reliability of in-service non-destructive testing (ndt)
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Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec
Speaker information
Reliability of In-Service NDT
Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec
Introduction
• NDT is a critical tool in our Integrity Management Toolbox
• The majority of In-Service Inspection we do is NDE
• Piping, vessels, exchangers, tanks, pipelines & structures
• We place a lot of FAITH in the NDT results and use it to determine FFS
• Is our FAITH justified?
Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec
Reliability of In-Service NDT
INDEPENDENTINTEGRITY
HEALTHCHECK
Corrosion Management
RBI Adequacy
IM Gap Analysis
In-Service NDT Adequacy
Integrity Database & CMMS Utilisation
IM Procedure Compliance
IM Strategy Compliance
Anomaly & Repair Management Process
Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec
Types of NDT applied for In-Service Inspection
• Ultrasonic
• Radiography
Advanced techniques –
• ToFD, Phased Array,……
• Digital / Computerised RT
• Slofec / MFL
Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec
Analysis
Build comprehensive Asset Register
Perform detailed Risk Based Inspection (RBI) studies
Determine applicable damage mechanisms
Great lengths – but can we detect, can we measure, does technician know what he is looking for????
HIGH
MED HIGH
MEDIUM
LOW
Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec
Construction NDT v In-Service NDT
• Training and Certification to support Oil & Gas Construction activity
• Increasing % of NDT in O&G is In-Service NDT / Non-Intrusive Inspection (NII)
• However most NDT training still reflects looking for weld flaws rather than in-service damage mechanism
• Often Opco’s not rigorous enough in specifying requirements
Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec
In-Service NDE – so what’s different?
• Different skills & mindset required
• Techniques / responses / interpretation differ greatly
• Corrosion and Erosion – random
• Defect locations and orientation and morphology not readily predictable………
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November 11-14, 2014 Adipec
Weld Root Corrosion & Erosion/Corrosion *
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Co2 Corrosion & SRBs
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Erosion & Crevice Corrosion
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Corrosion Under Insulation (CUI) *
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Pipelines
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November 11-14, 2014 Adipec
Influencing Factors for Consideration
• PANI (Programme for Assessment of NDT in Industry) requirements
• Take account of Human factors & enviromental conditions
• Training on specific samples
• Knowledge of damage mechanisms
• Appropriate Written Procedures and Reporting requirements
• Suitable POD to give desired Confidence Level
Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec
Typical Issues Observed
Competence – not received correct training for actual task
Experience / knowledge – no appreciation of what inside of pipe may actually look like!
Procedures – do not reflect in-service application (no DAC curve!)
Reporting – not clear & concise, poor layout and lack detail to support FFS
Appropriate technique – will not find and measure actual expected damage
Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec
New Inspection Technology
• Not always available in MEA region
• Sometimes equipment is available, but the Operator??
• In-Service training & experience with technique is still essential
Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec
What of Other Techniques?
Radiography
• Trained to interpret andidentify weld flaws
• Measurement ofremaining ligament
• Scale, sand, heat,vibration, debris…..
Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec
In-Service Radiographs
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November 11-14, 2014 Adipec
Inspection Technique Selection
• Consideration is required to ensure selection of most appropriate technique(s)
• Random deep, isolated, localised pitting on 6”dia piping – long lengths of straight pipe
• Manual ultrasonic scanning with 0 degree compression probe – is this the best approach?
• Looking for needle in a haystack! Applied Magnetic Flux Leakage (MFL) as a rapid screening, with detailed UT assessment of limited areas of interest
Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec
Typical Areas for Improvement
• In-Service orientated NDE Procedures
•Consider inspection conditions (access, weather, boredom, etc.)
• Make use of “hard copy” techniques
• Mix and match techniques (Slofec/TOFD/PE)
• Assurance/ x-checks on high criticality
• Ensure relevant training and awareness
Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec
Summary
- In-Service NDT is an essential tool in maintaining the Integrity of our Assets
- In-Service NDT requires specific skills, training, experience & procedures
- Be wary of putting too much FAITH in NDT results unless you also have the appropriate controls and assurance activities in place
- LR can help you have greater confidence in this critical data
Lloyd’s Register services to the energy industry
November 11-14, 2014 Adipec