Affecting Positive Change Ahead of IVP: Promising ILI and ITD technology options

Transcription

1 INGAA FOUNDATION NOV 2014 Affecting Positive Change Ahead of IVP: Promising ILI and ITD technology options LARRY LEGENDRE, WILLIAMS, Supervisor - Asset Integrity COE TIM CLARKE, BOARDWALK CHUCK HARRIS, TD WILLIAMSON LORI DALTON, EVAN GRAY, DAVID KATZ : WILLIAMS 1 Incomplete Fusion in the Seam Weld of Pre-1970 s ERW Pipe Detected by Transverse Field Inspection Tool October, The Williams Companies, Inc. All rights reserved.

2 INGAA FOUNDATION NOV 2014 Agenda Promising ILI Technologies for Long seams and Girth Welds: Case Histories using CMFL, CMFL + EMAT, Spiral, Magnetic Permeability/Hard Spots Coming Attractions: Integrity Verification Process (IVP is on it s way), Mega-Rule, etc. Well-documented Process on PMI - POSITIVE MATERIAL IDENTIFICATION under the Critical Assessment Box for IVP 2 Incomplete Fusion in the Seam Weld of Pre-1970 s ERW Pipe Detected by Transverse Field Inspection Tool October, The Williams Companies, Inc. All rights reserved.

3 ILI (In-Line Inspection) & Long Seams

4 So where is the issue and why does it bother us? LF-ERW ( yeah, I know: LF-ERW = Low Frequency Electrical Resistance Weld) CASE STUDY #1: > South Virginia Lateral (SVLA) Initial construction 1969 High concentrations of Youngstown (uh oh) and US Steel ERW pipe > Confidence level based on initial hydrostatic test performed in 1968/1969, then again 1990 > To better understand issues and threat, alternative inspection methods desired > Axial magnetic flux leakage (MFL) tools likely not finding this type defect MFL flux flows in longitudinal direction, CMFL flux flows Circumferentially and can highlight linear, longitudinal features 4 Incomplete Fusion in the Seam Weld of Pre-1970 s ERW Pipe Detected by Transverse Field Inspection Tool October, The Williams Companies, Inc. All rights reserved.

5 GE PII s TFI (= CMFL) tool used Tool capabilities and specifics > GE 20 TranScan tool Run in conjunction with stand alone geometry and MFL tools to get complete picture of the line Data analyzed for entire run (144.6 miles broken into two segments) > Tool looks for longer, axial features due to magnet orientation Field lines pass transversely through pipe as opposed to axially in traditional MFL tool Detects narrow axial features like seam weld defects as well as longer (roughly 5:1) metal loss features Depth accuracy spec is +20% at 80% confidence Ability to specify crack-like features open to ID or OD. Must be over 0.8 mm opening likely. Calls type-a, type-b, and seam weld anomalies Type-A usually one channel Type-B - usually multiple channels Seam weld anomalies, usually less defined and usually manufacturing related (i.e. inclusions, lamination, stringers, cold welds, luke-warm welds, etc.) 5 Incomplete Fusion in the Seam Weld of Pre-1970 s ERW Pipe Detected by Transverse Field Inspection Tool October, The Williams Companies, Inc. All rights reserved.

6 GPS data from IMU technology locates features ILI indications were located and excavated for evaluation Tool was very good at locating axial features TFI tool predicted versus in ditch measurements LOF open to the OD is clearly visible post MPI 6 Incomplete Fusion in the Seam Weld of Pre-1970 s ERW Pipe Detected by Transverse Field Inspection Tool October, The Williams Companies, Inc. All rights reserved.

7 Locations found by CMFL, PAUT (Phased Array UT) sizes defects PAUT onsite to size defects PAUT scan details > Array of multiple ultrasonic waveforms spread out at incremented angles to help size defects > Usual range: > Pipe wall thickness user specified and reflection of sound waves is recorded between ID and OD > PAUT can be indexed, allowing for very accurate sizing of feature length, for indications > 10-15% w.t. > Particular example shown is OD LOF planar to the centerline of the LS weld PAUT HIGHLY PEOPLE DEPENDENT - ASNT LEVEL II or III Required AND THEY NEED to HAVE EXPERIENCE ON PIPELINE, PREFERABLY EXPERIENCE ON YOUR PIPE 7 Incomplete Fusion in the Seam Weld of Pre-1970 s ERW Pipe Detected by Transverse Field Inspection Tool October, The Williams Companies, Inc. All rights reserved.

8 Several lessons learned from excavations and PAUT ITD Takeaways from this experience: CMFL technology is appropriate to manage threat on this line Presence of LOF in multiple locations Despite PHMSA PHASE 1 ERW STUDY CONCLUSIONS: ILI + EXCAVATION + ACCURATE UT In-The-Ditch WORKS 8 Incomplete Fusion in the Seam Weld of Pre-1970 s ERW Pipe Detected by Transverse Field Inspection Tool October, The Williams Companies, Inc. All rights reserved.

9 LOF likely a more stable, time independent, stable RESIDENT threat What our data tells us about LOF X-ray of LOF feature > PAUT shows uniform depth and length for all linear LOF features investigated > X-rays before PAUT show straight, uniform exposure > Based on knowledge of manufacturing process, no reason to believe LOF is dynamic Defect was induced in the factory No presence of hook cracks or evidence of any type of propagation Natural Gas service UNLIKELY to cause fatigue growth. Have seen some Hook Cracks in GAS Service, but very shallow depth LOF Lack of Fusion usually just PARTIAL LOF, not like our terminology used on Girth Welds 9 Incomplete Fusion in the Seam Weld of Pre-1970 s ERW Pipe Detected by Transverse Field Inspection Tool October, The Williams Companies, Inc. All rights reserved.

10 Hydro-tests were performed and no leaks were discovered One interesting case was a leaking, mid-wall lamination Mid-wall lamination through surface Pipe wall was actually slightly bulged Successful hydro-tests performed > 68 and 90 Hydro-tests: NO failures > Mid-wall (in most cases) laminations turned out to be just as much of an issue, likely due to center line segregation we continue to see 10 Incomplete Fusion in the Seam Weld of Pre-1970 s ERW Pipe Detected by Transverse Field Inspection Tool October, The Williams Companies, Inc. All rights reserved.

11 Move Larry along if we are overstaying our welcome More Good News from the LONG SEAM front out West 11 Incomplete Fusion in the Seam Weld of Pre-1970 s ERW Pipe Detected by Transverse Field Inspection Tool October, The Williams Companies, Inc. All rights reserved.

12 Background > Pre-1970 ERW exhibits industry wide susceptibility to longitudinal seam failure likely due to pressure cycle induced fatigue and selective corrosion on the bond-line region of the seam. > Oregon Area UNLOOPED Lateral Riggs Dam Road to Salem, OR 1960 installation of 1955 manufactured Lone Star 16 X X52 ERW Primarily Class 1 (non-hca Segment) MAOP 896 psig Confirmed threat of SCC, LOF and mid-wall laminations on 16 immediately Upstream Completed ILI assessment in 2012 due to high manufacturing risk score. ILI technologies included Geometry, MFL, CMFL and EMAT 2010 The Williams Companies, Inc. All rights reserved Template March 10,

13 Technology and Results Repair Guidelines for Lack of Fusion Indications - Surface or mid-wall indications less than 15% will not require repair - Lack of fusion indications that exceed 15% will likely require a Type A sleeve - Non crack-like indications with a measured depth less than or equal to 75% and less than 10 inches can be permanently repaired with a Type A sleeve - Non crack-like indications with a measured depth greater than 75% and longer than 10 inches can be temporarily repaired with a Type A sleeve or leak clamp and will need to be removed within 36 months - If SCC is found repair or removal will be required and will be based on consultation with Asset Integrity 2013 Field Results - Confirmed NO indications (cracking) located within roller-marks - Numerous lack of fusion (LOF) defects with two potential leaks resulting in repairs with leak clamps and petro-sleeves - No cracking or SCC identified 2014 Field Results - Continued confirmation of lack of fusion - Numerous lack of fusion defects repaired with leak clamps and petro-sleeves - No cracking or SCC Identified 2010 The Williams Companies, Inc. All rights reserved Template March 10,

14 ILI and PAUT Technology and Results The Williams Companies, Inc. All rights reserved Template March 10,

15 Seam Weld Defects > Cold Weld/Lack of Fusion ERW Pipe is produced by cold forming of previously hot-rolled plates into round and joining longitudinal edges by a combination of electrical resistance heating and mechanical pressure. Pressure causes extruding of excess material on the inside and outside which is trimmed. Intermittent loss current/heat inputs and/or inadequate mechanical pressure at the time of bonding can result is isolated or repeated areas of nonbonding called cold weld or lack of fusion. Due to the manufacturing process, there is no evidence that lack of fusion is dynamic = RESIDENT Indications NOT a likely THREAT to GROW The defects were induced during fabrication No presence of hook cracks or evidence of any type of propagation 2010 The Williams Companies, Inc. All rights reserved Template March 10,

16 Seam Weld Indications Cold Weld/Lack of Fusion Area Burst Testing confirms significant bonding thru entire wall thickness -- despite the high discoloration nearly 95% thru wall 2010 The Williams Companies, Inc. All rights reserved Template March 10,

17 ILI and Excavation Results : 1) GIRTH WELD and LONG SEAMS 2) Hi-Lo-SpirALL MFL Evaluation for Hard Spot, Lower Toughness areas

18 Girth Weld Crack Identified BY MFL Tool using Hall Sensors Actual Dig Results

19 Using TDW s MDS (Multiple DataSets) to assist in locating and sizing Hard Spots

20

21 Hard Spot 361 BHN

22 CMFL Identifying Seam Anomaly CMFL detected Seam Anomaly Along with A-Scan

23 Planar Seam anomaly CMFL tool Results X-Ray Anomaly area

24 Planar Seam Anomaly CMFL tool Seam Identified by CMFL Tool

25 Positive Material Identification (PMI) ahead of IVP Boardwalk, Transcanada, Spectra, Williams coordinating on an INGAA led initiative working closely with TDW on both ILI and ITD ( In-the- Ditch) PMI INGAA project can build synergy with ongoing industry sponsored projects using similar approach

26 Positive Material Identification (PMI) for IVP TDW s Patent-Pending non-destructive material identification in lieu of destructive testing In situ non-destructive evaluation Traceable, verifiable and complimentary records Fills in gaps on line pipe data No cut-out coupon test specimen required No line pressure reduction or shut down required Documentation Mechanical Properties Assessment Optical Emissions Spectrometry

27 Positive Material Identification (PMI) for IVP TDW s PMI process has been in development since 2011 PROCESS, which utilizes multiple NDE techniques, is key to material validation success TDW has conducted extensive internal and external validation Pipe samples with MTR s (INGAA efforts ongoing to supplement existing database) Unknown samples tested and sent to lab Third party laboratory blind tests Pipeline Operator testing and application All pipe vintages </= 60Ksi; pursuing Ksi Specifications and Accuracies established Worked very closely with PHMSA during initial validation

28 Positive Material Identification (PMI) for IVP using ILI & ITD Techniques Next Steps: note similarities to technologies BW used For entire pipelines, or significant pipeline lengths, without records: Utilize ILI, Multiple DataSets (MDS) specifically, to group joints by their material properties Pipe with similar manufacturing and milling should have similar material properties, and can be grouped together in bins PMI can then be used to validate each bin Low Field MFL (LFM) foundational dataset and exhibits: Mechanical properties of steel versus metal loss Background gauss Striations from milling Bin 1 LFM Bin 2 LFM High Field Axial MFL (MFL) used for confirmation Notice that most of the microstructure changes are magnetized out due to high field Bin 1 MFL Bin 2 MFL Helical or Spiral MFL (SMFL) used to determine differences in long seam signatures Notice changes in seam from Bin 1 to Bin 2 Can likely determine SAW, DSAW, ERW, EFW Bin 1 SMFL Bin 2 SMFL

29 INGAA FOUNDATION NOV 2014 Affecting Positive Change Ahead of IVP: Promising ILI and ITD technology options LARRY LEGENDRE, WILLIAMS TIM CLARKE, BOARDWALK CHUCK HARRIS, TD WILLIAMSON LORI DALTON, EVAN GRAY, DAVID KATZ : WILLIAMS 32 Incomplete Fusion in the Seam Weld of Pre-1970 s ERW Pipe Detected by Transverse Field Inspection Tool October, The Williams Companies, Inc. All rights reserved.