Monday, February 11
5:00 - 6:30pm
PIPE - Professional Institute of Pipeline Engineers Annual Meeting and Reception (non-members invited!)
Tuesday, February 12
5.00 – 7.00PM
COCKTAIL RECEPTION, EXHIBITION OPENS
Wednesday, February 13
8:15
Continental Breakfast Underwritten by |
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8.45
OPENING REMARKS
8.50
PIG TRAP DESIGN: RECENT INNOVATIONS AND THE IMPORTANCE OF PLANNED MAINTENANCE AND INSPECTION PROCEDURES
, PIPELINE ENGINEERING, CATTERICK, UK
9.25
BLACK POWDER MIGRATION IN GAS PIPELINES AND ASSOCIATED PROBLEMS
, JOHN SMART CONSULTING ENGINEERS, HOUSTON, TX, USA, AND
, SR PIPELINE SPECIALIST, CHAMPION TECHNOLOGIES, LAFAYETTE, LA, USA
Black powder, a mix of iron sulfides and oxides, can represent a serious threat to the integrity of gas pipelines by plugging pipelines, eroding compressor components, plugging pipeline drips, preventing valid inspection by In-Line Inspection (ILI) pigs, and causing damage to customer equipment. The velocity to cause movement of dry black powder in gas pipelines can be calculated, and is in the range of 12 ft/sec for 24-inch pipelines. Once black powder starts to move, it will continue to move until the flow rate is reduced or the gas is re-compressed. Examples of black powder problems in the field are presented, and rules of thumb about cleanliness in gas pipelines are discussed. Black powder can be partially controlled by using corrosion inhibitors, by using “slug catchers” or cyclones, or by cleaning the line by pigging. Suggested criteria for monitoring black powder movement are discussed.
10.00 Coffee and Exhibition
10.45
DEVELOPMENTS IN SPRAY PIG INHIBITOR APPLICATION
, SR PRINCIPAL ASSET INTEGRITY ENGINEER, IONIK CONSULTING, HOUSTON, TX, USA; , SR RELIABILITY ENGINEER, CHEVRON, HOUSTON, TX, USA;
, ENGINEERING MANAGER, AND
, SR ENGINEERING DESIGNER, TD WILLIAMSON, TULSA, OK, USA
In high-CO2, wet and/or multiphase gas production subsea pipelines, top of line (TOL) corrosion has been a significant problem experienced by many pipeline operators. The TOL corrosion mechanism has in some cases led to premature failure and/or early retirement of operational pipelines. TOL corrosion costs not only losses in production but, more important, it presents a serious threat to environmental contamination should a through-wall failure occur. It is estimated that TOL corrosion may cost the industry in excess of $500 million within the next five to ten years. To control TOL, many operators have adopted recently-developed specialized “spray pig” technology in an attempt to improve the distribution of corrosion inhibitor to the top of the pipeline. As part of an industry-wide R&D program, a “semi-smart” pig has been developed using existing smart-pig technology to aid in obtaining evidence of the spray pig’s ability to deliver the corrosion inhibitor to the top of the pipeline. In addition, information was also obtained to increase understanding of the tool’s performance parameters under various operating conditions.
This paper will discuss development and testing of the tool, and how the semi-smart pig technology may assist operators in understanding, planning and executing treatment programs to mitigate TOL corrosion.
11.20
ENHANCING PIPELINE EFFICIENCY THROUGH CHEMICAL CLEANING
AND , OPERATIONS DEPARTMENT, TRANSPORTADORA DE GAS DEL SUR, BUENOS AIRES, ARGENTINA
Over time, pipelines lose efficiency and therefore transportation capacity. This is one of the reasons why TGS keeps an updated pipeline simulation model that identifies inefficient operations in the system. One such simulation detected a decrease in the efficiency of one of the San Martín Pipeline sections. TGS conducted field pressure and flow measurements on the section, which were later compared to the data obtained in the simulation model, corroborating its accuracy. Later, conventional mechanical cleaning tasks were conducted without satisfactory results. This led TGS to explore several alternatives. Chemical cleaning was preferred as it allowed us to conduct the cleaning process while the transportation system remained in service.
Through several simulations conducted by means of the Gregg program, both the efficiency enhancement and its result were determined. One of the challenges of the project was to keep in service, during cleaning tasks, the Cerri Complex liquid processing plant. For this, a further process simulation tool was required: Hysys, which allowed us to define critical project variables, such as solvent to be used, flow management to keep delivered gas within quality specifications, and dew point calculation.
This work reflects the simulation tasks conducted and results achieved in the implementation of this cleaning method, which had never been used on an in-service pipeline in Argentina.
11.55 Lunch and Exhibition
1.00
COMMISSIONING THE WORLD’S LONGEST LPG PIPELINE, AND RETRIEVAL OF STUCK PIGS—
A CASE STUDY
, DEPUTY GENERAL MANAGER, GAIL (INDIA) LTD, JAMNAGAR, INDIA
A newly constructed pipeline requires pigging to ensure overall safety and fitness for purpose as well as removal of construction blockages. Contingency plans like hot tapping, etc., are tools to clear the line path, but they substantially increase cost, and above that there are future safety concerns when the transported fluid is Liquid Petroleum Gas (LPG).
The world’s longest LPG transmission pipeline, the Jamnagar-Loni Pipeline (approx. 800 miles/1298 km), is the lifeline of north India, the most densely populated part of the country, and where LPG is used as a major fuel for cooking. This paper reports on the commissioning of this pipeline and various safety practices in handling LPG. It was observed that nitrogen gas (as an inert media) and LPG columns were found much ahead of commissioning pigs. However, a sufficient N2 column was maintained ahead of the LPG column to avoid formation of an explosive mixture, resulting in successful and safe commissioning of the pipeline.
The paper also provides a case study of retrieval of four pigs stuck in the commissioning phase of the pipeline in a section where the line passed through difficult terrain.
1.35
MAKING THE LINK BETWEEN INHERENTLY-SAFE DESIGN, INTEGRITY MANAGEMENT, AND PIGGING
AND, IONIK CONSULTING, HOUSTON, TX, USA
Pigging to mitigate corrosion, scaling, or flow-assurance issues most frequently is done well into the lifecycle of the pipeline. For new or early-life deepwater pipelines, where future repair and retrofit are likely to be very expensive or virtually impossible, far greater assurance is demanded for design performance. Recent studies have shown that up-front attention to conceptual Integrity Management at the project FEED stage is paramount. The paper shows, through deepwater subsea tieback case examples, that team-based Inherently Safe Design methods, good materials selection, and sound predictive corrosion assessment can lead to far better integrity management and life-cycle performance. This in turn facilitates better planning and implementation of more cost-effective pigging regimes. The paper describes how these disciplines are related and must be deployed in combination rather than individually. The presentation follows some case histories developed in the GOM, where it is critical to eliminate, prevent, or greatly minimize any predictable corrosion problems.
2.10
INTEGRITY MANAGEMENT OF A PIPELINE CROSSING THE ANDES MOUNTAINS
, OPERATIONS AND MAINTENANCE DIRECTOR, OCP, QUITO, ECUADOR, AND , ENGINEERING MANAGER, OCP, QUITO, ECUADOR
The OCP Pipeline (Oleoducto de Crudos Pesados - Heavy Crude Oil Pipeline) in Ecuador crosses regions with of very dynamic geology and which feature many unique characteristics. Along its route, the pipeline crosses the Andes Mountains, reaching an altitude of 12,000 feet (4,060m). Within this regional geological context, OCP emphasizes the need for a Pipeline Integrity Management Plan that addresses and evaluates the areas that could be potentially vulnerable to certain geodynamic phenomena such as: volcanic (12 volcanoes), seismic (28 geological faults), and slope instability (landslides), etc., in order to define monitoring and control measures that allows it to maintain the integrity of the pipeline.
This paper the Integrity Management Plan that was executed for a pipeline subject to these extraordinary conditions and threats.
2.45 Coffee and Exhibition
Refreshment break sponsored by Synergy 
3.15
THROUGH-WALL RADIOGRAPHY FOR PIPELINE INTEGRITY ASSESSMENT AT LINE EXCAVATION SITES
AND
, BP AMERICA PRODUCTION CO, HOUSTON, TX, USA
This paper provides an overview of how through-wall radiography using variable densitometry analysis can be used to accurately assess corrosion networks and quantify remaining pipe strength. The cost effectiveness and potential technical advantages are discussed for the application of through-wall radiography to ILI follow-up line dig inspections.
3.50
ASSESSING, LOCATING, AND EXCAVATING ANOMALIES
, President, Precision Pigging, Bixby, OK, USA
Knowledge of anomaly assessment allows more accurate prediction and location of anomalies. Proper analysis of the geometry inspection data requires careful attention to several criteria, including pig speed, wall thickness, weld indications, and bend indications. This paper will review the key steps in planning and analysis of geometry inspection data prior to excavation of anomalies. It also discusses the decision-making process concerning pipeline repair or replacement after geometry inspection.
4.25
MANAGING INTEGRITY PROGRAMS IN A LITIGIOUS SOCIETY
, JOYCE & PAUL, TULSA, OK, USA
Pipeline integrity programs carry with them inherent legal issues and exposures.
A meaningful integrity program will by its very nature be self-critical, and the processes involved in evaluating pipeline systems may not only result in the positive outcome of increasing pipeline safety, but also in the creation of data and documentation that, if misused or viewed with the wisdom critics find in hindsight, could provide a roadmap for plaintiff attorneys or government investigators to question an operator’s decisions in the event of an accident. These issues are all the more problematic when one also recognizes the need for involving third parties in consulting arrangements and contracts for internal inspections, thus making data and documentation control more challenging. Also, management of documents provided to the government are subject to release to the public, raising security issues as well as putting information at increased risk of being misconstrued or taken out of context.
Building upon the presentation at the 2007 Conference, which was a broad discussion of legal issues in pipeline integrity programs, this paper will review data integration and records-retention requirements of the regulations and discuss how these could result in misinterpretation and misuse of data and documents. The bases for management and company exposure will be discussed, as will government criteria for determining whether or not information known by the company might result not only in simple liability, but also the possibility of criminal exposure.
The presentation will also take an updated look at how companies are dealing with improved ILI tools providing tremendous amounts of data that must be captured and integrated with other information on the operator’s pipeline systems. It will be emphasized that while companies want to do the right thing, they need to understand the legal risks involved so that they can do the right thing in the right way. Companies that are legitimately and thoroughly trying to identify, qualify, quantify and manage risks must understand how to handle documentation associated with their integrity programs to minimize the potential for data and information to be taken out of context and used to imply deficiencies in programs, whether this is done by government agencies or by private plaintiffs. This paper will discuss solutions to these issues along with a focus on specific language to include in the drafting of consulting and ILI contracts, and suggestions on how to manage documents that are made available to the government regarding integrity issues.
5.00 Cocktail Reception / Exhibition
hosted by ROSEN 
CLOSE OF DAY 1
Thursday, February 14
8:00
Continental Breakfast Underwritten by |
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8.30
THE FEELER SNAKE PIG:
A SIMPLE WAY TO DETECT AND
SIZE INTERNAL CORROSION
WINNER OF THE ASME GLOBAL PIPELINE AWARD, 2007
, PETROBRAS CENPES, RIO DE JANEIRO, BRAZIL; AND
, , AND , PUC-RIO-CETUC/CPTI, RIO DE JANEIRO, BRAZIL
Subsea pipeline inspection traditionally employs the same technologies used for onshore pipelines. One such technology is the instrumented pig, which usually runs under the same parameters and procedures as those used for onshore inspections. However, it’s very common to find subsea pipelines with special characteristics, such as varying diameters and small-radius bends, that prevent the use of conventional instrumented pigs. Other factors that make the inspection difficult are increased wall thickness, which significantly limits the use of magnetic instrumented pigs. An alternative currently available is the ultrasonic pig. But this method has limitations, such as the need for a homogeneous liquid with good acoustic properties, to serve as a couplant. In crude oil pipelines this couplant is not always available, as these lines often carry multi-phase fluids.
A new method has been developed to detect and size loss of wall thickness due to internal corrosion. A special pig was designed to deal with large variations in diameter, with no practical limit of wall thickness to be inspected, and to navigate through curves and geometric accessories with small-radius bends. The tool is called the Feeler Pig, as it consists of several feeler-type sensors that measure internal corrosion. The system was field tested and had its performance compared to a standard ultrasonic instrumented pig. Excellent defect correlation was observed between the Ultrasonic and Feeler Pig data, both in geometry and depth of internal corrosion. With this high confidence, other prototypes of Feeler Pigs were developed. A new design, named the Feeler Snake Pig, was implemented, mounting the feeler-type sensors over a flexible support, yielding a tool with ultra-high tolerance to geometric restrictions. The excellent results of the prototype and its robustness against line geometric restrictions immediately open a wide range of opportunities for the Feeler Snake Pig technology in field applications.
9.05
ROTATING PERMANENT MAGNET INSPECTION FOR UNPIGGABLE PIPELINES
AND , BATTELLE, COLUMBUS, OH, USA
A new eddy current inspection method has been developed that enables the internal inspection of pipelines that currently cannot be examined using established methods such as magnetic flux leakage and ultrasonics. Specifically, the method induces electrical current in the pipe wall by rotating pairs of high-strength permanent magnets around a shaft. Recent advances in high-strength permanent magnet technology have made the concept practical. The rotating permanent magnet system has the potential for broader application because the sensor configurations can be small in size, allowing them to pass obstructions that currently prevent inspection using available pigs. This paper will review the theory of operation of the method and will present detection and sizing data from corrosion defects.
9.40 Coffee and Exhibition
10.15
ULTRASONIC GUIDED WAVE INSPECTION IN GAS-PROCESSING PLANT PIPEWORK
, AND ,
PETROCHINA PIPELINE COMPANY, RESEARCH & DEVELOPMENT CENTER, INTEGRITY INSTITUTE, LANGFANG, HEIBEI, CHINA
While ILI technology has solved many problems in inspecting long-distance pipelines, it often cannot be satisfactorily used in many “non-piggable” situations, such as may occur in the pipeline network of a gas processing facility. These networks are complex in design, featuring pipes of many diameters, many bends, valves, and short-length segments. Ultrasonic guided wave technology has been used successfully to inspect such systems. The inspection process is fast, convenient, and especially fit for inspecting plant pipeline networks. This paper describes the application of this technology at a gas processing facility in China.
10.50
ASSESSMENT OF THE CAPABILITIES OF LONG-RANGE GUIDED-WAVE ULTRASONIC INSPECTIONS
AND , BP AMERICA PRODUCTION CO, HOUSTON, TX, USA
This paper presents the results from a case study that illustrates the detection limits for some long-range guided wave technologies. The authors have generated unique charts that are pipe-size specific. The charts translate cross-sectional detection criteria into corrosion features with different aspect ratios ranging from general corrosion to isolated pitting, thereby allowing a pipeline operator to determine the likelihood of detecting different corrosion anomalies.
11.25
CHARACTERIZATION OF SURFACE-BREAKING CRACKS
, AND ,
ELECTRICAL AND COMPUTER ENGINEERING DEPARTMENT, McMASTER UNIVERSITY, HAMILTON, ON, CANADA, AND
, INTRATECH INLINE INSPECTION SERVICES LTD, MISSISSAUGA, ON, CANADA
The ultimate objective of MFL data analysis is to predict the maximum safe operating pressure of the pipe. This analysis takes into account the defect’s depth and also its length-to-width ratio. The most critical defects associated with pipelines are crack-like defects (welding cracks, fatigue cracks, stress corrosion cracks, hydrogen-induced cracks, and sulfide corrosion cracks). For these surface-breaking cracks, the length and the depth are typically much larger than the crack width, such that the variation of the MFL signal with respect to the width is negligible. It is also assumed that the investigated cracks are straight along their lengths and the crack walls are perpendicular to the metal surface.
This paper reports a direct examination methodology to estimate the crack parameters only from the y-component of the leakage field. The proposed inversion procedure involves estimation of orientation, length, and depth.
The proposed method for crack sizing can be easily implemented on a personal computer using mathematical packages such as MATLAB or MathCAD, or even programmable ICs such as microcontrollers. Time and memory requirements are negligible. The authors examine the accuracy of the proposed inversion procedure via simulations based on the finite element method (FEM) and MFL measurements.
12.00 Lunch and Exhibition
1.00
ACCURATE DETECTION AND SIZING OF PIPELINE CRACKS COATING DISBONDMENT
, SAUDI ARAMCO PIPELINES DEPARTMENT, DHAHRAN, SAUDI ARABIA
The complexities of the various cracking processes that can occur on a pipeline have made accurate and reliable crack detection a great challenge. Different conditions give rise to different cracking mechanisms, which result in different crack types. Although we tend to talk of pipeline cracks as a uniquely defined type of structural feature, in reality we are talking about a whole class of features that can range from a single, small and isolated crack running axially along the pipe, to single, very large cracks, or even colonies of small structurally-interacting cracks that behave like one or more large features. The different physical morphologies of various crack types lead to different demands on any inline inspection tool designed to find them, thereby making the inspection challenge much more difficult. Add to this the enormous intrinsic difficulties of crack detection to begin with, and we begin to see why it has taken so long to produce truly effective inline inspection solutions.
This paper summarizes the different types of cracks that commonly affect pipelines and describes progress being made to detect and measure these flaws accurately using inline inspection technology. The tool in question is based on a customized, high-resolution configuration of the ElectroMagnetic Acoustic Transducer (EMAT) principle. Recent tests of this technology in transmission pipelines in Saudi Arabia and Germany are described, together with the results obtained.
While detecting and sizing cracks are clearly desirable capabilities for any crack-detection tool, the tool and subsequent data analysis processes must also be competent to recognize and reject crack-like signals arising from non-crack features such as laminations. This paper will discuss this aspect of discrimination performance. In particular, the use of multiple-parameter analysis to investigate the numerous properties of the inspection signals will be explained, leading to an exciting prospect for true high- performance discrimination between cracks and non-crack features in the future.
The presentation will also address the capabilities of EMAT inspection technology to measure the bond quality of external coatings to the pipe surface. Such information is useful not only for defect risk assessments; it is also useful for optimizing the cathodic protection on a pipeline.
1.35
RESPONDING TO CRACK DETECTION ILI
, CC TECHNOLOGIES, DUBLIN, OH, USA
2.10
FIELD EXPERIENCE DRIVES IMPROVEMENT IN EMAT INSPECTION TECHNOLOGY
DAVID ALLEN, GE OIL & GAS PIPELINE INSPECTION SERVICES, CRAMLINGTON, UK
This paper will discuss a technology developed five years ago and its evolution and recent improvement based on clients’ requirements and their in-field experience. The long-range EMAT technique will be examined for seam weld and dent inspection, and it will be compared to other inspection techniques. Case studies, complemented by dig data points, will validate technology advances such as sizing and reporting enhancements.
2.45 Coffee
3.00
COMBININED MFL AND ULTRASONIC TESTING FOR ENHANCED DETECTION OF METAL LOSS AND PIPELINE WALL FEATURES
ROSEN Technology and Research Center Germany
Magnetic Flux Leakage (MFL) technology is known to be versatile and robust for determining the geometry of metal loss in both liquid and gas pipelines, while the ultrasonic method allows a highly accurate direct measurement of pipeline wall thickness. The paper presents a solution that combines both technologies on a single in-line inspection tool.
It turns out that the two methods complement their respective limitations. Furthermore, the overall scope of the inspection is greater. General wall thinning and largely corroded areas are accurately and reliably scanned with the UT unit, while very detailed information about pitting corrosion is obtained from the MFL measurement. Blind spots of echo loss, occasionally observed in UT data, are overcome by the more robust measurement from the MFL sensors. This is because a magnetic pattern is typically larger than the anomaly that caused it, greatly improving the likelihood of detection.
ILI methods are chosen based on the specific threat identified by a pre-inspection risk analysis. Two typical threats are Microbiological Corrosion (MIC) and Top of Line Corrosion (TOL), which require careful selection of a suitable inspection technology. The combination of MFL and UT on a single tool has a broader range of application than either method alone, and the risk assessment effort can be reduced significantly with regard to the inspection strategy.
Combining two inspection technologies is also beneficial in reducing the operational risk and the cost of an in-line inspection. If both technologies were to be applied separately, the additional launching, receiving, and tracking would create additional risks associated with safe operation and cost. In addition a reduction in flow rate or pressure may be required during the inspection.
3.35
ASSESSMENT OF BURST PRESSURE FROM ILI DATA
, BJ PIPELINE INSPECTION SERVICES, CALGARY, AB, CANADA, AND
, DESJARDINS INTEGRITY LTD, CALGARY, AB, CANADA
Pipeline operators require both depth and burst pressure as measures of the severity of corrosion and other types of anomalies from ILI data. For an MFL run, depth and length are derived from the magnetic signals using proprietary software. Burst pressure is then calculated using depth and length using standard formulas or procedures such as B31G or RStreng. Each step in the calculation of burst pressure contributes some error or uncertainty to the final calculation. This paper investigates an alternative method of deriving burst pressure directly from the MFL magnetic data signals. The advantage of this approach is that the burst pressure is calculated in one step and thus reduces the sources of uncertainty in the calculation.
4.15 CLOSE OF CONFERENCE
