Sensor Technology
for Heavy Pipe Wall Inspection
Contents
Motivation
Measurement Principle
Mechatronic Principle
Inspection Tool Design
Combining SIC with MFL
Test Results
On-Site Example
Summary
Motivation
Risks for Pipeline Integrity and Operation
Manufacturing
Operational
Steel Production
Welding (SAW, ERW)
Pipeline
Integrity
Assessment
Corrosion
Erosion, Fatigue
Ground Movement
Mechanical Damage
Construction
Coating and CP
Motivation
Corrosion plays a crucial role in pipeline integrity
it is a time-dependent deterioration process
Heavy Wall Pipelines for Offshore Applications
Specified maximum corrosion growth rate
Controlled wall thickness reduction during the lifespan
Monitoring Internal Corrosion is inevitable for reliable
and save operation!
Motivation
Top of Line Corrosion (TLC) or Dewing Corrosion
starts as Shallow Internal Corrosion (SIC)
Origin of TLC
Unprocessed wet gas is transported
from an offshore well
Heat exchange between pipeline and
cold surrounding (such as sea water)
Low pH water droplet condensation on the upper
half of the pipeline
Dissolution of aggressive gases in droplets support corrosion
Motivation
Droplet Condensation
of Vapor Phase
Vapor
H2O, CO2, H2S
TExt TGas
Water Drain
TGas
TExt
Stratified Water Flow
Droplet Size Distribution ~ r -2/3 localized, small-scale corrosion
Motivation
TLC Controlling Parameters
Partial Pressure of CO2
Motivation
Measurement Principle
Alternating current triggers
Primary Magnetic Field
Magnetic flux change causes
Eddy Currents in conductive
material, e.g., pipe wall
Eddy Currents generate
Secondary Magnetic Field
Secondary Field modifies Primary
Field via mutual inductance
Eddy Currents imply change of
coil impedance
Measurement Principle
Coil Impedance: Z = R + j L
R
Ohmic Resistance
Frequency of driving
current
L
Inductance of Coil
L
In Air
Li
ft
Metal Loss
-O
ff
Material
In Air
R
Over Material
Lift-Off
Eddy Currents
Copyright ROSEN Group 2009 - Copy prepared for PPSA
Measurement Principle
Penetration Depth determined by Skin Effect
Skin Depth ~ 1/( )1/2
Mechatronic Principle
SIC Sensor = Contour Following Touchless Proximity Sensor
(Compensated Deflection)
Radius Measurement
=
Proximity Sensor (Lift-Off)
+
Electronic Angle Sensor
Copyright ROSEN Group 2009 - Copy prepared for PPSA
counts
SIC sensor
schematic view
Lift-Off
SIC Sensor Technology | O. Stawicki | 18-Nov-2009
SIC
100% coverage
6" 56"
relative
absolute
Compensation
for Lift-off
SIC Regime
Wall
Thickness
MFL Regime
Detection & Sizing of External Defects
14
MFL
SIC Probe
Test Results
SIC Scan of Steel Plate with Spherical Pits
Depth [mm]
y-direction [mm]
Lift-Off
3 mm
Resolution 2 x 2 mm
EDM-made pits
x-direction [mm]
Test Results
Surface Diameters
Aspect Ratio
P35.x
P30.x
P25.x
P20.x
P15.x
35
Depth t
Copyright ROSEN Group 2009 - Copy prepared for PPSA
Test Results
Depth [mm]
y-direction [mm]
x-direction [mm]
Test Results
Test Results
16" Pump Test Line
Dent Simulation
Spiral Weld
Internal
Defects
Flange
Dent
Test Results
16" Test Joint, WT = 12.6 mm
SIC
MFL
Test Results
TLC in 16" Test Pipeline
AUT
Copyright ROSEN Group 2009 - Copy prepared for PPSA
CDP
SIC
SIC Sensor Technology | O. Stawicki | 18-Nov-2009
CDP
624 MFL Channels
RoGeoXt 330 Geometry Channels
SIC
864 Channels
Copyright ROSEN Group 2009 - Copy prepared for PPSA
Summary
Based on Eddy Current Technology, SIC Sensors have
been developed for metal loss inspection on inner pipe
wall
Compared to other measurement technologies:
SIC:
Absolute depth of metal loss features
MFL:
Relative depth based on wall thickness
SIC tools have less friction compared to tools with
magnet yokes
SIC Inspection is contactless, i.e. no direct coupling to
the pipe wall
SIC sensor metal loss depth sizing
Typically between 1 mm and 10 mm depth