Are Smart Pigs Smart

Enough?
Pipeline Safety Trust
Conference
Geoff Foreman
November 2nd.2017
November 7, 2017
Confidential. Not to be copied, distributed, or reproduced without prior approval. © 2017 Baker Hughes, a GE company, LLC - All rights reserved.
In-line Inspection … did you know?
•  Running at 9 mph

•  Taking 1.2 Million measurements/second

•  Examining the same surface area as 70 football

pitches

•  Analyzing 100,000 potential defects, on 20,000

screens of data

•  Finding flaws the diameter of a quarter, or

thinner than a matchstick, well before it can
affect the safety of a pipeline

•  ILI, the pipeline equivalent to Medical diagnostics

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What is ILI and why do we use it?
•  A means of inspecting a pipeline from end to end, all around the pipe.
•  A robotic device (smart pig) that is pushed through the pipe by the product
•  It is none intrusive and means energy can be delivered continuously without
interruption during the inspection.
•  Can identify flaws well before they become threats to the integrity of the pipeline.
•  Running multiple ILI technologies , builds up confidence in identifying what and
where potential threats are contained in a specific pipeline.
•  When carried out on a regular basis, can determine the rate of defect growth, and
thereby gives the means for assessments and repairs in a timely and planned
manner.
•  It is the most comprehensive means of screening for defects. (medical analogy –
why do we have regular health screening tests?)
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In-line Inspection …is a process not a technology

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< MFL4 Animation Video>

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Practicalities Of The Pipeline Characteristics
Pipeline -  Tool compatibility

Operations -  Product Type, Flow rate, Trap Length

The Defect Types

-  Target features
associated with a
growth mechanism

The Required Accuracy

Selection process -  PoD, PoI & sizing capability

for the target cracks
of the ILI TOOL and
VENDOR!

November 7, 2017 6
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ILI for Corrosion & Other Threats
Identify and size Magnetic Flux
significant Leakage (“MFL”)
corrosion
(volumetric metal
loss)

Piezoelectric
NEAC & Grooving Ultrasonic Wall
corrosion Measurements
Discriminate and
identify more
complex threats
Eg Mechanical Damage
Transverse
MFL

Spatially map the

pipeline centerline
route (from the inside…) Geometry / Caliper
Identify deformation Mapping
threats

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 Geometry
(Dents and ovality)

Metal loss
(corrosion & gouges)

CD tools
(Cracks &
LOF
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ILI Evolution – Metal loss & Cracking
1st Digital POF Introduction
Initial combo tools
MFL ILI Mapping MFL HR Metal loss MFL + of Girth
tools (IMU) pig tools spec Caliper/IMU Weld spec
1965 1986 1998 1994 2006 2016

1975 1987 1990  1997 2013

initial Pressure Computer CMF (TFI) pin hole
High Res based disc (digital) tool spec
MFL tools reporting reporting
Initial crack
tool Elastic Absolute
Wave Initial EMAT depth sizing
1982 2002 2010

1994 2004  2017

Initial Initial USDuo. Phased HR CD tool
USCD tool Array tool

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People and Training: ANSI/ASNT ILI-PQ-2005

Trainee Level 1 Level 2 Level 3

36-60
months
6-12 18-24
months months
Level 3
Level 2
Level 1
Trainee Additional tasks and responsibility as level increases
Experience, Assessment, leadership

Long Term Commitment to Certification

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Confidential. Not to be copied, distributed, or reproduced without prior approval.
DUO ANIMATION VIDEO

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Ultrasonic Crack Detection Evolution - Analysis and
Reporting 1st
Multiple Phased angle CD
Crack EMAT Edge
inspections
Tool Gen I
EW DUO
CD Double Circumferential Higher
Hardware Resolution = 3mm Resolution
EMAT
Gen 3 CD
1st USCD
Inspection P

1974 … 88 1994 1995 … 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 2016 2017

Depth Crack
Estimation Abs
New SCC Min
Crack profiling & Depth
Analysis SCC mapping
Algorithm
Incl.
detection
Weld Length
New Tolerance 0.6”
Notch Absolute Depth Misalignment analysis
Depth
Feature based Reported Attributes
in %WT
Sizing 1 Million Cracks
Reported

Reporting cycle Reporting cycle Tailored reporting Priority Scan

Reporting 180-360 days 110 days CD 30-60 days EMAT 30 days

November 7, 2017 13
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POD diagram - Percentage confidence increases with crack
size.

POD

Defect depth in mm (0.04” =1 ) at least 1.2 inches long

What is the target crack size you need to detect? “x” times smaller than that which will fa

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UltraScan CD Edge

Surface-breaking feature with the appearance of a LOF

Peak Depth 100% Length 0.5”

November 7, 2017 15
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EMAT ANIMATION VIDEO

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EmatScan CD – ERW Seam Weld

EMAT Field
Crack-Like Feature Surface Breaking
Type
Lack of Fusion
> 0.2 inches Depth 0.16 inches

Dig Verification | lack of fusion in ERW

November 7, 2017 17
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Challenges for ILI – Potential
failures post ILI

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 What can cause ILI to miss report defects….
Cause Solutions
•  Debris in the pipeline can blind sensors•  Extensive cleaning - Data quality checks post
•  Using the wrong ILI tool for the threat •  ILI tool and Vendor capabilities – PRCI TDC te
•  Run the ILI too fast •  Post run Data quality check– Re-run
•  No or poor Dig verification •  Make sure the ditch NDE is good – feedback!
•  None Standard pipe •  Identify these areas and record their location
•  Store the attributes in the database
•  Train analysts/algorithms to identify these
•  Use alternative technologies not affected
•  Complex features •  Overlay of different ILI runs data
•  Use combo tools ILI different defects in 1 run
•  Derive unique analysis methodology
•  Not in the codes – No reporting std. •  Run experiments – burst test specimens
•  Bring in 3rd party expertise (i.e. PRCI)
November 7, 2017 19
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 EmatScan CD – None Standard Seam Weld Inspection

~3T
~3T

counter
T
clockwise clockwiseT
sensor sensor

November 7, 2017 20
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Crack in dent
Detection and sizing using EmatScan CD
tool & High Res Caliper.

2015 innovation in crack ILI

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EmatScan CD – Seam Weld

Ultrasonic
Transducer

a
Liquid Internal Crack
Steel
45°
External Crack

Conventual
Sound transmitted around the pipe USCD Shear
wave at 45
deg.
November 7, 2017 22
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UltraScan DuoTM
Crack Detection Phased
Arrays Acurate crack inspection
How do we make smart pigs
(liquid)

smarter?

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 3D Visualization
Concept
•  Provides 3D visual aid
•  Advances beyond 2D BScan enabling
accurate crack profiling
•  Tool does the heavy geometric thinking
•  Allows analyst to focus on accuracy &
morphology
What we are currently developing
Automated Learnings
Concept
•  Pattern Recognition with
search tool
•  Allows learning backwards
•  Improved QC of inspection
data
•  Automated classification of
new data
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 Crack in Corrosion

c d

Corrosion ;- Flat bottom vs steep pits?

Width – narrow vs wide?
Shallow or deep?
Need to know that the corrosion is present!
The shape of the corrosion can affect the amplitude of the returning sound at 45 deg?
Emat not affected as sound is travelling around the pipe therefore its reflector is not influenced.

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