Dealing With Low-Frequency-Welded ERW Pipe and Flash-Welded Pipe With Respect to HCA-Related Integrity Assessments

2002 ◽  
Author(s):  
John F. Kiefner
Keyword(s):  
Low Frequency ◽  
Metal Loss ◽  
Electric Resistance ◽  
Integrity Assessment ◽  
Systematic Procedure ◽  
Pipe Line ◽  
Welded Pipe ◽  
Integrity Assessments ◽  
Pipe Materials

The new regulations, Part 195 Section 195.452, require that special integrity assessments be made to address potential seam-defect problems in low-frequency-welded ERW (electric-resistance-welded) pipe materials where a failure of such materials could have an impact on a high-consequence area (HCA). The spirit of this requirement appears to require action if, and only if, significant seam-related deficiencies are in evidence or if they can be reasonably anticipated. This leaves open the option of categorizing these types of pipelines by performance such that potentially problematic pipeline segments can be subjected to special (i.e., seam-quality) inspections while those that show little or no propensity for such problems can be subjected to metal loss and deformation inspections only. This document is intended to establish a systematic procedure to permit an operator to characterize the relevant ERW pipe segments as to the likelihood of significant seam-related deficiencies. The author is particularly grateful to Rich Turley of Marathon Ashland Pipe Line LLC for helping to formulate the essential steps in deciding when an integrity assessment is needed. Rich made significant inputs to Figure 1 of this document.

In-Line Inspection in Lieu of Hydrostatic Testing for Low Frequency Electric Resistance Welded Pipe

2018 ◽  
Author(s):  
Matt Krieg ◽  
J. Bruce Nestleroth ◽  
Thomas Hennig ◽  
Harvey Haines
Keyword(s):  
Low Frequency ◽  
Field Evaluation ◽  
Assessment Method ◽  
Imaging Method ◽  
Electric Resistance ◽  
Destructive Testing ◽  
Line Pipe ◽  
Integrity Assessment ◽  
Negative Impacts ◽  
Welded Pipe

Hydrostatic testing is a costly, operationally-impactful method of verifying seam integrity in low frequency electric resistance welded (LF-ERW) line pipe. Pipeline operators seek an alternative seam assessment method that provides a sufficiently conservative integrity assessment without the potentially negative impacts of hydrostatic testing. As in-line inspection (ILI) and field nondestructive evaluation (NDE) improve, pipelines that have been historically hydrostatic tested can now use ILI to ensure operational integrity. The improved ILI technology assessed in this work is an enhanced ultrasonic crack ILI tool with higher circumferential resolution and finer axial sample intervals. Magnetic ILI data from previous assessments is used to assist in anomaly identification. In addition to utilizing NDE technologies such as phased array, the emerging full matrix capture (FMC) imaging method that quantifies the size, position, and orientation of seam weld anomalies was examined. This paper discusses the work performed to ensure the efficacy of the improved ILI and NDE methods to accurately detect and quantify all anomalies that could possibly fail a hydrostatic test. An early step in the process was removing three sections of pipe from service for technology calibration and assessment. Each spool was examined with ILI technology in a pump-through facility, inspected using many NDE methods and then destructively tested. These results were communicated to ILI analysts and used to calibrate and improve the interpretation of the inspection results. Then the pipeline was inspected as part of the scheduled integrity assessment. Using field evaluation of anomalies detected by ILI, pipes were selected for removal from service to examine destructively. This paper presents the inspection and destructive testing results in addition to prognosis for the use of the ILI in lieu of hydrostatic testing for LF-ERW pipe.

New Classification Approach for Dents With Metal Loss and Corrosion Along the Seam Weld

2016 ◽  
Author(s):  
J. Bruce Nestleroth ◽  
James Simek ◽  
Jed Ludlow
Keyword(s):  
Magnetic Field ◽  
Low Frequency ◽  
Metal Loss ◽  
Integrity Assessment ◽  
Seam Weld ◽  
Low Field ◽  
Electric Resistance Welding ◽  
Weld Corrosion ◽  
Pipeline Safety

The ability to characterize metal loss and gouging associated with dents and the identification of corrosion type near the longitudinal seam are two of the remaining obstacles with in-line inspection (ILI) integrity assessment of metal loss defects. The difficulty with denting is that secondary features of corrosion and gouging present very different safety and serviceability scenarios; corrosion in a dent is often not very severe while metal loss caused by gouging can be quite severe. Selective seam weld corrosion (SSWC) along older low frequency electric resistance welding (ERW) seams also presents two different integrity scenarios; the ILI tool must differentiate the more serious SSWC condition from the less severe conventional corrosion which just happens to be near a low frequency ERW seam. Both of these cases involve identification difficulties that require improved classification of the anomalies by ILI to enhance pipeline safety. In this paper, two new classifiers are presented for magnetic flux leakage (MFL) tools since this rugged technology is commonly used by pipeline operators for integrity assessments. The new classifier that distinguishes dents with gouges from dents with corrosion or smooth dents uses a high and low magnetization level approach combined with a new method for analyzing the signals. In this classifier, detection of any gouge signal is paramount; the conservatism of the classifier ensures reliable identification of gouges can be achieved. In addition to the high and low field data, the classifier uses the number of distinct metal loss signatures at the dent, the estimated maximum metal loss depth, and the location of metal loss signatures relative to dent profile (e.g. Apex, Shoulder). The new classifier that distinguishes SSWC from corrosion near the longitudinal weld uses two orientations of the magnetic field, the traditional axial field and a helical magnetic field. In this classifier, detection of any long narrow metal loss is paramount; the conservatism of the classifier ensures that high identification of SSWC can be achieved. The relative amplitude of the corrosion signal for the two magnetization directions is an important characteristic, along with length and width measures of the corrosion features. These models were developed using ILI data from pipeline anomalies identified during actual inspections. Inspection measurements from excavations as well as pipe removed from service for lab analysis and pressure testing were used to confirm the results.

Ultrasonic NDE Technology Comparison for Measurement of Long Seam Weld Anomalies in Low Frequency Electric Resistance Welded Pipe

2018 ◽  
Author(s):  
Luis Torres ◽  
Matthew Fowler ◽  
Jason Bergman
Keyword(s):  
Ultrasonic Testing ◽  
Low Frequency ◽  
Management Approach ◽  
Electric Resistance ◽  
Seam Weld ◽  
Tool Performance ◽  
Ultrasonic Nde ◽  
Welded Pipe ◽  
Continuous Technology ◽  
Non Destructive

In the pipeline industry, a widely accepted methodology for integrity crack management involves running ultrasonic In-Line Inspection (ILI) technologies. After an ILI tool run is completed, the performance of the tool is typically validated by excavating the pipeline and conducting in-the-ditch investigations. Ultrasonic Non-Destructive Evaluation (NDE) techniques are used in the field to characterize and measure crack-like features. These in-the-ditch measurements are compared back to ILI results in order to validate tool performance and drive continuous technology improvements. Since validation of the ILI tool relies on NDE measurements, acquiring accurate and representative data in the field is a critical step in this integrity crack management approach. Achieving an accurate field inspection comes with its challenges, some of which relate to complex long seam weld conditions present in older vintage pipelines including: weld misalignment, weld trim issues, and dense populations of manufacturing anomalies. In order to better understand the challenges associated with complex long seam weld conditions, an evaluation and comparison of the performance of NDE technologies currently available was conducted. In this study, a portion of a Canadian pipeline with complex long seam weld conditions was cut-out and removed from service. Multiple NDE crack inspection technologies and methods from three different vendors were used to assess the condition of the long seam weld. Conventional Ultrasonic Testing (UT), Phased Array Ultrasonic Testing (PAUT), Time of Flight Diffraction (TOFD), and variations of Full Matrix Capture Ultrasonic Testing (FMCUT) were used to assess the long seam weld and their results were compared. The performance of all NDE technologies is baselined by comparing them with destructive examination of sections of the long seam weld. The newer NDE assessment methodologies were shown to be consistently more accurate in characterizing long seam features.

Estimating Toughness for LF and DC Welded ERW Seams

2020 ◽  
Author(s):  
John Kiefner ◽  
Michael Rosenfeld ◽  
Peter Veloo ◽  
Troy Rovella
Keyword(s):  
Low Frequency ◽  
Bond Line ◽  
Large Database ◽  
Manufacturing Defects ◽  
Integrity Assessment ◽  
Level Of Confidence ◽  
Line Region ◽  
Management Plans ◽  
Integrity Management ◽  
Pipe Materials

Abstract ERW pipe materials, particularly those manufactured prior to 1970, have exhibited higher rates of failures from seam manufacturing defects than other types of pipe materials. Typically, the seam bond line regions of low-frequency (LF) and direct-current (DC) welded ERW pipe materials exhibit poor resistance to manufacturing defects. The toughness of the bond line region is difficult to determine, and it is likely to vary from one piece of pipe to another. Pipeline operators must address the risk of ERW seam failures as part of their integrity management plans, but it is unlikely that they will know the toughness levels in the seams of their pipelines comprised of such materials. To avoid having to know the toughness levels in the seams, a pipeline operator can utilize a hydrostatic test to verify the integrity of a vintage ERW pipeline, but there are disadvantages the main one being that the pipeline must be taken out of service. Most likely an operator will choose to use an ILI crack tool to locate ERW seam anomalies to avoid having to take the pipeline out of service. Even if the seam defects can be located, correctly sized, and classified, however, the operator may have no idea of the effective toughness that is the key to deciding whether or not a given crack has to be excavated and repaired. Presented herein are two options for improving the effectiveness of an ILI integrity assessment of a pipeline with low toughness ERW seams. • Option 1 involves assuming a conservative level of toughness. Some such levels are available in the publicly available documents. Data from a large database of ERW seam failures are used to show the effectiveness of a fixed level of toughness at identifying critical defects while minimizing unnecessary digs. • Option 2 consists of first: back-calculating the toughness levels associated with the known crack sizes and failure pressures of the defects in the database of ERW seam failures, and second: calculating the probability that each type of defect would have been correctly identified at a particular level of confidence using a particular level of toughness. Using either of these options, a pipeline operator can improve the effectiveness of an ILI-crack-tool integrity assessment of a pipeline comprised of LF or DC welded ERW seams by reducing the number of unnecessary excavations while still being able to find the critical defects with an acceptable level of confidence.

In-Line-Inspection (ILI) of a Pipeline in Constrained Condition and Establishing Integrity of the Pipeline

2021 ◽  
Author(s):  
Partha Bose
Keyword(s):  
Thermal Expansion ◽  
Natural Gas ◽  
Gas Pipeline ◽  
Bridge Structure ◽  
Site Specific ◽  
Integrity Assessment ◽  
Natural Gas Pipeline ◽  
Pipe Line ◽  
Specific Assessment ◽  
Mumbai City

Abstract One 24” Diameter and around 40 km length Natural Gas pipeline caters as energy life line for Mumbai city; supplying app 4.5 MMSCMD Gas for Auto Sectors (CNG), House Hold (PNG), Power, Fertiliser, Petrochemical Sectors. Though line is equipped with Launcher & Receiver; but onward became challenging one for executing pigging for many constraints: - Presence of One SR bend - Presence of 1.5 D bends - Presence of 1.5 D bends with Back to Back configuration - Three (3) no Thermal Expansion Loops, in 2 Km stretch passing as above ground pipeline through bridge (above Creek) section The pipe line is passing through High Consequence areas, including its interim stretch of 2km passing as above ground section through bridge structure. Intelligent pigging is an obvious first preference for online precise integrity assessment for any pipeline. Site Specific Assessment, Detail Engineering & Committed approach resulted in Feasibility & Development of ILI Tool, Practical Testing in fore hand before actual pigging & onward Integrity Assessment of the pipeline conducted by accomplishing Successful ILI run.

An Innovative Approach for Pipeline Repairs

2002 ◽  
Author(s):  
Don Robertson ◽  
Wayne Russell ◽  
Nigel Alvares ◽  
Debra Carrobourg ◽  
Graeme King
Keyword(s):  
Relational Databases ◽  
Cost Effective ◽  
Metal Loss ◽  
Final Report ◽  
Integrity Assessment ◽  
Maintenance Program ◽  
Oil Pipelines ◽  
New Methodologies ◽  
Reduced Costs

A strategic combination of integrity software, relational databases, GIS, and GPS technologies reduced costs and increased quality of a comprehensive pipeline integrity assessment and repair program that Greenpipe Industries Ltd. completed recently on three crude oil pipelines—two 6-inch and one 8-inch—for Enbridge Pipelines (Saskatchewan) Inc. Greenpipe analyzed metal loss data from recent in-line inspection logs, calculated real-world coordinates of defects and reference welds, prioritized anomalies for repair taking environmental risks into account, and prepared detailed dig sheets and site maps using PipeCraft™, Greenpipe’s advanced GIS-based pipeline integrity-maintenance software package. GPS technology was used to navigate to dig sites and the accuracy of the GPS approach was compared with traditional chainage methods. Pipelines were purged and all defects were cut out and replaced by new pipe during a two-day shutdown on each pipeline. A comprehensive set of data, including high-accuracy GPS location of anomalies, reference welds, and replacement pipe welds, was collected at each dig site and entered into the PipeCraft relational database. After all repairs were completed, the client was provided with a GIS-based electronic final report, allowing point-and-click access to all data collected in the field, including in-line inspection logs, dig information sheets and as-built drawings. The new methodologies employed on this project resulted in a high quality, comprehensive and cost-effective integrity maintenance program.

Electric Resistance Welded Seam Inspection Using Circumferential Flux

2008 ◽  
Author(s):  
Natalia K. Nikolova ◽  
Duane Cronin ◽  
Sabir M. Pasha ◽  
Reza K. Amineh ◽  
Ian Smith ◽  
...  
Keyword(s):  
Magnetic Field ◽  
Crack Detection ◽  
Axial Direction ◽  
Metal Loss ◽  
Electric Resistance ◽  
Field Uniformity ◽  
Axial Crack ◽  
Resistance Weld ◽  
Sensor Density ◽  
Welded Seam

For conventional magnetic flux leakage (MFL) inspection where an excitation magnetic field is generated in the axial direction of a pipeline, axially oriented crack detection is impossible [1][2]. A new MFL tool design is presented that creates an excitation field in the circumferential or transverse direction, allowing for axial crack detection, as well as the more conventional metal loss detection. Design criteria that ensure detection include sufficient sensor density and magnetic field uniformity at sensor locations. The result is a new type of circumferential MFL inspection tool that can not only detect corrosion and other metal losses, but also axially oriented cracks. Based on the results of a series of inspection runs 22 crack-like features in the electric resistance weld (ERW) were investigated with 19 of those being verified as linear long seam features and were subsequently permanently repaired. Further information on the efficacy of this design is clarified in [2].

Integrity Assessment of Subsea Pipeline Dent / Buckle Using ILI Data

2019 ◽  
Author(s):  
Gurumurthy Kagita ◽  
Gudimella G. S. Achary ◽  
Mahesh B. Addala ◽  
Balaji Srinivasan ◽  
Penchala S. K. Pottem ◽  
...  
Keyword(s):  
Numerical Simulation ◽  
Finite Element ◽  
Failure Modes ◽  
Structural Integrity ◽  
Mechanical Damage ◽  
Metal Loss ◽  
Stress Concentrations ◽  
Subsea Pipeline ◽  
Integrity Assessment ◽  
Finite Element Software

Abstract Mechanical damage in subsea pipelines in the form of local dents / buckles due to excessive bending deformation may severely threaten their structural integrity. A dent / buckle has two significant effects on the pipeline integrity. Notably, residual stresses are set up as result of the plastic deformation and stress concentrations are created due to change in pipe geometry caused by the denting / buckling process. To assess the criticality of a dent / buckle, which often can be associated with strain induced flaws in the highly deformed metal, integrity assessment is required. The objective of this paper is to evaluate the severity of dent / buckle in a 48” subsea pipeline and to make the rerate, repair or replacement decision. This paper presents a Level 3 integrity assessment of a subsea pipeline dent / buckle with metal loss, reported in in-line inspection (ILI), in accordance with Fitness-For-Service Standard API 579-1/ASME FFS-1. In this paper, the deformation process that caused the damage (i.e. dent / buckle) with metal loss is numerically simulated using ILI data in order to determine the magnitude of permanent plastic strain developed and to evaluate the protection against potential failure modes. For numerical simulation, elastic-plastic finite element analyses (FEA) are performed considering the material as well as geometric non-linearity using general purpose finite element software ABAQUS/CAE 2017. Based on the numerical simulation results, the integrity assessment of dented / buckled subsea pipeline segment with metal loss has been performed to assess the fitness-for-service at the operating loads.

INTEGRITY ASSESSMENT OF THICK WALLED INDUSTRIAL FURNACE TUBES

1993 ◽  
Vol 17 (2) ◽  
pp. 127-143
Author(s):  
R.K. Kizhatil ◽  
R. Seshadri
Keyword(s):  
Thermal Stresses ◽  
Furnace Operation ◽  
Remaining Life ◽  
Element Analysis ◽  
Integrity Assessment ◽  
Firing Rates ◽  
Linear Finite Element ◽  
Core Method ◽  
Furnace Tube ◽  
Integrity Assessments

This paper examines various simplified methods proposed to analyze stresses and predict damage and remaining life in furnace tubes subjected to sustained primary pressure stresses and cyclic secondary thermal stresses resulting from a typical furnace operation. Operational effects such as tube fouling, firing rates, startup-shutdown cycles are considered. Component integrity assessments are carried out using some recently developed techniques. A numerical example of a furnace tube made of HK-40 material is presented, and results obtained using a non-linear finite element analysis are compared with predictions obtained using the elastic-core method.

Pipeline Operation in the North Sea Area: Statoil’s Experience and Challenges

2006 ◽  
Author(s):  
Ove R. Samdal ◽  
Anders Kvinnesland ◽  
Kjell Edvard Apeland ◽  
Arthur Lind ◽  
Kjartan Vartdal
Keyword(s):  
Data Storage ◽  
North Sea ◽  
Response Times ◽  
Operating Cost ◽  
Metal Loss ◽  
Risk Levels ◽  
Integrity Assessment ◽  
The North ◽  
The North Sea ◽  
Sea Area

Statoil has since 1985 installed, commissioned and operated approximately 8000 km of pipelines in the North Sea area. Among these pipelines are several of the world’s largest offshore gas trunk lines with the onshore parts relatively short in length but often with complex landfalls, fjord and land crossings. Since 2002 Gassco has been the Operator for transporting Norwegian gas to continental Europe and the UK. Gassco is a fully state owned company. Statoil is now TSP (Technical Service Provider) for most of the trunk lines. Operating these pipelines represents several challenges, and the accumulated experience gained through successful operations of these pipelines has brought Statoil to the forefront within the pipeline industry. Through comprehensive research and development Statoil has improved pipeline technology within areas as inspection, maintenance and repair. Together with the development of risk based condition (integrity) assessment, inspection and monitoring planning tools and work processes, these technology achievements have significantly improved Statoil’s knowledge and understanding of the pipeline condition and associated risk levels. A significant reduction in operating cost has also been experienced. Together with its collaborating partners Statoil has among others improved internal inspection technology by improving the MFL technology to a level of extra high resolution (XHR-technology) making metal loss measurements more reliable and accurate. Multi diameter inspection tools (28”–42”) (MDPT) and optical laser tool (Optopig) have also been developed and put into operation. Sub sea pipeline survey by use of ROV has been significantly improved with regard to instrumentation and survey speed. A unique remote pipeline repair contingency system (PRS) with well defined response times (10–21 days), has also been developed. To get the full benefit of these developments a risk based pipeline condition (integrity) management system (PCMS/PIMS) has been developed with the development of DnV’s Orbit Pipeline as a key element. ORBIT Pipeline consists principally of data storage and administration and various risk based integrity assessment modules. This paper will discuss several topics related to these technology developments and development of risk based condition (integrity) assessment.

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