Exploring the Latest Breakthroughs in Inspection

and Remote Monitoring Techniques

Mahmoud Fathy
Lead Inspection – Asset Integrity
Oman Gas Co. - OQ

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Abstract

The aim of this presentation is to spotlight samples of latest Breakthroughs in Inspection and Remote Monitoring

Techniques for purpose of Corrosion Monitoring, Asset Integrity Management & Operational Effectiveness.

Contents :

- Introduction

1- Computerized & Digital Radiography Applications for Corrosion Monitoring (CUI & Thinning)

2- Installed Inspection Sensors & Cloud Based Software

3- Aerial- Drone Inspection

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Introduction

- Corrosion and erosion cost industries billions of dollars every year in,
“lost production, unplanned downtime, equipment failure, high
maintenance and repair costs.

- It’s estimated that direct annual cost of corrosion is $2.5 trillion

dollars, and represents ~6% of global GDP.

- NACE studies estimate that companies can save between 15% to 35%
of annual corrosion-related costs through optimum corrosion
management practices.

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Introduction

- Conventional inspection “NDT” methods are deployed in order to

measure, map, and monitor corrosion.

- Those inspections create significant cost, can result in downtime,

and present safety risks, especially those that required in
difficult-to-access locations.
In addition, each technology has limitations.

- human factors affect the accuracy and accountability of data for

long-term analyses or corrosion trending.

- Advanced NDT methods & Inspection techniques were

progressively deployed to help in corrosion management with
lower cost, high accuracies, time saving & limited human
interference.

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Introduction

Why Advanced Inspection is vital for Asset Integrity Management

Aging:
• Most assets are aged, “some of which now have been in operation for double the original design life”
• 60% of worlds pipelines are ~40 years old, with an elevated risk of failure
Cost
• Conventional Inspections for corrosion are expensive, require specialized skill sets, and are often
required in difficult-to-access locations
• Corrosion can result in unplanned downtime, maintenance, and costly repairs
Safety
• Dangerous site access “hard-to reach, high & low temperature, confined space entry”
• Hazardous environments: radiation, extreme temperatures, highly combustible gas, toxic or acidic vapor

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 Computerized & Digital Radiography
Applications for Corrosion Monitoring
(CUI & Thinning)

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1- CR & DR Applications for Corrosion Monitoring
(CUI & Thinning)

CUI is a phenomenon that has plagued the Oil, Gas Industry for years
with Billions of dollars spent worldwide due to CUI.

Conventional Method for detecting & monitoring CUI is direct visual

inspection for suspected areas.

Such Visual inspection shall requires Full / partial insulation removal

with the following disadvantages:

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1- CR & DR Applications for Corrosion Monitoring
(CUI & Thinning)

- More effort & manpower are required for insulation removal

- Time consuming process
- Expensive – remove and reinstallation of insulation
- May require additional funds and time for scaffolds
- HSE hazards (i.e Asbestos)
- Have to verify that all insulation repairs are reinstalled properly

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1- CR & DR Applications for Corrosion Monitoring
(CUI & Thinning)

Computed Radiography & Digital Radiography

Computerized Radiography CR Digital Detector Array Radiography DR

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1- CR & DR Applications for Corrosion Monitoring
(CUI & Thinning)
Advantages of CR/DR than Conventional Radiography

- CR uses a Phosphorous Image Plate instead of Conventional Film

- Image Plate is loaded into a laser scanner and translated into digital image
- DR uses Digital Detector to digitize the photon radiation directly through
scintillators into computerized image.
- No chemicals or darkroom needed
- Produces a sharper image than conventional film in less time
- 1-5 minutes for CR & less than a minute in DR VS. 10-20 minutes in traditional
films
- Less radiation energy needed to produce image compared to traditional film
- Images can easily be stored and electronically distributed to others

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1- CR & DR Applications for Corrosion Monitoring
(CUI & Thinning)

CR & DR Profile Radiography for CUI Detection

- Great tool for inspection at suspected areas of CUI
- No insulation removal
- Not only a screening tool but can also produce
accurate measurements of wall loss
- Will result in High Confidence Levels of Inspection

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1- CR & DR Applications for Corrosion Monitoring
(CUI & Thinning)
Advantages:
Conventional Digital
More Vivid / Clearer Image RT

Corrosion

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1- CR & DR Applications for Corrosion Monitoring
(CUI & Thinning)
Advantages: Digital Measuring Tools
- Wall Thickness measuring
- Area measuring ,
- Length measuring

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1- CR & DR Applications for Corrosion Monitoring
(CUI & Thinning)
Advantages:
- Hi Dynamic Range
(No Re shots / Re takes)
- Hi Sharpness / Contrast
- Can Detect internal thinning
(Erosion)
Raw Image

Erosion

Enhanced / Filtered
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1- CR & DR Applications for Corrosion Monitoring
(CUI & Thinning)
Advantages:
- Digital Storage
- Multi purpose inspection in same time (CUI,
internal thinning, Erosion, wall thickness
measuring, gap and spacing measurement,
internal debris.
- Soft annotation

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1- CR & DR Applications for Corrosion Monitoring
(CUI & Thinning)

Some Limitations:
- Large diameter lines are difficult to be handled by CR/DR for CUI
- Lines containing fluids may obscure getting the required image

Conclusion :
- CR/DR Radiography is a very effective mean for
Inspecting CUI
- Eliminating the need to remove insulation
- Saving time and money

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Installed Inspection Sensors & Cloud
Based Software

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2- Installed Inspection Sensors & Cloud Based
Software

- Regularly scheduled inspections are essential for getting corrosion rates

- The number and location of Thickness Monitoring (TMLs) that needs to be tested will depend on
the required confidence we are looking for.
- More locations should be used to monitor higher risk areas, driving cost & inspection time up.

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2- Installed Inspection Sensors & Cloud Based
Software

Traditional ultrasonic inspection is currently the most usable method to

monitor corrosion. This traditional method is having more challenges:

- Measurements are point-in-time, and often infrequent, rather than

continuous, not suitable for short-term corrosion rates

- Trained and certified inspector is required

- Gaining access to the site, including scaffoldings, rope access, excavation,

and insulation removal are time-consuming and expensive

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2- Installed Inspection Sensors & Cloud Based
Software

- Hazardous environments, and access during difficult

conditions

- Location repeatability … ensuring that the exact same spot

on the piping is going to be measured over a period of time

- Performance and accuracy factors: equipment used,

variation on the equipment calibration, surface roughness,
velocity variations, temperature

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2- Installed Inspection Sensors & Cloud Based
Software

Through using installed inspection sensors, we can eliminate most for those
challenges, save time, effort & money.
What is installed sensors & how it works ?
- Ultrasonic installed sensor, applied directly on the pipe and provide 0°
pulse-echo ultrasound measurements of the wall thickness.

- Designed for permanent installation on pipelines and process plants to

provide accurate and repeatable, on-demand wall thickness
measurements.

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2- Installed Inspection Sensors & Cloud Based
Software

Advantages to this type of sensor include:

• Footprint of only 1x1”, meaning a higher density of sensors can be achieved
• Low profile of only 16mm, meaning the sensors can easily be placed under
insulation
• Accuracy measurements of the wall thickness, with a resolution of 0.1 mm or
better.
• Precise measurements can be obtained with a repeatability margin of 0.02 mm.
• Sensors are ATEX certified.
• SolGel Ceramic Technology: Dry coupled, IP67, meaning sensors can be installed
without the need for a couplant.
• Sensors have estimated 15-20 years lifespan without SNR loss, even with
temperature cycles.
• Thermocouples are installed with sensors, meaning each A-scan is paired with a
temperature measurement.
• The sensors are clamped on as a non-intrusive method, no welding is required
to install, hence there is no shut down required.

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2- Installed Inspection Sensors & Cloud Based
Software

Data Collection :

Manually:
Through extending cable & data logger,
makes direct thickness reading using the
sensor.

Automated:
Through connected cables to
instrumentation in field & Field Data Loggers
(FDL) then to software / servers

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2- Installed Inspection Sensors & Cloud Based
Software

Data Collection :

Wireless Communication & Cloud Software:

- Sensors are coupled to gathering device

(Mote gateway), which send data to
Mote Manager.

- Mote Manager can handle up to 100

Motes & send data to a Mini Field Agent
which in turn communicate wirelessly to
the cloud.

- Software will perform analytical

calculations and generate corrosion
rates and thickness trending.

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2- Installed Inspection Sensors & Cloud Based
Software

Where to use / Key Benefits:

- Remote areas, unmanned locations, offshore platforms

- Elevated areas, hard to access location

(No rope access, No Scaffolding)

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2- Installed Inspection Sensors & Cloud Based
Software

Where to use / Key Benefits:

- Buried pipeline/piping sections

(no excavation)

- Critical items in confined space

(No man entry, eliminating hazards)

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2- Installed Inspection Sensors & Cloud Based
Software

Where to use / Key Benefits:

- Under Insulated sections

(no insulation removal)

- Critical areas that require frequent monitoring or accurate

readings
(No human errors, No equipment faults)

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2- Installed Inspection Sensors & Cloud Based
Software
Results from continuous monitoring through installed sensors:

Decrease inspection costs:

25% savings potential for average facility inspection budget
• Via Offsetting points with high cost-of-collection
• Optimize with better decisions from continuous data

Improve asset performance:

15% asset life extension potential, through better maintenance and the identification of equipment that may
need modification to its operating profile or chemical treatments.

Optimize process/operations:
15% improvement in process efficiency
• Extend run-times
• Optimize corrosion inhibition
• Make better decisions through predictive analytics

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Aerial – Drone Inspection

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3- Aerial – Drone Inspection

- Drone Inspection is revolutionary approach for remote-

access inspection, aerial mapping and survey.

- Drone inspections can provide critical inspection

information in a fraction of the time and cost of other
direct-access methodologies, with the added benefit of
removing most of the human risk factors.

- Drone inspections can be performed within most assets

and locations, providing required access for inspection
and monitoring purposes.

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3- Aerial – Drone Inspection

Flare Inspection:
• To perform (Manual) visual inspection of flare, we
require direct access to flare tip which is at very elevated
heights (50-80 Meter)

• Direct visual inspection by inspectors involves total flare

shutdown, enough time to cool down and working on
elevated heights.

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3- Aerial – Drone Inspection

Flare Inspection:
Using Aerial Drone inspection

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3- Aerial – Drone Inspection

Flare Inspection:
Using Aerial Drone inspection

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3- Aerial – Drone Inspection

Flare Inspection:
Using Aerial Drone inspection
Adding Value : Thermal camera

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3- Aerial – Drone Inspection

Using Aerial Drone

Optical Gas Imaging (Fugitive Emission Gas
detection)

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3- Aerial – Drone Inspection

Using Aerial Drone inspection

Pipeline ROW (Right of Way) inspection.
During construction or in-service inspection
- In service ROW inspection can be combined with OGI

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3- Aerial – Drone Inspection

Drone Surveying & Mapping

Help in building & visualizing 3d models of plants &
facilities
(Photos & Laser )

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3- Aerial – Drone Inspection

Benefits:

- Drones Minimize the Obvious Dangers and Health Risks

- Collection of In-Depth and Higher Detail Data
- Flexibility to Suit a Majority of Inspections
- Little to Zero Downtime for Equipment and Systems
- Ability to Inspect Difficult to get to and Hazardous Areas
- Save Time and Money
- Multi inspection methodologies in one go

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 Conclusion

With collaboration of advanced inspections, sensors and

remote monitoring, drone, robotics & cloud-based
technologies; the results utilizing these innovative
technologies are increased safety, increased productivity,
improved data quality, and overall improved asset integrity,
with reduced downtime, cost, and risk.

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Thank You

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