Advanced Non-Destructive Testing for Tanks and Pipelines Algeria, November 2016 Params. K
Details of Selected Advanced NDT Techniques On-Line Inspection What is On-Line Inspection? Check the Mechanical Integrity of Assets (pipelines, vessels, storage tanks Etc.) without removing them from service Purpose of On-Line inspection is to provide the maximum possible level of real world intelligence and information for the planning of a forthcoming shutdown Benefits of On-Line Inspection Optimize the Shutdown Inspection Schedule Eliminate an unplanned shutdown Eliminate unnecessary & costly removal of insulation Eliminate unnecessary & costly process of taking storage tanks offline Enormous cost savings $$$ms Reduction in NDT resource requirement 2
Pipeline AUT for Onshore & Offshore Context Automated Ultrasonic Testing is a latest Technology to inspect Pipeline Girth welds by using combination of Phased Array UT and TOFD. Advantages High Productivity Permanent Record Precision control of Inspection Better welding process control through rapid feedback Improved defect sizing Development and use of ECA AUT General Qualification as per DnV Standards Applications Diameter Tested : 4.5 to 48 inch Thickness Tested : 6.35 to 50.2 mm Total length of Onshore Pipeline Inspected 3525 Kms Total length of Offshore Pipeline Inspected 1600 Kms 3
Weld Testing by PAUT & TOFD Context Welding defects can compromise the stability and integrity of a welded structure. When you need confidence in testing of welds, PAUT & TOFD, a high performance non-destructive testing (NDT) technique offers you accurate detection of cracks, slag and lack of fusion. Advantages Radiation free ultrasonic technique Welds from 3/4 inch in diameter Wall thicknesses from 5mm Battery operation and irrigation system High Temperature Applications For High Temperature Application up to 480 Deg C X & Y axis scanner 3D Image Rapid inspections with digital recording of data Highly sensitive to fusion face flaws PHASED ARRAY ON SS/DSS/9% Ni WELDS To avoid the use of RT offshore / Onshore 4
Long Range Ultrasonic Testing & Conventional UT 5
Long Range Ultrasonic Technique (LRUT) Context LRUT waves are ultrasonic waves that propagate along the length of a structure, guided by and confined in the geometric boundaries of the structure. LRUT inspection is used as a screening tool for online Pipe testing, overhead piping, Cross country pipe line, Refineries Advantages Applications No need to remove complete insulation for inspection Road and river crossings High Temperature Application Rapid scanning tool Power plant tubing Risers Pipework Jetty lines & Jetty Supports Tank farm link lines Sphere legs Spiral welded pipe Sprinkler systems 6
Short Range Guided Wave Ultrasonic Technique (SRGUT) Context SRGUT was designed to test the annular plate of above ground storage tanks while the tank remains in-service. The technique is also being used to test for corrosion under pipe supports, corrosion at soil air interfaces, and similar difficult to access locations Advantages Rapid scanning Applications Tank Floor Annular Plate Testing By using multi frequency can identify all indications 100% of surface area Coverage (up to 2m length) Testing Concrete Coated Interfaces Testing Under Pipe Supports Scan Under Vessel Supports 7
Acoustic Emission Testing Context A phenomenon of ultrasound wave radiation in materials undergo deformation and fracture processes. When a material undergoes stress or a series of internal changes such as corrosion, it generates energy from localized sources which produces sound waves. Acoustic emission testing is a non-destructive testing method designed to monitor sound waves emitted during material stress or failure. Applications Advantages Corrosion & Crack Detection 100% floor inspection Identify stress risers Verified reliability Pre-Shutdown activities Significant money savings - No money wasted for opening of good tanks Ideal tool for application of risk-based inspection plans. Prevention of environmental losses - Early identification of potential leaks. Very fast, low-cost inspection with minimal interruption of operations and tank usage 8
Flange Face Testing by Using PAUT Context Crevice corrosion is a well known damage mechanism in industry. The crevice between two adjoining flanges is the ideal environment for crevice corrosion to initiate. Corrosion of the sealing area can cause loss of containment leading to catastrophic effect. Advantages Condition assessment of the sealing area without separating the flanges Increased safety due to the reduced potential for exposure to hazardous chemicals when separating the flanges Inspection while the equipment is on-line Applications On-line Flange Testing Pre-Shutdown Inspection Crack detection Detection of SCC in complex Flanges Planning for repair well in advance 9
Automatic Corrosion Mapping / HIC / HTHIC Context Corrosion and erosion can inflict significant damage upon petrochemical vessels and pipework. Other phenomena such as HIC & HTHAC can also prove costly in plant operation. Due to the risks involved, it is important to recognize corrosion damage as early as possible. Advantages Eliminating the need to use scaffolding or rope access Maximize the ability to detect corrosion Permanent hard and soft copy record Applications Above and below ground storage tank floors, shells and roofs Pressure vessels including identification of hydrogen blistering Process pipe work Offshore loading /unloading jetty lines Ships hulls and similar marine vessels 10
Scorpion for Tank Inspection Scorpion B-SCAN imaging system is developed to perform Ultrasonic thickness measurements on ferrous material. It can be used on vertical and horizontal surfaces like oil storage tank and pressure vessels. The minimum diameter the crawler can inspect: 1. Outside= circumferential is 1.5m and axial is 1.5m 2. Inside= circumferential is 3m and axial 1.5m The maximum surface temperature scorpion B-SCAN crawler can operate is 80 C Thickness measurement ranges from 2.5mm to 100mm approximately 11
Applications of Scorpion Inspection of Storage tanks, shells both external and internal surfaces Inspection of tank roof plates Corrosion mapping of pipeline 12
Pulsed Eddy Current Testing Context Pulsed Eddy Current is a unique corrosion survey method that allows to inspect ferrous materials with Insulation / Thick Coating / Concrete etc Measurements can be performed with insulation, asbestos, fireproofing, concrete or coating Advantages Wide temperature range: -100 to 550 C (-150 to 1000 F) Very good reproducibility of PEC readings at the same locations, typically ±0.05 mm There is no need for surface preparation The high costs for removal of insulation can be avoided Scaffolding can be reduced by using rope access or by using an extension pole or robotic crawler Applications Inspection Of Jetty support legs Support Legs of Tanks Inspection on rough surface Sheet piling Inspection 13
Implementation of PEC The PEC probe is usually portable and can often be used by a single operator. A dedicated jig has been developed to enable safe, fast and accurate data collection on the legs of storage spheres. A detailed visual inspection is carried out to look for signs of degradation, and PEC technology is used to measure the wall thickness of the metal behind the fireproofing. Inspection of column skirt through fire proofing bricks Inspection of a storage sphere legs 14
Testing & Results of PEC Pipe inspection direction h12 5 1 4 2 3 Typical 2D color plot and legend 15
Online robotic tank bottom inspection (OTIS) Uses submerged UT sensors to detect any variations in tank bottom thickness. The scan provides you with an API certified inspection of your tank bottom. Acquires detailed information about the amount of topside and bottom side corrosion, the thickness of the tank floor, the presence of floor or shell settling and the precise location of this information. If the tank's product has any optical clarity, then its camera can provide a video record of the tank's interior. Collects thousands of UT data samples. Eliminates the Shutdown costs All work is according to API 653 standards Inspection generates no waste You are ensured of safer operations. 16
IR Thermography Infrared thermography is equipment or method, which detects infrared energy emitted from object, converts it to temperature, and displays image of temperature distribution FIELD APPLICATION Preventive Maintenance Condition Monitoring Energy Performance Furnace & Boilers Mechanical Friction Tanks & Vessels Fluid Flow Problems 17
External Corrosion Mapping by Laser Technology 18
The LIXI PROFILER FOR CUI A major inspection challenge facing the factory process industries is how to examine insulated piping for blockage and corrosion, especially for corrosion under the insulation and internal erosion How It Works Using a Very Low Source X-RAY Tube with a Digital Phosphate Screen real time x-ray of the external surface of the pipe and insulation can be viewed, recorded, captured and reported. Real Time X-RAY CUI Inspection is extremely quick able to scan hundreds of feet of pipe daily.. Used on Short and Long Insulated Piping Used On Sphere Tank Legs With Fireproofing Expandable system for 2 up to 36 D. Pipe Able to look in odd geometric components I.E. Elbows, Flanges, Valves and Similar Offshore Risers with Neoplene Coating 19
Digital Radiography Digital Radiography is similar to RT Content Digital Radiography Radiogrpahy Source X ray and Gamma Ray X ray and Gamma Ray Receiver Electronic Plate Film Flexibility Fixed and Regid Flexible Reusing of Receiver Can be Re Usable Processing time Quick and 1min 40 min Can not be Re Usable 20
Vacuum Box testing as per API 653 Vacuum box testing is required for: new shell-to-bottom welds, unless diesel tested new bottom welds, unless tracer gas tested new roof plate welds for tanks designed to be gas tight potential bottom plate leak paths patch plates welded on to the bottom bottom plate restored by welding 21
MFL for Tank floor Inspection MFL Floor map Scanner Hand Scanner For Inaccessible areas 22
DESIGN REVIEW SERVICES Storage tanks require detailed design review & inspection during the manufacturing stage. Effective inspection ensures code compliance and prevents premature failure. Following design review services are offered during the design & construction stage of storage tanks:- Design Review as per API 650, IS 803, API 620 codes Review of fabrication drawings Tank-farm Piping Tank Foundations Instrumentation & Electrical items associated with Storage Tanks Fire fighting system including sprinkler, foam & smoke detection system Compliance to MB Lal committee recommendations 23
Technical Due Diligence (TDD) of Storage Tank Terminal Project: Technical Due Diligence for Petroleum Storage Terminal Scope: Physical verification & document review of the terminal equipment i.e. storage tanks (22 Nos.), spheres (03 Nos.),associated piping, E&I, Civil Foundations etc. Visual inspection (VI). Review of documents i.e. standard maintenance practices, NDT records, safety procedures, instrument calibration records etc. Client Condition Assessment of the entire facility including Storage tanks, Piping, E&I, Civil Foundations Agency for AIM Services 24
In-service Inspection of Storage Tank as per API 653 Guidelines On going (till Jan 2017) Project: In-service Inspection of Storage Tank as per API 653 Guidelines, at SHELL Markets India Pvt. Ltd. Mumbai. Scope of work: Performing NDTs such as MFL on Bottom plates, Crawler UT (Scorpion) on Shell plate & UTG on Sump, Nozzles & Roof. NDTs such as MFL on Bottom plates, Crawler UT (Scorpion) on Shell plate & UTG on Sump, Nozzles & Roof. Equipment to be inspected: Storage Tanks Agency for AIM Services No Of Tanks : 58 Agency for NDT 25
In-service Inspection of Storage Tank as per API 653 Guidelines @ July 2015 Project: In-service Inspection of Storage Tank as per API 653 Guidelines, at SHELL Markets India Pvt. Ltd. Mumbai. Scope of work: Performing NDTs such as MFL on Bottom plates, Crawler UT (Scorpion) on Shell plate & UTG on Sump, Nozzles & Roof. No Of Tanks : 3 NDTs such as MFL on Bottom plates, Crawler UT (Scorpion) on Shell plate & UTG on Sump, Nozzles & Roof. Equipment to be inspected: Storage Tanks Agency for NDT 26
In-service Inspection of Storage Tank as per API 653 Guidelines @ Aug 2016 Project: In-service Inspection of Storage Tank as per API 653 Guidelines, at SHELL Markets India Pvt. Ltd. Mumbai. Scope of work: Performing NDTs such as MFL on Bottom plates, Crawler UT (Scorpion) on Shell plate & UTG on Sump, Nozzles & Roof. NDTs such as MFL on Bottom plates, Crawler UT (Scorpion) on Shell plate & UTG on Sump, Nozzles & Roof. Equipment to be inspected: Storage Tanks Agency for AIM Services No Of Tanks : 3 Agency for NDT 27
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