THE EVOLUTION OF AN IN-LINE INSPECTION SOLUTION: AXIAL FLAW DETECTION

Thomas Beuker, ROSEN Technology and Research Center Bryce Brown, ROSEN USA

ABSTRACT In-line inspection (ILI) technologies have seen significant advances since their first application over 30 years ago. This has been even more evident over the last 5-10 years. Technological developments in electronics and computing power, as well as increased understanding of complex physical applications have led to the latest line of in-line inspection technologies commercially available over this same time period. Operators of the liquid and gas pipeline systems face an increased awareness of aging infrastructures and are looking to the experts and providers of the latest technological developments to assist them in their efforts to manage and maintain pipeline integrity. ILI has repeatedly proven to be the most useful tool the operator has to help ensure safe, reliable and economic operation of their pipeline system(s). ROSENs most recent addition to the in-line inspection market is their Axial Flaw Detection (AFD) tool. The AFD tool utilizes Magnetic Flux Leakage (MFL) technology and applies it in the circumferential direction of the pipe (CMFL) in order to locate and characterize mainly longitudinally or axially oriented anomalies. This development within The ROSEN Group spanned a time frame of 20 months and resulted in a technological solution for a specific pipeline operators requirement to manage and maintain integrity of their pipeline system. Based on this achievement for that single client, the technology is now commercially available from ROSEN since January, 2003 in the full range of diameters. This article is meant to give the reader a better understanding of the need for ILI tools and technologies as well as the development process of complex in-line inspection

technologies in todays comprehensive and demanding pipeline industry. It will also give emphasis to the relationship between the Operator and the ILI Service Provider in understanding the need (i.e., requirements) for such solutions. The reader will gain insight to the systematic approach to the development process, the need for intellectual assets, as well as the necessary related experience in the field of application.

NOMENCLATURE MFL: CMFL: AFD: ILI: GPS: ERW: EFW: FEM: SDA: EDM: POF: POD: Magnetic Flux Leakage (method) Circumferential Magnetic Flux Leakage (method) Axial Flaw Detection (In-Line Inspection Tool) In-Line Inspection Global Positioning System Electric Resistance Welded Electric Flash Welded Finite Element Modeling Smart Data Acquisition Electro Discharge Machining Pipeline Operator Forum Probability of Detection

INTRODUCTION The operators of todays pipeline systems are increasingly aware of the need to manage and maintain the integrity of an aging infrastructure. Pipeline design and construction codes, inhouse operations and maintenance practices, as well as regulatory requirements are the key drivers in their integrity management program.

In-line inspection (ILI) technologies have been utilized in the pipeline industry for more than 30 years. Over that time there has been a tremendous effort in the continued development of ILI technologies that can address the majority of the threats to pipeline integrity. Various ILI technologies are available to detect, measure, and characterize geometric or ID anomalies, metal loss (e.g., corrosion), as well as pipeline positioning (e.g., onboard inertial / XYZ systems or GPS). Each of the technologies available has its capabilities and limitations in detecting and characterizing certain features. The ROSEN Group has provided pipeline inspection services and technologies to the liquid and natural gas pipeline industry for more than 20 years. All developments accomplished over this time frame are a direct result of market needs, and are based on partnerships between The ROSEN Group and their customers. This partnering is a key determinant in the success of such developments. High Resolution Magnetic Flux Leakage (MFL) ILI systems have been successfully applied in both liquid and natural gas pipeline systems for many years [Bal 92]. MFL is the most reliable and most commonly used technology for detecting and characterizing metal loss pipe wall anomalies, such as: corrosion in the pipe body and girth weld areas, circumferential gouges, as well as girth weld defects. However, this technology is somewhat limited in its capability of detecting and characterizing anomalies which are oriented in the longitudinal or axial direction (reference figure 1).

Figure 2: Traditional MFL technology (left), the magnetic flux is parallel to the longitudinal axis of the pipe. CMFL technology (right), the magnetic flux is in the circumferential direction.

Historically, pipeline operators have seen a need to locate and mitigate longitudinally or axially oriented anomalies or defects. Recently, emphasis has been placed on the integrity of low frequency ERW (Electric Resistance Welding) welds in older pipe [Kiefner 02]. This is also reflected in the latest regulations issued by the U.S. government [CFR 195]. RESEARCH AND DEVELOPMENT The ROSEN Group has provided innovative inspection technologies to the pipeline industry since the mid-80s. Experience shows that a common understanding of your customers needs or requirements is one of the most important aspects of a successful ILI development project. To establish a close relationship with the customer is the number one goal: Closeness to the customer and supplying the best suitable technology. The development of the AFD tool was initiated at the request of a customer to provide an appropriate inspection solution for a pipeline system with a specific operation and maintenance history. The key drivers for the request were the already established procedures of the customer, as well as the influences from regulatory requirements to manage and maintain pipeline integrity. Partnering with the customer, The ROSEN Group recognized the necessity to provide the CMFL technology. Providing technological solutions for the pipeline industry requires a strong engineering background and the in-house capability to develop, design and manufacture inspection solutions. For the ILI business, the different disciplines of Physics, Mechanics, Electronics and Software are inter-related and dependent on each other due to the strong requirements dictated by a pipelines internal environment. A parallel development and optimization of all disciplines is essential for a successful solution and short turn around time. Such a parallel effort requires well-defined internal processes. The ISO 9001 guidelines are used to manage the quality from the design and construction phase through to the final product. The development process of the AFD tool can be summarized as follows:

Figure 1: Example of anomalies oriented in the axial direction.

There is now a reliable ILI technology available to detect and characterize anomalies associated with the longitudinal weld seam, long narrow axial corrosion, as well as others oriented in the longitudinal or axial direction. This is accomplished by the introduction of the High Resolution MFL technology applied in the circumferential direction of the pipe (CMFL) (reference figure 2). The ROSEN Group is one of the few ILI service providers offering this technology to the global pipeline industry with their Axial Flaw Detection (AFD) tool.

Feasibility Study Sensor Design and Analysis Electronic Design and Testing Mechanical Design Construction and Testing of Prototype Field Trials of Prototype

Construction of Commercial Tool Customer involvement throughout the entire process was the key to the ultimate success of this development. Feasibility Study One of the major aspects of the Feasibility Study was to analyze the introduction of the magnetic field into the circumferential direction of the pipe wall. A number of designs were studied from which the final design was chosen. Figure 3 shows the FEM conducted for one of the magnetic yoke designs. The inspection requirements, the anticipated solutions and the impacts for the tool development were summarized in the feasibility study. CMFL Technology The Magnetic Flux Leakage method has been established in the ILI industry for several decades, but it has been only recently that the method was applied in the circumferential direction to detect and characterize axially oriented anomalies. It is not only the change in direction of magnetization which has to be considered for the development of such a tool [Graaf 02]. Other technical challenges and their impact on the tool development that were also considered are: two magnet units to allow a full circumferential coverage of the pipeline, magnetic saturation of circumferential direction, the pipeline in the

Full Coverage Inspection of Pipe Wall To achieve a full circumferential coverage of the pipe wall, two magnet units were built (i.e., the second unit covers the areas obstructed by the brushes of the first unit, and vice versa). To reduce the length of the overall tool, the sensing devices for the internal/external discrimination were packaged into the housing of the magnetic field probes (i.e., sensors). This operational requirement had an impact on the development of the electronics as discussed below. These efforts resulted in a relatively short (w.r.t. industry standards) inspection tools in this category (reference figure 4).

Figure 4: Functional overview of 20 AFD. The compact design allows a reduced total length of 3250mm and a 1.5D bend passage.

a circumferential sensor resolution matching the axial sampling rate of traditional MFL inspection tools.

Magnetic Saturation of Ferromagnetic Pipeline Steel Although the CMFL application is more complex, a magnetization excitation of at least 10kA/m must be established around the entire circumference. The need for an excitation level to saturate the pipeline has been addressed in several publications [Jansen 94], [Crouch 03], [Beuker 99]. An appropriate magnetization level significantly reduces the spurious effects caused by remnant magnetization, pipe stresses, and tool velocity effects. Furthermore, the signal-tonoise ratio for signal amplitudes is improved and was confirmed by measurements obtained at the in-house test facility (reference figure 5).
WT = 9.0 mm WT = 13.0 mm

Axial Circumferencial

Figure 3: FEM design of 20 AFD yoke. The purple areas indicate magnetic saturation.

Figure 5: Color plots of CMFL obtained from two test pipes with identical anomalies. The magnetization level on the left is 18.2 kA/m and on the right is 7.6 kA/m. At the higher magnetization level the signal-to-noise ratio decreases significantly.

To achieve this level of magnetization at a requested passage of 1.5D bends a new generation of coupling brushes were used. These so-called lamella brushes are a spin-off from recent developments of the ROSEN inspection tools. The mechanical behavior is similar to soft-wire brushes, but with 4X better magnetic conductivity. By using 3D Finite Element Modeling (FEM) calculations and the properties of this new material, the required magnetization level was realized over the requested wall-thickness range. The sufficient magnetization level is the foundation of the Performance Specifications described later. Circumferential Sensor Resolution An industry-wide accepted axial sampling rate for High Resolution MFL inspection tools is 3mm. Considering the difference in the signal pattern between MFL and CMFL, it was necessary to establish a circumferential separation of 2.9mm between the individual sensors to accomplish a High Resolution CMFL tool. As a consequence of the increased amount of data to be recorded, digital data transfer between sensor and electronics became a requirement. It was necessary to optimize the sensor suspension and use two rows of sensors for each magnetic unit to allow a radial displacement of the sensors. In addition, the radial field component and the already mentioned internal/external discrimination component had to be packaged and wired into the sensor housing. Digital Data Acquisition (DDA) The DDA solution developed by ROSEN is a spin-off from the 4" High Resolution MFL tool development. The analog measurements are processed within the limited space of the sensor into digital format. A single sensor housing of 24mm width can carry up to 8 independent measurement channels. The digital information and the power supply are managed over a two-wire cable connecting the sensor with the smart data acquisition (SDA) unit. One of these units can process up to 384 channels (reference figure 6). In the case of the CMFL technology, typically two units are used allowing the connection of up to 768 channels. The digital transfer yields a significant improvement in the data quality of in-line inspection tools (i.e., checksum and error flags, as a part of the data flow, allow to clearly identify the status of the measured data).

These examples illustrate the necessity to consider all components of such an inspection tool simultaneously. Requirements in mechanical passage impact the electronics. Mechanical considerations of the brushes support the required magnetization level. The demand for the sensing devices led to optimized sensor suspensions, digital data transmission and a composite sensor housing. DESIGN AND MANUFACTURING A prototype tool was developed virtually using rapid prototyping and computer aided design. This "prototype" was then tested by modeling the impact of various mechanical loads. From this, the in-house manufacturing and assembly of more than 1800 non-standard parts was initiated (reference figure 7).

Figure 7: Assembled 10 AFD tool, length = 2800mm, bend passage = 1.5D

PERFORMANCE SPECIFICATION Extensive tests were performed in pipe sections with more than 200 different anomalies and defects. These performance tests aided in the determination of the detection and sizing capabilities of the CMFL technology. Artificial defects were used as well as other types of natural defects like gouges, dents or cracks. The defect geometries varied in size from very small and narrow (0.2mm wide, 20% deep) to very large defects, which are several millimeters in length and width (reference figure 8). The test condition varies from pull-test to real pipe conditions in a test loop. Numerous tests were performed to establish a statistically valid database. Statistics of inspection data have become more important with the increasing demand for risk-based analysis of pipeline assets [Bea 03] and statistical analysis of measurement accuracy [Morrison 02].

w = 0.5mm l = 25mm d = 50%

w = 0.2mm l = 25mm d = 50%

Figure 6: Data Acquisition Unit. Front: SDA unit with 384 channels. Back: Several electronic components mounted into a frame (max. 1536 channels).

Figure 8: Electro-Discharge Machining (EDM) notches and corresponding AFD data.

AFD wall loss [%]

The determination of the performance specification is a well-defined process supported by the worldwide-accepted reporting standard developed by the Pipeline Operators Forum (POF) under the auspices of Shell [Shell 98]. The figures provided in the section below, Sizing and Detection Accuracy, are summarized from the Performance Specification published by ROSEN. After proving reliable tool operation, the first commercial inspection was pursued. High-resolution data of detailed quality were obtained from various defect types (reference figure 9 and figure 10). An extensive field verification program supplied by the client justified the performance specification of the AFD Tool, especially with regards to the various longitudinal weld seam defects (reference figure 11).

60 50 40 30 20 10 0 0 10 20 30 40 50 60 NDE wall loss [%]

Figure 11: Field verification program dig results. 55 anomalies analyzed. Most defects were found within or close to the longitudinal weld seam.

COMMERCIAL SYSTEM The feasibility study for the CMFL technology was initiated in November 1999. The first run with a commercial AFD tool was performed in July 2001. Based on the results of this development and additional customer requests, ROSEN was encouraged to extend the fleet of available tools. At present, ROSEN AFD tools are available in 6", 8", 10", 12", 14", 16", and 20" (reference figure 12).

Figure 9: Top Right, corrosion and dent at longitudinal seam. Top Left, UT results. Bottom: AFD data.

Figure 12: 14 AFD at receiver site.

These tools are designed to inspect for, and detect:

22 %

12 %

26 %

longitudinal grooving due to certain types of internal corrosion. external corrosion due to preferential cracking of the coating in the axial direction. longitudinal seam weld anomalies introduced during the manufacturing process (e.g., low-frequency ERW). preferential longitudinal seam weld corrosion. mechanically induced, axially oriented gouges. detection of macroscopic cracks.

Figure 10: AFD data, longitudinal seam defects. The percentage of wall thickness loss is indicated. Also visible, a shallow corrosion pattern.

Sizing and Detection accuracy Detection of notches, gouges and channeling starting at 0.2mm wide X 25mm long and 0.2*t deep with a POD of 90% (t = wall thickness). Sizing capabilities (according to [Shell 98]), Depth +/0.2*t, width and length +/-15mm, all at 80% confidence interval. More detailed specifications can be provided on request.

REFERENCES [Bal 92] Bal, C., Latest developments in magnetic-flux type inspection pigs, Proc. of Pipeline Pigging and Integrity Monitoring Conference, Amsterdam, 1992. [Beuker 99] Beuker, T., Brown, B. et al., Advanced magnetic flux leakage signal analysis for detection and sizing of pipeline corrosion: field evaluation program, GRI report GRI-00/0109, 1999. [CFR195] CFR Part 195, Transportation of hazardous liquids by pipelines, Section 195.452, Pipeline integrity management in high consequence areas, 2003. [Crouch 03] Crouch, A.E., Beuker, T., Brown, B.: Flux leakage signals from corrosion defects in pipeline subjected to bending loads, Pipeline Pigging & Integrity Technology 3rd ed., Ed. Tiratsoo, 2003, pp. 267 282. [Graaf 02] Graaf, van der, J., New technology for inspection of longitudinal welds and axially orientated flaws in pipeline, 3R international, 41, 2002, pp 103 105 [Jansen 94] Jansen, H.J.M., et al., Magnetization as a key parameter of magnetic flux leakage pigs for pipeline inspection, Insight, 36, 1994, pp 672 677. [Kiefner 02] Kiefner, J.F., Procedure analyzes lowfrequency ERW, flash-welded pipe for HCA integrity assessment, OGJ, 100.31, 2002, pp. 56 62. [Morrison 02] Morrison, T., Worthingham, R., et al., Bayesian estimates of measurement error for in-line inspection and field tools, Proc. of IPC, Calgary, 2002. [Bea 03] Bea, R., Beuker, T., Vargas, P., Reliability based fitness-for-service assessment of corroded defects using different burst pressure predictors and different inspection techniques, Proc. of OMAE, Cancun, 2003. [Shell 98] Shell International Exploration and Production b.v., Specification and requirements for intelligent pig inspection of pipelines, Version 2.1, The Hague, The Netherlands, 1998.

Operational details are as follows: magnetization level to saturation full coverage inspection high resolution (2.9mm in circumferential and axial direction) wrap-resistant sensor suspension for high accuracy compact tool length, typically 3 segments minimum bend radius 1.5D (for 10" and higher) inspection of pipeline sections up to 400 km in length tool velocity range 0.3 - 3 m/s

CONCLUSION The ROSEN Group strives to meet their customers needs by placing the requirement of a close relationship as the number one priority. By partnering with the customer, The ROSEN Group is able to fully understand their needs, and thus initiate the necessary developments using a well-defined internal process. High Resolution MFL ILI tools have evolved over the last decade to become one of the most reliable and most useful tools in managing and maintaining pipeline integrity. ROSEN recognized the need, with their customer, for a new and technologically innovative solution for inspecting pipelines for specific threats to integrity (e.g., longitudinally or axially oriented anomalies). The need for High Resolution CMFL tools was there, and ROSEN responded with the introduction of their AFD tool to the industry. The evolution of the ROSEN AFD tool, from concept to the complete range of commercially available tools, was driven and continues to be so, by the customers increasing need to manage and maintain their pipeline systems integrity.