The Added Value of In-Line Inspection to Hydrostatic Testing Programs

Transcription

1 The Added Value of In-Line Inspection to Hydrostatic Testing Programs René Irani Business Development Director, Pipeline Resources, Middle East & Africa

2 The Complementary Benefits of Using Both: Hydro-test and In-Line Inspection A hydro-test is effective for both cracks and metal loss and provides positive proof of a pipeline s fitness. An ILI program will gather condition monitoring information and if the ILI is run ahead of the hydrotest, critical flaws that have been identified can be repaired to avoid test failures. A combination of the two is generally more effective than either on its own. 2

3 Pipeline System Natural Gas System Spans 70,000 square miles and serves one out of every 20 Americans 6,700 Miles Transmission 42,000 Miles Distribution Serving four million people More than 21,000 men & women support the utilities services If built in a straight line, the gas pipeline network would run from California to Boston and back 15 times By the Numbers Largest combined gas & electric company in the US with 70,000 miles of services area Area stretches from Malin, CA on the border of Oregon down to Needles, CA on the border of Arizona Client delivers 970 billion cubic feet (BCF) of gas per year (2.6 BCF/day) 3

4 Pipeline Safety Enhancement Plan Pipeline Safety Enhancement Plan In June 2011, the Californian Government ordered intrastate gas transmission operators to file an Implementation Plan to pressure test/replace all in-service natural gas transmission pipelines that have never been pressure tested. Client s Strength Test program was set up in 2011 and was prioritized to address all Class 3, Class 4, and HCA piping first. To date, the Strength Test Program has tested approximately 650 miles of transmission pipeline. 4

5 A Look at Hydro-Test & In-Line Inspection Data A hydro-test can show you this But only ILI data can tell you this 5

6 Value for Money In 2014 the Strength Test Program ran a pre-inspection ILI Tool on 13 Tests totaling 32.5 miles. The pre-inspection program increased costs approximately 10% relative to the strength test alone. 6

7 2014 Program Challenges Challenges: Dynamic Schedule (3 Day Window) Temporary Piping Unknown Pipeline Features (Bends, Old Repairs, Fittings) Bi-Directional ILI Runs Low Pressures Lines (Tool Speed Issues) Miters Bends Dual Diameter Mueller / Pressure Control Fittings Acetylene Welds / Chill Rings Old 1920's Pipe Confined Work Areas Traffic Control / City Streets 7

8 2014 ILI Project Requirements In-Line Inspection Tool - Quest UT InVista (Unscrapable) Single Run Inspection - Dual Diameter and/or Custom Tools Dents, Ovalities, Metal Loss, Bends, Take-Offs, Fittings, etc. Project Management / Procedures Batching Services Monitor Cleaning Flow Rates & Pumping AGM Establishment & Deployment Tracking (Batching & InVista ) XYZ Services (Centerline) Reporting 48 Hour Report 48 Hour Quick XYZ Reporting 45 Day Final Report with XYZ In-Field - Anomaly Locating Digging Assistance Launch & Receiver Barrels Valves & Hardware 8

9 Case Study #1 6-Inch / 8-Inch (Dual Diameter) M.P (4.82 Miles) Orinda, CA Dual Diameter wall wall Line Fill 37,615 gal. Challenges: Unknown Pipe Details Residential Area Elevation Changes 800 Feet Variations Dual Diameter Multiple Transitions Traffic Control 9

10 Case Study #1 6-Inch / 8-Inch (Dual Diameter) ILI Results: 48 Hour preliminary report provided in the field After review of the report high risk anomalies identified prior to Hydro-test Locating Indications: High resolution GPS used Quest located dig areas and identified and marked Anomalies repaired or pipe replaced 10

11 Case Study #1 EML 2960 at 7186 ft. 11

12 Case Study #1 DNT at 7293 ft.: 13% Dent at a Field Bend 12

13 Case Study #2 10 Inch M.P (2.97 Miles) Napa, CA wall Line Fill 64,442 gal. Challenges: Earthquake Schedule Movement Permitting Access to Locations Environmentally Sensitive Hydro-test Procedure Issue Accessibility Issues 13

14 Case Study #2 10 Inch Inspection Findings: 48 Hour preliminary report provided in the field After review of the report no wall loss anomalies needed to be repaired prior to Hydro-test. Hydro-test Complication Issue: Suspicion of service taps leaking under pressure Quest dataset and GPS coordinates allowed for quick location of taps for examination. Test procedural error discovered. Line was split, tested successfully. 14

15 Case Study #3 10 Inch M.P (2.41 miles) San Rafael, CA & wall ILI Direction: On-site procedural changes Batch Fill 35,498 gal. Challenges: Late change to inspection procedure due to MAOP concerns. Contemplated waving ILI. Ran line in two sections to avoid exceeding MAOP (175 psi max). Chill ring received with tool on first run. 15

16 Case Study #3 Buckles with Metal Loss Indications Found 16

17 Case Study #3 Small Diameter Pitting 17

18 Conclusion 1. For minimal additional cost, ILI added significant value to the strength test program. 2. The strength testing program adds benefits for Pipelines with limited or outdated records. a) Updated alignment sheets and corrected segment lengths b) Nominal pipe wall thicknesses c) Pinpointed historic repair locations 3. Assists in remediation and repair planning a) Catholic Protection Effectiveness b) MAOP Evaluation & Pressure Ratings Review c) Pipeline coordinates, GIS information, and HCA evaluations 4. Overall better decision making & outage time reductions a) General Integrity Management planning & remediation b) Budgeting c) New construction d) Statistical analysis 18

19 Pick Any Two Good Pick any Two Fast Cheap 19