The Annual 2021 | ADV Integrity

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When Complex Problems Call For Customized Solutions Ahmed Hassanin • April 12, 2021


Applications of Digital Image Correlation in Material Integrity Testing Chantz Denowh • April 12, 2021


Powerful Collaboration: Seeking Industry Partnerships Through Cross-Functional Cooperation in JIPs Chantz Denowh • April 12, 2021

ADV Integrity thrives with strong personal relationships with clients, employees, and partners


IDT EXPO: Where It All Comes Together


Something to Add: Validating Additive Manufacturing for Critical Applications in Oil & Gas

Wendy Courtright • April 12, 2021

Atul Ganpatye • June 30, 2021


Spoolable Solutions: ADV Integrity Advances Study of Spoolable Pipe Testing & Integrity Management Solutions Chantz Denowh • June 30, 2021


The Futch Factor: ADV Integrity’s Failure Analysis and Metallurgical Services Are Ready for Operators’ Toughest Challenges David Futch• June 30, 2021



Innovative Inspection Analysis Automates Dent Processing Ahmed Hassanin • October 6, 2021


In-Line Inspection Test Spools Build Confidence and Certainty Chantz Denowh • October 6, 2021


Mitigating the Risks of Early Failures in High Strength, New Construction Girth Welds David Futch • December 17, 2021


Fatigue Fortune: Improving Accuracy in Fatigue-Life Assessments and Predictions Atul Ganpatye • December 17, 2021


What’s Next? Applications of CO2 and Hydrogen in the Energy Transition David Futch• December 17, 2021


Thing 20 & Thing 21 Enhance Comprehensive Pipeline Integrity Engineering Services Rhett Dotson & Christopher De Leon• December 17, 2021


New Coating Qualification Testing Expands ADV Integrity’s Testing Services David Futch • December 17, 2021


New Beginnings: ADV Integrity to Start Construction for New Facility Chris Alexander • December 17, 2021

President’s Note Wow! Never in my wildest dreams could I have imagined all that would transpire in a four-year period of time. If you’re reading this magazine there’s a good chance you’re one of our clients (if you’re not, we hope you soon will be). We started ADV to help clients. Our employees understand the importance of high-quality service. We don’t just do it because we have to. We do it because that’s how we’re wired as individuals. We are also excited about the future. We expect by September 2022 to be in our new facility located in Magnolia. In our new “home” we’ll have a 14,000 ft2 full-scale test facility, a 16,000 ft2 office building, and a conference center that will seat 180 people. This facility will allow us to serve more clients and provide space for meeting, collaborating, and working together. We look forward to continuing to serve the energy industry, with our continued focus on high-pressure transmission pipelines. Don’t be a stranger and feel free to come out and see us!

ADV Integrity uses advanced technology and state-of-the-art equipment in its fullscale testing lab.

ADV Integrity | 2021 Ahmed led the project to develop a customized biaxial load frame to test cruciform specimens.


When Complex Problems Call For Customized Solutions April 12, 2021 - In order to address a client’s specific need in material testing, ADV Integrity and ADV Fabworks have joined forces to develop a customized biaxial load frame capable of testing cruciform specimens. The resulting product will offer in-house testing that is easily transportable and universally adaptable. This project, which is currently in the early stages of the calibration processes, began when ADV Integrity set out to meet the needs of its client to develop a costeffective biaxial load frame. From the inception of the idea to the final product, ADV Integrity ensured the load frame would deliver the desired specifications. Ahmed Hassanin, Engineering Analyst at ADV Integrity and Technical Manager of this project, said that the goals of the client were ADV Integrity’s top priority. “If you have an idea and we do not have a method of testing it, we can design it to meet your needs. In this case, we took it from a napkin sketch, modeled it in CAD software, ran all necessary analyses from hand calculations to Finite Element Analysis, and then fabricated it,” he said. Next, Hassanin and his team will work through calibration and running test cases on the load frame. The resulting material testing implications of the biaxial load frame are promising. Its compact size means that tension and compression, as well as fatigue testing, can be run in-house. The primary test specimens that will be tested in this load frame are cruciform samples to test sensors; however, the versatility would

ADV Integrity | 2021

Ahmed Hassanin Engineering Analyst

Ahmed is an expert in Finite Element Analysis and validates results with testing. Using ADV Integrity’s full-scale testing, Ahmed validates numerical results from FEA with experimental testing.

be especially beneficial for testing on wrinkle bend coupons, a service frequently performed by ADV Integrity. “In my experience loads are not necessarily uniaxial, so this testing ability gives us more detailed insights on the response of the material to combined loading in different axes,” Hassanin said. While built for biaxial testing, the load frame can also run more standard uniaxial testing as well, widening the scope of usage possibilities even further. The flexibility of the final product will potentially increase both the client’s and ADV Integrity’s capabilities in material integrity testing.

Hassanin elaborated on the adaptability of the new load frame: “You can run the four hydraulic cylinders separately, so you can run two in one direction alone versus the other two, or you can run them at the same time. So, even though it is a biaxial load frame, we can still do uniaxial testing, which provides us with additional flexibility.”

The biaxial load frame is fully customized, compact, and easily transportable.


ADV Integrity | 2021

Applications of Digital Image Correlation in Material Integrity Testing April 12, 2021 - Accurately and efficiently measuring deformation and material strain is essential to understanding material behavior. Even though they are the typical choice, strain gauges and extensometers are limited to providing mechanical information at only a single point. Fortunately, a more effective alternative is available to ensure asset integrity: Digital Image Correlation, or DIC. DIC provides non-contact full-field 3D deformation analysis. The DIC technology used by ADV Integrity is the ARAMIS Adjustable, which is a modular and expandable system. Currently, ADV Integrity’s DIC setup measures volumes of 50 x 38 [mm] (2” x 1.5”) to 350 x 260 [mm] (14 3/4” x 10 1/4”). According to Emmanuel Valencia, Engineering Assistant at ADV Integrity trained in DIC, this technology is “just as good, if not better, than strain gauges. It provides full-field data, which allows us to understand both the global and local behaviors of the parts we analyze. Therefore, during post-processing, we can analyze any point of the patterned region without needing to retest. It is very powerful when calibrated correctly, and more efficient.” Because less retesting is required when using DIC, the technology has cost-saving implications as well. DIC is not a new technology, but it is new to the oil and gas industry. Typically, it was used in vehicle and impact testing and in other laboratory environments. Valencia said, “Although this technology is not unique to ADV, I believe we are in a unique place because we have DIC-trained engineers with sub-scale and full-scale testing experience that can integrate DIC testing to our clients’ needs.”


UP TO THE CHALLENGE The testing capabilities of DIC cameras include static and dynamic testing with motion compensation. It is especially useful for testing a bigger area without knowing where a sample may fail—a key advantage compared to extensometers or strain gauges. Some examples of the tests that can be performed are tensile tests, shear tests, buckling tests, impact tests, and non-destructive testing (NDT). In addition, the DIC technology can do dynamic photogrammetry for point tracking and digital image correlation for optical strains. DIC technology can also validate numerical simulations with full-field data. Despite this impressive range of capabilities, Valencia believes the applications of DIC technology can expand even further: “In the future, we will experiment using our DIC technology for pressure tests. The DIC camera can be calibrated for glass distortion in order to record a pressurized vessel through a transparent shield. Because the camera can be calibrated, it can account for any glass distortion from the shield.”

ADV Integrity’s current DIC setup is certified for volumes below 300 mm for displacement testing. This certification is the same used by the ISO 9513 Class 0.5 Extensometer and ASTM E83 Class B1 Extensometer.

Chantz Denowh

Vice President, ADV Integrity Dr. Chantz Denowh has spent the last seven years conducting fullscale testing and analysis to create, calibrate, and validate integrity assessments and remediation methods for the midstream industry.

Powerful Collaboration

ADV Integrity | 2021

Seeking Industry Partnerships Through Cross-Functional Cooperation in JIPs April 12, 2021 - Connecting various industry partners to achieve a shared goal can lead to significant advancements industry-wide. ADV Integrity, seated in the ideal position to connect end-users (operators), technology providers, and regulators, is encouraging cross-functional cooperation through Joint Industry Programs (or JIPs). The possible subjects for JIPs are limitless, but they are always focused on meeting the needs of industry partners. “Joint Industry Projects are great for the industry to come together to solve a common problem,” said Chantz Denowh, Vice President at ADV Integrity. Denowh facilitates multiple JIPs led by ADV Integrity, including the recently completed Combined Loading Assessment of

Spoolable Pipe Systems (CLASPS-01) JIP involving 7 operators and 8 technology providers. JIPs, such as CLASPS-01, can tackle highcost testing and research programs at low cost to the individual participants. Partners within JIPs form a collaborative workgroup and contribute to solving a common problem or issue that benefits the industry as a whole. ADV Integrity is well-positioned to act as a connector in the industry because of its pre-established relationships with end-users, technology providers, and regulators, and its advanced industry knowledge. Denowh said, “Due to our relationships that we have with our clients and a number of connections that we have across the

industry, we’re definitely in a great position to organize JIPs. After organizing multiple companies together, not only are the costs more manageable, but it gets the information out to the industry faster.” Because JIPs establish open communication channels among partners, the resulting research and solutions are usually better than those from independent projects. Operators have more access to the resources provided by technology providers, and vice versa. The combination of resource-sharing, cooperation, and open communication creates synergistic relationships that benefit all parties. In addition to CLASPS-01, ADV Integrity has also recently completed a composite crack-reinforcement JIP. Several future JIPs are planned, including CLASPS-02, focusing on inspection and characterization of spoolable pipe threats, and a girth weld reinforcement study using composites.

Chantz Denowh

Vice President, ADV Integrity Dr. Chantz Denowh has spent the last seven years conducting fullscale testing and analysis to create, calibrate, and validate integrity assessments and remediation methods for the midstream industry.


ADV Integrity | 2021

IDT EXPO April 12, 2021

this critical idea-exchange to continue, despite the challenges posed by the COVID-19 pandemic. Through the IDT EXPO platform, participants can engage in constructive conversations and exchange of technical know-how no matter where they are within the industry network.

Where It All Comes Together Bridging the gap between operators and innovators is IDT EXPO, a platform dedicated to facilitating connections, exchanging technical knowledge, and offering solutions. On June 4th, IDT EXPO will host the Pipeline Inspection & Monitoring Technologies workshop series. The series will feature presentations from subject matter experts within the inspection industry and demonstrations from vendors and innovators. IDT EXPO conferences are unique in their ability to provide tailored presentations and workshops to a focused audience. Participants can attend for free and gain unfettered access to speakers, SMEs, and vendor representatives. Unlike other conferences with overwhelmingly large crowds and cluttered agendas, IDT Expo


events are forums, focusing on impactful personal interactions. Atul Ganpatye, Senior Associate at ADV Integrity, is one of the lead coordinators for the event. He said, “IDT Expo creates a forum to exchange ideas and showcase emerging technology. It also provides a forum to understand how the technology can be implemented to benefit end users and operators.” The smaller structure of IDT Expo’s workshops and conferences has allowed

“There needs to be a constant interaction between those who use technology, and those who develop and market the technology,” Ganpatye said. “The intent of IDT EXPO in hosting multiple events of this type a year is to provide a constant and consistent forum where participants can attend, ask questions, show data, and discuss applications and improvement of these technologies.” Wendy Courtright, Vice President of IDT EXPO, created the concept with Chris Alexander, President of ADV Integrity. She said, “Inspection needs are growing, but the forums, the resources, and platforms to discuss these needs have shrunk during

ADV Integrity | 2021 the pandemic. IDT EXPO provides the opportunity to come back together and start a discussion among all sides of the industry again.” To learn more about IDT EXPO and future events, visit the website here.

Wendy Courtright Vice President, IDT EXPO

Wendy has served as Vice President of Operations at ADV Integrity, Inc. for the last 3 years. In addition, Wendy is also co-founder and Vice President of IDT EXPO.

IDT EXPO’s June event featured experts in pipeline inspection and monitoring.


ADV Integrity | 2021

Something to Add: Validating Additive Manufacturing for Critical Applications in Oil & Gas June 30, 2021 - Additive manufacturing (AM) is set to become a credible (and disruptive!) alternative to traditional manufacturing in cases involving on-demand, customized, and highly specialized products and/or components. AM can readily and efficiently incorporate complex solutions culminating from generative design or light-weighting efforts—sometimes rather difficult to achieve using traditional manufacturing methods. Cutting-edge advances in the AM field are poised to bring about a paradigm shift in the conventional manufacturing and supply chain approaches in the industry. Atul Ganpatye, Senior Associate at ADV Integrity, studies AM processes and applications at ADV Integrity. He said, “AM opens a world of opportunities for the industry in terms of realizing complex designs with fast turnaround, efficient component inventory management, reduced failure rates, and specialty applications—provided that AM processes and parameters are properly understood and managed. The key to success will be in understanding when and how to use AM for your specific applications, and more importantly, when not to use AM. This understanding needs to be guided


by carefully thought-out qualification programs.” The relatively slower adoption of AM in the oil and gas industry is symptomatic of the lack of confidence in the applicability and suitability of AM materials, processes, and finished products, which primarily result from the lack of demonstrated or validated performance data. Some of ADV Integrity’s most recent initiatives are seeking to close this gap by integrating verification (analysis), inspection, and validation (testing) of additively manufacturing components for the oil and gas industry. “With deep experience and expertise in mechanics and materials, ADV Integrity stands well-positioned to facilitate improved understanding of AM methods and products by building customized analysis, inspection, and testing programs to benefit our partners,” Mr. Ganpatye said. “We are in a unique position to bring a broad, systemic perspective to the table for AM applications, starting from feed material considerations, all the way to performance demonstration using full-scale testing. And if things have gone too far, too fast for you, and you are dealing with failure of AM components in your application, ADV Integrity can also help with failure analysis of AM parts.” Like most disruptive innovations in human history, AM will provide incredible opportunities to be at the forefront of change. Industry players should make the most of these opportunities and create value for innovators and end users. Atul led a project to test a 3D-printed PEEK hook manufactured by Roboze ARGO 500.

Atul Ganpatye Senior Associate

Atul has over 12 years of engineering consulting experience specializing in integrity assessment of onshore and offshore equipment.

ADV Integrity | 2021

ADV Integrity Advances Study of Spoolable Pipe Testing & Integrity Management Solutions


June 30, 2021 - Spoolables might be the future of pipelines, but, as with any innovative technology, uncharted territory still exists around various aspects of their application and management. ADV Integrity is conducting extensive studies on spoolable pipe systems to provide validation and guidance for their safe and efficient operation. As a testing service provider, ADV Integrity provides third-party testing and validation for spoolable pipes, including API SPEC 15S qualification tests and client-specific tests. In addition to providing independent evaluations as needed, ADV Integrity also provides specialized testing for atypical applications or requirements beyond industry standards. For any questions not solvable by current protocols, ADV Integrity can also form a Joint Industry Program (JIP) to address industry-wide problems and develop standard practices. One such JIP project, the Combined Loading Assessment of Spoolable Pipe Systems (CLASPS-01), was completed to address the limited research on the effects of combined loading on spoolable pipe end connections, providing more insight into the proper management and deployment of these systems. The derivative CLASPS-02 JIP is currently being developed to focus on defect assessment and inspection of spoolable pipe systems to help operators develop integrity management programs to manage their assets, ensure safety, and mitigate risks. At this time, there are currently no established NDE inspection protocols or integrity management standards for spoolable pipes systems—a clear deficiency that the CLASPS-02 is set to remedy. Chantz Denowh, Vice President at ADV

Integrity, facilitated the CLASPS-01 program and is currently managing the CLASPS-02 program. Through these JIPs, he hopes to improve the reliability of spoolable pipe technology so operators can have confidence in spoolable pipe deployments. The advantages of using spoolable pipes instead of steel pipes include economical installation and ability to transport corrosive fluids. They can also be used for pipeline rehabilitation or repurposing. By pulling the composite pipe through failing or under-productive pipelines, the spoolable pipe creates an internal liner capable of high-pressure transmission. In a study with TC Energy, ADV Integrity researched the ability of this rehabilitation and repurposing solution to provide a beneficial, costefficient alternative to current practices. Spoolable pipelines represent a technology that could be richly beneficial across the industry. ADV Integrity is committed to continuing to study and advance the

existing knowledge of this and other technologies to keep the industry working at its best.

Chantz Denowh

Vice President, ADV Integrity Dr. Chantz Denowh has spent the last seven years conducting fullscale testing and analysis to create, calibrate, and validate integrity assessments and remediation methods for the midstream industry.


ADV Integrity | 2021


The Futch Factor

ADV Integrity | 2021

ADV Integrity’s Failure Analysis and Metallurgical Services Are Ready for Operators’ Toughest Challenges June 30, 2021 - With the recent addition of David Futch, PE as a Senior Associate and Director of Materials Engineering, ADV Integrity has launched its failure analysis and metallurgical assessment services for operators. For Mr. Futch, offering failure analysis services not only complements the already comprehensive full-scale testing and numerical modeling capabilities at ADV Integrity, but it also capitalizes on his unique set of diverse experiences.

Scan the QR code below to download a copy of David’s failure analysis brochure and Collection Guide.

“We’re looking to be the operator’s trusted partner in the failure analysis process,” Mr. Futch said. “My experience on the operator side gives ADV Integrity a distinct point of view when conducting failure analysis. My goal is to provide a comprehensive service that is unique in its ability to understand and diagnose problems encountered on a pipeline, then summarize those findings while taking the operator’s point of view into consideration.”

As part of ADV Integrity’s launch of failure analysis services, Mr. Futch plans to unveil ADV Integrity’s new ACER approach for failure analysis in a livestream on June 17th at 2 PM CST. The approach incorporates steps that take into account regulatory requirements, comprehensive data collection, efficient analysis, and customizable reporting options, so operators can walk away knowing the key insights pertinent to safe, reliable, and efficient decision-making. It also takes advantage of the support systems in place in ADV Integrity’s full-scale testing center, providing a one-stop-shop to evaluate and understand even the most complex failures.

David works closely with operators to assess and verify material properties.

“Adding the failure analysis services supplements ADV Integrity’s already impressive range of capabilities, so we have the ability to tackle any operator’s toughest challenge,” Mr. Futch said.

David Futch

Senior Associate, Director of Materials Engineering David has worked in the oil and gas industry since 2012, specializing in midstream pipeline materials, welding, and corrosion. At ADV Integrity, he leads the Materials Engineering department.


ADV Integrity | 2021

Innovative Inspection Analysis Automates Dent Processing

October 6, 2021 - After a high-resolution caliper in-line inspection (ILI) tool is run, pipeline operators receive an internal map of their system that includes various defects and features (girth/seam welds). The number of discovered defects could number in the hundreds for operators. Without an accurate, detailed analysis of these discovered defects, operators might be led to remediate more defects than necessary and incur the large price tag that follows. However, the necessary analysis of these large sets of data can quickly get expensive, as it typically requires manual processing of each defect.

Example of stress contour around a dent defect

Potential applications for this innovative technology go beyond processing dents from inline inspections.

Example of pre-processing

At ADV Integrity, Ahmed Hassanin, Engineering Associate, and Emmanuel Valencia, Engineering Assistant, are working to automate the processing of ILI data for dent defects. The programmed parametric tool, which is still in development, is set to provide an alternative solution to clients that is cost-effective, more efficient, and produces results that simplify integrity management decisions. The software has three distinct phases: pre-processing, processing, and postprocessing. In the pre-processing phases, raw data from the ILI tool is cleaned using various smoothing techniques, and prepared for finite element analysis (FEA). Next, the data is analyzed using a commercially-available FEA software to generate stresses and/or strains. The

outputs are then post-processed and transformed into actionable insights for operators. This type of processing calculates key outputs about the detected dent features, such as the stress concentration factors (SCF), which are used to estimate the remaining life. This information is then used to determine the best course of action for operators, whether that be to remediate, leave and monitor, or repair and monitor. These recommendations are verified by detailed engineering analysis and compared with the limits provided in the respective codes and standards. Potential applications for this innovative technology go beyond processing dents from inline inspections. According to Mr. Hassanin, there are future opportunities for other types of defects to be processed, such as corrosion or crack-like features. There are also possible applications for inspections performed with magnetic flux leakage (MFL) and 3D scanning. In addition, Mr. Valencia is looking forward to when the program will eventually incorporate Machine Learning for even quicker results. Through transforming a formerly manual process into an automatic analysis that incorporates engineering judgment, ADV Integrity hopes to use this tool to work with companies for better inspection results in the future.

Ahmed Hassanin Engineering Analyst

Ahmed is an expert in Finite Element Analysis and validates results with testing. Using ADV Integrities full-scale testing, Ahmed validates numerical results from FEA with experimental testing.


ADV Integrity | 2021

In-Line Inspection Test Spools Build Confidence and Certainty October 6, 2021 - Pipeline integrity management practices commonly rely on various inline inspection (ILI) systems for threat assessments to ensure the safe operation of pipelines. Each ILI system is somewhat unique and provides a vast amount of data that is used to make integrity management decisions. In addition, each ILI system’s measurement principle and performance has an understood level of uncertainty in the detection, identification, and sizing of defects. These uncertainties can lead to various outcomes, including over-conservatism, unnecessary digs, or elevated risk due to inaccurate data. These outcomes can put people, the environment, and limited resources at risk. Now, it is possible to evaluate and account for these uncertainties using prefabricated ILI test spools. Small-scale testing methods can be used to gain confidence in the ILI system by utilizing test spools focused on the ILI system’s accuracy in the probability of detection (POD), probability of identification (POI), and sizing for specific flaw sizes. At ADV Integrity, our consultants work with operators in four distinct phases of spool development and ILI validation: test design, fabrication, pull testing, and results analysis. The purpose of this process is to understand if the goal of the inspection

will be achieved. While each project’s goals are similar, each project often has unique circumstances, such as critical flaw size, material characteristics, defect morphology, operating conditions, etc. ADV Integrity’s phased approach considers these unique characteristics to reduce uncertainty in the actual tool run. In the first phase, ADV Integrity designs custom spools for blind testing of POD, POI, and/or sizing accuracy validation. ADV Integrity’s engineers can provide recommendations on defect types, sizes, and quantity to meet project requirements related to statistical confidence or integrity management objectives. After the test spool is designed, ADV Integrity works with multiple fabricators to implement the test spool designs. These fabricators use methods such as electric discharge machining (EDM) and conventional machining to create the test spool. To put the newly machined test spool to work, ADV Integrity uses its on-site pullrig to collect inspection data. From that data, ADV Integrity’s engineers evaluate the accuracy of the ILI system’s performance and stated specifications and interpret the results, all of which

are protected with strict confidentiality measures. From this spool development and ILI validation process, operators will gain the comprehensive understanding of their ILI systems they need to make informed integrity decisions. Both operators and ILI service providers can benefit from this approach as it can provide the basis for the ILI project goals, scope, and requirements.

Chantz Denowh

Vice President, ADV Integrity Dr. Chantz Denowh has spent the last seven years conducting fullscale testing and analysis to create, calibrate, and validate integrity assessments and remediation methods for the midstream industry.


ADV Integrity | 2021

Mitigating the Risks of Early Failures in High Strength, New Construction Girth Welds October 6, 2021 - Recently, the industry has identified several new construction girth welds that have failed within the first few years after construction. Despite the welding procedures used in these situations meeting industry standards, these failures occurred as a result of traditional welding techniques being applied to stronger, more advanced line pipe base material. As such, the girth welds were undermatched, and the heat affected zone (HAZ) displayed high levels of softening. David Futch, who presented findings on these girth weld failures at the 2021 API/ AGA Joint Committee on Pipeline Welding Practices, is the Director of Materials Engineering at ADV Integrity. He said, “One of the problems facing operators in these situations is that the current techniques used to qualify welding procedures produce a limited understanding of what is actually happening in and around the welding site.”

Mr. Futch argues for two supplementary testing alternatives for qualifying welding procedures and, consequently, mitigating risk. One is Digital Image Correlation (DIC) of cross weld tensile specimens that provides more accurate information about the accumulation of strain in these welds. DIC provides a visual representation of where the strain is concentrated, which results in a clearer understanding of the failure mode of the weld. Mr. Futch’s second recommendation is performing sub-load hardness testing maps along the weld’s cross-section, which visualizes the relative strength in a sample. Sub-load hardness testing maps and the associated color outputs help visualize the softening of the heat affected zone much more accurately than traditional methods. “For qualifying procedures on high strength material, operators can gain a better understanding of the risks associated with welding by running DIC of cross weld tensile specimens and fully automated hardness maps. As a result, you’ll confirm that your procedures help mitigate these early girth weld failures,” added Mr. Futch. Much in the same way magnifying glasses make clear what was not visible before, the combination of these two tests allows for much more accurate assessments of welding procedures. Where traditional techniques may fail to pick up on key

indicators of potential failure, DIC of cross weld tensiles and hardness testing can produce clear and accurate assessments. In addition, these processes are not limited to girth weld qualifications. The applications of these tools could be applied to a wide range of assessments for better pipeline protection. “For a marginal cost, operators could see a large return in terms of asset protection and risk mitigation if they supplement these two techniques to their qualification procedures,” Mr. Futch said. ADV Integrity is fully equipped and ready to perform these assessments at its test facility in Waller, Texas.

David Futch

Senior Associate, Director of Materials Engineering David has worked in the oil and gas industry since 2012, specializing in midstream pipeline materials, welding, and corrosion. At ADV Integrity, he leads the Materials Engineering department.

Hardness testing is one of David’s recommendations for mitigating failures in high strength, new construction girth welds.


Fatigue Fortune ADV Integrity | 2021

Improving Accuracy in Fatigue-Life Assessments and Predictions December 17, 2021 - One of the biggest challenges for integrity management in the oil and gas industry is the ability to accurately predict the fatigue life of critical mechanical components. Understanding fatigue as a failure mode is straightforward at first glance — components subjected to cyclic loading become vulnerable to fatigue damage and potential failure. Unfortunately, translating a cyclic loading problem into a tangible fatigue analysis process for predicting when and how failure will occur is rarely simple. Without the right input and assumptions, fatigue analysis can quickly turn into a random numbergenerating exercise! Might as well ask Zoltar! For accurate fatigue-life predictions, integrity engineers must be able to view cyclic loading issues on a systemic level. An ideal fatigue analysis process involves a careful consideration of cyclic loads (think demand) and fatigue curves (think resistance or capacity). Furthermore, complex mechanical systems will sometimes need to be evaluated on two different levels – a global level for general system response to loading, and a local level for very localized, concentrated response in a component due to unique design features. The calculations then need to be presented in a manner that can be readily used by an integrity team to manage operations and/or modify

designs to resolve any undesirable fatigue performance issues. Fatigue analyses routinely require substantial domain knowledge and operational familiarity, along with strong analytical capabilities to allow successful navigation through uncertainties in load and resistance predictions and ambiguous statistical judgments on the outcomes. Uncertainties in analytical fatigue performance prediction also elevate the need for validation testing. Without a proper understanding of the system, comprehensive planning, and statistical sampling considerations, validation testing can quickly become extremely resourceintensive. Successful fatigue assessment requires a systemic approach that utilizes a wide range of tools from numerical analysis, such as finite element analysis (FEA) and damage modeling, to sub-scale and full-scale testing. The ability to view cyclic loading problems from multiple perspectives is critical in formulating effective solutions. ADV Integrity is uniquely equipped with expertise in advanced numerical modeling, and full-scale and sub-scale testing for comprehensive fatigue assessments. The breadth and depth of ADV’s expertise enable a holistic approach for advancing the industry’s understanding of fatigue assessments for integrity management.

In fatigue assessments, the range of possible outcomes makes interpretation of results especially challenging. That’s why an advanced knowledge of statistical models and validation through testing are important.

Atul Ganpatye Senior Associate

Atul has over 12 years of engineering consulting experience specializing in integrity assessment of onshore and offshore equipment.


ADV Integrity | 2021

Applications of CO2 and Hydrogen in the Energy Transition

December 17, 2021 - The midstream industry is rushing into a new era. Energy is on the verge of a global shift towards more sustainable practices. The forthcoming changes are a function of consumer demand, technology advancements, recent legislation, and fundamental changes to the methods by which companies create shareholder value. ADV Integrity is currently supporting industry players in navigating this transition, including considering the factors outlined in this article that influence the safe and profitable operation of new fuel alternatives.

1. ESG: Your Score Matters With the introduction of environmental, social, and governance (ESG) factors, businesses must manage their ESG “scorecard” to attract capital. This is in addition to managing the current state of affairs with erratic oil price trends and a global pandemic. For companies in the energy industry, this “scorecard” is especially relevant to sustainability, decarbonization, and carbon sequestration activities.

What’s Next? 16

ADV Integrity | 2021 Not only does ESG put pressure on the energy industry to undergo this major transition, but it also incentivizes companies from other industries to pursue more “green” practices. These practices will drive up demand for alternative energy sources and drive the transition to decarbonized alternatives for the oil and natural gas pipeline grid. Two highlydiscussed alternatives include carbon dioxide and hydrogen, each with unique challenges that will force the industry to learn and adapt.

2. CO2: It’s Happening Now

There are currently between 5,000 to 10,000 miles of carbon dioxide pipelines in the United States—a fraction of what currently exists for oil and natural gas. However, the opportunity for growth in this area increased exponentially as the Biden administration included more than $12 billion for carbon capture and sequestration (CCS) in recently passed infrastructure legislation. CCS is an integral component of emissionreduction technology. During capture, carbon is compressed and then transported via pipeline. Carbon dioxide is then injected underground for storage, but it can also be used for other end uses such as enhanced oil recovery (EOR), food and beverage manufacturing, paper manufacturing, and metal fabrication. The U.S. Department of Energy estimates that between 2.6 to 21 trillion metric tons of carbon dioxide could be stored in the sequestration process, the equivalent of hundreds or even thousands of years of emissions at current levels in the United States. Since 2001, 63 incidents related to CO2 pipeline failures were reported to the PHMSA Hazardous Liquid Incident database, with no reports of fatalities or injuries. However, an incident in early 2020 in Satartia, Mississippi resulted in numerous hospital visits from carbon dioxide poisoning. Many of the incidents reported to the PHMSA database were related to failures of non-metallic sealing elements, such as a non-metallic elastomer, grease, or packing rather than issues with the pipeline’s steel. Because non-metallic elements absorb CO2 and subsequently swell, non-metallic materials become susceptible to cracking or failure upon pressure release. Therefore,

CO2 pipelines require strict criteria for nonmetallic material selection. Another major concern is long-running fractures. Carbon dioxide is typically transported in a dense phase at pressures greater than 1,070 psi (73.8 bar) and 88 F (31.1 C). If a failure occurs, CO2 will have a pressure driving force for a much longer distance than methane in natural gas pipelines. Preventing long-running fractures involves a fracture control program that assesses and monitors fracture toughness, pipeline dimensions, operating pressure, and may require the use of crack arrestors. Decreasing the operating pressure would reduce the risk of long-running fractures but also decrease throughput—a potentially economically disadvantageous outcome. Overall, carbon dioxide transportation, while posing its own unique set of challenges, is happening today, and with recent investments in CCS initiatives, it is posed to grow. Due to the challenges associated with it, engineered solutions will be required to find the appropriate operating conditions for CO2 transportation.

3. Hydrogen: Something to Watch There are approximately 1,600 miles of hydrogen pipeline currently in the U.S. Hydrogen is primarily transported blended with natural gas. In the United States, 3% blended hydrogen is typical. Above 5%, more research is necessary to understand material concerns. The primary challenge with hydrogen is embrittlement and cracking as a result of hydrogen’s active electron migrating into the crystal structure of most metals. Because of the risk posed by hydrogen to traditional steel pipelines, non-metallic liners or pipes is a potential solution for converting pipelines for hydrogen. However, operators should know that the permeation of hydrogen through some elastomer seals and soft goods is higher than methane (natural gas). There are viable non-metallic options, but testing may be required to validate their efficacy as liners for converted pipelines. The challenges posed by hydrogen make its potential application especially complex. However, with the demand for decarbonized alternatives to oil and natural gas, it will inevitably have its place in the energy infrastructure.

4. Applications of Non-Metallics ADV Integrity has extensive experience with studying and testing applications of nonmetallic and composite materials, including several Joint Industry Projects (JIPs) that bring together industry players to develop integrity management solutions. In converting pipelines for both carbon dioxide or hydrogen transport, there is a need for testing and engineered analysis of non-metallic material applications. Without a doubt, more research is necessary to support operators as they make this shift towards carbon-neutral alternatives and implement ESG initiatives. Currently, ADV Integrity’s engineers are actively engaged with researching the implications of the energy transition and ESG to serve as a resource for the industry. ADV Integrity is looking forward to continuing to serve operators as they explore the cutting edge of technology and innovation in the energy transition. Brady, Jeff. (2021, November 17). The infrastructure bill could boost the industry removing carbon dioxide from the air. NPR. Agency. (2017, January 19). Carbon Dioxide Capture and Sequestration: Overview. EPA: 19 January 2017 Snapshot. carbon-dioxide-capture-and-sequestration-overview_.html NACAP. (2015). The North American Carbon Storage Atlas. The U.S. Department of Energy (DOE), Natural Resources Canada (NRCan), and the Mexican Ministry of Energy (SENER). https:// pdf United States Environment Protection Agency, 2017. Zegart, Dan. (2021, August 26). The Gassing of Satartia. Huffington Post. 0ddc8f Hydrogen and Fuel Cell Technologies Office. (n.d.) Hydrogen Pipelines.

David Futch

Senior Associate, Director of Materials Engineering David has worked in the oil and gas industry since 2012, specializing in midstream pipeline materials, welding, and corrosion. At ADV Integrity, he leads the Materials Engineering department.


ADV Integrity | 2021

THING 20 & THING 21 December 17, 2021

Thing 20 & Thing 21 Enhance Comprehensive Pipeline Integrity Engineering Services Rhett Dotson and Christopher De Leon know how to have fun with pipeline integrity. As the 20th and 21st addition to ADV Integrity’s growing business (otherwise known as Thing 20 and Thing 21), both bring extensive industry experience and pipeline integrity expertise to ADV Integrity’s services. Their pipeline integrity expertise includes integrity assessments focused on in-line inspection (ILI) and regulatory consulting as it pertains to PHMSA regulations for materials properties verification, maximum allowable operating pressure (MAOP) reconfirmation, and engineered critical assessments (ECAs). And, most notably, they’re bringing in new ideas to fundamentally improve integrity management consulting for the midstream industry. Rhett has a background in applied engineering for critical problem-solving in pipeline integrity. He is an experienced


Rhett echoes this sentiment, emphasizing the availability of ADV Integrity’s engineers for clients.

“Operators should feel like they can call us just to talk about the issues they’re facing. If you have a question, pick up the phone and consultant who has dealt with a wide range call us. As consultants, that’s what we’re of technical problems facing operators. He here for,” Rhett said. gained a deep appreciation for ILI-based Rhett and Christopher are looking forward assessments from his work at Rosen, to bringing their expertise to enhance ADV which broaden his consulting capabilities Integrity’s already full suite of testing, from his days at Stress Engineering engineering, and consulting services. Their Services. Christopher brings in years of previous experience with working with notable experience with comprehensive operators to implement comprehensive pipeline integrity management from his integrity management systems positions work as a pipeline integrity engineer at Energy Transfer and leadership as a service them to serve clients on a larger scale. manager and ILI expert from his work with Rhett said, “ADV Integrity historically Rosen. Both are passionate about serving is extremely good at solving complex clients to improve their asset integrity problems for operators. Christopher and I management. are exceedingly good at understanding how to take that problem and broadly apply “We want to be your first call when you need support, and to do that, we know we it to an operator’s integrity management system.” have to earn your trust,” Christopher said. “We’re not traditional. ADV Integrity is not ADV Integrity engineers are well-equipped traditional. Building trust and meaningful to support operators with comprehensive relationships are our first priority, not plans that reduce inefficiencies and make pushing proposals at you.”

ADV Integrity | 2021 integrity management more effective. Rhett and Chris want operators to begin with the end in mind, starting with clear definitions and objectives before jumping into potentially overwhelming inspection, testing, or analysis. Whether that’s providing consulting on regulations, ECAs, or ILI management, ADV Integrity is ready and eager to serve clients in these areas to enable operators to strategically allocate their resources. As Rhett said, “Thing 20 and Thing 21 have your back.”

Rhett Dotson Chief Engineer, Pipeline Integrity

Rhett Dotson is a professional engineer with 16 years of experience in the pipeline industry. Rhett specializes in in-line inspection, analysis, and fullscale testing.

Chris De Leon

Director, Pipeline Integrity With 12 years of experience in the pipeline industry, Chris has expertise in ILI technologies, integrity management plans, MAOP reconfirmation, and material verification.


ADV Integrity | 2021

New Coating Qualifications Testing Expands ADV Integrity’s Testing Services December 17, 2021 - Every pipeline is exposed to the risk of external corrosion. Coatings are a first line of defense, but no coating system is 100% failure-proof. In order to avoid potentially disastrous consequences, operators are responsible for ensuring the coating system used meets or exceeds the requirements specified in Codes and Standards. These include the ability to mitigate corrosion, have sufficient adhesion, and ductility. Qualifying, or performing tests on a coating system, can help verify the selected system meets the documented requirements. High-quality coating qualification testing demands superior material testing expertise and equipment. With the addition of a full suite of new equipment, ADV Integrity has added an array of coating testing capabilities to its suite of services available to operators as part of its fullscale testing and consulting. Combined


with capabilities such as numerical modeling and analysis, ADV Integrity is uniquely situated to address the demand for coating qualification services by providing tests, including: • Cathodic Disbondment • Adhesion • Wet Adhesion • Impact Resistance • Bendability • Penetration Resistance Coating qualification testing may be necessary for a variety of situations: • Testing and validating new coating products and technology • Qualifying coating products and processes for new pipeline construction • Verifying coating protection on current pipeline systems

David Futch

Senior Associate, Director of Materials Engineering David has worked in the oil and gas industry since 2012, specializing in midstream pipeline materials, welding, and corrosion. At ADV Integrity, he leads the Materials Engineering department.

This mix of mechanical and environmental testing proves coating strength, ductility, impact resistance, and abrasion resistance. It also verifies the expected life of the coating, given its environment. ADV Integrity looks forward to continuing to provide coating testing services in addition to its current services offerings. It is another step in ensuring the best possible operating conditions for the pipeline industry.

Elevated temperature cathodic disbondment equipment

New Beginnings ADV Integrity | 2021

ADV Integrity to Start Construction for New Facility

December 17, 2021 - When ADV Integrity officially moved into our current 17,000 ft2 facilities in January 2019 located in Waller, Texas, we had six employees, one blast box, a single pressure cycle unit, and a very simple data acquisition system. Our first engineer, lab manager, and technician were Dr. Chantz Denowh, Cory Duncan, and Zack Hurst, respectively. These gentlemen ran activities in the lab, and I spent time on the road drumming up work. I was optimistic we would grow the company, but as a new entrepreneur will tell you – starting a company is scary! The significant costs associated with running a full-scale test lab added an additional level of burden to what we were trying to do. By early 2021, we had made significant progress in terms of expanding our list of equipment, filling up our yard with vintage pipe, and occupying all available offices. With our ADV Marketing staff, on some days we had 20 people on-site in a facility that was designed for at most 15 people. We even had to bring a mobile mini-unit to house three of our engineers.

ADV Integrity’s new facility is set to be move-in ready in 2022

At ADV Integrity, we spend a healthy amount of time thinking about the future and realized we needed more space. Unfortunately, there are not many facilities in north Houston that include office space for 50 people, an in-house conference center for training, and access to airconditioned full-scale test facilities with overhead cranes. We realized we were going to have to build our own facilities. We started looking for land and found a 7.5 acre tract in the High Meadow Industrial Park located in Magnolia, Texas. We purchased the land in May of this year and also started working with Boatman Construction and ML REID Architects. We’re also working with Frost Bank is securing funding for the project.

16,000 ft2 office building that will include a conference center for 180 people. Dr. Chantz Denowh, who serves as our Director of Lab Operations, and Lab Manager, Ryan Phillips, have identified appropriate locations for all of our testing equipment. We have also allocated space for our materials test lab that will be under the direction of our metallurgist, David Futch. We plan to break ground in January 2022 and move in by September 2022. We’ll keep you apprised of our progress, including periodic photographs and videos taken by ADV’s drone.

We’re extremely excited about ADV Integrity’s new facility. We’ll have a 14,000 ft2 full-scale test lab, combined with a

Chris Alexander President, ADV Integrity

Dr. Chris Alexander, PE is the Founder and President of ADV Integrity, Inc. He has more than 25 years’ experience in designing, evaluating, and testing a wide range of technologies, including the use of composite materials. ADV Integrity’s facility in 2019 (top) and 2021 (left)



Photography by: Ivy Robinson Marketing Associate Articles written and curated by: Sarah Roberts Marketing Associate

28246 FM 2920 Waller, Texas 77484 832.509.4606