Shallow Internal Corrosion

Sensor Technology
for Heavy Pipe Wall Inspection

ROSEN Technology & Research Center Germany

Dr. Olaf Stawicki
18-Nov-2009

Contents

Motivation
Measurement Principle
Mechatronic Principle
Inspection Tool Design
Combining SIC with MFL
Test Results
On-Site Example
Summary

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SIC Sensor Technology | O. Stawicki | 18-Nov-2009

Motivation
Risks for Pipeline Integrity and Operation
Manufacturing

Operational

Steel Production
Welding (SAW, ERW)

Pipeline
Integrity
Assessment

Corrosion
Erosion, Fatigue
Ground Movement
Mechanical Damage

Construction

Coating and CP

Girth Weld Faults

Poor Pipe Support

Poor Surface Preparation

Inadequate Material Storage

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Motivation
Corrosion plays a crucial role in pipeline integrity
it is a time-dependent deterioration process
Heavy Wall Pipelines for Offshore Applications
Specified maximum corrosion growth rate
Controlled wall thickness reduction during the lifespan
Monitoring Internal Corrosion is inevitable for reliable
and save operation!

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Motivation
Top of Line Corrosion (TLC) or Dewing Corrosion
starts as Shallow Internal Corrosion (SIC)

Origin of TLC
Unprocessed wet gas is transported
from an offshore well
Heat exchange between pipeline and
cold surrounding (such as sea water)
Low pH water droplet condensation on the upper
half of the pipeline
Dissolution of aggressive gases in droplets support corrosion

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Motivation
Droplet Condensation
of Vapor Phase

Vapor
H2O, CO2, H2S

TExt TGas

Organic Acid (HAc)

Water Drain

TGas
TExt
Stratified Water Flow
Droplet Size Distribution ~ r -2/3 localized, small-scale corrosion

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Motivation
TLC Controlling Parameters
Partial Pressure of CO2

Partial Pressure of H2S

Water Condensation Rate
Gas Pressure, Velocity, Temperature
Organic Acid (HAc) Concentration

TLC can reveal high growth rates, up to several mm/year

(Singer et al., 2009)

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Motivation

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Measurement Principle
Alternating current triggers
Primary Magnetic Field
Magnetic flux change causes
Eddy Currents in conductive
material, e.g., pipe wall
Eddy Currents generate
Secondary Magnetic Field
Secondary Field modifies Primary
Field via mutual inductance
Eddy Currents imply change of
coil impedance

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Measurement Principle
Coil Impedance: Z = R + j L
R
Ohmic Resistance

Frequency of driving
current
L
Inductance of Coil

L
In Air
Li
ft

Metal Loss
-O

ff

Material

In Air

R
Over Material

Over Metal Loss

Lift-Off

Eddy Currents
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Eddy Current Distortion

SIC Sensor Technology | O. Stawicki | 18-Nov-2009

Measurement Principle
Penetration Depth determined by Skin Effect
Skin Depth ~ 1/( )1/2

Eddy Current Density decreases with depth.

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SIC Sensor Technology | O. Stawicki | 18-Nov-2009

Mechatronic Principle
SIC Sensor = Contour Following Touchless Proximity Sensor
(Compensated Deflection)

Radius Measurement
=
Proximity Sensor (Lift-Off)
+
Electronic Angle Sensor
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counts

SIC sensor
schematic view

Lift-Off
SIC Sensor Technology | O. Stawicki | 18-Nov-2009

Inspection Tool Design

RoCorrMFL/SIC 24" Combo Tool
MFL

Two plane sensor system

Available tool sizes

SIC

100% coverage
6" 56"

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Combining SIC with MFL

Depth Measurement of Metal Loss Features
MFL
SIC

relative
absolute

Compensation
for Lift-off

Sensitive Pitting Discrimination

Inner Pipe Wall Surface

SIC Regime

Wall
Thickness

MFL Regime
Detection & Sizing of External Defects

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Outer Pipe Wall Surface

SIC Sensor Technology | O. Stawicki | 18-Nov-2009

14

Combining SIC with MFL

SIC feature sizing customizes MFL sizing model

Defect Depth [mm]

Sample pipe with WT = 20 mm

Detection
Regime

MFL

SIC Probe

Depth Sizing Accuracies

MFL
2 mm
SIC
0.5 mm
Defect Diameter [mm]

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Test Results
SIC Scan of Steel Plate with Spherical Pits

Depth [mm]

y-direction [mm]

Lift-Off
3 mm
Resolution 2 x 2 mm

EDM-made pits

x-direction [mm]

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Test Results
Surface Diameters

Aspect Ratio

P35.x
P30.x
P25.x
P20.x
P15.x

35

Aspect Ratio D/t 3

Depth t
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Test Results

Depth [mm]

y-direction [mm]

SIC Scan of Steel Plate with TLC

x-direction [mm]

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Test Results

SIC Depth [mm]

SIC Scan of Steel Plate with TLC

Real Depth [mm]

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Test Results
16" Pump Test Line
Dent Simulation

Spiral Weld

Internal
Defects
Flange
Dent

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SIC Sensor Technology | O. Stawicki | 18-Nov-2009

Test Results
16" Test Joint, WT = 12.6 mm

SIC

MFL

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SIC Sensor Technology | O. Stawicki | 18-Nov-2009

Test Results
TLC in 16" Test Pipeline

AUT
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CDP

SIC
SIC Sensor Technology | O. Stawicki | 18-Nov-2009

On-Site Example - World Longest Subsea Run

Requirements - 42" /44" Langeled Pipeline
Inspection Range 1200 km
Gas Speed 8 m/s
Active Speed Control
set at 3 m/s
WT Range 3 38 mm
Maximum Pressure 220 bar

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SIC Sensor Technology | O. Stawicki | 18-Nov-2009

On-Site Example - World Longest Subsea Run

CDP
624 MFL Channels
RoGeoXt 330 Geometry Channels
SIC
864 Channels
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SIC Sensor Technology | O. Stawicki | 18-Nov-2009

On-Site Example - World Longest Subsea Run

Run Results
Traveling time 127.3 hrs
Tool velocity 1.5 3.0 m/s
Almost full pipeline length recorded
3.82 km2 of pipe wall inspected ( = 521 football fields)
11,7 measurement points per cm2
450 billion measurement points
374 GB data recorded
but data evaluation is still in process

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SIC Sensor Technology | O. Stawicki | 18-Nov-2009

Summary
Based on Eddy Current Technology, SIC Sensors have
been developed for metal loss inspection on inner pipe
wall
Compared to other measurement technologies:
SIC:
Absolute depth of metal loss features
MFL:
Relative depth based on wall thickness
SIC tools have less friction compared to tools with
magnet yokes
SIC Inspection is contactless, i.e. no direct coupling to
the pipe wall
SIC sensor metal loss depth sizing
Typically between 1 mm and 10 mm depth

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SIC Sensor Technology | O. Stawicki | 18-Nov-2009

Thank you for joining this presentation.