PIPE GRADE DETERMINATION AND MAOP VALIDATION
USING SOPHISTICATED SCRAPER TECHNOLOGY
Thomas Eiken, Werner Thale, Mohammed Jaarah
7th MENDT Conference Bahrain · 09/15/2015
Slide 2
CONTENT
1. Pipe Grade in the Context of PIM
2. RoMat PGS - Development of an ILI
Solution for Pipe Grade
Determination
3. RoMat PGS - Field Experience with
the Sophisticated Technology
4. RoMat PGS – The Data Evaluation
Process
5. Process of MAOP Reconfirmation
6. Key Benefits and Conclusion
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 3
0.0%
10.0%
20.0%
30.0%
40.0%
50.0%
60.0%
70.0%
80.0%
90.0%
100.0%
0.0%
5.0%
10.0%
15.0%
20.0%
25.0%
30.0%
Inst
alle
d b
y D
eca
de
Cu
mu
lati
ve (
red
lin
e)
Inst
alle
db
yD
eca
de
(blu
eco
lum
s)
Percentage of gas transmission pipeline mileage installed in
the USA [1]
Ageing pipelines:
• E.G. approx. 50% of all
pipelines installed
between 1950 and 1970
in the US..
PIPE GRADE IN CONTEXT OF PIM
1) J. F. Kiefner, M. J. Rosenfeld, The Role of Pipeline Age in Pipeline Safety, Final Report
No. 2012.03, INGAA Foundation, October 2012
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 4
PIPE GRADE IN CONTEXT OF PIM
• Effective integrity management requires holistically pipeline data.
• The pipe grade is a critical input for defining allowable operating pressure.
• Pipe grade is also needed for the accurate assessment of anomalies found
in pipelines.
• Pipe grade is uncertain for some pipelines due perhaps to changes in
ownership or the accidental destruction of records.
• Historical emergency repairs or diversions may have resulted in pipe of
unknown grade being introduced.
• The complete and accurate determination of pipe grade will allow effective
integrity management in line with industry best practice.
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 5
Resulting Diagnostic Challenges:
• Validated In Situ NDT delivers no holistic survey.
• Until now, no economic, holistic method to measure yield strength of an
entire pipeline section has been available.
• Holistically inline inspection solutions are needed for decoding the pipeline
design of pipeline sections with insufficient records to reconfirm MAOP/MOP.
PIPE GRADE IN CONTEXT OF PIM
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 6
Proportional limit stress
Yield Strength (YS)
Fracture
(Ultimate Strain)
Ultimate Tensile
Stress (UTS)
xx x
Barlow Equation
MAOP: Maximum Allowable Operating Pressure
t: Nominal Wall Thickness
PY: Specified Minimum Yield Strength (SMYS)
D: Outer Pipe Diameter
SF: Safety Factor
Including according to ASME B 31.8 :
- Design Factor
- Joint Factor
- Temperature Derating
Factor
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
PIPE GRADE IN CONTEXT OF PIM
Slide 7
CONTENT
1. Pipe Grade in the Context of PIM
2. RoMat PGS - Development of an
ILI Solution for Pipe Grade
Determination
3. RoMat PGS - Field Experience with
the Sophisticated Technology
4. RoMat PGS – The Data Evaluation
Process
5. Process of MAOP Reconfirmation
6. Key Benefits and Conclusion
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 8
ROMAT PGS - DEVELOPMENT OF AN ILI
SOLUTION FOR PIPE GRADE DETERMINATION
Destructive testing
• Our calibration data set are supported by destructive testing and mill test reports
• As of today we used 23 vintage pipe sample with unknown properties for destructive testing
• The properties of five modern grades are supported by mill test reports
Tensile Testing (ASTM A 370)
Charpy Testing (ASTM A 370)
Micro-sections
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 9
ROMAT PGS - DEVELOPMENT OF AN ILI
SOLUTION FOR PIPE GRADE DETERMINATION
100
150
200
250
300
350
400
450
500
350 400 450 500 550 600 650
Measu
rem
en
t [a
.u.]
Ultimate tensile strength [MPa, N/mm2]
st37, S235JR+AR
A516_Grade70
ST52, S355MC
X65, API 5L X65 PSL2
X70, SAWL 485 IFD
Results
Coefficient of determination:
UTS: r2 = 0.92
Laboratory tests:
Conjunction between mechanical
and electro-magnetic steel
properties
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 10
a.b
.
Schematic view
WT measurement
from MFL
Color scan of the
PGS response
PGS response
clearly
independent
from WTMedian in
circumferential
direction of
PGS response
Conducting performance pull tests at the
ROSEN Technology and Research
Center test field, Lingen/Germany
ROMAT PGS - DEVELOPMENT OF AN ILI
SOLUTION FOR PIPE GRADE DETERMINATION
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 11
Color scans of pull tests with varying velocities
PGS response
independent
from tool velocity
ROMAT PGS - DEVELOPMENT OF AN ILI
SOLUTION FOR PIPE GRADE DETERMINATION
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 12
Color scan of the PGS response
ROMAT PGS - DEVELOPMENT OF AN ILI
SOLUTION FOR PIPE GRADE DETERMINATION
Unity plot of performance pull tests is within the tool performance
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 13
Development conclusion:
• Pipe Grade Sensor (PGS): Electro-Magnetic sensor technology
• High resolution approach, high circumferential resolution
• Vintage UTS and YS value are based on destructive testing according to
ASTM A 370
• Laboratory and full-scale testing proved the capabilities to quantify UTS and
YS values
ROMAT PGS - DEVELOPMENT OF AN ILI
SOLUTION FOR PIPE GRADE DETERMINATION
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 14
CONTENT
1. Pipe Grade in the Context of PIM
2. RoMat PGS - Development of an ILI
Solution for Pipe Grade
Determination
3. RoMat PGS - Field Experience
with the Sophisticated
Technology
4. RoMat PGS – The Data Evaluation
Process
5. Process of MAOP Reconfirmation
6. Key Benefits and Conclusion
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 15
Pipeline data:
• Natural gas transmission pipeline
• 16” pipeline, 70,000 ft.
• Nominal wall thickness 0.250”
• Pipe line was constructed and partial replaced with
new and used (refurnished) pipes
• Known pipe grades: X42, X52, X60
• Unknown pipe grades: X24 according to 49 CFR
• 1583 pipe segments and fittings
ROMAT PGS – FIELD EXPERIENCE WITH THE
SOPHISTICATED TECHNOLOGY
Performance test of the tool in the field
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 16
• The ILI survey was executed in January 2014
• 11 Inspection System Results verifications were carried out in fall 2014
• Validation Digs and NDE program has been completed in Q4 2014.
• Data comparison with mill test reports of known pipe properties were carried
out.
• Discrepancy analysis and case studies confirmed the technology.
ROMAT PGS – FIELD EXPERIENCE WITH THE
SOPHISTICATED TECHNOLOGY
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 17
CONTENT
1. Pipe Grade in the Context of PIM
2. RoMat PGS - Development of an ILI
Solution for Pipe Grade
Determination
3. RoMat PGS - Field Experience with
the Sophisticated Technology
4. RoMat PGS – The Data Evaluation
Process
5. Process of MAOP Reconfirmation
6. Key Benefits and Conclusion
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 18
0
8
16
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40
48
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72
80
0
100
200
300
400
500
600
0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000
Yie
ld S
tre
ng
th [k
si]
Yie
ld S
tren
gth
[M
PA
]
Log Distance
Determination per pipe joint
Sections with unknown grade
Sections with unknown grades – 165 MPa (X 24) in accordance with 49 CFR
ROMAT PGS – THE DATA EVALUATION PROCESS
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 19
Co
un
ts [
a.u
.]
[ft]
ROMAT PGS – THE DATA EVALUATION PROCESS
Color scan of the PGS response for 1583 pipe segments47 P
ipe S
egm
ents
282 P
ipe S
egm
ents
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 20
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0.00
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600.00
0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000
Yie
ld S
tren
gth
[k
si]
Yie
ld S
tren
gth
[M
PA
]
Log Distance
Determination per pipe joint
Yield strength per joint (ILI) Sections with unknown grade
RoMat PGS determines yield strength values
ROMAT PGS – THE DATA EVALUATION PROCESS
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 21
0
8
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0.00
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0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000
Yie
ld S
tre
ng
th [k
si]
Yie
ld S
tren
gth
[M
PA
]
Log Distance
Determination per pipe joint
Yield strength per joint (ILI) yield strength per joint (hardness testing) Sections with unknown grade
RoMat PGS determined yield strength values are compared with Inspection
System Results verification
ROMAT PGS – THE DATA EVALUATION PROCESS
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 22
Inspection System Result verification according to API 1163 - by the use of mobile
hardness testing
Unity plot: UTS determined by ILI versus UTS determined mobile hardness testing
ROMAT PGS – THE DATA EVALUATION PROCESS
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 23
0
8
16
24
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40
48
56
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0.00
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500.00
600.00
0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000
Yie
ld S
tren
gth
[k
si]
Yie
ld S
tren
gth
[M
PA
]
Log Distance
Determination per pipe joint
Yield strength per joint (ILI) yield strength per joint (hardness testing)
Sections with pipeline records Sections with unknown grade
RoMat PGS determined Yield strength values are compared with existing pipeline
records
ROMAT PGS – THE DATA EVALUATION PROCESS
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 24
0
8
16
24
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40
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0.00
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500.00
600.00
0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000
Yie
ld S
tre
ng
th [k
si]
Yie
ld S
tren
gth
[M
PA
]
Log Distance
Determination per pipe joint
Yield strength per joint (ILI) Sections with pipeline records Sections with unknown grade RoMat determined Pipe Grade
Yield strength values (ILI) complemented with determined SMYS (Pipe Grade)
Closing the gap in the pipelines DNA
ROMAT PGS – THE DATA EVALUATION PROCESS
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 25
0
8
16
24
32
40
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56
64
72
80
0.00
100.00
200.00
300.00
400.00
500.00
600.00
0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000
Yie
ld S
tre
ng
th [k
si]
Yie
ld S
tren
gth
[M
PA
]
Log Distance
Determination per pipe joint
Sections with pipeline records Sections with unknown grade RoMat determined Pipe Grade
Pipeline DNA is complemented with pipe grade
ROMAT PGS – THE DATA EVALUATION PROCESS
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 26
0
8
16
24
32
40
48
56
64
72
80
0.00
100.00
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300.00
400.00
500.00
600.00
0.000 10,000.000 20,000.000 30,000.000 40,000.000 50,000.000 60,000.000 70,000.000
Yie
ld S
tre
ng
th [k
si]
Yie
ld S
tren
gth
[M
PA
]
Log Distance
Determination per pipe joint
Sections with pipeline records RoMat determined Pipe Grade
Pipeline DNA is completed => process MAOP validation is starting
ROMAT PGS – THE DATA EVALUATION PROCESS
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 27
CONTENT
1. Pipe Grade in the Context of PIM
2. RoMat PGS - Development of an ILI
Solution for Pipe Grade
Determination
3. RoMat PGS - Field Experience with
the Sophisticated Technology
4. RoMat PGS – The Data Evaluation
Process
5. Process of MAOP Reconfirmation
6. Key Benefits and Conclusion
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 28
PROCESS OF MAOP RECONFIRMATION
COMPLETION OF RECORDS
Incomplete
pipe tally (PT)
Pro
gre
ss
ILI
Segmentation
based on
measured YS
Determination
of outliers in
YS
Preliminary
data analysis YS per joint
Determination of
YS equivalent
SMYS
Final
data analysis
YS per joint
Completed
pipe tally
Determination
of verification
locations
Integrate YS
from mill
certificate
Field
verification
using NDE
Tensile tests
on pipe
samples
Mill
report?
no
yes
ILI & Data Analysis Data Integration Verification Testing
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 29
known
SF
WT
OD
MAOP
SMYS (RoMat)
SMYS (before) Partially unknown > As low as 24 ksi (as per CFR)
>=42>=46>=42known
Resulting MAOP segments further used for integrity assessments such as
• FFP/FFS Analysis
• Risk Assessments
• Pressure Uprating
• …
PROCESS OF MAOP RECONFIRMATION
COMPLETION OF RECORDS
known known
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 30
CONTENT
1. Pipe Grade in the Context of PIM
2. RoMat PGS - Development of an ILI
Solution for Pipe Grade
Determination
3. RoMat PGS - Field Experience with
the Sophisticated Technology
4. RoMat PGS – The Data Evaluation
Process
5. Process of MAOP Reconfirmation
6. Key Benefits and Conclusion
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 31
KEY BENEFITS
• Deliverable is a holistically view of the pipeline design. All potential “rogue” pipes will be
located and part of a replacement program
• High availability and a wide range of proven tool configurations addressing
individual operational pipeline requirements
• RoMat PGS is the solution for pipe grade determination without costly excavations to
fulfil regulatory long or short term statistical material sampling programs
• A holistically ILI-service for pipe grade determination is a first step in an integrity
verification process to replace destructive testing, in the long run
• Holistically, the pipe grade determination service increases the accuracy of pipeline
integrity management, better understanding the presence of risks along the pipeline
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 32
CONCLUSION
• RoMat PGS complies a holistically high resolution pipe grade data gathering. Scatter
plots of the holistically recorded yield strength (for each joint) values divides the pipeline
in segments for MAOP calculation and MAOP reconfirmation
• The Inline inspection service is embedded within the API 1163. This standard identified
the need of field verifications and validates confidence
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
www.rosen-group.com
THANK YOU FOR JOINING
THIS PRESENTATION.
Slide 34
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0 10,000 20,000 30,000 40,000 50,000 60,000 70,000
Yie
ld S
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th [k
si]
Yie
ld S
tren
gth
[M
PA
]
Log Distance
16” Pipeline – Pipe Grade Determination
Yield strength per joint (ILI) Sections with pipeline records Sections with unknown grade RoMat determined Pipe Grade
CASE STUDIES – PIPE GRADE RESULTS
Case study one
Re-Allocation of pipeline at a gravel pit
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 35
Re-Allocation of pipe line at a gravel pit
Ordered pipe: X 42; API 5 L
Delivered pipe: X42/ X52; API 5L
Requirement for yield strength
X 42 Min./Max. Yield 42 ksi/72ksi
X 52 Min./Max. Yield 52 ksi/77ksi
Investigation on mill certs: yield strength between 58 ksi and 62 ksi
Tool measurements: yield strength between 60 ksi and 63 ksi
Inspection System Result Verification: verification joint = 63.02 ksi
CASE STUDY ONE
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
Slide 36
0
8
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56
64
72
80
0
100
200
300
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500
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0 10,000 20,000 30,000 40,000 50,000 60,000 70,000
Yie
ld S
tre
ng
th [k
si]
Yie
ld S
tren
gth
[M
PA
]
Log Distance
16” Pipeline – Pipe Grade Determination
Yield strength per joint (ILI) Sections with pipeline records Sections with unknown grade RoMat determined Pipe Grade
Case study two
Re-Allocation at a river
crossing
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015
CASE STUDIES – PIPE GRADE RESULTS
Slide 37
Re-Allocation of pipe line at a river crossing
Ordered pipe: X 52; API 5 L
Delivered pipe: X 52; API 5L
Requirement for yield strength
X 52 = Min./Max. yield 52 ksi/77ksi
Tool measurements: Section: 55 ksi until 58 ksi
Outlier 1 yield strength 47.94 ksi
Outlier 2 yield strength 47.09 ksi
Outliers were confirmed by subsequent visual inspection of existing
pipeline records by operator
CASE STUDY TWO
Pipe Grade Determination and MAOP validation using sophisticated scraper technology · © ROSEN Group · 09/15/2015