HOIS JIP for Improved NDT in the oil, gas & petroleum industries

Transcription

1 HOIS JIP for Improved NDT in the oil, gas & petroleum industries Tor Harry Fauske (Statoil) Steve Burch, Project Manager (ESR Technology) ESR Technology Ltd

2 HOIS Joint Industry Project (JIP) HOIS is a well established JIP HOIS stands for Harwell Offshore Inspection Service Historical no longer directly relevant Members comprise: Oil and Gas producers NDT service companies NDT equipment vendors A regulatory authority (UK HSE) Managed by ESR Technology (formerly AEA Technology) Dr Steve Burch is Project Manager ESR Technology Ltd Slide 2

3 HOIS Joint Industry Project (JIP) Current members AGR EMI Aker Kvaerner BIS Salamis BP Exploration Can (Offshore) Ltd Chevron ConocoPhillips Det Norsk Veritas Doosan Babcock Gasco GE Inspection Technologies Guided Ultrasonics Ltd HSE ISQ Lloyds Register Marathon Oil Mechanical Integrity Inc. Oceaneering International Services Ltd OlympusNDT Petrobras RTD (UK) SGS Shell Global Solutions International B.V. Statoil Talisman UK Total Sonomatic Sonovation BV ESR Technology Ltd Slide 3

4 HOIS overall vision & themes The HOIS Vision: To be the prime industry forum for discussing inspection issues and developing and exploiting new or improved inspection technology The programme aims to achieve this though a number of broad themes defined by the Members: Development of improved techniques, procedures and recommended practices for Non-intrusive inspection (NII) Impartial trials and modelling to better quantify, assess and optimise the performance of inspection technology Independent state of the art technology reviews Provision of a source of information on NDT (Internet accessible) Technology development (e.g. for permanently installed monitoring) ESR Technology Ltd Slide 4

5 Benefits for HOIS Members Join the leading forum on oil & gas NDT for interchange of information, ideas and experiences face-toface or using dedicated website; Membership includes oil & gas majors, in-service inspection companies and equipment vendors ESR Technology Ltd Slide 5

6 Benefits for Members (cont) Access to results from 500,000 annual programme Access to improved procedures and recommended practice documents on technique selection and application Access to results from equipment and technique trials Better understanding of and increased reliability of inspection Opportunity to exploit equipment and techniques developed within HOIS programme ESR Technology Ltd Slide 6

7 Management Work programme specified and directed by Strategy Group of all members. (cat 2 members do not have voting rights) Overall Work programme fixed annually. Individual projects monitored by Project Champions Typically three 2-day meetings per year: Day 1: Presentations on work carried out Day 2: Strategy Group meeting to review work & make recommendations on way forward Additional working group meetings on specific projects As and when needed to discuss individual project in greater depth ESR Technology Ltd Slide 7

8 ESR Technology Manage HOIS project and undertake much of project work Formerly the National NDT Centre at Harwell (AEA Technology) Divested from AEA Technology in October 2005 ESR Technology Turnover 10 million/year 110 staff 60+ graduates 20+ PhDs 2 visiting Professors ESR Technology Ltd Slide 8

9 ESR Technology heritage and resources A world-class, independent, engineering, safety and risk consultancy 30 years of experience with in-depth technical knowledge UK-based with customers world-wide Outstanding consultants delivering outstanding solutions Extensive understanding of specific industrial sectors In-house laboratories, software, modelling tools and products ESR Technology Ltd Slide 9

10 ESR Technology services... Delivers independent technical expertise, products and services to help clients: Ensure Asset Integrity Improve Machine Reliability Manage Safety & Risk Transfer Best Practice ESR Technology Ltd Slide 10

11 ESR Capabilities in NDT area Highly experienced and qualified experts Independent of inspection services providers and NDT equipment vendors Broad-ranging technical expertise especially in: Advanced ultrasonic techniques Radiography, including computed radiography Electromagnetic techniques Analysis of experimental probability of detection (POD) data POD Modelling for ultrasonics and radiography In-house experimental facilities for digital ultrasonics ESR Technology Ltd Slide 11

12 Start of HOIS Started in early 1980 s. Founded by UK Atomic Energy Authority (UKAEA) Dr Bill Gardner Seeking to diversify from nuclear work Exploit expertise in imaging and data analysis Start-up meeting of 10 major oil & gas companies Initially focus on TOFD for defect detection and sizing for oil & gas industry Including complex geometries (node welds etc), sub-sea. Other early projects included eddy current development ESR Technology Ltd Slide 12

13 HOIS - Track-record in successful Innovation (previous projects) TOFD - ideal for internal flaw detection in welds and complex geometries - fast, accurate defect sizing CHIME - solution to screening inaccessible geometries for corrosion. LIZARD - licensed eddy current system MAPS - stress measurement technology ESR Technology Ltd Slide 13

14 Project categories ESR Technology responsible for management of all projects Technical work on projects in Core programme carried out mainly by ESR Technology (with subcontracts if needed) Tendered Programme projects carried out by third parties. Examples: Development of Permanently installed sensors (PIMS) CRIS POD trials ESR Technology Ltd Slide 14

15 Main themes of current HOIS projects Procedures and recommended practices Non intrusive inspection (NII) Computed radiography (CR) Weld root erosion/weld corrosion Evaluation of NDT techniques State of the Art Reviews Experimental evaluation trials Blind probability of detection & sizing trials Performance modelling Development of new inspection techniques M-skip for inspection of inaccessible components (pipe supports, clamps, vessel saddles etc) ESR Technology Ltd Slide 15

16 Main themes of current HOIS projects (cont) Application studies Inspection of FPSOs and flexible risers Development of a magnetic method for inspection of risers Development of new technology Development of permanently installed monitoring sensors (PIMS) Angled beam flexible arrays Development of source of information on NDT Interactive knowledge base (IKB) ESR Technology Ltd Slide 16

17 New NICE facility for specimen storage and trials Now commissioned ESR Technology Ltd Slide 17

18 Selection of current HOIS Projects Non-intrusive inspection (NII) related projects: Development of a recommended practice covering guidance document for NII of pressure vessels Development of NII techniques for difficult to inspect features (e.g. pipe supports) Recommended practice for computed radiography (CR) Recommended practice for inspection of weld corrosion Blind trials of techniques for inspection of wall loss flaws in pipes (CRIS) Evaluation of techniques for bolt, flange and pipe support inspection Development of permanently installed monitoring sensors (PIMS) Autonomous wireless sensors (initially UT) Next generation Flexible ultrasonic arrays Inspection of FPSOs and flexible risers Development of a magnetic method for inspection of risers Technology reviews, including EMATs, Single Sided Radiography and Microwave NDT. Development and maintenance of Internet-based NDT Interactive knowledge base (IKB) ESR Technology Ltd Slide 18

19 Procedures and recommended practices ESR Technology Ltd Slide 19

20 HOIS Project - Non-intrusive Inspection (NII) decision guidance NII Project - Development of a decision guidance process for when to inspect pressure vessels, using non-intrusive techniques instead of conventional internal visual inspection. Highly successful NII seminar in Aberdeen Application of HOIS NII methodology by members to assets Recent extension of document to include guidance on setting inspection intervals after an NII inspection Integration with Mitsui Babcock RP from GSP 235 Now published complete document as a DNV RP - DNV-RP-G103 Download from ESR Technology Ltd Slide 20

21 HOIS Project Recommended Practice for computed radiography (CR) Background: Performance of CR in blind trials did not meet expectations Some relatively large wall loss defects missed CR equipment has high inherent capabilities Procedures in use for in-service CR inspection need improvement Lack of quality control HOIS project Develop improved quality control techniques for in-service corrosion inspection (both tangential & double wall techniques) Collaboration with technical experts at BAM Institute GE Inspection Technologies input Series of evaluation trials of CR equipment from leading equipment vendors ESR Technology Ltd Slide 21

22 HOIS CR RP Scope CR for in-service inspection of pipes for wall loss type flaws Techniques covered: Double Wall Single Image (DWSI) Double Wall Double Image (DWDI) Tangential (source on pipe C/L) Offset tangential (source offset by pipe radius) Two different qualities of inspection: Standard quality for general wall loss CR inspections Improved quality for applications needing higher quality (e.g. detection of small pits) ESR Technology Ltd Slide 22

23 HOIS CR RP - status Recommended practice to be made publically available via open HOIS website Aiming to progress to a European (EN) standard Field not covered adequately by existing radiography or CR standards (EN1435, EN parts 1 & 2 etc) ESR Technology Ltd Slide 23

24 HOIS recommended practice for weld corrosion inspection No international standards or agreed procedures/approaches for weld corrosion inspection Lack of published information on performance of techniques for inspection of weld corrosion Need for a recommended practice covering in-service inspection of weld corrosion (detection and sizing) RP developed on basis of supporting trials and input from members experiences ESR Technology Ltd Slide 24

25 HOIS RP: Main recommendations regarding inspection techniques Preferred technique is TOFD Where TOFD not possible: Use Tangential CR, combined with DWDI to locate the areas of greatest wall loss If circumstances preclude the usage of these two preferred techniques, consider other techniques: double wall radiography (no quantitative through-wall information) specialised techniques for inspection through the weld cap using stand-off (water column) 0º pulse-echo probes. Recommended that these techniques are fully validated with regards to detection reliability and/or sizing accuracy. Manual angled beam UT known to give false positives and false negatives. Inherently inaccurate sizing Document to be published shortly on HOIS website ESR Technology Ltd Slide 25

26 Novel technique development ESR Technology Ltd Slide 26

27 Multi-skip shear wave TOFD (M-skip) for inspection of inaccessible components Concept: Tx Obstruction Rx Use shear waves to avoid mode-conversion losses at reflections Potential benefits Defect detection Accurate measurements of wall loss (arrival time analysis) Application to clamps, pipe-supports, compensating sleeves (probably less well suited to nozzles) etc ESR Technology Ltd Slide 27

28 M-skip current status Novel technique for inaccessible areas developed within HOIS Application to clamps/saddles & pipe supports Can provide quantitative wall loss information Potential for rapid screening of vessels and pipes Very high POD in recent blind trial (97%) Already used successfully on member s offshore plant in conjunction with CHIME ESR Technology Ltd Slide 28

29 Technique evaluation and trials ESR Technology Ltd Slide 29

30 HOIS Project - Sponsor of CRIS Probability of Detection (POD) trials Sponsor of now completed CRIS PoD trials. Internal wall-loss flaws in straight-pipe. POD measured for several techniques for corrosion inspection Some performed better than anticipated Others did not meet expectations Follow-up to understand why Further HOIS sponsored trials of newly developed techniques Most recently trialled technique: GW EMAT ESR Technology Ltd Slide 30

31 HOIS Other current trial/evaluation projects Trials of PA techniques for inspection of bolts and flanges using phased arrays Trials of techniques for pipe support inspection Flange-face inspection ESR Technology Ltd Slide 31

32 Technology Development ESR Technology Ltd Slide 32

33 HOIS project - PIMS technology Development of permanently installed monitoring sensors (PIMS) for monitoring of plant degradation (e.g. corrosion/erosion & cracking) Wireless data communication Collaboration with other projects (SENS-IT) ESR Technology Ltd Slide 33

34 PIMS development Collaboration with Strathclyde University and iicorr led SENS-IT project Development of wireless version of Advanced Guided Lamb Wave system from ClampOn (Bergen, Norway) Field trials on members plant of ClampOn equipment in progress (first trial complete) ESR Technology Ltd Slide 34

35 NDT modelling ESR Technology Ltd Slide 35

36 NII - Development of Probability of Detection (POD) modelling software Windows-based software for determining POD of UItrasonic corrosion mapping Computed radiography of pipes Results validated against experimental trials/tests ESR Technology Ltd Slide 36

37 Applications studies ESR Technology Ltd Slide 37

38 FPSO (Floating Production Storage & Offloading) vessels NDT methods for inspection of FPSOs. Established a FPSO Working Group and website for information exchange Development of an FPSO Interactive Knowledge Base Experimental trials of methods for flexible riser inspection MAPS technology development ESR Technology Ltd Slide 38

39 HOIS FPSO/Flexibles project Highlight Development within HOIS of MAPS magnetic stress measurement technique for monitoring flexible riser integrity Detection of broken tensile armour wires within inaccessible end fittings/terminations Successful load trials at flexible riser manufacturer Prototype now being developed for a HOIS member Separate contract outside HOIS ESR Technology Ltd Slide 39

40 Source of information on NDT ESR Technology Ltd Slide 40

41 HOIS Project - NDT IKB Development and maintenance of the Internet accessible interactive knowledge base (IKB) - contains a wealth of information about NDT techniques, performance limits, PoD's, as well as "recommend a technique". HOIS members have free unlimited use ESR Technology Ltd Slide 41

42 Conclusions HOIS is a long standing JIP. Currently has 28 members (major recent increase) Major oil & gas companies Also HSE, NDT service providers & two major equipment vendors Annual budget of 500,000 Wide range of current projects: Recommended practices Technique evaluation and development Technology development Improved NDT information ESR Technology Ltd Slide 42