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ASSESSING MECHANICAL DAMAGE

USING MULTIPLE DATA SETS IN ILIAbel Lopes

Market Development Manager EH

14th November 2012

2Source: 8th Report of the European Gas Pipeline Incident Data Group

Failure Causes

3

Failure Causes

Source: Performance of European cross-country oil pipelines Statistical summary of reported spillages in 2010 and since 1971

Prepared by the CONCAWE Oil Pipelines Management Group’s Special Task Force on oil pipeline spillages (OP/STF-1)

4

Introduction

Technology Limitations

5

TDW Offer

SPIRALL/MDS

6

Value of Multiple Datasets

MFL w/IDOD

• Volumetric Anomalies

• Mill Anomalies

• Extra Metal

• Internal/External Classification

• Dents

DEF

• Ovalities

• Dents

• Misalignments

• Other bore changes

Residual / Low Field Magnetization

• Permiability Anomalies – Hard spots

• Mechanical Stress

• Pipe Characteristic Changes

SMFL

• Gouging

• Narrow Axial Corrosion

• Selective Seam Corrosion

• Planar / Crack-like Seam Anomalies

• Volumetric Anomalies (pipe body or seam)

• Mill Anomalies Dent with

residual

stress

Dent with Volumetric

Metal Loss

Dents with Metal Loss

Pipe Characteristic Changes

Gouging/ML without dent

Planar versus Volumetric

Axially oriented Anomalies

Metal Loss in Seamless Pipe

Metal Loss crossing Girth Welds

7

Axial MFL

80 1 2 3 4 5 6 7 8

0

1

2

3

4

5

6

7

8

Normalized Defect Length, L/A

Norm

aliz

ed D

efe

ct

Wid

th,

W/A

Axial Slotting

Axial GroovingPitting

General

Pinhole

Circum

fere

ntial S

lott

ing

Circum

fere

ntial G

roovin

g

Axial MFL

Axial MFL

9

SpirALL™ MFL Technology

10

SpirALL™ MFL Technology

0 1 2 3 4 5 6 7 80

1

2

3

4

5

6

7

8

Normalized Defect Length, L/A

Norm

aliz

ed D

efe

ct

Wid

th,

W/A

Axial Slotting

Axial GroovingPitting

General

Pinhole

Circum

fere

ntial S

lott

ing

Circum

fere

ntial G

roovin

g

SpirALL™ MFL

11

• Magnetizer• SMFL concept enables Multiple DataSet platform

SpirALL™ MFL Technology

12

Axial MFL + SMFL

130 1 2 3 4 5 6 7 8

0

1

2

3

4

5

6

7

8

Normalized Defect Length, L/A

Norm

aliz

ed D

efe

ct

Wid

th,

W/A

Axial Slotting

Axial GroovingPitting

General

Pinhole

Circum

fere

ntial S

lott

ing

Circum

fere

ntial G

roovin

g

Axial MFL

SpirALL™ MFL

Overlap = Enhanced

Characterization

Axial MFL + SMFL

14

• 16-inch inspection tool runs indicated that SpirALL™ MFL technology

successfully identifies narrow axial defects that normally would not be

reported by axial MFL alone.

SMFLMFL

Axial MFL + SMFL

15

• By combining axial MFL with SpirALL™ MFL in the same run, it

becomes possible to identify the anomaly as a metal loss feature that

happens to be in the seam weld instead of a crack-like feature in the

seam

Axial MFL + SMFL

16

The Multiple DataSet Advantage

17

Single Dataset – MFL

18

Multiple Datasets

19

MFL SMFL

Characterization

Metal Loss crossing and within a girth weld

20

Characterization

• Mechanical Damage

MFL data – not able to capture

anomaly extent

SMFL data - reported accurately as

continuous anomalies

21

Characterization

• Axial (Planar) Defects

22

Characterization

• Seam Weld Defects

23

MFL SMFL

Seam Anomalies

Long Seam

1 2 3

Planar / Crack-like Anomalies

Characterization

24

Anomaly 1, 2 and 3 (left to right): zoomed in SMFL screenshot with dig photo

# Descr. ILI % Field % ILI

Length

(mm)

Field

Length

(mm)

ILI Width

(mm)

Field

Width

(mm)

1 Planar 19 16 109 140 1.3 Linear

2 Planar 29 14 61 73 1.8 Linear

3 Planar 15 16 188 198 2.0 Linear

Planar / Crack-like Anomalies

Characterization

25

Residual and Low Field MFL

26

Residual and Low Field

B

Time

BMFL max saturation

Har

dnes

s

1

2

• Two different steel lattices will produce two different

residual measurements (1,2)

• This happens with hard spots, heat affected zones, and

stress.

27

Steel Microstructure

28

Steel Microstructure

• Low Carbon

29

Steel Microstructure (High-carbon)

• High Carbon

30

Hard Spot / Crack

Analysis of High-Collapse Grade P110 Coupling Failures - A Case Study by Stork Materials

31

Mechanical Damage

32

Re-rounded versus Cycled Dents

33

Re-rounded versus Cycled Dents

Re-rounded dent signature

Cycled dent signature,notice the strong

“halo” effect

34

• ASME B31.8 provides non-mandatory Appendix R which outlines methods

for estimating strains in a dent

• Enhancements to the ASME formulas, suggested by recent industry

research, have been incorporated

• Computations can be carried out using high resolution deformation data

• Local dent strain can be estimated by analyzing the deformed shape

• The Battelle prioritization model is then supplemented:

• If a dent exhibits strain > 6% then considered higher priority

Strain Calculations

35

• Mechanical Damage

• Utilization of Battelle Mechanical Damage

Prioritization Model developed in 2002

• PRCI L52084

• Supplemented with:

• Dent Strain

• SMFL for gouging and metal loss

• Proximity to girth and seam weld

D e c o u p le d

S ig n a l? N o

N o

N o

Y e s

Y e s

Y e s N o

N o N o

Y e s

Y e s

N o

N o

Y e s

Y e s

N o

A p p ly

D e c o u p lin g

H ig h

M a g n e t iz a t io n

D a ta

L o w

M a g n e t iz a t io n

D a ta

Y e s N o

Y e s R e s id u a l

D e n t?

G o u g e

S ig n a l?

R e ro u n d in g

H a lo ?

Y e s

N o Y e s

M e ta l

L o s s ?

C y c l ic

L o a d s ?

P lo w in g

S ig n a l?

R e s id u a l

D e n t? N o

M e ta l

L o s s ?

T o p o f

P ip e ?

R e s id u a l

D e n t?

R e s id u a l

D e n t?

L o w

P r io r i ty

M o d e ra te

P r io r i ty

M o d -H ig h

P r io r i ty

M o d -L o w

P r io r i ty

H ig h

P r io r i ty

Y e s

Prioritization

36

Prioritization

37

Case Study

38

Conclusion

• Individual technologies have limitations when used independently as

defined by NACE SP0102-2010

• Multiple Datasets (DEF+SMFL+MFL+RES):

• Overcome limitations of individual technologies

• Provide clarity of axial anomalies, and because of combination of

Axial MFL with SpirALL,

• More effectively detects and characterizes crack-like and metal loss

anomalies whether seam or pipe body

• Accurately detects and characterizes 3rd party damage for

prioritization

• Will ultimately translates into greater accuracy of results

• Proven to eliminate unnecessary seam anomaly excavations

39

Thank You!Trusted Performance / Innovative Solutions