TEST REPORT Pipe-abc Line Inspection Project

Transcription

1 TEST REPORT Pipe-abc Line Inspection Project Client YYYYYY / XX Facility Pipe-abc Cooling Spool Item Inspected General Pipe Inspection Method SLOFEC Date Commenced November 2007 Date Completed November 2007 Type of Report Report Number Test Report TR A-AB-XX Unit 27/28 Howemoss Avenue - Unit 1 Webb Ellis Park Kirkhill Industrial Rugby CV21 2NP Dyce AB21 0GP Warwickshire, UK Aberdeen, UK Phone: +44 (0) Phone: +44 (0) Fax: +44 (0) Fax: +44 (0) INFO@INNOSPECTION.COM

2 Page 1 of 20 Content 1. Inspection Task Qualification Test / Demo Test Setup Test Performance Test Results Conclusion Documentation...20 Attachments : Skteches of Test Samples

3 Page 2 of Inspection Task On the request of XX through YYYYYY, Innospection has adapted its marinised Riser Pipe inspection tool to an extended umbilical length and tool design in order to be able to run the marinised SLOFEC inspection on the 10inch Pipe-abc Cooling Spool Line, which is laying horizontally on approx 100m sea depth. Picture 1-3 Marinised Riser Pipe Inspection Tool Target of the inspection is, to use the SLOFEC marinised pipescanner to scan the three 21m length pipe sections for internal and external corrosion. Due to the expected possible corrosion mechanism, the requirement is to cover the top 180 of the pipe. The details of the pipe to scan are the following :? 10 diameter pipes,? wall thickness 18.3 mm,? Material : Carbon Steel, API 5L, X60? Coating : external, type FBE, 0.5 1mm? Length : 3 x 21m spools The details to the inspection itself are described in the report: OCEANEERING CNS-PL-WS- 119 R1 (Pipe-abc Cooling Spool Subsea Inspection Workscope 2007)

4 Page 3 of Qualification Test / Demo To analyse the detection capabilities of the marinised inspection unit, a test sample has been produced with the same geometric details as the pipe to be inspected. A 2m pipe section has been selected with the same geometrical and material. The pipe section is cut in two half pipe, though that mainly internal defects could be produced. Whereas the one half is coated the same way as expected at the Pipe-abc spool, the other half is not coated. Picture 4 Sketch of the 10inch Pipe-abc test Sample The type and dimension of artificial defects to be produced in the test sample were partly requested by XX, partly by Innospection. The artificial defects by Innospection should be used at the same time as calibration reference defects, therefore the test sample would be a calibration sample at the same time. Test defects selected by Innospection Test defects selected by XX Picture 5 Test defect overview

5 Page 4 of 20 The artificial defects selected by Innospection are similar to the standard calibration reference defects, which are : - Internal Flat bottom holes, diameter 10mm and 20mm, depth 20%, 40%, 60% and 80%. - External bottom holes, 10mm diameter depth 20% and 40% - 8 through wall hole 3mm diameter The through wall holes are spaced in the same distance as the individual sensors of the eddy current sensor array in order to be able to set all eddy current channels equal. Picture 6 Artificial Test & Calibration defects, as per request of Innospection

6 Page 5 of 20 XX has additionally test defects proposed as per below sketch. Picture 7 Artificial Test & Calibration defects, as per request of XX The red ring in the sketch above and picture below describes the area in which 2 unwanted artificial defects were produced In the non coated test sample, Picture 8 Internal artificial defects, defects in the red ring were unplanned and not marked in the sketch.

7 Page 6 of Test Setup The setup for the demo & test at the 15 th November 2007 at Innospection premises in Aberdeen was including all equipment to go for the Pipe-abc pipe inspection. The test & demo was performed at the test sample described above. Picture 9 Overview setup for Pipe-abc pipe test & demo Picture 10 Multiplexer System for ET sensor array Picture 11 Eddy Current Computer System Picture 12 Video Monitor & DVD Recorder Picture 13 Controle Unit for Scanner Magnet Unit

8 Page 7 of 20 Pipe Scanner type M-PS 200 : Details magnetic type electro magnet wall thickness range for carbon steel up to 32mm Scanning width 200mm Number of sensors 2 to 8 Sensor width 25mm Tangential positioning decrement encoder Weight 80kg Others Camera & Light in front Picture M-PS200 Scanner, views: side front, below

9 Page 8 of 20 In case of reduced access on the side of the Pipe-abc spools, the design at the scanner has been changed in order to allow the electronic bottle to be turned upwards. Picture 17 M-PS200 Scanner, electronic bottle position change The winch to operate the scanner is fitted with a 290m umbilical, which contains Kevlar, though that the lifting of up to 1t is allowed. The winbch is operated with 440V 3 phase. A remote control unit is adapted. Picture 18 PipeScanner - winch

10 Page 9 of Test Performance For the test performance, Innospection has upfront selected the appropriate eddy current frequency and magnetisation. The difference between either test samples is that the one has no coating on top of the pipe, whereas the other with the same artificial test defects has the simulated same coating as expected at the Pipe-abc line. The difference for the scanning unit is in this case the stand off to the steel, which can be compensated by adapting the electromagnet drive and the eddy current sensitivity setting. Consequently the same detection sensitivity can be achieved. As the test pipe has flat supports welded either side, the scanner can only be moved to the plate, which leaves a dead zone of 180mm either side. For the test the front camera has been taken off, in order to reduce the dead zones to minimum. The multiple sensor array of the scanner is made for 8 sensors with a width of each 25mm, however the short time of preparation for brought forward mobilisation did allow a main connector delivery for use of the middle 6 sensors only. Therefore the test result is shown also over the 6 middle sensors of the array. The test setup describes the scanners is to be moved in longitudinal direction along the pipe sample, covering a circumferential width depending on the scanner 150mm. As the scanner runs along the pipe the eddy current data is online displayed and according to the scanner encoder run the signals are displayed in accordance to their longitudinal position. sensor channel 1 to 6 from left to right sensor 1 to 6 chart, 1 on top, 6 on bottomt Picture 19 SLOFEC Screen Shot, recorded with a 6 sensor scanner

11 Page 10 of 20 The analysis of the eddy current signals allow the signal phase for defect position information (external-/internal defects, inclusions etc.) the signal amplitude allows the analysis of the defect severity in 10percent wall thickness loss display. Following the signal phase analysis window and amplitude depth analysis is displayed. External Defect analysis Internal Defect analysis external side phase to defect depth analysis window underside phase to defect depth analysis window COLOUR PALETTE DEFECT CLASSIFICATION: < 20% 20-30% 30-40% 40-50% >50% Picture 20 SLOFEC signal phase & amplitude analysis

12 Page 11 of Test Result Following the screen shots and color images of the non coated areas are explained. When running the scanner along the pipe section, indications of defects or others are online shown, however recorded the complete scan is displayed. The eddy current signal display and colour related analysis can be transferred into a color 2D and 3D image as displayed following. In the following pages the individual scans and indications are discussed and described. Some notes to be addressed: - The encoder allowing defect location/ position was not finished at the time of the requested test/demo, therefore all test runs are recorded on a time base. This might have an influence on position and extension of the imaging. The scan pictures shown below are displaying the direct reading respectively the colour images, which are used for the general report, which has additional information about the positions and locations. Further analysis of individual defects are possible and are planned for the inspection. On the short notice of the test and delivery of report this wasn t possible.

13 Page 8 of Result Non Coated Pipe Section internal analysis 6 x TWH Ø3mm Internal 4 x 3 small diameter flat bottom holes Int. FBH Ø20mm 80% 60% 40% 20% Grinded Section with 3 flat bottom holes in the area Int. FBH Ø10mm 80% 60% 40% 20% Longitudinal grooves: depth a: 2mm b: 12mm Unplanned internal slot (see picture 8)

14 Page 9 of 20 2D Image of the Non Coated Pipe Section Int. FBH Ø20mm: 20% 40% 60% 80% 6 x TWH Ø3mm Internal 4 x 3 small diameter flat bottom holes Grinded Section with 3 flat bottom holes in the area Int. FBH Ø10mm 80% 60% 40% 20% Unplanned internal slot (see picture 8) Int. FBH Ø10mm: 20% 40% 60% 80% Longitudinal grooves: depth a: 2mm b: 12mm

15 Page 10 of 20 3D Image of the Non Coated Pipe Section

16 Page 11 of Result 0.5mm Coated Pipe Section internal analysis 6 x TWH Ø3mm Internal 4 x 3 small diameter flat bottom holes Int. FBH Ø20mm 80% 60% 40% 20% Grinded Section with 3 flat bottom holes in the area Int. FBH Ø10mm 80% 60% 40% 20%

17 Page 12 of 20 2D Image of the Coated Pipe Section Int. FBH Ø20mm: 20% 40% 60% 80% 6 x TWH Ø3mm Internal 4 x 3 small diameter flat bottom holes Grinded Section with 3 flat bottom holes in the area Int. FBH Ø10mm 80% 60% 40% 20% Longitudinal grooves: depth a: 2mm b: 12mm Int. FBH Ø10mm: 20% 40% 60% 80%

18 Page 13 of 20 3D Image of the Non Coated Pipe Section

19 Page 11 of Conclusion The marinised SLOFEC test at the 10inch x 18.3 coated and non coated pipe sections have shown that all artificial defects produced were well detectable. The important signal to noise factor is very good, though that an increase of sensitivity is always possible. The resolution of the smaller volumetric defects was limited in specific when the small volumetric defects are close to each other. It is possible that with the encoder attached in comparison to the time run the resolution can be improved. The sensitivity setting to match the colour image was based on the artificial 10mm diameter defect row 20-80%. As the inspection technique is also based as volumetric dependant technique consequently larger diameter defects are higher evaluated in depth. However it shall be noted that an additional individual indication analysis algorithm can corrugate the factor. It shall finally concluded that as the requested fast screening and detection tool the testy has shown its capabilities. Marked specific detected findings could further be evaluated by the Sonomatic Nautilus Ultrasonic system. 7. Documentation The inspection result and signal data is stored on disk for the Innospection archive system. Aberdeen 20 th November 2007 Andreas Boenisch Innospection Ltd.