M A R C H 2 0 1 9 / I G U M E E T I N G A B U D H A B I
LEAK DETECTION ON NATURAL GAS
BURIED PIPELINES AND SMART
TORQUEING OF BOLTED JOINTS IN
GAS INSTALLATIONS
JONATHAN MARTINEZ
© C o p y r i g h t B u r e a u Ve r i t a s
01
The need –The stakes
02
Methodology and equipment used
Conclusion
03
AGENDA
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01
The need –The stakes
02
BV & Cumulus’ partnership
Conclusion
05SMART TORQUEING OF
BOLTED JOINTS IN GAS
INSTALLATIONS
LEAK DETECTION ON
NATURAL GAS BURIED
PIPELINES
Our technical solution
03
Deliverables & benefits
04
LEAK DETECTION ON NATURAL GAS BURIED PIPELINES
THE NEED – THE STAKES
LEAKS IMPACT AND EXCAVATION WORKS COSTS
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Accidental large leaks have always significant impact
Safety
Communication / Reputation
Excavation costs in case of suspected leak generates heavy and expensive works
Unprecise leak location can result in wrong / too important excavation zone
Direct and indirect cost
Sometimes for Biogas emissions
Environment
THE NEED – THE STAKES
DIFFERENT CAMPAIGN’S CONTEXT
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Preventive campaign
Determination of a strategy (frequency of recurrent controls)
Scheduling of the survey
Leak suspicion
Definition of the concerned portion(s) of pipeline (s) where leaks are suspected
Appointment for data collection
Scheduling of the survey
Appointment for data collection
Intervention on an urgent basis
Definition of the perimeter of the survey with milestone determination
02Methodology and equipment used
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METHODOLOGY AND EQUIPMENT USED
MAIN PHASES
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Preparation
Collection of drawings showing the concerned pipeline(s)
Reporting and deliverables
Data analysis
Documented report
Collection of aerial pictures and GPS coordinates (if available)
Collection of pipe’s material information
Collection of pipe’s length
Field campaign
Methane detection from the ground at the vertical of the pipeline
Gas analysis when Methane is detected
Data collection for detected leaks
List of deliverables
METHODOLOGY AND EQUIPMENT USED
EQUIPMENT USED FOR PIPE LOCATION DETERMINATION
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First approach of the right location
Use of collected drawings showing the concerned pipeline(s)
Use of collected aerial pictures and GPS coordinates (if available)
Precise determination of the pipeline location
Use of a signal generator connected to cathodic protection markers
Pipe visual indicators + Use of collected data in case of cathodic protection not available
METHODOLOGY AND EQUIPMENT USED
METHANE DETECTION
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Classic transportation of the detector
Our 2-Inspectors team walks above the pipeline hand-carrying the dedicated Methane detector
Optional use of a smartphone (with adequate programme installed) to record measurement values
associated with time data and GPS coordinates
Alternative transportation of the detector
Case by case, drone transportation of the detector can be studied
METHODOLOGY AND EQUIPMENT USED
LEAK VALIDATION BY BIOGAS EXCLUSION
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Gas analysis
For preventing reporting “Biogas Emissions” instead of “Gas Leaks” from the pipeline, we analyse the detected gas composition
The transported Natural Gas contains typically 3 to 5 % of Ethane
When Ethane is detected into the emitted gas, this means it’s a leak from the pipe and not Biogas
METHODOLOGY AND EQUIPMENT USED
LEAK VALIDATION BY BIOGAS EXCLUSION
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Gas analyser demonstration
METHODOLOGY AND EQUIPMENT USED
DATA COLLECTION
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When a Natural Gas leak is detected we collect all necessary pieces of information for allowing the
Transmission Operators to launch excavation works
Picture of the place where the Natural Gas emissions was detected
GPS coordinates
Leaks list with:
Maximum measured value in surface (in ppm.m) with “Laser Methane”
Maximum measured value in surface (in ppm) with “Gas analyser”
Presence of Ethane or not (= Natural gas or Biogas)
Picture and drawing reference
Leak reference transfer on the provided drawing showing the concerned pipeline
METHODOLOGY AND EQUIPMENT USED
REPORTING AND DELIVERABLES
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Documented report
Campaign’s highlights
Campaign duration
List of detected leaks (and Biogas emissions detected)
Detection means
Additional deliverables
Leaks pictures
Leaks GPS coordinates
Leak reference transfer on drawings
Detection means
Access to our Download Centre
Permanent backup
Access protected by Login / Password
03Conclusion
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CONCLUSION
LEAK DETECTION ON BURIED PIPELINES
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Time has a direct impact on buried gas pipelines leak apparition and increasing
A well structured leak detection plan allows detecting leaks before they become significant
and dangerous
Leak Detection on buried pipelines is strategic as they can improve Safety, Health &
Environment, save product and save money
Bureau Veritas has the necessary experience, size and solidity to be a long term partner for
Transmission Operators
Bureau Veritas, Global QHSE company, is a world leader in LDAR, that has developed
advanced tools in order to provide a world class service with trained and experienced teams
worldwide
SMART TORQUEING OF BOLTED JOINTS IN GAS INSTALLATIONSPowered by the CUMULUS SMART TORQUE SYSTEM ™
I n t e g r a t e d D i g i t a l B o l t e d J o i n t M a n a g e m e n t S O L U T I O N P o w e r e d b y t h e C U M U L U S S m a r t T o r q u e S Y S T E M ™
THE NEED – THE STAKES
01
THE NEED
THE STAKES
NEED
One of the most critical aspects during the plantsconstruction, commissioning, and start-up aftershutdown is the assembly and installation of boltedjoints.
VALUES
Health, Safety and Environment issues also pose agreat threat to companies reputation if not addressedproperly.
CHALLENGE
The short availability of trained specialized techniciansand lack of specific planning for bolted joint is reflectedin increasing of the risk of accidents, with legal andeconomic consequences, start-up delay(commissioning of a new plant or restarting after turnaround) and high costs.
SOLUTION
Bureau Veritas offers integrated solutions for servicesoptimization management related to bolted jointsleveraging on Maintenance Engineers know-how andfield expertise.
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BUREAU VERITAS & CUMULUS PARTNERSHIP
02
BUREAU VERITAS & CUMULUS
PARTNERSHIP
Bureau Veritas,
world leader in Testing,
Inspection and Certification
services (TIC)
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Cumulus,
an innovating spin-out from Shelland
Have established in 2019 a partnership unifying their respective competences to provide their
common customers with an innovative solution in the field of Bolted Joints Management
2019 Industrial Internet-of-Things (IoT) Innovation of the Year
OUR TECHNICAL SOLUTION
03
OUR TECHNICAL
SOLUTION
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The innovative solution we have developed consists
in building a database fully dedicated to torqueing.
This database is created and operated using a
specialized Flange Management Platform (software)
installed on a tablet PC. This database is linked to
the site flanges by means of QR code tags
000001
SMART TORQUEING SYSTEM (STS)
When the maintenance operator reads the QR code
using the tablet, (even offline) he’s instantaneously
connected to the flange’s database records
containing all necessary pieces of information to
perform the right tightening (tightening torque,
torque sequence…)
1
2
OUR TECHNICAL
SOLUTION
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The torque wrench is connected to the tablet by
Bluetooth which allows a direct reading of the
tightening torque on the tablet
The software + database ensure a direct control of
the tightening operations, guiding the maintenance
operator with a visual and intuitive color code till
reaching the expected range
3
4
OUR TECHNICAL
SOLUTION
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Cloud-HostedDatabase
TorqueFit Mobile
Application (Windows 10
OS)
Control Center Dashboard
Control Center Dashboard
Work Execution and Data
Collection (Manual and
Hydraulic/Pneumatic Tools)
Fitter Team
Bolted Joint
Event Execution
Management
(Supervisor/Q-Captain)
Event Progress
Review (QA,
site mgmt.,
etc.)
* Via Existing Network Connection
Flange Management System
Database populated with
data imported via
spreadsheet/Web portal
Bluetooth Connectivity
Wi-Fi/4G/3G
Connectivity
Access via web-portal (cloud
based)
000001
SMART TORQUEING SYSTEM (STS)
OUR TECHNICAL
SOLUTION
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DELIVERABLES & BENEFITS
04
DELIVERABLES &
BENEFITS
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Service deliverables
Hardware
Bluetooth torque wrench(es)
ATEX Bluetooth pressure gauges” (with hydraulic pumps)
ATEX tablet(s) - Windows
Software
Login/password to access the online software
Data
Database records
Reports
P&IDs quality check feedback
Project management
Supervision of the Smart Torqueing System
DELIVERABLES &
BENEFITS
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STS provides facility managers detailed, near-real time contractor
performance data
Torque-time per flange
Work quality and rework
Delay between completion and QC
This data can aid in the selection of appropriate contractors and
provide performance benchmarking
The value of the data set will grow exponentially over time
0,5 0,75 1 1,5 2 3 4 6 8 10 12
Avg.
Tim
e (
min
)
Flange Size (inch)
Contractor A vs. B Avg. Torqueing Time
Contractor A Contractor B
0,5 0,75 1 1,5 2 3 4
Avg.
Tim
e (
min
.)
Flange Size (inch)
Contractor A’s Efficiency Improvement After Data Challenge
13-Mar 15-Mar
Contractor performance transparency
CONCLUSION & QUESTIONS
06
CONCLUSION &
QUESTIONS
Bureau Veritas offers integrated solutions for digital bolted joints management optimisation, managing& supervising the entire process from beginning to end
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Bureau Veritas allows translating “Assembling” to “Cost saving”
Leverage on maintenance engineers and field expertise
Digitalisation of the process
Training and certification of staff members
Access to a powerful dedicated software
Monitoring the performance of execution