pressure pipeline condition assessment
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BRYON LIVINGSTON, P.E.
IMPLEMENTING CONDITION ASSESSMENT: KNOWING WHICH TECHNOLOGIES TO USE FOR PRESSURE PIPELINES
AGENDA
Definition of Condition Assessment
Where Do I Start
Available Technologies
Best Practices
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CONDITION ASSESSMENT DEFINITION
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The collection of data and information through direct and/or indirect methods, followed by analysis of the data and information, to make a determination of the current and/or future . . . . status of the pipeline.
ACCORDING TO THE EPA, CONDITION ASSESSMENT IS…
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How much data needs to be collected?
WHERE DO I START
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IMPLEMENTING CONDITION ASSESSMENT REQUIRES A PROCESS
Step 1 GET STARTED
• Develop framework and requirements for program
• Prepare list of pipeline materials, age, diameters • Coordinate GIS
with Operations
• Develop Program Funding • Identify inspection
technologies • Develop criteria for
risk analysis (LOF, COF)
• Conduct inspections; indirect and direct
• Estimate remaining life of pipe
• Develop future inspection frequency for pipelines
• Develop planning level Repair/Rehab/Replace Action Plan
• Prioritize high risk assets for rehabilitation
Step 2
Develop Strategy
Step 3
Identify Inventory, Update
GIS
Step 4
Prioritize Pipelines
Step 5
Conduct Condition
Assessment
Step 6
Incorporate Results into CIP
• NOW or AFTER the NEWS
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MANY FACTORS IMPACT LIFE OF A PIPE – ALL PIPE INSTALLED IN ONE YEAR WON’T FAIL IN THE SAME YEAR
External Loads
Soil Traffic Overburden
Bedding Condition and Material
Internal Corrosion
External Corrosion
Design and Construction Practices
Leakage
Soil Characteristics
Contraction Loads
Temperature
Movement
Water Quality
Internal Pressures
• Risk Analysis can be Simple or Complex
• Based Upon
• Likelihood Of Failure (LOF)
• Consequence Of Failure (COF)
• LOF X COF = RISK
DESKTOP PRIORITIZATION
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0 1 2 3 4 5 6 7 8 9 10
10 G G G G D C B A A A
9 H H H H D C B A A A
8 H H H H D C B A A A
7 Z Z Z Z D C B B B B
6 Z Z Z Z D C C C C C
5 Z Z Z Z D D D D D D
4 Z Z Z Z Z Z Z F F E
3 Z Z Z Z Z Z Z F F E
2 Z Z Z Z Z Z Z F F E
1 Z Z Z Z Z Z Z F F E
Likelihood of Failure
Co
ns
eq
ue
nc
e o
f F
ail
ure
• Pipe Length • Pipe Material • Pipe Age • AWWA Standard
PHYSICAL FACTORS FOR LIKELIHOOD OF FAILURE
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• Pipe Break (Leaks) Data • Multiple Material In
Pipeline
• Pipe Diameter
• Pipe Alignment
• Pipe Physical Location
• Service Areas
FACTORS FOR CONSEQUENCE OF FAILURE
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• Estimated Duration of Service Interruption
• Land Use
• Specific Customers
• Provide a Numerical Ranking Based on Risk Exposure
• Method Allows Adjusting of Weighting on Factors to Meet Specific Concerns
RESULTS ARE INSPECTION PRIORITIES
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0 1 2 3 4 5 6 7 8 9 10
10 10 20 30 40 50 60 70 80 90 100
9 9 18 27 36 45 54 63 72 81 90
8 8 16 24 32 40 48 56 64 72 80
7 7 14 21 28 35 42 49 56 63 70
6 6 12 18 24 30 36 42 48 54 60
5 5 10 15 20 25 30 35 40 45 50
4 4 8 12 16 20 24 28 32 36 40
3 3 6 9 12 15 18 21 24 27 30
2 2 4 6 8 10 12 14 16 18 20
1 1 2 3 4 5 6 7 8 9 10
Likelihood of Failure
Co
nse
qu
en
ce o
f Fa
ilu
re
Asset Risk Index
MIAMI-DADE PROJECT
• Over 7,760 Miles of Pipe
• 16” and Larger (3,755,000 feet)
• 4.7 Miles Ranked High Priority
• Expanded Existing Inspection of PCCP to Include Cast Iron
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• About 12.6 miles of Concrete Mains
• Installed from 1950’s to 1970’s and 1990’s
• Diameter ranges from 16 Inch to 36 Inch
• No history of Failures (except Contractors)
LAWRENCE, KANSAS
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AVAILABLE TECHNOLGIES
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• Indirect Testing
• Corrosion Potential Surveys
• Leak Detection
• Pipeline In Service
• Pipeline Out of Service
• Technologies for Specific Pipe Materials
• Metallic (Ductile/Cast Iron, Steel)
• Concreter(Reinforced Concrete Pipe (RCP), Prestressed Concrete Cylinder Pipe (PCCP)
• Plastic (PVC and HDPE) and Asbestos Cement
WHAT ARE YOUR OPTIONS
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IN SERVICE TECHNOLOGIES
• Indirect Testing Methods
• Leak Detection with Closed Circuit TV
• Electromagnetic (pipeline pig)
• Broadband Electromagnetic
• Ultrasonic Testing
• Magnetic Flux Leakage
• Coupon Analysis
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• Assessment included
• In-situ Soil Resistivity Using Wenner 4-Pin Method
• Potential External Pipeline Corrosion and Stray Currents Using DC Cell-to-Cell Survey
• Survey Run Along Pipeline Route Limited to Segments of Pipeline Not Covered by Asphalt and Concrete Pavement
INDIRECT CORROSION ASSESSMENT
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• Assessment Included
• In-Situ Soil Resistivity Using Wenner 4-Pin Method
INDIRECT CORROSION ASSESSMENT
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CURRENT ELECTRODE CURRENT ELECTRODE POTENTIAL ELECTRODES
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INDIRECT CORROSION ASSESSMENT
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IN-SITU SOIL RESISTIVITY MEASUREMENT PIPELINE LOCATION MARKING
DC CELL TO CELL SURVEY PIPELINE LOCATER
LEAK DETECTION - CORRELATORS
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ADVANTAGES
• Pipe Remains in Service
• No Entry Required
• Wide Range of Tools Available
• Provides Information Immediately on Pipe’s Condition
LIMITATIONS
• Dependent on Method Selected
IN THE PIPE – JD-7, SAHARA, SMART BALL
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• Free Swimming or Tethered
• Data Collected Real Time or Analyzed Later
• Range Varies with System
CCTV & LEAK DETECTION: WITH PIPE IN SERVICE
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• Inline Video Inspection of up to 4,000 Feet while the Line Remains in Service
• Possible Uses: • Liner Inspection • Location of Lost Valve • Zebra Mussel
Investigation • Corrosion /
Tuberculation • Repair Planning
ELECTROMAGNETICS REMOTE FIELD EDDY CURRENT - METALLIC
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ADVANTAGES
• Able to Detect Internal and External Pipe Defects
• Measures Wall Thickness and Location of Pits
• Doesn’t Require Contact
LIMITATIONS
• Only Works on Metallic Pipe
• Insertion and Retrieval can be Problematic
LAUNCH TUBE AND TOOL READY FOR INSERTION
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ISP INSPECTION IN 2013
ISP INSPECTION IN 2013 RAYMORE, MISSOURI
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REMOTE FIELD EDDY CURRENT – CONCRETE PCCP
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BROADBAND ELECTROMAGNETIC (BEM)
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ADVANTAGES • Able to detect internal and
external pipe defects • Measures wall thickness
and location of pits • Can inspect through coating
LIMITATIONS • Only works on metallic pipe • Provides average wall
thickness
ULTRASONIC GUIDED WAVE, A- & B-SCAN (METALLIC PIPE)
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ADVANTAGES
• Accurate to a .003 inch
• Displays the Cross Sectional Thickness of the Material
• Portable can go about anywhere
LIMITATIONS
• Short Lengths or Area can be Inspected
• Requires Access to the Pipe
• Cannot Scan Pipes with Heavily Corroded Exterior surfaces
GUIDED WAVE TESTING (GWT)
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• Consisting of a Collar Mounted on the Pipe being Inspected. • Low-Frequency Ultrasonic (>20kHz) Waves are Generated
in the Pipe Wall. • The wave travels in the pipe wall and is scattered/reflected
by changes in the pipe cross section (i.e. by corrosion, welds or other wall thickness changes).
BENEFITS OF GUIDED WAVE TESTING
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• 100% Volumetric Coverage • Inspection over Long
Distances from a Single Sensor Position.
• Ability to Inspect Hidden Structures and Structures under Water, Coatings, Insulations and Concrete.
• Defect Classification and Approximate Circumferential and Axial Sizing.
• Avoidance of Removal/ Reinstatement of Insulation or Coating, except at Location of Transducer Tool
ULTRASONIC – CONCRETE PIPE
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• Able to Detect Delamination from Rebar Corrosion
• Identify Cracks in Mortar
• More Accurate than Manual Sounding
• Impact Echo
• Slab Impulse Response
• Spectral Analysis of Surface Waves
GLENDALE ARIZONA
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• SIR Tested 9 locations
• IE Tested 40 locations
• Mortar Coating Could be Easily Scored to Shallow Depth
TYPICAL IE TESTING
TYPICAL TESTING GRID
Avg Frequency Spectrum, T = 4.36 in V = 144000 in/sec
Frequency (Hz)
0 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
in
0
5e-005
0.0001
0.00015
TYPICAL IE TEST DATA
POSSIBLE DELAMINATION DETECTED
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• SIR Tested 27 Locations
• Portion of Steel Joint Ring Exposed
16-INCH AERDS PIPELINE - SITE 3
POSSIBLE DELAMINATION LOCATION CORROSION AT JOINT
MISSING MORTAR AND CORROSION ON JOINT RING
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SIR RESULTS
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• Sound Location
• Questionable Location
• Delamination Location
MAGNETIC FLUX LEAKAGE – METALLIC PIPE
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• Used Primarily in the Oil Industry
• Provides Information on Wall Thickness
• Free Swimming Tool so Pipe can Remain in Service
• Limited Applications Requires Contact with Pipe Wall
MFL
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COUPON ANALYSIS
• Requires Excavation and Hot Tap on Pipe
• Results Requires Engineering Evaluation
• Size of Tap Impacts Analysis
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PLASTIC PIPE - PVC AND HDPE
• Failures Occur
• Installation is Critical
• No Non-Destructive Testing
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PIPELINE OUT OF SERVICE VISUAL INSPECTION MAN ENTRY
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ADVANTAGES
• Ability to use Multiple Tools - including Some that Require Human Operation
• Detailed Visual Inspection
LIMITATIONS
• System Must Be Shut Down and Drained
• Only for Large Diameter Pipes (36 inch?)
• Health & Safety Risks
ROBOTIC CRAWLERS WITH CCTV, EDDY CURRENT
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EMERGING TECHNOLOGIES
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INLINE ENHANCED EM PIPE ASSESSMENT
• Enhanced Electromagnetics
• Similar to PCCP Assessment Technology
• Provides Data on Wall Loss for Metallic Pipe
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BEST PRACTICES
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THE CONDITION OF CONDITION ASSESSMENTACCORDING TO THE EPA
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• Condition assessment is either not used or not used routinely by a most utilities
• Utilities often have little data in system besides the type of pipe, type of service and installation date
• If inspections have been conducted usually only have qualitative (Good/Poor) information – not useful
• Utilities are leery of new inspection techniques and need to be educated on how to use effectively
• Repair or replacement typically only occurs after major failure event and associated negative attention
BEST PRACTICES
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• Empowers Utility to act as Steward of Community Water Infrastructure
• Encourages Proactive Investment
• Facilitates Continuous Improvement
• Requires Prioritization of Pipes in the System and Condition
• Significant Emphasis on Collecting the Quantity and Quality of Data Collected Needed to Determine Status of Pipeline
R3 = Replace RIGHT pipe, RIGHT time, RIGHT material
JUST DROPPED IN TO SEE WHAT CONDITION MY CONDITION WAS IN (KENNY ROGERS AND THE FIRST EDITION, 1968)
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• Overcome Individual Barriers
• Develop a Plan For Your System
• Determine the Value of Condition Assessment for Your System
• Implement a Logical Approach for Technologies
• Use the Information to Develop Repair/Replacement Plan
R3 = Replace RIGHT pipe, RIGHT time, RIGHT material
Questions
Bryon Livingston, P.E.
Black & Veatch
8400 Ward Parkway
Kansas City, MO 64114
913-458-3368
CLOSED CIRCUIT TV REMOTE OPERATED VEHICLE
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ADVANTAGES
• Inspection takes place while pipe in service (Intakes, Tunnels)
• CCTV HD Video
• 2- D and 3-D sonar
• No manned entry
LIMITATIONS
• Low flow velocity required < 1 ft/s
• Range < 10,000 ft
Image Courtesy of Hibbard Inshore