scraper challenges in the transport of seawater by …
TRANSCRIPT
SCRAPER CHALLENGES IN THE TRANSPORT
OF SEAWATER BY PIPELINES –NEW TECHNOLOGIES AND POTENTIAL BUSINESS OPPORTUNITIES
RIDHA H. ABBAS
M. RASHID KHAN
2
Agenda
1. WHERE: SEAWATER INJECTION SYSTEM
2. WHY: CHALLENGES OF SEAWATER TRANSPORT BY PIPELINES
3. HOW: GATES FOR SCRAPER SELECTION PROCESS
4. WHICH: SCRAPER SELECTION FOR SWID WANTS AND NEEDS
5. WHAT’S MISSING: INNOVATION & BUSINESS OPPORTUNITIES
6. SUMMARY
7. LITERATURE REVIEW: SAMPLE OF SCRAPER TECHNOLOGY TRENDS
4
Saudi Aramco: Company General Use
Saudi Aramco’s SWID operates the world’s largest seawater
treatment plant for oil reservoir injection.
•Gulf
45
3
•Surge Tanks
Plant D
QSWP
Plant B
Plant A
Plant C
Surge Tanks
Plant F
1
5
Saudi Aramco: Company General Use
• Immense treatment capacity:
- 14 million bpd
- Approx. 900 Olympic swimming pools
• Vast pipeline network
- Over 1,500 km
- Wide range of sizes (60” down to 2”)
- Large geographic area
- Extensive branching
- A series of diameter reductions
- Mostly underground
• Both treatment and transport of pipelines present
challenges for scraper technologies.
The scale of production and extent of pipeline network
present challenges for scraper technologies.
7
Saudi Aramco: Company General Use
SWID launched an operational excellence effort focused on
corrosion management within a water treatment strategy.
Water Treatment Strategy
Corrosion Management Program (CMP)
Water Quality Management
Chemical Treat.
Microbial Management
HSE Impact
Evaluate Toxicity
Projects reducing impact
Biocides with less HSE impact
Less FORM
FORM-free
“Green” Biocide
R.O. compatible
Biocide Performance
Fluid Sampling
Plan
Lab Practices & Procedures
MIC Risk
Risk-based injection
Pipeline Integrity Management (PIM)
Scraper Technologies
Pipe Type
Anti-MICNon-
metallic
Solar-Powered
R.O.
SWID personnel received
certified training on
developing strategy maps.
8
Saudi Aramco: Company General Use
The Corrosion Management Program identified treatment
corrosion challenges and explained effects on pipelines.
H2SO3
N2
Disinfected
DeaeratorHorizontal Filters
Disinfected
Intake
ChannelIntake
Screens
Above
Grade
Canal
To
Transport
Pipeline
Treatment ModuleFiltered
Filtered Noncorrosive
Non-scaling
Corrosion Management Program (CMP)
Water Quality/ MIC Risk Pipeline Integrity Management (PIM)
9
Saudi Aramco: Company General Use
SWID’s mission is fraught with corrosion challenges
affecting the pipeline network.
MISSION CORROSION CHALLENGES
Treat
• Filtration
• Deoxygenation
• pH adjustment
• Disinfection
• Hypochlorite (before deoxygenation)
• Biocide (after deoxygenation)
Transport
Inject
• may lead to corrosion especially in internally bare pipelines.
Insufficient deoxygenation
• may lead to corrosion in the filter’s laterals, from which filtration media (sand) can pass through and damage the internal coating of the pipelines, causing erosion and corrosion and present a fertile environment for microbial activity.
Incorrect dosing of hypochlorite
• may further allow microbial activity to accelerate the rate of corrosion
• may further lead to Microbially-Enhanced NORM.
Inappropriate dosing of biocide
• may disrupt production
• may interrupt traffic should it occur under road crossing.
Corrosion may develop into leaks
10
Saudi Aramco: Company General Use
The corrosion challenges require use of scrapers, for debris
removal or In-Line Inspection, with their own challenges.
Challenges of the 56/60–inch
Bare Pipelines
Challenges of the Pipelines
Network
Monitor in Real-Time with Minimal Human Intervention
Detect NORM
Navigating Multi-diameter Pipelines
Navigating Extensive Branching and series of diameter reductions
Detecting Internal Coating Damage
Detecting Pinhole Leaks
Detecting Under Railroad and highway crossings
12
Saudi Aramco: Company General Use
• Individual scraper providers will highlight unique capabilities to gain
an edge over the competition.
• This study focuses on scraper selection criteria.
Selecting which technology to use and provider to partner
with is a process which goes through several gates.
Scraper Selection
Range of Services
Reliable Mobilization
Scale of Application
14
Saudi Aramco: Company General Use
SWID’s criteria for ranking and selecting surveyed scrapers
is guided by the department’s strategy map.
15
Saudi Aramco: Company General Use
The processes and enablers of learning and growth relevant
to Pipeline Integrity Management identify scraper purposes.
• Process Category: Protect Equipment
- Perform a condition assessment/fit for
service of the pipeline network.
- Reduce occurrence of leaks in the off-
plot pipeline network.
- Increase pipeline reliability,
availability and serviceability.
• Process Category: Adopt Flexibility
- Introduce flexibility to the system.
• Review pipeline network design and
propose measures for more
flexibility to deploy scrapers for ILI
and/or mechanical cleaning and
protect people from the
consequences of leaks (such as
under railroad crossings).
16
Saudi Aramco: Company General Use
The processes and enablers of learning and growth relevant
to Pipeline Integrity Management identify scraper purposes.
• Process Category: Address Social
Responsibility
- Protect people and the environment
from leaks.
• Propose technologies to detect
leaks in the pipeline network.
• Inspect condition of pipelines under
highways and railroad crossings to
assess the potential for leaks.
- Acquire technologies for safer
maintenance activities.
• Monitor scraper passage with little
or no human intervention.
- Measure NORM in the pipelines and
seek to reduce it.
• Seek to detect NORM in the pipeline
network
17
Saudi Aramco: Company General Use
• Enabler: Leverage Data
- Collect relevant, reliable and representative data to accurately and promptly
calculate the rate of thickness loss.
• Review the distribution and frequency of inspection methods to monitor corrosion
in a resource-effective manner in terms of cost and manpower.
• Propose technologies to inspect the condition (thickness data) of pipelines:
- Under highways and railroad crossings
- Single-diameter pipelines (i.e. shipping and transfer lines).
- Multi-diameter (telescopic) pipelines (i.e. flanks and laterals).
- Organize data for ease of access and analysis while maintaining integrity of data.
- Create feedback loop from data, to engineering evaluation, to decisions of operation
and/or maintenance.
The processes and enablers of learning and growth relevant
to Pipeline Integrity Management identify scraper purposes.
18
Saudi Aramco: Company General Use
According to the strategy’s PIM internal processes related
to scraping, eight (8) selection criteria have been derived.
Flexible Application
Location Tracking of Scraper
Detection of NORM
Relevant Data
Reliable Data
Representative Data
Organized Data
Analysis of Data (feedback loop)
19
Saudi Aramco: Company General Use
Scraper features in the market are categorized by selection
criteria in a scorecard to evaluate providers and to identify
development opportunities.
Location
Diameter(s)
Launcher/receiver available?
Internally coated?
Above- or under-ground?
Construction date
# of leaks since construction
Fluid type
Flow volume and velocity
Fluid temperature
MAOP
# Want Various Feature Descriptions
Adopt Flexibility (Some are sample from Quest Integrity's In-Vista)
1 Introduce Flexibility Accommodates limited or missing launcher/receiver facilities
Accommodates single entry/exit, line stoppage, plugged valves
Traverses bottom unbarred tees, wyes and mitre bends
Navigates bore restrictions, step changes, reduced port valves
Navigates back-to-back bends with >90° short radius turns
Inspects pipelines in the range of xx" to yy"
Inspects dual-diameter pipeline with a % difference of …….
Passes multi-diameter pipelines with up to XX % reduction.
Functions in no-flow or limited flow conditions
Functions in multiphase conditions
Accomodates internally coated pipelines
May be diverted in excessive pipe branching conditions
Inspects internally cement lined pipelines
Address Social Responsibility
2 Measure NORM Detects radiation level of NORM deposits at a specific location
Measures quantity of NORM deposits at a specific location
3 Safer Maintenance Activities Track using hand-held scraper passage indicator (magnetic-based)
Track using hand-held scraper passage indicator (vibration-based)
Track "real-time" using "physical" fixated indicators
Track "real-time" using "digitized" fixated indicators
Track and report features using GPS coordinates
Leverage Data
4 Collect Data: Relevant Measures thickness loss
Detects coating damage even if minimal thickness loss
Detects pinhole leaks
Detect leaks in subsea
Detect external corrosion
Inspects cracks
Inspects non-standard and bulging pipe material
5 Collect Data: Reliable (Accurate) Resolution (e.g. Short Range Distance SRD technology)
Speed up to (e.g. 5 min per 600 mm X 1000 mm)
MFL based
UT based
6 Collect Data: Representative Provides 100% overlapping coverage of pipeline geometry
Sufficient data in single pass
7 Organize Data Web-based interface available to user
Represent data in powerful graphs
Supply raw data in spreadsheets
8 Feedback Loop: Data Analysis Report practical recommendations
Report results in a timely manner
Relevance
Pipe
line
Info
rmat
ion
Endu
ro
Hal
libur
ton
Am
eric
an In
nova
tion
s
T. D
. Will
iam
son
Que
st In
tegr
ity
ROSE
N
Company Score Card
Scraper Selection/Development Scorecard
Oth
er (2
)
Oth
er (1
)
3P S
ervi
ces
A. H
ak
Para
digm
Flo
w S
olut
ions
GE
Oil
& G
as P
ipel
ine
Solu
tion
s
Pipe
line
Insp
ecti
on C
ompa
ny L
td
Mar
ket (
over
all)
add
ress
es W
ant?
Is fe
atur
e a
Wan
t for
our
faci
lity?
20
Saudi Aramco: Company General Use
Scraper features in the market are categorized by selection
criteria in a scorecard to rank providers and to identify
development opportunities.
Location
Diameter(s)
Launcher/receiver available?
Internally coated?
Above- or under-ground?
Construction date
# of leaks since construction
Fluid type
Flow volume and velocity
Fluid temperature
MAOP
# Want Various Feature Descriptions
Adopt Flexibility (Some are sample from Quest Integrity's In-Vista)
1 Introduce Flexibility Accommodates limited or missing launcher/receiver facilities
Accommodates single entry/exit, line stoppage, plugged valves
Traverses bottom unbarred tees, wyes and mitre bends
Navigates bore restrictions, step changes, reduced port valves
Navigates back-to-back bends with >90° short radius turns
Inspects pipelines in the range of xx" to yy"
Inspects dual-diameter pipeline with a % difference of …….
Passes multi-diameter pipelines with up to XX % reduction.
Functions in no-flow or limited flow conditions
Functions in multiphase conditions
Accomodates internally coated pipelines
May be diverted in excessive pipe branching conditions
Inspects internally cement lined pipelines
Address Social Responsibility
2 Measure NORM Detects radiation level of NORM deposits at a specific location
Measures quantity of NORM deposits at a specific location
3 Safer Maintenance Activities Track using hand-held scraper passage indicator (magnetic-based)
Track using hand-held scraper passage indicator (vibration-based)
Track "real-time" using "physical" fixated indicators
Track "real-time" using "digitized" fixated indicators
Track and report features using GPS coordinates
Leverage Data
4 Collect Data: Relevant Measures thickness loss
Detects coating damage even if minimal thickness loss
Detects pinhole leaks
Detect leaks in subsea
Detect external corrosion
Inspects cracks
Inspects non-standard and bulging pipe material
5 Collect Data: Reliable (Accurate) Resolution (e.g. Short Range Distance SRD technology)
Speed up to (e.g. 5 min per 600 mm X 1000 mm)
MFL based
UT based
6 Collect Data: Representative Provides 100% overlapping coverage of pipeline geometry
Sufficient data in single pass
7 Organize Data Web-based interface available to user
Represent data in powerful graphs
Supply raw data in spreadsheets
8 Feedback Loop: Data Analysis Report practical recommendations
Report results in a timely manner
Relevance
Pipe
line
Info
rmat
ion
Endu
ro
Hal
libur
ton
Am
eric
an In
nova
tion
s
T. D
. Will
iam
son
Que
st In
tegr
ity
ROSE
N
Company Score Card
Scraper Selection/Development Scorecard
Oth
er (2
)
Oth
er (1
)
3P S
ervi
ces
A. H
ak
Para
digm
Flo
w S
olut
ions
GE
Oil
& G
as P
ipel
ine
Solu
tion
s
Pipe
line
Insp
ecti
on C
ompa
ny L
td
Mar
ket (
over
all)
add
ress
es W
ant?
Is fe
atur
e a
Wan
t for
our
faci
lity?
Location
Diameter(s)
Launcher/receiver available?
Internally coated?
Above- or under-ground?
Construction date
# of leaks since construction
Fluid type
Flow volume and velocity
Fluid temperature
MAOP
# Want Various Feature Descriptions
Adopt Flexibility (Some are sample from Quest Integrity's In-Vista)
1 Introduce Flexibility Accommodates limited or missing launcher/receiver facilities
Accommodates single entry/exit, line stoppage, plugged valves
Traverses bottom unbarred tees, wyes and mitre bends
Navigates bore restrictions, step changes, reduced port valves
Navigates back-to-back bends with >90° short radius turns
Inspects pipelines in the range of xx" to yy"
Inspects dual-diameter pipeline with a % difference of …….
Passes multi-diameter pipelines with up to XX % reduction.
Functions in no-flow or limited flow conditions
Functions in multiphase conditions
Accomodates internally coated pipelines
May be diverted in excessive pipe branching conditions
Inspects internally cement lined pipelines
Address Social Responsibility
2 Measure NORM Detects radiation level of NORM deposits at a specific location
Measures quantity of NORM deposits at a specific location
3 Safer Maintenance Activities Track using hand-held scraper passage indicator (magnetic-based)
Track using hand-held scraper passage indicator (vibration-based)
Track "real-time" using "physical" fixated indicators
Track "real-time" using "digitized" fixated indicators
Track and report features using GPS coordinates
Leverage Data
4 Collect Data: Relevant Measures thickness loss
Detects coating damage even if minimal thickness loss
Detects pinhole leaks
Detect leaks in subsea
Detect external corrosion
Inspects cracks
Inspects non-standard and bulging pipe material
5 Collect Data: Reliable (Accurate) Resolution (e.g. Short Range Distance SRD technology)
Speed up to (e.g. 5 min per 600 mm X 1000 mm)
MFL based
UT based
6 Collect Data: Representative Provides 100% overlapping coverage of pipeline geometry
Sufficient data in single pass
7 Organize Data Web-based interface available to user
Represent data in powerful graphs
Supply raw data in spreadsheets
8 Feedback Loop: Data Analysis Report practical recommendations
Report results in a timely manner
Relevance
Pipe
line
Info
rmat
ion
Endu
ro
Hal
libur
ton
Am
eric
an In
nova
tion
s
T. D
. Will
iam
son
Que
st In
tegr
ity
ROSE
N
Company Score Card
Scraper Selection/Development Scorecard
Oth
er (2
)
Oth
er (1
)
3P S
ervi
ces
A. H
ak
Para
digm
Flo
w S
olut
ions
GE
Oil
& G
as P
ipel
ine
Solu
tion
s
Pipe
line
Insp
ecti
on C
ompa
ny L
td
Mar
ket (
over
all)
add
ress
es W
ant?
Is fe
atur
e a
Wan
t for
our
faci
lity?
21
Saudi Aramco: Company General Use
To visualize the ranking, a Spider Chart may be developed
based on the technology selection criteria derived from
PIM-related strategy goals
22
Saudi Aramco: Company General Use
To visualize the ranking, a Spider Chart may be developed
based on the technology selection criteria derived from
PIM-related strategy goals (example).
24
Saudi Aramco: Company General Use
Technology providers compete in
• support services provided: which could help gain an advantage in the gated selection
process.
• technology features: which are prevalent in the industry.
Trends in technology development in the market are driven by issues such as:
• Automation to offset the cost of man hours associated with routine pigging operations.
• The development of shale gas reserves has become a new driver for pipeline pigging.
• Government regulations and international pipeline construction.
Technology providers compete in support services and
technology features.
25
Saudi Aramco: Company General Use
SWID needs/wants not addressed by the market include:
• Detecting NORM.
• Navigating a series of diameter reductions with extensive branching.
• Reporting real-time location with little or no human intervention.
• Detecting coating disbondment.
• SWID is open to collaborate utilizing systemic innovation techniques, such as
- TRIZ
- InnovationCUBE and Lean Product Design
- Other
There is room for technology feature improvements to
address SWID needs and to develop business opportunities.
27
Saudi Aramco: Company General Use
Using a strategy map to guide pipeline management led SWID to identify challenges in the
use of scrapers, survey scraper technology trends, and identify opportunities for potential
innovation and business development.
A strategic approach to operating a facility is useful to
explore opportunities for technology developments.
Strategy Map
Corrosion Management Program
Pipeline Integrity Management
Scraper Challenges
Selection Criteria
New Technologies
29
LITERATURE REVIEW:
Sample of scraper technology trends
1. “American Innovations” PIG Bullhorn Asset Tracker (BAT™)
2. Innovations by L22M Search and Track Receiver
3. Development of New Technology by Halliburton
4. Innovative Technology by Quest Integrity’s InVista
5. Enduro Pipeline Services: DigiTel Flux Logger (DfL™)
6. Pipeline Inspection Company, Ltd.: SPY® pig-tracking products
7. GE Oil & Gas: ’ MagneScan™ MFL
8. TDW Offshore Services: SmartPlug and STOPPLE Train
9. Paradigm Flow Solutions: Pipe-Pulse system
10. Rosen: Magnetic Flux Leakage (MFL)
11. 3P Services
12. A. Hak Pipeline Services
Thank You!Ridha H. Abbas
M. Rashid Khan
31
Saudi Aramco: Company General Use
• Users the ability to track a PIG's progress through a
pipeline system with remote monitoring devices at pre-
determined points in "real time.”
• The system monitors and collects data and provides
immediate notification of alarm conditions by voice,
email and/or text.
• BAT™mobile provides users with on-the-go access to BAT
in a smartphone optimized format.
American Innovations
PIG Bullhorn Asset Tracker (BAT™)
32
Saudi Aramco: Company General Use
• Can remotely monitor and record the passage of pigs
using an ELF transmitter or MFL magnets.
• The unit will record the passage of a metallic pig using
only its intrinsic low level magnetic field.
• As a lightweight (< 3 lbs.) hand-held device.
• The unit contains a GPS receiver and uses Bluetooth®
communication.
• The system costs about half as much as older units.
• Can view pig passage signals and wirelessly notify the
operator of the passage.
Innovations by L22M Search and Track Receiver
33
Saudi Aramco: Company General Use
• The Hal-AT® real-time remote subsea data system by
Halliburton helps the operator reduce project time and
costs.
• Pipeline Pressure Monitoring: Can be utilized for most
applications such as recording pressure anomalies during a
pigging run, determining when a pig reaches
destination/location and recording pressure during a
hydrostatic test.
• Haltrax: This enables one or more pig trains to be
monitored remotely without requiring an ROV to view
externally mounted indicators.
• Haltest: During subsea hydrostatic testing, it enables a
vessel to move off station to work elsewhere while still
monitoring the pressure trend in the pipeline.
Development of New Technology by Halliburton
34
Saudi Aramco: Company General Use
• A hand-held ultrasonic in-line intelligent pig capable of
detecting pipeline wall loss and corrosion in difficult-to-
inspect pipelines.
• Provides 100% overlapping coverage of geometry and
metal-loss features in one pass.
• Inspects 3"-24” diameter and dual diameter pipelines.
• Navigates bends with >90° short radius turns, bore
restrictions, step changes, reduced port valves.
• Identifies wall thickness changes and wall loss.
• Accommodates single entry/exit, line stoppage, and
plugged valves.
Innovative Technology by Quest Integrity’s InVista
35
Saudi Aramco: Company General Use
• Acquires data from several sources simultaneously all in
one pass.
• Provides data sets for conducting metal loss, deformation
and inertial surveys.
• Internal and external discrimination and residual field
data are taken in one pass.
• Processing and analyzing the closely coupled data allows
software users/analysts to more readily recognize
pipeline features and assess conditions.
Enduro Pipeline Services
DigiTel Flux Logger (DfL™)
36
Saudi Aramco: Company General Use
• Offers its line of for mainline transmission lines, gathering
lines, subsea lines, municipal gas, water and wastewater
lines and the refining and process industries.
• These transmitter-locating devices are portable and
capable of producing a visual and audio output. They can
also be provided for 10,000-foot subsea applications.
Pipeline Inspection Company, Ltd.
SPY® pig-tracking products
37
Saudi Aramco: Company General Use
• The tool simultaneously maps the pipeline and checks for
corrosion
• Uses high-resolution MFL sensors
• Delivers high-quality data to identify and locate metal
loss and is suitable for GIS analysis
GE Oil & Gas:
MagneScan™ MFL
38
Saudi Aramco: Company General Use
• Delivers safe integrity solutions for subsea pipeline work,
including challenging pipeline blockages.
• The SmartPlug isolation plug modules can be used with its
remotely-operated SmartTrack tracking and pressure-
monitoring system: for example the removal of an object
or blockage, or replacement of a faulty shutdown valve.
• Patented STOPPLE Train plugging system allows double
block at each isolation point during hot tapping
procedures.
TDW Offshore Services
SmartPlug and STOPPLE Train
39
Saudi Aramco: Company General Use
• Paradigm's Pipe-Pulse technology removes the need for
traditional physical interventions, such as divers or
ROVs.
• The Pipe-Pulse system offers a remote method that can
accurately detect blockages and leaks in subsea
infrastructure.
• Highly successful tests included the clearing of a
multiphase flow-line that had been blocked with sand
and wax for 11 years.
Paradigm Flow Solutions
Pipe-Pulse system
40
Saudi Aramco: Company General Use
• The ROSEN tool carries multiple technologies and can
identify the smallest defects or deviations of the pipe
wall.
• The data is analyzed and a reliable report is produced, to
inform the customers about the integrity of the industrial
assets.
• A ROSEN cleaning pig is sent through the pipeline,
removing dirt from the inside of the pipe wall as well as
collecting excess particles and debris. Once the lines are
clean, a specialized inspection tool is inserted to the
transmission network
Rosen
Magnetic Flux Leakage (MFL)
41
Saudi Aramco: Company General Use
• “Intelligent pigs” that measure different integrity
parameters while pumped through the pipeline together
with the product.
• Large distances of buried pipeline can be inspected
regarding metal loss (e.g. internal and external
corrosion), mechanical deformations or other features
without interrupting the transportation process.
3P Services
42
Saudi Aramco: Company General Use
• A.Hak Pipeline Services can provide the most suitable
quality pig from suppliers.
• The company also builds their own pigs to required
specifications to guarantee the best possible service.
• For pipelines without launchers and receivers, they also
provide temporary installations to ensure a safe pipeline
pigging process. About a dozen different pigs can be used
in a pipeline at some stage during its life span.
A. Hak Pipeline Services