Asset Integrity & Reliability Management (AIRM) Magazine

Issue 1, Vol. 1 August-September 2019

Magazine Asset Integrity & Reliability Management (AIRM) Magazine–maintaining safety, reliability & integrity

Pigging of Upstream Natural Gas Distribution Pipelines with the use of Natural Gas Pressure from Well

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Published by rity & Reli

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Content

Content

POSITIVE MATERIAL IDENTIFICATION. BECAUSE YOU ONLY GET ONE CHANCE TO GET IT RIGHT.

Magazine Issue 1, Vol. 1 August-September 2019

Editorial

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Pigging of Upstream Natural Gas Distribution Pipelines with the use

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of Natural Gas Pressure Published by: Institute of Asset Integrity & Reliability Management

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Editing: Sudeeksha Malwal, Riya Jha

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Articles: Swati Pawal Contributors: Pulak Jyoti Sarma, CGM (OGPL&P), Oil India Limited Abhijit Bora, Dy. CE (OGPL&P), Oil India Limited Satyajit Chakrabarty, Sr. Engg(OGPL&P), Oil India Limited Vincent Demers-Carpentier, Eddyfi Technologies Maxime Rochette, Eddyfi Technologies Charles Tremblay, Eddyfi Technologies Marco Michele Sisto, Eddyfi Technologies Andreanne Potvin, Eddyfi Technologies Vineet Upadhyay, Planys Technologies Manas Galipalli, Planys Technologies Ashish Antony Jaco, Planys Technologies Tanuj Jhunjhunwala, Planys Technologies

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Inspection of Underwater Assets Using Robotic Technology

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WITH BEST COMPLIMENTS

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elcome to the first issue of Asset Integrity & Reliability Management (AIRM) Magazine. This initiative has been taken to provide a platform to all the technologists, educationists, scientists, academicians and professionals of various industries to share their knowledge and discuss issues pertaining to Asset Integrity, Reliability, Corrosion Control, Inspection & NDT, Material of Construction, Welding & Fabrication, Operational Excellence, Process Control, and Chemicals etc.

Integrity Management is vital in managing Industrial assets effectively to gain maximum value, profitability and returns while safeguarding personnel, the community, and the environment. From a life cycle perspective, which includes the design, installation, operation and maintenance, an asset should always perform to its required design function both effectively and efficiently. The assets may be susceptible to physical damage and/or external/internal corrosion which may lead to pre-mature failure, safety, integrity and environmental issues, affecting brand image, huge replacement/repair cost and production loss. Many of the process plants, offshore/ onshore, installations, pipelines, Power etc worldwide are operating beyond their nominal design life, raising concerns for potential loss of hazardous materials and adverse business impact. The understanding of Asset Integrity & Reliability Management incorporates design, maintenance, inspection, process, operations, and management concepts since all these disciplines impact the integrity of the infrastructure and equipment.

Through this magazine we want to spread the knowledge of asset integrity management among industry professionals. The magazine will contain articles, reports, case studies, discussions, problems and solutions, information about new technology, materials and processes and other products & services related to asset integrity & Reliability. We invite all professionals to contribute in the mission of spreading knowledge of asset integrity through exchange of information. Your feedback is important to us and your suggestions will helps us to improve it further.

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MANUAL DATA LOGGING

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NON- DESTRUCTIVE TESTING SPECIALISED SERVICES PULSED EDDY CURRENT (PRESSURE VESSELS & PIPE LINE, INSPECTION OVER INSULATION) ULTRASONIC THICKNESS GAUGING SURVEY ON SHIP, OIL RIGS & REFINERIES ULTRASONIC IMAGING A, B & C SCAN CORROSION MONITORING LONG RANGE ULTRASONIC HIGH PRESSURE PIPE LINES (LRUT) ULTRASONIC DATA (MANUAL) LOGGING ‘C’ SCAN SOFTWARE FLU. MAGNETIC PARTICLE INSPECTION DIGITAL RADIOGRAPHY IMAGING FLU. DYE PENETRANT TESTING

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Articles

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been initiated and pigging of some of the old and important gas pipelines have been taken up.

I) NECESSITY OF PIGGING IN WET(UPSTREAM) GAS PIPELINES Pigging is carried out in a gas pipeline for the following factors: 1. Removal of accumulated condensate, water and debris thereby reducing corrosion.

2. Break colonies of bacteria to reduce bacterial corrosion.

Pattern of flow in wet gas pipeline Liquid condensation in Wet natural gas transmission pipelines commonly occurs due to the thermodynamic and hydrodynamic imperatives was studied by Xu and Gong [Ref-1]. Condensation subjects the gas pipeline to two-phase flow, and the presence of condensation in gas pipelines dramatically affects their delivery ability and operational modality.

Pigging of Upstream Natural Gas Distribution Pipelines with the use of Natural Gas Pressure from Well Authors: Mr. Pulak Jyoti Sarma, CGM (OGPL&P), Mr. Abhijit Bora, Dy. CE (OGPL&P), Mr. Satyajit Chakrabarty, Sr. Engg (OGPL&P), Oil India Limited [Presented in 5th ICEPIM 2019] Abstract: This paper deals with the methodology that was adopted for carrying out pigging of the Natural Gas Distribution Pipelines with the use of upstream natural gas pressure from wells and describes selection of pigs, arrangement for controlling of liquid driven out of the pipelines, the overall field operation and seeks input from industry for improving the process.

Introduction OIL India ltd(OIL) produces Natural Gas in two forms from the oil fields in Assam:  Associated gas from wells that are linked with oil reservoir.

The well fluid produced from oil wells is a mixture of crude oil, formation water and associated gas.  Non-Associated (NA) gas from gas reservoirs. Non-associated gas contains minor percentage of liquid hydrocarbon and water.

The fluid from oil wells is treated in Oil Collecting Station (OCS) and crude oil, formation water and the associated gas are separated during the treatment process. Fluid from NA Gas wells is treated in Field Gas Gathering Stations (FGGS) where the gas and liquid are separated. However, both associated and non-associated gas is

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The paper by Xu and Gong [Ref-1] presents a compositional hydrodynamic model that describes the hydrodynamic behavior of gas/gas condensate flow in pipelines, in which gas is condensing/ vaporizing at some section of the pipeline. One of the most difficult features of this system is that the condensing/ vaporizing section must be identified. Meanwhile, the onset of condensation means that two phases coexist in the pipeline, with continuous mass and momentum transfer between phases.

This coexistence creates an additional complication because the mass transfer rate depends on the system’s temperature, pressure and composition. The general condensate characteristics in gas distribution pipelines of OIL are as follows:  Condensate is a low-density, high-API Gravity (above 45) liquid hydrocarbon phase that generally occurs in association with natural gas.  Its presence as a liquid phase depends on temperature and pressure conditions in the system allowing condensation of liquid from vapor. During production, there is a risk of the condensate changing from gas to liquid.

Fig-1b: Typical Production Seperator

Fig-1c: Typical Schematic of FGGS

pockets [Ref 4-6]

The natural gas from OCS and FGGS is transported through distribution pipeline network at around 17 kg/cm2 to 25 kg/cm2.

The network comprises of 625 Km pipeline of various diameters from 100mm to 600mm and length from 2 km to 37 km. Vintage of the pipelines ranges from 1 year to 30 years. As the field pipelines are generally of short life and are laid as per contour of available route, they are mostly not constructed with appropriate features required for pigging. Moreover, the natural gas emerging from OCS and FGGS are not fully dry. Hence accumulation of liquids including water in the pipelines and resultant corrosion and subsequent failure is a clear possibility. However, despite the afore stated conditions instances of failures related to internal corrosion have been limited and the older pipelines have lasted beyond the expected life. These pipelines are very important from the point of view of gas production and distribution. The wet gas is transported through the distribution network from OCS and FGGS to the Central Gas Gathering Station (CGGS), where dehydration of the gas is carried out before final distribution to end customers.

Efforts for better integrity management of the pipelines have

With multiphase flow regime in wet upstream gas pipelines there is flow instability, due to a series of liquid pockets followed by continuous gas. This flow causes pressure fluctuations that affect the receiving facilities and increase solid deposits and corrosion.

Slugging occurs in multiphase flow regimes, where flow in a section of pipe under the influence of gravity, liquid will settle at the bottom and gas will occupy the top half of the pipe. These fluids will travel unevenly distributed in the pipeline either mostly as liquid or gas, forming large plugs known as slugs. The flow patterns that exist in horizontal and near horizontal pipes are classified as (Figure 2): • Dispersed bubble flow: At high liquid flow rates ‘dispersed bubble flow’ occurs. The liquid phase is the continuous phase and the gas phase is dispersed as discrete bubbles [Ref-2].

• Stratified flow (smooth and wavy): ‘Stratified flow’ occurs when the flow rate is low. At higher gas flow rates, the interface between the liquid and gas becomes wavy; this flow regime is called stratified wavy.

• Annular-mist flow: ‘Annular-mist flow’ occurs at higher gas flow rates [Ref-3]. The liquid phase flows as a thin film by the pipe wall forming an annulus form, and the gas phase flows through the centre of the pipe, which may contain entrained liquid droplets.

• Slug flow: At relatively high flow rates, the slug flow regime occurs and exhibits a series of liquid slugs separated by gas

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not 100% dried and hence contains traces of liquid hydrocarbon and water.

Fig-1a: Process Flow Diagram of OCS

Fig-1d: Typical Schematic of gas production, collection & distribution

• Elongated bubble flow: Elongated bubble flow (EB) is a multiphase flow regime in which most of the gas, moves as large bubbles dispersed within a continuous liquid.  The commonly encountered flow phenomenon in OIL’s gas distribution pipelines is that gas-condensate flow with low liquid loading. The same can be explained as in Fig. 2(a) which is the schematic description of the liquid holdup in horizontal gascondensate pipelines. The pipeline is divided into two sections, that is, gas section (Ao) with no condensate near the input for the higher pressure and temperature, and two-phase flow section (Bo) with condensate for lower pressure and temperature.  Moreover, in OIL’s gas distribution pipelines as the gas flow

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6th ICEPIM

Articles

Fig 2: Flow Patterns in Horizontal Pipes

Fig 2a: Schematic description of holdup in gas-condensate pipelines

of medium penetration and local corrosion. The presence of condensate water at the bottom of a pipeline results in corrosion. In areas where condensate water is present, corrosion is considerably more than that in other areas. Corrosion of steel pipe in a gaseous environment only occurs in spots in which condensate water droplets exist. Therefore, local corrosion occurs. The presence of water is a necessary condition for oxygen absorption corrosion and hydrogen evolution corrosion. Dehydration treatment of the transmission gas is suggested to be the main measure to control the corrosion failure of the associated gas pipeline.

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 The analysis of the gas sample carried out by OIL confirms the presence of CO2 in natural gas produced in the fields of OIL. The gas wells are known to have CO2 in the range of 1-5 mol %.

The absence of sour regime reservoir in OIL has shown negligible presence of H2S. The above analysis shows presence of condensate water, oxygen absorption and CO2 in gas distribution pipelines of OIL, which makes the gas distribution pipelines susceptible to internal corrosion. Thus, it was decided to carry out pigging of the gas pipelines in phases.

2b: Schematic description of pigging model for gas-condensate pipelines

rate is high, the flow pattern encountered in the gas distribution pipelines is either ‘annular mist’ or ‘stratified wavy’ type. The pigging model in OIL’s gas distribution pipelines will somewhat resemble the one as described in Fig 2b. The pipeline can be divided into three sections. Just ahead of the pig is the liquid slug section Sl. Name of Pipeline (B). The region to the left of the pig is the upstream single Well# 328 to Kathalguri 1 Forest gate pipeline phase gas flow section (A). To the right of the liquid slug is the FGGS Kusijan to Savitri 2 downstream transient twoTiniali Distribution line phase flow section (C).

Baghjan to CGGS gas 3 pipeline Types of Corrosion in Gas Barekuri EPS to Makum Pipelines 4.

OCS Study [Ref-7] reports show

II) PLANNING a. Selection of Pipelines for 1st Phase of Pigging Operation: The following pipelines were selected in consultation with operation group for carrying out pigging operation in the first phase: Size

Pigging Section

Length [Km.]

Year of Commissioning

Pigging History

400 mm OD

1

6

2008

No Pigging since Commissioning

300 mm OD

1

11

2008

No Pigging since Commissioning

400 mm OD

1

37

2015

No Pigging since Commissioning

200 mm OD

1

14.6

2007

No Pigging since Commissioning

that in a gas pipeline, the Tingkhong to OCS-1 No Pigging since 300 mm 1 20 1992 5. (NHK#296 Well plinth) corrosion products mainly Commissioning OD rich gas pipeline compose of FeO(OH) and FeCO3, and the corrosion of steel pipe is controlled by oxygen absorption corrosion and CO2 b. Study of the pigging operation in different sectors: corrosion. Hydrogen sulfide (H2S) is another dangerous element Experience from association with downstream operator in which exists in oil and gas reservoir. H2S acidifies water which gas pipeline pigging and training courses helped in observing causes pitting corrosion to carbon steel pipelines. Corrosion the following differences between pigging of upstream and reaction will increase when H2S combines with oxygen and downstream gas pipelines In the Downstream pipelines, flow of gas is regulated by carbon dioxide (CO2). compressor whereas in the Upstream pipelines pressure of wells As per studies [Ref-8], the direct reduction of H2S is only feasible is used for maintaining the flow. if the amount of H2S is high enough, which means the system has  In the Downstream pipelines flow is steady whereas in the to be either H2S dominated system (sour regime) or CO2/ H2S Upstream pipelines flow may not be regular as it depends on (mixed system). The presence of H2O is a necessary condition that flowrate from the downhole fluid and constraints to production produces FeO(OH) and FeCO3. H2O and O2 together with CO2 are from wells.  Pigging in the Upstream pipelines require controlling of key factors that induce pipeline corrosion. production from the wells and handling of gas and liquid from Flow rates of the transmission medium affect the structure of the the pipeline at the receiving station. In the Downstream pipelines corrosion scale and defects in pipe metal promote the occurrence such issues do not arise.

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6th ICEPIM Theme Topics • Pipeline Integrity, Safety and Reliability Management • Planning, Design and Construction of pipeline • Pipeline Materials, various issues in Pipeline Welding, Fabrication & Repair • Corrosion Control & Management • Latest Inspection Techniques in Pipelines Risk Management • Operation, Maintenance Repair & Rehabilitation of Aging Pipelines • Challenges and Development in Offshore & Deep Water Pipeline • Integrated Operations & Maintenance Solutions for CGD/PNG Distribution Networks • Integrated Operations & Maintenance Solutions for LNG Panel Discussion: • Pipeline Integrity Management for Deepwater & subsea pipelines • New Inspection of Non-Piggable Pipeline

Organizer:

Contact No: +91-98213 71009/011-46545757 Email: technical@pipelineintegritymanagement.in, consultmatcorr@gmail.com Website: www.pipelineintegritymanagement.in

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Constraints in Carrying out Pigging Operation in OIL’s Gas Distribution Pipeline  As the gas distribution pipelines transports natural gas from production installations, a number of factors had to be taken to account before undertaking the pigging operation:  As the pipelines are in operation continuously for more than 30 years, there could be accumulation of high quantity of condensate, water and sediments in the pipelines.  The liquid cannot be drained and collected at receiving barrel as the pigging operation will be carried out at pressure of distribution gas network i.e. 17- 25Kg/Cm2.  Field pipeline scrapper barrel are located by the side of public road or in the vicinity of forest and hence adequate care needs to be taken to ensure public and environmental safety.  The liquid and sediments scrapped during pigging operation cannot be directly diverted to an installation as this will lead to depositions in plant piping thereby choking the instruments which will eventually disrupt plant operation. Proper arrangement has to be made to divert the liquid to test tank of nearest production facility such that operation is not hampered and the liquid is collected appropriately and measured to ascertain efficiency of the pigging operation.  The scrapper barrels in older field gas pipelines are not of standard dimension.  Constructional details and maintenance record of the pipelines of more than 30-year vintage are not readily available.

The pipelines have been in operation continuously but complete operational records are not readily available. c. Methodology: A methodology had been drawn up taking into consideration the above stated constraints.

I. Study of operational parameters:The following parameters were considered in determining the methodology of the pigging operation: • Differential pressure in the pipeline.

• Number of injection points between launching and receiving stations.

• Interconnections of subject pipelines with other pipelines.

• Necessity of stopping injection at in-between points during pigging and affect on gas production.

• Necessity of closing interconnections and affect on production and supply to customers.

• Necessity of handling the swiped out line liquid in safe and environment friendly manner in off-site pig receiving stations.

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connected to test manifold of the nearest production installation by a separate 100mm NB pipeline; this will allow the liquid displaced during pigging operation to flow to the test manifold.

From the Test manifold the liquid will be diverted to the test tank for measurement.

IV. Efficiency of Pigging:– The liquid that will be collected during the pigging operation in the Test Tank can be measured. Any improvement in operation of the pipeline in terms of pressure drop or increase in flow rate shall be observed.

V. Pig muck test in R&D laboratory of OIL:The pig muck that will be collected during pigging operation shall be sent to R&D Department of OIL for further studies.

VI. Selection of Pig:A large variety of cleaning pigs of different manufacturers are available in the market and the necessity was to select appropriate cleaning pigs for our purpose. The basic requirement for carrying out pigging of the gas pipelines conceived are as numerated below: 1. Ability to swipe out maximum liquid and solid debris 2. Ability to negotiate 1.5D bends and geometric defects due to insufficiency of geometric data of the pipelines.

The reasons behind selecting the solid cast hollow shaft polyurethane pig are as follows• Hollow Shaft Can Handle 20% Reduction in Pipe ID. • Can Manoeuvre Less Than 1.5D Radius Bends.

• Does not get saturated by absorbing the condensate/liquid particles in the pipeline.

Advantages: • Non Brittle, Abrasion Resistant.

Disadvantages: • Breaks Down in Higher Temperature  Maximum Operating Temperature is 65 °C.  Absolute differential pressure in the range 30-40 bar subjected to internal line conditions is generally the disintegration pressure.  This is not an issue in OIL’s gas pipeline network, since the pressure and temperature of the fluid in these pipelines is not very high.

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• Dissolves in Certain Chemicals.  Ketones, Aromatics compounds, MTBE are some of the Chemicals for which specialty compounds are required to be used in sealing components  The gas pipelines of OIL do not contain different chemical products, hence there is no probability of the pig getting dissolved.

II. CALCULATIONS DONE BEFORE FIELD EXECUTION The following Calculations have been carried out for pigging operation in FGGS Kusijan to Savitri Tinali Gas Distribution Line, Specs- 324 mm OD API 5L Grade B, ERW and Length- 11km.

Similar calculation is done for each pipeline before pigging.

P1

18.0 ksc

256 psig

270 psia

P2

16.0 ksc

228 psig

242 psia

S.G

0.6629

Z

0.95

T1

25 Deg C

77 Deg F

537.0 R

L

11 km

=

6.88 miles

Qg

0.7

Fig 5: Schematic of pipeline from Scrapper Receiving Trap to Production Installation.

Qg = flow rate , SCMD

700000

D= pipe ID, mm.

300

P1 = Pr. At points 1, Kpa

1765.2

P2 = Pr. At points 2, Kpa

1569.1

Tb= Base Temperature, K

288

T= Average Gas flowing temperature

308

T1= Temperature of gas at inlet, °R

537

Z= Compressibility factor of gas

0.95

Pb=Base Pressure, Kpa

101.33

FIG 6: Launching of Pig

•

1. VELOCITY of GAS CALCULATION: Formula Used [Ref- 9]

II. Pig Runs:In consideration of the above factors, it was decided to carry out cleaning pigging in each line as follows: • The 1st (First) pig run shall be mildly-aggressive and carried out with a soft pig.

• Depending on success of the first pig run the 2nd (Second) pig run shall be moderately aggressive and carried out with a Steel Mandrel Cup Pig capable of negotiating minimum 1.5D bend. The Cup pig run shall be done with Electronic Pig Tracking Device by deploying experienced personnel for tracking.

III. Handling of line fluid at Receiving Stations:Diversion to production installation: Receiving barrel shall be

Fig 4- Steel Mandrel Cup pigs and Tracker Pig

FIELD EXECUTION As per the above conceived methodology, field execution was carried out as per the following steps• The receiving barrel was connected to test manifold of the nearest production installation by a separate 100mm NB pipeline.

• The pig signalers were installed in the scrapper barrels.

• Before the commencement of gas pipeline pigging operation, few of the wells were diverted to reduce the inlet pressure in the gas distribution pipelines thus facilitating smooth pig launching operation. This in turn reduced the pressure differential of the pipeline, which ensured proper scrapping of the gas pipeline.

• The first pig run was carried out by a Solid cast flexi scrapper pig.

• The liquid displaced during pigging operation was diverted to the test manifold and then to the test tank, the tank dip was measured to calculate the amount of liquid received during the operation.

FIG 7: Receiving of Pig after 1st Pig Run and 2nd Pig Run

Parameters Velocity at upstream pressure (m/s) Fig 3- Solid cast hollow shaft polyurethane pigs (Flexi-Pig)

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Velocity at downstream pressure (m/s)

Result 6.68 7.51

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FIG 8: Condition of Pig after receipt and Pig Muck collected for further laboratory tests.

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After successful completion of the first pig run, the 2nd (Second) pig run was carried out using a Steel Mandrel Cup Pig capable of negotiating minimum 1.5D bend. The Cup pig run was done with Electronic Pig Tracking Device by deploying experienced personnel for tracking.

• The 2nd Pig Run was carried out in normal operating condition of the gas pipeline. Thus the time required for second pig run was less compared to the first pig run.

• The pig muck and black powder was collected and sent to R&D Department of OIL for tests.

III) FINDINGS General Data of the Gas Pipeline-

Wear On Pig Cup

Yes

Tear On Pig Cup

No

Crack On Pig Cup

No

Overall Condition Of Pig Mandrel

Found Ok

Second Pig Run– Description

DATA

Details of Pig Type of Pig Used

Steel Mandrel Cup pig including Electronic Pig Tracking Device.

Pig Manufacturer

M/s V.P. Engineers.

Parameters

FGGS Kusijaan to Savitri Tinali 324mm OD Distribution Line

Pipeline Specification

324 mm OD API 5L Grade B, ERW

Date of Procurement

09.10.2018

Pipeline Name

FGGS Kusijan to Savitri Tinali Gas Distribution Line

Material of Pig Cup

Polyurethane

Material of Pig Body/Mandrel

Steel

Line Location

FGGS Kusijan to Savitri Tinali

Electronic Pig Locator Manufacturer

M/s T.D. Williamson

Pipeline Length

11 km

Date of Pigging

20.11.2018

Commissioning Year

2008

Type Of Coating

Coal Tar Enamel

Pigging History

No Pigging since Commissioning

First Pig RunDescription

Data

Details Of Pig Type Of Pig Used

Solid Cast Flexi Scrapper Pig.

Pig Manufacturer

M/S Vee Kay Vikram.

Date Of Procurement

09.10.2018

Material Of Pig Cup

Polyurethane

Material Of Pig Body/Mandrel

Polyurethane

Date Of Pigging

19.11.2018

Details Of Pig Launching & Receiving

Date: 13-14 December 2019 Venue: Hotel Holiday Inn, Mayur Vihar, New Delhi

Details of Pig launching and receiving Initial Pressure at Launching Trap

18 kg/cm²

Initial Pressure at Receiving Trap

16 kg/cm²

Final Pressure at Launching Trap

18 kg/cm²

Final Pressure at Receiving Trap

16 kg/cm²

Launching Time

12:00 P.M

Receiving Time

12:32 P.M

Total Time Required *

32 mins

Slippage or early receipt vis-à-vis calculated time

7 mins delay

Quantity of dirty product/ sludge/ muck received

1 kg

Any Other Material received with muck

Black Powder

Liquid received in Test Tank

Nil

Condition of pig after receipt

Initial Pressure At Launching Trap

7.5 Kg/Cm²

Initial Pressure At Receiving Trap

6.5 Kg/Cm²

Final Pressure At Launching Trap

14 Kg/Cm²

Final Pressure At Receiving Trap

14 Kg/Cm²

Launching Time

03:28 P.m

Receiving Time

05:33 P.m

Total Time Required

2Hr 5Min

Quantity Of Dirty Product/ Sludge/ Muck Received

2 Kgs

Liquid Received In Test Tank

2000 Liters

Diameter of Pig Cup before Launch

324mm

Diameter of Pig Cup after Receipt

306mm

Ovality on pig cup

No

Wear on pig cup

Yes

Tear on pig cup

No

Crack on pig cup

No

Overall condition of pig mandrel

Found OK

Diameter Of Pig Cup Before Launch

324Mm

Diameter Of Pig Cup After Receipt

306Mm

Ovality On Pig Cup

No

Important Deadlines Abstract Submission: 15Th August 2019 Full Paper Submission: 15th October 2019 Presentation Submission: 15th November 2019

Platinum Partner

Condition Of Pig After Receipt

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Gold Partner Organizer

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Pig residue test carried out by R&D Department, OIL: • 200 gram of muck was collected during 1st Pig Run. • 200 gram of muck & black power were collected during 2nd Pig Run. The pig muck was tested by R&D Department and the results are as follows:

Sl No. Sample De** scription

Pig muck collected from FGGS Kusijan to Savitri Tiniali 12” NB Gas pipeline on 19.11.18

Pig muck collected from FGGS Kusijan to Savitri Tiniali 12” NB Gas pipeline on 20.11.18 Pig Muck

Black Powder

1.

LOI (% Loss)

99.6

33.1

23.1

2.

Solvent Extraction (% Extracted)

95.6

18.85

Nil

3.

Effervescence Test

Nil

Strong

Nil

4.

SRB & APB

Nil

Nil

Nil

5.

XRD analysis

Negligible Inorganic Content

Major: Quartz, Siderite; Minor: Iron Oxide

Major: Siderite, Iron (II) diiron (III) oxide Minor: Quartz

6.

HTGC Analysis (n-alkanes)

Existent: nC13 to nC69 Major: nC27to nC35

Existent: nC10 to nC61 Major: nC16 Pristane,nC18 to nC34

HTGC analysis of sample could not be done as the sample is not soluble in either n-hexane or cyclohexane.

**Notes: 1. The Loss on Ignition (LOI) test indicates the presence of substantial amount of organic and volatile components.

2. The Solvent Extraction test gives an estimate of the percentage of xylene soluble hydrocarbon in the sample.

3. The effervescence test gives a possible indication of presence of carbonates in the sample.

4. The tests for microbial growth/ activity require a period of 28 days and therefore the results will be intimated subsequently upon completion of the test.

CONCLUSION The following conclusion can be drawn from the gas pipeline pigging operation carried out in 324mm OD X 11 km Gas Distribution Line from FGGS Kusijan to Savitri Tinali – • A quantity of 2000 litres of liquid has been swiped out from the pipeline during the pigging operation.

• The pipeline is not an independent pipeline and it is interconnected to a broader network. Flow characteristics in the pipelines depend on the production rate from wells and offtake by customers on day to day basis. Therefore, any gain from the pigging operation in the terms of pressure drop or increase in flow could not be ascertained.

• The XRD analysis of the pig muck and black powder sample carried out by R&D Department, OIL confirms traces of FeO(OH) and FeCO3 in OIL’s gas distribution pipelines. H2S related corrosion in gas distribution pipeline is absent. This conforms to assessment carried out prior to the pigging operation.

• The major gain from the pigging operation is that piggability of the pipeline has been established and henceforth pigging operation can be carried out in the pipeline on a regular basis by a moderately aggressive pig so that integrity of the gas pipeline is maintained. Thus, it has enhanced confidence to carry out pigging

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of the gas pipeline network progressively in phases. It has also opened the possibility of integrity assessment of the pipelines by ILI tool.

REFERENCES [1] Xiao-Xuan Xu, Jing Gong, Pigging stimulation for horizontal gas condensate pipelines with low liquid loading, Journal of Petroleum Science and Engineering, 2005, pp:272-280 [2] Beggs, HD, Brill JP (1973) A study of two-phase flow in inclined pipes. SPE Paper, pp 1-9.

[3] Guo B, Song S, Chacko J, Ghalambor A(2005) Offshore pipelines, (5th edn), Oxford: Elsevier publication.

[4] Irmann-Jacobsen TB(2013) Flow assurance – a system perspective, MEK4450-FMC Subsea technologies, Available from: (Accessed 1 January 2014).

[5] Kjoraas (2012) Modelling of Wax Deposition in Subsea Pipelines, Norwegian University of Science and Technology, Department of Petroleum Engineering and Applied Geophysics.

[6] Lee HS (2008) Computational and rheological study of wax deposition and gelation in subsea pipelines, PhD Thesis,University of Michigan.

[7] Corrosion Failure Mechanism of Associated GasTransmission Pipeline by Weimin Zhao,Timing Zhang, Yonglin Wang, Jianhua Qiao and Zerui Wang [8] Hausler R.H and Godard H.P, Advances in CO2 Corrosion.

NACE Publication, 1984.

[9] Gas Pipeline Hydraulics by E.Shashi Menon, pp-40.

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Pulsed Eddy Current Array Technology for the Inspection of Corrosion Under Insulation Authors: Vincent Demers-Carpentier, Maxime Rochette, Charles Tremblay, Marco Michele Sisto, Andreanne Potvin, Eddyfi Technologies [Presented in AIM & INM 2018] Keywords: Pulsed eddy currents, Array probes, NDT Abstract In this paper we present a pulsed eddy current array system for detection and sizing of corrosion under insulation in low-alloy carbon steel structures. The system is based on a novel pulsed eddy current probe featuring a linear array topology. The proposed probe design offers 18 inches(46 cm) of coverage in one single pass, improving the productivity of a pulsed eddy current inspection by a factor 4to 10 compared to non-array solutions. The probe can be used on flat and curved surfaces with diameter down to 6 inches (15 cm). This is made possible by the non-rigid mechanical design of the probe, so that it’s main axis can be wrapped around a pipe or otherwise bent to follow the curvature of the inspected surface.

Proper analysis of array raw data requires an adapted analysis algorithm, whose sizing performance on insulated components is presented in this paper along with examples of defect sizing maps of a typical insulated pipe.

1) Introduction Pulsed Eddy Currents (PEC) is a versatile non-destructive testing uniquely suited to detect corrosion under insulation, one of the most important issues facing the petrochemical industry today[1–3,5,6]. PEC have been shown to work through weather jacket (or cladding) and present major upsides compared to the brute force approach which consists in removing the insulation to perform a visual or ultrasounds inspection. Compared to

competing technologies like real-time or digital radiography, PEC represents an interesting alternative particularly in inspections of structures with restricted access. In addition, the PEC technology avoids operator health concerns related to exposure to X-rays or radioactive materials.

recording of data positions along a scan axis[4]. When operating in this mode, the inspector does not need to draw a full grid but only the scan axis lines. Dynamic scan modes increase the overall productivity of a PEC inspection and are boosting the adoption of this screening technique in many industrial environments.

To further improve PEC productivity, in this paper we propose a novel PEC probe featuring a linear 6-elements array configuration.

In the following sections we first present the probe design and briefly discuss the productivity improvement provided by this new probe. Then, we discuss the probe sizing and SNR performance, and conclude presenting examples of 2D sizing maps on insulated pipes.

2) PEC Array Probe Design One image of the probe is shown in Fig.1.

Asset integrity inspection is a time-sensitive activity: asset owners need to balance inspections schedule and dedicated shutdown times with appropriate inspection coverage. Owing to its ability to inspect in-service components through insulation and cladding, PEC permits the expansion of inspection scope and frequency without increasing its schedule and without extending shutdown times.

Most advanced PEC technology implementations adopt several techniques to maximize the inspection productivity. First, one can improve the data collection rate by acting on the PEC system design: optimized designs maximize the PEC signal-to-noise ratio (SNR), lessening the need for averaging over multiple data points. In addition, PEC data analysis can be made robust to noise through software techniques like smart filtering and optimized PEC sizing algorithms, further reducing the need for averaging.

Still, these techniques do not address one unavoidable and timeconsuming inspection preparation task, i.e. drawing the grids required to identify the position of collected data points on the inspected component. Recent PEC solutions include encoders and implement a dynamic scan mode that eases and accelerates the

Figure 1. The PEC array (PECA) probe

Table 1. Experimental inspection time in minutes for full coverage of a 8 inch (200 mm) pipe with 2 inch (50 mm) insulation.Pipe length: 80 feet (24.3 m)

Figure 2. The PECA probe with its system of straps used to secure the probe under a pipe.

Clip-on removeable handles are also shown.

2.1) Mechanical Design The probe design is based on a linear array topology with 6 sensors placed side by side and spaced by 3 inches (76 mm) center-tocenter. The sensors are encased in separated plastic bodies, linked through hinges that allow bending the probe around a pipe or a curved surface with radius of curvature ranging from flat down to 3 inches (76 mm). A single electrical cable passes through all probe sections, routing all the electrical connections. The cable follows the probe neutral axis, so that the bending does not causes mechanical stress on the electrical connections. Coverage extends over 18 inches (457 mm) along the array axis. An encoder attached to the probe allows supporting dynamic mode acquisitions. The probe lays on removable wheels, which provide 0.5 inches(12.7 mm) of clearance beneath the sensor bodies. This space is useful to pass over weather jacket retention straps and buckles when the probe is moved on insulated pipes.

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The probe bending radius can be locked, so that the probes maintains its shape when wrapped around a pipe. The locking mechanism offers a twofold advantage: first, the probe remains mechanically stable even if the pipe weather jacket is damaged or irregular. Second, the relative position and angle of the sensors is maintained constant over the inspection, which improved the probe repeatability and accuracy of sizing results.

Straps can be attached to the probe to stabilize and secure it when wrapped around a pipe. The straps also ease the inspection of the pipes bottom section by relieving the inspector from supporting the probe weight. An example of probe configured for inspection under a pipe is shown in Fig. 2.

2.2) Productivity improvements The 6 sensors in the array are used simultaneously, with no temporal interleaving. The PEC pulse repetition rate, which is mainly influenced by the wall thickness of the component under test, is similar to the rate achievable with single-sensor probes (for identical averaging settings). However, while single-sensor probes capture one data point at one position per PEC pulse, the array probe captures 6 data points simultaneously. This provides a theoretical 6-folds improvement in inspection productivity compared to a conventional single-sensor probe for equal gridding resolution and averaging settings. Grid drawing time during inspection preparation is also reduced, as only one over 6 scan axis lines must be drawn. In many cases, gridding may just be unnecessary altogether.

In order to quantify a realistic comparison between single-sensor PEC (in grid and dynamic modes) and the proposed pulsed eddy current array (PECA) probe, we estimate the time spent by an inspector to inspect an8-inch (200 mm) nominal diameter, schedule 40, 80-feet-long pipe (24.3 m) with 2 inch(50 mm) insulation. The estimation, reported in Table 1, is based on actual measured inspection times for the three inspection modes (singlesensor grid, single-sensor dynamic and array dynamic) including the time required for gridding and excluding initial setup time that is common to all modes. Gridding was adapted depending on the techniques: for the array, only one over 6 axis grid lines were traced.

In all cases, the same numbers of data points were captured. The array probe in dynamic mode reduces the inspection of the pipe below 1h, while a 3.5 h and 7.5 h are required with a single-sensor probe in dynamic and grid modes.

Mode

Measured inspection time [h]

Single-sensor probe, grid mode

7.5

Single-sensor probe, dynamic mode

3.5

Array probe, grid mode

1.2

Array probe, dynamic mode

0.8

Note that, in this example, 3 passes of the array are required to cover the pipe circumference. The last pass overlaps the first pass by more than 5 inches (127 mm), corresponding to 2 array elements. This in part justifies why the array inspection is about 4.5 five faster than a single-sensor probe in dynamic mode and did not reach the theoretical 6-fold productivity improvement.

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Also, moving the array around pipe supports takes more time as the probe is wrapped and strapped around the pipe.

3) Working Principle and Optimization of the Array Configuration The working principle of a single-sensor PEC system is described as following: a magnetic pulse is generated by a coil placed at some elevation (or lift-off) from the surface of a component under inspection, which must be ferromagnetic and conductive.

During a first excitation phase, the pulse remains active long enough for the magnetic field to penetrate the full thickness of the component. Following the abrupt extinction of the pulse, eddy currents are generated in the metal mass. These currents induce a secondary magnetic field which can be sensed by a magnetic sensor and decays over time. In this phase, referred to as the reception phase, the sensor generates a voltage signal that is recorded and analyzed. The shape and decay rate of this voltage signal are directly related to the thickness of the component being inspected.

The working principle of the PECA system is substantially identical, but the 6 excitation coils are connected together to generate the excitation pulse simultaneously on all the positions covered by the array probe. The PEC signal for the 6 position is also recorded simultaneously during the reception phase by 6 independent magnetic sensors.

3.1) Optimizing the sizing performance Compared to a time interleaving strategy, the PECA working principle described above maximizes the productivity gain over a single sensor probe but comes with additional complexity in the sensor design and analysis algorithms.

In fact, as all the excitation coils pulse simultaneously, the eddy current field generated in the tested component extends over a much larger surface compared to a single-element probe.

In addition, adjacent coils interact electrically through mutual inductance. The net effect is an enlargement of the probe magnetic footprint along the array axis.

Regardless the array or non-array design of the PEC sensor, the PEC technique provides the best estimation of the wall loss of a defect (the best sizing accuracy) on defects that are much larger than the probe’s magnetic footprint. When a PEC probe inspects over a small defect compared to its footprint, the PEC signal is influenced by both the defect and the surrounding nominal plate thickness. In this situation, the thinnest region (the defect) is averaged out by the thicker wall surrounding it, leading to an underestimation of the defect wall loss, i.e. defect under sizing.

Unless appropriate countermeasures are adopted, the enlargement of magnetic footprint in array configuration amplifies the under sizing effect, reducing the sizing depth and the system probability of detection of defects smaller of the probe footprint.

An example of this penalty is shown in Fig. 3, where are plotted four sizing curves captured by a single-sensor probe (dotted red curve) and three array configurations on the same defect. All the sizing values are captured at the same 6 positions spaced by 3 inches (76 mm). The single-sensor probe sizing curve is captured by moving the probe step-by-step over the six positions, while the 6 data points on each array cures are captured simultaneously in a

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single measurement. The defect is a flat bottom hole on a 0.5inch (12.7 mm) nominal wall thickness, with minimum remaining wall thickness of 33%. Defect under sizing brings the minimum reading for the single-sensor probe up to 53%.

Figure 3. Sizing of various probes configurations on the same defect at the same positions

The enlargement of magnetic footprint caused by array elements interaction in array configuration is demonstrated by comparing the dotted red curve (single-sensor probe) with the grey curve, captured with an array built by simply placing side-by-side the same sensor design used for the single-sensor probe: the defect appears larger and the minimum depth rises to 60% due to the footprint increase.

One first mitigation technique required to avoid the footprint penalty in array configuration is to adapt the PEC excitation coil and magnetic sensor design to minimize the array element magnetic footprint. In the proposed array probe, we implemented a novel (patent pending) PEC sensor design that effectively reduces the element footprint and minimized the interaction between elements of the array. The net effect is a substantial reduction of the footprint penalty, which brings the sizing performance back to being comparable to the single-sensor probe design. An example of such improvement is given in Fig. 3, where the solid blue curve represents the sizing obtained with the array configuration employing the optimized PEC element design. The blue curve is almost superposed to the dotter red curve obtained with the single-sensor design at the same positions, demonstrating that the array footprint penalty is largely mitigated.

The array configuration opens opportunities for additional improvements. Indeed, when capturing a set of data pints with a single-element probe, one must assume that each point is independent form the others as the relative spatial positions of the data points are unknown. In contrast, in array configuration the relative spatial position of the points is precisely known and all the data is captured simultaneously. This additional information can be exploited to improve the analysis algorithms and further mitigate the under sizing effect on defects smaller than the probe footprint.

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An example of the improvement achievable with array-optimized analysis algorithm is again given in Fig. 3. The solid yellow line is the sizing curve obtained from array raw data analyzed with the array-optimized algorithm. The yellow curve should be compared with the solid blue curve, that is the sizing curve obtained from the same raw array data but analyzed with conventional analysis algorithms: the array-optimized algorithm shows deeper sizing at the center of the defect (47% estimated remaining wall thickness, i.e. a 6% improvement over the single-sensor probe value) as well as steeper edges.

We validated the improvement provided by the array configuration on 45 reference defects milled in carbon steel plates with nominal wall thickness ranging from 0.25 inch to 1 inch (6 to 25 mm) and lift off ranging from 1 to 3 inches (25 to 76 mm). On average, the array-optimized algorithm provided a sizing that is 2.5% deeper than single-sensor probe results. Further work is in progress to improve this result.

In conclusion, appropriate PEC sensor design and optimized analysis algorithms result in array sizing performance that is favorably comparable to single element design.

conventional “yoke”-type design. The noise source is a 10inchdiameter (254 mm) coil driven by a 75 Hz sinusoidal source.

The noise frequency was chosen to lay within the bandwidth of the PEC pulses but outside the bandwidth of the line frequency filters included in the PEC system used for capturing the data.

The data points are recorded on a nominal 0.25inch (6 mm) wall thickness plate with 2 inches (50 mm) liftoff. The noise intensity is controlled by moving the noise emitting coil farther away from the PEC sensor. The noise-screened sensor design is more resilient to noise as demonstrated by the better sizing uniformity up to experiment #5, compared to the conventional sensor design that is heavily perturbed since experiment #3. The same information is quantified in table2.

Table 2. Standard deviation (in % of nominal) of the sizing in Sensor Design

Experiment number #1

#2

#3

#4

#5

#6

Conventional sensor design (Fig. 4B)

2.9

7.6

11

17.2

21.6

22.7

Noise-screened sensor design (Fig. 4A)

1.6

2.1

2.7

4.5

7

14.6

3.2) Array Probe Signal-to-Noise Ratio Practical PEC inspection systems are typically portable and battery operated. The amount of electrical power available to the excitation coils is finite and limits the peak magnetic field during the PEC excitation pulses. Assuming optimum coil design for a given volume of copper, the peak magnetic field B_nin array configuration with n elements decreases as per the equation below:

Bn=B1/√n ,#(1)

improved productivity, the proposed array design improves several performance metrics with respect to more conventional single-sensor designs. More specifically, small defects under sizing are mitigated by controlling the array magnetic footprint and implementing advanced raw data analysis algorithms that exploits the multi-sensor nature of the array design. Also, the immunity from external electromagnetic noise is improved taking advantage of noise screening.

Figure 5. Example of array scan on 8 inch(200 mm) nominal pipe with 2 inch (50 mm) insulation covered by 0.024 inch (0.5 mm) aluminum weather jacket.

4) Example of inspection on insulated pipe In Fig. 5 we present the 2D sizing map (C-Scan) resulting from the inspection of an8-inch (200 mm) outer-diameter (OD) pipe, schedule 40 (nominal wall thickness: 0.365 inches or 9.3 mm) insulated with 2 inches (50 mm) of mineral wool and covered with 0.024inch-thick (0.5 mm) aluminum weather jacket. The pipe is 6 feet (1.8 m) long and has a total circumference (including jacket and insulation) of 40 inches (1 m). Full coverage of the circumference is obtained with only 3 passes of the array probe, which were completed in 1.3 minutes.

5) Conclusions In this paper we present a pulsed eddy current array system for detection and sizing of corrosion under insulation in low-alloy carbon steel structures. The system is based on a novel pulsed eddy current probe featuring a linear array topology with 6 sensors capturing data simultaneously at every PEC pulse. This solution improves the PEC inspection productivity by a factor ranging from 4(minimum) to 10. The most important challenges in the design of a PECA probe are briefly presented, and the solutions included in the proposed design are discussed. In addition to

References [1] Smith, R. A., and Hugo, G. R., 2001, “Transient Eddy-Current NDE for Aging Aircraft – Capabilities and Limitations,” Insight: Non-Destructive Testing and Condition Monitoring, 43(1), pp. 14– 25.

[2] Moulder, J. C., Kubovich, M. W., Uzal, E., and Rose, J. H., 1995, “Pulsed Eddy-Current Measurements of Corrosion-Induced Metal Loss: Theory and Experiment,” Review of Progress in Quantitative Nondestructive Evaluation, Springer, Boston, MA, pp. 2065–2072.

[3] Demers-Carpentier, V., Rochette, M., Grenier, M., Tremblay, C., Sisto, M. M., Hardy, F., and Turgeon, M., 2016, “Pulsed Eddy Current as an Inspection Tool for Nuclear Power Plants,” NDT in Canada 2016 & 6th International CANDU In-Service Inspection Workshop, Burlington, ON. [4] Grenier, M., Demers-Carpentier, V., Rochette, M., and Hardy, F., 2016, “Pulsed Eddy Current: New Developments for Corrosion Under Insulation Examinations,” Munich, Germany.

[5] Cheng, W., 2012, “Pulsed Eddy Current Testing of Carbon Steel Pipes’ Wall-Thinning through Insulation and Cladding,” Journal of Nondestructive evaluation, 31(3), pp. 215–224.

[6] Crouzen, P., and Munns, I., 2006, “Pulsed Eddy Current Corrosion Monitoring in Refineries and Oil Production Facilities– experience at Shell,” signal, 2(3), p. 4.

Where B1 is the peak field of a single-element probe.

The intensity of the received signal during the PEC reception phase is proportional to the intensity of the excitation field.

Hence, a reduction of the excitation magnetic field in array configuration comes with a potential penalty in the system SNR during the reception phase, unless appropriate countermeasures are implemented in the PEC sensor design and the PEC pulser electronics. Sensitivity to external electromagnetic noise is especially a concern as PEC inspection systems are commonly used near pumps, motors and other electromagnetically active machinery.

Indeed, one straightforward solution consists in increasing the electrical power available to the excitation coils. The downside of this solution is a reduction in the battery life of battery-powered systems, or an increase of the system weight if additional batteries are added to the system.

A more fundamental solution is to screen the reception magnetic sensors from external noise. This solution, implemented in the patent pending sensor design used in the proposed array probe, can improve the SNR up to a factor 4, depending on the relative position of the noise source with respect to the probe. An example of SNR improvement is shown in Fig. 4. The two images (A) and (B) show the sizing obtained from 64 data points captured on 6 experiments with increasing electromagnetic noise intensity from experiment #1 to #6. The dataset (A) is obtained from the screened PEC sensor design, while the dataset (B) is obtained with a more

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Figure 4. Noise test with noise-screened array probe(A) and conventional single-sensor probe(B). The 2D maps represent 64 consecutive measurements on a 0.25 inch(6 mm) nominal wall.

Deviations of sizing from 100% are shown as variations of colors in the 2D maps. The deviations are caused by the noise affecting the measurement: the more uniform the 2D map colors are, the lower is the sensitivity of the probe to external electromagnetic noise. The noise source is a 10 inch(254 mm) diameter coil driven with 75 Hz sinusoidal current placed above the probe with a 45° angle with respect to the probe axis. The 6 rows in the maps correspond to 6 experiments with increasing noise intensity(from 1 to 6). The noise intensity is controlled by increasing the distance between the probe and the noise-emitting coil.

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This paper is organized as follows. Following a brief introduction to the need for inspection of underwater structures, the advantages and limitations of the method of inspection using divers and remotely controlled robots, a description of the ROV and their key features is described in Sec. 2. Some examples of ROV based inspection routines and key observations are briefed in Sec. 3.

Finally the paper concludes with a summary and future work.

Inspection of Underwater Assets Using

Robotic Technology

3) Methods 3.1) ROV Mike ‘Mike’ is a compact electric underwater robot specifically built for robust and calibrated visual inspection of offshore immersed structures [1], and is shown in Fig. 1. Mike has the capability of reaching 100 m depth and possesses unlimited endurance.

Multiple on-board HD cameras with high intensity LED illumination provide live and stable visual feedback to robot pilot & surveyor [2]. The design allows for control station to be positioned at a safe on-shore/on-ship site and rapid assembly and operation at field conditions.

1) Abstract Periodic underwater inspection of underwater assets is crucial to minimize unscheduled downtimes, and catastrophic damage to property and lives. Conventionally, inspection of underwater structures has been performed by divers. This methodology of inspection is subject to numerous limitations including personal risk, limited depth of operation, endurance and communication, and limited capability to carry payloads. This paper presents inspection case studies using a submersible remotely operated vehicle (ROV) developed indigenously by Planys Technologies, an IIT Madras incubated company, of single buoy mooring (SBM), pipelines, channels, ports and terminals. The results show the damage detection and inspection capabilities using visual payloads. This work will be of much interest to offshore platform and marine asset integrity and plant safety professionals.

2) Background and Introduction Ageing infrastructure is an consistent and vital issue worldwide.

Subsea structural assets are inspected regularly by various techniques to avoid costly outages or catastrophic failures. These periodic inspections, conducted in various domains including oil and gas industries, shipping, ports, dams and power plants, are also mandatory under guidelines prepared by certification bodies. Currently, most inspections of offshore/ submerged structures are done by divers or deep sea underwater robots.

While human divers have limitations like productivity, depth ranges for inspections, environmental conditions and have an inherent risk factor involved. The underwater robots that are currently manufactured only by western countries weigh in several tons resulting in extremely challenging logistics and are not customizable to our inspection applications.

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In order to develop an alternate solution to this problem and mitigate the risks involved, the development of indigenous and completely ‘Made in India’ Planys underwater robots capable of performing shallow water inspection as per our industrial standards and needs began. Planys is an IIT-Madras incubated start-up involved in developing indigenous remotely operated vehicles (ROVs) offering submersible robotic inspection and survey solutions. Planys is first and currently the only OEM of compact ROVs in India. Planys drones navigate to hazardous/inaccessible conditions, higher depths with unlimited endurance and can collect robust and repeatable data. Inspection capabilities include performing visual, ultrasonic, radiation measurement, corrosion protection, and acoustic (SONAR) inspection. Planys develops drones with design features like modularity, compactness, portability and high degree of maneuverability - making them ideal for a variety of inspection applications.

Planys has undertaken inspection of dams located in remote locations in India that had not been inspected for over 30 years and are currently in talks of engaging in Search and Rescue Operations as well. Planys is creating roadways for new applications for the first time globally including intake/ outfall pipeline inspection, low draft bathymetry & fuel tank inspection. This has opened up new markets in India and globally, thereby generating employment opportunities. Over the past 3 years since its establishment, Planys has already completed over 40+ projects across various sectors like ports/terminals (L&T, Visakhapatnam, Chennai, and Cochin ports), offshore oil & gas (HOEC - Chennai, BPCL - Cochin), desalination plants (in Chennai), power plants (at Nellore) and dams (Sathanur, Tamil Nadu and Kakki Dam, Kerala). Our vision is to emerge as a world-leading provider of diagnostics-driven marine robotics, and this has potential to impact various industries and strategic sectors in India, such as Indian Railways, Central water commission, Oil & Gas and Maritime.

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• HD live underwater visual inspection (photography and videography) of submerged structures [5, 6] for detection of corrosion, cracks, cavities, collision damage and anode loss • Water depth sounding for detection of scour around foundations • Clear Box Technology for inspection in extremely Turbid Waters • Laser Scaling for assessing dimensions of cracks, cavities and other defects • Inspection of interiors and exteriors of the Well foundations • Side scan sonar surveys, bathymetric surveys, electric spotcleaning or cavitation cleaning tool for marine growth cleaning (soft to medium hardness) • Wide range underwater metallic ultrasonic thickness measurement [7] 4) Case Studies 4.1) Single Buoy Mooring Inspection Planys was invited to perform underwater survey of a Single Buoy Mooring (SBM) and a Pipeline End Manifold (PLEM) situated off the coast of Paradip, Orissa during the pre-monsoon season. The water depth in the region was around 31 m while a rough 3 m swell was observed at the surface.

Author: Vineet Upadhyay, Manas Galipalli, Ashish Antony Jaco, Tanuj Jhunjhunwala Planys Technologies [Presented in AIM & INM 2018] Keywords: Remotely Operated Vehicles (ROVs), Underwater Inspection, Immersed inspection

3.3) Inspection Capabilities Some of the key inspection capabilities which have been developed are, as follows.

Fig. 1. An illustration of ROV Mike and its key features

3.2) ROV Beluga ROV Beluga is a compact, modular and portable ROV that can sustain 2-4 meters of wave height, moderately rough swell, up to 1 m/s of sea currents and can dive up-to 200 meters of depth [3]. Classified under the observation class of ROVs, its design has a state-of-the-art dual hull, heavy bottom hydrodynamic design, which provides it with static and dynamic stability in the harsh underwater environment. It is equipped with eight thrusters, providing control in 5 degrees of freedom along with forward thrust of 17.5 kg-f and an operating speed of 3-4 knots. The heavy bottom feature of the vehicle inhibits roll motion. It consists of an IMU for orientation feedback, a pressure sensor for depth feedback and a GPS for position feedback on the water surface.

Its modular architecture allows it to carry a variety of payloads such as high-definition cameras, high-intensity lights, LASERs as crack measurement unit, Altimeter, Side-Scan SONAR, Ultrasonic thickness measurement unit, Cathodic Potential measurement unit, bio-fouling cleaning equipment, 2D & 3D Imaging/Scanning SONARs [4].

Fig. 2. An illustration of ROV Beluga and its key features

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Scope of Work: The task involved detailed underwater inspection of the buoy underwater structure, catenary mooring chains, risers, spool piece, parts of the PLEM and a portion of pipeline at its landfall location.

Methodology: ROV operation involves various equipment setup and crew members in different roles. A photograph showing some aspects of the configuration and deployment of the ROV is shown in Fig. 3. The operation was conducted aboard a Diving Support Vessel (DSV) anchored close to the SBM. A Power Distribution and Safety Unit (PDSU) is connected to the main supply source from which all the required equipment draws their power. A Control Station is setup which houses a computer inside, a screen to watch live data and a joystick for remote control of the ROV. The connection between the ROV and the Control Station is made using a power plus data hybrid cable running over a cable drum.

The different crew members involved in the operation are the Operation Supervisor, ROV Pilot, ROV Co-Pilot, ROV Technicians and additional support staff.

The ROV was launched manually from the stern of the DSV on the approach of wave crests. Two vertical dives were taken each around an hour in duration observing various structures present underwater. In order to reach the PLEM situated on the sea-bed the risers were traced from the underside of the buoy to the PLEM. Underwater visibility was found to be less than a meter at the seabed due to the approaching rough weather season.

Key Observations: Majority of the operations revealed nothing abnormal on buoy underside except heavy marine growth which perhaps encourages the requirement of a drydock. Some photographs of the condition of key elements of structures are shown in Fig. 4. The condition of the risers and the cable glands

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3a

4a 3b

4b Fig. 3. (a) A photograph of the ROV Pilot and the surveyor at the Control Station (b) crew members configuring the ROV while the SBM is seen in the background

was found to be good. Several cracks and cavities were found on the pipeline at its landfall location which required immediate remedial action.

4.2) Pile Inspection of an Offshore Tanker Terminal Planys Technologies conducted an underwater visual inspection of rubble slope and D-Wall for a coal berth (CB) and earth retaining structure (ERS) at a port. Average water depth at the beginning of the slope was around 20m which gradually reduces to 5m towards the end of slope near the diaphragm wall.

Scope of work: The area inspected lies within breakwaters with restricted currents. The entire inspection tasks carried out for the CB and ERS were divided into 94 dives, over duration of 8 days.

The inspections were conducted using Planys’ ROV Beluga with 120m of tether length, one high definition 720p 50 frames per second (FPS) frontal colour camera with two scaling LASERs, a standard definition 30 FPS bottom looking colour camera and an altimeter.

Methodology: The operations crew consisted of one supervisor, two technicians and one ROV pilot, one support engineer and additional supporting staff provided by the terminal authorities. A photograph of the deployment of the ROV is shown in Fig. 5. The tether management for the operation was a coordinated effort of two technicians, with one stationed on Berth area and the other technician stationed on a movable Pontoon deployed adjacent to Berth. Low visibility and turbidity near sea bed poised as key challenges in inspecting objects closer to the sea-bed.

4d

(6a)

Fig. 4. Photograph of (a) a riser with one of its collar, (b) close-up of a joint showing healthy conditions of nuts, bolts and the flange (c) heavily fouled I-Beam and (d) close-up of a cavity observed in the pipeline coating Fig. 5. A photograph of the ROV deployment by the team at the site

(6b)

Key observations: Observations and analysis of enhanced and high-resolution videos captured during the survey exposed major defects to diaphragm wall in the form of exposed concrete rebars and moderate to minor defects in the rubble slope like voids between two layers of rubble slope stones as well as exposure of geotextile due to improper filling of stones on the slope.

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indigenously by Planys Technologies, Chennai. ROV based inspection discussed in the case studies have key observations and inferences, basis which key decisions relating to repair and reuse of the assets can be reached. Planys is continually working towards developing better robotic inspection solutions capable of handling newer methods of NDE, harsh ocean currents, corrosive and explosive environments.

4c

Fig. 6. (a) A photograph of the Geotextile sheet exposed due to improper filling of stones on rubble slope (b) exposure of concrete rebars at the diaphragm wall

Conclusions and Future Work This paper brings to light an alternate inspection methodology for submerged structures - ROV based inspection developed

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References [1] “ROV Mike, Planys Technologies”. Online link: http://www. planystech.com/product/mike/ [accessed: 25-07-2018] [2] T. Jhunjhunwala, V. Upadhyay, R. Sirikonda, K. Balasubramaniam and P. Rajagopal, MIKE: A remotely operated vehicle (ROV) for visual inspection of underwater structures, Proc. National Seminar & Exhibition on Non-Destructive Evaluation, NDE Hyderabad 2628 Nov 2015 [3] “ROV Beluga, Planys Technologies”. Online link: http://www. planystech.com/product/ beluga/ [accessed: 25-07-2018] [4] Patent application, Indian patent office, “Multi-functional remotely operated submersible vehicle (ROV) system”, appln. no.

201741022485, Planys Technologies [5] Patent application, Indian patent office, “Underwater lights”, appln. no. 201741000411, Planys Technologies [6] Patent application, Indian patent office, “A ROV system for underwater data processing and method thereof”, appln. no.

201741022484, Planys Technologies.

[7] Patent application, Indian patent office, “Underwater Ultrasonic thickness measurement unit”, appln. no. 201641041814, Planys Technologies

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Participation Details Silver Partner

Special Acknowledgement

Branding Partners

Bangalore Chapter

Aapsee Controls And Systems Pvt Ltd.

Conference Coverage 3rd Technical Conference on

Student Chapter

Knowledge Partners

Media Partners

Participating Companies

Asset Integrity – Reliability Management – Inspection/NDT Techniques Date: 5-6 August 2019 Venue: Hotel Crowne Plaza, Mayur Vihar, New Delhi Organized by

Supported by

A I R M

Manag em

t en

A te of sset I itu

a lity

Ins t

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rity & Reli

bi

eg nt

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Eminent Speakers from 3rd “Asset Integrity – Reliability Management – Inspection/NDT Techniques” Conference

Abstracts from 3rd “Asset Integrity – Reliability Management – Inspection/NDT Techniques” Conference

Paper Presentations Mr. R. Suresh President & Business Head (O&M), RGPL

Mr. E. S. Ranganathan Managing Director IGL

Mr. Sambasiva Rao Uppala Sr. VP (O&M) PIL- Reliance

Mr. Alok Gurtu VP & Head Pipeline Integrity, RGPL

Mr. Mark James Vining Jr. Director of Consultation Services, Mistras Group

Mr. Pramod Kumar Sapra President, SP Bumi Armada

Mr. Robert Colton Business Manager & Director EMEA, Garlock Pipeline Technologies

Mr. S. L. Chakravorty Former Director-OISD MOP&NG

Dr. Dipak Jyoti Kalita Chemical(Lab) Chemical Department, Oil India

Mr. Mahendra Nimkar Business Manager – Analytical Science, Hitachi High Tech

Mr. Uday Purohit Managing Director, Neptunus Power Plant Services

Mr. Nagmani Kumar Sinha Sales Specialist DNV GL

Mr. R. N. Verma Consultant, Ex-IOCL

Mr. Alok Kumar Sr Mgr.-Mech.Maintenance, MRPL

Mr. Srinivas Kumar Technical Sales Specialist, Eddyfi Technologies

Mr. Shibu John Quality Manager Special Oilfields

Mr. Mottito Togo Technology Specialist Honeywell Aerospace

Mr. Sagar Pramod Bhutada Engineer – R&D, ERDA

Title: “Owner User Modifications of the API-581 Levels of Inspection” - Mark Vining , MISTRAS Group Abstract: The intent of this document is to clarify that Owner User interpretation of Part 2, Annex 2.C of the API 581 base resource document (BRD) can justify the modification of the Levels of Inspection Effectiveness (LoIE) procedures used to plan and document a risk based inspection program.

Additional value is derived from improved application of inspection techniques based on more appropriate inspection related activities designed specifically for the organization by internal and external subject matter experts (SMEs).

Modification of the procedures can generate exceptional value when performed in collaboration with individuals trained in the generation and execution of professionally developed procedures.

The Owner User/SME collaboration aids in the reduction of a facility risk profile through the creation and utilization of professionally engineered and customized risk based inspection plans.

Title: “Pipeline Asset Management – A Journey of Excellence” -Sambhasiva Rao Uppala, Sr. VP (O&M), PIL

Mr. Praveen Bhat EE-Civil, Structure ONGC IEOT, Panvel

Mr. Vishal Devadas GM- Business Development Planys Technologies

Mr. K. V. Badri Narayan AkzoNobel India

Mr. Jitendra Yadav Senior Technical Sales Specialist, Eddyfi Technologies

Mr. Saurav Kumar Student IIPE

Mr. Akash J Academy of Maritime Education and Training

Mr. Suresh Manikam Principle Consultant (TA & RMA) , DNV GL

Mr. Kumar H. Rokade Managing Director ROKADE Group of Cos

Md. Arshad Uddin Product Specialist- NDT Olympus

Authors of Poster Papers

Ms. Rudipta Bhuyan Student- University of Petroleum and Energy Studies

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Ms. Amritha B. Academy of Maritime Education and Training

Ms. Minakshi Koundal Research scholar IIT Roorkee

Ms. Usha Pandey Research scholar IIT Roorkee

Mr. Pradap. P. Academy of Maritime Education and Training

Mr. Dallas Franklin P. Student- Academy of Maritime Education and Training(AMET)

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Abstract: Pipelines are the safest and economical means of transporting hazardous petroleum products. An expanding economy and a growing population have resulted in increased consumption of primary energy resources especially Natural gas, necessitating newer Cross-Country Pipelines.

At the same time, the existing hydrocarbon delivery infrastructure is rapidly aging and hence maintaining operational demand along with high standards of pipeline integrity has assumed paramount importance. Also, there is an increasing demand for advanced technologies or tools to cater to manage the entire lifecycle of a pipeline from Implementation, Commissioning, Operation and Maintenance.

The excellent journey should always begin with reviewing of current asset management systems, methods, challenges & limitations, along with opportunities for improvement. Then the degree to which consideration of remaining life and the influence of maintenance activities are used to drive improved asset management strategy.

To remain significant and competent, an Operator need to be safe & reliable throughout and shall focus on transport costs, emission norms, capacity utilization, and Integrity assurance to help achieve world class operations.

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This paper discusses in detail a proven approach for accomplishing such successful asset management program from Design to Decommissioning phases of pipeline. The journey of excellence could be possible through working on following principles like Concept, Risk and Prioritization, Integrity & Disaster Management, Bench Marking, Competency Development, Moving from Compliance to Culture.

With establishment and practice of coordinated activities of above principles on sustainable basis, a pipeline asset can become a world-class system and will continuously evolve to meet the long-term requirements for entire life cycle.

To remain significant and competent, a pipeline operator should demonstrate safety, Integrity and efficiency in entire life cycle.

To achieve such objective, the methodology selected should be structured, cost effective yet simple to manage. This Paper dwells on five principles through which the journey of excellence was achieved.

This paper discusses in detail a proven, established and simple approach for accomplishing a successful Pipeline Asset Management program in line with global bench markings to achieve a world class operation.

Title: “Role of effective Communication in successful of implementation of Pipeline Integrity Management System (PIMS)” - Alok Gurtu, VP & Head Pipeline Integrity, RGPL Abstract: As per ASME B 31.8S, the five elements of managing pipeline integrity are: • Integrity Management Plan(IMP) • Performance Plan • Communications Plan • Management of Change • Quality Control Plan Out of the above five elements, communication plays a very important role in effectively managing the integrity of pipeline.

Communication could be both, internal or external. While internal communication can very well be managed through mails, messages, Standard Operating Procedures (SOP’s) or verbal communication, the challenge lies in communicating to external stakeholders. The pipelines, unlike process plants, are linear assets running thousands of KM’s in different terrains, states and even countries having different languages, cultures, beliefs and economies. In India itself, having many languages and dialects, one can imagine the difficulty an operator would face in effectively communicating their IMP’s to all stakeholders particularly the farmers and the landowners, many of them, may not even be literate. The communication to all external

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stakeholders commonly known as Public.

Awareness Program (PAP) can be done using different tools like stickers, banners, markers, media, letters, films, pamphlets etc.

The most effective method is through face to face interaction or door to door contacts where the effectiveness of this type of communication, can easily be measured or assessed. Some of the other important stakeholders generally covered through PAP are the Govt. Officials, customers and contractors who can, not only help in preventing the incidents of damage to pipeline, but can also play an important role in managing an emergency.

To conclude, Communication, though often not given the priority it deserves, is one of the most important key elements of PIMS which can make or break the success of any IMP. Most of us think that communication is just simply sending mails, messages, writing good procedures or verbal interactions but we often fail to judge as to what extent the message is correctly understood by the intended recipient. The industry statistics reveal that most of the incidents/accidents happen due to communication being totally ineffective. We often fail to communicate the right message, to the right people, at the right time. The success of implementing PIMS therefore lies on how effectively the operator can communicate their intended plans to all stakeholders including their own employees.

Communication done effectively is half the battle won in the fight against all disruptive forces threatening the integrity of the pipeline.

Title: “Asset Integrity & Process Safety (The key to managing major accident risk in Oil & GasIndustry)” - Pramod Kumar Sapra, President, SP Bumi Armada Abstract: In the history of Oil & Gas industry, there have been many catastrophic accidents which led to the loss of many lives and billions of dollars wealth e.g. Piper Alfa- an oil platform in North sea-UK is known to be one of the deadliest accident of Oil & Gas industry which happened on 6th July 1988. The cause of accident was inadequate Maintenance & Safety processes & control. This resulted in continuous explosions and eventually destruction of the platform killing 167 men out of 226. Only 67 survived the accident.

Looking at such tragic accidents, a dire need was felt to have Management systems which ensure that enough controls are in place to avoid Loss of Primary containment leading to major accident event and it led to the development of Asset Integrity and Process Safety Management systems. For the oil and gas industry the emphasis of process safety and asset integrity is to prevent unplanned releases which could result in a major incident.

A major incident is typically initiated by a hazardous release; it may also result from a structural failure or loss of stability that escalates to become a major incident.

Asset Integrity and Process Safety Management systems drive us towards systematic approach in design, construction, handover, Operating & maintaining the oil & Gas facility and its equipment using multiple BARRIERS. There are two primary types of barrier: hardware barriers and human barriers. They are put in place to prevent a specific threat or cause of a hazard release event, or to reduce the potential consequences if barriers have failed and an event has occurred. Both hardware and human barriers are supported by the processes and procedures contained within the Management System Elements.

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Author will deliberate significance of these barriers with Swiss cheese model and Bow Tie model and explain PROCESS SAFETY & ASSET INTEGRITY Management system contribution in controlling major accident events.

Deadlines for abstracts: Aug. 15, 2019

Title: “Enhancing Asset Integrity, Plant Reliability and Safety – A system approach of Integrated Hazop” - S. L. Chakravorty, Independent Consultant- Oil & Gas, Former Director-OISD, MOP&NG Abstract: Asset integrity & Abnormal situation issues in the process plant operations especially with highly complex process coupled with uncertainties, comes in the way to plant reliability and efficient operations. The critical factors triggering abnormal situation(s) and the asset the integrity issues, needs review at the incipient design stage itself, and also during plant operation with anticipation on - what can go wrong. Use of appropriate tools, brain storming & knowledge assimilation are the ways to manage such issues and achieve success in reliable operation.

Achieving plant Reliability & efficient operations requires system approach & success thru competencies in Process Safety(Design, Hazop- C- Hazop, and LOPA-SIL), Asset Integrity(Damage Control Mechanism- metallurgy- measurement and monitoring, RCM- Appropriate type of maintenance- or review for Design change), Human Reliability(Engagement, Error management, Visual Literacy).

The paper deliberates the approach of Integrated Hazop - to be institutionalised by new generation Industry, integrates the abovementioned success factors to attain Asset Integrity & reliability and safety, viz: Challenging design thru Process Safety(Operability issues- Hazard & operability reviews / Computer Hazop & MOCs), Layers of protection analysis(providing appropriate barriers - Safety Integrated Level identification of safety integrated systems), Asset Integrity(where corrosion is considered as one of the process parameters, critical review with ‘damage control mechanism’ for current & future operations coupled with), Human reliability aspects(focusing error management in safety critical operations to meaningfully protect the plant & facility from known & unknown hazards, the uncertainties and enhance plant reliability).

Title: “Onshore Plant RBI–Software Approach Advancements” - Nagmani Sinha, Sales Specialist, Panos Topalis, DNV-GL

and

Abstract: The Risk Based Inspection(RBI) methodology is widely used internationally, especially in the Oil & Gas Industry and is well accepted in many countries. Several RBI projects have been reported in the literature demonstrating the strengths of the approach in controlling risks and optimizing inspection schedules.

API RP 581 is a well-established methodology for conducting RBI in the downstream industry and the 3rd edition of the standard was published in April 2016, while a first addendum to the standard came in April 2019. This paper presents a software approach for applying quantitative RBI according to API 581 and describes a cloud-based enterprise deployment of the RBI model, using DNV GL’s Veracity platform, and Microsoft Azure. The Software as a Service(SaaS) deployment allows users to share data and run RBI through a web browser, while the software installation and

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2nd International Conference on

“Protective Coatings & Surface Treatment”

PCST 2019

Date: November 18-19, 2019 Venue: Hotel Holiday Inn, Mayur Vihar, New Delhi With a focus on

• Organic Paint Coatings, • Inorganic Metal Coatings such as Hot Dip Galvanization & aluminium coatings Convenor & Chief Technical • Thermal Spray Coatings & Prof. A. S. Khanna • Surface Modification using, CVD/ Chairman, SSPC India Proprietor, Surface Engineering & Coating Consultant PVD and Laser Surface Treatment Fellow NACE, Fellow ASM

Knowledge Partners

Organizer

Co-Organizer

Media Partners

For registration please contact: Swati Pawal, M.: +91 9773776934, E: contact@industrialcoating.in Priyanka Bose, M.: +91 7428400320, E: technical@industrialcoating.in Website: www.industrialcoating.in

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maintenance costs are minimised. This approach is demonstrated through a recent RBI implementation for an international Refining and Chemicals company.

Title: “PMI- An Important Tool For RBI” - Mahendra Nimkar, Business Manager-Analytical Science, Hitachi High Tech Abstract: Risk based Inspection and maintenance is the process of identifying, quantifying and then developing plans to ensure that all risks arelimited to acceptable levels that are well below the set limits. In this concept Risk is the product of the Probability of Failure and the Consequences of Failure. The kind of equipment that are usually covered by RBI are Pressure vessels, Piping, Storage Tanks, Boilers, Heat Exchangers, Rotating Equipment etc. During the lifetime of such equipment, degradation and corrosion is bound to occur. The role of Inspection in Risk based Management is to identify the extent of such degradation and thereby reduce the risk and probability of failure. But just carrying out inspection does not stop the failure from occurring and timely repair and replacement has to be done in order to prevent any failure. PMI(Positive Material Identification) plays an important part in identifying the grade of the material that needs to be replaced. Using the correct alloy is extremely important not only in corrosive environments but also where one needs to deal with high pressure and temperature.

There have been several unfortunate incidents that have led to loss of life and property due to the wrong materials being used – the Consequences of Failure can be very high. PMI techniques employ Optical emission Spectroscopy or X-Ray analysis to identify the grades of metal alloys. Optical Emission Spectroscopy gives the advantage of identifying Carbon and other lighter elements that cannot be done by X-Ray analysis. A common application for OES is identifying L or H grades of Stainless Steel. It is also possible to identify the level of nitrogen in Duplex steels using Optical Emission Spectroscopy. Measurement times can typically be from 2 seconds to 10 seconds and coupled with a comprehensive Grade database, grade Identification has become an easy and routine job using either technique.

Title: “Pulsed Eddy Current Array Design and Applications” - Jitendra Yadav, Senior Technical Sales Specialist, Vincent Demers-Carpentier, Maxime Rochette, Charles Tremblay, Marco Michelesisto, Andréanne Potvin, Eddyfi Technologies Abstract: Pulsed Eddy Current(PEC) has been successfully deployed over the last decades for a variety of corrosion-related applications, most notably for Corrosion Under Insulation(CUI) Inspections, Corrosion Under Fireproofing(CUF) and Flow Accelerated Corrosion(FAC). This technology has proven to be an efficient inspection tool, allowing for the detection of corrosion without having to remove coating or insulating material over typical pipes, tanks and vessels. Despite the success of the technique, one limitation of the conventional PEC systems is that achievable productivity is relatively low, especially on thick walls and when an inspection with high spatial resolution is required. Recently, we developed Pulsed Eddy Current Array(PECA) solutions which greatly increase the productivity of the technique. The system is based on a novel pulsed eddy current probe featuring a linear array topology. The proposed probe design offers 46 cm of

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coverage in one single pass, improving the productivity of a pulsed eddy current inspection by a factor 4 to 10 compared to non-array solutions. The probe can be used on flat and curved surfaces with a diameter down to 15 cm. This is made possible by the nonrigid mechanical design of the probe, so that it’s main axis can be wrapped around a pipe or otherwise bent to follow the curvature of the inspected surface. Proper analysis of the array raw data requires an adapted analysis algorithm, whose sizing performance on insulated components is presented in this paper along with examples of defect sizing maps of a typical insulated pipe. After more than a half year on the market, significant field experience has been gathered with this technology making it now possible to show results acquired on real-life components. Some of these will be presented, analyzed and discussed. The sizing and productivity performance of the latest improvements of PEC technique are compared to prior art technology, and benefits are discussed.

Title: “Smart Robotic solutions for Inspection of Underwater Assets” -Vishal Devdas, General Manager-Business Development, Tanuj Jhunjhunwala1, Planys Technologies Abstract Catastrophic failures and costly outages of Underwater Infrastructure can be prevented by their periodic Inspection and Maintenance. Underwater Inspection using Planys Remotely Operated Vehicles (ROV) is a safe, reliable and cost efficient alternate to limitations caused by conventional and manual diverbased operations. Planys Technologies, an IIT Madras incubated company, is an Indian deep technology start-up specializing in smart underwater inspection services and caters to multiple sectors. Planys is pioneering in the maintenance and inspection space with its disruptive innovations in the field of marine robotics and novel NDT methods. Planys envisions to steer the industry from time-based Inspection to Risk Based Inspection by helping asset owners in taking an Informed approach to efficient planning of maintenance and repair through data-driven decision making.

This paper presents use cases demonstrating its value to the Asset Maintenance and Integrity industry, using a submersive ROV developed indigenously by Planys. This work will be of high interest to marine asset integrity and plant maintenance professionals.

Title: “Plate Type Heat Exchanger in CCRU- A Unique Experience of Preventive Maintenance & Inspection” - Alok Kumar, Senior Manager-Mechanical Maintenance, Mangalore Refinery And Petrochemicals Limited, An Ongc Group Company Abstract: Plate type heat exchanger in Combined feed/effluent streams of Catalytic Cracking & Reforming Unit(CCRU) is always been a challenging task for refinery maintenance and inspection team. Reliability and integrity of plate type exchanger can only be ensured through preventive maintenance & inspection plan at fixed interval. These exchangers are considered to be very compact, highly efficient and known for their constant good performance with minimum maintenance. The challenges confronted by refiners during troubleshooting of plate type heat exchanger are 1) Unique exchanger design 2) Uncertainty about the location & extent of the failure

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Manufacturer’s Agent for: All type of Paint Testing, Material Testing & Process Control Equipments.

This is a INDIAN MAKE DIGITAL COATING THICKNESS GAUGE FERROUS / NON FERROUS ALONG WITH NABL ACCREDITATION CALIBRATION CERTIFICATE I YEAR GUARANTEE AND AFTER SALE SERVICE AVAILABLE CONTACT. Contact: M/S. Roshan Instrumentation, B-103, Milap Complex Chs Ltd., P&T Colony, Gnadhinagar, Dombivli (East) – 421204, Thane (Dist), Maharashtra Tel No.: 0251– 2820331 Mobile: +91 9820504370/9326736910 Email: roshaninstrumentation@gmail.com / cnknair2004@vsnl.net Website: www.Roshaninstrumentation.Com

inside the exchanger 3) Intricate & specialized repair methodology 4) Elusiveness about the repair outcome In MRPL, plate type heat exchanger in catalytic reforming unit was commissioned in March 1996 & was in operation since its inception.

After over 2 decades of efficient service, preventive maintenance & inspection of plate type Combined Feed/Effluent Exchanger has been taken up for the first time. The Plate type Heat Exchanger is a very large welded plate heat Exchanger composed essentially of a welded plate heat transfer bundle, designed to optimize the thermal & hydraulic performance of exchanger, placed inside a pressure vessel. This unique configuration of modern plate heat exchanger technology is having several advantages of shell-andtube heat exchangers under high temperatures and high pressures.

With this special and complicated configuration, these exchangers are challenging task for maintenance & inspection team.

This paper presents the stepwise elucidation of the exchanger design, execution methodology, and maintenance & inspection outlook of its troubleshooting during turnaround shutdown of CCRU unit. The paper is also deals with its advantages over conventional heat exchangers. The intent of this paper is to make refiners acquainted with all the aspects of plate type heat exchanger of CCRU from maintenance & inspection outlook.

The paper has the potential to break the pre-established myth and instigate the new viewpoint about compact plate type heat exchanger.

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Title: “Simplification of Isolation Product Selection Through Advance Design” - Robert Colton, Business Manager & Director EMEA, Garlock Pipeline Technologies Abstract: The selection and installation of isolation kits has seemed pretty simple throughout the years. Simply select a gasket that stated it was an “isolating gasket” and pair it with isolating sleeves and washers. Then, install the gasket as any normal gasket would be installed. This practice however, has led to countless isolation and leakage failures. But what lead to these failures?

First, one must recognize that isolating gaskets are typically considerably thicker than standard sealing gaskets. Additionally, many isolating gaskets actually absorb moisture reducing their electrical resistivity(this can be a concern especially after hydrotest).

One must also consider other factors such as high pressure, high temperature and fire safety among other considerations when selecting the proper gasket. The installation of an isolating gasket must be dealt with differently than a standard sealing gasket.

Seals typically sit proud in isolating gaskets and can be damaged during installation. Simple installation techniques can avert these issues and create much better and even loading on the gasket. This paper will dramatically simplify the selection process for isolation gaskets/kits and will also provide a better integrity program for installation and testing of isolation kits.

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Title: “An Investigation of Corrosion in Formation Water Disposal line of an Installation of OIL and its Mitigation” - Dr. Dipak Jyoti Kalita, Chemical Department, Oil India Limited Abstract: Corrosion in petroleum industry causes a loss of billions of dollars every year. Corrosion related failures constitute over 25% of failures experienced in the oil and gas industry. In E&P industry many cases of extensive corrosion have been observed in production tubing, valves, and in flow lines from the wellhead to the processing equipment. Uniform corrosion taking place causes 30% failures and other 70% is caused by localized corrosion1.

The wide-ranging environmental conditions prevailing in the oil and gas industry necessitates the appropriate and cost effective materials choice and corrosion control measures.

Frequent flow-line leakage problems due to corrosion were observed in the formation water disposal lines of ABC OCS, an installation of Oil India Limited. There have been numerous repairs/replacement of water disposal lines within a short span of time and leaks were reported in various surface facilities of the installation. The issue of failure analysis of “Formation water disposal line” was taken up for study to ascertain the cause of corrosion phenomena and suggest remedial measures.

As a part of the investigation, field visits, inspection of installation and laboratory analysis of the formation water, material analysis of deposits, Gravimetric tests and thickness measurements of the flow-line were carried out to understand the cause of corrosion.

General corrosion rate study were carried out in HPHT Autoclave under simulated pipeline conditions of temperature, pressure, flow rate to determine the corrosion rate and corrosive nature of the fluid. Water analysis of untreated formation water and bactericide treated formation water was performed to substantiate the findings of the study. Effectiveness of corrosion inhibitor in combination with bactericide in the same environment and pipe material were also studied.

The findings of the study and recommendations are presented in this paper.

Title: “Asset Inspection Management System a reliable Inspection Tool to optimize the asset utilization & serviceability and to enhance overall efficiency of Service Provision” - Shibu John, Quality Manager (ASNT Level III), Special Oilfield Services, Muscat Sultanate of Oman Abstract: Engineering asset management(EAM) is the management of engineering assets and it provides guidelines on the effective usage of all the physical engineered assets within the organization.

Similarly, Non-Destructive Testing [NDT] is being used as a handy tool for integrity assessment of Assets in scheduled maintenance & inspection program. Though Asset Inspection in Oil & Gas Industry were using conventional NDT methods, now ASME, API and others came up with inspection procedures based on fracture mechanics, where each user to ascertain how their tool/regional operating condition deviate from the assumptions herein, then employ their engineering and technical judgment in deciding how and when to employ any part of these standard. At present there is no regular validation for these procedures being performed as presumed. As Severity of failure in North Sea offshore should not be compare to that in MENA, the custodian should tailor their

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Service Quality Plan and inspection procedures, as per applicable operating limits and risks.

The purpose of this paper to emphasize the importance of optimizing the Asset utilization and serviceability to enhance overall efficiency by establishing Asset Inspection Management System[AIMS]. Case study refer our AIMS, a tool to track all Equipment data[Images, OEM/CoC Document, Inspection Reports/Certificates, track analysis of major attributes] through a single channel - Master Asset [Inspection] Register. Uniquely numbered Assets in each category Drilling Tubular, Hosting & Handling Equipment and/or Lifting Equipment Item is captured in respective Master Asset Inspection Register with all related Equipment data & Inspection records. Inspection records provide all its inspection related history since its commissioning and manufacturing OEM/CoC Documents. ‘SOS INSPECTIONEERING App’s compliance to API Q2, ISO9001:2015 and ISO17020:2012 ensures its certifying requirements to, (1) relevant Industry standard and bench mark (2) Competence of Inspection Personnel and (3) Compliance of Measuring Devices & Equipment.

In last two years [2016-2018] by ensuring Acceptance Benchmark only, more than 70% reduction in premature failure[Crack in Thread Connection; where 50% of those are potential NPT cases] in drilling Tools achieved. Our App provides the user to analyze Inspection data. The trend analysis of tools helps in its planning and utilization. The trend analysis also can be directly input to modify Service Quality Plan to optimizing the asset utilization & serviceability. The above are some of the immediate befit to Oil Company and Drilling Contractor by AIMS. This paper also discusses one more dimension of it, Reliability in Service Quality. As this AIMS Tool is synchronized with our, (1) ERM software that manages company’s all assets and resources, and (2) OMS controlling the process, the integration of all three increases the overall efficiency of the service and results in profitability of a business.

Title: - “Olympus Advanced NDT Solutions for Weld inspection and Corrosion Mapping” - Mohd. Arshad Uddin, Product Specialist-NDT, Olympus Abstract: Non-destructive testing (NDT) is the process of inspecting, testing, or evaluating materials, components or assemblies for discontinuities, or differences in characteristics without destroying the serviceability of the part or system. In other words, when the inspection or test is completed the part can still be used.

Olympus has an extensive portfolio of ultrasonic and eddy current flaw detectors with advanced features for applications ranging from weld inspection to detecting hidden cracks, voids, porosity, and other internal irregularities in metals, composites, plastics, and ceramics. Our high-quality flaw detectors are rugged, versatile, and easy to use and have numerous practical measurement features and application-specific software.

Our phased array (PA) instruments produce accurate, detailed cross-sectional pictures of internal structures at fast inspection speeds. Phased array technology uses multiple ultrasonic elements and electronic time delays to create beams that can be steered, scanned, swept, and focused electronically for fast inspection, full data storage, and multiple angle inspections.

Phased array technology provides precise measurement with the most reliable results.

Olympus Industrial XY(motorized and manual) and manual

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weld/corrosion inspection scanners provide reliable, accurate performance in a range of heavy duty industrial applications where scanners are used to improve quality and reduce costs.

Phased array scanners and accessories such as motor controllers and water pumps complete the Olympus line of scanner products.

Title: “Optimization of Underwater Inspection of Fixed Jacket Structures in Western Indian Offshore” -Praveen Bhat, EE-Civil, Nitin Nehra, Institute of Engineering and Ocean Technology (IEOT)-ONGC Abstract: India’s offshore domestic Oil & Gas production is primarily carried out by Oil & Natural Gas Corporation Limited(ONGC) which is a major national Exploration & Production company and contributes around 70% of the hydrocarbon supply in the country. The major contribution of these fossil fuels is from western offshore region of India where ONGC operates a fleet of more than 300 bottoms founded steel jacket platforms. These steel tubular structures are designed for strength adequacy to withstand extreme environmental conditions as well as for fatigue damage due to prevalent sea states. These structures have been designed with an intended design lives of 20-25 years as per provisions of API RP 2A(WSD). These platforms are required to be reanalyzed for modifications and/or for life extension requirements. Therefore, in addition to the strength point of view, the accumulated fatigue damage of joints due to incident waves needs to be aptly captured which will control the design of the inspection campaign.

The inspection campaign development for addressing fatigue assessment results is based on the risk evaluated and comparing it to the acceptable target risk. Risk is dependent upon the likelihood and consequence of failure which is obtained as the product of probability of fatigue failure (PFfatigue) and consequential probability of collapse given fatigue failure occurs (PFcollapse|fatigue). Risk = PFfatigue x PFcollapse|fatigue In this paper, the optimization and prioritization of the inspection of the tubular joints has been carried out based on the criticality, location and importance, on the basis of type of braces/Chords (Diagonal brace, Main leg, Horizontal brace, Launch Truss member, etc.) and their utilization ratios. Based on the results of screening and member importance analysis, the optimized RBI plan has been developed as per API RP 2SIM, Clause No. 6.5.2.2.

Title: “Online Partial Discharge Detection Technique for GIS based on UHF Sensors” -Sagar Bhutada, Engineer- R&D, Umesh Soni, Dr. Satish Chetwani, ERDA Abstract: Gas-Insulated Switchgear(GIS) have been in operation for more than 45 years and show a high level of reliability. However, experience indicates that some of the in-service failures are related to defects in their insulation system. Many of these defects can be detected by Partial Discharge(PD) diagnostics.

PDs generate electromagnetic and acoustic waves, emit light and produce chemical decomposition of insulation materials; these physical and chemical effects can be detected by various diagnostic methods and appropriate sensing elements(sensors).

Besides the so-called ‘conventional’ electrical method described in IEC 60270, it is possible to detect and measure PDs with various ‘non-conventional’ methods. The Ultra-High Frequency(UHF)

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measurement method, which was introduced in the late 1980’s for PD detection, is used worldwide by GIS manufacturers during routine testing in factory, during commissioning on-site and by utilities for continuous monitoring in service. The UHF method is less sensitive to noise, so easier to handle in comparison with the conventional method according to IEC 60270. To avoid technical misinterpretation, there was a special need to give recommendations for this non-conventional method. This paper is based on the experience and describes its practical applications for GIS. A detailed description of the procedure is given and supported by examples. Guidelines will help the users for the effective application of the UHF method for Online PD detection on GIS. Title: “Enhanced Oil Recovery Using Bacteria Pseudomonas putida MTCC 2422 for Heavy Oil Reservoir And Higher Production Rate” - Akash J, Student- Academy of Maritime Education and Traininig (AMET) Abstract: Enhanced oil recovery (EOR) is one of the advanced technologies which is used in improving oil recovery involving chemicals, surfactants, polymer, thermal and microbes. In the present work, microbial enhanced oil recovery(MEOR) is implemented using produced bio surfactant from bacteria. Microbes play a valuable role in recovery of crude oil from the depleted formation. Bacteria Pseudomonas putida(MTCC 2422) is subjected to pH and other growth parameters(carbon and nitrogen). Experiments were carried out at laboratory scale and analysis such as physical/ biological parameters were studied to determine the optimal conditions for growth and bio surfactant production. Surface activity such as surface tension and interfacial tension were analysed using digital tensiometer. Produced bio surfactant is subjected to stability on temperature, pH and Salinity. The results obtained shows that Pseudomonas putida(MTCC 2422) has the potential to grow and produce maximum bio surfactants which eventually reduce interfacial tension from 69 mN/m to 31 mN/m at pH 7.0 and 30° C. Further produced bio surfactant is subjected to oil recovery application in porous media. Pseudomonas putida procured is efficient for bio surfactant production and stable at reservoir conditions and effective for oil recovery applications.

For the production of bio surfactant, effect of different carbon sources such as glucose, sucrose and starch on bio surfactant production by Pseudomonas putida MTCC 2422 had been carried out. Used carbon sources, glucose had been identified to produce maximum of 2.4 g/L biomass and 3.1 g/L bio surfactant(Fig. 1A & 1B). Confirmation for production of bio surfactant and reduction of interfacial tension of medium was analyzed at regular intervals of time. Interfacial tension analysis showed that it got decreased with time and it is due to increased bio surfactant concentration only (Fig. 1C). It is attributed that decrease in interfacial tension and its was maximum when P. putida was grown in medium containing glucose as the carbon source(Fig. 1C). This is further confirmed that maximum bio surfactant production can be obtained using glucose as the best carbon source. Hence, glucose of 2 %(w/v) was used as carbon source for further studies.

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Title: “Advanced Digital Corrosion Survey Technology to enhance Asset Integrity” - K. V. Badri Narayan, NACE Certified Coating Inspector Level 3, NACE CIP instructor Abstract: Asset integrity can be defined as the ability of an asset to perform its required function effectively and efficiently while protecting health, safety and the environment.

Asset integrity management is the means of ensuring that the people, systems, processes and resources that deliver integrity are in place, in use and will perform when required over the whole lifecycle of the asset.

Aging of installations are major concern an installation’s location and type of environmental condition it is exposed to, can be challenging for the maintenance crew who need to maintain the integrity.

Corrosion maintenance on offshore installations is a high priority for maintaining the lifespan of the Instillations, it is essential to keep the assets operating safely and productively over its full lifecycle.

Big asset owners understand, corrosion has major safety-critical factors attached to it, consider the potentially explosive release of hydrocarbons from corroded pipe work, vessels, valves and flanges. The safety critical factor increases as an oil installation grows older, the very fabric of the Modules begins to wear.

Owner Maintenance strategy is to avoid doing minimal coating maintenance as this equates to the loss of integrity and can prove to be catastrophic, so it is of high importance that owner’s maintenance operators implement continued proactive and planned maintenance for their Assets.

Aging is not about how old the equipment is; it’s about what you know about its corrosion condition, and how that’s changing over time.

Akzo Nobel survey team regular updates the Inter planTM baseline surveys. This is done to evaluate and offer new data to highlight any new or unexpected defective areas Title: “High Resolution Phased Array Imaging using the Total Focusing Method and its applications” - Srinivas Kumar, Technical Sales Specialist, Eddyfi Technologies Abstract: Total Focusing Method also called as sampling phased array is known for about 10 years. This technique uses Full Matrix Captured ultrasonic data which is transmitted and received from several incidence points within the same phased array probe. This data yields an ultrasonic image of very high resolution. New Portable industrial equipment with full-parallel capabilities allows handling of matrix-array probes, 3D imaging and advanced techniques for optimal focusing. Total Focusing Method, a reconstruction based technique, will be discussed in the presentation, it allows better sizing of the defects during inspections, a clear detection of small defects and defect characterization using mode conversion or corner effect mode. TFM provides a high lateral image resolution in the array direction almost independent of reflector depth due to focusing to every point in the ROI. It allows the increase of the scan width due to the extreme divergence angle with single element excitation and reception. TFM allows the measurement of the size of defects using the 6dB drop technique, even for small defects, and works with longitudinal and shear waves,

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even considering different mode conversion modes with the reconstruction algorithm. It delivers a much higher probability of detection(POD) for inclined defects, and allows the measurement of crack depth or size of vertical defects using the TTT mode (tandem scan reconstruction).

TFM reduces the dead zone and improves the signal-to-noise ratio. Using different reconstruction algorithms TFM offers a significant step forward towards defect sizing in the image – a possible alternative to amplitude evaluation techniques. More future TFM applications with destructive control measurements may prove the advantages and applicability of sizing in the image even more, since technical solutions are available now.

Title: “NADCAP Accreditation - An Aerospace Special Process Requirement” - Mottito Togo, Honeywell Aerospace Abstract: Outsourcing of Aerospace parts in India is growing at high rate in last three years. India being one of the largest economy in manufacturing and skilled manpower, many Aero primes are look at India as a manufacturing hub. Further given that India is a high growth region and Make in India policy is calling for various Aero primes to get the parts manufactured in India. Given this opportunity it is important to know and create awareness among the Indian community on the Aerospace requirements. Special processes plays are key role in the manufacturing of parts and the aero primes give almost importance to control their processors’ special process. Given the importance of special process, apart from the Aerospace Quality Management system requirements of AS9100, Aero primes expect their processors to have National Aerospace and Defence Contracts Accreditation Program (NADCAP). In this presentation, an effort is made to create awareness about Nadcap accreditation for special processes with an example of NDT. Title: “Deformation Monitoring Using Finite Element based Digital Image Correlation(DIC) Method” -Saurav Kumar2, Bharath Maheshwari2, Chamanth Sai Reddy1, Debasis Deb1, Rakesh Kumar Gupta1 1Dept of Mining Engineering, IIT Kharagpur 2Dept of Petroleum Engineering, IIPE Visakhapatnam Abstract: Digital Image Correlation(DIC) is a non-contact and nondestructive testing(NDT) technique for monitoring and analysis of structures and has a wide range of applications. DIC uses digital images and computational algorithms to measure full displacement fields on the surface of the test object. The surface should be randomly speckled to have one to one correspondence.

A finite element based digital image correlation(FEM-DIC) algorithm is developed and implemented for determining deformation behaviour of samples under load. The performance of the FEM-DIC algorithm is evaluated for generalized types of loading conditions(translation, rotation, pure shear, uni-axial tensile) using numerically simulated images. This algorithm is employed for monitoring the deformation process of a concrete cube under laboratory conditions using in-house developed DIC hardware. The results show that DIC can predict the formation of cracks on the surface of the cube well ahead of its visible fractures and cracks. DIC technique have potential applications is

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structural health monitoring of aerospace, civil, mining structures and the infrastructure developed for thermal and nuclear energy generation.

Title: “Corrosion in the Oil and Gas Industry” - Dallas Franklin P, Student- Academy of Maritime Education and Training(AMET)

Title: “Industry 4.0 – The Predictive Maintenance” - Kumar H. Rokade, Managing Director, ROKADE Group of Cos

Abstract: Oil and gas fields consume a high amount of iron and steel pipe, tubing, pumps, valves, and sucker rods. Leaks cause loss of oil and gas and also permit infiltration of water and silt, thus increasing corrosion damage. Saline water and sulphides are often present in oil and gas wells. Corrosion in wells occurs inside and outside the casing. Surface equipment is subject to atmospheric corrosion. In secondary recovery operations, water is pumped into the well to force up the oil.

Corrosion the deterioration of a metal or its properties attacks every component at every stage in the life of every oil and gas field.

From casing strings to production platforms, from drilling through to abandonment, corrosion is an adversary worthy of all the high technology and research. Oxygen which plays such an important role in corrosion is not normally present in producing formations.

It is only at the drilling stage that oxygen contaminated fluids are first introduced.

Identifying the Causes and Applying Controls there are many sources of corrosion and many more methods of slowing the process down. Cathodic protection works by forcing anodic areas to become cathodes. Corrosion mechanisms corrosion encountered in petroleum production operations involves several mechanisms. These have been grouped into electrochemical corrosion, chemical corrosion and mechanical and mechanical/ corrosive effects.

Any sudden machine breakdown can play havoc with plant running and production losses. In this highly competitive world, no one can ever think of the consequences arising out of such a situation, especially when huge investment has been made on plant & machinery.

Regular machine check and effective predictive maintenance almost eliminate such a scenario. Which is why, pre-planned asset reliability check plays a vital role in any plant – be it refinery, engineering, chemical, aerospace, defense, oil, petrochemicals – small and big alike. Therefore, installation of a more technologically advanced health monitoring unit makes sense and worthwhile.

POSTER PAPER PRESENTATION Title: “Spacer Fluid and its Optimization through Surfactants” - Rudipta Bhuyan, Student- University of Petroleum and Energy Studies Abstract: Fulfilment issues amid the cementing of casing or liners in wellbores have faced the oil and gas industry for a long time.

For the most part, after the borehole has been penetrated, the drilling mud utilized and is displaced by the bond utilized as a part of cementing the casing or liner. Properties of drilling mud furthermore, cement slurries shift broadly. Such variety may result in unfavourable physical and concoction responses at the interfacial contact. For example, when a high viscosity, highthickness penetrating liquid is utilized, the contradiction may add to directing in the annulus and may keep the required cement to formation bond. Subsequently, interaction may happen amongst zones and perhaps even to the surface.

Rheological measurements revealed the fact that the mixture of mud and spacer were incompatible at certain compositions. So, in order to make it compatible with the mud, surfactants have to be added in the spacer fluid in different compositions or ratios to obtain the appropriate or required properties. The experiment has to be conducted a smaller scale where we take up Mud sample and a Spacer and then we add surfactants and emulsifiers in different ratio to obtain the data.

We observed that we have to always keep the density of spacer more than the mud for optimal cleaning of the wellbore. The main function was to keep the cement slurry from contamination with Oil Based Mud(OBM) from the drilling fluid. Spacer fluids also ensured a much better cement job. Shear Bond Strength(SBS) was tested and it was found out that cement was well bonded with the formation and the casing. Hence, the required wettability and compatibility were successfully tested through SBS.

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Title: “Causes of internal corrosion in oil transportation pipelines” - Amritha B., Academy of Maritime Education and Training Abstract: Pipelines play an important role in oil and gas industries. Up to now pipeline are the most economical and efficient means of large scale fluid transportation for crude oil and natural gas compared to rail, truck and tanker transportation in term of the flexibility of routes and large quantities to be moved on. Pipeline is commonly made of carbon steels due to some reasons, i.e. carbon steels have good mechanical properties, low cost and wider availability despite their corrosion resistance is relatively low. Corrosion in wells generally occurs inside and outside the casing due to the oxidation or any other chemical activities. The leaks are generally observed at the inner surface of the pipeline. The leaks are resulted from combined effect of electrochemical corrosion and fluid flow.

Chemical composition of the water phase present in the crude oil is determined by atomic adsorption method. The main ions detected were chloride(Cl−), bicarbonate(HCO3−) and sulphate (SO42−) where the chloride(Cl−) has been known as aggressive ion.

Water was identified to have pH of 8.5 or basic condition. Due to the natural composition of crude oil with oxygen, nitrogen and sulphur compounds as its major constituents, one would say that corrosion will not be a problem in the internal off-lines. Water is essential to low temperature corrosion. Pure water containing no dissolved substances is mildly corrosive to iron, Water containing impurities or dissolved substances can be corrosive or noncorrosive, depending upon the nature of dissolved substances.

For example chromate and phosphates are added to water for the purpose of inhibiting or reducing corrosion. On the other hand substances such as sodium chloride, hydrogen sulphide,

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carbon-dioxide and oxygen can increase the rate of corrosion when combined with oil field water. Flow induced corrosion seems to be the main cause of leakages that occur locally at the horizontal subsea pipeline near an elbow section. Combined effect of pitting corrosion and erosive flow increases corrosion rate along the flow direction resulting in undimensioned shaped pits. The damage prevention options are suggested: first, prevent water separation by increasing oil flow sufficiently so that the pipeline surfaces are maintained oil wetted and secondly, give inhibitor injection into an oil pipeline fluid stream. Inhibitors generally play a major role in corrosion control

corroding fluid. The concept is that the organic inhibitor will strongly adsorb on the metal wall to form a barrier, possibly only a few molecules thick, which will prevent access to the corrodant and possibly leave the surface oil-wet. The inhibitor can interact with the corrosion product to increase its adherence and to lower its permeability. Such layers are likely to be far thicker than a few molecules.

Title: “Challenges in Corrosion control and Remedies” - Pradap. P, Academy of Maritime Education and Training

Abstract: Microbial influenced corrosion(MIC) is one of the most major concerns in industries due to the huge economic loss. Sulphate reducing bacteria is well studied and highly corrosive in nature.

Among the corrosion causing bacteria, Iron oxidizing bacteria (IOB) play a significant role in industries. MIC mechanism of IOB not yet elucidated. To protect steel from the MIC, it is very essential to know the exact mechanism of MIC. In this context, the present study was designed to investigate the corrosion behaviour of mild steel in presence of IOB(strain DASEWM2) isolated from canal water. EPS constituent’s concentration was measured from 0-144h incubation time(according to bacterial cell growth curve).

To correlate the EPS constituents concentration with corrosion rate, tafel curve were measured from 0-144h incubation time. To know the extent of localized corrosion, anodic, cyclic polarisation, and potentiostatic curves were measured. Immersion tests were carried out for the incubation time 6 months in case of control and inoculated media. Results show higher corrosion in case of inoculated media than control media. Corrosion products were also analysed using XRD and FTIR techniques. On the basis of results, mechanism of MIC was proposed.

Abstract: The chemical, refinery, and petrochemical industries are facing new challenges in order to develop more environment friendly processes and to manufacture “green” products. Corrosion management is an essential element for the development of a sustainable industrial society, including issues such as the selection and development of corrosion resistant materials, coatings, and environment friendly inhibitors. Another issue for the refinery industry concerns for new feedstock’s such as crudes containing corrosive naphthenic acids or the transformation of biomass feed into bio‐oils and biomaterials. Synthetic gas is also becoming a crucial intermediate in natural gas, coal or biomass to hydrocarbon liquids processes. The implementation of advanced inspection and corrosion control management is also a major element of progress for a sustainable development of the chemical, refinery, and petrochemical industries. Oilfield corrosion can be divided into corrosions due to oxygen, “sweet” corrosion, and “sour” corrosion.

Corrosion because of oxygen is found with surface equipment and can be found down hole with the oxygen introduced by water flooding pressure maintenance, gas lifting, or completion and/or work over fluids. It is the major corrodant of offshore platforms, at and below the tide line.

Sweet corrosion is generally characterized first by simple metal dissolution followed by pitting. The corrodant is H+, derived from carbonic acid(H2CO3) and the dissolution of CO2 in the produced brine. The pitting leaves distinctive patterns which leads to the metallurgical processing used in manufacturing the tubing. Sour corrosion (H2S) results in the formation of various insoluble iron sulfides on the metal surface. Not only is H2S an acidic corrodant, it also acts as a catalyst for both the anodic and cathodic halves of the corrosion reaction. Galvanic corrosion or bimetallic corrosion is caused by the coupling of a corrosive and noncorrosive metal in the presence of a corrodant.

The appropriate addition of chemicals can often inhibit corrosion problems, including some effects of H2S. The delivery techniques are often the same, but the inhibition mechanisms and types of chemicals are different. Some of the Neutralizing inhibitors reduce the hydrogen ion in the environment. They are: Amines, Ammonia, and Morpholine. They are effective in weak acid systems but are stochiometric reactants: one molecule equivalent of inhibitor per molecule of acid. Scavenging inhibitors are compounds that also remove the corrodant. Oxygen scavengers are commonly used in the oil field.

The majority of the corrosion inhibitors employed during production form thin barrier layers between the casing and the

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Title: “Electrophoretic deposition of graphene oxide on mild steel and its electrochemical assessment in saline media” - Usha Pandey, Research scholar, IIT Roorkee

Title: “Synergistic inhibition of mild steel corrosion by SDS and Imidazolium salt” - Minakshi Koundal, Research scholar, IIT Roorkee Abstract: The selection and installation of isolation kits has seemed pretty simple throughout the years. Simply select a gasket that stated it was an “isolating gasket” and pair it with isolating sleeves and washers. Then, install the gasket as any normal gasket would be installed.

This practice however, has led to countless isolation and leakage failures. But what lead to these failures?

First, one must recognize that isolating gaskets are typically considerably thicker than standard sealing gaskets. Additionally, many isolating gaskets actually absorb moisture reducing their electrical resistivity(this can be a concern especially after hydrotest).

One must also consider other factors such as high pressure, high temperature and fire safety among other considerations when selecting the proper gasket.

The installation of an isolating gasket must be dealt with differently than a standard sealing gasket. Seals typically sit proud in isolating gaskets and can be damaged during installation.

Simple installation techniques can avert these issues and create much better and even loading on the gasket.

This paper will dramatically simplify the selection process for isolation gaskets/kits and will also provide a better integrity program for installation and testing of isolation kits.

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Magazine Submit an Article “Asset Integrity & Reliability Management Magazine”, is an important initiative for sharing information and knowledge to increase integrity, reliability and safety of assets. The Magazine will deliberate on the state-of-the art material & corrosion science and technologies outlining various ways to control corrosion, exploring application of advanced materials and various Inspection/NDE techniques to assess/ monitor the prevailing problems.

We welcome all the authors and professionals for contributing your technical articles for publishing.

Gifts and Reward Systems Based on the review by the editorial board and feedbacks from the readers, few authors will be selected for special gifts or rewards to encourage. Implementing PIMS therefore lies on how effectively the operator can communicate their intended plans to all stakeholders

Advertisement It is one of the largest circulated e-magazine dedicated exclusively on the “Asset Integrity Management”. With a significant no of free circulation(more than 108,000 worldwide) covering almost all the industry, service provider, contractors, supplier as well as endusers, this is the right place to present your company/product.

Details of the Advertisement Half Page Full Page Double Spread Ad (2-page side by side) Inside Front/Back Cover Page Outside Back Cover Page

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Send your all queries to E-mail: assetintegritymagazine@gmail.com Contact No. +91-97737 76934/011-46545757 w w w. a i r m i n s t i t u t e . co m /a i r m - m a g a z i n e

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Events & Exhibitions – Calendar National and International Event

Venue

Date

Website

Assetmanagement for critical infrastructure 2019

Swissotel, Sydney

20-21 August 2019

www.assetmanagementevent.com.au

Rio Pipeline

Rio de Janeiro, Brazil

3-5 September 2019

www.riopipeline.com.br

2nd Edition of Indian Oil & Gas Chemistry, Chemicals and Additives Conference

Ahmedabad, India

16-17 September

www.oilfieldchemical.org

Gastech

Houston, US

2019 17-19 September

www.gastechevent.com

2019 IPLOCA 2019 The Annual IPLOCA Convention

Bangkok, Thailand

30 Sept.-4 Oct. 2019

www.iploca.com

Offshore Energy Exhibition and Conference

Amsterdam, Netherlands 7-9 October 2019

www.offshore-energy.biz

6th Annual Asset Integrity And Total Maintenance Summit

London, United Kingdom

17-18 October 2019

www.opex-aim.com

Offshore Technology Conference (OTC)

Rio de Janeiro, Brazil

29-31 October 2019

www.otcbrasil.org

Pipeline Leadership Conference

Houston, US

6 - 7 November 2019

www.plconference.com

2nd International Conference & Exhibition on “Protective Coatings & Surface Treatment”

New Delhi

18-19 November 2019

www.industrialcoating.in

3rd “Water Treatment & Management New Delhi (WTM 2019)” Conference

13-14 December 2019

www.industrialwatermanagement.in

32nd International Pipeline Pigging and Integrity Management Conference and Exhibition(PPIM2020)

Houston, US

17-20 February 2020

www.clarion.org/ppim/ppim20

6th International Conference on Pipeline Integrity Management

Mumbai

6-7 Feb 2020

www.pipelineintegritymanagement.in

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Magnetic Analysis Corporation Elmsford, NY, USA. www.mac-ndt.com Official Representatives in India

Inmar Engineering Services Pvt. Ltd. Mumbai inmarengineering@gmail.com / inmarengineering@inmargroup.in Tel: +91-22-24096170 / +91 9892100864