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© ESR Technology Ltd

HOIS JIP for Improved NDT in the oil, gas & petroleum industries

Tor Harry Fauske (Statoil) Steve Burch, Project Manager (ESR Technology)

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© ESR Technology Ltd Slide 2

HOIS Joint Industry Project (JIP)

• HOIS is a well established JIP• HOIS stands for ‘Harwell Offshore Inspection

Service’– Historical – no longer directly relevant

• Members comprise: – Oil and Gas producers– NDT service companies– NDT equipment vendors– A regulatory authority (UK HSE)

• Managed by ESR Technology (formerly AEA Technology)– Dr Steve Burch is Project Manager

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HOIS Joint Industry Project (JIP)

• Current members

• AGR EMI • Aker Kvaerner • BIS Salamis • BP Exploration • Can (Offshore) Ltd • Chevron • ConocoPhillips • Det Norsk Veritas • Doosan Babcock • Gasco • GE Inspection Technologies • Guided Ultrasonics Ltd • HSE • ISQ

• Lloyds Register • Marathon Oil • Mechanical Integrity Inc. • Oceaneering International Services Ltd • OlympusNDT • Petrobras • RTD (UK) • SGS • Shell Global Solutions International B.V. • Statoil • Talisman UK • Total • Sonomatic • Sonovation BV




HOIS – overall vision & themes

• The HOIS Vision:“To be the prime industry forum for discussing inspection

issues and developing and exploiting new or improved inspection technology”

• The programme aims to achieve this though a number of broad themes defined by the Members: – Development of improved techniques, procedures and

recommended practices for Non-intrusive inspection (NII) – Impartial trials and modelling to better quantify, assess and optimise

the performance of inspection technology– Independent state of the art technology reviews– Provision of a source of information on NDT (Internet accessible)– Technology development (e.g. for permanently installed monitoring)




Benefits for HOIS Members

• Join the leading forum on oil & gas NDT– for interchange of information, ideas and experiences – face-to-

face or using dedicated website;– Membership includes oil & gas majors, in-service inspection

companies and equipment vendors




Benefits for Members (cont)

• Access to results from ∼£500,000 annual programme

• Access to improved procedures and recommended practice documents on technique selection and application

• Access to results from equipment and technique trials

• Better understanding of and increased reliability of inspection

• Opportunity to exploit equipment and techniques developed within HOIS programme




Management

• Work programme specified and directed by “Strategy Group” of all members.– (cat 2 members do not have voting rights)

• Overall Work programme fixed annually.• Individual projects monitored by “Project Champions”• Typically three 2-day meetings per year:

– Day 1: Presentations on work carried out– Day 2: Strategy Group meeting to review work & make recommendations

on way forward

• Additional working group meetings on specific projects– As and when needed to discuss individual project in greater depth




ESR Technology

• Manage HOIS project and undertake much of project work• Formerly the National NDT Centre at Harwell (AEA

Technology)• Divested from AEA Technology in October 2005• ESR Technology

– Turnover £10 million/year– 110 staff– 60+ graduates– 20+ PhDs– 2 visiting Professors




ESR Technology heritage and resources…

• A world-class, independent, engineering, safety and risk consultancy

• 30 years of experience with in-depth technical knowledge

• UK-based with customers world-wide

• Outstanding consultants delivering outstanding solutions

• Extensive understanding of specific industrial sectors

• In-house laboratories, software, modelling tools and products




ESR Technology services...

• Ensure Asset Integrity• Improve Machine Reliability• Manage Safety & Risk• Transfer Best Practice

Delivers independent technical expertise, products and services to help clients:




ESR – Capabilities in NDT area

• Highly experienced and qualified experts– Independent of inspection services providers and NDT equipment

vendors

• Broad-ranging technical expertise especially in:– Advanced ultrasonic techniques– Radiography, including computed radiography– Electromagnetic techniques– Analysis of experimental probability of detection (POD) data– POD Modelling for ultrasonics and radiography– In-house experimental facilities for digital ultrasonics




Start of HOIS

• Started in early 1980’s.• Founded by UK Atomic Energy Authority (UKAEA) – Dr

Bill Gardner• Seeking to diversify from nuclear work• Exploit expertise in imaging and data analysis• Start-up meeting of 10 major oil & gas companies• Initially focus on TOFD for defect detection and sizing for

oil & gas industry – Including complex geometries (node welds etc), sub-sea.

• Other early projects included eddy current development




HOIS - Track-record in successful Innovation (previous projects)

• TOFD - ideal for internal flaw detection in welds and complex geometries - fast, accurate defect sizing

• CHIME - solution to screening inaccessible geometries for corrosion.

• LIZARD - licensed eddy current system• MAPS - stress measurement technology




Project categories

• ESR Technology responsible for management of all projects

• Technical work on projects in “Core programme”– carried out mainly by ESR Technology (with subcontracts if needed)

• “Tendered Programme” – projects carried out by third parties. Examples:– Development of Permanently installed sensors (PIMS)– CRIS POD trials




Main themes of current HOIS projects

• Procedures and recommended practices– Non intrusive inspection (NII)– Computed radiography (CR)– Weld root erosion/weld corrosion

• Evaluation of NDT techniques– State of the Art Reviews– Experimental evaluation trials– Blind probability of detection & sizing trials– Performance modelling

• Development of new inspection techniques– M-skip for inspection of inaccessible components (pipe supports,

clamps, vessel saddles etc)




Main themes of current HOIS projects (cont)

• Application studies– Inspection of FPSOs and flexible risers

• Development of a magnetic method for inspection of risers

• Development of new technology– Development of permanently installed monitoring sensors (PIMS)– Angled beam flexible arrays

• Development of source of information on NDT– Interactive knowledge base (IKB)




New ‘NICE’ facility for specimen storage and trials

• Now commissioned




Selection of current HOIS Projects

• Non-intrusive inspection (NII) related projects:– Development of a recommended practice covering guidance document for NII of pressure vessels – Development of NII techniques for “difficult to inspect” features (e.g. pipe supports)

• Recommended practice for computed radiography (CR)• Recommended practice for inspection of weld corrosion• Blind trials of techniques for inspection of wall loss flaws in pipes (CRIS)• Evaluation of techniques for bolt, flange and pipe support inspection• Development of permanently installed monitoring sensors (PIMS)

– Autonomous wireless sensors (initially UT)– “Next generation” Flexible ultrasonic arrays

• Inspection of FPSOs and flexible risers– Development of a magnetic method for inspection of risers

• Technology reviews, including EMATs, Single Sided Radiography and Microwave NDT.

• Development and maintenance of Internet-based NDT Interactive knowledge base (IKB)




Procedures and recommended practices




HOIS Project - Non-intrusive Inspection (NII) decision guidance

• NII Project - Development of a decision guidance process for when to inspect pressure vessels, using non-intrusive techniques instead of conventional internal visual inspection.

– Highly successful NII seminar in Aberdeen– Application of HOIS NII methodology by members to assets

• Recent extension of document to include guidance on setting inspection intervals after an NII inspection

• Integration with Mitsui Babcock RP from GSP 235• Now published complete document as a DNV RP - DNV-RP-G103

– Download from http://webshop.dnv.com/global/category.asp?c0=2624&c1=2627




HOIS Project – Recommended Practice for computed radiography (CR)

• Background:– Performance of CR in blind trials did not meet expectations– Some relatively large wall loss defects missed– CR equipment has high inherent capabilities– Procedures in use for in-service CR inspection need improvement– Lack of quality control

• HOIS project– Develop improved quality control techniques for in-service

corrosion inspection (both tangential & double wall techniques)– Collaboration with technical experts at BAM Institute– GE Inspection Technologies input– Series of evaluation trials of CR equipment from leading equipment

vendors




HOIS CR RP – Scope

• CR for in-service inspection of pipes for wall loss type flaws

• Techniques covered:– Double Wall Single Image (DWSI)– Double Wall Double Image (DWDI)– Tangential (source on pipe C/L)– Offset tangential (source offset by pipe radius)

• Two different qualities of inspection:– Standard quality – for general wall loss CR inspections– Improved quality – for applications needing higher quality (e.g.

detection of small pits)




HOIS CR RP - status

• Recommended practice to be made publically available via open HOIS website www.hois2000.com

• Aiming to progress to a European (EN) standard– Field not covered adequately by existing radiography or CR

standards (EN1435, EN 14784 parts 1 & 2 etc)




HOIS recommended practice for weld corrosion inspection

• No international standards or agreed procedures/approaches for weld corrosion inspection

• Lack of published information on performance of techniques for inspection of weld corrosion

• Need for a recommended practice covering in-service inspection of weld corrosion (detection and sizing)

• RP developed on basis of supporting trials and input from members experiences




HOIS RP: Main recommendations regarding inspection techniques

• Preferred technique is TOFD• Where TOFD not possible:

– Use Tangential CR, combined with DWDI to locate the areas of greatest wall loss

• If circumstances preclude the usage of these two preferred techniques, consider other techniques:

– double wall radiography (no quantitative through-wall information)

– specialised techniques for inspection through the weld cap using stand-off (water column) 0º pulse-echo probes.

– Recommended that these techniques are fully validated with regards to detection reliability and/or sizing accuracy.

• Manual angled beam UT known to give false positives and false negatives.

– Inherently inaccurate sizing• Document to be published shortly on HOIS website

www.hois2000.com




Novel technique development




Multi-skip shear wave TOFD (M-skip) – for inspection of inaccessible components

• Concept:

• Use shear waves to avoid mode-conversion losses at reflections

• Potential benefits– Defect detection– Accurate measurements of wall loss (arrival time analysis)– Application to clamps, pipe-supports, compensating sleeves (probably less

well suited to nozzles) etc

Rx Tx Obstruction




M-skip – current status

• Novel technique for inaccessible areas developed within HOIS

• Application to clamps/saddles & pipe supports• Can provide quantitative wall loss information• Potential for rapid screening of vessels and pipes• Very high POD in recent blind trial (97%)• Already used successfully on member’s offshore plant in

conjunction with CHIME®




Technique evaluation and trials




HOIS Project - Sponsor of CRIS Probability of Detection (POD) trials

• Sponsor of now completed CRIS PoD trials.

• Internal wall-loss flaws in straight-pipe.• POD measured for several techniques for

corrosion inspection• Some performed better than anticipated • Others did not meet expectations • Follow-up to understand why• Further HOIS sponsored trials of newly

developed techniques• Most recently trialled technique: GW

EMAT




HOIS – Other current trial/evaluation projects

• Trials of PA techniques for inspection of bolts and flanges using phased arrays

• Trials of techniques for pipe support inspection• Flange-face inspection




Technology Development




HOIS project - PIMS technology

• Development of permanently installed monitoring sensors (PIMS) for monitoring of plant degradation (e.g. corrosion/erosion & cracking)– Wireless data communication– Collaboration with other projects (SENS-IT)




PIMS development

• Collaboration with Strathclyde University and iicorr led SENS-IT project

• Development of wireless version of Advanced Guided Lamb Wave system from ClampOn (Bergen, Norway)

• Field trials on members’ plant of ClampOn equipment in progress (first trial complete)




NDT modelling




NII - Development of Probability of Detection (POD) modelling software

• Windows-based software for determining POD of– UItrasonic corrosion mapping– Computed radiography of pipes

• Results validated against experimental trials/tests




Applications studies




FPSO (Floating Production Storage & Offloading) vessels

• NDT methods for inspection of FPSOs.– Established a FPSO Working Group and website for

information exchange– Development of an FPSO Interactive Knowledge Base– Experimental trials of methods for flexible riser inspection

• MAPS technology development




HOIS FPSO/Flexibles project –Highlight

• Development within HOIS of MAPS magnetic stress measurement technique for monitoring flexible riser integrity

– Detection of broken tensile armour wires within inaccessible endfittings/terminations

• Successful load trials at flexible riser manufacturer

• Prototype now being developed for a HOIS member– Separate contract outside HOIS




Source of information on NDT




HOIS Project - NDT IKB

• Development and maintenance of the Internet accessible interactive knowledge base (IKB) - contains a wealth of information about NDT techniques, performance limits, PoD's, as well as "recommend a technique".

• HOIS members have free unlimited use




Conclusions

• HOIS is a long standing JIP. Currently has 28 members (major recent increase)– Major oil & gas companies– Also HSE, NDT service providers & two major equipment vendors

• Annual budget of ∼£500,000• Wide range of current projects:

– Recommended practices– Technique evaluation and development– Technology development– Improved NDT information



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