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THE TECHNOLOGIES OF FUTURETHE TECHNOLOGIES OF FUTURE
UNIQUEUNIQUE METHOD OF METHOD OF THE CONTACTLESS THE CONTACTLESS
PIPELINES PIPELINES INSPECTION INSPECTION
IN YOUR HANDS TODAYIN YOUR HANDS TODAY
Address: Ligovsky pr., 254, St. Petersburg, Russia, 196084E‐mail: [email protected]: http://www.polyinform.com
Tel.: (+7‐812) 458‐ 85‐73Tel.: (+7‐812) 458‐85‐74Fax: (+7‐812) 485‐85‐76
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SINCE 1989 ON THE MARKET
"Halliburton " (USA); "Total Fina Elf" (France); "Mahrukat" (Syria); USAID (USA); Unilever
SNG (Great Britain); NKK Corporation (Japan); "Lukoil" Oil Company; "Transneft" Corp;
"Lukoil" Co. Ltd; "Diamonds of Ruissia‐Sakha" Co. Ltd; "TNK‐BP" Corp; "Moscow Oil Refinery"
Corp; "Rosneft" Corp; Russian Open Society "United Power Systems of Russia"; "Jukos" Inc;
JSC "Russian Railways"; Ministry of Defense of the Russian Federation; Ministry of the
Natural Resources.
OUR CUSTOMERS :
7 doctors of sciences
Up to 200 professional employees
Own scientific and industrial equipment
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POLYINFORM MAIN ACTIVITY
Providing environmental safety
Expertise of industrial safety
Industrial construction
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Industrial safety expertise
Contactless magnetometric defectoscopy
Electometry
Visual inspection control
Ultrasonic thickness and hardness measurement
Ultrasonic defectoscopy
POLYINFORM MAIN ACTIVITY
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PROBLEMPipelines TEAR‐AND‐WEAR, operating for more than 20 years
Lots of the pipelines (about 30%) are IMPASSIBLE for in‐tube (traditional) inspection
Pipe's outburst at the corrosion place »
Removing the pigs stuck in the pipe »
Technical (visual) control of underwater pipelines »
NO ADEQUATE SOLUTION for inspection of underwater pipelines
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The principally new approach to pipelines technical inspection by contactless magnetometric diagnostic method using high‐tech system KMD‐01M
The contactless magnetometric diagnostic system KMD‐01M consists of:
SOLUTION
3-component magnetometers unit Data saving and visualization unit
Additionalequipment
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The systems work is based on the Villari effect (magneto‐elasticity effect ) which means the changing of the magnetic field form of a ferromagnetic when deformation.
The tree‐component vector sensors are used in the device as the primary transducers. The main principal of their work is based on the anisotropic magnetoresistive effect (AMR‐effect). AMR‐sensors has pure active resistance, low weight and low hysteresis
Each type of defect causes certain type of magnetic field anomaly, which allows classification of defects types: ‐ local corrosion‐ stressed‐deformed state‐ cracks zones‐ cracks‐like defects
PHYSICAL PRINCIPLES of KMD-01M OPERATING
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SENSE OF TECHNOLOGYThe principle of the contactless magnetometry requires applying high sensitive sensors, able to register magnetic field anomalies from the distance of pipelines' metal
The device is manufactured applying of 3‐component vector sensors (primary transducers of the magnetic field).
The main sensitive element of magnetic field sensors is magnetoresistor, made as the nanofilm on a silicon basement.
Magnetoresistive nanofilms provide high sensitivity of the device, speed, selectivity and noise immunity.
The system realizes method of gradientometry ‐ registration of the results of measuring of 3 components of the magnetic field in four points of space as well as their gradients (up to 30 parameters)
Nano-sensors key advantages:
• High magnetic sensitivity• Wide range of operating
frequencies• Low hysteresis• Low voltage bias• Low temperature drift• Low level of self-noise
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Discovering, localization and classification of defects is performed remotely by means of interpretation of constantly registered parameters of the magnetic field.
The signal received from the magnetic sensors is processed with the help of analog‐digital converter into the code, going to a computer.
The software allows processing of the received data and displaying it on the monitor in a real time.
Example of the different local defects magnetogram
SENSE OF TECHNOLOGY
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SCIENCE AND TECHNICAL FEASIBILITY AND APPROVING
New design, technological solutions and software developed for the diagnostic equipment are protected by patents
In 2010 the project received a positive conclusion of the Scientific‐Technical Council of State Corporation "Russian Corporation of Nanotechnologies", signed by three active members of the Russian Academy of Sciences
In 2011 the project has passed the technical expertise of 10 independent experts of the Skolkovo Found for receiving the status of the innovation project. The company became a participant of Skolkovo Found
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The system is certified by State Standard of Russia as a measuring tool. The inspection method and the system are patented in the State Register of the Useful Models of Russia (7 patents). The company processes the License on the activity on executing of expertise of industrial safety.
PATENT PROTECTION
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ADVANTAGES
REMOTE diagnostics of pipelines' state
STOPPING or CHANGING the mode of operating is NOT REQUIRED
ON‐LINE detecting of anomalies
HIGH EFFICIENCY (up to 20 km daily per 1 shift)
NO PREPARATION NEEDED
ACCURACY for the critical level defects up to 93 %
Creating DIGITAL MAP of the defects with GPS links and AUTOMATIC TRACING
Inspection of the IMPASSIBLE for in‐tube and contact defectoscopy methods AREAS
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SPECIFICATION OF KMD-01M
ValueParameter
From ‐ 35 °C up to + 55 °COperating temperature range
Up to 20 km daily per the shift (2 persons)Productivity
Enough for non‐stop writing of information about 500
km of pipelineMemory size
from 20 % of metal loss
(the pipes wall thickness)The definable defects
± 0,5mThe instrumental error of current coordinate
defining
from 159 mmThe diameters of inspected pipelines
Up to 10 pipes diameters depends on operating pressure
The distance between the magnetometers block and the pipeline
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OBJECT: field and gas gathering pipelines (ø159 - 600 mm) of Oil Company «Lukoil - West Siberia», 2010
Scope of work:inspection of pipelines via NDT (nondestructive testing) methods with the help of magnetometric system KMD-01M
OBJECT: main water pipeline and oil pipeline(ø 1220 mm andø1020 mm), OA "KazTransoil" (Kazakhstan), 2012
Scope of work:Diagnostics of pipelines with the system of magnetometric diagnostics system KMD-01M
EXPERIENCE
OBJECT: filed oil pipeline of TPP «Langepasneftegaz», (ø 159-420 мм), of Oil Company «Lukoil - West Siberia», 2011
Scope of work: Inspection of the pipeline with the system of magnetometric diagnostics system KMD-01M
OBJECT: field pipeline(diameter 273 mm) Oil Company «PetroChina»(China), 2012
Scope of work: Diagnostics of the pipeline with the help of magnetometric system KMD-01M
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EXPERIENCE The diagnostics using the system KMD‐01M was carried out on the pipelines of different types, destinations and level of readiness for operating:
OOO «Lukoil ‐West Siberia», Russia
‐ gas collecting pipeline TPP «Yamalneftegaz», ø 260‐400 mm
‐ field oil pipelines TPP «Kogalymneftegaz», «Pokachineftegaz», «Langepasneftegaz», «Urajneftegas» ‐ ø 159‐400 mm
OAO «Bashneft», Russia
‐ field pipeline, ø 159‐420 mm
OAO «Oil Company «Rosneft», Russia
‐ field pipeline «RN‐Uganskneftegas», ø 530 mm
OAO «GAZPROM», СУ «Lenorgenergogaz», Russia
‐ gas pumping stations ‐ КС «Rhevskaya», КС «Smolenskaya», КС «Volhovskaya», ø 1020 mm
«Saudi Aramco», Saudi Arabia
‐main pipeline, ø 31”
Oil Company «CNPC», China
‐main gas pipeline, ø 600 mm.
Oil Company «PetroChina», China
‐ field oil pipelines «Shi Xi Oil Field», ø 273 mm.
Oil Company «Sinopec», China
‐main oil pipeline, ø 426 mm
AO «KazMunayGaz», Kazakhstan
‐main gas pipeline «Middle Asia ‐ Center», ø 1220 mm
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I stage Collecting all necessary information and preparing the measuring equipment.
II stage Field inspection with KMD‐01M – magnetometric contactless measuring with the simultaneous data visualization. At the same time detecting of GPS ‐ coordinates is made. While working the received data can be transferred to the Data Processing Centre through Internet.
III stage The processing and interpretation of the received data is held. By the customers request the opening of the pipeline can be made with the NDT ‐ additional control by non‐destructive methods (measuring of thickness and hardness).
IV stage The analysis of the received information is executed, the digital maps of the discovered anomalies are designed and then the final objects technical condition conclusion is made.
THE TECHNIQUE OF PIPELINES COMPLEX DIAGNOSTICSThe complex diagnostics of oil & gas pipelines technical conditions is carried out in four stages:
KMD‐01M is certified by State Standard
of Russia
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METHODIC OF MEASURING WITH KMD-01M
Complex is operated by two operators: :
The first operator locates the pipeline with the pipeline finderas well as links the route with the GPS receiver to the reference points
The second operatormeasures the fluctuations of the constantmagnetic field with the magnetometers.
Based on the received data the areas of stress concentration due to the corrosion teat‐and‐wear, stressed‐deformed condition, pipelines geometry failure, and other defects are defined
While measuring the system automatically records the GPS‐geographical coordinates.
The processing and interpretation of the received data take place after the measuring.
The developed device successfully passed through industrial tests at the objects of OAO «Gazprom», OAO«Orgenergogaz», OAO «TNK‐Niagan», OAO «Lukoil», OOO «Basheft‐Diagnostica»,
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TYPES OF DEFINABLE DEFECTS:
Stress-deformed condition
Corrosion fatigue
Local damage (pitting, scuff, mechanical damages, etc)
Changing the pipelines geometry
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Inspection of the pipeline. Operators follows the slope of sand dune of the height more than 10 diameters of the pipe
Magnetogram of the pipelines part under the sand dune
STRESSED-DEFORMED STATE
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Open pit at the anomaly location
Digital map of super critical level anomalies caused by stressed‐deformed state of the pipe
STRESSED-DEFORMED STATE
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Magnetogram of stressed‐deformed state at the place of anomaly caused by soil pressure
Magnetogram of anomaly zone made after removing of soil pressure as the result of opening
STRESSED-DEFORMED STATE
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The super critical level anomaly caused by stressed‐deformed state (bend) of the pipeline due to the drift of sand
STRESSED-DEFORMED STATE
Open pit at the anomaly location
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Magnetograms of stressed‐deformed state at zone of anomaly, caused by drift of sand
STRESSED-DEFORMED STATE
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The digital map of supercritical level anomalies caused by local defects of pipeline
LOCAL DEFECTS OF PIPELINE
Open pit at the anomaly location
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The open pit at the place of anomaly with the marker put under the results of the contactless magnetometric diagnostics according to GPS device of KMD‐01M system.
The length of corrosion zone is 1,7 m
Magnetogram of anomaly caused by outer corrosion while no stressed‐deformed state
LOCAL DEFECTS OF PIPELINE
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The open pit at the place of anomaly. Local defects of the pipeline (outer pit corrosion) appeared as the result of penetration of high chemically aggressive ground water through the damages of pipeline's isolation.
The accuracy of corrosion centers detection with the help of KMD‐01M was 0.5 m
The loss of metal at anomaly zone ‐ 15 ‐ 22%
LOCAL DAMAGE OF PIPELINE
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Magnetograms of anomalies caused by mechanical damage of pipe
The open pit at the places of anomalies. The mechanical damage ("scuffs").
The loss of metal in anomaly zone – 12‐19%.
LOCAL DEFECTS OF PIPELINE
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Executing diagnostics on ski
INSPECTION UNDER WINTER CONDITIONS
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Using snowmobile for diagnostics of the field pipelineThe speed ‐ 20 km/h
INSPECTION UNDER WINTER CONDITIONS
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Executing of additional diagnostic control in the open pit The unauthorized insert discovered by KMD‐01M
INSPECTION UNDER WINTER CONDITIONS
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Magnetogram of the pipelines part located under the unauthorized logging road
STRESSED-DEFORMED STATE
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Magnetogram of the defect part of pipeline
Magnetogram of undamaged part of pipeline
TESTS FOR OAO "GAZPROMTRANSGAS"
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The not covered part of the oil pipeline with the stressed‐deformed state of supercritical level
Magnetogram of stressed‐deformed state caused by pipeline sagging at the open area
PILOT PROJECT FOR "PETROCHINA" OIL COMPANY
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KMD-01M system successfully passed through the arbitrage tests at the objects of ZAO "LUKOIL-West Siberia", OAO "Sibur neftehim", OOO «Bashneft-Dobycha» and PetroChina (China), and received positive expert conclusions from State Corporation "Rosnano" and "Skolkovo" Fund
REFERENCES
OUR SOLUTION FOR INDUSTRIAL SAFETY EXPERTISE
Address: Ligovsky pr., 254, St. Petersburg, Russia, 196084E‐mail: [email protected]: http://www.polyinform.com
Tel. +7(812) 458‐ 85‐73Tel. +7(812) 458‐85‐74Fax. +7(812) 485‐85‐76
