Pigging In OIL INDUSTRY
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This document provides an overview of intelligent pigging and the intelligent pigging survey of a 14-inch crude oil pipeline from Barauni Pump Station to Pump Station 5 that is 756 km long. Intelligent pigging uses specially designed tools called "pigs" to inspect and clean pipelines without stopping flow. The document discusses the types of pigs used for different pipeline activities like construction, maintenance, and operation. It also summarizes the goals and activities of the survey conducted by Rosen Europe B.V. on the 14-inch pipeline, including using a corrosion detection pig (CDP) to detect metal loss and pipe wall defects.
Pigging In OIL INDUSTRY
- 1. INTELLEGENT PIGGING I. P. Survey of 14’’ Crude Oil Pipeline (756 Kms) from PS5 to BPS
- 2. Pipeline Overview 16” line 14” line
- 3. Pipeline System • Duliajan-Guwahati, 16"dia : 401 Km • Guwahati-Barauni, 14" Dia : 756 Km Total, M/Line = 1157 Km • Duliajan-Digboi, 8"dia : 35 Km • Badulipar-Numaligarh, 16" Dia : 13.5 Km • Numaligarh-Siliguri, 16" Dia : 600 Km (Under Construction)
- 4. Pipeline System • Injecting Pump Station : 4 Nos. • Booster Pump Station : 6 Nos. • Terminal Station : 4 Nos. • Repeater Station : 17 Nos. • Maintenance Base : 3 Nos. • Pumping Units : 51 Nos. • Generating Units : 21 Nos. • Gen. Sets at Repeater : 45 Nos.
- 5. What is pigging ? Pigging can be defined as running a specially designed tool in a pipeline to get a better performance of the pipeline in a way that can not be achieved in any other way. Why pig pipelines ? A better performance for pipelines means : * Lower installation cost * Lower energy requirement for moving the product * Lower maintenance cost * More efficient separation of product batches * Longer pipeline lifetime The following are the various areas (stages) in which pigging can be considered : CONSTRUCTION : * Removal of construction debris (Soil, sand and mill scale in gas line feeding to power plants.) * Test water filling and removal (Air pocket at high points) * Drying of the pipelines before commissioning. (Swab pig, industrial alcohol drying)
- 6. COMMISSIONING : * Introduction of pipeline products leading up to the process point. MAINTENANCE : * Pipeline cleaning (removal of aggressive debris from product so that corrosion is minimized. * Pipeline Inspection. OPERATION : * Pipeline cleaning (removal of obstruction debris for maintaining designed flow area, wax) * Paraffin, asphaltenes, liquid built-up in gasline. * Batch pumping of different products. REPARING : * Product evacuation and re-introduction. CONSTRUCTION : * Product evacuation
- 7. The types of defects that threatens the pipeline’s integrity : > Corrosion at the internal pipe wall surface * Wet sour medium (H2S) attack * CO2 attack * Bacterial attack * Salt water > Corrosion at the external pipe wall surface * Incidental coating damage during construction * Incorrect pipeline coating material * Incorrect pipeline coating application > Cracks on the inside pipeline surface * SCC (Stress Corrosion Cracking) > Inside pipe wall defect due to manufacturing faults * Lamination * Inclusion > Weld defects * Cracks in the weld * Cracks in heat affected zone * Improper welding > Mechanical damage to the pipe wall * Gouge * Dents * Buckles * Wrinkles * Ovality
- 8. Pipeline Cleaning Tools And Accessories Pipelines - no matter what they transport, should have clean inner surface. A clean inner surface insures good operating conditions resulting efficient pipelines with lower operating cost. Types of Cleaning Tools : Disc Type – The disc type tool is ideal for dewatering, batching applications, commissioning and for general cleaning activities. Standard configurations have bi-directional capability and high cleaning performance. Cup Type – It moves uni-directional. This tool type is recommended to be one of the first tools in the cleaning program, specially in cases where pipeline has not been cleaned for a long period. These Rosen cleaning tools can be fitted with transmitters to ensure tool tracking, if needed. Pig Accessories – Brush (Metallic) , Magnets, Transmitters, Sealing Disc, Gauging plate etc.
- 9. WHY IPS ? • It is said that the strength of a chain is equal to its weakest link. • To minimize the risk of operating a petroleum pipeline, it is required to have a detailed knowledge about the structural integrity, the information about the pipe wall condition. • Only a few meters of the pipeline is visible & can be inspected from outside. • IPS (Intelligent Pigging Survey) tool is a NDT tool, designed to check the health and integrity of a pipeline to enhance the safety & efficiency of a pipeline. • CDP is a kind of IPS tool to detect & size the metal loss features of a pipeline.
- 10. Cleaning before Inspection Important - Why ? A clean inner pipe surface is a pre condition for high quality in-line inspection results. Inefficient cleaning may affects inspection survey performance - b) Mechanical failure of the CDP. E.g. Jamming odometer wheels c) Lift off of the magnetizing Brushes, Loss of magnetic strength. d) Lift off of the sensors, limiting detection with magnetic flux leakage. e) Accumulation of metallic debris disturbing the sensors.
- 11. PIGGABLE A pipeline system consist of two parts: OD(mm) 355.6 355.6 355.6 2. Pipeline 3. Pig Traps Thickness OIL’s pipeline has variable 7.92 9.52 11.91 (mm) ID due to three thickness with constant OD. It requires cleaning/guiding discs of ID(mm) 339.76 336.56 331.76 different diameter.
- 12. PIGGING TRAPS • The ROSEN designs compact MFL tools for specific projects to work with the existing traps. The length of the tool depends on the diameter of the pipeline to accommodate the components. The size reduces with the increase in the diameter of the pipeline. • Receiving Trap strainer may have to be removed before receiving the CDP to avoid damage of the sophisticated sensors. • Trap design is important for arresting debris/wax and to regulate the pig pushing force. • Launching Trap should accommodate the pig in such a way that pressure equalization can be done properly to avoid accidental collision of the pig with the gate valve.
- 13. INTELLIGENT PIGGING SURVEY OF 14” PIPELINE FROM BARAUNI PS TO PS5 TYPE OF INSPECTION : Corrosion Detection pigging based on magnetic flux leakage method NUMBER OF SECTION : 15 no, Average Length of 50km each TOTAL LENGTH : 756 Km from BPS to PS5 PROJECT CONTRACTOR: Rosen Europe B.V.,The Netherlands. PERIOD OF OUR VISIT : 19.06.2007 to 26.06.2007 PROJECT MANAGER : Jeroen Dirven
- 14. At Oldenzaal,The Netherlands During the visit to Rosen Europe B.V. at Netherlands, we covered the following areas by way of presentations, plant & facility visits and by open discussion with the project manager & software engineer at Oldenzaal. • Introductory presentation about the company and it’s activities. • Latest technology adopted for in-line inspection and pipeline integrity management. • Presentation on CDP and it’s components, benefits and limitations. • Visit to the workshop, carrying out repairing and maintenance jobs on various types of in-line inspection tools received from fields. • Visit to storage facilities, pig storage and spare parts storage area. • Presentation on Rosoft software used for handling database collected from in-line inspection. • Discussion and question-answer session.
- 15. Rosen Training & Research Center (RTRC), Germany • Repeat presentation about the company. • Presentation on different types of in-line inspection tools and its accessories. • Visit to Production Line; Manufacturing Units (Metallic parts). • Visit to Polyurethane and Plastic component Manufacturing Units. • Visit to full scale test facility area and simulation of Pull-through test with CDP. • Visit to data storage device section meant for testing and preparing the devices for in-line inspection tools • Visit to equipment testing lab & facility section for tool calibration. • Visit to electronic component & circuit board designing , testing and developing section of the company. • Visit to see the CDP and actual accessories and components to be used in IP survey of OIL pipeline. • Visit to data analysis and interpretation section
- 16. SPIDER NOSE PIG : To clean the forehead of the pig during pigging, to reduce the back pressure. The spider nose creates turbulence and avoids accumulation of debris and wax in front of the tool.
- 17. DESCALING PIG: - used to clean the hard scale from inner surface of the pipe wall.
- 18. PIG YARD Bi-Di high performance cleaning pigs
- 19. In-line Metal loss Inspection CDP (Corrosion Detection Pig) • The basic element of the metal loss survey is the high-resolution Magnetic Flux Leakage (MFL) technology. • The pipe wall is magnetized axially to saturation level using the very latest permanent magnets. • High magnetization levels are necessary to differentiate corrosion from other pipeline features such as hard spots, stress and strain variations and to minimize the effects of permanent magnetization and velocity. • In a pipeline with no flaws, the magnetic flux travels undisturbed through the walls. • Internal and external metal loss due to corrosion that turns steel into non-ferromagnetic iron oxide and magnetic flux “leaks” out of the pipeline and is recorded by its sensors. • Mechanical damage can be detected because the magnetic properties of steel are changed locally due to plastic deformation. • High magnetization levels of >10 kA/m ensure the validity of the results.
- 20. MFL Inspection Tool (CDP) The CDP is a high-resolution MFL inspection tool utilizing longitudinal pipe magnetization, and it is optimized to detect and accurately measure pipeline anomalies such as corrosion, gouging, construction features, pipe mill defects and others.
- 23. PARTS OF CDP Magnet Unit: To achieve the required magnetization level in both straight pipes with varying thickness and bends – the tool is equipped with multiple spring supported permanent magnet units mounted on the central body. Sensor Unit: Spring loaded sensor units prevent vibration and maintains the parallel guiding along the pipe wall in bends and internal diameter changes etc. Field sensors (25x8=200 nos) measure the actual magnetic field strength in the pipe wall and the flux leakage at the anomalies. Odometer Unit: Odometer wheels measure the distance covered during an inspection. It has various applications: – To derive the location of anomalies and pipeline features – To evaluate the dynamic performance of the MFL tool Computer Unit: The on-board computer is used to process and store all recorded pipeline data as well as the speed and the acceleration of the tool. It can withstand temperature up to 65 degree C.
- 24. CDP Tool Components Magnetic Unit Odometer Sensor Power supply Unit Computer and data recorder Unit On/Off Switch Universal Joint
- 25. Pipeline Data Logger (PDL) Rosen’s pipeline Data Logger can record data for pipelines up to 500 km or pig runs of more than 30 days. Key Benefits : • Bolts onto any cleaning tool. • Fast-response sensors recording high- resolution data. • Supplied with user-friendly operational and graphic software. Time-Based Recorded Profiles : • Temperature profile. • Absolute and deferential pressure profile. • Three axis acceleration profile (also providing for inclination and rotation of the pig).
- 26. ITX Transmitter ITX transmitters are new generation of Rosen pig transmitters having compact design with higher signal range (up to 23 meters), longer operating time (more than 500 Hrs) and improved handling and safety features. Key Benefits : • Easy replacement of batteries. • On/Off switch without dynamic seal. • Max. pressure 200 bar. On/Off Switch • Max. operating temperature 85 ºC. • Bolts onto any cleaning and ILI tool. • Operating time up to 500 Hrs. • Signal Range up to 23 mts. • Applicable in all media due to stainless steel housing. ITX Transmitters
- 27. Above Ground Marker – BM6 Benchmarker System
- 28. Above Ground Marker – BM5 (CDP) Benchmarker Systems
- 29. Marker Magnet 20×10×5 cm3 Wt. = 2 Kg Benchmarker System
- 30. Picture 18 High Quality Inspections High Level low Level
- 31. High Quality Inspections Importance of high magnetization level Identical Anomalies seen at different magnetization levels 18.2 KA/m Magnetization 7.6 KA/m Magnetization
- 32. Pull-Through Test (simulation run of CDP) At RTRC, Germany, Pull-Through test area was shown to us having facilities to carry out simulation runs for in-line inspection tools on the test pieces having length of 30 meter and diameter from 8” to 56”. We also observed a test piece of 30 meter length, vertically standing to carry out simulation test on straight vertical pipeline. All these test pieces were having a predefined artificially created defects to carry out calibration on in-line inspection tools for certification. In our presence, a sample simulation run was carried out with a 12” CDP tool on a 30 m pipeline test piece to show the calibration process. After this test we were taken to calibration and certification section and were shown the process of data downloading. It was informed that all in-line inspection tools are calibrated and certified at this centre before sending to the working site.
- 33. Rosoft Data Management For In-line Inspection of a Pipeline This pipeline based software suit consists of the following components : 1.1 Rosoft for pipelines – It gives digital information on all the data recorded during the survey and on all the reported results of the inspected pipeline. 1.1.1 Rosoft maps – Rosoft map publishes the pipeline trajectory, characteristics and height profile to perform location based analysis. 1.1.2 Rosoft 3D pipe – It presents a 3 – dimensional virtual view of the pipeline including features, locations and characteristic. 1.2 Rosoft Risk Management – It identifies pipe sections most at risk using assessment criteria to develop integration and control measures to minimize susceptibility from active threats. 1.3 Administration – It assists installing, removing and managing pipeline data. 1.3.1 Line Manager – The line manager is a task which assist installing, selecting and removing pipeline data. 1.3.2 Backup Manager – The backup manager provides an integrated backup and restore system along with the ability to store intermediate results 1.3.3 Security – It administrates different user right levels of Rosoft users. 1.4 Data services (ETL) – ETL module is used to extract, transform and upload Rosoft data to SPDW (Standardized Pipeline Data Warehouse).
- 34. Other In-line Inspection Tools Extended Geometry Tool (RoGeo-Xt) – RoGeo-Xt tool is based on an innovative hybrid concept. It combines a traditional mechanical caliper arm with an electronic distance measurement system thereby optimizing measurement accuracy and –providing 100 % circumferential coverage. It consists of two sensor units which are connected to each other : a touch less sensor is integrated inside the sensor head and a position sensor monitoring the mechanical position of mthe sensor arm attached at the bottom. Since the non-contact electronic sensor compliments data obtained from caliper arm so even sharp transition on the internal surface is recorded accurately. Axial Flaw Detection Tool (AFD) – The AFD tool also uses high resolution MFL technology and induces a magnetic field perpendicular to the pipeline’s longitudinal axis. On the basis of disturbances in magnetic field, seam welds, their position in circumferential direction and seam weld flaws can be accurately detected.
- 35. EMAT Crack Detection & Coating Disbondment Tool - This tool is based on an electromagnetic-acoustic conversion resulting from the application of an eddy current within a static magnetic field. The Lorentz force and Magnetostriction generated thereby lead to an interaction between the EMAT tool and the metal surface. This interaction in turn produces an acoustic wave within the material. Crack features such as stress corrosion cracking and other individual cracks like fatigue cracks disturbs the guided waves and produce echo. On the basis of the detection and measurement of the echo, the features and condition of the pipe wall can be accurately inferred. Robotic Pipe Scanner (RPS) – The basic principle of RPS metal loss survey is also based on High resolution MFL method. The semi-automatic mechanism of RPS system is able to clear and bypass pipeline supports and it is useful where traditional methods (ILI) cannot be used.
- 36. Automatic Coiled Tubing Integrity Monitoring (ACIM) – The failure of on/off shore coiled tubing are significant in terms of non-availability of services and operational losses (financial). The Rosen ACIM tool detects critical defects (metal loss, corrosion) using MFL technology. It performs real- time measurements of the coiled tubing condition and the measured data and report can be read and analyzed with the Rosen software. Based on these results, an operator can take appropriate corrective action in time to avoid unwarranted failure of the tubing. Electronic Geometry Tool (EGP) – It has a fully computerized measuring system designed to inspect the internal geometry of the pipelines ( such as bends, ovalities, dents etc.) and to locate hidden third party damage to confirm a free passage for any other tool. All possible obstructions are indicated, located and sized by this tool in most cost effective way. The unique touch less measuring system of EGP ensures a full circumferential coverage of the pipe wall due to overlapping sensors and allows bi-directional operation of the equipment. The measurement principle is based on multi-channel eddy current technology.
- 37. XYZ Mapping Tool – XYZ mapping is a new service in range of Rosen inspection activities. It has been developed for identification of 3- dimensional geographical pipeline coordinates by an inertial navigation unit which is a combination of accelerometer and gyroscope. MFL sensors and geometry measurement system with touchless eddy current technology are also incorporated for the detection geometrical anomalies and accurate weld detection Tank Bottom Inspection Tool (TBIT) – Rosens Tank Bottom inspection tool forms an essential part of tank integrity and risk management as required by the new government standards. It is a self contained battery operated unit requiring no cable for inspection of tank bottom plate by using MFL floor scanners.It has a very high inspection capacity, short inspection period and can inspect both lined and coated bottom floors.
- 38. Rosen Combo ILI Technology Tools Units available for combination : Possible Combinations with CDP as central body : Speed Control Unit XYZ Mapping Unit CDP Extended Geometry incl. XYZ Mapping CDP CDP CDP CDP Other tool combinations : High-resolution Geometry Unit (XGP) (including XYZ Mapping) in combination with different high resolution metal loss inspection tools are – > Axial Flaw Detection (AFD) + XGP (incl. XYZ) > Corrosion Detection (CDP) + XGP (incl. XYZ) > XGP (incl. XYZ)