentially providing risk mitigations.
The objective of the Lockheed Martin study is to:
• identify existing and emerging technologies for vessel inspection and CUI detection, both within and outside the oil and gas industry;
• assess these with respect to maturity, applicability, cost, risk and benefit;• highlight the main bodies involved in providing relevant technologies, products and services.
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2.7 MethodologyData collectionRelevantinformationwascollectedusingacombinationofthefollowing:
• face-to-faceandtelephonediscussionwithstakeholders;• surveyquestionnaire(emailedtostakeholders);• onlineresearch(vendorpublicationsandotherpublicdomainsources).
Inpractice,thesurveyquestionnairesprovedoflimitedvalueandmostinformationwasderivedfromdiscussionandonlineresearch.
AnalysisAsmuch of the information is subjective and even anecdotal in places, the key question becamehowtodeviseamethodforanalysisandcomparisonthatprovidessufficientrigourwhileretainingtransparencywithrespecttotheunderlyingjudgements.
Themethodadoptedwastoidentifycriteriaforassessingtherelevanttechnologiesandtechniquesandthen,whereappropriate,tosub-dividetheseintocomponentswhichcouldberatednumericallyaccordingtosimpleguidelines.
Thecriteriaselectedwere:
Criteria DescriptionAnexistingmethod‘TechnologyReadinessLevel’(TRL),devisedbyNASA,wasadopted
Sub-divided into six components:plant running; retrofit;offshore;dependencyonspecialistskills;typesofplantitem;sampleorfullarea
Sub-divided into four components: precautions required to maintain safety;requirementforculturalchange;complexity;industrybacking
Sub-dividedintothreecomponents:initialinstallation,initialstafftrainingandotherpreparation;annualoperationandmaintenance
Sub-divided into two components: maintenance cost reduction; plant safetyimprovement
Maturity
Applicability
Risk
Cost
Benefit
Apart fromtheNASATRLscore,whichdirectlyproducesanumeric result,eachcomponentof theabovecriteriawasassignedascorerangeandassociatedguidelines.AllofthecriteriaaresetoutindetailinSection3.Thenetresultwastoderiveforeachtechnology,asetoffivescoresintherange0–10,oneforeachassessmentcriterion.
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2.8 Summary of resultsBased upon the analysis approach described above there are a number of techniques that offerencouragingpotential.Allofthetechniquesevaluatedaredisplayedintabularandgraphicalformatbelow.
Vessel inspectionTheanalysisresultsarepresentednumericallyinthefollowingtable.The“Strength”hasbeencalculatedbycombiningapplicabilityandbenefits,withthe“Weakness”beingcalculatedbycombiningcostandrisk.The“OtherMaturity (TRL)” isLockheedMartin’sassessmentof thematurityof thetechniquewithinotherindustries.Ahigherfigureindicatesabetterresult.
Technology/Technique
O&GMaturity (TRL)
ApplicabilityLimitations
9
9
9
9
7
6
6
6
6
4
3
3
2
2
Lowfrequencyelectromagnetictechnique
Phasedarrayultrasonic
Digitalimagecorrelation
Guidedwaveultrasonic
Acousticresonance
Autonomousinspection
Fullmatrixcapture
Remotemobileinspection
3Dlaserscanning
Unmannedaerialvehicles
Environmentandhealthmonitoringsystem
Widebandsonarbeamsteering
Electromagneticinductance
Terahertzspectralimaging
Risk Cost Benefit Strength Weakness
7
7
7
6
8
8
8
6
6
6
7
6
7
8
8
6
7
7
7
6
6
7
6
5
4
7
6
6
7
5
6
6
7
6
7
5
4
8
3
6
7
5
7
6
5
4
4
8
7
7
4
5
6
3
4
7
14
13
12
10
12
16
15
13
10
11
13
9
11
15
15
11
13
13
14
12
13
12
10
13
7
13
13
11
OtherMaturity (TRL)
9
9
9
9
7
6
6
6
6
4
3
3
2
2
Thevessel inspectionoptionsarecomparedinthediagrambelowbycombiningthetwo‘Strength’attributes(applicability/limitations,benefits)ontheY-axiswiththetechnicalmaturitylevelshownontheX-axis.Thetwo‘Weakness’attributes(cost,risk)arecombinedandformthesizeofthebubbles.Thediameterofthebubblesreflectstheperceivedweakness/challengeofthetechnology.Alargebubblehasfeweridentifiedweaknessesandislikelytobemoreeasilyadoptedgiventheappropriate
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R&Dspend.Theyellowcolouredbubblesaresensortechnologiesandthegreenrepresentenablingplatforms.
A simpler comparison,usingonly the ‘maturity’ indication (NASATRL) ispresented in thediagrambelow.Theyellowcolouredbarsarethe‘maturity’indicationwhenthetechnologyisassessedforuseintheindustryitwasprimarilydevelopedforandthebluecolouredbarsarethe‘maturity’indicationwhenthetechnologyisassessedforuseinoilandgas.
0 1 2 3 4 5 6 7 8 9
Terahertz spectral imagingFull matrix capture
Acoustic resonance
Digital image correlationWideband sonar beam steering
Environment and health monitoring systemElectromagnetic inductance
3D laser scanning
Autonomous inspectionGuided wave ultrasonic
Unmanned aerial vehicles
Remote mobile inspection
Low frequency electromagnetic techniquePhased array ultrasonic
Vessels -TRL Score
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CUI DetectionTheanalysisresultsarepresentednumericallyinthefollowingtable.The“Strength”hasbeencalculatedbycombiningapplicabilityandbenefits,withthe“Weakness”beingcalculatedbycombiningcostandrisk.The“OtherMaturity (TRL)” isLockheedMartin’sassessmentof thematurityof thetechniquewithinotherindustries.Ahigherfigureindicatesabetterresult.
The CUI detection options are compared in the diagram below by combining the two ‘Strength’attributes(applicability,benefits)ontheY-axiswiththetechnicalmaturitylevelshownontheX-axis.Thetwo‘Weakness’attributes(cost,risk)arecombinedandformthesizeofthebubbles,thelargerthebubblethelowertheweakness.AlargebubblehasfeweridentifiedweaknessesandislikelytobemoreeasilyadoptedgiventheappropriateR&Dspend.
Therearenoenablingplatformsshowninthediagrambelow.HowevertheplatformslistedforvesselinspectioncouldpotentiallybedevelopedforusewithCUIdetection.
Technology/Technique
O&GMaturity (TRL)
ApplicabilityLimitations
9
8
8
9
8
8
8
0
7
0
3
3
3
3
0
3
2
0
Guidedwaveultrasonic
Radiographic-digitaldetectorarray
Radiographic-openvision
Snifferdogs
Pulsededdycurrent
Microwavesensing
Microwavedetectionofwaterwithininsulation
Vapourphasecorrosioninhibitor
LateralwaveLFET
Corrosionradar
Acousticresonance
Sacrificialwire
Electromagneticinductance
Electrochemicalimpedancespectroscopy
Ultrasonicsurvey
Terahertzspectralimaging
Acousticemission
Ultrasoundtomography
Risk Cost Benefit Strength Weakness
6
8
7
7
8
7
7
8
7
7
8
7
7
2
7
8
5
7
6
6
6
7
8
6
6
6
8
8
7
8
6
7
6
6
5
6
5
7
7
7
7
6
6
7
7
7
7
7
7
7
7
5
6
7
5
5
5
6
7
7
7
6
7
5
4
5
4
2
3
7
4
4
11
13
12
13
15
14
14
14
14
12
12
12
11
4
10
15
9
11
11
13
13
14
15
12
12
13
15
15
14
15
13
14
13
11
11
13
OtherMaturity (TRL)
9
9
9
8
8
8
8
8
7
4
3
3
3
3
3
2
2
2
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Asimpler comparison,usingonly the ‘maturity’ indication (NASATRL) ispresented in thediagrambelow.Asbeforetheyellowcolouredbarsarethe‘maturity’indicationwhenthetechnologyisassessedforuseintheindustryitwasprimarilydevelopedforandthebluecolouredbarsarethe‘maturity’indicationwhenthetechnologyisassessedforuseinoilandgas.
Heat MapThematrixbelowprovidesavisualisationofhowtheindividualtechnologiesdetailed inthisreportperformagainsteachofthechallengestypicallyencounteredbyCUIandvesselinspectiontechnologies,givingaquickandeasymeanstoidentifywhichinnovationsbestapplytospecificchallenges.
Thetechnologiesarelistedalongthetopofthematrixandthechallengesarelisteddowntheleft,withtrafficlightsymbolsusedattheintersectionstodenoteeachtechnology’sabilitytomeeteachchallengeforCUI,vesselinspection(VI),orboth.
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2.9 Management and Cultural ImpedimentsUnderstandably,upstreamoilandgashasaconservativecultureandsomeresistance tochange isinevitable.Itisthereforeessentialthatmanagementandculturalfactorsaretakenintoconsiderationwhen selecting among technical options that have potential to hold promise for reducing costs,increasing production efficiency and/or improving safety. Broadly speaking, techniques that are insomewayfamiliar,orappeartoberelatedtoacceptedpracticeinsomeway,standabetterchanceofacceptancethanthosethatappearalienoroutlandish.
2.10 Technology GapsThecurrenttechniquesusedintheoilandgasindustryforvesselinspectiondonotcurrentlypermitinternalinspectionwithoutmanualentry,andforCUImanagementanddetectionthecurrentlyusedtechniqueseitherhavelimitedcoverageorresolution,and/orrequiretheremovalofinsulation.
There are some promising techniques described in the study which can potentially close thesetechnology gaps and Lockheed Martin recommends that a shortlist is drawn by the relevantstakeholdersforfurtherpursuit.Werecommendthatstakeholders:
• review the scoring guidelines and Lockheed Martin suggested scores contained within thisdocument;
• forshort-termpossibilities(i.e.,thosemore-or-lessreadytogo),identifyopportunityforrealisticplant trial andprovide thenecessary funding, technical supportand logistics toallow this toprogress;
• forlongertermprospects,providetechnicalandfundingsupportsothatthesecanbemovedtowardsthe‘trial-ready’state.
Adefinite‘gap’thatcanbeclosedquitequicklyisthatofcombiningsomeofthesensingtechnologiesreviewedwithremotemobileandautonomousinspectionplatforms.Itislikelythatthiswillrequiresomeencouragementandsupporttogetthedifferentvendorsanddeveloperstoworktogether.
2.11 Conclusions and RecommendationsVessel inspectionGeneralThestudyteambelievesthattheassessmentmethodologyadoptedissound,althoughthematurity,applicability,cost,riskandbenefitscoresandassociatedguidelineswouldbenefitfromwiderreviewandvalidationbytherelevantstakeholders.
The studywas undertakenwithin an agreedtimeperiodwhich allowed sufficient interactionwithrelevantstakeholders,butdidnotallowforexhaustiveidentificationandinteractionwithalltechniquesandtheirproviders.
TLB Asset Integrity Theme WorkshopsTheTLBorganisedthemeworkshopsonvesselinspectionanddetectionofcorrosionunderinsulationatMaryculterHouseHotelAberdeenon24thand25thFebruary2016.
The Lockheed Martin Asset Integrity Landscape Draft Report was used as a pre-read for the workshops.Theaimoftheworkshopswastoinformfurtherworktodevelopproductsandserviceswhich can reduce costs, increase production efficiency and/or improve safety when carrying outprocess vessel inspections and detection of corrosion under insulation. This further work will becoordinatedbytherecentlyannouncedOil&GasTechnologyCentre.
For furtherdetailsplease refer to theTLB IntegrityTheme–WorkshopOutputReport,whichwasissuedbyOGICtoallworkshopattendeeson17thMarch2016.
Vessel inspectionThelowfrequencyelectromagnetictechniqueappearstooffergoodprospectsatmoderatecostandriskandhasahighmaturityscore.
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Fullmatrixcapture(FMC)hasasimilarprofile,butislessmaturesocouldbeseenasagoodlonger-termprospect.
Althoughrobotsandremotelyoperatedvehiclesontheirownhavearelativelylowbenefitscore,suchdevices are becoming increasingly common (e.g., in the nuclear industry) andmight be profitablycombinedwithothersensortechnologiestoallowasignificantreductionintheneedformanualentryintoprocessvesselsandotherconfinedspaces.
CUI DetectionThepulsededdycurrenttechniqueappearstooffergoodprospectsatmoderatecostandrisk.Ithasahighmaturityscoreandthereisasenseofsignificantindustrycommitmenttoproductdevelopment,marketinganddeployment.
Vapourphasecorrosioninhibitorstandsoutasbeingaprevention(asopposedtodetection)technique.Themainconcernhereisthenatureofthechemicalsrequiredfortheprocess,especiallyoffshore.Nevertheless,thistechniqueseemsworthyoffurtherinvestigationasitofferstheprospectofreducingtheextentandnatureoftheunderlyingproblemofCUI.
Aswith vessel inspection, someof the sensing techniques identified in this studymightprofitablybecombinedwithremotelyoperatedvehiclessuchaspipeandvesselcrawlers.Ofparticularbenefitwouldbeanycombinedtechniquethatreducedtherequirementforscaffolding.
Further ResearchLockheedMartinrecommendsthatfurtherresearchisundertakenintoclosingperceivedtechnologygapsthatcouldpreventtheuptakeofsomeofthemethodsandtechnologiesdescribedinthestudy.WerecommenddevelopinganITarchitecturethatfacilitatesthedevelopmentanduseofnewvesselinspectionandCUIdetectionandmonitoringtechniquesastheybecomeavailable.Inparticularthearchitectureshouldincludethefollowing.
Open StandardsDeveloping open standards is key tomaximising the rapid take up of any new techniques, it alsofacilitatesthedevelopmentofopenmarketsandminimisesvendorlock-in.
Werecommendthattomaximisetheimpact,newstandardsshouldbedevelopedinconjunctionwiththeappropriatenationalandinternationalstandardsbodies.
Secure Sharing of DataWerecommendthattechniquesaredevelopedacrosstheoilandgasindustrytosharetherawdatafrommultiple installations in a securemanner. This data can be provided to all stakeholders andprovideaplatformforfutureinnovation.
Automate data collection, transformation and storageMake use of existing technologies such as COTS data historians, IP protocols, and transmissiontechnologiessuchasWiFiandLowPowerBluetooth,coupledwithnewdevelopmentsinlowcost/lowpowersensorsbeingdevelopedfortheInternetOfThings.
Develop standard analysis techniquesTomaximisere-useandportability,standardanalysistechniquesshouldideallycomeintheformofopen-sourcelibrary/softwaredevelopmentkitsofstandardtechniquesoptimisedforusewithvesselinspectionandCUIdetectionandmonitoring.
Develop standard visualisation techniques
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Standardvisualisationtechniquesshouldbedevelopedwithtwomainaudiences inmind–controlroomstaffandmaintenance/supportengineers.
Controlroomstaffwanttoknowaboutsuddenchangesinplantconditions,typicallythroughscreensandalarmsondistributedcontrolsystems(DCS)andsupervisorycontrolanddataacquisition(SCADA)systems.Thereforeappropriatestandardsshouldbedevelopedforvisualisationincollaborationwiththeleadingcontrolsystemsproviders.
Maintenance /Support engineers want to know in more depth about gradual changes in plantconditions,eithercontinuouslymonitoredorthroughanalysisresultingfromspotchecks.Thereforeappropriate standards for visualisation should be developed in collaborationwith leading desktopvisualisationandanalysisproviders.
AggregationAsouranalysisindicatesthatnoonemethodisprevalentforeithervesselinspectionorCUIdetectionandmanagement,itislikelythatoperatorswillemployseveraldifferent,possiblyoverlappingmethods.Thereforeanalysistechniquesshouldbedevelopedinsuchawayastopermitaggregationofresults,andvisualisationtechniquesshouldincludetheabilitytooverlayresultsfromseveraldifferentsources.
ThediagrambelowshowstheproposedstandardsbasedITarchitecture.
Proposed Standards Based IT Architecture
Industry collaborationThestudyfoundthattherelationshipsbetweenthevariousstakeholdersarecomplex,andthatthereisalackoffocusonvesselinspectionandCUIdetectiontechnologieswithintheoilandgasindustry.Wealsonotethatsomeofthetechnologybeingdevelopedinitiallyoriginatedinotherindustrysectors.
LockheedMartin recommends that a single leading organisation is given overall responsibility forfocussingvesselinspectionandCUIresearchanddevelopmenteffortswithintheoilandgasindustry.Thisorganisationshouldfocusonseveralstrands:•Developmentofthestandards-basedITarchitectureasdescribedabove;•DevelopmentofpromisingvesselinspectionandCUIresearch;•Cross-sectorinitiativeswithrelationtovesselinspectionandCUIresearch.
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2.12 Next StepsReview and Validate ScoringAsdiscussedin2.7above,thenumericalscoresassignedbythestudyteam,andpossiblytheassociatedguidelines,shouldbereviewedandvalidatedbyawiderrangeofstakeholders.
Achieve ConsensusAbroad consensus is required among stakeholders regardingwhich technology options should beactivelypursuedinthenearterm,whichmeritactivelonger-termsupport,andwhicharebestsubjecttoawatchingbriefonly.
Industry PartnershipsOtherwisepromisingtechnologiesrequireactivesupporttoattainthenecessarymaturitytopermitrealisticsiteoroffshoretrials,andthisshouldbeachievedbycreatingindustrypartnershipstotakeforwardcollaborativeR&Dprogrammes.
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SECTION 3
DATA COLLECTION AND ANALYSIS
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3.1 ApproachThe intention of the study was to include representatives of all the key groups involved in bothprocessvesselinspectionandmanagingCUI.Thisincluded:oilandgasoperators,Tier1contractors(includingdutyholders),specialistconsultantsandserviceproviders,equipmentsuppliers,technologydevelopers,researchorganisationsandacademia.
ThestudywascommissionedbytheAssetIntegritysubgroupoftheTLBandpaidforbyOGUK.Thesubgroupmembers provided a list of potential stakeholderswho could be approached to providerelevant and contemporary information on current techniques, and Lockheed Martin includedadditional stakeholders from their own contacts and experience. A table of organisations thatcontributedtothestudyispresentedinAppendixA.OrganisationsidentifiedasonthelandscapebutwhodidnothavesignificantcontributiontothisstudyarealsopresentedinAppendixA.Allthosewhoagreedwerecontactedandinterviewedface-to-faceorbytelephone.
Toobtainthemaximumbenefitandensureconsistency,asurveyquestionnairewasdevelopedandrefined, and thiswasusedduring structured interviewsof those stakeholderswhowereprovidinginformation.ThequestionnaireispresentedinAppendixB.
Theinterviewswerevaluableinprovidingpragmaticandinsightfulevidenceofthemethodologiesandtechniquesaswellastheassociatedchallengesfacedwhenaddressingtheissueofvesselinspectionand managing CUI. The information gathered identified further research into the inspection anddetectiontechniqueswhich,inturn,helpedclarifythefinaltechnicalsummarieswhicharecontainedinsubsequentsectionsofthisreport.
Theinformationobtainedfromthesurveywassupplementedbyliteratureandonlinesearchesintoexistingandnewtechnologiessothatthereviewcouldfocusonthemostrelevantsystems.
3.2 LimitationThe studywas undertakenwithin an agreedtimeperiodwhich allowed sufficient interactionwithrelevantstakeholders,butdidnotallowforexhaustiveidentificationandinteractionwithalltechniquesandtheirproviders.
3.3 Analysis MethodologyAssessment criteriaThecentralproblemfacedbythestudyteamwashowtoderivemetricsthatwouldallow:
• thevarious technologiesand techniques reviewed tobeassessed individually ina consistentmanner;
• meaningfulcomparisonstobeobtainedacrossvesselinspectionandCUIcategories.
Asmuchoftheinformationobtainedissubjectiveandevenanecdotalinnature,thequestionresolvestooneofconvertingsubjectiveassessments intonumericalscores inawaythatprovidessufficientrigourwhileretainingtransparencywithrespecttotheunderlyingjudgements.
Themethod adoptedwas to identify a set of criteria for assessing the relevant technologies andtechniques and, where appropriate, to sub-divide these into components which could be ratednumericallyaccordingtosimpleguidelines.
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Criteria Description
Anexistingmethod‘TechnologyReadinessLevel’(TRL),devisedbyNASA,wasadopted
Sub-divided into six components:plant running; retrofit;offshore;dependencyonspecialistskills;typesofplantitem;sampleorfullarea
Sub-divided into four components: precautions required to maintain safety;requirementforculturalchange;complexity;industrybacking
Sub-dividedintothreecomponents:initialinstallation,initialstafftrainingandotherpreparation;annualoperationandmaintenance
Sub-divided into two components: maintenance cost reduction; plant safetyimprovement
Maturity
Applicability
Risk
Costs
Benefits
Thecriteriaselectedwere:
Apart fromtheNASATRLscore,whichdirectlyproducesanumeric result,eachcomponentof theabovecriteriawasassignedascorerangeandassociatedguidelines.Thesearedescribedbelow.
Scoring GuidelinesMaturity (NASA Technology Readiness Level)
Stage Level
Basicprinciplesobservedandreported
Technologyconceptand/orapplicationformulated
Proofofconcept
Experimentalpilotinlaboratoryconditions
Demonstrationpilotinsimulatedenvironment
Industrialpilotinidealisedconditions
Initialproductionuse(lessthan3years)
Productionuse>3yearsormultipledeployments<3yearswithlimitedtrackrecord
Widespreadusewithextensivetrackrecord
1
2
3
4
5
6
7
8
9
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Applicability / Limitations
Risk
Costs
Factor Range Explanation0=no1 = yes
0=no1 = yes
0=no1 = yes
1=highlydependentonlimitedskills2=somenewskills/resourcesrequired3=largelyachievablewithexistingcapability
1=restricted(<50%ofitems)2=significant(50–75%ofitems)3=majority(>75%ofitems)
0=extrapolationfromlimitedsamples1=fullareacovered
0–1
0–1
0–1
1–3
1–3
0–1
Practicablewithplantrunning
Retrofitpracticable
Offshorepracticable
Dependentonspecialistskills/resources
Rangeofplant
Fullareacoverage
Factor Range Explanation1=high(~£10m)2=medium(~£1m)3=low(~£100K)
1=high(~£1M)2=medium(~£100K)3=low(~£10K)
1=high(~£10M)2=medium(~£1M)3=low(~£100K)
0=significant1=negligible
1–3
1–3
1–3
0–1
Installandcommission (one-off)
Stafftraining(one-off)
Routineoperationandmaintenance(annual)
Productionimpactofuse
Factor Range Explanation1=largelynewandunfamiliar2=broadlyfamiliar;somenewaspects3=minorextensiontocurrentpractices
1=additionalprecautionsrequired2=broadlysimilar3=clearreductiontorisk/exposure
1 = high2=medium3=low
0=no1 = yes
1–3
1–3
1–3
0–1
Cultural/resistancetochange
Safety(personnel/environment)
Complexity(technical/procedural)
Significantindustrybacking(e.g.,majorvendor)
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Benefit
Thenetresultwastoderiveforeachtechnology,asetoffivescoresintherange0–10,oneforeachassessmentcriterion.Asitisdifficulttocompareacrossoptionsusingfivecriteria,thetwo‘Strength’attributes(applicability,benefit)andthetwo‘Weakness’attributes(cost,risk)weresummedforeachoptiontofurtherdepictthedata.
PresentationItwas felt important topresent the results inways thatwouldalloweasier visualassessmentandcomparisonratherthanatableofrawnumbers.For individualassessment,the‘spider’ (or ‘radar’)plotwithfiveaxeswas selected. Thisprovidesaquick visual indicationof the scoresonfiveaxes.Furthermore,criteriawhosescoresaresignificantlyoutofbalancewiththeothersarereadilyseen.Goodprospectsarelikelytobemoreevenlybalanced,withnodistinctweaknesses.
In the examples shown below the first graph indicates a ‘good’ prospect with evenly balancedattributes,thesecondgraphindicatesaprospectwhereoneoftheattributesislesswellrepresented(inthiscasetheTRL).
Evenly Balance Unevenly Balance
Factor Range Explanation1=insignificant(~£100K)2=minorbutworthwhile(~£500K)3=moderate(~£2.5M)4=significant(~£10M)5=radical(~£25M)
1=insignificant2=minor3=moderate4=significant5=radical
1–5
1–5
Annualcostsaving(plantoperationandmaintenance)
Safetyimprovement (plantintegrity)
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3.4 ResultsIndividual assessmentsDetailed assessment scores for each technology or technique reviewed are presented for vesselinspectioninSection4,andforCUIdetectioninSection5.Atabularsummaryoftheresultsispresentedbelow. Here the “Strength” has been calculated by combining applicability and benefits, with the“Weakness” being calculated by combining cost and risk. The “OtherMaturity (TRL)” is LockheedMartin’sassessmentofthematurityofthetechniquewithinotherindustries.Ahigherfigureindicatesabetterresult.
Vessel inspectionTheanalysisresultsforvesselinspectionare:
Technology/Technique
O&GMaturity (TRL)
ApplicabilityLimitations
9
9
9
9
7
6
6
6
6
4
3
3
2
2
Lowfrequencyelectromagnetictechnique
Phasedarrayultrasonic
Digitalimagecorrelation
Guidedwaveultrasonic
Acousticresonance
Autonomousinspection
Fullmatrixcapture
Remotemobileinspection
3Dlaserscanning
Unmannedaerialvehicles
Environmentandhealthmonitoringsystem
Widebandsonarbeamsteering
Electromagneticinductance
Terahertzspectralimaging
Risk Cost Benefit Strength Weakness
7
7
7
6
8
8
8
6
6
6
7
6
7
8
8
6
7
7
7
6
6
7
6
5
4
7
6
6
7
5
6
6
7
6
7
5
4
8
3
6
7
5
7
6
5
4
4
8
7
7
4
5
6
3
4
7
14
13
12
10
12
16
15
13
10
11
13
9
11
15
15
11
13
13
14
12
13
12
10
13
7
13
13
11
OtherMaturity (TRL)
9
9
9
9
7
6
6
6
6
4
3
3
2
2
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CUI DetectionTheanalysisresultsarepresentednumericallyinthefollowingtable:
Comparison of options
Vessel inspectionThevessel inspectionoptionsarecomparedinthediagrambelowbycombiningthetwo‘Strength’attributes(applicability/limitations,benefits)ontheY-axiswiththetechnicalmaturitylevelshownontheX-axis.Thetwo‘Weakness’attributes(cost,risk)arecombinedandformthesizeofthebubbles.Thediameterofthebubblesreflectstheperceivedweakness/challengeofthetechnology.AlargebubblehasfeweridentifiedweaknessesandislikelytobemoreeasilyadoptedgiventheappropriateR&Dspend.Theyellowcolouredbubblesaresensortechnologiesandthegreenrepresentenablingplatforms.
Technology/Technique
O&GMaturity (TRL)
ApplicabilityLimitations
9
8
8
9
8
8
8
0
7
0
3
3
3
3
0
3
2
0
Guidedwaveultrasonic
Radiographic-digitaldetectorarray
Radiographic-openvision
Snifferdogs
Pulsededdycurrent
Microwavesensing
Microwavedetectionofwaterwithininsulation
Vapourphasecorrosioninhibitor
LateralwaveLFET
Corrosionradar
Acousticresonance
Sacrificialwire
Electromagneticinductance
Electrochemicalimpedancespectroscopy
Ultrasonicsurvey
Terahertzspectralimaging
Acousticemission
Ultrasoundtomography
Risk Cost Benefit Strength Weakness
6
8
7
7
8
7
7
8
7
7
8
7
7
2
7
8
5
7
6
6
6
7
8
6
6
6
8
8
7
8
6
7
6
6
5
6
5
7
7
7
7
6
6
7
7
7
7
7
7
7
7
5
6
7
5
5
5
6
7
7
7
6
7
5
4
5
4
2
3
7
4
4
11
13
12
13
15
14
14
14
14
12
12
12
11
4
10
15
9
11
11
13
13
14
15
12
12
13
15
15
14
15
13
14
13
11
11
13
OtherMaturity (TRL)
9
9
9
8
8
8
8
8
7
4
3
3
3
3
3
2
2
2
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CUI DetectionThe CUI detection options are compared in the diagram below by combining the two ‘Strength’attributes(applicability,benefits)ontheY-axiswiththetechnicalmaturitylevelshownontheX-axis.Thetwo‘Weakness’attributes(cost,risk)arecombinedandformthesizeofthebubbles,thelargerthebubblethelowertheweakness.AlargebubblehasfeweridentifiedweaknessesandislikelytobemoreeasilyadoptedgiventheappropriateR&Dspend. Therearenoenablingplatformsshowninthediagrambelow.HowevertheplatformslistedforvesselinspectioncouldpotentiallybedevelopedforusewithCUIdetection.
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Heat MapThematrixbelowprovidesavisualisationofhowtheindividualtechnologiesdetailed inthisreportperformagainsteachofthechallengestypicallyencounteredbyCUIandvesselinspectiontechnologies,givingaquickandeasymeanstoidentifywhichinnovationsbestapplytospecificchallenges.
Thetechnologiesarelistedalongthetopofthematrixandthechallengesarelisteddowntheleft,withtrafficlightsymbolsusedattheintersectionstodenoteeachtechnology’sabilitytomeeteachchallengeforCUI,vesselinspection(VI),orboth.
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SECTION 4
VESSEL INSPECTION
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4.1 Low Frequency Electromagnetic Technique
Low Frequency Electromagnetic TechniqueSource:
O>RL: 9
Description
The Low Frequency Electromagnetic Technique (LFET) is used to detect defects by passing a low frequency magnetic field though metal plate or pipe. By using several sensors in a LFET scanner, a 3D image of the collected data is produced so that the shape and depth of the defect can be determined. LFET scanners are used to inspect storage tanks and other convex or concave ferrous surfaces, as well as non-ferrous metal tubing & piping surfaces. Scanners are available in flatbed, pipe crawler and modular crawler variations, allowing scanning of horizontal or vertical magnetic surfaces.In most situations minimal or no surface preparation is required but if surface preparation is required beyond basic preparation, time involved along with cost will both increase
Key Attributes
Inspection of pipe or flat surfaces
Both magnetic and non-magnetic metals can be scanned
Minimal pipe preparation and in some cases no preparation required
Real-time display with some LFET scanners
Inspects through ID or OD scale
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 2
Significant Industry Backing 1
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 3
Safety Benefits 4
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryLowFrequencyElectromagneticTechnique(LFET)worksbyinjectingalowfrequencymagneticfieldintoametalplateortubeandusingscanner-mountedpickupcoilstodetecttheinducedACmagneticfieldinthematerialmeasuringthedistortionsintheresultingmagneticfieldthatoccuroveraflaw.Thispickupcoil isplacedsuchthatthereturnpathforthemagneticfieldisthroughtheareatobetested.Flawsaredetectedbymeasuringthemagneticfielddirectlyovertheflawareawithsensorcoils.
A flaw or defect causes the magnetic flux linesin that area to be distorted or different thanexpected. This distortion can bemeasured as achangeinphaseand/oramplitude.Withsuitablecalibration tables the flaw can be analysed andadeterminationofflawdepthandshapecanbemade. By using several sensors in the scannerarray it is possible to display a 3D image of thecollecteddatasothattheshapeanddepthoftheflawcanbedetermined.
LFETproductsareusedto inspectstoragetanks,otherconvexorconcaveferroussurfaces,aswellasnonferrousmetaltubing/pipingsurfaces.
LFETscannerscanbeusedinsettingswherecompetingtechnologiesfailorareinconvenient
LFETscannersdetectsflaws,includingcorrosioncellsandhydrogendamage,causticandphosphategouging,oxygenpitting,departurefromnucleateboiler,IDpitting,corrosion,anderosion.
Crackingisalsodetectableanditsdetectioncanbeoptimisedbymodifyingthepick-upcoilconfiguration.
TherearevariousscannersystemsthatemployLFETtechnologymanufacturedwithspecificapplicationorsituationsinmind.Flatbedscannersforabovegroundtankscanninghavealargescanningarea,pipecrawlerswhichrunabovepipesofvaryingdiameter,360pipecrawlerscannerswhichautomaticallyadjusttopipediameterandmodularcrawlerscannersthatcanbeusedtoscaneitherhorizontalorverticalmagneticsurfaces.
Key Attributes• Technologyisinuseandreadilyaccessiblefromvendors;• Inspectionofpipeorflatsurfaces;• Bothmagneticandnon-magneticmetalscanbescanned(ascaneconomizertubing);• MinimalPipePreparationandinsomecasesnopreparationrequired;• Real-TimedisplaywithsomeLFETscanners;• InspectsthroughI.D.orO.D.scale.
Limitations• Ifpipeorsurfacepreparationisrequiredtimescaleisimpactedasarecosts.
Sources• testex-ndt.com/products/lfet-products
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 9 – Widespread production use with extensive track record.
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4.2 Phased Array Ultrasonic
Phased Array UltrasonicSource:
O>RL: 9
Description
Uses multi-element ultrasonic probes, pulsed individually in a programmed pattern under computer control allowing a large area to be swept from a fixed probe point. PA systems can greatly simplify the inspection of components with complex geometries. The small footprint of the transducer and the ability to sweep the beam without moving the probe also aids inspection of such components in situations where there is limited access for mechanical scanning. Systems are available in a variety of models with increasing complexity and capability. Instruments range from basic models that perform simple sector and linear scans with 16-element probes to advanced systems that offer multi-channel capability and advanced interpretive software with probes of up to 256 elements.
Can be applied to Vessels externally or internally and used to determine vessel wall thickness.
Key Attributes
Beam focus and steering
Linear or sector scans
Display enables flaw visualisation
Higher cost than traditional ultrasonic techniques
High degree of operator expertise required
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 1
Operations/Maintenance 2
Production Impact 0
Benefits
Cost Benefits 2
Safety Benefits 4
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryIn conventional (non-PhasedArray) single-element ultrasonic probes, a beam is emitted in a fixeddirection.Totestalargevolumeofmaterial,aconventionalprobemustbephysicallyscanned(movedorturned)tosweepthebeamthroughtheareaofinterest.Incontrast,thebeamfromaPhasedArray(PA)probecanbefocusedandsweptelectronicallywithoutmovingtheprobe.
ThebeamiscontrollablebecausePAultrasonicsystemsutilisemulti-elementultrasonicprobes,whichareindividuallypulsedinaprogrammedpatternundercomputercontrol.Byexcitingeachelementinacontrolledmanner,beamscanbesteeredandfocussedwithasingletransducerassembly.Thebeamissweptlikeasearch-lightthroughtheobjectbeingtestedandthedatafrommultiplebeamsareconsolidatedtoproduceanimageshowingaslicethroughtheobject.Twoandthreedimensionalviewscanbegeneratedshowingthesizesandlocationsofanyflawsdetected.
PAsystemscangreatlysimplifytheinspectionofcomponentswithcomplexgeometries.Thesmallfootprintofthetransducerandtheabilitytosweepthebeamwithoutmovingtheprobealso aids inspection of such components insituations where there is limited access formechanicalscanning.
PA systems are commonly used for weldinspection. The ability to test welds withmultiple angles from a single probe greatlyincreases the probability of detection ofanomalies. Electronic focusing permits
optimisingthebeamshapeandsizeattheexpecteddefectlocation,thusfurtheroptimisingprobabilityofdetection.Theabilitytofocusatmultipledepthsalsoimprovestheabilityforsizingcriticaldefectsforvolumetricinspections.
PAsystemsareavailableinavarietyofmodelswithincreasingcomplexityandcapability.Instrumentsrange from basicmodels that perform simple sector and linear scanswith 16-element probes toadvancedsystemsthatoffermulti-channelcapabilityandadvancedinterpretivesoftwarewithprobesofupto256elements.PAtransducersmaybeusedwithvarioustypesofwedges,inacontactmode,orinimmersiontesting.Theirshapemaybesquare,rectangular,orround,andtestfrequenciesaremostcommonlyintherangefrom1to10MHz.
PAsystemscanpotentiallybeemployedinalmostanytestwhereconventionalultrasonicflawdetectorshavetraditionallybeenused.Weldinspectionandcrackdetectionarethemostimportantapplications,andPAscanalsobeusedtoprofileremainingwallthicknessincorrosionsurveyapplications.
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Key Attributes• Beamfocusingandsteering;
• Linearorsectorscans;
• Displayenablesflawvisualisation.
Limitations• Highercostthantraditionalultrasonictechniques;
• Highdegreeofoperatorexpertiserequired.
Sources• OlympusIMSNDTTutorials;
• TheWeldingInstitute(TWI);
• “NDTDatabase&JournalofNon-DestructiveTesting”
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 9 – Widespread production use with extensive track record
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4.3 Digital Image Correlation
Digital Image Correlation Source:
TransportTRL: 3
Description
Digital Image Correlation (DIC) is a methodology for obtaining and comparing images to highlight changes and defects, accurately and to high precision. DIC can compare not only optical images, but images from thermographic cameras and laser scanners, to highlight new or changing hot spots, or changing dimensions of vessels.Additional DIC software would have to be developed for Vessel Inspection purposes, and based on their respective measurement specifications. The measurement specification identifies the types of defects to identify and therefore provide information as to the accuracies in instrumentation and the required DIC system.
Key Attributes
Rapid data capture compared to conventional inspection methods
Direct run-to-run inspection comparison highlighting differences to 1mm
Full record of the structure via archived time history of appearance and shape
More efficient use of experienced inspectors
Reduction in cost and improvement in workforce safety, particularly for hazardous or difficult-to-access environments
Richer, more detailed 3D spatial data
Applicability / Limitations
With Plant Running 0
Retrofit 1
Offshore 1
Need for Specialist Skills 2
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 2
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 0
Benefits
Cost Benefits 2
Safety Benefits 3
Other Industries
TransportNuclear
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryDigital image correlation (DIC) is amethodology for obtaining and comparing images to highlightchangesanddefects,accuratelyandtohighprecision.DICcancomparenotonlyopticalimages,butimagesfromthermographiccamerasandlaserscanners,tohighlightneworchanginghotspots,orchangingdimensionsofvessels.
DIC involves digitally comparing images to highlight any areas that are different to images takenpreviously.Itdoesthisveryaccuratelyandtoalevelthatcouldnotbedonevisuallyfromthesamedistanceorwithoutbeingveryclosetoobjects.Forthisreason,itisextremelyversatile.
DIFCAM StudyTheNationalPhysicalLaboratory (NPL)andpartnersdevelopedabespokesystemforNetworkRailusingDICthatcouldbeusedtoenhancevisualinspectionsofrailtunnels.
TheaimofthisDigitalImagingForConditionAssetManagement(DIFCAM)projectwastodevelopaworld-classcapabilityintheuseofopticaltechniquestorapidlymonitor&assessassetcondition.Thisinvolvedthedevelopmentofademonstratorformonitoringtheinteriorofrailtunnels,reducingoreliminatingtheneedfortrackaccess&subjectivehumanvisualinspectionsasanexampleofagenerictechnologyplatform,thatcouldbedeployedinothersectors.Railtunnelexaminationwasidentifiedasagooddemonstratorforthistypeoftechnologyasitisacurrent,high-costproblem,withaclear,identifiedmarketneedandanaccessiblepartner/customerbase.
The main feature of the DIFCAM system is that it relies on application of DIC techniques in thecomparisonofonemeasurementrunwithanother,potentiallytakenmonthsoryearsapart.WorkatNPLestablishedthatthismeasurementtechniquecouldbeappliedtolargecivilengineeringstructuresand used for in-situ measurements, and therefore it was applied to tunnel imagery to comparesuccessivetunnelimagestakenovertime.
Correlatingtheimagestakenusingahighresolutioncameraarrayfromdifferentrunsidentifiesanychanges ormovement in the tunnelwall appearance. A similar processwas usedwith the shapemeasurementdatacapturedfromalaserscannertoidentifychangesinshapefromruntorun.Thiswasenabledbyaccuratelymeasuringthepositionandorientationofthevehicleonwhichthecameras/sensorsweremountedduringeachrun.
Themainbenefitsofusingthismeasurementapproachwere:• Speedofmeasurementimprovedovermanualinspection;• Highresolutionimagery;• Combinedshapeandappearancemeasurements;• Archivalstorageofhighqualitydata;• Automateddatageneration;• Automatedscreeningcapability;• Automateddefectreportgeneration.
ForlaboratoryDICmeasurements,particularlymaterialtesting,agreyspecklecoatingisoftenappliedtoensurelocalcontrast.Howeverwithlargeengineeringstructuresitwasfoundthat,withsuitablelighting,therewassufficientlocalcontrasttoallowreliablemeasurementstobemadewithoutanysurfacepreparation.
Thesystemperformanceforthedemonstrationsystem,whichrunsprimarilyondesktopcomputers,meant thatapairof24megapixel imagescouldbeprocessed in30 secondsusinga12processorcore.Forthedemonstratortherewere11picturespermetre,thereforeatwindesktopsystemcouldprocessabout1metreoftunnelperhour.Theimagestoragerequirementswereapproximately10GBytespermetreperrun.Shapemeasurementdatacouldbeprocessedmorequicklyandhadalaser
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scannerstoragerequirementofabout10Mbytespermetre.Notethattheanalysisofbothformsofdataiswellsuitedtoparallelprocessingandcaneasilybescaledtoasystemwithmanyprocessors,resultinginaperformancethatscalesalmostlinearlywiththenumberofprocessors.
During trials and in-between two successive inspection runs, inspectionengineerswalked throughthetunnelstocreateman-madedefectstodeterminetheeffectiveness inthesystem.Theseman-madedefectsincludedanareawheresootwasscrapedoffthewall,ascrewhadbeenleftonsomeabandonedandnot-in-servicerail,andabucketofwaterwasthrownonthewall.Uponthesecondpass,theDIFCAMsystemidentifiedallofthesedefects(withinan800mtunnel).Inadditiontothis,theDIFCAMsystemhighlightedthechangesintherandompatternofgravelcausedbytheinspectionengineers’footprints.
Theimagesbelowshowthetunnelwallbeforeandaftertheman-madedefectsareintroducedandthecorrespondingDIFCAMprocessedimages.
AnareaofthetunnelwallatWansfordpriortoanintroduceddefect.
Thesameareacapturedinasubsequentmeasurementrun,thereisasmallchangeinthecoverageofapatchofsootnearthemiddleofthe
fieldofview
Amapofverticaldisplacementforthetunnelwallshownabove.Thescaleisinmmofmovement.
Theareanearthemiddleisprimarilycomposedofdisplacementsthatareoutofrange
Amapofcorrelationcoefficientforthetunnelwallshownabove.Areasthataredarkerhavepoorer
correlation.
Similarsystemshavebeendeveloped,orareunderdevelopment,fordifferentapplications,highlightedbelow:• Monitoringcrackgrowthofcementsurroundingnuclearreactors;
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• UtilisingDICforconditionmonitoringorvisualinspectionofcablesubwaysforelectricalnetworksowners/operators;
• Determinewhethermedicationhasbeentamperedwith;• UsingCCTVtodetectblockagesoflargedrainagefacilitiesfortheenvironmentalagency.
Key Attributes• Rapiddatacapturecomparedtoconventionalinspectionmethods;• Directrun-to-runinspectioncomparisonhighlightingdifferencesto1mm;• Fullrecordofthestructureviaarchivedtimehistoryofappearanceandshape;• Moreefficientuseofexperiencedinspectors;• Reductionincostandimprovementinworkforcesafety,particularlyforhazardousordifficult-to-
accessenvironments;• Richer,moredetailed3Dspatialdata;• Modulararchitecturetoallowelementreuseandadaptationformultipleapplicationsindifferent
sectors.
LimitationsAdditionalDICsoftwarewouldhavetobedevelopedforVessel Inspectionpurposes,andbasedontheirrespectivemeasurementspecifications.ThemeasurementspecificationidentifiesthetypesofdefectstoidentifyandthereforeprovideinformationastotheaccuraciesininstrumentationandtherequiredDICsystem.
Sources• “AlternativeMethods forRailwayTunnelExamination–AReviewandRecommendations”;NPL
ReportMAT42;• “Digitalimagingforconditionassetmanagement(DIFCAM)(November2013)”;NationalPhysical
Laboratory.
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 9 – Widespread production use with extensive track record.
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4.4 Guided Wave Ultrasonic
Guided Wave UltrasonicSource:
O>RL: 9
Description
Guided Wave Ultrasonic Testing (GWUT) utilises stress waves that propagate along an elongated structure while guided by its boundaries. This allows the waves to travel a long distance with little loss in energy. GWUT uses very low ultrasonic frequencies, between 10~100kHz, compared to those used in conventional ultrasonic testing. At higher frequencies the range is significantly reduced. Also, the underlying physics of guided waves is more complex than bulk waves. The physical reflection of guided waves enables the detection of defects with a depth much smaller than a wavelength. Commonly used for routine pipeline inspection, the same principles can be used for defect detection in vessels. Industrial pilots are taking place focussed on monitoring vessel floors using permanently attached sensors.
Key Attributes
Potential for continuous monitoring
Non-invasive once fitted
Potentially high cost to retrofit
Applies to vessel floor only
Not yet proven effective
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 1
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 1
Significant Industry Backing 1
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 0
Benefits
Cost Benefits 2
Safety Benefits 2
Other Industries
Marine transport
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryGuidedWaveUltrasonicTesting(GWUT)fortankmonitoringhasbeenunderdevelopmentatTWIforanumberofyearsandiscurrentlydeployedinoilandgasstoragefacilitiesaspartofanongoingpilottoprovethetechnology.GWUTfortankmonitoringinvolvestheuseoflowfrequencyultrasoundtoexamineabovegroundstoragetanksinternalfloorplatesforcorrosion.Thetechniqueusesanumberofpermanentlyattachedsensorswhicharebondedtothelipoftheannularplateextendingbeyondthetankwall.Thelongdistancepropagationcharacteristicsoftheultrasonicwavesusedallowsignalsfromonesideofthetanktobepickedupbyasensorontheotherside(upto30mdiameter).
Byusingcombinationsoftransmitandreceiveamongstthesetofsensors,itispossibletocoverthewholefloorarea.Bytakingreadingsfromthesensorsregularlyandwiththecirculargeometryofthetanksstructureitallowsatomographicmethodtobeusedtoreconstructanimageofthetankfloorfromthetransmittedultrasonicsignals.
Theimageisformedbycollectinginformationatmanyangularpositionsaroundthecircumferenceofthetankso long term trends in the conditionof thefloor canbedetermined.The techniquealsoallows short termvariations, forexample fromtemperaturefluctuationsorchangesinthefilllevelsinthetank,tobeseparatedfrom changes in the physical condition of the floor.In this way, tanks needing priority attention may beidentifiedandthemorerigorousinternalexaminationsmaybeconcentratedonthese.
Theweldinginstitute(TWI)hasproventhatthetechnologyiscapableofdetectingcorrosionandthattheprincipleofthedetectionofdegradationoftheconditionoftankfloorshasbeendemonstrated.Thecurrentpilotcontinuesasitisvitalthattheabilityofthisnon-invasivetechniquetodetectandtoidentifyadequatelyrealservice-inducedcorrosionorcrackingisdetermined,ifitisevergoingtobeusedasaprimaryonlinemonitoringmethodinliveplants.
ImperialCollegeLondonisalsoconductingstudiesusingGWUTforvesselinspectioninconjunctionwithworktheyaredoingusingthistechnologyforCUI inpipeline inspection.AlthoughatanearlystageImperialCollegeLondoniscontinuingtobuildonvesselinspectionusingGWUTbyusingsensorsthatsweepthesectionundertest(almostlikealighthousebeacon)andisalsolookingataroboticmethodofdeployingGWUTtechnology
Key Attributes• Allowscontinuousmonitoring;• Non-invasiveoncefitted.
Limitations• Requiresretro-fittingtovessels;• Potentiallyhighcost;• Researchhasmainlybeenforvesselfloormonitoringonly;• Requireshighlevelsofexpertisetoapplyandinterpretresults;• Stilltobeprovenasaneffectivetechnique.
Sources• www3.imperial.ac.uk/nde/researchthemes/inspection/guidedultrasonicwaves;• TWI research paper• Long RangeGuidedWave InspectionUsage – Current Commercial Capabilities and Research
Directions,2006,M.J.S. LoweandP.Cawley.DepartmentofMechanicalEngineering ImperialCollegeLondon;
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• BS9690-2:2011 ’Non-destructivetesting.Guidedwavetesting.Basicrequirements forguidedwavetestingofpipes,pipelinesandstructuraltubulars’.BritishStandardsInstitute.ISBN9780580 73794 7.
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 9 – Widespread production use with extensive track record.
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4.5 Acoustic Resonance
Acoustic ResonanceSource:
O>RL: 7
Description
A sending transducer transmits a broad-band acoustic signal towards the pipeline. The signal then spreads in the structure, exciting half-wave resonances, and the structure's response signal is then detected by the receiving transducer.Analysis of the frequency content of the response signal gives the resonance peak frequencies, from which the base resonance frequency - and ultimately the structure's thickness - can be estimated. During post-processing, multiple measurements can be combined to estimate the size and depth of flaws, such as wall loss, in the metal structure.
Key Attributes
Potentially very accurate
Does not directly detect corrosion, detects wall loss and may not be able to distinguish between external and internal wall loss;
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 2
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 2
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 2
Safety Benefits 2
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryAcoustic resonance technology (ART)usesa sending transducer to transmitabroad-bandacousticsignal towards the metal structure. The signal then spreads in the structure, exciting half-waveresonances,andthestructure’sresponsesignalisthendetectedbythereceivingtransducer.
Analysis of the frequency content of theresponse signal gives the resonance peakfrequencies,fromwhichthebaseresonancefrequency–andultimatelythestructure’sthickness–canbeestimated.Duringpost-processing,multiplemeasurementscanbecombined to estimate the size and depthof flaws, such as wall loss, in the metalstructure.
Thistechniquecanpotentiallybeusedfordetectingcorrosionandwalllossinvesselswithoutenteringthevessels,howeverwearenotawareofanyproductsortrialslookingatthisarea.
Key Attributes• Measuresinternalandexternalwallthickness;• Potentiallyveryaccuratescans;• Scansthroughfirecoatings.
Limitations• Accuracyislimitedwithirregulargeometry;• Needs360degreeaccesstopipeline;• The deployment of the technique is slow with the receiving sensor needing to be in close
proximitytotransmitter;• Can’tyetscanthroughmetalcladding.
SourcesHalfwavewebsite:http://www.halfwave.com/acoustic-resonance-technology-art/
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 7 – Initial production use (less than 3 years)
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4.6 Autonomous Inspection
Autonomous InspectionSource:
O>RL: 6
Description
Autonomous inspection technologies build on the capability of remote mobile inspection techniques by completely removing operator dependence. Developments in processing, battery, sensor and decision-making technologies allows for devices with the potential to autonomously navigate objects and perform inspections without human involvement, taking advantage of the ongoing improvements in the portability, automation and consistency of the scanners available for a range of NDT techniques.Underwater Autonomous Vehicles (UAVs) and autonomous crawlers for topside use offer a potentially transformational platform for future inspection operations.
Key Attributes
Able to operate without human involvement.
Reduces likelihood of operator error during often lengthy, tedious human-controlled inspection.
Not subject to the same inspection range limitations of remotely operated devices.
Can carry out work where humans are unable or unwilling.
Can allow work to be carried out remotely onshore, offshore, topside and subsea.
Multiple application within the oil and gas domain.
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 2
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 1
Safety 3
Complexity 1
Significant Industry Backing 1
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 0
Benefits
Cost Benefits 4
Safety Benefits 4
Other Industries
Medical Industry Agriculture Space exploration AerospaceManufacturing MilitaryNuclear
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryAutonomousinspectiontechnologiesbuildonthecapabilityofremotemobileinspectiontechniques(andalloftheirassociatedsafetyandeconomicadvantages)byremovingoperatordependencefrominspection devices. Developments in processing, battery, sensor and decision-making technologieshasnowallowedfordeviceswiththepotentialtoautonomouslynavigateatargetenvironmentandperforminspectionswithouthumaninvolvement.
ThetwoprimaryareaswhereremotemobileinspectiontechniquesprimarilyapplyissubseaviaROVsand plant inspection via remotely operated robotic devices such as crawlers. Both of these areashaveseensignificantresearch,developmentand,insomecases,productdevelopmentfocussedonautonomousvariants,whetherthatbeautonomousvehicles(AV)orautonomouscrawlers.
AV currently under development are capable ofautonomously homing and docking, providingthe ability to deploy and recover a vehicle atdepth. Once deployed, AV can carry out facilityinspections, including “as built” surveys, baselinesurveys of existing structures, decommissioningsurveys, and the use of high res sonar forstructural integrity assessment and generationof3Dstructuralmodels.Theyarealsocapableofautonomously locating, tracking and surveyingpipelines/flowlines, operating at depths of up to4,000metres.
Autonomouscrawlershavebeenusedforsometimeinelectricitynetworks,aerospaceandshippingfortheautomatedinspectionofhighvoltagepowerlines,military/commercialaircraftandhullinspection.They take advantage of the ongoing improvements in portability, automation and consistency ofthe scanners available for a range ofNDT techniques. Crawlers can either be pre-programmed toperform(andrepeat)inspectionsatpre-definedlocations,orhavetheon-boardcapabilitytosenseandmanoeuvrearound/overobstaclesencountered,typicallyusingrollers,magnetism,suction,oracombinationofthese,totraverseanobject.
Unlike remotely operated inspection, autonomous vehiclesalsorequireautonomyofpowerandsotheiroperationtimecanbelimitedbythelifespanoftheiron-boardpowersupply.Inresponsetothis,devicescanbeprogrammedtoreturntoabasestationforchargingwhenthepowersupplyissufficientlydiminished.
Autonomousoperation typically requires alternatemethodsofdatacaptureandrecordingtobeusedthanthoseonremotemobilesolutions.Commonalternativesincludewirelessdatatransferand/oron-boardrecordingofdataduringoperationforsubsequenttransferuponreturntoabasestation.
Key Attributes• Abletooperatewithouthumaninvolvement;• Reduceslikelihoodofoperatorerrorduringoftenlengthy,tedioushuman-controlledinspection;• Notsubjecttothesameinspectionrangelimitationsofremotelyoperateddevices;• Cancarryoutworkwherehumansareunableorunwilling;• Canallowworktobecarriedoutremotelyonshore,offshore,topsideandsubsea;• Multipleapplicationwithintheoilandgasdomain.
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Limitations• Autonomyofpowersupplycanlimitoperationaltimebetweenpowersupplyreplenishment;• Mayrequireadditionalinfrastructuretosupportpoweranddatatransferrequirements;• Eachdifferent inspectionrequirementtypicallyrequiresadifferentrobotspecificallydesigned
forthatrequirement.
Sources• LockheedMartinMSTUnderseaSystems
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 6 – Industrial pilot in idealised conditions.
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4.7 Full Matrix Capture
SummaryFullmatrixcapture(FMC)isadataacquisitiontechniquethatallowsforthecaptureofeverypossibletransmit-receivecombinationforagivenultrasonicphasedarray(PA)transducer.
InspectionusingPAultrasonictechniquesisnowrelativelywellestablished,withseveraladvantagesoverconventionalultrasonictechniquesresultingfromtheabilitytosteerandfocusultrasonicwaves
Full Matrix CaptureSource:
O>RL: 6
Description
Full matrix capture (FMC) is a data acquisition technique that allows for the capture of every possible transmit-receive combination for a given ultrasonic phased array (PA) transducer.Inspection using PA ultrasonic techniques is now relatively well established, with several advantages over conventional ultrasonic techniques resulting from the ability to steer and focus ultrasonic waves using a single transducer containing multiple probes. By utilising beam steering and focussing, a single transducer can perform a task which usually requires multiple conventional ultrasonic transducers.
Post-processing of FMC data can provide much more information than standard PA processing; focusing depths and beam angles can be optimised after the inspection
Key Attributes
Fully focused images
High sensitivity to small flaws
High resolution
Ease of inspection setup as no need to apply complex focal laws
Ease of interpretation
In comparison to Phased Array, FMC offers:
Better perspective
Improved vertical resolution
Improved flaw definition, allowing for better sizing
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 2
Coverage 3
Sample/Full Area 0
Risks
Cultural Change 3
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 3
Operations/Maintenance 2
Production Impact 0
Benefits
Cost Benefits 3
Safety Benefits 4
Other Industries
Nuclear
0123456789
10TRL
App/Lim
RisksCosts
Benefits
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usingasingletransducercontainingmultipleprobes.Byutilisingbeamsteeringandfocussing,asingletransducercanperforma taskwhichusually requiresmultipleconventionalultrasonic transducers.Electronicbeamsteeringalsominimisestherequirementformechanicalmovementofthetransducer,whichcansavetime,improvesflawsizingaccuracy,andisadvantageouswhenaccesstoacomponentislimited.
FMCisadataacquisitionprocesswhichcapturesandstoresA-scan(time-amplitude)dataforeverytransmitter-receivercombinationofelementsinaPhasedArray.Thetechniqueusesa“transmitononeand receiveonall” data capture approach. Initially, a singleelement in thearray is usedas atransmitter,whileallelementsthenreceive.Thisprocessrepeatsuntilallelementsinthearrayhavebeenfired.
TheimagebelowillustratestheFMCprinciples.
During the standard PA acquisition process, the raw signals are processed at the hardware levelandarenotavailable for subsequentoff-lineprocessing.However,withFMCall raw information isavailableaftercapturetosyntheticallygeneratethedataresultingfromanygivenbeamthroughoff-lineprocessingusinganalgorithmsuchastheTotalFocussingMethod(TFM).
Post-processing of FMC data can provide much more information than standard PA processing;focusingdepthsandbeamanglescanbeoptimisedaftertheinspectiontobettercharacterisedetectedindications. This is a significant benefit over the standard PAprocess and itmight, in some cases,preventcostlyre-scans.
AcomparisonofimagesobtainedusingstandardPAandFMCisshownbelow.HeretheimageontheleftwastakenusingstandardPIandthehigherresolutionimageontherightwithFMC.
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Key Attributes• Fullyfocusedimages;• Highsensitivitytosmallflaws;• Highresolution;• Easeofinspectionsetupasnoneedtoapplycomplexfocallaws;• Easeofinterpretation;• IncomparisontoPhasedArray,FMCoffers:oBetterperspective;o Improvedverticalresolution;o Improvedflawdefinition,allowingforbettersizing;oReducedmisinterpretationofgeometryechoesvs.defects.
Limitations• Equipmentusedmustsupportveryhighdatatransferratesandtheabilitytohandlelargedata
files;• Equipmentusedmustprovideaveryhighsignalqualitywithlowlevelsofelectronicnoise.
Sources• TheWeldingInstitute(TWI)• “Real-time fullmatrix capture for ultrasonic non-destructive testingwith acceleration of post-
processingthroughgraphichardware”;NDT&EInternational;October2012;• “DevelopmentandValidationofaFullMatrixCaptureSolution”,PatrickTremblay,DanielRichard;
ZETEC,Canada;• “Full-Matrix Capture with a Customizable Phased Array Instrument”; Gavin Dao, Dominique
BraconnierandMattGruber.
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 6 – Industrial pilot in idealised conditions.
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4.8 Remote Mobile Inspection
Remote Mobile InspectionSource:
O>RL: 6
Description
Remote mobile inspection can provide significant advantages over current manual methods of inspection; this includes the ability to support human inspectors, and the ability to operate in hazardous, harsh and dirty environments. There are different kinds of remotely operated inspection solutions in the oil, gas and petrochemical industry, ranging from remotely operated subsea vehicles to mobile robotic systems for topside use that can perform inspection and maintenance operations on assets.This has placed remote mobile inspection in an ideal position to be an integral part of the inspection and maintenance strategies.
Key Attributes
Assist human inspectors.
Can carry out work where humans are unable or unwilling.
Can allow work to be carried out remotely onshore, offshore, topside and subsea.
Some robotic technology allows maintenance and checks to be carried out without shutdown of assets.
Systems perform multiple tasks or can be fitted with sensor or control arms to suit the situation or requirements of that specific task.
Applicability / Limitations
With Plant Running 0
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 2
Safety 3
Complexity 1
Significant Industry Backing 1
Costs
Install/Commission 2
Staff Training 1
Operations/Maintenance 2
Production Impact 0
Benefits
Cost Benefits 3
Safety Benefits 4
Other Industries
Medical Industry Agriculture Space exploration AerospaceManufacturing MilitaryNuclear
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryTherearedifferentkindsofremotelyoperatedinspectionsolutionsintheoil,gasandpetrochemicalindustry, ranging from remotely operated subsea vehicles to mobile robotic systems for topsideusethatcanperforminspectionandmaintenanceoperationsonassets.Systemsrangefromtailor-madesolutionsbyinspectioncompaniestocommerciallyavailableinspectionsystems.Themajorityof these remote systems have implemented a limited number of inspection technologies; theseinclude,amongstothers,visualandcamerasystems(mostoftheremotesystemsarefittedwithvisualinspection technology), ultrasonic sensors for thickness gauging, andmagnetic or electromagneticsystems.
Oneofthemainadvantagesofremotemobile inspectionsolutionsisthattheycanreachlocationsinaccessiblebyhumansbecauseofsizeconstraints,temperature,andimmersioninliquids,hazardousconditions,orheightrestrictionswithsafetyconcern.
Theremotemonitoringofhazardouson-shoreplantsandrefineriesisanemergingfieldforremotelyoperatedmobileroboticsystems. Intelligentandreliableroboticand instrumentationsystemshavebeendevelopedtoenableonshoreoperatorstomonitorandcontrolvariouspartsoftheplantfromasafelocation.Remotelyoperatedroboticsystemsarebeingusedtoallowhumanoperatorstoperformtaskssuchasgaugereadings,valveandleveroperationsandmonitoringofgaslevel,leakage,acousticanomaliesandsurfaceconditionsremotelyandsafely.
Applications in the oil, gas and petrochemical industry forasset inspectionsare limited,but the roboticsolutions thatarebeingusedaretypicallyremote-controlledcrawlersthatusemagneticwheels.Theseareabletoclimbthewallsandeventheroofof(horizontal)assets.Someareabletocoverthewholeinsideareaofanasset(withoutinternals)andevennegotiatesimpleobstaclesthemselves.Sofartheyhavebeenusedforapplicationsliketheinspectionofcleansteamchests,pressurevessels,andAboveGroundStorageTanks(AST)fromthe outside. Although asset inspection typically requiresassetstobetakenoutofoperation,roboticsolutionswiththecapability to inspectanASTfloorwhile the tankremains inserviceareavailable.Examplesofremotely-controlledroboticsystems that can be used for asset inspection include theOTIS,developedbyA.Hak,MagneBikeandFAST,developedbyAlstomInspectionRobotics,andalineofcrawlersystemsdevelopedbyTesTex.
Robotic solutions for the inspection andmaintenance of assets in the oil, gas and petrochemicalindustryhavetheirfoundationsinthesubseadomain.Duetotheinaccessibleenvironment(mainlydeepseaoperations),RemotelyOperatedVehicles,commonlyreferredtoasROVs,havebeenusedtoassistinthedevelopmentofoffshoreoilfields.Theirtasksrangefromsimpleinspectionofsubseastructures,pipelinesandplatforms,toconnectingpipelinesandplacingunderwatermanifolds.Theyareusedextensivelyboth in the initial constructionof a subseadevelopmentand the subsequentrepair andmaintenance of the assets. Most ROVs are equipped with video cameras and lightingsystems,withadditionalequipmentaddedtoexpandthevehicle’scapabilities.Theseoften includestill cameras,manipulators or cutting arms, water samplers, and instruments thatmeasurewaterclarity,lightpenetration,andtemperature.Therearealsoinspectionandmaintenancesystems(suchasunderwaterwelding)andmagneticorelectromagneticsystemsforinternalandexternalinspectionsofpipelinesandthestructuraltestingofoffshoreplatforms.
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Key Attributes• Assisthumaninspectors24/7;• Cancarryoutworkwherehumansareunableorunwilling;• Canallowworktobecarriedoutremotelyonshore,offshore,topsideandsubsea;• Somerobotictechnologyallowsmaintenanceandchecktobecarriedoutwithoutshutdownof
assets;• Multipleapplicationwithintheoilandgasdomain;• Manyroboticsystemsperformmultipletasksorcanbefittedwithsensororcontrolarmstosuit
thesituationorrequirementsofthatspecifictask.
LimitationsAlthoughsubseaROVsystemshavebeeninoperationforaconsiderabletimeandhaveabigindustryandtrackrecordbehindthem,theuseofremoteroboticsinoil,gasandpetrochemicalmaintenanceandinspectionislessmature.Howeveritisagrowingindustry,thereisaneedforthistypeoftechnologyanditexpectedtogrowandexpandasthetechnologyandmethodsofdeployingitdevelop.• Remote inspection typically takes longer thanhuman inspection (althoughoverall inspection
operational time may be reduced because fewer and/or less stringent safety measures arerequired);
• Rangeofremoteinspectioncanbelimitedbytheacceptablelengthandflexibilityofpower/datacables;
• Eachdifferent inspectionrequirementtypicallyrequiresadifferentrobotspecificallydesignedforthatrequirement.
Sources• testex-ndt.com/products/lfet-products/viper-crawler• a-hak-is.com/en/home/what_we_do/markets/tank_storage/integrated_tank_services/
inspection/online_robotic_tank_bottom_inspection• petrobotproject.eu• inspection-robotics.com/products
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 6 – Industrial pilot in idealised conditions
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4.9 3D Laser Scanning
3D Laser ScanningSource:
O>RL: 6
Description
3D Laser Scanning enables non-invasive surveys and measurements for various industries and is already in widespread use to provide accurate recording of asset infrastructure for onshore and offshore assets within the oil and gas industry. The resultant data point clouds can then be joined to form an accurate 3D digital model of the asset which allows engineers to perform 3D walkthroughs to assist in the planning of changes and because they are sufficiently accurate to take measurements from, can be used to identify placement for new piping and vessels.
Key Attributes
Extremely Accurate measurements (millimetres)
Elimination of Rework
Reduced man hours for on-site inspections
Non-invasive survey and inspection
Inspections can take place whilst the plant is still in operation
Reduces the risk of safety to personnel
Open Source Software compatibility
Applicability / Limitations
With Plant Running 0
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 1
Staff Training 1
Operations/Maintenance 2
Production Impact 0
Benefits
Cost Benefits 2
Safety Benefits 2
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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Summary3D Laser Scanning enables non-invasive surveys and measurements for various industries andisalready inwidespreaduse toprovideaccurate recordingofasset infrastructure foronshoreandoffshoreassetswithintheoilandgasindustry.Theresultantdatapointcloudscanthenbejoinedtoformanaccurate3Ddigitalmodeloftheassetwhichallowsengineerstoperform3Dwalkthroughstoassistintheplanningofchangesandbecausetheyaresufficientlyaccuratetotakemeasurementsfrom,canbeusedtoidentifyplacementfornewpiping,vesselsandsoon.Thetechnologyeliminatesissueswithmanualmeasurementsandreferencetooriginaldrawings,whichcanbetimeconsumingandpossiblyinaccurate.
Laser Scanning - How it worksAlaserisfiredandforeverypointthatthelaserhits,apointinspaceisrecorded.Ascannerrecordsthereflectivityofthesurface,withcamerasprovidingcolourandRedGreenBlue(RGB)values.Thepointsthatarecapturedcanbeamillionormorepointsofdatapersecondandthiscreateswhatisknownaspointclouddata–a3Dendproductforprocessingthecaptureddata.Pointcloudscanbeuseddirectlyortransferredintootherfilesystemsformanipulation.
This scanned data can then be provided as photo realistic drawings and simulations – which areparticularlyusefulincaseswherenodrawingsexistorwereoriginallyonlyhardcopieswereavailable.Thedatacanalsobeconvertedintomeshedor3Dsurfacedmodels.
Theimagesbelowshowanexampleofascanandtheresultant3Dmodelandprintedmodel.
Scan 3D Model 3D Printed Models
Studieshavebeencarriedandareon-going,inrelationtoutilisingdronestocarrythelaserscanningequipment.
Therearecommerciallyavailablesolutionsforgeneralcorrosiondetection,andthereareproposedusesforexternalinspectionofpressurevessels,howevernonecurrentlyforinternalinspection.Laserscanningcould,ifshowntoworkforvesselinspection,assistengineersinmakingquickdecisionsoncorrectivemaintenanceworktoaidandextendthelifetimeofonshoreandoffshoreassets.Therisktoemployeescanbereducedsignificantlybyallowingscansremotelyandthusminimisingmanualscanningandmeasuring.
Benefits• ExtremelyAccuratemeasurements(millimetres);• EliminationofRework;• Reducedmanhoursforon-siteinspections;• Non-invasivesurveyandinspection;• Inspectionscantakeplacewhilsttheplantisstillinoperation;
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Limitations• Thefilesproducedcanbeverylarge;• Usingtheequipmentrequirestrainedandcompetentpersonnel;• Datainterpretationrequiresskilledpersonnel;• Hasnotyetbeenshowntobeofbenefitinvesselinspection.
Sources• InterviewswithTech27andABB;• BS5970:2001“Codeofpracticeforthermalinsulationofpipeworkandequipment”;• HSEDocument-RR659;• HSEDocument-RR509;• API 571; 581.
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 6 – Industrial pilot in idealised conditions.
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4.10 Unmanned Aerial Vehicle
Unmanned Aerial Vehicle Source:
O>RL: 4
Description
The use of various types of Unmanned Aerial Vehicles (UAV), popularly known as drones, has increased rapidly in recent years - both for private leisure use, and for commercial aerial work.A UAV can survey areas where there is a high risk of explosions due to the presence of flammable gases and/or vapours. While operating in incendiary environments, a UAV avoids generating any sparks or risks of inciting an explosive reaction.
The UAV can help accurately assess and help plan in advance upgrade work required by providing vital information in real time
Key Attributes
Can be used in a variety of situations
Rapid deployment
Real time data, still image and video capabilities
Cheaper and safer than conventional methods of inspection at height
Certified for use in potentially explosive atmospheres
Height limitations
Payload limitations
Flight restrictions may limit deployment
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 1
Sample/Full Area 1
Risks
Cultural Change 2
Safety 1
Complexity 1
Significant Industry Backing 1
Costs
Install/Commission 3
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 3
Safety Benefits 2
Other Industries
Nuclear
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryTheuseofvarioustypesofunmannedaerialvehicles(UAV),popularlyknownasdrones,hasincreasedrapidly inrecentyears-bothforprivate leisureuse,andforcommercialaerialwork.Thissummaryfocusesontheuseofthistechnologyasaninspectionandsurveyingtool.
XamenTechnologiesmanufactureUAVwhichcanbeusedinavarietyofsituationsandoneinparticular,theLE4-8XDualATEX, isofparticular reference for vessel inspectionbecause it is compliantwithEuropeanExplosiveAtmosphereEnvironmentsDirective94/9/ECandthereforesuitableforusewithintheoilandgassectorwherethereisahighriskofexplosionsduetothepresenceofflammablegasesand/orvapours.
Directive 94/9/EC (also known as ‘ATEX 95’ or ‘the ATEX Equipment Directive’) provides guidanceontheapproximationofthelawsofmembersstatesconcerningequipmentandprotectivesystemsintendedforuseinpotentiallyexplosiveatmospheres.AlthoughtheUKfollowsthesamestandardstherearesomedifferencesinheightandpayloadrestrictionswhichthiscertificationallowsintheUKwheretheUKrestrictsUAVstoaheightof393ft.withapayloadof44lb.Thisisadropinheightandpayloadwhencompared to restrictions inFrancewhichhasamaximumheightallowanceof492ftandapayloadallowanceof55lbbutbotharecoveredbyDirective94/9/EC.TheXamenLE4-8XDualATEXiscertifiedforATEXzone2operationgenerallyandcomplieswiththeUKrestrictionsprovideditspayloadisrestrictedto44lb.
TheLE4-8XDualATEXisdedicatedtotheoilandgasandchemicalprocessingsectorsandisdesignedtoreducetheriskandoverheadcostsassociatedwithinfrastructuremaintenanceandsurveillance.
UAVs can help accurately assess and plan in advance upgrade work required by providing vitalinformation inrealtime.Manybodiesofscheduledworkrequirepre-planningtoorderequipmentandparts.Unscheduledmaintenanceorchecksalsorequirespre-planningtosomedegree.Anotherbenefitof this technology is rapiddeploymentwhichallowsa significant reduction in investigativetime,andthisparticularUAVcanbereadytodeployin5minutes.
TotalhastrialledtheLE48XDualATEXandhascertifieditforuseinitsATEXenvironments.
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UAVtechnologyissuitableforrapidinspectionexternal(abovesurface)inspectionofoiltankersandLNG carriers, and external inspection of assets such as platforms, floating production storage andoffloading(FPSO)vesselsandonshoreinstallations.Itisalsopotentiallysuitableforinternalinspectionoflargervessels.
For example, Total recentlyusedaUAVdrone to inspect aholding tank todetermine the stateofits structure and contents. Total reported a significant time and cost reduction in comparison toconventionalmethodsofinspection,andtheriskfactorwasalsosignificantlyreduced.
UseofdronetechnologytocompletetheassessmentforTotalcost$11,000,whichincludedonedaypreparation followedby3 x 6minutesflights carriedoutby a teamof 2people. In comparison ifthisworkhadbeencarriedoutwithconventionalmethodsthentheinspectionwouldhavetakenaday’spreparationfollowedby2.5daysofworkbyateamof8peoplecosting$66,000.Conventionalinspectionmethodsalsocarryahigherlevelofriskforthepeopleinvolved.
Onebenefitofthistechnologyisbeingableinspectanasset inrealtime,capturinghighresolutionstills,HDvideoandinfraredimagesgivingadetailedpictureoftherequiredpieceofinfrastructure.Thepayloadcanbechangedtosuitthesituationitistobeusedin.XamenisundertakingResearch&Development(R&D)whichistestingdifferentsensortypesusedintheoilandgasindustryaspayloadsratherthangyroscopicvideocameras,gasdetectorsbeingoneofthese.
Key Attributes• Canbeusedinavarietyofsituations;• Rapiddeployment;• Realtimedata,stillimageandvideocapabilities;• Cheaperandsaferthanconventionalmethodsofinspectionatheight;• Certifiedforuseinpotentiallyexplosiveatmospheres;• Trainingfacilityallowingmaintenancetechnicianstobecertifiedintheuseof(UAV);• IfforanyreasonthereispowerfailureorlossofcontroltheUAVdeploysaparachuteandland
safelyforsubsequentretrieval.
Limitations• Operatingheightrestrictions;• Payloadlimitations–MaxpayloadintheUKis44lbwhichalthoughasignificantweighttocarry
couldreducethetypesofsensorequipmentthatcanbefitted;• Deploymentmayberestrictedduetopoorweatherconditions;• Maynotprovidefullcoveragewheretheequipmentbeingobservedisobscuredfromview,or
airspacesurroundingtheequipmentisobstructed;• Flight restrictionsmay limit deployment – current accepted practice is for drones to remain
withinLineofSight(LOS)oftheoperator.
Sources• hse.gov.uk/fireandexplosion/atex.htm; • ec.europa.eu/growth/sectors/mechanical-engineering/atex;• linkedin.com/pulse/total-has-approved-use-le-4-8x-dual-atex-uav-designed-richard-vinuesa;• atexshop.com/atex-misc-c-170/atex-drone-le-48x-dual-p-904.html;• drone-atex.fr/index.php/fr;• news.directindustry.com/press/xamen-technologies/le-4-8x-dual-atex-innovation-inspection-
hazardous-atmosphere-161858-435313.html
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 4 - Experimental Pilot in laboratory conditions.
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4.11 Environment and Health Monitoring System
Environment and Health Monitoring SystemSource:
O>RL: 3
Description
HUMS provide a way to monitor the condition of complex equipment, and derive prognostic analysis such as Remaining Useful Life (RUL). As a multi-sensor system, EHMS collects data on the subsea environment as well as MTS asset measurements. Although operating completely autonomously during deployment, secure wireless functionality has been implemented in order to communicate with the system for maintenance and data reclamation. The EHMS is intended to operate autonomously throughout the deployment of an asset, gathering data on the environment the asset is exposed to, the usage profile and key operating parameters which provide an indication of the health of the asset.
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 3
Sample/Full Area 0
Risks
Cultural Change 1
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 1
Staff Training 1
Operations/Maintenance 1
Production Impact 0
Benefits
Cost Benefits 4
Safety Benefits 2
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
Key Attributes
Can monitor the condition of complex equipment
Multi-sensor system
Can operate autonomously
Requires no pressure hull penetration
Suitable for installation during both life extension programmes and new builds
Can be integrated into holistic platforms
Secure and encrypted data transmission
System is still undergoing trials and is not ready for market
SummaryConditionmonitoringofassetspresentsmanypotentialbenefits in termsof reducedmaintenancecosts and, critically for submarine assets, higher reliability and availability. Historically, conditionmonitoring has been used primarily in industrial applications where access to equipment to bemonitoredisrelativelystraightforward.Datagatheringhaseitherbeenbyperiodicmanualaccesstoequipment,orthroughsensorsfeedingdatatoacentrallocationaspartofasupervisorycontrolanddataacquisition(SCADA)typesystem.
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Conditionmonitoringforoutsidepressurehullsubmarineequipmenthashistoricallybeenunachievableduetotheneedforenvironmentallycapable,powerefficientsensingtechnologywiththecapabilitytooperatewithlittleornointeractionwiththeinternalsubmarineenvironment.DevelopmentoftheHealthandUsageMonitoringSystems(HUMS)enablesmeaningfuldataonsystemperformanceandoperatingenvironmenttobegatheredthroughoutavesseldeployment,inapackagethatrequiresnopressurehullpenetrations.
HUMS provides a way to monitor the condition of complex equipment, and derive prognosticanalysissuchasRemainingUsefulLife(RUL).Thiscanbringmanybenefits,suchasenablingauxiliaryequipmenttotakeoveroperationofkeyfunctionsbeforefailureofprimaryequipment,theincreasedunderstandingandinsightintoequipmentbeingmonitoredhighlightingdevelopmentopportunities,andanticipationofmaintenanceandlogisticalrequirementswhichcanreducemaintenancecosts.
Furthermore,withinthemaritimeindustrytherehashistoricallybeenaviewthatmethodsrelatingtoProductLifecycleManagement(PLM)donotapplytobespokedesignandmanufactureofcomplexone-offassets.However,advancesintechnologyandanalysisstrategiesenableHUMScapabilitiestobeintegratedintoholisticplatformssuchasIntegratedPlatformManagementSystems(IPMS)thereforeprovidinghealthmonitoringandenhancedinsightintotheinterdependencesofcomponentsandsub-systemswithinacomplexasset.
Asamulti-sensorsystem,EHMScollectsdataonthesubseaenvironmentaswellasassetmeasurements,to be stored securely using awell-respected encryptionprotocol for retrieval. Althoughoperatingcompletelyautonomouslyduringdeployment,securewirelessfunctionalityhasbeenimplementedinordertocommunicatewiththesystemformaintenanceanddatareclamation.
TheEHMSisintendedtooperateautonomouslythroughoutthedeploymentofanasset,gatheringdataon theenvironment theasset is exposed to, theusageprofileandkeyoperatingparameterswhichprovideanindicationofthehealthoftheasset.Thisdataisprocessedlocallytotheequipmenttoprovideareadyindicationtoserviceengineersoftheassetconditionandremainingusefullifewhentheyaccesstheequipmentduringmaintenanceperiods.Thisapproachmakestheequipmentsuitablefor installation during both life extension programmes and new build, allowing condition basedmaintenancedecisionstobemade, improvingtheavailabilityoftheassetwhilemaintainingacosteffectiveapproachtomaintenance.Theequipmentalsohasthecapabilitytocapturekeyoperatingevents,highlightedbythemeasures,whichmayassistinrefiningequipmentspecificationsforfuturegenerationsandcharacterisingroutecauseandroguefailures.
ThefirstgenerationEHMSsystemhasrecentlycompletedfunctionalevaluationandisbeingpackagedfordeployment trials. Initially the fullypackagedunit shallbe subject toenvironmental testing forshockandelectromagneticcompatibility(EMC)toproveitworthyofseatrial.
ThefirstgenerationEHMSsystemoffersmonitoringandindicationcapabilitiesofdirectapplicationtoplannedmaintenancestrategiesandoffersinsightintoequipmentusewhichmayinfluencefutureequipment specification. Development of the EHMS system could implement current state of theart prognostic healthmonitoring techniques, allowing equipment health over time and expectedremainingusefullifetobepredicted.
Key Attributes• Canmonitortheconditionofcomplexequipment;• Multi-sensorsystem;• Canoperateautonomously;• Requiresnopressurehullpenetration;• Suitableforinstallationduringbothlifeextensionprogrammesandnewbuilds;• Canbeintegratedintoholisticplatforms;• Secureandencrypteddatatransmission.
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Limitations• Systemisstillundergoingtrialsandisnotreadyformarket.
Sources• Dr. David Flynn, “Health and usage monitoring systems: Enabling the future prediction of
remainingusefullifeforsubmarines,”Proceedingsofthe12thInternationalNavalEngineeringConferenceandExhibition(INEC)2014,pp850-860;
• S.Cheng,K.Tom,L.Thomas,andM.Pecht,“Awirelesssensorsystemforprognosticsandhealthmanagement,”SensorsJournal,IEEE,vol.10,pp.856-862,2010.
Readiness AssessmentWeestimatethatontheNASAscalethistechnologyscores:NASA TRL 3 – Proof of concept.
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4.12 Wideband Sonar Beam-steering
Wideband Sonar Beam-SteeringSource:
O>RL: 3
Description
Multibeam Wideband Sonar (MBWS) is a technique for detection, classification and true recognition beneath the seafloor. The technique offers enhanced imaging and wideband processing in replay and in real-time
This technique has the potential to allow environmental, seabed and subsea structures to be inspected with greatly increased resolution. The equipment can be deployed on range of nautical vehicles, including autonomous underwater vehicles (AUVs) and ROVs
Key Attributes
Greater details over alternative sonar based solutions
Cost efficient
Modular design for easy upgrade path
Complements existing sensor suites
Can be used in multiple situations/applications
Applicability / Limitations
With Plant Running 0
Retrofit 1
Offshore 1
Need for Specialist Skills 2
Coverage 1
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 2
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 0
Benefits
Cost Benefits 2
Safety Benefits 1
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
SummaryNew signal processing techniques in wideband sonar sensor technology inspired by BottlenoseDolphinscanhelpextendthelifeofoilandgaspipelinesbyusingremotelyoperatedvehicles(ROVs)todetectblockages,asaresultofanewcollaborativeresearchprojectinScotland.
The LFMultibeamWideband Sonar (MBWS) delivers new sub-bottom imaging and capability fordetection, classificationand true recognitionbeneath the seafloor. Fulldata rateoverall channelsgivesSpotlightLFcompletecontroloverimagingandwidebandprocessinginreplayandinreal-time.
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The initiative, involving Heriot Watt University’s Ocean Systems Laboratory, high-tech sonar andunderwater systems company,Hydrason Solutions, andCENSIS, the Scottish InnovationCentre forsensorandimagingsystems,istodevelopanenhancedwidebandsonarsystembasedontheprinciplesofthemarinemammals’detectioncapabilities.
Using signalprocessing techniques fromprevious researchconductedonBottlenoseDolphins, theprojectdramaticallyimprovestherangeofdatacollectedbywidebandsonardevices.
The technology is unique in enabling users to accurately locate underwater objects, as well asidentifying their structure and composition, without making any direct contact. Existing sensorproductscannotpenetrateobjects,insteadprovidingonlyanimageoutline.Thesystemcouldhaveavarietyofapplications,helpingsurveyorstofindblockagesinPipelinesanddeterminewhetheranunderwatersupportisstillstructurallysound.
Thistechniquehasthepotentialtoallowenvironmental,seabedandsubseastructurestobeinspectedwithgreatlyincreasedresolution.Itcould,forexample,beusedtodetecthairlinecracksinoilrigs’supportlegsorchangestothesedimentontheseafloor.
The equipment canbedeployedon rangeof nautical vehicles, including autonomousunderwatervehicles(AUVs)andROVs.Multiplesurveyscanbeconductedfromoneship,makingthedeviceaneconomicwayofcollectingdata.
Theoil andgas sectoralreadymakesextensiveuseof acoustic surveysparticularlyas installationsbegintobedecommissioned.Thistechniquehasthepotentialtosetanewstandardinacousticobjectdetectionandidentificationincomplexsubseaenvironments.Itcouldalsoreducethecostsofexpensivesurveys,througharangeofefficienciesandaspartofawidertransitiontowardsautonomousworking.
Withinthespecificremitofthisreview,focussingonpressurevesselandCUIinspection,theadvantagesofthistechnologyarelessobvious.
Key Attributes• Greaterdetailsoveralternativesonarbasedsolutions;• Costefficient;• Modulardesignforeasyupgradepath;• Complementsexistingsensorsuites;• Canbeusedinmultiplesituations/applications.
Limitations• Limitedusefulnessforpressurevesseland/orCUIinspection;• StillunderdevelopmentbutbeingusedintheindustrywhileR&Dcontinues.
SourcesNodirectlinkstodocumentationusedtoproducesummaryreport.
Readiness AssessmentWeestimatethatontheNASAscalethistechnologyscores:NASA TRL 3 – Proof of concept.
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4.13 Electromagnetic Inductance Degradation
Electromagnetic Inductance Degradation Source:
O>RL: 2
Description
Electromagnetic inductance degradation technique has the potential to monitor the microstructure of steel during processing or in service. By measuring the magnetic properties using a portable probe it is possible to determine the materials properties to quantify degradation during service, such as creep damage or embrittlement, or to identify the signs of microstructural pre-cursors to fatigue crack development.Although this technology is at an early stage in its development it has the potential to add another NDT technique with a range of applications including those in the oil and gas domain.
Key Attributes
Can scan large areas
Provides accurate material measurements
Can penetrate deep into structures
Provides condition based analysis on a the materials microstructure
Can be used to perform quality test inspection during steel production and fabrication.
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 2
Safety Benefits 2
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
SummaryTheNationalPhysicalLaboratoryhasundertakenresearchinusingelectromagneticinductanceforthedetectionofdegradationinsteelstructureswithinanumberofindustries.
Steelistheengineeringmaterialofchoiceinmanydemandingandsafetycriticalapplications,includingsub-seapipelinesandrisersintheoilindustry,tubeandboilercomponentsinelectricalgeneration,andpressurevesselsinthenuclearindustry.
Intheseapplicationsitisveryimportanttobeabletomonitortheconditionofthemicrostructure,
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especially to quantify degradation during service, such as creep damage or embrittlement, or toidentifythesignsofmicrostructuralpre-cursorstofatiguecrackdevelopment.
Themicrostructureofsteelgovernsitselectromagnetic(EM)propertiesand,therefore,EMsensingoffers potential measurement techniques to monitor the microstructure during processing or inservice.Bymeasuringthemagneticpropertiesusingaportableprobeitispossibletodeterminetherequiredmaterialproperties.
An example is the determination of the stress in 316 stainless steel using the relative magneticpermeability.BuildingonNPL’sexperience inmeasuring thepropertiesofmagneticmaterialswithstressapplied,a techniquehasbeenestablished thatusesNPL referencematerialsandcalibrationcurvestoremotelymeasurethestresswithinsafetycriticalassets.
NPLhasarangeofelectricalconductivityreferencematerialsusedbytheautomotiveandaerospacesectorstodeterminethehardnessofaluminiumandaluminiumalloysandcombinedwithanextensiverange ofmagneticmaterialmeasurement facilities andmagnetic field standards are applying thisknowledgetodevelopNonDestructiveTesting(NDT)solutionsforarangeofapplications,includingthoseintheOil&Gasdomain.
Key Attributes• Canscanlargeareas;• Providesaccuratematerialmeasurements;• Canpenetratedeepintostructures;• Providesconditionbasedanalysisonamaterialsmicrostructure
Limitations• Nosolutionshaveyetbeendevelopedforuseinthefield.
Sources• NationalPhysicalLaboratory(NPL).
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 2 – Technology concept and/or application formulated.
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4.14 Terahertz Spectral Imaging
Terahertz Spectral ImagingSource:
NuclearTRL: 1
Description
Terahertz (THz) waves occupy the wavelength range between microwave and infrared. In THz imaging, the internal structure of an object is determined by analysing changes in a THz signal applied to the object. THz waves can penetrate opaque materials and detect internal defects within non-metallic materials which visible light cannot, such as foam, ceramics, glass, resin, paint, rubber, composites, and concrete.THz imaging has been extensively used in the Space and Aerospace sectors for testing of thermal protection, foam insulation and carbon composites. Experimental results also show that THz imaging may be used for detection of corrosion under paint and detection of corrosion within steel reinforced concrete.
Key Attributes
Can detect defects within non-metallic, opaque materials which visible light cannot
No human radiation hazard, unlike microwaves
Relatively new NDT technique, unproven for corrosion detection
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 0
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 1
Staff Training 2
Operations/Maintenance 2
Production Impact 0
Benefits
Cost Benefits 2
Safety Benefits 2
Other Industries
Nuclear
Space
Aerospace
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryLong-termcorrosionofsteelinconcretestructuresisaparticularconcernfornuclearpowerplantsasthereiscompellingpublicinterestinthesafeoperationoftheseplantsforthemanydecadesthattheyareinoperationandtheadditionaldecadesittakesforthemtobedecommissioned.
Inspectiontechniquesthatarebothnon-destructiveandwhichcandetectlong-termcorrosionatitsearlieststagesareneededtoidentifywhenremedialstepsneedtobetakentoinsuretheintegrityofconcretestructuresatnuclearpowerplants.
PhysicsMaterialsandAppliedMathematicsResearchLLCisconductingresearchintohowterahertzimaging can be used to detect corrosion of steel in concrete structures. The overall objective ofthis researchprogram is toestablish terahertz imagingand spectroscopyas thepre-eminentnon-destructiveexaminationtechniqueforlocatingandidentifyingcorrosioninsteelreinforcedconcretestructures.
Thisisaccomplishedbypushingthelimitsofhigh-powerterahertzsystemstoincreaseimagingdepthand by enhancing the detection sensitivity of terahertz spectroscopic methods to directly detectcorrosionby-productsinconcrete.
InPhase Ieffort isspentto identifywhichcorrosionby-productor promoting agent is most strongly detected with terahertzimagingandspectroscopy.This isestablishedviaacombinationof theoretical and numerical modelling and experimentalbenchmarkingatterahertzfrequencies.
Imagesaretakenofsteelinconcretetoevaluatetheimagingdepthandquality.Theproposedtechniqueenablesrapidinspectionofnuclearplantstructuresanddetectionofcorrosioninconcrete.
Similarcorrosionissuesafflictaginginfrastructureincludinghighways,bridges,tunnels,buildings,anddams.Earlieridentificationofcorrosioninthesestructuressignificantlyenhancespublicsafetyaswellasreducingthecostofcorrosion,estimatedtobeinthehundredsofbillionsofdollarsannually.
Key Attributes• Initialresearchprogramsosometimebeforekeyattributescanbeestablished.
Limitations• Initialresearchprogramsosometimebeforeanylimitationsbecomeapparent.
Sources• Physics,Materials,andAppliedMathematicsResearchL.L.C
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 2 – Technology concept and/or application formulated.
69
SECTION 5
CUI DETECTION
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5.1 Guided Wave Ultrasonic Testing
SummaryInitially designed as a screeningmethod to allowmore focussed non-destructive testing, NDT, ofpipelinesusingGuidedWaveUltrasonicTesting,GWUThasnowdeveloped intoa routinepipelineinspectiontechnique.
Guided Wave Ultrasonic TestingSource:
O>RL: 9
Description
Guided Wave Ultrasonic Testing (GWUT) utilises stress waves that propagate along an elongated structure while guided by its boundaries. This allows the waves to travel a long distance with little loss in energy. GWUT uses very low ultrasonic frequencies, between 10~100kHz, compared to those used in conventional ultrasonic testing. At higher frequencies the range is significantly reduced. Also, the underlying physics of guided waves is more complex than bulk waves. The physical reflection of guided waves enables the detection of defects with a depth much smaller than a wavelength. It allows rapid screening of long lengths of pipework for defects such as corrosion. As it requires only a small section of pipework to be exposed to attach a single transducer array it has significant benefits in relation to the detection of corrosion under insulation in pipework. GWUT is not suitable for complex pipelines with a lot of T-Joints, bends, flanges and valves therefore not particularly useful for offshore use.
Key Attributes
Allows rapid screening of long lengths of pipeline up to 200m
Limits the amount of lagging which needs to be removed to permit the testing
Data is automatically logged for subsequent analysis
Only suitable for straight pipe runs
Relatively coarse, suitable for detection of large areas of corrosion or erosion
Highly skilled staff required
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 1
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 1
Operations/Maintenance 2
Production Impact 0
Benefits
Cost Benefits 2
Safety Benefits 3
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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Itallowsrapidscreeningoflonglengthsofpipeworkfordefectssuchascorrosion.Asitrequiresonlyasmallsectionofpipeworktobeexposedtoattachasingletransducerarrayithassignificantbenefitsinrelationtothedetectionofcorrosionunderinsulationinpipework.Itispossibletoexamineover50minlength(25mineachdirectionfromthetransducerposition).Thisisaveryeffectivemethodforlonglengthsbutitcan’tbeusedforcomplexpipelineswithalotofT-Joints,bends,flangesandvalves.GWUTcanbeusedonabovegroundpipelinesinsectionsofupto200m,commonly20-30metres.ThistechniqueisreferencedinseveralstandardsincludingBS9690-2:2011’Non-destructivetesting.Guidedwave testing.Basic requirements forguidedwave testingofpipes,pipelinesandstructuraltubulars’.
Themethodutilisedgeneratesstresswavesthatpropagate along an elongated structure whileguidedby itsboundaries.Thisallowsthewavestotravelalongdistancewithlittlelossinenergy.GWUT uses very low ultrasonic frequencies,between 10~100 kHz, compared to those usedin conventional ultrasonic testing. At higherfrequencies the range is significantly reduced.Also, the underlying physics of guided wavesismore complex than bulkwaves. The physicalreflectionofguidedwavesenablesthedetectionof defects with a depth much smaller than awavelength.
Anaxiallysymmetricwaveisgeneratedinthepipelinefromthearrayoflowfrequencytransducersattachedaroundthecircumferenceofthepipetogenerateanaxiallysymmetricwavethatpropagatesalong the pipe in both the forward and backward directions. The Torsional wave mode is mostcommonlyused,althoughthere is limiteduseof the longitudinalmode.Theprocessusesapulse-echoconfigurationwherethearrayoftransducersisusedforboththeexcitationanddetectionofthesignals.
Achangeincrosssectionalareaorstiffnessgeneratesanechoandthetimingofthereceiptoftheechoanditspredictedspeedatadesignatedfrequencyallowsthelocationofthedefecttobedetermined.GWUTusesdistanceamplitudecurves (DAC) tocorrect forattenuationandamplitudedropswhenestimatingthecross-sectionchange(CSC)fromareflectionatacertaindistance.TheDACsareusuallycalibratedagainstaseriesofechoeswithknownsignalamplitudesuchasweldechoes.
OncetheDAClevelsareset,thesignalamplitudecorrelateswelltotheCSCofadefect.GWUTdoesnotmeasuretheremainingwallthicknessdirectly,butitispossibletogroupthedefectseverityinseveralcategories.Onemethodofdoingthisistoexploitthemodeconversionphenomenonoftheexcitationsignalwheresomeenergyoftheaxiallysymmetricwavemodeisconvertedtotheflexuralmodesatapipefeature.Theamountofmodeconversionprovidesanaccurateestimateofthecircumferentialextentofthedefect,andtogetherwiththeCSC,operatorscouldestablishtheseveritycategory.
Fixturesandfeaturessuchasflangescauselargereflectionsandlimitstherangeofthetest.AlsomorethanoneortwobendsinthepipelinecauseslargereflectionsasdoesaTjunctionwhichiseffectivelyformawholeinthepipeformtheendlimitofthetestrange.Multiplefeaturewhichrisetocomplexreflectionslimittheeffectiverange.
Key Attributes• Allowsrapidscreeningoflonglengthsofpipelineupto200m;• Costeffective;• Limitstheamountoflaggingwhichneedstoberemovedtopermitthetesting;
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• Dataisautomaticallylogged.
Limitations• Requireshighlevelsofexpertisetoapplyandinterpretresults;• Rangeislimitedbyflanges,bendsandTJunctions;• Difficulttofindareasofsmallpittingcomparedtooveralllossofthickness.
Sources• www3.imperial.ac.uk/nde/researchthemes/inspection/guidedultrasonicwaves;• Long RangeGuidedWave InspectionUsage – Current Commercial Capabilities and Research
Directions,2006,M.J.S. LoweandP.Cawley.DepartmentofMechanicalEngineering ImperialCollegeLondon;
• BS9690-2:2011 ’Non-destructivetesting.Guidedwavetesting.Basicrequirements forguidedwavetestingofpipes,pipelinesandstructuraltubulars’.BritishStandardsInstitute.ISBN9780580 73794 7.
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 9 – Widespread production use with extensive track record.
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5.2 Radiographic - Digital Detector Array
Digital Detector ArraySource:
MedicalTRL: 9
Description
A Digital Detector Array (DDA) is a sensor device that converts ionising radiation into digital information for display as a digital image, typically in real-time on a computer display.
An x-ray or gamma ray source is used to emit ionising radiation through an object and those rays then interact with micro-electronic sensors contained within the flat panel DDA, creating a digital image which corresponds to the energy pattern.
Originally developed for medical applications, DDAs are capable of detecting moderate to heavy corrosion under insulation (CUI), moderate to heavy pitting, and pipes distorted from mechanical damage. They can also find features such as welds or transverse joints under insulation.
Key Attributes
No surface preparation required.
Easily interpreted.
Portable (battery operated; wireless)
Can scan through insulation.
Provides a permanent digital record of the scan.
Suitable for use with different radiation sources.
Limited by the penetrating power of the source.
Vessel inspection limitations (requires hardware placement on both sides of the surface to be scanned).
Radiation safety considerations. Potentially subject to more stringent regulation via Ionising Radiations Regulations 1999 (IRR99).
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 2
Coverage 3
Sample/Full Area 0
Risks
Cultural Change 2
Safety 1
Complexity 2
Significant Industry Backing 1
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 3
Safety Benefits 2
Other Industries
Medical
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryADigitalDetectorArray(DDA)isasensordevicethatconvertsionisingradiationintodigitalinformationfordisplayasadigitalimage,typicallyinreal-timeonacomputerdisplay.
Anx-rayorgammaraysourceisusedtoemitionising radiation through an object andthoseraystheninteractwithmicro-electronicsensorscontainedwithintheflatpanelDDA,creatingadigitalimagewhichcorrespondstotheenergypattern.
BrighterareasontheimageresultfromhigherlevelsofradiationhittingtheDDA,indicatingthinneror lessdensesectionsoftheobject.Inversely, darker areas on the image resultfromlowerlevelsofradiationhittingtheDDA,indicatingsectionswheretheobjectisthicker.Areasthatarecorrodedorhaveotherdefectscanbeidentifiedbyevaluatingthecolourcontrastoftherepresentation.
Originally developed for medical applications, DDAs are capable of detecting moderate to heavycorrosion under insulation (CUI),moderate to heavy pitting, and pipes distorted frommechanicaldamage.Theycanalsofindfeaturessuchasweldsortransversejointsunderinsulation.
Withthedevelopmentofnewelectronic,batterypoweredportableandevenwirelessdigitaldetectors,DDA radiography has grown in effectiveness over recent years for awide range of plant and fieldinspectionsandprovidesseveraladvantagesovertraditionalfilm-basedandcomputedradiographytechniques.Theseincludeimprovedsafetythroughreducedpersonnelexposuretoradiation(duetothehighsensitivityofdetectorsandtheassociatedreductioninenergyrequiredtocreateanimage),high image quality, high Signal to Noise Ratio (SNR), high dynamic range, instantaneous feedback(eliminatingtheneedforlaterre-imaging),andlowerenvironmentalimpact(duetotheeliminationofchemicalfilmprocessing),allcontributingtoanoverallreductionininspectiontimeandthedeliveryofconsiderablecostsavings.
Additionally, depending on the software used, digital images captured usingDDAs can be digitallyadjusted and enhanced, providing the ability to change properties such as brightness, contrast,sharpness,rotation,colouring,magnificationandtoapplynoisereduction.Inthisway,smallorhiddenfeaturescanbebetteridentifiedandcharacterised.
Key Attributes• Nosurfacepreparationrequired.• Easilyinterpreted.• Portable(batteryoperated;wireless)• Canscanthroughinsulation.• Providesapermanentdigitalrecordofthescan.• Suitableforusewithdifferentradiationsources.
Limitations• Limitedbythepenetratingpowerofthesource.• Potentialimpactonadjacentjobsites.• Vesselinspectionlimitations(requireshardwareplacementonbothsidesofthesurfacetobe
scanned).• Radiation safety considerations. Potentially subject to more stringent regulation via Ionising
RadiationsRegulations1999(IRR99).
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Sources“Drivingdigitalconversionforweldandcorrosioninspection”;GEInspectionTechnologies.“FieldRadiographywithAdvancedDigitalDetectorArrays”;GEInspectionTechnologies.“NDTWikiX-ray–theDigitalX-rayEncyclopedia”;VidiscoLtd.“AdvancementsinIndustrialDigitalRadiographyTechnology”;InspectioneeringJournal.“InformationForTheProcurementAndConductofNDT–Part3:RadiographicInspectioninIndustry”;HealthandSafetyExecutive
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 9 – Widespread production use with extensive track record.
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5.3 Radiographic - Digital Detector Array
Open VisionSource: Oil
& GasTRL: 9
Description
OpenVision is a light-weight, self-contained live video x-ray imaging system designed for portable, hand-held radiographic inspection. It includes a battery-operated 70kV x-ray tube designed for portable field operation and a highly sensitive radiographic imaging sensor, both located at either end of an adjustable C-arm.
The system is commonly used for Corrosion Under Insulation (CUI) inspection and operates without the requirement to remove insulation or undertake surface preparation. The real-time nature of its x-ray imaging means that the unit can be continuously moved around and along pipework (including bends and joints), enabling rapid detection of defects or the presence of water
Key Attributes
Can scan through insulation, no surface preparation required
Easily interpreted, portable (battery operated; wireless)
Can detect CUI and water
Provides a permanent digital record of the scan
Suitable for use with different radiation sources
Limited by the penetrating power of the source, pipe diameter, access constraints and has limited field of view
Vessel inspection limitations (requires hardware placement on both sides of the surface to be scanned)
Radiation safety considerations. Potentially subject to more stringent regulation via Ionising Radiations Regulations 1999 (IRR99)
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 2
Coverage 2
Sample/Full Area 0
Risks
Cultural Change 2
Safety 1
Complexity 2
Significant Industry Backing 1
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 3
Safety Benefits 2
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryOpenVisionisalight-weight,self-containedlivevideox-rayimagingsystemdesignedforportable,hand-held radiographic inspection. It includes a battery-operated 70kV x-ray tubedesigned for portablefieldoperationandahighlysensitiveradiographic imagingsensor,both locatedateitherendofanadjustableC-arm.
Inordertocarryoutaninspection,theC-armunitisplacedaroundtheobjecttobeimagedandaproprietaryimagingsystemthencapturesanddisplaysavideorepresentationofthex-raysdetectedbythesensor.Thisvideoisdisplayedinreal-time(at30framespersecond)onahand-heldLCDviewer,head-mounteddisplay,orportable recorderwithLCDdisplay.
The system is commonly used for Corrosion UnderInsulation (CUI) inspection and operates without therequirement to remove insulation or undertake surfacepreparation. The real-time nature of its x-ray imagingmeans that theunit canbe continuouslymovedaroundandalongpipework (includingbendsandjoints),enablingrapiddetectionofdefectsorthepresenceofwater.
Pipeworkup to25 inches indiameter canbe inspected,withafieldofviewof4inchesby6inches.Thesystemcanoperate in temperatures ranging from-34C to 49, and asinglebatterychargewillpermit40minutesofcontinuousx-ray emission, which allows approximately 4 hours ofinspectionundertypicalconditions.
Theimagesproducedbythesystemarerelativelyeasytointerpret,meaningthatminimalfieldengineertrainingisrequired.Anengineercantypicallybeexpectedtoinspect300-500feetofpipeperdayusingthissystem.
Key Attributes• Canscanthroughinsulation,withnosurfacepreparationorinsulation/jacketremovalrequired.• Portable(batteryoperated).• Capturedvideoiseasilyinterpreted,minimaltrainingrequired.• Candetectwateraswellasdefects.
Limitations• Potentialimpactonadjacentjobsites.• Limitedpipediameter.• Limitedfieldofview.• Thepresenceofwatercannegativelyimpactimagequality.• Radiation safety considerations. Potentially subject to more stringent regulation via Ionising
RadiationsRegulations1999(IRR99).
SourcesQSAGlobalGlobalX-Ray&TestingCorporation
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 9 – Widespread production use with extensive track record.
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5.4 Sniffer Dogs
Sniffer DogsSource:
O>RL: 6
Description
Sniffer Dogs are used as detectors in remote scent tracing (RST) technology, usually to detect the presence of explosives or contraband in scent samples collected by sucking air from containers or air freight. Here dogs are trained to detect CUI on pipes in scent samples collected at oil and gas plants. In tests funded by the oil and gas industry, controlled laboratory conditions trained dogs are able to differentiate between insulation samples taken from corroded pipes and samples taken from clean pipes to an accuracy of circa 92%.
Key Attributes
Relatively low cost
Relatively quick process
Proven and well understood
Minimally invasive, requires insulation samples to be taken
Analysis conducted offsite
Requires trained handlers
Coverage dictated by sample size
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 3
Sample/Full Area 0
Risks
Cultural Change 1
Safety 2
Complexity 3
Significant Industry Backing 1
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 3
Safety Benefits 3
Other Industries
Police
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
SummaryInatwoyearproject fundedbyGassco(withan investmentofNOK6.5million)andsupportedbyStatoil, theFjellangerDetectionandTrainingAcademy (FDAT)addressed theproblemofdetectingCorrosion Under Insulation (CUI) using a Remote Scent Tracing (RST) technique: a system wherevolatilesassociatedwithcorrosionare sampledand the sensitivenoseofa traineddog isused todetectthesevolatileswithinthesamples.
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Dogs used as detectors in remote scent tracing (RST) technology usually detect the presence ofexplosivesorcontrabandinscentsamplescollectedbysuckingairfromcontainersorairfreight.Inthisstudy,fivedogsweretrainedtodetectCUIonpipesinscentsamplescollectedatagasprocessingplant.
Thetechniqueconsistsoftwomainstages:thesamplingstageattheplantitself(whichcouldbedonebytheplantownerorbyFDTA),andthesubsequentanalysisstageusingthetraineddogsatFDTA.
Scentsamplesweremadeusingspeciallydesignedsamplingequipment,withairsuckedthroughdrainplugsintheinsulationmaterialsurroundingthepipesontofiltercartridges.
Aftertheirtraining(whichwascarriedoutusinginsulationmaterialcollectedearlierfromothercorrodedlocationsattheplant),thedogswerepresentedwiththesamplescollectedinthefield.Notethatthedogswerenotdeployedin the actual plant, and instead sniffed at the samples once brought tothe laboratory. Thedogswere able to discriminatebetweenfield samplescollected near corroded pipes and samples collected from non-corrodedlocationsequallywellastheydiscriminatedbetweentrainingsamples.
Anumberoflocationsweretesteddouble-blind:asituationwherenooneatthetimeofsamplingoranalysisbythedogsknewifthelocationwascorrodedornot.Locationsthatthedogsrespondedtowereopenedsubsequentlyforavisualinspection,andcorrosionwasfoundundertheinsulation.Nocorrosionwasfoundatlocationswhichthedogshadnotrespondedto.
Arefinedapproachwaschosenwheretheresponseofanumberofdogswascombinedtofurtherimprove reliability. In thismanner, areas thatwereanalysed couldbedivided intohigh, lowornosuspicionofcorrosion,offeringanimportantaidtosettingvisualinspectionpriorities.
Preliminary results showed that thesensitivityof thedetectionoffield sampleswas92%,and theselectivity93%.
Theconclusionofthestudywasthatthetechniqueisnowaproventechnologyandisreadytobeintegratedintoplantmaintenancesystems.
TheapplicationofsuchatechniqueinapreventivemaintenanceprogramatOilandGasfacilitiescouldbeusefultodetermineprioritisationandschedulingofmaintenance,thusallowingamoreefficientallocationofthecostlyresourcesnecessaryformoretraditionalvisualinspection.
Theresearchhasbeenpresentedatinternationalconferences(HOISconference,InternationalWorkingDogBreedingAssociation2013)andhasbeenpublishedintwoscientificjournals(MaterialsEvaluationandAppliedAnimalBehaviourScience).
Alternative Approach – Electronic Nose LockheedMartin,inconjunctionwiththeirstrategicpartnersattheUniversityofPennsylvania,haveusedacombinationofmolecularbiologyandmaterialssciencetodevelopedanano-biotechnologyelectronic nose (“E-Nose”) equivalent, using DNA-wrapped carbon nanotubes (CNTs) to mimicnature’sincrediblesensitivityandselectivity.Workisnowunderwaytotransferthistechnologyfromthelaboratorytothemarketplace,combiningitwithLockheed’scarbonnanotube,fibre-basedCNT
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chemicalsensortechnologytocreatehand-heldanddistributedsensorsforawiderangeofenvisionedapplications,including:
• Monitoringtheinternalenvironmentofaspacecapsule;• Detectingchemicalweaponsandexplosives;• Recognitionofindividualsbasedonfingerprint-likebodyodours;• Diagnosingcancerandotherdiseasesfromexhaledbreath.
The E-Nose works by affixing DNA strands to single-wall carbon nanotubes (SWCNTs), which areexcellentelectricalconductorswithsignaltransductionpropertiesthatchangewhentheattachedDNAmolecules interactwithevenminuteamountsofvolatilechemicals.When thechemicalmoleculesbindtotheDNA,theychangeitsstructure.Thosechangeselicitanelectricalsignalthatistransmittedalongthecarbonnanotube.Ineffect,thenanotube“feels”thechangesexperiencedbytheDNAasitinteractswithothermolecules.ThechangesdependontheDNAsequence,eachofwhichwillhaveadifferentresponsetochemicalanalytes,
Whileasingle-wallnanotubeDNAcombinationcannot identifyaparticularchemical, theelectricalsignalproducedbyanarrayofmanydifferent single-wallnanotubeDNAcombinations can indeedidentifyachemical,inthesamewaythatthemyriadreceptorsinthemammaliannoseworkinconcert.Thispatternrecognition isbothspecificandreproducible foragivenchemical,andcandistinguishbetween two chemicals, differing evenby a single atomor isomeric (left-handedor right-handed)configuration.
Themainobstacle todevelopingapractical sensor is thedifficultyofpredicting the responseofagivenDNAsequencetoaparticularchemical,particularlygiventheextraordinarilyfinedistinctionsthe techniquecanmake.Rather thanattempt tobuildpredictionmodelsbasedonempirical, trialanderrorresults,LockheedMartinscientistshaveadoptedamoresystematicapproach,utilisingthecompany’sprograminintegratedcomputationalmaterialsengineering(ICME).
Thehigh-levelobjectiveofICMEistoremoverelianceontrialanderror,andinsteadapplyanarrayofcomputationaltechniquestopredictthepropertiesandbehaviourofnewmaterialsandnewdevicesbeforetheyarebuilt.Inthecaseofthecarbonnanotubesensors,moleculardynamicssimulationsareusedtounderstandhowthebindingofachemicalodorantalterstheconfigurationofaDNAstrandwithaparticularsequence.Thosestructuralresultsarethenfedintoquantummodelsoftheelectronicstructureofthenanotubetopredicthowitsconductivitywillchange.
Theoutputsofthemodelsguideexperimentalinvestigations,theresultsofwhichareusedtofurtherrefine themodelling. At that stage, data analytics and pattern recognition techniques are used to
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optimisethesetofDNAsequencesformosteffectivelyprovidingresponsestoawiderangeofchemicalodorants.
Eachodorantwillproduceadifferentpattern,which is thenstoredandassociatedwith the smell.Inthiswaythesensoris“trained”torecognizeodours,muchlikesnifferdogsdo.Assuch,whenthesensorencountersthatodouragain,itcanpinpointitexactlybycomparisontothepreviouslystoredpatterns.
Key Attributes• Accuracyoftheapproachiscirca92%;• Analysisisconductedoff-siteincontrolledconditions.
Electronic Nose:• Usinga techniquecombiningDNAandcarbonnanotubes, this techniquemimics thenoseof
snifferdogs.• Carbonnanotubes “feel” changesexperiencedby surroundingDNAas it interactswithother
molecules.• Patternrecognitiontechniquesareusedtodetectandidentifychemicalswithahighdegreeof
sensitivity,selectivityandrepeatability.
Limitations• Potentiallyperceivedcredibilitygap–mightnotbetakenseriously;• Requiressamplestobetakenfrominsulationandsamplesitestobesealedpotentiallyintroducing
weakspotsintotheremaininginsulation.Electronic Nose:• Experimentalwork,notyettransferredto,orprovenin,acommercialscenario;• AswithSnifferDogs,thisrequiressamplestobetakenfrominsulationandsamplesitestobe
sealed,potentiallyintroducingweakspotsintotheremaininginsulation.
Sources• “Detectioncorrosionunderinsulationusingdogs”;FjellangerDetectionandTrainingAcademy;• Sniffingouttrouble,Gassco;• “Thesciencebehinddetectiondogtraining”;AlfaDogTrainingAcademy,Fano,Italy;• “Using dogs to detect hidden corrosion”; Journal of AppliedAnimal Behaviour Science, April
2014.Electronic Nose:• LockheedMartin;• Physics Today; http://scitation.aip.org/content/aip/magazine/physicstoday/news/10.1063/
PT.5.5003
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 8 – Production use >3 years or multiple deployments <3 years with limited track record.
Readiness Assessment – Electronic NoseWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 4 – Experimental pilot in laboratory conditions.
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5.5 Pulsed Eddy Current
Pulsed Eddy CurrentSource:
O>RL: 8
Description
Pulsed eddy works by driving an electromagnetic field though the insulation and into the pipe. Pickup sensors detect variations in the field that are caused by changes in the pipe. Proprietary software plots the scans and provides data such as delta phase, delta amplitude, phase angles and voltage spans. Once this data has been gathered and analysed it is used to identify and differentiate between welds, corrosion and wire ties.
The technique is potentially able to detect larger areas of corrosion even through jacketing
Key Attributes
Non-invasive, works through 4" stainless steel, 3" aluminium or 1" galvanised cladding
Can detect wall loss, pitting and larger areas of corrosion
Works for most common insulation materials
Hand-held scanner available
Market Ready
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 3
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 2
Significant Industry Backing 1
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 4
Safety Benefits 3
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
SummaryThepulsededdycurrent(PEC)techniqueprovidestheabilitytomeasuresteelwallthicknesswithoutcontactbetweentheinstrumentandsteel.Theadvantageofthismeansthatcoatedorinsulatedpartscanbeinspectedwithouthavingtode-lagorremovethickpaints,protectivematerials,etc.
PECtechnologyallowsspecialistoperatorstomeasurethewallthicknessofanycarbonsteelproductbymeasuring the depletion of eddy currents within the steel. By takingmultiple readings acrossthesurface,PECcanthenprovideanoverallmapoftheareatoclearly identifyareasofcorrosion.
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ThetablebelowshowseachmeasurementpositionfromaPECunit,witheachpointidentifyingthethicknessvaluepresentedinmillimetres.
Typically, PEC is applied where there is no access to a steel surface (due to insulation, coating,fireproofing,marinegrowth,ornarrowaccess),where inspectionsarerequiredunderwateror inasplashzone,orwherethereisaspecificrequirementforwall-thicknessmonitoring.
SignificantindustryinvestmentanddevelopmentiscurrentlybeingappliedtothePECtechnique.Anewerimprovedimplementationwhichsignificantlyimprovestheefficienciesofthetechnique,whilstalsoimprovingmeasurementaccuracy,isscheduledforreleaseduring2016.
Key Attributes• Abilitytomeasurewallthicknesswithoutrequiringdirectcontactonthepart;• Noneedtoremovelagging,coatingsorprotectivematerialssuchasweathersheeting;• Nosurfacepreparationrequired;• Canbedeployedontopside,splashzoneandsubsea(viaROV);• Probeliftoffrangecanbeupto250mmawayfromthesteel;• Steelthicknessmeasurementrangefrom4mmto50mm;• Temperaturerangefrom-100Cto+500C;• Verygoodreproducibilityofrepeatmeasurement+/-0.05mm;• Providesapermanentrecordofthescanningdata,allowingcomparisonovertime;• TypicalApplications:
o Compositewarps;o Vesselskirts;o SphereLegs;o Risers;o Caissons;o CorrosionBlisters.
Limitations• Worksforcarbonsteelandlow-alloysteelonly;• Measurementsareanaverageacrosstheprobefootprint,notanabsolutemeasurementofa
spotcheck;• Cannotdifferentiatebetweeninternalandexternaldefects;• PECreadingsdependontheelectro-magneticpropertiesofthematerial;• Scanareageometryshouldbesimple.Readingscanbeaffectedbynozzles,welds,internaland
supportstructures.
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Sources• AdvancedNDTInspectionServices,BilfingerSalamisUKLimited
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 8 – Production use >3 years or multiple deployments <3 years with limited track record.
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5.6 Microwave Sensing
SummaryWorkhasbeenundertakenwithintheUKResearchCentreinNDE(partofImperialCollegeLondon)exploringthepossibilityofdetectingthepresenceofwaterwithininsulation,anecessaryprecursortoCUI.
Severalcurrentmethodsofpipelineinspectionaresensitiveonlytoregions inwhichcorrosionhasalreadyinitiatedandcausedareductioninwall-thickness.Instead,thisworkfocussedondetecting
Microwave SensingSource:
O>RL: 8
Description
Microwaves of varying frequencies are injected into the insulation surrounding a pipe, and propagate down the length of the pipe. Any areas of disruption to the insulation including water ingress cause reflections which are picked up by the receiving device. Calculations then permit determination of reflection locations along the pipe. This technique can also detect defects and corrosion in the underlying pipeline directly as these introduce reflections into the signal. Works well with straight pipes and can propagate well beyond bends of up to 90% in small diameter (8" or less) pipes. Bends in larger pipes can cause significant signal degradation. Works well with rockwool and polyurethane foam, but is not suitable for glass foam insulation.
Requires further work to determine effectiveness in real plant conditions
Key Attributes
High sensitivity to water presence
Works well with smaller pipes and copes with bends and pipe supports
Less effective where insulation is 100% saturated
Effective for common insulation types
Not yet trialled in industry
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 1
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 3
Safety Benefits 4
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
ENERGY // ASSET INTEGRITY THEME LANDSCAPING STUDY
REPORT // ENERGY
86
thepresenceofwaterwithintheinsulation,asanearlywarningofCUI.Existingmethodsofinspectingpipelinesforthepresenceofwater,suchasthermographyandneutronbackscatter,haveparticularlimitationswhichrenderthemimpracticalfortheinspectionofentirelengthsofpipeline(theformerhas lowsensitivityduetothepresenceof thecladdingandthe latterhasasmall inspectionarea).Theobjectiveofthisworkwastoidentifyanon-destructiveexamination(NDE)techniquetomonitorlengthsofpipelineforthefirstingressofwaterintotheinsulation,providinganearlywarningofthelikelyoccurrenceofCUIandprompting remedial action to reseal the cladding, therebypreventingcorrosionfrominitiating.
The focusof thework inparticularwas thepossibilityof apipe and cladding forming a coaxial waveguide which canbe used to propagate low frequency microwaves withinthe insulationalongthe lengthofapipe.Sincewaterhasarelative permittivity (a measure of a substance’s effect onelectric fields) much higher than that of the surroundinginsulation,anypatchesofwateralongthepipelinegiverisetoastrongreflectionoftheinputmicrowavesignal,providingamethodtodetectandlocatewaterpatches.
The pipe acts as the inner conductor of the coaxialwaveguide,andthecladdingactsastheouterconductor.Themicrowavespropagatedownthelengthofthepipelinewithintheinsulationlayerbetweenthetwoconductors,excitedbyanantennainsertedintotheinsulation.Ifdamagedcladdinghasallowedtheingressofwaterintotheinsulation,thenthewetinsulationactsasanimpedancediscontinuity,causingapartialreflectionofthemicrowavesignal.Thesepulseechoreflectionscanbeusedtodetectandlocatethepresenceofwater patches.
Experimentsundertakeninvolvedacoaxialwaveguidewithdimensionsequivalenttoa6inchpipewith3inchinsulation,totesttheprincipleoffilteringoutinterferencefromhigherorderelectromagneticmodesusinganantennaarrayi.e.multipleantennasinacirculararrayaroundthepipecircumference,specifically8antennaspositionedat45degreeintervals.Aspartofthisdesignwork,anoptimisationroutinewasdevelopedtofindtheoptimumantennadesignforawidevarietyofpipelinespecifications(pipediametersandinsulationthickness).
A vector network analyser (VNA) was used to generate the microwave frequency signal, with afrequencyrangefrom10MHzto67GHz.TheVNAwouldsweepthroughthe inputfrequencyrangeand record the reflection coefficient from thedevice under test. From this information, a processcalledTimeDomainReflectometry(TDR)wasusedtotransformthefrequencydomaindataintothetimedomain,byFourieranalysis.Thevelocityofpropagationisthenusedtocalibratethetimeaxistodistance,inordertodeterminethepositionsofthereflectors.
Sensitivityof this guidedmicrowave techniquewas found tobeexcellent,witha volumeofwaterpresentingonlya5%cross-sectionbeingreadilydetectable.
Aswellasdetectingofwaterwithinlengthsofstraightpiping,thetechniquehasbeenvalidatedwhenappliedtopipeswhichfeaturebends.Forsmallpipediameters(thosethatare8”orless),andfor90degreebends(themostcommonlyencounteredbendangle)thetransmissioncoefficientistypicallybetween99%and90%,indicatingthattheguidedmicrowavetechniqueisalmostunaffectedbythepresenceoftypicalindustrialbendsinpipelinesofthesedimensions.Largerpipelinesizes,intherangeof12” to24”,demonstrate transmissioncoefficients thatarebetween90%and34%, the latterofwhichwouldrenderinspectingbeyondsuchbendsimpractical.
ENERGY // ASSET INTEGRITY THEME LANDSCAPING STUDY
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SeparatelyHeriot-WattUniversityhasalsoundertakendesignanddevelopmentofasensorsystemfordetectionofCUIbasedonMicrowaveSensingtheoryandusinganOil&Gaspipelineastheprimaryassetforresearchandtestpurposes.
Thedesignmakesuseofasensor“horn”,constructedfromPolyMethylMethacrylate(PMMA)withaconductivecopperfibrelining.Thehornisdesignedtooperateinthefrequencyrange24-25.5GHzandfunctionsinananalogousmannertoradar.
Anumberofdifferentexperimentalscenarioswereundertakenwiththeaimofreplicatingthevariousconfigurations of a pipe with multi-layer insulation configurations. Defects in the materials weremachinedbyhighprecisionmachinerytoensuretheymetwithspecification.Sensorperformanceineachconfigurationissummarisedbelow:
Copper Defects• ThisexperimentalconfigurationwasdesignedtodemonstratetheprincipaloftheCUIsensor;• Defectsweremachinedat3depths(1.5mm,1.0mm,0.5mm)and5diameters(15mm,10mm,
8mm,5mm,2mm);• Resultsshowedclearphaseshiftsbetweenthedefects,withthesignaturebeingdeterminedby
thepermeabilityoftheareabeingmeasured.
Copper Defects With insulation• Thisconfigurationwasdesignedtoprovethesensorcoulddeterminedefectsthroughinsulation,
andusedthesametestpiecefromabovewiththeadditionofPMMAlayers;• ThePMMAsimulatedtheinsulationlayerofthepipe,withthecoppertestpiecerepresenting
the pipe; • A clearphase shiftbetween thedefects couldbe seen for all thedefects, as in theprevious
experiment;• Astheinsulationdepthincreased,theintensityofthesignaldecreasedduetothepermittivityof
thePMMAreducingthenetelectricfield.
Water Ingress• Wherewaterlevelsincreasewithintheinsulation,thisisdetectedviaaparticularphaseshift(to
theright).Thisphaseshiftindicatestwothings:o Anincreasedpermittivityduetotheincreaseinwater;o Anearlierreflectionoftheinputwaveduetotheincreasedreflectionoftheinsulationnowthatitcontainswater.
• A particular amplitude change was also detected due to the scatter effect and attenuatingpropertiesofwater.
Polymer Ageing• The(PMMA)samplewasagedforvaryingamountsoftime;• Thepermittivityofamaterialwouldbeexpectedtochangeasitages.Aparticularphaseshiftin
theresultswasdetected,consistentwithwhatwouldbeexpectedasaresultofageing.
Accelerated Corrosion• SampleswereexposedtochlorinesolutionswithaDCcurrentof880mAforincreasingperiods
oftimetosimulatebothrustformationandthenmetallossandpitting;• Resultsshowedmagnitudedecreasesincomparisontothehealthysampleduetothechangesin
surfacefinish,reducingreflection;• Aphaseshiftwasdetected,attributabletotheoxidelayer,whichfunctionsasadielectric(itisa
poorconductor).
ENERGY // ASSET INTEGRITY THEME LANDSCAPING STUDY
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Painted Coating• Asamplewasprovidedbyacompanywhoproducecommercialcoatingsforpipelinesandother
assets;• Thesamplewaspreparedbyhandsothecoatingwasnotuniformalongthetotallength;• ThecoatingcontainedAluminiumpigmentswhichcouldpotentiallydisruptthesignalandmask
thecorrosionarea(3cmx3cm);• Thecorrosionwasdetectedbyaphaseshiftduetothepermittivityofthecorrosionspot;• Varyingmagnitudeswereobservedinthehealthybasematerial,duetothescattereffectofthe
aluminiumpigmentsaswellasthevarianceinthecoatingapplication.
Future Work / Vision• Designofahand-heldtool;• Designofacollararray;• Designofahornantennalens.
Key Attributes• Highlysensitivetowatervolumes,downtoa5%cross-sectionalarea;• Arobustdetectiontechniqueacrossarangeofpipelineconditions;• Theeffectofmostcommoninsulationtypesisminimal;• Itispossibletoinspectbeyondatypicalindustrialpipebend;• Itispossibletoinspectbeyondtypicalpipesupports.
Limitations• This technique has been successfully tested with both rockwool and polyurethane foam
insulation, but thismethod cannot beused for glass foam insulationdue to its high level ofattenuation;
• In scenarios where the transition from completely dry insulation to insulation that is fullysaturatedwithwater,thereflectioncoefficientdropsbyafactoroftwooveralengthof0.25m.Thismayintroduceproblemsforfieldimplementationiftransitionlengthsbetweenwetanddryaresignificantlylongerthanthis;
• Furtherwork required toobtainevidenceof theeffectivenessof the technique inconditionssubjecttopipelinedeviationssuchasdents,ovalityandnon-concentricity.
Sources• “MicrowaveBasedMonitoringSystemforCorrosionUnderInsulation”;SchoolofEngineering&
PhysicalSciences,Heriot-WattUniversity,Edinburgh;• “Use of Microwaves For The Detection Of Corrosion Under Insulation”; Robin Elllis Jones,
DepartmentofMechanicalEngineering,ImperialCollege,London;• “UseofMicrowavesForTheDetectionOfCorrosionUnderInsulation”;REJones,FSimonetti,M
JSLoweandIPBradley;ImperialCollegeLondon,UniversityofCincinnatiandBPExploration&ProductionCompany.
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 8 – Production use >3 years or multiple deployments <3 years with limited track record.
ENERGY // ASSET INTEGRITY THEME LANDSCAPING STUDY
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5.7 Microwave Detection of Water within insulation
SummaryWorkhasbeenundertakenwithintheUKResearchCentreinNDE(partofImperialCollegeLondon)exploringthepossibilityofdetectingthepresenceofwaterwithininsulation,anecessaryprecursortoCUI.
Severalcurrentmethodsofpipelineinspectionaresensitiveonlytoregions inwhichcorrosionhasalreadyinitiatedandcausedareductioninwall-thickness.Instead,thisworkfocussedondetecting
Microwave Detection of WaterSource:
O>RL: 8
Description
This technique utilises a coaxial waveguide formed from the pipe and cladding which can be used to propagate low frequency microwaves within the insulation along the length of a pipe. Since water has a relative permittivity (a measure of a substance’s effect on electric fields) much higher than that of the surrounding insulation, any patches of water along the pipeline give rise to a strong reflection of the input microwave signal, providing a method to detect and locate water patches.
Key Attributes
High sensitivity to water presence
Works well with smaller pipes and copes with bends and pipe supports
Less effective where insulation is 100% saturated
Effective for common insulation types
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 1
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 3
Safety Benefits 4
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
ENERGY // ASSET INTEGRITY THEME LANDSCAPING STUDY
REPORT // ENERGY
90
thepresenceofwaterwithintheinsulation,asanearlywarningofCUI.Existingmethodsofinspectingpipelines for thepresenceofwater, suchas thermographyandneutronbackscatter,haveparticularlimitationswhichrenderthemimpracticalfortheinspectionofentirelengthsofpipeline(theformerhas low sensitivitydue to thepresenceof the claddingand the latterhasa small inspectionarea).Theobjectiveofthisworkwastoidentifyanon-destructiveexamination(NDE)techniquetomonitorlengthsofpipelineforthefirstingressofwaterintotheinsulation,providinganearlywarningofthelikely occurrence of CUI and prompting remedial action to reseal the cladding, thereby preventingcorrosionfrominitiating.
Thefocusoftheworkinparticularwasthepossibilityofapipeandcladdingformingacoaxialwaveguidewhichcanbeusedtopropagatelowfrequencymicrowaveswithintheinsulationalongthelengthofapipe.Sincewaterhasarelativepermittivity(ameasureofasubstance’seffectonelectricfields)muchhigherthanthatofthesurroundinginsulation,anypatchesofwateralongthepipelinegiverisetoastrongreflectionoftheinputmicrowavesignal,providingamethodtodetectandlocatewaterpatches.
Thepipe acts as the inner conductor of the coaxialwaveguide, and the cladding acts as theouterconductor. The microwaves propagate down the length of the pipeline within the insulation layerbetweenthetwoconductors,excitedbyanantennainsertedintotheinsulation.Ifdamagedcladdinghasallowed the ingressofwater into the insulation, then thewet insulationacts as an impedancediscontinuity,causingapartialreflectionofthemicrowavesignal.Thesepulseechoreflectionscanbeusedtodetectandlocatethepresenceofwaterpatches.
Experimentsundertakeninvolvedacoaxialwaveguidewithdimensionsequivalenttoa6inchpipewith3inchinsulation,totesttheprincipleoffilteringoutinterferencefromhigherorderelectromagneticmodesusinganantennaarrayi.e.multipleantennasinacirculararrayaroundthepipecircumference,specifically8antennaspositionedat45degreeintervals.Aspartofthisdesignwork,anoptimisationroutinewasdevelopedtofindtheoptimumantennadesignforawidevarietyofpipelinespecifications(pipediametersandinsulationthickness).
A vectornetwork analyser (VNA)wasusedto generate the microwave frequencysignal,withafrequencyrangefrom10MHzto 67GHz. The VNA would sweep throughthe input frequency range and record thereflectioncoefficientfromthedeviceundertest.Fromthisinformation,aprocesscalledTimeDomainReflectometry(TDR)wasusedto transform the frequency domain datainto the time domain, by Fourier analysis.Thevelocityofpropagationisthenusedtocalibratethetimeaxistodistance, inordertodeterminethepositionsofthereflectors.
Sensitivity of this guidedmicrowave techniquewas found to be excellent,with a volume ofwaterpresentingonlya5%cross-sectionbeingreadilydetectable.
Aswellasdetectingofwaterwithinlengthsofstraightpiping,thetechniquehasbeenvalidatedwhenappliedtopipeswhichfeaturebends.Forsmallpipediameters(thosethatare8”orless),andfor90degreebends(themostcommonlyencounteredbendangle)thetransmissioncoefficientistypicallybetween99%and90%,indicatingthattheguidedmicrowavetechniqueisalmostunaffectedbythe
ENERGY // ASSET INTEGRITY THEME LANDSCAPING STUDY
REPORT // ENERGY
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presenceoftypicalindustrialbendsinpipelinesofthesedimensions.Largerpipelinesizes,intherangeof12”to24”,demonstratetransmissioncoefficientsthatarebetween90%and34%,thelatterofwhichwouldrenderinspectingbeyondsuchbendsimpractical.
Key Attributes• Highlysensitivetowatervolumes,downtoa5%cross-sectionalarea;• Arobustdetectiontechniqueacrossarangeofpipelineconditions:o Theeffectofmostcommoninsulationtypesisminimal;o Itispossibletoinspectbeyondatypicalindustrialpipebend;o Itispossibletoinspectbeyondtypicalpipesupports.
Limitations• This technique has been successfully tested with both rockwool and polyurethane foam
insulation,butthismethodcannotbeusedforglassfoaminsulationduetoitshighlevelofattenuation;
• In scenarioswhere the transition from completely dry insulation to insulation that is fullysaturatedwithwater,thereflectioncoefficientdropsbyafactoroftwooveralengthof0.25m.Thismayintroduceproblemsforfieldimplementationiftransitionlengthsbetweenwetanddryaresignificantlylongerthanthis;
• Furtherworkrequiredtoobtainevidenceoftheeffectivenessofthetechniqueinconditionssubjecttopipelinedeviationssuchasdents,ovalityandnon-concentricity.
Sources• “Use ofMicrowaves For The Detection Of Corrosion Under Insulation”; Robin Elllis Jones,
DepartmentofMechanicalEngineering,ImperialCollege,London;• “UseofMicrowavesForTheDetectionOfCorrosionUnderInsulation”;REJones,FSimonetti,
MJSLoweandIPBradley;ImperialCollegeLondon,UniversityofCincinnatiandBPExploration&ProductionCompany.
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 8 – Production use >3 years or multiple deployments <3 years with limited track record.
ENERGY // ASSET INTEGRITY THEME LANDSCAPING STUDY
REPORT // ENERGY
92
5.8 Vapour Phase Corrosion Inhibitor
Vapour Phase Corrosion Inhibitor Source:
O>RL: 8
Description
A vapour phase corrosion inhibitor is a volatile compound and forms a stable bond at the interface of the metal, preventing penetration of corrosive substance to metal surfaces. VCI offers an alternative way to protect stored equipment, facilities and their contents.Adsorption of the inhibitor on to the metal surface provides a protective hydrophobic inhibitor layer to slow corrosion significantly. Compared to other methods of corrosion prevention such as gas blanketing and dehumidification, vapour phase corrosion inhibitors (VPCI) provide substantially better corrosion control at lower cost and require very low dosage rate.
Key Attributes
Requires low dosage rate (12-24 month intervals)
Stable up to 176°C
Rapid penetration through insulation jacket or thermal insulation to reach pipe surface
Can be applied through gravity fed system or portable injection pump
Can prevent further corrosion of surfaces already oxidised
Volatile until bonded with surface and requires materials to have stable passivating properties, strong tendencies towards surface adsorption
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 2
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 1
Complexity 2
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 3
Operations/Maintenance 2
Production Impact 0
Benefits
Cost Benefits 3
Safety Benefits 3
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
SummaryVapourphasecorrosioninhibitors(VPCI)areanalternativeprotectionmethodthatisbotheffectiveatcontrollingcorrosionandinexpensive.AVPCIisavolatilecompoundandformsastablebondattheinterfaceofthemetal,preventingpenetrationofcorrosivesubstancetometalsurfaces.VPCIoffersanalternativewaytoprotectstoredequipment,facilitiesandtheircontents.
ENERGY // ASSET INTEGRITY THEME LANDSCAPING STUDY
REPORT // ENERGY
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Adsorptionoftheinhibitorontothemetalsurfaceprovidesaprotectivehydrophobicinhibitorlayerto slow corrosion significantly. Compared to other methods of corrosion prevention such as gasblanketinganddehumidification,VPCIsprovidesubstantiallybettercorrosioncontrolatlowercostandrequireverylowdosagerate.
Thissummaryfocusesonthe(VPCI)CorroLogicVPCI-658whichismanufacturedbycorrosionprotectionsolutionscompanyCortecCorporation.AstudywasundertakentoascertaintheeffectivenessofVPCI-658againstacontrolgroup.
Four sampleswereassembled, two sampleswereusedas controls (no inhibitorapplied), and twosampleswerewrappedwiththermalinsulationthatwasimpregnatedwithCorroLogicVPCI-658.
Theeffectivenessof this inhibitoratminimisingCUIdamageswasevaluatedbydifferentcorrosiontests.Twosamples(onewithinhibitor,1control)wereplacedininacycliccorrosiontestchamberfor4800hours.A24hourcycleconsistedof8hourssaltspray,8hourshumidityatambienttemperature,and8hoursdrycycleat45°C.
Thesamples(onewithinhibitor,1control)weredisassembledevery720hours(30days)toevaluatetheirsurfaceconditionanddocumenttheextentofcorrosiondamageatpipe/insulationinterfaces.Theremainingtwosamplesweretestedinwetanddrycycles.A200ppmsodiumchloridesolutionwasinjectedbytubeintothepipe/insulationinterfacesevery48hours.Hotdryair(120-140oC)wasblownthroughthepipes(innerdiameter)fortwohoursperdayandtenheldatambienttemperature.Thesesampleswerealsodisassembledevery720hours(30days)forvisualinspectionandevaluation.CorrosionrateswerecontinuouslymonitoredusingMetalSamplesMS3500E(adata-loggerfordatastorage)andelectricalresistanceprobes.
Themostnoticeable changeswere thepositive shift in thebreakdownpotential andexpansionofthepassiverangeforthesealloysinthepresenceofCorroLogicVPCI-658.TheinhibitorchangedthereactivitybyreducingthepHlevel,increasedthepassivationrangesignificantly,andwasbeneficialinreducinglocalisedcorrosiondamage.
EachoneofthetestsshowedsignificantcorrosionattackonthecontrolsamplesbuttherewaseithernocorrosionorindiscerniblerustformationonthesamplestreatedwithVPCI-658.Cortecstatesthatthe results have demonstrated that CorroLogic VPCI-658 can successfully reduce corrosion attackunderinsulationdespitethepipesurfacesbeingmaintainedincontinuouslywet/drycyclicconditions.
Key Attributes• Lowcost;• Requireslowdosagerate(12-24monthintervals);• Easytoapply;• Versatile;• Canandisbeusedtoprotectmultiplemetaltypesinavarietyofindustries;• Hydrophobic(excludewatermolecules)filmofroughly6.35micrononthesurfacethatisstable
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upto176°C;• Rapidpenetrationthroughinsulationjacketorthermalinsulationtoreachpipesurface;• Canbeappliedthroughgravityfedsystemorportableinjectionpump;• Canpreventfurthercorrosionofsurfacesalreadyoxidised.
Limitations• Volatileuntilbondedwithsurface;• Requires materials to have stable passivating properties, strong tendencies towards surface
adsorption.
Sources• cortecvci.com/index2.php;• cortecvci.com/Publications/Papers/CorroLogic-VpCI-658-inhibitor-effects-on-CUI-final-report.
pdf;• cortecvci.com/Publications/PDS/VpCI-658.pdf.
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 8 – Production use >3 years or multiple deployments <3 years with limited track record.
ENERGY // ASSET INTEGRITY THEME LANDSCAPING STUDY
REPORT // ENERGY
95
5.9 Lateral Wave LFET
SummaryLowFrequencyElectromagneticTechnique(LFET)worksbyinjectingalowfrequencymagneticfieldintoametalplateortubeandusingscanner-mountedpickupcoilstodetecttheinducedACmagneticfieldinthematerialmeasuringthedistortionsintheresultingmagneticfieldthatoccuroveraflaw.Thispickupcoil isplacedsuchthatthereturnpathforthemagneticfieldisthroughtheareatobetested.Flawsaredetectedbymeasuringthemagneticfielddirectlyovertheflawareawithsensorcoils.
Low Frequency Electromagnetic TechniqueSource:
O>RL: 7
Description
The Low Frequency Electromagnetic Technique (LFET) is used to detect defects by passing a low frequency magnetic field though metal plate or pipe. By using several sensors in a LFET scanner, a 3D image of the collected data is produced so that the shape and depth of the defect can be determined. LFET scanners are used to inspect storage tanks and other convex or concave ferrous surfaces, as well as non-ferrous metal tubing & piping surfaces. Scanners are available in flatbed, pipe crawler and modular crawler variations, allowing scanning of horizontal or vertical magnetic surfaces.In most situations minimal or no surface preparation is required but if surface preparation is required beyond basic preparation, time involved along with cost will both increase
Key Attributes
Inspection of pipe or flat surfaces
Both magnetic and non-magnetic metals can be scanned
Minimal pipe preparation and in some cases no preparation required
Real-time display with some LFET scanners
Inspects through ID or OD scale
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 2
Significant Industry Backing 1
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 3
Safety Benefits 4
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
ENERGY // ASSET INTEGRITY THEME LANDSCAPING STUDY
REPORT // ENERGY
96
Aflawordefectcausesthemagneticfluxlinesinthatareatobedistortedordifferentthanexpected.Thisdistortioncanbemeasuredasachangeinphaseand/oramplitude.Withsuitablecalibrationtablestheflawcanbeanalysedandadeterminationofflawdepthandshapecanbemade.Byusingseveralsensorsinthescannerarrayitispossibletodisplaya3Dimageofthecollecteddatasothattheshape
anddepthoftheflawcanbedetermined.
LFET scanners can be used in settings wherecompetingtechnologiesfailorareinconvenient
LFETscannersdetectsflaws, includingcorrosioncells and hydrogen damage, caustic andphosphate gouging, oxygen pitting, departurefrom nucleate boiler, ID pitting, corrosion, anderosion.
Cracking is also detectable and its detectioncan be optimised bymodifying the pick-up coilconfiguration.
TherearevariousscannersystemsthatemployLFETtechnologymanufacturedwithspecificapplicationorsituationsinmind.Flatbedscannersforabovegroundtankscanninghavealargescanningarea,pipecrawlerswhichrunabovepipesofvaryingdiameter,360pipecrawlerscannerswhichautomaticallyadjusttopipediameterandmodularcrawlerscannersthatcanbeusedtoscaneitherhorizontalorverticalmagneticsurfaces.
Key Attributes• Technologyisinuseandreadilyaccessiblefromvendors;• Inspectionofpipeorflatsurfaces;• Bothmagneticandnon-magneticmetalscanbescanned(ascaneconomizertubing);• MinimalPipePreparationandinsomecasesnopreparationrequired;• Real-TimedisplaywithsomeLFETscanners;• InspectsthroughI.D.orO.D.scale.
Limitations• Ifpipeorsurfacepreparationisrequiredtimescaleisnegativelyimpactedasarecosts.• Maynotseethroughmetalcladding/galvanisedsteel/certainothermetals• Doesnotworkwellwithirregulargeometry• Requireshighlyskilledoperatives
Sourceshttp://testex-ndt.com/products/lfet-products/http://www.russelltech.com/http://jenteksensors.com/oilgaspetrol.php
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 7 – Initial production use (less than 3 years)
ENERGY // ASSET INTEGRITY THEME LANDSCAPING STUDY
REPORT // ENERGY
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5.10 Corrosion Radar
SummaryCorrosion Radar is a technology developed and patented by Cranfield University in response tothe industrial need for remote corrosion inspectionandmonitoring. It is a sensing technology formonitoringcorrosioninapplicationssuchascorrosionunderinsulation(CUI),corrosionunderpipesupport(CUPS)andburiedpipecorrosion. Itaimstoassistwithpinpointingthe locationofhiddencorrosion,therebyreducingtheriskofleakagesandthecostofinspection.
Corrosion RadarSource: Oil
& GasTRL: 4
Description
Corrosion Radar is a technology developed and patented by Cranfield University in response to the industrial need for remote corrosion inspection and monitoring. It is a sensing technology for monitoring CUI, corrosion under pipe support (CUPS) and buried pipe corrosion.
The Corrosion Radar system operates using permanently installed flexible long-range sensors mounted along the outer surface of pipes (inside any insulation), eliminating the need for inspection scaffolding. The sensors consist of 1mm wide lengths of flexible electromagnetic waveguide (resembling a wire from the exterior, but having geometrical features inside) which support wave propagation, and an innovative metallic sacrificial coating. This coating oxidises along with any external surface pipe corrosion around it.
Key Attributes
Long range remote corrosion monitoring technology with continuous pipe coverage.
Permanently installed sensors.
Locates corrosion under insulation from several hundred metres away.
Works even in a complex network of pipes.
Insulation needs to be removed for sensor installation.
Experimental technique, not yet transferred to, or proven in, a commercial scenario
Applicability / Limitations
With Plant Running 1
Retrofit 0
Offshore 1
Need for Specialist Skills 3
Coverage 2
Sample/Full Area 0
Risks
Cultural Change 3
Safety 2
Complexity 3
Significant Industry Backing 0
Costs
Install/Commission 1
Staff Training 3
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 3
Safety Benefits 2
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
ENERGY // ASSET INTEGRITY THEME LANDSCAPING STUDY
REPORT // ENERGY
98
The Corrosion Radar system operates using permanently installed flexible long-range sensorsmountedalongtheoutersurfaceofpipes(insideanyinsulation),eliminatingtheneedforinspectionscaffolding. The sensors consist of 1mm wide lengths of flexible electromagnetic waveguide(resemblingawirefromtheexterior,buthavinggeometricalfeatures inside)whichsupportwavepropagation, and an innovative metallic sacrificial coating. This coating oxidises along with anyexternalsurfacepipecorrosionaroundit.
Wavesaresentinthewaveguideusingahardwaredeviceandproprietaryalgorithmsthendetectthelocation(s)ofdegradedsacrificialcoatingwithanaccuracyof+/-10cmfromupto500maway.Thissignificantlyreducesthecostsassociatedwithblindinspection,bydirectingfurtherinspectionstoonlythecorrosionpronelocationsidentifiedbyCorrosionRadar.
Thewaveguidesensoritselfisinexpensiveanddoesn’trequirespecialistskillstoinstall.ThesensorispassiveundernormalcircumstancesandisactivatedonlywhenafieldengineerconnectsaCorrosionRadar Instrumentononeendduringperiodic data collection.Note that theuseof permanentlyinstalleddatacollectioninstrumentson-siteforonlinemonitoringisalsofeasible,butthishasnotbeendevelopedyet.
CorrosionRadarbuildsupon the strengthsof theSacrificialWire techniqueandeliminates someof that technique’s shortcomings. Firstly, SacrificialWire canonly indicatewhether corrosionhasoccurredatsomepointalongthewire’slengthusingacontinuitytest,butitcannottellthelocation,meaningseveralsmallerwireswithtwoendsneedtobelaidoneaftertheothertomonitorapipe.Also,oncecorroded,awireneedstobereplaced. Incomparison,CorrosionRadar isdesignedtolocatethecorrosion(within+/-10cm)usingasinglesensormonitoredfromoneend.Thesensorcontinuestoworkevenwhenitscoatingiscorrodedatmultiplelocationsbecausethewavecontinuestopropagate.Assuch,multiplecorrodedsectionscanbedetectedandlocatedbyasinglesensor.Sensorsofachosenlength(e.g.100m)eachareconnectedtogetherinapreferredarrangementtoenablereplacementofasectionifrequired.
ThecapabilityofCorrosionRadarhasbeendemonstrated in labconditions,witha labprototypeavailablefordemonstrationpurposes.CranfieldUniversityarenowlookingforindustrialsponsors,partnersandfieldtestsitesinordertofurtherproveanddevelopthetechnology.Beyondperiodicinspectionofpipelines,theCorrosionRadarteamiscontinuingitsresearchintoonlinemonitoringofcorrosionandalgorithmstoquantifytheseverityofcorrosionandmoisture.
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Key Attributes• Longrangeremotecorrosionmonitoringtechnologywithcontinuouspipecoverage.• Permanentlyinstalledsensors.• Locatescorrosionunderinsulationfromseveralhundredmetresaway.• Workseveninacomplexnetworkofpipes.
Limitations• Insulationneedstoberemovedforsensorinstallation.• Experimentaltechnique,notyettransferredto,orprovenin,acommercialscenario.
SourcesCranfieldUniversityCorrosionRadar;http://www.corrosionradar.com/
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 4 – Experimental pilot in laboratory conditions.
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5.11 Acoustic Resonance
Acoustic ResonanceSource:
O>RL: 3
Description
A sending transducer transmits a broad-band acoustic signal towards the pipeline. The signal then spreads in the structure, exciting half-wave resonances, and the structure's response signal is then detected by the receiving transducer.Analysis of the frequency content of the response signal gives the resonance peak frequencies, from which the base resonance frequency - and ultimately the structure's thickness - can be estimated. During post-processing, multiple measurements can be combined to estimate the size and depth of flaws, such as wall loss, in the metal structure.
Key Attributes
Potentially very accurate
Does not directly detect corrosion, detects wall loss and may not be able to distinguish between external and internal wall loss;
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 2
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 2
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 2
Safety Benefits 2
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryAcoustic resonance technology (ART)usesa sending transducer to transmitabroad-bandacousticsignal towards the metal structure. The signal then spreads in the structure, exciting half-waveresonances,andthestructure’sresponsesignalisthendetectedbythereceivingtransducer.
Analysisof the frequencycontentof the response signal gives theresonance peak frequencies,from which the base resonancefrequency – and ultimately thestructure’s thickness – can beestimated.Duringpost-processing,multiple measurements can becombinedtoestimatethesizeanddepthofflaws,suchaswallloss,inthemetalstructure.
This technique can potentially beusedfordetectingcorrosionandwalllossinvesselswithoutenteringthevessels,howeverwearenotawareofanyproductsortrialslookingatthisarea.
Key Attributes• Potentiallyveryaccuratescans;
Limitations• Accuracyislimitedwithirregulargeometry• Needs360degreeaccesstopipeline• The deployment of the technique is slow with the receiving sensor needing to be in close
proximitytotransmitter.
SourcesHalfwavewebsite:http://www.halfwave.com/acoustic-resonance-technology-art/
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 3 – Proof of concept
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5.12 Sacrificial Wire
Sacrificial WireSource:
O>RL: 3
Description
Currently under trial by BP and Shell, this technique is based on the location of thin wire adjacent to the pipe and under the insulation, where the thickness and material of the wire is chosen to corrode at the same rate as the pipe itself. The wire is typically wrapped around the pipe as a continuous spiral forming a complete circuit and can be extended to a suitable monitoring point. Should corrosion occur then the wire loses the ability to conduct electricity. This can be detected by operators using COTS hand-held resistance meters or multi-meters to determine the resistance of the wire. Wires of varying thicknesses can be employed simultaneously to provide an estimate of rate of corrosion.
This technique is relatively low cost both to install and to monitor and can be applied to new pipes and retrofitted to existing pipes following a repair
Key Attributes
Minimal equipment to install and use
Minimal training
Potential for automated continuous data collection
Depends on element failure to detect corrosion
Indicates presence/absence of corrosion but not rate of corrosion
Applicability / Limitations
With Plant Running 1
Retrofit 0
Offshore 1
Need for Specialist Skills 3
Coverage 2
Sample/Full Area 0
Risks
Cultural Change 3
Safety 2
Complexity 3
Significant Industry Backing 0
Costs
Install/Commission 1
Staff Training 3
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 3
Safety Benefits 2
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
SummaryThissolutionforCUIdetectionisbasedonthelocationofthinwireadjacenttothepipeandundertheinsulation,wherethethicknessandmaterialofthewireischosentocorrodeatthesamerateasthepipeitself.Thewireistypicallywrappedaroundthepipeasacontinuousspiralformingacompletecircuitandcanbeextendedtoasuitablemonitoringpoint.
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Should corrosion occur then the wire losesthe ability to conduct electricity. This can bedetected by operators using COTS hand-heldresistancemetersormulti-meters todeterminethe resistance of the wire. Wires of varyingthicknessescanbeemployedsimultaneously toprovideanestimateofrateofcorrosion.
Thistechniqueisrelativelylowcostbothtoinstallandtomonitorandcanbeappliedtonewpipesandretrofittedtoexistingpipesfollowingarepair.
Inadditiontothecontinuouscorrosion“fuse”techniquedescribedabove,Cosascoofferstwoothervariantsonthistechnology:• Insertedprobearray;• ElectricalResistance(ER)Probe.
The Inserted Probe Array consists of a set of 4probesinsertedthroughtheinsulationatdiscretepointssymmetricallyroundthecircumferenceofthe pipe and is designed to be used followinga repair to the pipe and/or insulation. As theprobes can be insertedwithout removal of theinsulation, this technique is also suitable forretrofittingexistingpipes.
Electrical Resistance Probe provides ameasurementofcorrosionataspecificpointon thepipeline.Thesensorelementcanbe insertedthroughexistinginsulation.
Whilst the costof installation is relatively low, it shouldbenoted that sacrificialdetection sensorsdetectcorrosionbyfailing,andrequirereplacementasandwhenaneventisdetectedandthepipeand/orinsulationisrepaired.
The techniquesdescribedhereandasdescribedbyCosascoare intended tobeused inamanualoperator/engineerbasedscheduledrotaandcanalsobeusedwithinariskassessmentbasedapproach.
LockheedMartin notes that with the advent of low cost/low powerWifi and Bluetooth enabledsensors(InternetofThings)itmayprovefeasibletocombinebasicremotesensorsandthesacrificialwiretechnologytoprovideautomatecontinuousinputtoaplantdatahistorianallowingforearlierandmoreconsistentdetection.
History of UseCosascooriginallydevelopedSacrificialWiredetectionforBPforuseinAlaska.FollowingsuccessfullaboratorytrialsBPinstalled200wiresinAlaskacirca3yearsago.BPhasnotreportedbackontheeffectivenessofthetechniqueyet,possiblybecausethepipelinesinthetrialaremanagedeffectivelyandhavenotsufferedsignificantrecentcorrosion.
Theproductshavealsobeenusedoffshore inThailand,howeveraswithBPtheproductshavenotbeeninplacelongenoughforsignificantcorrosiontooccur.
CosascoisalsocurrentlyconductingseparatetrialswithBPandShell,theresultsofwhicharenotyetavailableatthetimeofwriting.
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Key AttributesThekeyattributesofthesemethodsforCUIdetectionare:• RelativelyLowCost;• Can be fitted to new pipes or retrofitted to existing pipes with minimal impact on existing
insulation;• Minimaltrainingrequiredbothforinstallationteamsandforoperators/supporttechnicians;• Minimalequipmentrequiredtoinstallanduse;• Potentialforautomatedcontinuousdatacollection.
Limitations• Relativelynewproductsetcurrentlyundergoingfieldtrialssoeffectivenessisunknown;• As it dependson failureof elements todetect corrosion it is essentiallybinary innature. It is
possibletoinstallmultiplewirestopermitasteppedresponse;• Whilstasinglewiremeshcanbeusedtocoverlargeareas/lengthsofpipe,anyfailureatanypoint
onthewirenecessitatestheremovalof insulationforthewholeofthemeshcoveredareaforvisualinspectionofthepipeandreplacementoftheentiremesh;
• Asthewiresaredesignedtocorrodeatthesamerateasthepipe,butarethinner,theywillrequirereplacementthroughoutthelifetimeofthepipe.LifespanoftheproductisthereforebasedonthequalityofoverallCUIcontrolbytheoperator;
• Wheretheproductsareusedinaperiodicorriskbasedassessmentregime,itispossibleforsometimetoelapsebetweenthesensorwirefailingandthisbeingpickedupbytechnicians,duringwhichtimethepipemaydeterioratefurther.Thusasinglewireinstallationcannotbereliedontoindicatehowmuchcorrosionhashappened,onlythatcorrosionhastakenplacesincethelastinspection.
Sources• “CUISensorsRev5Feb15.pdf”availableonrequestfromCosasco;• “CUIDataSheet2016.pdf”availableonrequestfromCosasco;• InterviewconductedbyLockheedMartinwithDerekMortonofCosascoon20January2016.
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 3 – Proof of concept.
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5.13 Electromagnetic Inductance
Electromagnetic Inductance Degradation Source:
O>RL: 3
Description
Electromagnetic inductance degradation technique has the potential to monitor the microstructure of steel during processing or in service. By measuring the magnetic properties using a portable probe it is possible to determine the materials properties to quantify degradation during service, such as creep damage or embrittlement, or to identify the signs of microstructural pre-cursors to fatigue crack development.Although this technology is at an early stage in its development it has the potential to add another NDT technique with a range of applications including those in the oil and gas domain.
Key Attributes
Can scan large areas
Provides accurate material measurements
Provides condition based analysis on a the materials microstructure
Can be used to perform quality test inspection during steel production and fabrication.
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 2
Safety Benefits 2
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryTheNationalPhysicalLaboratoryhasundertakenresearchinusingelectromagneticinductanceforthedetectionofdegradationinsteelstructureswithinanumberofindustries.
Steel is the engineering material of choice in many demanding and safety critical applications,includingsub-seapipelinesandrisers intheoil industry,tubeandboilercomponents inelectricalgeneration,andpressurevesselsinthenuclearindustry.
Intheseapplicationsitisveryimportanttobeabletomonitortheconditionofthemicrostructure,especially to quantify degradationduring service, such as creepdamageor embrittlement, or toidentifythesignsofmicrostructuralpre-cursorstofatiguecrackdevelopment.
Themicrostructureofsteelgovernsitselectromagnetic(EM)propertiesand,therefore,EMsensingoffers potentialmeasurement techniques tomonitor themicrostructure during processing or inservice.Bymeasuringthemagneticpropertiesusingaportableprobeitispossibletodeterminetherequiredmaterialproperties.
An example is the determination of the stress in 316 stainless steel using the relativemagneticpermeability.BuildingonNPL’sexperienceinmeasuringthepropertiesofmagneticmaterialswithstressapplied,atechniquehasbeenestablishedthatusesNPLreferencematerialsandcalibrationcurvestoremotelymeasurethestresswithinsafetycriticalassets.
NPLhasarangeofelectricalconductivityreferencematerialsusedbytheautomotiveandaerospacesectorstodeterminethehardnessofaluminiumandaluminiumalloysandcombinedwithanextensiverangeofmagneticmaterialmeasurement facilitiesandmagneticfieldstandardsareapplying thisknowledgetodevelopNonDestructiveTesting(NDT)solutionsforarangeofapplications,includingthoseintheOil&Gasdomain.
Key Attributes• Canscanupto250mmawayfromthesurface;• Providesaccuratematerialmeasurements;• Canpenetratedeepintostructures;• Providesconditionbasedanalysisonamaterialsmicrostructure;• Minimaloperatortrainingrequired.
Limitations• Anunproventechniqueforcorrosiondetection;• Scanningarealimitedbyarraysize.
SourcesNationalPhysicalLaboratory(NPL).
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 3 – Proof of concept.
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5.14 Electrochemical Impedance Spectroscopy
SummaryElectrochemical Impedance Spectroscopy (EIS) is an inspection method used to characteriseelectrochemicalprocessessuchascorrosion.ThemethodworksbyapplyingasmallamplitudeACcurrent(usuallyintherange5to50mV)ofvaryingfrequencies(0.001Hzto100,000Hz)toamaterialandmeasuring its response. It is a non-destructivemethod for the evaluationof awide range ofmaterials,includingcoatings,anodisedfilmsandcorrosioninhibitors.
Electrochemical Impedance SpectroscopySource:
O>RL: 3
Description
Electrochemical Impedance Spectroscopy (EIS) is an inspection method used to characterise electrochemical processes such as corrosion. The method works by applying a small amplitude AC current (usually in the range 5 to 50 mV) of varying frequencies (0.001 Hz to 100,000 Hz) to a material and measuring its response. It is a non-destructive method for the evaluation of a wide range of materials, including coatings, anodised films and corrosion inhibitors.
Applicability / Limitations
With Plant Running 0
Retrofit 0
Offshore 0
Need for Specialist Skills 1
Coverage 1
Sample/Full Area 0
Risks
Cultural Change 3
Safety 2
Complexity 2
Significant Industry Backing 0
Costs
Install/Commission 3
Staff Training 1
Operations/Maintenance 3
Production Impact 0
Benefits
Cost Benefits 1
Safety Benefits 1
Other Industries
Key Attributes
Successfully applied to the study of corrosion systems for 30 years
Very well suited to the study of paints and coatings used to prevent corrosion, to the extent that there are ISO norms developed for such tests
Requires an accurate control of the operating/testing conditions
Results can be challenging to interpret, particularly the assignment of correct circuits/equations to the experimental data
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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Analysisoftheresponseisusedtoextractinformationabouttheinterface,itsstructureandreactionstakingplacethere.Chemical reactions such as corrosion tend to dominate atcertain frequencies. The responses are then modelled ascomplex impedance circuits (where impedance is definedas theopposition to theflowofAC current) and analysedgraphicallyusingNyquistplotsandBodeplots..Forexample,theBodeplottotherightshowstheimpedancevsfrequencypropertiesovertimeofacoatingsubmergedinasolutionofsodiumchloride(NaCl).
EIS canprovidedetailed informationof the systemsunderexamination,includingparameterssuchascorrosionrate,anddirectionoflocalisedcorrosion.Infact,EIS has been successfully applied to the study of corrosion systems formany years and has beenproventobeapowerfulandaccuratemethodformeasuringcorrosionrates.
Inparticular,defects, limitationsandthepresenceofcorrosion incoatingsaredetectablewith theuseofEIS.Themetalcoatedsystemisgenerallyfairlycomplexandconsistsofametalsubstrate,asurfacepre-treatmentandsome layersofpaintwithdifferentchemicalandphysicalproperties.AlltheseparameterscaninfluencetheelectrochemicalbehaviourmeasuredbyEIS,andthereforealsotheelectricalmodelsusedtoexplaintheimpedanceresults.
EISisahighlysensitivetechniquewhichmakesitagoodreferenceforotherNDTmethods.However,this is a laboratory technique typically applied either to simulations of corrosion (often aligned toASTMstandardG189)ortocoatingsamples.Assuch,itisacomplementarytechnique,typicallyusedinconjunctionwithothercorrosiondetectiontechniques.
Key Attributes• Successfullyappliedtothestudyofcorrosionsystemsfor30years;•Verywellsuitedtothestudyofpaintsandcoatingsusedtopreventcorrosion,totheextentthatthereareISOnormsdevelopedforsuchtests.
Limitations• Requiresanaccuratecontroloftheoperating/testingconditions;• Resultscanbechallengingtointerpret,particularlytheassignmentofcorrectcircuits/equations
totheexperimentaldata.
Sources• “Electrochemicalimpedancespectroscopyasatoolforinvestigatingunderpaintcorrosion”;P.L.
Bonora,F.Deflorian,L.Fedrizzi;.• “ElectrochemicalImpedanceSpectroscopyanditsApplications(2014)”;AndrzejLasia;• Electrochemicalimpedancespectroscopy(EIS)• “Use of Electrochemical Impedance Spectroscopy (EIS) for the Evaluation of Electrocoatings
Performances”;Marie-GeorgesOlivierandMireillePoelman;UniversityofMons,Belgium.
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 3 – Proof of concept
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5.15 Ultrasonic Surveys
Ultrasonic SurveysSource:
O>RL: 3
Description
Uses high frequency sound energy to inspect pipes and vessels. Works on steel, castings, welds and composites. Can detect discontinuities, moisture and corrosion. Ultrasonic waves are introduced into a material, where they travel in a straight line and at a constant speed until they encounter a surface. At the surface interface, some of the energy is reflected and some is transmitted. The amount of reflected or transmitted energy can be detected and provides information about the size of the reflector. The travel time of the sound can be measured and this allows the distance the sound has travelled to be calculated.Recent improvements in techniques developed in the health industry and the use of an ultrasonic array roller allow long lengths to be inspected for signs of corrosion under insulation once the array has been attenuated for the insulating medium. Requires access to pipes and vessels but can be restricted by insulating materials and casings such as aluminium.
Key Attributes
Detects discontinuities, moisture and corrosion
Non-invasive, can be used whilst plant is running
Works through some types of insulation not through metal cladding
Better suited for straight pipes
Requires skilled staff to interpret results
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 2
Safety Benefits 1
Other Industries
Health
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
SummaryTheUltrasonicInspectiontechniqueisanon-destructivetesting(NDT)methodinvolvinghighfrequencysoundenergytocarryoutinspectionsandmakemeasurementsonpipesandvessels.Inspectionscanbeconductedonawidevarietyofmaterialsincludingcastings,weldsandcomposites.Theinformationcollected fromanobject includesthepresenceofdiscontinuity,presenceofmoistureandsignsofcorrosion.
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Ultrasonicwavesareintroducedintoamaterial,wheretheytravelinastraightlineandataconstantspeeduntiltheyencounterasurface.Atthesurface interface,someoftheenergy isreflectedandsome is transmitted.Theamountof reflectedor transmittedenergycanbedetectedandprovidesinformationaboutthesizeofthereflector.Thetraveltimeofthesoundcanbemeasuredandthisallowsthedistancethesoundhastravelledtobecalculated.
Recent improvements intechniques developed in themedicalindustryandtheuseofanultrasonic array roller allow longlengths to be inspected for signsofcorrosionunderinsulationoncethearrayhasbeenattenuatedfortheinsulatingmedium.
Thetechniqueisveryeffectiveforeasy to access pipes and vesselsbutcanberestrictedbyinsulatingmaterials and casings such asaluminium.
Research intosuitable typesofcladdingand insulationtoaid this typeof inspection is requiredsothatitcanbedesignedintotheplant.Researchintotransducerdesigntoenablescanningthroughmaterialssuchasaluminiumcladdingisalsorequired.
Key Attributes• Canbeusedtomonitordefectsanddetectthepresenceofwater;• Monitoringcantakeplacewhilsttheplantisstillinoperation,thereforethereisminimalimpact
onoperations;• Canbeusedtomonitorcorrosion,weldingandplantintegrity;• Candetectsurfacecorrosionthroughinsulation;• Canbeverycosteffectiveprovidingvesselsandpipesareinaneasyconditiontoscan.i.e.,long
lengthsofpipewith“ultrasonicfriendly”claddingoreasilyaccessiblevessels.
Limitations• Maynotworkonallvessels;• Islimitedtolengthsofpipewithfewjointsorbends;• Limitedbyinsulationcladding.Aluminiumcladdingmakespenetrationdifficult;• Datainterpretationrequiresskilledpersonnel,althoughthereareanumberofhighlydeveloped
proceduresandcodeswhichreducetheneedforexpertinterpretation.
Sources• HSE Technical Document- Corrosion under insulation of plant and pipework v3- SPC/TECH/
GEN/18;• SauravKumarGupta–SeminaronUltrasonicTechniqueforCorrosionDetection; • Svein-EricMasoy–InPhaseSolutions.
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 3 – Proof of concept
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5.16 Terahertz Spectral Imaging
Terahertz Spectral ImagingSource:
NuclearTRL: 2
Description
Terahertz (THz) waves occupy the wavelength range between microwave and infrared. In THz imaging, the internal structure of an object is determined by analysing changes in a THz signal applied to the object. THz waves can penetrate opaque materials and detect internal defects within non-metallic materials which visible light cannot, such as foam, ceramics, glass, resin, paint, rubber, composites, and concrete.THz imaging has been extensively used in the Space and Aerospace sectors for testing of thermal protection, foam insulation and carbon composites. Experimental results also show that THz imaging may be used for detection of corrosion under paint and detection of corrosion within steel reinforced concrete.
Key Attributes
Can detect defects within non-metallic, opaque materials which visible light cannot
No human radiation hazard, unlike microwaves
Relatively new NDT technique, unproven for corrosion detection
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 2
Coverage 2
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 1
Staff Training 2
Operations/Maintenance 2
Production Impact 0
Benefits
Cost Benefits 4
Safety Benefits 3
Other Industries
Nuclear
Space
Aerospace
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
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SummaryLong-termcorrosionofsteelinconcretestructuresisaparticularconcernfornuclearpowerplantsasthereiscompellingpublicinterestinthesafeoperationoftheseplantsforthemanydecadesthattheyareinoperationandtheadditionaldecadesittakesforthemtobedecommissioned.
Inspectiontechniquesthatarebothnon-destructiveandwhichcandetectlong-termcorrosionatitsearlieststagesareneededtoidentifywhenremedialstepsneedtobetakentoinsuretheintegrityofconcretestructuresatnuclearpowerplants.
PhysicsMaterialsandAppliedMathematicsResearchLLCisconductingresearchintohowterahertzimaging can be used to detect corrosion of steel in concrete structures. The overall objective ofthis researchprogram is to establish terahertz imagingand spectroscopyas thepre-eminentnon-destructiveexaminationtechniqueforlocatingandidentifyingcorrosioninsteelreinforcedconcretestructures.
Thisisaccomplishedbypushingthelimitsofhigh-powerterahertzsystemstoincreaseimagingdepthand by enhancing the detection sensitivity of terahertz spectroscopic methods to directly detectcorrosionby-productsinconcrete.
In Phase I effort is spent to identify whichcorrosion by-product or promoting agent ismoststronglydetectedwithterahertzimagingand spectroscopy. This is established via acombination of theoretical and numericalmodellingandexperimentalbenchmarkingatterahertzfrequencies.
Images are taken of steel in concrete toevaluatetheimagingdepthandquality. Theproposedtechniqueenablesrapidinspectionof nuclear plant structures and detection ofcorrosioninconcrete.
Similarcorrosionissuesafflictaginginfrastructureincludinghighways,bridges,tunnels,buildings,anddams.Earlieridentificationofcorrosioninthesestructuressignificantlyenhancespublicsafetyaswellasreducingthecostofcorrosion,estimatedtobeinthehundredsofbillionsofdollarsannually.
Key Attributes• Initialresearchprogramsosometimebeforekeyattributescanbeestablished;• Stand-offsensor;• Abilitytodetectchemicalsignatures.
Limitations• Initialresearchprogramsosometimebeforeanylimitationsbecomeapparent;• Noneoftheresearchanddevelopmentprogramshaveanyoilandgasfocus.
Sources• Physics,Materials,andAppliedMathematicsResearchL.L.Cwebsite-http://physics-math.com/
pmam/.
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:
NASA TRL 2 – Technology concept and/or application formulated
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5.17 Acoustic Emission
Acoustic EmissionSource:
O>RL: 2
Description
Uses the detection of high frequency acoustic (elastic) stress waves that occur and radiate within a solid material when it undergoes changes in its internal structure. The waves are generated by the changes themselves and can be the result of localised yielding or cracking of the base material, or of the products resulting from corrosion.The waves are converted to electrical signals by surface mounted piezoelectric sensors, or, in the case of high temperature structures, on the end of metal waveguides which are attached to the structure. Can be used for spot checks or for long term monitoring during production
Extensive used in multiple scenarios, including corrosion detection, pressure vessel inspection, leak detection, crack formation during welding and detecting creep damage in High Energy Piping (HEP) systems
Key Attributes
Can monitor active, inner, outer and embedded defects and corrosion during plant operation on temporary or permanent basis
Non-invasive inspection technique
Some disturbance of insulation may be required
Remote monitoring possible
No external energy is applied to the target
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 1
Coverage 0
Sample/Full Area 1
Risks
Cultural Change 2
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 1
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 2
Safety Benefits 2
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
SummaryAcoustic emission (AE) is a non-destructive testing (NDT) method which utilises the detection ofhighfrequencyacoustic(elastic)stresswavesthatoccurandradiatewithinasolidmaterialwhenitundergoeschangesinitsinternalstructure.Thewavesaregeneratedbythechangesthemselvesandcanbetheresultof localisedyieldingorcrackingofthebasematerial,oroftheproductsresultingfromcorrosion.
Thewavesareconvertedtoelectricalsignalsbysurfacemountedpiezoelectricsensors,or,inthecaseofhightemperaturestructures,ontheendofmetalwaveguideswhichareattachedtothestructure.
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ThepicturebelowillustratestheAEprocess.
Fordetection thesourcemustbeactiveduring themonitoringperiod,whichmeans thestructureneedstobestressedoroperating.Inthecaseofashort-termtest,additionalstressisusuallyappliedtothestructuretostimulateactivity.Alternatively,thestructurecanbemonitoredforanextendedperiod,orevencontinuously,undernormaloperation.
TheAEtechniqueisdifferentthanotherNon-DestructiveTesting(NDT)techniquesintwokeyregards:
• Insteadofsupplyingenergytotheobjectunderexamination,AElistensforenergyreleasedbytheobjectnaturally;
• AE works with the dynamic processes within the object material i.e. only active/developingfeaturesaredetected.Thus,itispossibletodistinguishbetweendevelopingandstagnantdefects.
TheAEtechniqueiscapableofdetectinginner,outerandembeddeddefects.Thetechniquecanalsoidentifydefect locationbymeasuring the relativetimeofarrivalof signalsatmultiple sensorsandcarryingouttriangulation.
AEsystemsareusuallybasedaroundspecialistperipheralcomponentinterconnect(PCI)boardswithdigitalsignalprocessing(DSP),installedinanindustrialPCorspecialistchassisrunningPCsoftware.Thesignalsfromthesensorsarefirstfilteredandamplifiedusinglow-noisepre-amplifiers,whicharetypicallylocatedwithinthesensorsthemselvesandalsoprovidelinedrivefunctionalityforlongcables.ThePCsoftwareanalysesthecollectedsignals,removingextraneousnoiseandidentifyingtheseverityandlocationofdefects.
Acoustic emissions can be detected in frequency ranges under 1 kHz, and have been reported atfrequenciesup to100MHz,butnon-destructive testingofmaterials typically takesplacebetween30 kHz and1MHz.Unlike othermethodsof ultrasonic testing, theAE techniquedetects acousticemissionsproducedby/withinamaterialduringstress,ratherthanactivelyinputtingacousticwavesandthendetectingthemaftertheyhavetravelledthroughthematerial.
Asaresultoftheversatilityofthetechnique,ithasseenextensiveuseinmultiplescenarios,includingcorrosiondetection,pressurevessel inspection, leakdetection,crackformationduringweldinganddetectingcreepdamageinHighEnergyPiping(HEP)systems.
StandardsfortheuseoftheAEtechniqueforNDThavebeenproducedandpublishedbytheAmericanSocietyofMechanicalEngineers(ASME),byISOandbytheEuropeanCommunity.
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Key Attributes• Canbeusedtomonitoractivedefects;• Monitoringcantakeplacefrommultiplelocations,withminimaldisturbancetopipeorvessel
insulation,whilsttheplantisstillinoperation;• Canbeusedtomonitorcorrosion,weldingandplant integrityonanextendedorpermanent
basis; • Candetectinner,outerandembeddeddefectsandisnotaffectedbydefectorientation;• ComparedtootherNDTtechniques,AEdetectsenergygeneratedinsideamaterialitself,rather
thanneedingtoapplyandthendetectsomeformofenergy;• Oncesensorsareinplace,AEmonitoringandanalysiscanbecarriedoutremotely,whichisof
benefitwhenoperatinginharshenvironments;• AEsensorsareavailableforuseuptooperatingtemperaturesof550C.Waveguidescanbeused
atanytemperature.
Limitations• Reliesondefectactivity/growthfordetection;• Onlyprovidesaqualitativeassessmentofdefectactivity.Assuch,follow-upquantitativetesting/
inspection is required tomeasure defect size. However, the use of AE to direct subsequentinspectionimprovesinspectioneffectiveness,allowingknownproblemareastobeprioritised;
• Datainterpretationrequiresskilledpersonnel,althoughthereareanumberofhighlydevelopedproceduresandcodeswhichreducetheneedforexpertinterpretation;
• Susceptibletosignaltonoiseissueswhenutilisedinnoisyenvironments,thusrequiringahighlevelofcorrectivesignalprocessing.Processactivitiesareonesourceofbackgroundnoiseandmightpreventacquisitionofconclusivesensordata.
Sources• “CorrosionMonitoringandTestingFacilities”;SchoolofEngineering,RobertGordonUniversity,
Aberdeen;• “RR659: Evaluation of the effectiveness of non-destructive testing screeningmethods for in-
serviceinspection”;HealthandSafetyExecutive;• “IntroductiontoAcousticEmissionTesting”;NDTResourceCentre;• “UseofAcousticEmissiontoDetectLocalisedCorrosion–PhilosophyofIndustrialUse,Illustrated
WithRealExamples”;• “UsingAcousticEmissioninFatigueandFractureMaterialsResearch”;JournalofTheMinerals,
Metals&MaterialsSociety;• “AcousticEmissionTesting(AET)”;InspectioneeringJournal
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 2 – Technology concept and/or application formulated.
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5.18 Ultrasound Tomography
Ultrasonic TomographySource:
O>RL: 2
Description
Ultrasound Tomography (UST) is a tomographic technology that enables non-invasive online imaging and measurement of media inside an industrial pipe or tank. The technology is suitable for example for measuring emulsion interfaces. The measurement is based on the speed of sound. Monitoring systems are based in tomographic technologies, which are non-invasive, non-nuclear techniques for cross sectional or 3D imaging of material properties and distributions in various industrial positions such as in pipes and tanks. The target is exposed to acoustic waves and the response measured. Calculations then determine areas of material change. In principal, initial surveys would be undertaken using a portable instrument to determine where issues are most likely to occur and then fixed sensors would be installed to provide live online data feeds.
Key Attributes
Can be used to monitor defects and detect the presence of water and surface corrosion, also welding defects
Non-invasive, can be used whilst plant is running
Doesn't work through aluminium cladding
Effective for long lengths of pipe
Applicability / Limitations
With Plant Running 1
Retrofit 1
Offshore 1
Need for Specialist Skills 2
Coverage 1
Sample/Full Area 1
Risks
Cultural Change 3
Safety 2
Complexity 1
Significant Industry Backing 0
Costs
Install/Commission 2
Staff Training 2
Operations/Maintenance 2
Production Impact 1
Benefits
Cost Benefits 2
Safety Benefits 2
Other Industries
0
1
2
3
4
5
6
7
8
9
10TRL
App/Lim
RisksCosts
Benefits
SummaryUltrasoundTomography(UST)isatomographictechnologythatenablesnon-invasiveonlineimagingandmeasurementofmediainsideanindustrialpipeortank.Thetechnologyissuitableforexampleformeasuringemulsioninterfaces.Themeasurementisbasedonthespeedofsound.
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Monitoring systems are based in tomographic technologies, which are non-invasive, non-nucleartechniques for cross sectional or 3D imaging of material properties and distributions in variousindustrialpositionssuchasinpipesandtanks.
ThefigurebelowillustratestheUSTprocess.
Ultrasoundtransducersareplacedaroundthemeasuredobject.Themeasurementisperformedbysendingasoundpulsewithonetransducer,andthematerialbetweenalltransducersmodulatestheshapeofthepulse.Thesemeasurementsareutilisedforreconstructingthespeedofsounddistributioninsidetheobject,fromwhichtheimageandtrendsarecalculated.
MonitoringsystemsarebeingdevelopedfortheOilandGasProcessIndustriesandaredesignedtoensurethebestpossiblelevelofflowassurance.Byseeinginsidepipesandtanksinreal-time,systemsallowoperatorstoovercometoughandcostlyflowassurancechallenges,forexamplepreventionofdepositionandcorrosioninpipesoroptimizationoflayersinseparatortanks.
ThenextfigureillustratesapotentialuseofUSTtomonitorpipesandtanks.
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Inordertomakesystemssaferforpeopleandtheenvironment,tomographictechnologiesareutilisedtoperformtheprocessimagingandmeasurementwithoutusingaradioactivesource.
Solutionsarebasedontomographictechnologies,whichenablewholevolumeimagingofaprocesspipeortankwithoutusingaradioactivesource.Tomographictechnologiesareespeciallysuitableformeasuringandcontrollingmultiphaseflows.Resultsinprocesstomographicimagingaredisplayedasanimageandindices.
Thegeneralideaintomographicmeasurementsistoexposethetargetofinteresttoacousticwavesandmeasuretheresponsecausedbythetarget.Fromtheresponsesignalsitispossible,withtheaidofmathematicalmodels,toinferthedistributionofdifferentmaterialwithinthetarget.
Inprincipal,initialsurveyswouldbeundertakenusingaportableinstrumenttodeterminewhereissuesaremostlikelytooccurandthenfixedsensorswouldbeinstalledtoprovideliveonlinedatafeeds.
This technology is currentlyunderdevelopmentandas such there is limited information from thedeveloper. Theyhave indicated that the technology is likely to be available in themarket place in2017/2018.Duetothedevelopment,itisalsodifficulttodiscussthekeyattributesandlimitationsofthetechnology.
Key Attributes• Canbeusedtomonitordefectsanddetectthepresenceofwater;• Monitoringcantakeplacewhilsttheplantisstillinoperation,thereforethereisminimalimpact
onoperations;• Canbeusedtomonitorcorrosion,weldingandplantintegrity;• Candetectsurfacecorrosionthroughinsulation;• Canbeverycosteffectiveprovidingvesselsandpipesareinaneasyconditiontoscani.e.,long
lengthsofpipewith“ultrasonicfriendly”claddingoreasilyaccessiblevessels.
Limitations• Maynotworkonallvessels;
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• Islimitedtolengthsofpipewithfewjointsorbends;• Limitedbyinsulationcladding.Aluminiumcladdingmakespenetrationdifficult;• Datainterpretationrequiresskilledpersonnel,althoughthereareanumberofhighlydeveloped
proceduresandcodeswhichreducetheneedforexpertinterpretation.
Sources• Rocsole
Readiness AssessmentWeestimatethatthistechnology’sscoreontheNASATRLscaleis:NASA TRL 2 – Technology concept and/or application formulated.
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SECTION 6
MANAGEMENT AND CULTURAL IMPEDIMENTS
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InadditiontophysicalandtechnicalconstraintsoneffectiveCUIandvesselinspectiontherecanbeconstraintsinvolvingpeopleandprocesses.Whilstphysicalandtechnicalconstraintsareusuallyeasytoidentifyifnotnecessarilyresolve,managementandculturalconstraintsaresometimeslessobviousandhencehardertoquantify.
ManagementandCulturalconstraintscaninclude:
• Knowledgeoflatesteffectiveprocessesandtechniquesandtheskillstousethem;• Financial;• Supervision;• Training;• Requirementsmanagement;• AvailabilityofresourcesandWorkscheduling;• Competencyofstaff;• InformationManagement;• Contractual.
Management and Cultural factors may exist at different levels including the activity, facility andorganisationallevels,andaneffectivereviewprocessneedstolookatthewholepicturenotjustthetechnicalmethodsforinspection.
Effective training and regular competency assessments, quality supervision and recognition bymanagement of the importance of regular inspection regimes are vital to timely prevention anddetectionofcorrosionanditsconsequences.
Somefactorsaremorespecifictooffshoreoperations.Thehighlevelofcontractorandsub-contractorusecoupledwithahighrotationofstaffbetweenplatformscanintroducealackofcommunicationbetweengroupsandpreventa joinedupapproach.Routine inspectionscanbedelayedormissedentirelywhenstaffaremovedfromtheplatformtomakeroomforhigherprioritywork,orstaffmaybedivertedintounplannedmaintenanceactivitiesatthecostoftheplannedinspectionprocess.
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SECTION 7
TECHNOLOGY GAPS
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7.1 Technology GapsThecurrenttechniquesusedintheoilandgasindustryforvesselinspectiondonotcurrentlypermitinternalinspectionwithoutmanualentry,andforCUImanagementanddetectionthecurrentlyusedtechniqueseitherhavelimitedcoverageorresolution,and/orrequiretheremovalofinsulation.
There are some promising techniques described in the study which can potentially close thesetechnology gaps and Lockheed Martin recommends that a shortlist is drawn by the relevantstakeholdersforfurtherpursuit.Werecommendthatstakeholders:
• review the scoring guidelines and Lockheed Martin suggested scores contained within thisdocument;
• forshort-termpossibilities(i.e.,thosemore-or-lessreadytogo),identifyopportunityforrealisticplant trial andprovide thenecessary funding, technical supportand logistics toallow this toprogress;
• forlongertermprospects,providetechnicalandfundingsupportsothatthesecanbemovedtowardsthe‘trial-ready’state.
Adefinite‘gap’thatcanbeclosedquitequicklyisthatofcombiningsomeofthesensingtechnologiesreviewedwithremotemobileandautonomousinspectionplatforms.Itislikelythatthiswillrequiresomeencouragementandsupporttogetthedifferentvendorsanddeveloperstoworktogether.
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SECTION 8
CONCLUSIONS AND RECOMMENDATIONS
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8.1 General conclusions and recommendationsThestudyteambelievesthattheassessmentmethodologyadoptedissound,althoughthematurity,applicability,cost,riskandbenefitscoresandassociatedguidelineswouldbenefitfromwiderreviewandvalidationbytherelevantstakeholders.
The studywas undertakenwithin an agreedtimeperiodwhich allowed sufficient interactionwithrelevantstakeholders,butdidnotallowforexhaustiveidentificationandinteractionwithalltechniquesandtheirproviders.
8.2 TLB Asset Integrity Theme WorkshopsTheTLBorganisedthemeworkshopsonvesselinspectionanddetectionofcorrosionunderinsulationatMaryculterHouseHotelAberdeenon24thand25thFebruary2016.
TheLockheedMartinAssetIntegrityLandscapeDraftReportwasusedasapre-readfortheworkshops.Theaimoftheworkshopswasto informfurtherworktodevelopproductsandserviceswhichcanreducecosts,increaseproductionefficiencyand/orimprovesafetywhencarryingoutprocessvesselinspectionsanddetectionofcorrosionunderinsulation.ThisfurtherworkwillbecoordinatedbytherecentlyannouncedOil&GasTechnologyCentre.
For furtherdetailsplease refer to theTLB IntegrityTheme–WorkshopOutputReport,whichwasissuedbyOGICtoallworkshopattendeeson17thMarch2016.
8.3 Vessel InspectionThelowfrequencyelectromagnetictechniqueappearstooffergoodprospectsatmoderatecostandriskandhasahighmaturityscore.
Fullmatrixcapture(FMC)hasasimilarprofile,butislessmaturesocouldbeseenasagoodlonger-termprospect.
Althoughrobotsandremotelyoperatedvehiclesontheirownhavearelativelylowbenefitscore,suchdevices are becoming increasingly common (e.g., in the nuclear industry) andmight be profitablycombinedwithothersensortechnologiestoallowasignificantreductionintheneedformanualentryintoprocessvesselsandotherconfinedspaces.
8.4 CUI DetectionThepulsededdycurrenttechniqueappearstooffergoodprospectsatmoderatecostandrisk.Ithasahighmaturityscoreandthereisasenseofsignificantindustrycommitmenttoproductdevelopment,marketinganddeployment.
Vapourphasecorrosioninhibitorstandsoutasbeingaprevention(asopposedtodetection)technique.Themainconcernhereisthenatureofthechemicalsrequiredfortheprocess,especiallyoffshore.Nevertheless,thistechniqueseemsworthyoffurtherinvestigationasitofferstheprospectofreducingtheextentandnatureoftheunderlyingproblemofCUI.
Aswith vessel inspection, someof the sensing techniques identified in this studymightprofitablybecombinedwithremotelyoperatedvehiclessuchaspipeandvesselcrawlers.Ofparticularbenefitwouldbeanycombinedtechniquethatreducedtherequirementforscaffolding.
8.5 Further ResearchLockheedMartinrecommendsthatfurtherresearchisundertakenintoclosingperceivedtechnologygapsthatcouldpreventtheuptakeofsomeofthemethodsandtechnologiesdescribedinthestudy.WerecommenddevelopinganITarchitecturethatfacilitatesthedevelopmentanduseofnewvesselinspectionandCUIdetectionandmonitoringtechniquesastheybecomeavailable.Inparticularthearchitectureshouldincludethefollowing.
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Open StandardsDeveloping open standards is key tomaximising the rapid take up of any new techniques, it alsofacilitatesthedevelopmentofopenmarketsandminimisesvendorlock-in.
Werecommendthattomaximisetheimpact,newstandardsshouldbedevelopedinconjunctionwiththeappropriatenationalandinternationalstandardsbodies.
Secure Sharing of DataWerecommendthattechniquesaredevelopedacrosstheoilandgasindustrytosharetherawdatafrommultiple installations in a securemanner. This data can be provided to all stakeholders andprovideaplatformforfutureinnovation.
Automatedatacollection,transformationandstorage
Make use of existing technologies such as COTS data historians, IP protocols, and transmissiontechnologiessuchasWIFIandLowPowerBluetooth,coupledwithnewdevelopmentsinlowcost/lowpowersensorsbeingdevelopedfortheInternetOfThings.
Develop standard analysis techniquesTomaximisere-useandportability,standardanalysistechniquesshouldideallycomeintheformofopen-sourcelibrary/softwaredevelopmentkitsofstandardtechniquesoptimisedforusewithvesselinspectionandCUIdetectionandmonitoring.
Develop standard visualisation techniquesStandardvisualisationtechniquesshouldbedevelopedwithtwomainaudiences inmind–controlroomstaffandmaintenance/supportengineers.
Controlroomstaffwanttoknowaboutsuddenchangesinplantconditions,typicallythroughscreensandalarmsondistributedcontrolsystems(DCS)andsupervisorycontrolanddataacquisition(SCADA)systems.Thereforeappropriatestandardsshouldbedevelopedforvisualisationincollaborationwiththeleadingcontrolsystemsproviders.
Maintenance /Support engineers want to know in more depth about gradual changes in plantconditions,eithercontinuouslymonitoredorthroughanalysisresultingfromspotchecks.Thereforeappropriate standards for visualisation should be developed in collaborationwith leading desktopvisualisationandanalysisproviders.
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AggregationAsouranalysisindicatesthatnoonemethodisprevalentforeithervesselinspectionorCUIdetectionandmanagement,itislikelythatoperatorswillemployseveraldifferent,possiblyoverlappingmethods.Thereforeanalysistechniquesshouldbedevelopedinsuchawayastopermitaggregationofresults,andvisualisationtechniquesshouldincludetheabilitytooverlayresultsfromseveraldifferentsources.
ThediagrambelowshowstheproposedstandardsbasedITarchitecture
8.6 Industry collaborationThestudyfoundthattherelationshipsbetweenthevariousstakeholdersarecomplex,andthatthereisalackoffocusonvesselinspectionandCUIdetectiontechnologieswithintheoilandgasindustry.Wealsonotethatsomeofthetechnologybeingdevelopedinitiallyoriginatedinotherindustrysectors.
LockheedMartin recommends that a single leading organisation is given overall responsibility forfocussingvesselinspectionandCUIresearchanddevelopmenteffortswithintheoilandgasindustry.Thisorganisationshouldfocusonseveralstrands:
• Developmentofthestandards-basedITarchitectureasdescribedabove;• DevelopmentofpromisingvesselinspectionandCUIresearch;• Cross-sectorinitiativeswithrelationtovesselinspectionandCUIresearch.
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APPENDIX A
ORGANISATIONS CONTACTED
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ORGANISATIONS CONTACTEDLockheedMartincontactedthefollowingorganisationsduringthecourseofthestudy.Organisations who have contributed to study
Organisation Category
Technologysupplier
Technologysupplier
Technologysupplier
Engineeringcontractor
Technologysupplier
Engineeringcontractor
Oilandgasoperator
AcademicInstitution
Technologysupplier
Technologysupplier
Technologysupplier
Academicinstitution
Engineeringcontractor
Engineeringcontractor
Technologysupplier
Industrybody
Industrybody
Industrybody
Technologysupplier
Academicinstitution
Research
Industrybody
Technologysupplier
Academicinstitution
Industrybody
Technologysupplier
Industrybody
Engineeringcontractor
Technologysupplier
Technologysupplier
Technologysupplier
Researchinstitution
ABB
Absoft
AdvancedCorrosionTechnologiesandTraining
AmecFosterWheeler
ArnleaSystems,Aberdeen
BilfingerSalamis
BP
CranfieldUniversity
CortecCorporation
Cosasco
Cyberhawk
DepartmentofMechanicalEngineering,ImperialCollege
DetNorskeVeritas
DoosanBabcock
Eddyfi
EnergyInstitute
EPSRC
ESRTechnology
GuidedUltrasonicsLtd.(GUL)
Heriot-WattUniversity
HighValueManufacturingCatapult
HOIS
HydrasonSolutionsLtd
ImperialCollegeLondon.
InnovateUK
InphaseSolutions,Norway
InstituteofCorrosion
ForsysSubseaLtd
Intertek
JentekSensors
LockheedMartin
NationalPhysicalLaboratory(NPL)
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ORGANISATIONS CONTACTED CONTINUED
Organisation Category
Industrybody/research
Oilandgasoperator
Technologysupplier
Technologysupplier
Academicinstitution
Technologysupplier
Technologysupplier
Technologysupplier
Oilandgasoperator
Technologysupplier
Researchinstitution
Engineeringcontractor
Oilandgasoperator
Technologysupplier
Engineeringcontractor
Technologysupplier
Engineeringcontractor
Technologysupplier
Industrybody
Technologysupplier
Researchinstitution
Oilandgasoperator
Technologysupplier
Technologysupplier
Industrybody
Academicinstitution
Academicinstitution
Academicinstitution
Academicinstitution
Academicinstitution
Academicinstitution
Academicinstitution
Technologysupplier
Technologysupplier
NERC
NexenPetroleumUKLtd
Permasense
PixelThermographics
RobertGordonUniversity
Rocsole
RohrbackCosasco
RussellTech
Shell
SIGTechnicalInsulation
SINTEF
Sonomatic
StatoilTechnologyInvest(STI)
SteerEnergy
Stork
Tech27SystemsLtd
Technip
TesTex
TheNationalBoardofBoiler&PressureVesselInspectors
ThermalImagingLimited
TNO,ScienceandIndustry,BusinessUnit:OilandGas
Total
Trac
Tracerco(International)
TWI
UniversityofAberdeen
UniversityofCambridge(ChemEngDept)
UniversityofCambridge(EngDept)
UniversityofCambridge(InstituteofManufacturing)
UniversityofCambridge(MaterialScienceDept)
UniversityofManchester(IncludingBP-ICAM)
UniversityofStrathclyde
VREOInnovation
XamenTechnologies
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OTHER ORGANISATIONS ONTHE LANDSCAPE
Organisation Category
Technologysupplier
Engineeringcontractor
Researchinstitution
Researchinstitution
Technologysupplier
Oilandgasoperator
Governmentbody
Engineeringcontractor
Engineeringcontractor
Academicinstitution
Technologysupplier
Technologysupplier
Technologysupplier
Technologysupplier
Oilandgasoperator
Oilandgasoperator
Technologysupplier
AspenAerogels,Incs
Capeplc
ChristianMichelsenResearch
CorrosionDoctors
FjellangerDetectionandTrainingAcademy
Gassco
HSE
Innospection
Keir
LondonSouthBankInnovationCentre
MetalcareInspectionServicesInc.
QSAGlobal
ReeceInnovation
SEInnovation
TalismanSinopec
Taqa
ThorCorrosion
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APPENDIX B
SURVEY QUESTIONNAIRE
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B.1 Initial Questions (all respondents)• Whichsectordoesyourorganisationworkin?• Whichbestdescribesyourremit?
B.2 Oil & Gas Operator Questions• IsyourorganisationawareoftheWoodReport?• DidyouoryourorganisationreviewtheWoodReport?• Wereanyactionsgeneratedwithinyourorganisationfollowingreviewofthereport?• DoesyourorganisationsufferfromCUI?• WhatcausesofCUIaffectyourorganisationsassets?• Whichofthefollowingcausesofvesseldegradationoccurswithinyourorganisation?• HasfundingbeenapprovedoralreadyinplacewithinyourorganisationforCUItesting
and/orVesselinspections?• DoesyourorganisationhavecurrentmaintenanceplansinplacetodealwithCUIand/or
vesselinspections?• Isyourcurrentmaintenanceplaneffective?• Isyourorganisationcurrentlyinvestigatingwaystoundertakesafervesselinspections?• Whichofthebelowtechniques,ifany,doesyourorganisationcurrentlyemploytodetect
potentialCUI?• Doyou feelyourorganisationhas implementedaneffectivesolution fordetectionof
CUI?• DoesyourorganisationutilisethirdpartiesforCUItesting?• DoesyourorganisationuseaHazardratingforinspectionofpartssusceptibletoCUI?• IstrainingprovidedforCUItestingandvesselinspectiontechniques?• Hasconsiderationbeengiventonewinstallationswithreferencetoanti-corrosion?
B.3 Solution Provider Questions• IsyourorganisationawareoftheWoodReport?• DidyouoryourorganisationreviewtheWoodReport?• IsyourorganisationawareofthedifferenttypesofCUIthatcanoccur?• WhichcausesofCUIdoesyourorganisationstechniquesdetect?• Which of the below techniques does your organisation currently employ to detect
potentialCUI?• Whichofthefollowingcausesofvesseldegradationdoyouprovidesolutionsfor?• DoesyourorganisationresearchthedifferentNDT/inspectionmethodsfor identifying
CUI?• Isadequatefundingandresourcesbeenapprovedormadeavailabletoconsidertheuse
ofanyalternativeinspectionmethodsforCUI?• Are the potential impacts of implementing alternative solutions for CUI testing,
understoodandquantified?• IstrainingprovidedforCUItestingandvesselinspectiontechniques?Do you think that all the potential hazards for undertaking CUI inspections and vessel
inspectionsusingyoursolutionsareunderstood?
B.4 Contractor Questions• AreyouawareoftheWoodReport?• DidyoureviewtheWoodReport?• AreyouawareofthedifferenttypesofCUIthatcanoccur?• WhichofthefollowingcausesofCUIareyoufamiliarwith?• Whichofthefollowingcausesofvesseldegradationareyoufamiliarwith?• Pleaseprovidedetailsof themain issues you feel therearewith testing forCUI and
vesselinspection
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• WhatdoyoufeelarethemainimpactsonsiterelatingtoCUItestingandvesselinspection?• AreyouawareofthehazardsrelatedtoCUItestingandvesselinspections?• HaveyoureceivedanytrainingforCUItestingandvesselinspectiontechniques?
B.5 Researcher/Academic Questions• AreyouawareoftheWoodReport?• DidyoureviewtheWoodReport?• DoyouagreewiththefindingsintheWoodReport?• AreyouawareofthedifferenttypesofCUIthatcanoccur?• Pleaseprovidedetails,ifany,ofthemainissuesyoufeeltherearewithtestingforCUI.• WhichcausesofCUIdoyouoryourorganisationcurrentlyresearch?• WhichofthebelowCUIdetectiontechniquesdoyouoryourorganisationcurrentlyresearch?• AreyouoryourorganisationresearchingdifferentNDT/inspectionmethodsforvessels?• Which of the following causes of vessel degradation are you or your organisation currently
researching?• Areyouoryourorganisationcurrentlyinvestigatingwaystoundertakesaferand/ormoreefficient
vesselinspections?• HaveyoureceivedanytrainingforCUItestingandvesselinspectiontechniques?
B.6 CUI and Vessel Inspection Questions (all respondents)• Isinformationsourcedandreviewedfromothersuitableindustriesthatyouoryourorganisation
maybeabletoutilise?• Isknowledgesharedwithothersorsimilarorganisations,withreferencetoCUItestingandvessel
inspections?• DoyouoryourorganisationutiliseorreferencestandardsandguidestoassistinundertakingCUI
testing,e.g.BS5970• Ifstandardsandguidesareutilised,doyoufindtheseuseful?• Pleaseprovideanyothercommentsyoufeelarevalid.
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APPENDIX C
GLOSSARY
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APPENDIXC:GLOSSARYTermsusedwithinthisdocumentarelistedbelow Term
3-D
3DLaserScanning
AcousticEmission(AE)
AcousticResonanceTechnology(ART)
AST
ATEX
AUV
BS5970
CAPEX
CCTV
COTS
CSC
CUI
DAC
DIFCAM
DigitalImageCorrelation(DIC)
FDTA
FullMatrixCapture(FMC)
GuidedWaveUltrasonicTesting(GWUT)
HOIS
Explanation
Threedimensional
Technique typically using a tripodmounted laserscannertotakeseriesofimagesin360oformingadatasetcalledapointcloud
Technique involving measurement of naturallyoccurring stress waves in material to determinelocationandsizeofanomalies
Technique using propagation of acoustic signalthroughmetalanddetectingtheresponse
AboveGroundStorageTank
AppareilsdestinésàêtreutilisésenATmosphèresEXplosibles – European directive on use ofequipmentinexplosiveatmospheres
AutonomousUnderwaterVehicle
Codeofpracticeforthermalinsulationofpipework
CapitalExpenditure
CloseCircuitTelevision
CommercialOffTheShelf
CrossSectionChange
CorrosionUnderInsulation
DistanceAmplitudeCurves
DigitalImagingForConditionAssetManagement
Methodofdetectingchangesbycomparingimages
FjellangerDetectionandTrainingAcademy
Dataacquisition techniqueused toenhancedatacapturefromaPhasedArrayTransducer
Technique involves inducing stress waves thatpropagate along the material and measuringresponse to determine location and size ofanomalies
HOIS is a joint industry project (JIP) focussed onnondestructivetestingwhichhasbeenrunningformorethanthirtyyears.TheprojectismanagedbyESRTechnology
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GLOSSARY CONTINUEDHSE
ITF
LowFrequencyElectromagneticTechnique(LFET)
MER
MicrowaveSensing
Microwave
NASA
NDE
NDT
NPL
OGA
OGIC
OGUK
OPEX
PhasedArrayProbe
PMMA
PulseEddyCurrent(PEC)
RGB
ROV
RST
SacrificialWire
HealthandSafetyExecutive
IndustryTechnologyFacilitator
Worksbyinjectinglowfrequencymagneticfieldintometaltargetanddetectsdistortionsinthemagneticfieldduetovariancesinthetarget
MaximisingEconomicRecovery
Techniquethatworksonprinciplethatmicrowavesareabsorbedatdifferentratesbydifferentmaterials.Canbeusedtodetectwaterwithininsulationandareasofcorrosion
Electromagneticradiationwithwavelengthsrangingfromonemetertoonemillimetre;withfrequenciesbetween300MHz(100cm)and300GHz(0.1cm)
NationalAeronauticsandSpaceAdministrationoftheUnitedStatesofAmerica
NonDestructiveExamination
NonDestructiveTesting
NationalPhysicalLaboratory
OilandGasAuthority
OilandGasInnovationCentre
OilandGasUK
OperationalExpenditure
Aprobewhosesignalcanbefocusedandsteeredelectronicallywithoutmovingtheprobe
PolyMethylMethacrylate
Measureseddycurrentswithinasteeltarget,wherethecurrentsaredistortedbychangesinmaterialthicknessormakeup
RedGreenBlue
RemotelyOperatedVehicle
RemoteScentTracing
Techniquewherethinwireislocatedadjacenttothetargetmaterialandcorrodesatthesameratecausingthewiresresistancetochangewhichcanbedetectedusingameter
ENERGY // ASSET INTEGRITY THEME LANDSCAPING STUDY
REPORT // ENERGY
138
GLOSSARY CONTINUEDSpider,RadarPlotorGraph
TDR
THzSpectralImaging
THz,Terahertz
TLB
Tomography
TRL
UAV
UKCS
UltrasonicNDTSurveys
Ultrasonic,Ultrasound
UltrasoundTomography(UST)
VapourPhaseCorrosionInhibitor(VPCI)
VI
VNA
WoodReport
Agraphicalplotwithmultipleaxesdesignedforquickcomparisonbetweensubjects
TimeDomainReflectometry–amathematicalprocessusedtotransformfrequencydomaininformationintothetimedomain
Techniqueusingterahertzradiationandspectroscopytocapturehighresolutionscansofmetalwithinconcrete
ElectromagneticradiationwithintheITU-designatedbandoffrequenciesfrom0.3to3terahertz(THz;1THz=1012Hz)
OilandGasTechnologyLeadershipBoard
Imagingbysectionsorsectioningthroughtheuseofanykindofpenetratingwave
TechnologyReadinessLevel
UnmannedAerialVehicle
UKContinentalShelf
TechniqueusingdetectionofreflectedultrasonicwavestodeterminelocationandsizeofanomaliesSoundwavesgreaterthanhumanhearingrangei.e.,>20KHz
Soundwavesgreaterthanhumanhearingrangei.e.,>20KHz
Techniquebasedonintroducingultrasoundtotargetmaterialandrecordingthetimeandamplitudeoftheresponse.Multiplesensorsareusedtoprovidea3Dimageofthetarget.
Techniqueusedtopreventcorrosionbycoatingmetalobjectswithawaterrepellent(hydrophobic)chemical
VesselInspection
VectorNetworkAnalyser,adeviceusedtotransmitandreceivemicrowaves
SirIanWood’sreportonMaximisingEconomicRecoveryfortheUKContinentalShelf
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APPENDIX D
REFERENCES
Below is a list of references used throughout the study. References specific to individuals and technologies are
detailed in the section relating to that technology.
1. “UKCS Maximising Recovery Review: Final Report” - Sir Ian Wood, 24 February 2014 and available to
download from www.gov.uk
2. “RR659 Evaluation of the effectiveness of non-destructive testing screening methods for in-service
inspection” – prepared by Doosan Babcock Energy Limited for the Health and Safety Executive, 2009 and
available to download from hse.gov.uk
3. “HOIS RP2 HOIS Recommended Practice for the Non-destructive Inspection of Weld Corrosion” – HOIS,
2012. Available to download from hoispublications.com
ISBN 1 903 004 72 4© 2016 The UK Oil and Gas Industry Association Limited, trading as Oil & Gas UK