Implementing Condition Assessment Knowing Which Technologies To Use For Pressure Pipelines by Bryon Livingston

IMPLEMENTING CONDITION ASSESSMENT:
KNOWING WHICH TECHNOLOGIES TO USE

16 Dec. 2015
FOR PRESSURE PIPELINES

BRYON LIVINGSTON, P.E.
AGENDA
Definition of Condition Assessment
Where Do I Start
Available Technologies
Best Practices
2
CONDITION
ASSESSMENT
DEFINITION
3
Black & Veatch 16 Dec. 2015
ACCORDING TO THE EPA, CONDITION

ASSESSMENT IS…
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.
How much data needs to be collected? 4

WHERE DO I START
5
Step 1
Step 2 Step 3 Step 4
GET STARTED
• NOW or AFTER Develop Strategy Identify Prioritize
the NEWS Inventory, Update Pipelines
• Develop
GIS
framework and • Develop Program
requirements for • Prepare list of Funding
program pipeline materials, • Identify inspection
age, diameters technologies
• Coordinate GIS • Develop criteria for
with Operations risk analysis (LOF,
COF)
Step 5 Step 6
Conduct Incorporate
Condition
Assessment
Results into CIP
IMPLEMENTING
• Develop planning level
• Conduct inspections;
indirect and direct
Repair/Rehab/Replace
Action Plan
CONDITION
• Estimate remaining • Prioritize high risk ASSESSMENT
life of pipe assets for rehabilitation
• Develop future
inspection frequency REQUIRES A PROCESS
for pipelines
6
MANY FACTORS IMPACT LIFE OF A PIPE –

ALL PIPE INSTALLED IN ONE YEAR WON’T FAIL IN THE SAME YEAR
Soil Characteristics
External Loads
Soil
Temperature Traffic External Corrosion
Overburden
Contraction
Loads
Water Quality
Internal Corrosion
Internal Pressures
Bedding Condition and Material

Leakage
Movement
Design and Construction Practices
7
DESKTOP PRIORITIZATION
• Risk Analysis can be
Simple or Complex
• Based Upon
• Likelihood Of
Failure (LOF)
Likelihood of Failure
• Consequence Of 0 1 2 3 4 5 6 7 8 9 10
Failure (COF) 10 G G G G D C B A A A
Consequence of Failure 9 H H H H D C B A A A
• LOF X COF = RISK 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
8
PHYSICAL FACTORS FOR LIKELIHOOD OF

FAILURE
• Pipe Length • Pipe Break (Leaks) Data
• Pipe Material • Multiple Material In
• Pipe Age Pipeline
• AWWA Standard
9
FACTORS FOR CONSEQUENCE OF FAILURE

• Pipe Diameter • Estimated Duration of
• Pipe Alignment Service Interruption
• Pipe Physical • Land Use
Location • Specific Customers
• Service Areas
10
RESULTS ARE INSPECTION PRIORITIES
• Provide a Numerical Ranking Based on Risk Exposure

• Method Allows Adjusting of Weighting on Factors
to Meet Specific Concerns
Likelihood of Failure
0 1 2 3 4 5 6 7 8 9 10
10 10 20 30 40 50 60 70 80 90 100
Consequence of Failure
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
Asset Risk Index
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
11
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
12
LAWRENCE, KANSAS
• 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)
13
AVAILABLE
TECHNOLGIES
14
WHAT ARE YOUR OPTIONS

• 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
15
IN SERVICE TECHNOLOGIES
• Indirect Testing Methods
• Leak Detection with Closed Circuit TV
• Electromagnetic (pipeline pig)
• Broadband Electromagnetic
• Ultrasonic Testing
• Magnetic Flux Leakage
• Coupon Analysis
16 16
INDIRECT CORROSION ASSESSMENT

• 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
17

• Assessment Included
• In-Situ Soil Resistivity Using Wenner 4-Pin Method
CURRENT ELECTRODE POTENTIAL ELECTRODES CURRENT ELECTRODE
18
IN-SITU SOIL RESISTIVITY MEASUREMENT PIPELINE LOCATION MARKING
DC CELL TO CELL SURVEY PIPELINE LOCATER 19

LEAK DETECTION - CORRELATORS

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
20
IN THE PIPE – JD-7, SAHARA, SMART BALL

• Free Swimming or
Tethered
• Data Collected Real Time
or Analyzed Later
• Range Varies with System
21
CCTV & LEAK DETECTION:

WITH PIPE IN SERVICE
• 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
22
ELECTROMAGNETICS
REMOTE FIELD EDDY CURRENT - METALLIC
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
23
LAUNCH TUBE AND TOOL READY FOR

INSERTION
ISP INSPECTION IN 2013
RAYMORE, MISSOURI ISP INSPECTION IN 2013

24
REMOTE FIELD EDDY CURRENT –

CONCRETE PCCP
1 2 3 4
25
BROADBAND ELECTROMAGNETIC (BEM)

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
26
ULTRASONIC GUIDED WAVE, A- & B-SCAN

(METALLIC PIPE)
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
27
GUIDED WAVE TESTING (GWT)

• 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).
28
BENEFITS OF GUIDED WAVE TESTING

• 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
29
Location of Transducer Tool
ULTRASONIC – CONCRETE PIPE

• Able to Detect • Impact Echo
Delamination from • Slab Impulse Response
Rebar Corrosion
• Spectral Analysis of
• Identify Cracks in Surface Waves
Mortar
• More Accurate than
Manual Sounding
30
GLENDALE ARIZONA
• SIR Tested 9 locations
• IE Tested 40 locations
• Mortar Coating Could
be Easily Scored to
Shallow Depth
TYPICAL IE TESTING
Avg Frequency Spectrum, T = 4.36 in V = 144000 in/sec

0.00015
0.0001
in
5e-005
0
0 10000 20000 30000 40000 50000 60000 70000 80000 90000 100000
Frequency (Hz)
TYPICAL IE TEST DATA TYPICAL TESTING GRID

31
POSSIBLE DELAMINATION DETECTED

• SIR Tested 27
Locations
• Portion of Steel Joint
Ring Exposed
16-INCH AERDS PIPELINE - SITE 3
POSSIBLE DELAMINATION LOCATION CORROSION AT JOINT

32
MISSING MORTAR AND CORROSION ON

JOINT RING
33
SIR RESULTS
• Sound Location
• Questionable
Location
• Delamination
Location
34
MAGNETIC FLUX LEAKAGE – METALLIC PIPE

• 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
35
MFL
36
COUPON ANALYSIS
• Requires Excavation and Hot Tap on Pipe

• Results Requires Engineering Evaluation
• Size of Tap Impacts Analysis
37
PLASTIC PIPE - PVC AND HDPE

• Failures Occur
• Installation is Critical
• No Non-Destructive
Testing
38
PIPELINE OUT OF SERVICE

VISUAL INSPECTION MAN ENTRY
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
39
ROBOTIC CRAWLERS WITH CCTV, EDDY

CURRENT
40
EMERGING TECHNOLOGIES
41
INLINE ENHANCED EM PIPE ASSESSMENT
• Enhanced Electromagnetics
• Similar to PCCP Assessment
Technology
• Provides Data on Wall Loss
for Metallic Pipe
42
BEST PRACTICES
43
THE CONDITION OF CONDITION

ASSESSMENTACCORDING TO THE EPA
• 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 44
BEST PRACTICES
• 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
45
JUST DROPPED IN TO SEE WHAT CONDITION

MY CONDITION WAS IN (KENNY ROGERS AND THE FIRST EDITION, 1968)
• 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, 46

RIGHT material
Questions
Bryon Livingston, P.E.
Black & Veatch
8400 Ward Parkway
Kansas City, MO 64114
913-458-3368
livingstonb@bv.com
CLOSED CIRCUIT TV REMOTE

OPERATED VEHICLE
ADVANTAGES
• Inspection takes place
while pipe in service
(Intakes, Tunnels)
• CCTV HD Video Image Courtesy of Hibbard Inshore
• 2- D and 3-D sonar

• No manned entry
LIMITATIONS
• Low flow velocity
required < 1 ft/s
• Range < 10,000 ft
48

Implementing Condition Assessment Knowing Which Technologies To Use For Pressure Pipelines by Bryon Livingston

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IMPLEMENTING CONDITION ASSESSMENT:

KNOWING WHICH TECHNOLOGIES TO USE

FOR PRESSURE PIPELINES

ACCORDING TO THE EPA, CONDITION

The collection of data

How much data needs to be collected? 4

MANY FACTORS IMPACT LIFE OF A PIPE –

Bedding Condition and Material

PHYSICAL FACTORS FOR LIKELIHOOD OF

FACTORS FOR CONSEQUENCE OF FAILURE

RESULTS ARE INSPECTION PRIORITIES

• Provide a Numerical Ranking Based on Risk Exposure

• Over 7,760 Miles of Pipe

• About 12.6 miles of

WHAT ARE YOUR OPTIONS

INDIRECT CORROSION ASSESSMENT

INDIRECT CORROSION ASSESSMENT

CURRENT ELECTRODE POTENTIAL ELECTRODES CURRENT ELECTRODE

INDIRECT CORROSION ASSESSMENT

IN-SITU SOIL RESISTIVITY MEASUREMENT PIPELINE LOCATION MARKING

DC CELL TO CELL SURVEY PIPELINE LOCATER 19

LEAK DETECTION - CORRELATORS

IN THE PIPE – JD-7, SAHARA, SMART BALL

CCTV & LEAK DETECTION:

LAUNCH TUBE AND TOOL READY FOR

ISP INSPECTION IN 2013

RAYMORE, MISSOURI ISP INSPECTION IN 2013

REMOTE FIELD EDDY CURRENT –

BROADBAND ELECTROMAGNETIC (BEM)

ULTRASONIC GUIDED WAVE, A- & B-SCAN

GUIDED WAVE TESTING (GWT)

BENEFITS OF GUIDED WAVE TESTING

ULTRASONIC – CONCRETE PIPE

Avg Frequency Spectrum, T = 4.36 in V = 144000 in/sec

TYPICAL IE TEST DATA TYPICAL TESTING GRID

POSSIBLE DELAMINATION DETECTED

16-INCH AERDS PIPELINE - SITE 3

POSSIBLE DELAMINATION LOCATION CORROSION AT JOINT

MISSING MORTAR AND CORROSION ON

MAGNETIC FLUX LEAKAGE – METALLIC PIPE

• Requires Excavation and Hot Tap on Pipe

PLASTIC PIPE - PVC AND HDPE

PIPELINE OUT OF SERVICE

ROBOTIC CRAWLERS WITH CCTV, EDDY

INLINE ENHANCED EM PIPE ASSESSMENT

THE CONDITION OF CONDITION

• Empowers Utility to act as Steward of

R3 = Replace RIGHT pipe, RIGHT time,

JUST DROPPED IN TO SEE WHAT CONDITION

R3 = Replace RIGHT pipe, RIGHT time, 46

CLOSED CIRCUIT TV REMOTE

• 2- D and 3-D sonar

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