Advanced Non-Destructive Testing for Tanks and · PDF fileAdvanced Non-Destructive Testing for...

Advanced Non-Destructive Testing for Tanks and Pipelines

Algeria, November 2016

Params. K

2Advanced NDT for Tanks and Pipeline

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 fromservice

• Purpose of On-Line inspection is to provide the maximumpossible 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


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

► 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

AUT General Qualification as per DnV Standards


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

• Rapid inspections with digital recording of data

• Highly sensitive to fusion face flaws

► High Temperature Applications

• For High Temperature Application up to 480 Deg C

• X & Y axis scanner

• 3D Image

PHASED ARRAY ON SS/DSS/9% Ni WELDS To avoid the use of RT offshore / Onshore


Long Range Ultrasonic Testing & Conventional UT


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

• No need to remove complete insulation for inspection

• High Temperature Application

• Rapid scanning tool

► Applications

• Road and river crossings

• Power plant tubing

• Risers

• Pipework

• Jetty lines & Jetty Supports

• Tank farm link lines

• Sphere legs

• Spiral welded pipe

• Sprinkler systems


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

• By using multi frequency can identify all indications

• 100% of surface area Coverage (up to 2m length)

► Applications

• Tank Floor Annular Plate Testing

• Testing Concrete Coated Interfaces

• Testing Under Pipe Supports

• Scan Under Vessel Supports


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.

► Advantages

• 100% floor inspection

• Verified reliability

• 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

► Applications

• Corrosion & Crack Detection

• Identify stress risers

• Pre-Shutdown activities


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

• Planning for repair well in advance

► Applications

• On-line Flange Testing

• Pre-Shutdown Inspection

• Crack detection

• Detection of SCC in complex Flanges


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


Scorpion for Tank Inspection

Scorpion B-SCAN imaging system is developed to performUltrasonic thickness measurements on ferrous material.

It can be used on vertical and horizontal surfaces like oil storagetank and pressure vessels.

The minimum diameter the crawler can inspect:1. Outside= circumferential is 1.5m and axial is 1.5m2. Inside= circumferential is 3m and axial 1.5m

The maximum surface temperature scorpion B-SCAN crawler canoperate is 80°C

Thickness measurement ranges from 2.5mm to 100mmapproximately


Inspection of Storage tanks, shells both external and internal surfacesInspection of tank roof plates Corrosion mapping of pipeline

Applications of Scorpion


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


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


Testing & Results of PEC

5 1

4 2

3

Typical 2D color plot and legend

h12

Pipe inspection direction


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.


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


External Corrosion Mapping by Laser Technology


The LIXI PROFILER FOR CUI

A major inspection challenge facing the factory process industries is how toexamine insulated piping for blockage and corrosion, especially for corrosionunder the insulation and internal erosionHow 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


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 Can not be Re Usable

Processing time Quick and 1min 40 min


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


MFL for Tank floor Inspection

MFL Floor map Scanner

Hand Scanner For Inaccessible areas


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

EEMUA


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.

Agency for AIM Services

Technical Due Diligence (TDD) of Storage Tank Terminal

• Visual inspection (VI).

• Review of documents i.e.

standard maintenance practices,

NDT records, safety procedures,

instrument calibration records

etc.

• Condition Assessment of the

entire facility including Storage

tanks, Piping, E&I, Civil

Foundations

Client


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.

In-service Inspection of Storage Tank as per API 653 Guidelines –On going (till Jan 2017)

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

Agency for NDTNo Of Tanks : 58




In-service Inspection of Storage Tank as per API 653 Guidelines @ July 2015


Agency for NDT

No Of Tanks : 3




In-service Inspection of Storage Tank as per API 653 Guidelines @ Aug 2016


Agency for AIM

Services

Agency for NDTNo Of Tanks : 3

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