DVGW G 501. CHARM - CH 4 Airborne Remote Monitoring

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1 DVGW G CHARM - CH 4 Airborne Remote Monitoring For several years OGE has been inspected its pipelines with old and new, unconventional and efficient method of gas detection Evolution of pipeline monitoring OGE has developed a new technology to detect natural gas via a helicopter-based system CHARM is based on an infrared laser system that is capable of precisely detecting even gas layers with very low methane concentrations

2 DVGW G CHARM - CH 4 Airborne Remote Monitoring CHARM can be used for inspecting pipelines both in open country as well as in urban areas The measurement method of CHARM is based on the absorption of specific infrared light wavelengths by methane, the main constituent of natural gas = Differential Absorption Lidar (DIAL) The measurement beam can be targeted at the pipeline corridor automatically and extremely precisely (CHARM Auto Tracking, CAT)

3 DVGW G CHARM - CH 4 Airborne Remote Monitoring CHARM is state of the art of inspecting natural gas transmission systems and is based on a high-performance combination of innovative technologies. Automatical alignment of the mesurement beam Accurate geographic positioning of measurement beam with CHARM Auto Tracking (CAT) < 0,5 m Authorisations DVGW authorisation (inspecting) LBA- und EASA authorisation (aviation) Accuracy of measurement Area-wide inspection of pipeline route High methane sensitivity of system (operational detection limit < 25 ppm m) Automated documentation of pipeline inspection and real-time reporting of incidents High patrol speed (50 90 km/h) High detection resolution (100 double pulse measurements per second)

4 DVGW G 495 / GasCam - Remote Gas Detection The CasCam is based on Infrared Radio Spectrometry and allows real-time gas detection of gas clouds against real backgrounds Developed to monitor and inspect facilities, pipeline networks and constructions measures on gas-carrying systems of natural gas The analyzing software provides comprehensive documentation material (measurements, video recordings, pictures)

5 53 GasCam - Remote Gas Detection The system was developed jointly by OGE and project partners from the gas industry. Key Benefits Rapid detection of gas releases and precise localisation of leakages In-situ valuation via real time visualisation Improved safety level Significant reduced inspection time of gas facilities Avoidance of emissions economise on resources Audit compliant documentation High detection sensitivity also at far distances All-purpose for gas-carrying facilities

6 54 GasCam - Remote Gas Detection OGE offers the service of inspecting and evaluating facilities, pipeline networks and constructions measures on gas-carryings systems. Application Recurrent tightness checks at gas carrying facilities Safety Approval Monitoring of gas releases Definition of safety zones Detection of emission sources Quality Inspections in the course of constructing and re-constructing facilities

7 55 Contents OGE at a Glance, OGE Pipelines in Germany Integrated Management System Pipeline Design & Safety Philosophy Pipeline Integrity Management System Corrosion Control Hydrostatic and Tightness Testing Inline Inspection Techniques Defect and Failure Investigation Troubleshooting & Repair-Techniques Conclusions

8 56 Defects are reliably detected by ILI MFL-Pigging Calliber Pigging IMU TFI-MFL-Pigg. EMAT-Pigging US-Pigging Loss of wall thickness (corrosion, grinding) Milling defects (inclusions) Mechanical damage Weld anomalies Expansions Dents Ovalities Displacement Bending Additional Strain (Mapping) Axial grooving Coating disbondment Cracks Standard method Optional method

9 DVGW G 466-1, G ILI leads to pipeline safety and increasing level of information IST PLAN km/jahr Learning curve US-Pigging EMAT-Pigging RunCom IMU/Strain Assessment Inspection of approx km until 2011 (incl. reinspection) approx km inpected at last once MFL-Pigging Dummy-Pig (Multi-Channel) Calliber Pig HR-MFL-Pigging

10 RN Defect Assessment Example ILI Assessment Excavation and NDT Standard repair (if needed) Gauging Modelling and FE- Calculation Assessment, Certified experts statement and documentation Repair (if needed)

11 Corrosion Damage, Example Direct (Defect) Assessment Methods 59 Detected by pig Excavated defect Measured (OPTO-CAM) FEA model Calculation of stress, burst pressure: 100,5 bar Component test, burst pressure: 97,2 bar

12 Depth [% of Wallthickness] RN Direct Defect Assessment Methods DNV or ASME Det Norske Veritas ASME/ASTM to be repaired safe Length [mm]

13 Verification of Calculation Model 61 Depth [% of Wall thickness] DNV: Just safe enough with S = 1.8 DNV (S=1,8) ASME external metal loss external MFG internal MFG external metal loss (SN) excavation FEA: Bursting at 193 bar S real = Length [mm] Test: Bursting at 199 bar S real = 3.2 External Metal Loss Pig 52%, 137 mm long, 5:10 Excavation 69%, 150 mm long, 5:30 Calculation is Conservative compared to real Pipe Behaviour

14 Verification of Calculation Model 62 Depth [% of Wall thickness] DNV: to repair with S = Length [mm] DNV (S=1,8) ASME external metal loss external VFF internal VFF external metal loss (SN) internal VFF (SN) excavation FEA: Bursting at 121 bar S real = 1.79 Test: Bursting at 122 bar S real = 1.80 Pig 90%, 71 mm long Excavation 92%, 83 mm long Calculation is Conservative compared to real Pipe Behaviour

15 DIN Evaluation ILI Data Inteligently Corrosion Growth Calculated usage factor at time of ILI 1,6 Calculated usage factor at e.g. 20 1,6 years (with corrosion growth) usage factor 1,4 Usage factor 1,2 1,0 0,8 0,6 Safety against failure = 1.8 usage factor 1,4 Usage factor 1,2 1,0 0,8 0,6 0,4 0,2 0,4 0,2 short term measure recommended 0,0 0,0 0% 20% 40% 60% 0% 80% 20% 100% 40% 60% Loss of wall thickness reduction of wall thickness Loss of wall thickness reduction of wall thickne Sheduling of next ILI is condition based

16 DIN Typical Corrosion Rates Type of corrosion Typical corrosion rate max. metal loss rate (100 a) DIN max. penetration rate L,max (30 a) General corrosion (aeration cell) 0,1 0,2 mm/a 0,005 0,06 mm/a 0,03 0,4 mm/a Corrosion by contact element up to 0,5 mm/a 0,01 0,2 mm/a 0,05 1 mm/a Stray current corrosion bis zu 1 mm/a AC corrosion commonly 0,1 0,2 mm/a up to 1 mm/a TGL

17 Development of feature depth (% WT) 65 Determining Corrosion rates by ILI Run Comparison external features with significant growth +5% accuracy (reproducability) Depth (% of wall thickness), % accuracy (reproducability)

18 Caliper Pigging 66 Defects at Construction Ovality Dents Dents and Ovalities at Construction (Caliper Pig)

19 67 Caliber Pigging Assessment of Dents Ovalities Expansions Up to 4% increase in diameter after stress testing because of wrong material selection Assessment criteria approved by TÜV Expansion

20 Expansion (%) Expansion (%) IMU - Strain Assessment 68 Profile measured by pig Measured profile

21 IMU - Strain Assessment 69 Strain Assessment Identification of areas with environmentally induced pipeline deformations, for example due to landslides, thermal load, frost heave, sea bed movement, ships dragging their anchors Accuracy to be expected within one tenth of a centimeter or +/-0.01% strain

22 Strain Assessment Field Verification IMU - Strain Assessment 70 Surveyor: 2.09 m IMU: 2.15 m (horizontal displacement)

23 Results from excavation [%] MFL versus IMU 71 Vergleich Messwerte GE PII und PLEdoc Result IMU [mm] MESSUNG FREILEGUNG [%] Displacement Lageverschiebung measured aus IMU by IMU Wanddickenminderung Wall thickness reduction, von MFL MFL Linie 1:1 +/-10% Result Excavation [mm] ERGEBNIS MOLCH [%] Results from MFL - ILI [%]

24 72 Contents OGE at a Glance, OGE Pipelines in Germany Integrated Management System Pipeline Design & Safety Philosophy Pipeline Integrity Management System Corrosion Control Hydrostatic and Tightness Testing Inline Inspection Techniques Defect and Failure Investigation Troubleshooting & Repair-Techniques Conclusions