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Latest Inspection Technologies
for Pipelines
Hiromitsu Saito
Japan Cooperation Center, Petroleum
(JCCP)
http://www.cosmo-oil.co.jp
2
1.Crude Oil Pipeline Corrosion
in Refineries and Oil Depots
1-1 Self propelled SLOFEC
1-2 Self propelled Multi UT
1-3 Manual UT
1-4 TOFD UT
1-5 Long range UT
00.5
11.5
22.5
33.5
44.5
0 10 20 30 40
Max.
Corr
osi
n D
epth(m
m)
Duration of Service(Year)
Max. Corrosion Depth of Crude Oil Pipeline
( Report in 2004 )
Refineries & Oil Depots
National Oil Stockpiling Base
Slop Line etc.
Ref. ARef. B
Dep.D
Dep.CDep.E
Dep.A
Dep.F Dep.G Dep.I
Dep.B
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2. Pipeline Inspection Technologies
from the outer surface
2-1 Self propelled SLOFEC
2-2 Self propelled Multi UT
2-3 TOFD UT
2-4 Long range UT
2-5 Application for Pipelines
http://www.cosmo-oil.co.jp
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2-1 Self propelled SLOFEC
2-1-1 The Principle of SLOFEC
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2-1-2 Distinction of Defects
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2-1-3 Self propelled Manipulator
SLOFEC Manipulator
The SLOFEC manipulator
that reflects the field check.
http://www.cosmo-oil.co.jp
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2-2 Self propelled Multi UT
Multi UT Manipulator
The Multi UT manipulator
that reflects the field check.
http://www.cosmo-oil.co.jp
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2-3 TOFD UT
The Principle of TOFD UT
Definition of The Flaw Size measuring
Time of Flight Diffraction for each Wave
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2-4 Long range UT
Applying to Tank annular plate corrosion
Applying to Pipeline corrosion under the patched plate
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2-5 Application for Pipelines
2-5-1 Self propelled SLOFEC
Detection and screening for corrosion
SLOFEC - Saturation Low Frequency Eddy Current -
Whole area of the pipeline etc.
Fast inspection characteristic
- Measuring by SLOFEC Probes mounted
on Manipulator -
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2-5-2 Self propelled Multi UT
Detail inspection for corrosion
Multi UT
- Measuring by Ultrasonic Probes mounted
on Manipulator -
Bottom of the pipeline
Accurate measurement characteristic
http://www.cosmo-oil.co.jp
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2-5-3 Manual UT
Detail inspection for corrosion by hand
Manual UT
-Measuring by a Hand using Ultrasonic Probe -
・Area where self –propelled inspection techniques are
difficult to implement
・Area where required for check after rough inspection
Accurate measurement characteristic
http://www.cosmo-oil.co.jp
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2-5-4 TOFD UT
Inspection for defects in the material
TOFD UT -Time of Flight Diffraction -
Bottom part of circumferential weld inside from
the outer surface
Accurate detection characteristic
- Measuring by a couple of Ultrasonic Probes
http://www.cosmo-oil.co.jp
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1-5 112-5-5 Long range UT Range UT
Inspection for corrosion in a remote area or covered area
Long Range UT
-Measuring by a low frequency Ultrasonic Probe -
Area under patched plate of piping support
system from the outer surface
Far propagation characteristic
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2-5-6 Complete Inspection
http://www.cosmo-oil.co.jp
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2-5-6 Complete Inspection
http://www.cosmo-oil.co.jp
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3. Pipeline Inspection Technologies
from the inner surface
3-1 Visual Inspection System inside of
Pipelines
3-2 Magnetic Flux Leakage
Intelligent Pig Inspection System
3-3 Ultrasonic Wave Testing
Intelligent Pig Inspection System
http://www.cosmo-oil.co.jp
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3-1 Visual Inspection System inside of
Pipelines
1.Evaluation of Safety
for the Inside Pipeline
2.Pig Washing(special
solvent) & Gas free
3.Visual Inspection for
the Inside Pipeline by
Electric Vehicle
4.Data Collection and
Report
Visual Inspection inside Pipe
by Electric Vehicle
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3-1-1 Inspection Work inside of the
Pipeline
※ Work : 2 Team × 2 Shift
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3-1-2 Inspection Report
0
100
200
300
400
500
2.5~2.9
3.0~3.4
3.5~3.9
4.0~4.4
4.5~4.9
5.0~5.4
5.5~5.9
6.0~
Depth (mm)
Nos.
No. Bead No. Distance from Location Depth Longitudinal Circumferential
Bead (mm) (hr) (mm) (mm) (mm)1 382 890 5 2.5 10φ2 960 5 2.5 10φ3 3300 6 3.0 20 504 4150 6 2.8 20φ5 4770 6 2.5 20φ6 381 0 3~9 0.5-1.0 3~97 120 5 3.0 30 108 1700 7 2.5 170 709 2000 7.5 2.5 20φ
10 2200 7.5 3.0 10φ11 2300 5 2.5 20φ12 2400 7 2.5 20φ13 2450 7.5 3.0 20φ14 2600 6 2.5-3.0 150 50015 380 0 3~6 1.0 3~616 3730 6 3.0 10φ17 379 0 5 1.0-2.0 100φ18 270 6 2.5 30 2019 3100 6 3.0 20φ20 3260 7 2.5 10φ21 3770 5 2.8 10φ22 4010 4.5 2.9 10φ23 4880 6 2.5 10φ24 5250 6 2.9 10φ
Visual Inspection Report
Statistics
Field Photo
Field data
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・Magnetic flux leakage from corroded parts by generating magnetic flux of axial direction is detected by sensor and is measured after magnetizing pipe loc- ally using magnetizing unit equipped with pig
3-2 Magnetic Flux Leakage
Intelligent Pig Inspection System
Defect Magnetic Circuit
Measurement Principle
Pipe
Wall Brush
Sensor
Magnet
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3-2-1 Inspection Report
http://www.cosmo-oil.co.jp
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3-3 UT Intelligent Pig Inspection System
・Pipe thickness and deformation etc. will be measured by ultrasonic probes mounted on pig circumferentially.
http://www.cosmo-oil.co.jp
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3-3-1 Inspection Report
http://www.cosmo-oil.co.jp
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3-4 Comparison of Inspection Method
(1) Visual Inspection Magnetic Flux
Leakage (MFL)
Ultrasonic Wave
Testing (UT)
1.Measurement
Principle
2.Applied Condition
1)Size 26”~56”
(Experience)
5”~50” 6”~56”
2)Length 11km(Experience) ~250km ~250km
3)Passing Capability 1.5D(90°Elbow) 1.5D(90°Elbow) 1.5D(90°Elbow)
4)Two Way Capability No Limitation Not Applicable Not Applicable
5)Degree of
Deformation flatness
No Limitation Pipe Dia ±10% Pipe Dia ±10%
6)Applicable Fluid Gas Free Liquid, Gas Liquid only
7)Running Speed 600~3000m/d 0.5~4m/s 0.8~5m/s
Defect Magnetic Circuit
Measurement Principle
Pipe
Wall Brush
Sensor
Magnet
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3-4 Comparison of Inspection Method (2)
Visual Inspection Magnetic Flux
Leakage (MFL)
Ultrasonic Wave
Testing (UT)
3.Pretreatment
1) Cleaning Possible to enter
into pipe
Rough compared to
UT
Clean compared to
MFL
2) Internal
Confirmation
Cleaning
Condition
Gauge Profile Pig Gauge Profile Pig
4.Inspection Accuracy
1)Detection site ( Inner
Surface and Outer
Surface )
Inner Surface only Inner and outer
Surface
Inner and outer
Surface
2)Corrosion Detection
at Welding Part
Available Available Difficult
3)Corrosion Detection
at Elbow
Available Available Available with
Condition
4)Limit of Detection
Depth
1.0mm 0.2 ×thickness 2mm
http://www.cosmo-oil.co.jp
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3-4 Comparison of Inspection Method (3)
Visual Inspection Magnetic Flux
Leakage (MFL)
Ultrasonic Wave
Testing (UT)
5)Detectable Size 5.0mm (0.4t)× (0.4t) or
7mm×7mm
10mmφ
6)Measurement
Accuracy (Depth)
±0.5mm ±0.1 ×thickness ± 0.5mm
(Location) ±0.1m ±0.2m ±0.2m
5.Inspection Report On-line Reporting Prompt Report only
for Serious Defect
Prompt Report only
for Serious Defect
Analysis Anytime during
Inspection
Approx 40 Days Approx 40 Days
6.Relative
Inspection Cost
100 150 200
http://www.cosmo-oil.co.jp
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Selection of Inspection Method for Pipelines
・ Inspection Cost ・ Downtime of Operation ・ Capability of Repair Work ・ Other conditions
Selection of Inspection Method
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Selection of Inspection Method
Inspection Work
Execution
Evaluation of Inspection Result & Condition
Long term Planning
PLAN
DO
SEE
ACTION
Selection of Inspection Method for Pipelines
http://www.cosmo-oil.co.jp
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The End of Slides
Thank you for your attention
Japan Corporation Center Petroleum (JCCP)