Extending FMC Based Ultrasonic Imaging Practices to Smaller Wall Thickness

2021 ◽  
Author(s):  
Niels Pörtzgen ◽  
Ola Bachke Solem
Keyword(s):  
Carbon Steel ◽  
Wall Thickness ◽  
Oil And Gas ◽  
Ultrasonic Inspection ◽  
Ultrasonic Imaging ◽  
Advanced Technology ◽  
Front Wall ◽  
Thin Wall ◽  
Destructive Testing ◽  
Girth Welds

Abstract During the construction of pipelines for the transportation of oil and gas, the inspection of girth welds is a critical step to ensure the integrity and thereby the safety and durability of the pipeline. In this paper we present an advanced technology ‘IWEX’ for the non-destructive testing of welds based on 2D and 3D ultrasonic imaging. This technology allows for safe, fast, and accurate inspection whereby the results are presented comprehensively. This will be illustrated with results from a recent project. The IWEX technology is based on an ultrasonic inspection concept, whereby ‘fingerprints’ of ultrasonic signals are recorded, also referred to as ‘full matrix capture’ (FMC) data. Then, an image area is defined, consisting out of pixels over an area large enough to cover the inspection volume. With the FMC data, image amplitudes are calculated for each pixel so that the shape of geometry (back wall, front wall, cap, and root) and possible indications are revealed. As opposed to traditional ultrasonic testing strategies, the detection and sizing of indications is therefore less dependent on its orientation. The project concerned the inspection of J and V welds from a 5.56″ diameter carbon steel pipe with an 8.4mm wall thickness. The wall thickness is relatively thin compared to common inspection scopes. Therefore, the inspection set-up was adapted, and procedural changes were proposed. Consequently, additional validation efforts were required to demonstrate compliance with the required inspection standard; DNVGL-ST-F101: 2017. As part of this, welds were scanned with seeded indications and the reported locations were marked for macro slicing under witnessing of an independent representative from DNVGL. The resulting images from the indications in the welds showed great detail with respect to the position, orientation and height of the indications. A quantitative comparison with the results from the macro slices was performed, including a statistical analysis of the height sizing and depth positioning accuracies. From the analysis, it could be observed that the expected improvements with respect to the resolution and sizing accuracy were indeed achieved. Thereby, the procedure has proven to be adequate for the inspection of carbon steel girth welds within the thin wall thickness range (~6mm to ~15mm). The IWEX technology is a member of the upcoming inspection strategy based on imaging of ultrasonic FMC data. This strategy can be considered as the next step in the evolution of inspection strategies after phased array inspection. The IWEX technology has been witnessed and qualified by independent 3rd parties like DNVGL, this makes the IWEX technology unique in its kind and it opens opportunities for further acceptance in the industry and other inspection applications.

scholarly journals Special Phased Array Applications for Pipeline Girth Weld Inspections

2006 ◽  
Author(s):  
Michael Moles ◽  
Simon Labbe´
Keyword(s):  
Wall Thickness ◽  
Temperature Compensation ◽  
Phased Array ◽  
Phased Arrays ◽  
Pipe Wall ◽  
Small Diameter ◽  
Thin Wall ◽  
Seamless Pipe ◽  
Pipe Wall Thickness ◽  
Girth Welds

Ultrasonic phased arrays present major improvements over conventional multiprobe ultrasonics for inspecting pipeline girth welds, both for onshore and for offshore use. Probe pans are lighter and smaller, permitting less cutback; scans are quicker due to the smaller probe pan; phased arrays are considerably more flexible for changes in pipe dimensions or weld profiles, and for different scan patterns. More important, some of the potential advantages of phased arrays are now becoming commercially available. These include: • Compensating for variations in seamless pipe wall thickness. • Wedge temperature compensation. • Improved focusing for thick and thin wall inspections. • Premium inspections for risers, tendons and other components. • Small diameter pipes. • Multiple displays. • Clad pipe. The paper describes the latest phased array UT results for special applications.

Inspection of Clad and Plain Carbon Steel Girth Welds on Offshore Caisson Risers Using Semi-Mechanised Ultrasonic Testing (SMUT)

2008 ◽  
Author(s):  
Robert J. Conder ◽  
Ryan McPherson ◽  
Ton Kooren ◽  
Allan Parlane
Keyword(s):  
Carbon Steel ◽  
Oil And Gas ◽  
Plain Carbon Steel ◽  
Gas Production ◽  
Carbon Steels ◽  
Inconel 625 ◽  
Inspection System ◽  
Oil And Gas Production ◽  
The North ◽  
Girth Welds

Caisson risers installed through drilling slots are an increasingly common method to add additional riser access to existing oil and gas production platforms. This paper describes the inspection methodology used for two new caisson risers on the Talisman Energy owned Tartan platform in the North Sea. The methodology for qualification of the inspection system for both plain carbon steels and Inconel 625 (UNS N06625) clad carbon steel is described. The offshore performance of the SMUT system is discussed and the time and safety benefits of this system are highlighted.

Evaluation of Welding Practices on Sour Service Performance of Carbon Steel Pipeline Girth Welds

2021 ◽  
Author(s):  
Harpreet Sidhar ◽  
Neerav Verma ◽  
Chih-Hsiang Kuo ◽  
Michael Belota ◽  
Andrew J. Wasson
Keyword(s):  
Carbon Steel ◽  
Oil And Gas ◽  
Pipeline Steel ◽  
Oil And Gas Industry ◽  
Welding Parameters ◽  
Line Pipe ◽  
Steel Pipeline ◽  
Weld Root ◽  
Girth Welds ◽  
Sour Service

Abstract In recent past, there have been unforeseen sour service pipeline failures in the oil and gas industry. Sub-optimal microstructure resulting in high hardness (above 250 HV10) in pipeline steel is one of the root causes of such failures. Poor girth weld quality is another leading cause which adversely affects pipeline integrity and safe operations in sour environments. While advancements in welding technologies have led to consistency in production girth welds, effects of welding parameters on performance of carbon steel pipeline girth welds for sour service are not well understood. So, a systematic study is needed to understand the effects of various welding parameters on weld properties and performance. This paper aims at evaluating the effects of various welding parameters on performance of girth welds to provide welding practice guidelines for sour service pipeline applications. In this effort, several welds on X65 grade line pipe girth welds using commercially available welding consumables were made to study the effects of preheat, hot pass tempering, copper backing, root pass heat input, wire consumable chemistry, single vs. dual torch, metal transfer mode, pipe fit-up (root gap, misalignment), on weld root performance. Detailed microhardness mapping and microstructural characterization were conducted. It was evident that the welding parameters studied have a significant impact on root performance. While preheat and pipe fit-up showed most significant impact on weld root performance, other parameters also affected the root performance by varying degree. Based on these results, recommendations for industry are provided to improve reliability of pipeline girth welds in sour service application.

Brittle Fracture of Thin Wall Pressure Equipment

2006 ◽  
Author(s):  
Yasushi Ogayu
Keyword(s):  
Carbon Steel ◽  
Low Temperature ◽  
Brittle Fracture ◽  
Crude Oil ◽  
Wall Thickness ◽  
Welded Joint ◽  
Wall Pressure ◽  
Thin Wall ◽  
Industrial Experience ◽  
Fracture Assessment

Even for ferritic materials, it has been assumed that no consideration for the brittle fracture at low temperature is necessary on condition that the wall thickness of pressure equipment is less than roughly half an inch (12.7mm) from industrial experience. Nevertheless, brittle fracture incident occurred at a welded joint of a carbon steel pipeline used for transportation of crude oil at low temperature of −6°C in one of our refineries recently. The pipeline was 12.0 mm in thickness and it was found that significant crack-like flaw existed along inside of the welded joint. In this study, the assessment of the brittle fracture of thin wall welded joint with crack-like flaw was performed in accordance with Section 9 in API RP 579 (2000). Then it was concluded that brittle fracture assessment is necessary regardless of the wall thickness when significant crack-like-flaw is detected in pressure equipment, especially at low temperature condition.

Corrosion Condition Research and Bearing Capacity Analysis of a Space Truss Base on Corrosive Environments

2010 ◽  
Vol 163-167 ◽  
pp. 838-841
Author(s):  
Xu Yan ◽  
Tie Ying Li ◽  
Ning Yang
Keyword(s):  
Carbon Steel ◽  
Finite Elements ◽  
Bearing Capacity ◽  
Wall Thickness ◽  
Capacity Analysis ◽  
Thin Wall ◽  
Finite Elements Analysis ◽  
Corrosion Condition ◽  
Space Truss ◽  
Corrosive Environments

A certain natatorium is selected as the object for the corrosion researches on common carbon steel which has been used in the corrosive environments for 20 years. Bearing and deformation capacities are calculated to simulate corrosion by elastic and elasto-plastic finite elements analysis with ANSYS. The result is shown that corrosion condition should be considerable to the space truss with thin wall thickness in the severely corrosive environments.

A Practical Ultrasonic Inspection Method for Detecting and Characterising Defects Found Within Composite Repairs

2018 ◽  
Author(s):  
J Downing ◽  
A Hook
Keyword(s):  
Wall Thickness ◽  
Steel Substrate ◽  
Ultrasonic Method ◽  
Ultrasonic Inspection ◽  
Heat Exposure ◽  
Matrix Cracking ◽  
Ultrasonic Technique ◽  
Inspection Method ◽  
Composite Repairs ◽  
Layered Matrix

Two steel substrate test panels were developed to represent common plate thicknesses found on naval vessels and scanned using the Babcock developed ultrasonic technique. One sample comprised of a series of slotted surface breaking flaws of varying widths and through thicknesses to represent fracturing/cracking. The inspection method detected simulated cracking to a depth of 2mm and 0.5mm in width. The second sample included numerous loss of wall thickness areas of varying diameters and through thicknesses, with the smallest detectable loss of wall thickness being 0.1mm at a 15mm diameter. After proving confidence in detection, there was a need to characterise flaws to provide support and ascertain a repair action. Samples were produced that were subjected to either impact or heat exposure to induce realistic representative damage. The practical ultrasonic method was successfully used to independently characterise between the samples, with induced de-laminations caused by blisters, and multi layered matrix cracking caused by varying levels of projectile impacts, due to their unique morphology.

scholarly journals Ce-Bearing FeSi Alloy Inoculation of Electrically Melted, Low Sulphur Grey Cast Irons for Thin Wall Castings

Metals ◽  
2021 ◽  
Vol 11 (7) ◽  
pp. 1122
Author(s):  
Irina Varvara Balkan ◽  
Iulian Riposan
Keyword(s):  
Wall Thickness ◽  
Structural Characteristics ◽  
Cooling Curve ◽  
Thin Wall ◽  
Cast Irons ◽  
Iron Castings ◽  
Grey Cast ◽  
The Difference ◽  
Thermal Cooling ◽  
Fesi Alloy

Electrically melted and over-heated (>1500 °C) grey cast iron at less than 0.04%S, as commonly used, solidifies large amounts of carbides and/or undercooled graphite, especially in thin wall castings; this is necessary to achieve a stronger inoculation. The efficiency of Ce-bearing FeSi alloy is tested for lower ladle addition rates (0.15 and 0.25 wt.%), compared to the base and conventional inoculated iron (Ba,Ca-bearing FeSi alloy). The present work explores chill and associated structures in hypoeutectic grey iron (3.6–3.8%CE, 0.02%S, (%Mn) × (%S) = 0.013–0.016, Alres < 0.002%), in wedge castings W1, W2 and W3 (ASTM A 367, furan resin sand mould), at a lower cooling modulus (1.1–3.5 mm) that is typically used to control the quality of thin wall iron castings. Relatively clear and total chill well correlated with the standard thermal (cooling curve) analysis parameters and structural characteristics in wedge castings, at different wall thickness, displayed as the carbides/graphite ratio and presence of undercooled graphite morphologies. The difference in effects of the two inoculants addition is seen as the ability to decrease the amount of carbides and undercooled graphite, with Ce-bearing FeSi alloy outperforming the conventional inoculant, especially as the wall thickness decreased. It appears that Ce-bearing FeSi alloy could be a solution for low sulphur, electric melt, thin wall iron castings production.

Designing CO2 Transmission Pipelines Without Crack Arrestors

2010 ◽  
Author(s):  
Graeme G. King ◽  
Satish Kumar
Keyword(s):  
Wall Thickness ◽  
Carbon Capture ◽  
Power Plants ◽  
Oil And Gas ◽  
Cost Optimization ◽  
Operating Conditions ◽  
Operating Pressure ◽  
Design Work ◽  
Industrial Facilities ◽  
Pipeline Network

Masdar is developing several carbon capture projects from power plants, smelters, steel works, industrial facilities and oil and gas processing plants in Abu Dhabi in a phased series of projects. Captured CO2 will be transported in a new national CO2 pipeline network with a nominal capacity of 20×106 T/y to oil reservoirs where it will be injected for reservoir management and sequestration. Design of the pipeline network considered three primary factors in the selection of wall thickness and toughness, (a) steady and transient operating conditions, (b) prevention of longitudinal ductile fractures and (c) optimization of total project owning and operating costs. The paper explains how the three factors affect wall thickness and toughness. It sets out code requirements that must be satisfied when choosing wall thickness and gives details of how to calculate toughness to prevent propagation of long ductile fracture in CO2 pipelines. It then uses cost optimization to resolve contention between the different requirements and arrive at a safe and economical pipeline design. The design work selected a design pressure of 24.5 MPa, well above the critical point for CO2 and much higher than is normally seen in conventional oil and gas pipelines. Despite its high operating pressure, the proposed network will be one of the safest pipeline systems in the world today.

scholarly journals Fast, Robust, and Low-Cost Microwave Imaging of Multiple Non-Metallic Pipes

Electronics ◽  
2021 ◽  
Vol 10 (15) ◽  
pp. 1762
Author(s):  
Yuki Gao ◽  
Maryam Ravan ◽  
Reza K. Amineh
Keyword(s):  
Antenna Arrays ◽  
Oil And Gas ◽  
Imaging System ◽  
Imaging Techniques ◽  
Low Cost ◽  
Microwave Imaging ◽  
Airport Security ◽  
Destructive Testing ◽  
Security Screening ◽  
Industrial Sectors

The use of non-metallic pipes and composite components that are low-cost, durable, light-weight, and resilient to corrosion is growing rapidly in various industrial sectors such as oil and gas industries in the form of non-metallic composite pipes. While these components are still prone to damages, traditional non-destructive testing (NDT) techniques such as eddy current technique and magnetic flux leakage technique cannot be utilized for inspection of these components. Microwave imaging can fill this gap as a favorable technique to perform inspection of non-metallic pipes. Holographic microwave imaging techniques are fast and robust and have been successfully employed in applications such as airport security screening and underground imaging. Here, we extend the use of holographic microwave imaging to inspection of multiple concentric pipes. To increase the speed of data acquisition, we utilize antenna arrays along the azimuthal direction in a cylindrical setup. A parametric study and demonstration of the performance of the proposed imaging system will be provided.

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