scraper challenges in the transport of seawater by · pdf filescraper challenges in the...

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

3

WHERE?

SEAWATER INJECTION SYSTEM

1

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


• 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.

6

WHY?

CHALLENGES OF SEAWATER TRANSPORT BY

PIPELINES

2

7


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


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


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


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

11

HOW?

GATES FOR SCRAPER SELECTION PROCESS

3

12


• 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

13

WHICH?

SCRAPER SELECTION FOR SWID WANTS AND

NEEDS

4

14


SWID’s criteria for ranking and selecting surveyed scrapers

is guided by the department’s strategy map.

15


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




• 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


• 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.



18


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


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


Scraper features in the market are categorized by selection

criteria in a scorecard to rank providers and to identify

development opportunities.

Location

Diameter(s)


Internally coated?


Construction date


Fluid type


Fluid temperature

MAOP
























Leverage Data






Inspects cracks




MFL based

UT based








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


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)


Internally coated?


Construction date


Fluid type


Fluid temperature

MAOP
























Leverage Data






Inspects cracks




MFL based

UT based








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


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


To visualize the ranking, a Spider Chart may be developed

based on the technology selection criteria derived from

PIM-related strategy goals

22


To visualize the ranking, a Spider Chart may be developed

based on the technology selection criteria derived from

PIM-related strategy goals (example).

23

WHAT’S MISSING?

INNOVATION & BUSINESS OPPORTUNITIES

5

24


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


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.

26

SUMMARY

6

27


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

28

Literature Review

Sample of scraper technology trends

7

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

[email protected]

M. Rashid Khan

[email protected]

mailto:[email protected]






31


• 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


• 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


• 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


• 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


• 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


• 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


• 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


• 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


• 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


• 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


• “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


• 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

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