09 - Olaf Stawicki (ROSEN) - Combined ILI Approach For Pipelines With Top of Line Corrosion and CRA Layer

7/28/2015
CONTENT
ILI Perception of top of line corrosion
Overcoming TLC: Corrosion Inhibitor & Corrosion Resistant Alloy (CRA)
ILI Technologies: Magnetic Flux Leakage & Eddy Current
ILI Technologies: Combined world
Inspection Example: Carbon Steel Pipe without CRA
Trial Program with CRA Pipe
Conclusions
COMBINED ILI APPROACH FOR PIPELINES WITH

TOP OF LINE CORROSION AND CRA LAYER
Dr. Olaf Stawicki
ROSEN Technology and Research Center, Germany
NACE TOL Conference Jakarta Indonesia 27-29 July-2015
NACE TOL Conference Jakarta Indonesia 27-29th July 2015 Dr. O. Stawicki ROSEN Group 2015
Slide 2
7/28/2015
ILI PERCEPTION OF TOP OF LINE CORROSION
ILI PERCEPTION OF TOP OF LINE CORROSION
Top of Line Corrosion
Condensation rate depends on Temperature

Temperature equilibrium between pipeline and surrounding
TLC typically occurs in the first kilometers of pipelines
Droplet
T TGas
Condensation Ext
Water Drain
Localized, small-scale corrosion (PINH, PITT)
Dissolution of aggressive gases in
droplets support corrosion
Stratified Water Flow
Can reveal high growth rates, up to several mm/year

Corrosion Inhibitor or CRA pipes applied for such high risk areas
Slide 3
Slide 4
7/28/2015
OVERCOMING TLC: JET PIG APPROACH
OVERCOMING TLC: CORROSION RESISTANT ALLOY
Traditional Spray Pig Approach based on Venturi Effect and/or Bypass
Typical types of CRA
Standard Carbon Steel
Mechanical bonded (lining)

Jet Pig Approach utilizes a battery powered motor with pump:
Metallurgical bonded (cladding)
a)
Pig 1 and 2 include Corrosion Inhibitor (CI) batch. Pig 2 pumps CI out of
the batch and spread it to the top of line.
b)
Concept works effectively even under low pressure conditions.
c)
No bypass or Venturi effect required
Typical CRA materials

Stainless steel 316L
Corrosion Resistant Alloy (CRA)

Layer Thickness: ca. 3 mm
Lined or cladded
Austenitic: Non-magnetic
Inconel 625, 825

Prior to installment/construction
No concerns for integrity
Inspection not considered
Since installment/construction
Concerns emerged
Actual incidents occurred
Slide 5
Slide 6
7/28/2015
OVERCOMING TLC: CORROSION RESISTANT ALLOY
ILI TECHNOLOGIES
Expected defects in CRA pipe
In offshore pipelines
a) reference outside measurements or
b) local repairs
are impossible or at least difficult.
External defects in carbon steel (CS),

e.g. corrosion
Internal defects between carbon steel
and stainless steel
Erosion in CRA due to e.g. sand
Pitting in the CRA e.g. caused by
seawater ingress or galvanic corrosion
ILI is an inevitable measure for assessing the current state of the asset:
Geometric deformations in CRA

(e.g. wrinkles, dents)
Ultrasonic inspection requires batching for gas pipelines

=> cost intensive, environmental concerns
Magnetic Flux Leakage (MFL) and Eddy Current (EC) are robust ILI
techniques with reliable data coverage even under harsh conditions
but are BOTH applicable to BOTH the CRA layer and CS carrier?
Slide 7
Slide 8
7/28/2015
ILI TECHNOLOGIES - MAGNETIC FLUX LEAKAGE

FEM simulations for 8: 10 mm CS, 3 mm CRA Layer
48 RoCombo MFL-A/IEC
Without CRA Layer
With CRA Layer
Speed effects are worsening magnetization and detection capabilities

Internal and external metal loss can be sized
Slide 9
Slide 10
7/28/2015
ILI TECHNOLOGIES - EDDY CURRENT
FEM simulations for 8: External defect in CS, 24 mm x 24 mm, depth 65%

48 RoCombo MFL-A/IEC
MFL susceptible to ferromagnetic material only, but not to austenitic steel

CRA layer results in degradation in magnetization
Austenitic CRA layer roughly represents air gap
Pipe wall
Sensor over full pipe wall
Sensor over metal loss
Internal metal loss can be sized from response signal

Slide 11
Slide 12
7/28/2015
ILI TECHNOLOGIES - EDDY CURRENT
ILI TECHNOLOGIES COMBINED WORLD

General Material Response
MFL is suitable for ferromagnetic materials only (CS)
MFL is not suitable for non-magnetic steels (316L, alloys 625 & 825)
EC is suitable for ferromagnetic materials (CS) and non-magnetic, but
conductive materials (316L, alloys 625 & 825)
Compensated Signal
12
10
8
6
4
0
0.04
0.08
0.12
0.16
0.2
0.24
0.28
0.32
0.36
0.4
0.44
0.48
Time (sec)
Absolute sensor position is known in every moment:

compensate scaling (negative radius impact),
size general metal loss (positive radius anomaly)
monitor for ID anomalies
Radius Measurement
=
Lift-Off Sensor
+
Electronic Angle Sensor
Slide 13
For Carbon Steel Pipe without CRA:

MFL and EC complement each other for internal metal loss (TOLC)
Direct assessment of defect shape via EC
Indirect improvement of MFL depth sizing based on EC shape
For Carbon Steel Pipe with CRA:
MFL and EC complement each other
MFL for detection of metal loss in CS carrier
EC for monitoring inner surface of CRA layer
Slide 14
7/28/2015
CARBON STEEL PIPE WITHOUT CRA

MFL picks up smallest indications, but blooming dominates
Data interpretation is ambiguous examples a,b,c
1m Offshore Pipeline with Internal Pinholes

AUT 1 mm sampling; significant depth values in % of wall thickness
Slide 15
Slide 16
7/28/2015
EC data reflect even tiniest pinholes

Accurate shape from EC, subsequent more accurate depth from MFL
MFL Stand Alone Result
EC
MFL
Slide 17
Slide 18
7/28/2015
LARGE SCALE TRIAL PROGRAM WITH CRA PIPE
Combined result, higher accuracy, significantly reduced oversizing
8 Pump tests
MFL, EC and UT ILI tools
Test spool
8, 10 mm WT CS, 3.9 mm WT CRA (cladded, Alloy 825)
with artificial defects of class Pitting
Ext. Feature
CS
Ext. Feature
CS &CRA
Int. Feature
CRA
Slide 19
Int. Feature
CRA &CS
Slide 20
10
7/28/2015
Defect #1: ext. in CS, 6.5 mm depth
Defect #3: int. in CRA, 3.0 mm depth
MFL (NIC)
IEC
MFL (NIC)
Defect #4: int. in CS & CRA, 10.9 mm depth
Defect #2: ext. in CS & CRA, 13.0 mm depth
IEC
Slide 21
Slide 22
11
7/28/2015
CONCLUSIONS
Systematic and even single metal loss over-sizing is of specific
concern for offshore and specifically TOLC affected pipelines.
Oversizing is reduced significantly by employing different but
complementing ILI technologies: Eddy Current & Magnetic Flux
Leakage.
TOLC monitoring is complemented with the accurate assessment of
severe general and embedded corrosion, with the high definition
caliper component.
Jet Principle Pig for effective CI distribution is considered
THANK YOU FOR JOINING

THIS PRESENTATION.
Combined MFL/EC approach allows to inspect CRA and CS in

lined/cladded pipes
Liquid coupling (cost intensive batching) as for UT inspection not
required
www.rosen-group.com
Slide 23
12

09 - Olaf Stawicki (ROSEN) - Combined ILI Approach For Pipelines With Top of Line Corrosion and CRA Layer

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7/28/2015

COMBINED ILI APPROACH FOR PIPELINES WITH

ILI PERCEPTION OF TOP OF LINE CORROSION

ILI PERCEPTION OF TOP OF LINE CORROSION

Top of Line Corrosion

Condensation rate depends on Temperature

Stratified Water Flow

Can reveal high growth rates, up to several mm/year

OVERCOMING TLC: JET PIG APPROACH

OVERCOMING TLC: CORROSION RESISTANT ALLOY

Traditional Spray Pig Approach based on Venturi Effect and/or Bypass

Typical types of CRA

Standard Carbon Steel

Mechanical bonded (lining)

Metallurgical bonded (cladding)

Concept works effectively even under low pressure conditions.

No bypass or Venturi effect required

Typical CRA materials

Corrosion Resistant Alloy (CRA)

Inconel 625, 825

OVERCOMING TLC: CORROSION RESISTANT ALLOY

Expected defects in CRA pipe

External defects in carbon steel (CS),

Geometric deformations in CRA

Ultrasonic inspection requires batching for gas pipelines

ILI TECHNOLOGIES - MAGNETIC FLUX LEAKAGE

ILI TECHNOLOGIES - MAGNETIC FLUX LEAKAGE

Without CRA Layer

With CRA Layer

Speed effects are worsening magnetization and detection capabilities

ILI TECHNOLOGIES - MAGNETIC FLUX LEAKAGE

ILI TECHNOLOGIES - EDDY CURRENT

FEM simulations for 8: External defect in CS, 24 mm x 24 mm, depth 65%

MFL susceptible to ferromagnetic material only, but not to austenitic steel

Sensor over metal loss

Internal metal loss can be sized from response signal

ILI TECHNOLOGIES - EDDY CURRENT

ILI TECHNOLOGIES COMBINED WORLD

Absolute sensor position is known in every moment:

For Carbon Steel Pipe without CRA:

CARBON STEEL PIPE WITHOUT CRA

CARBON STEEL PIPE WITHOUT CRA

1m Offshore Pipeline with Internal Pinholes

CARBON STEEL PIPE WITHOUT CRA

CARBON STEEL PIPE WITHOUT CRA

EC data reflect even tiniest pinholes

MFL Stand Alone Result

CARBON STEEL PIPE WITHOUT CRA

LARGE SCALE TRIAL PROGRAM WITH CRA PIPE

Combined result, higher accuracy, significantly reduced oversizing

LARGE SCALE TRIAL PROGRAM WITH CRA PIPE

LARGE SCALE TRIAL PROGRAM WITH CRA PIPE

Defect #1: ext. in CS, 6.5 mm depth

Defect #3: int. in CRA, 3.0 mm depth

Defect #4: int. in CS & CRA, 10.9 mm depth

Defect #2: ext. in CS & CRA, 13.0 mm depth

THANK YOU FOR JOINING

Combined MFL/EC approach allows to inspect CRA and CS in

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