Number : PIT 266

Revision : 0
Date : 15-08-2016
Project no. : 1141-108979
Client : PTTGC
Object : 48” Loading line

FINAL REPORT

ULTRASONIC INSPECTION OF THE 48” Loading line

Client : PTTGC Thailand

Applus RTD-project number : 1141-108979

Location : Map Ta Phut Tank Terminal, Rayong, Thailand

Inspected pipeline : Diameter: 48”

Length: 17,746.52 m

Period of inspection : 23rd of June, 2016, until the 5th of July, 2016

Inspection carried out by : Dayshift Nightshift

F. de Gier, D. Carolus,
A. Jain, M. Voogdt,
M. de Ridder, M. Wisse
W. de Waal

Report by : M. Vedder,
M. Wisse

Development - Revisions
Revision No. Prepared By Date Approved By Date Amendment Details

0 J. Mulder 15-08-2016 R. Wevers 15-08-2016 Final report

J. Mulder R. Wevers H.J.E. Cornelissen
PIT Reporting Project Manager Operations Manager
Applus RTD Global Project Services Applus RTD Global Project Services Applus RTD Global Project Services

Date 15-08-2016 Date 15-08-2016 Date 15-08-2016

Address
Delftweg 144, 3046 NC Rotterdam
P.O. Box 10065, 3004 AB Rotterdam
The Netherlands
www.Applus RTD.com

This publication is the intellectual property of Applus RTD and may not be used in whole or in part for any purpose other than the
business of Applus RTD and may not be used for the business of the recipient and may not be passed to any other person without
the permission of Applus RTD.

Applus RTD Nederland is the trading name of Röntgen Technische Dienst bv

If this is a copy, unless otherwise specified, it is uncontrolled. You must verify the revision before use.

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Client : PTTGC
Object : 48” Loading line

CONTENTS

EXECUTIVE SUMMARY 3

1 INTRODUCTION 5

2 THE PIT SYSTEM 6

2.1 General 6
2.2 The PIT Vehicle 6
2.3 PIT control systems 7
2.4 Electronics system 8
2.5 U.T. unit and recording 9
2.6 Ultrasonic transducers 10
2.7 Winch 11
2.8 Pinger unit 12

3 PREPARATIONS 13

4 CALIBRATION 14

5 LOCATION 16
5.1 Location 16
5.2 Parameters 16
5.3 Data collection 16
5.4 Data analysis 16
5.5 Result explanation 18

6 EXPLANATION OF M.A.O.P. CALCULATIONS 20

7 EXPLANATION OF GPS LOCATIONS 21

7.1 General 21
7.2 Results 21
7.3 Accuracy 21

8 RESULT DISCUSSION 22
8.1 General information 22
8.2 Specific information 22

9 CONCLUSION 23

LIST OF ENCLOSURES 24

LIST OF ABBREVIATIONS 25

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Number : PIT 266
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Date : 15-08-2016
Project no. : 1141-108979
Client : PTTGC
Object : 48” Loading line

EXECUTIVE SUMMARY
General;
The actual inspection of the 48” loading line was performed from the 29th of June, 2016 until the 4th of July,
2016.
This pipeline has been previously inspected, in 2009 and 2011. During the inspection in 2011, only the first
3,784.03 m. was inspected to determine the ovality.
During the inspection the pipeline was filled with Crude Oil.
The inside surface of the pipeline was clean, allowing a reliable ultrasonic inspection.
The flange of the existing pipeline at the entrance of the pipeline is the zero point. All axial distance
information is related to this point.
Two 90 degree bends are present at the beginning of the pipeline, but not visible in the inspection data
due to the crude oil level in the pipeline. The first bend is going 90 degrees down and the second bend is
90 degrees back to horizontal and 90 degrees to the right.
The distance covered during this inspection is 17,746.52 m against 19,000 m inspection distance as per
service contract requirement; at this point the tool was not capable to drive forward.
The pipeline is constructed out of longitudinal welded pipe sections.
No indications of internal corrosion were detected in the pipeline.
A total of 3 external wall loss indications were detected in the pipeline.
The ovality present in the first 2.043.62 m of the pipeline is calculated by using the following equation:
(IDmax – IDmin) / (IDmax + IDmin) x 100%.
An overview of the ovality and a comparison can be found in Enclosure 2.0 List of Anomalies.
All features detected during the inspection are listed in Enclosure 2.0 List of Anomalies.
For general details see Enclosure 1.0, the layout of the site and Enclosure 6.0, the system Block Diagram.

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Object : 48” Loading line

Pipeline Inspection Details

Inspection Details
Date of actual inspection: 29th of June, 2016 until the 4th of July, 2016
Diameter of pipeline: 48”
Pipeline material API 5L - X60
Total length of pipeline inspected: 17,746.52 m
Inspection medium: Crude Oil
Average wall thickness: 19.2 mm
Average pipe section length: 12.5 m

Inspection Results
Number of welds: 1,423
Number of external metal loss: 3
Number of internal metal loss: 0
Number of bends: 2
Number of flanges 0
Number of high points 0
Number of low points 7
Ovality (distance) From 85.56 m till 2,044.25 m
Ovality (percentage) From 0.7 % till 6.5%
Number of longitudinal welds around 6 o’clock 0
Number of longitudinal welds with the same 0
clock position in adjacent pipe sections

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Object : 48” Loading line

1 INTRODUCTION

PTTGC decided to have their 48” Loading line inspected with the Applus RTD Pipeline Inspection Tool. The
Applus RTD PIT is an umbilical operated tool with a maximum range of, for this job, 21,000 m.

This tool has several unique features:

Reliable straightforward ultrasonic technique
Ultrasonic inspection gives quantitative results
A cable-controlled tool allows on-line control and instant display of results
All analogue and digital data is recorded, enabling off-line reproduction and evaluation

This report describes:

PIT operation system
Preparation needed for the inspection
Calibration of the UT system
Inspection Approach
Inspection results
Conclusion

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Number : PIT 266
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Object : 48” Loading line

2 THE PIT SYSTEM

2.1 General
The Pipeline Inspection Tool is an umbilical operated system that performs ultrasonic inspections from the
inside of a pipeline. The PIT system is able to detect and quantify internal and external surface defects. If the
internal surface is clean and not (or only slightly) affected by corrosion, the remaining wall thickness can be
measured.
On the internal surface, defects of any depth can be measured.
For remaining wall thickness of external defects, the minimum value that can be measured depends on the
transducers applied and the inner surface condition of the pipeline.
In optimal conditions, the minimum wall thickness that can be measured is 2.6 mm.
The PIT system contains the following items:
The PIT vehicle measurement unit with 32 ultrasonic transducers
21,000 m reinforced optical fiber umbilical cable
Two winches, motor powered
Electronic and ultrasonic system
One computer system with two monitors for ultrasonic settings and measurements, color presentation
and data storage of the inspection results
One computer system for driving and inclination monitoring.
One computer for off-line data analysis
Enclosure 6.0 Block diagram shows an overall view of the PIT inspection system.

2.2 The PIT Vehicle

The PIT vehicle consists of; a rotating transducer head unit, two PIT traction units, an INS unit and two units
containing electronic controls and UT system.

The PIT is driven by the 8 wheels of the traction unit and is electrically powered.
Electric power is supplied to the inspection tool via the umbilical cable.

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Object : 48” Loading line

Typical speed of the system for this job is between 100 and 150 mm/sec (between 360 and 540 m/hr.).
The top wheel of the traction unit is pressed against the pipe inner wall by adjustable air pressure, causing
extra pressure on the traction wheels. This is required to drive the vehicle and to pull the umbilical.
Position and speed are continuously displayed at the PIT Control Unit and the various computers inside the
electronic equipment container. A side wheel connected to the electronic module acts as an odometer.
Proximity switches detect notches machined in the wheel and provide distance pulses, from which the position
and speed of the PIT are determined.
The transducer ring contains the ultrasonic transducers and is mounted at the very front of the vehicle.

2.3 PIT control systems

The PIT Control Unit is used to control and monitor the performance of the PIT vehicle.
Performance and parameter controls are constantly visible on a monitor and show:
PIT Position (cm)
PIT speed (mm/s)
Motor revolutions (RPM)
Motor current (A)
Revolutions of the rotor head (RPM)
Motor current (A) of the rotor head
Inclination uphill/downhill (degrees)
Inclination radial (degrees)
Temperature in all units (̊ C)
Leakage alarms
Pulling force (kg)
Various pressures (bar)

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Object : 48” Loading line

2.4 Electronics system

During the inspection, the above ground electronics were housed in an air-conditioned 20' office container.
The picture below shows the setup of the electronics in the container.

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Object : 48” Loading line

2.5 U.T. unit and recording

The pipeline was inspected with ultrasonic immersion technique. This means that the ultrasonic transducers
do not touch the inner pipe wall and are able to pass dents and other deformations. It also prevents wear and
tear of the transducers itself.
The main item of this part of the system is the multi-channel ultrasonic unit. For each transducer, two
separate measuring gates are assigned.
The ultrasonic system used is elucidated below.
The first measuring gate measures the liquid path (=stand-off) from transducer to the inner pipe wall (A),
allowing the detection of inside surface defects.

The second measuring gate for each transducer is used in the so-called "echo start" technique. (B) This
measuring gate is calibrated in mm steel and is used for measuring the remaining wall thickness.

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2.6 Ultrasonic transducers

The ultrasonic transducers that were used have a single crystal.
For the inspection of this pipeline, the PIT was equipped with 32 transducers. Each transducer has a
frequency of 2.5 MHz, with a crystal diameter of 12.5 mm.
This type of transducers is able to detect internal circular metal loss-type defects of 10.0 mm and larger, no
depth limitations apply.
External circular defects of 3.0 mm and larger can be detected.
The same transducers were used in the so-called "echo start technique" to measure remaining wall thickness.
These transducers are able to reliably determine remaining wall thickness with a minimum of 2.6 mm.
The final performance of the transducer strongly depends on crystal material, acoustic damping and matching,
transducer stand-off, frequency and medium in which the measurement is carried out.

No defect Internal defect External defect

Transducer arrangement and measurement coverage

During the inspection, 32 transducers were mounted in a rotating ring.
Circumferential coverage:
With each revolution of the transducer ring, 960 readings are recorded over the circumference of the pipeline
per transducer.
This means that every 4.0 mm of the circumference, a reading was recorded.
Axial coverage:
Axial coverage is controlled by the revolutions of the transducer ring combined with the axial speed.
Average speed in this line was approximately 500 mm/s.
Axial resolution was approximately 7.5 mm.
Hence, in the circumference as well as in the axial direction ample overlap between measurements has been
achieved.
The transducer arrangement is shown in Enclosure 5.0.

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2.7 Winch
The 2 winches that contain a total of 21,000 m cable are both mounted in a frame with similar dimensions as
a 20' shipping container.
A winch is equipped with an electrical driven motor providing constant and adjustable torque (pulling force)
and speed by means of a remote control unit.

The PIT umbilical cable is specially designed for this purpose.

The main items are:
Kevlar Stress inner core, tensile strength 5,000 kg
Optical fibers for data communication
Copper conductors for power supply to the PIT drive motor and auxiliary equipment

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Object : 48” Loading line

2.8 Pinger unit

The pinger device was mounted on top of the PIT vehicle traction unit. This pinger can be used to locate the
PIT inside the pipeline. A special receiving unit, of which an underwater and land version is available, is
capable to receive the transmitted electromagnetic signals.
If the tool stops unexpectedly or to mark a specific location, this system can be used to locate the position of
the tool.
The pictures below are showing the pinger and receiving units.

A: Underwater Receiver
B: Pinger Unit
C: Land Receiver

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Object : 48” Loading line

3 PREPARATIONS

To get open access to the 48” pipeline, a spool piece was removed from the pipeline and a launch platform
was placed in front of the pipeline. See the illustrations below for details.

A support has been fabricated and placed in front of the pipeline entrance, to support the guiding wheel.
The reference for circumferential locations is transducer no. 1 (12’ o’clock) on the transducer array at the front
of the tool.
All axial distance information of the inspection is recorded from the existing flange (zero point) of the pipeline.

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Object : 48” Loading line

4 CALIBRATION

With the PIT inspection two different types of measurements are carried out at the same time, as explained
earlier in chapter 2.5.
Measurement in liquid, from initial pulse to first echo (= pipe inner wall) gives the internal profile of the pipe.
Measurement in steel from first echo (= pipe inner wall) to the next echo gives the wall thickness.
The calibration was done with immersion technique while the transducer was mounted in a calibration set up
and the tray was filled with crude oil. During the inspection, the pipeline was filled with the same liquid.
The stand-off measurement and the wall thickness measurement were calibrated separately using a special
step wedged calibration block increasing and decreasing in steps of 2.0 mm.
See below for a drawing of the PIT calibration block.
The actual calibration was carried out with one transducer and recorded in the appropriate recorder channel
on the computer. All other channels were programmed identical and all transducers were checked with a
special caliper gauge.

CRUDE OIL

PIT CALIBRATION BLOCK

For calibration of the stand-off distance, the transducer was moved over the calibration-block from B to A and
back to B. This shows the stand-off distance in 2.0 mm steps. For calibration of the wall thickness, the
transducer was moved over the calibration piece from B to C and back to B. This shows the wall thickness in
2.0 mm steps, from 4.0 mm to 20.0 mm.

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Object : 48” Loading line

The below color plot shows an example of the calibration for one transducer as presented on the PIT
computer screen. The calibration for the stand-off, as well as the calibration for the wall thickness
measurements is visualized in this plot.

Inspection gain settings:

During the test run in the actual pipeline, amplifications of each transducer in the transducer array were set
individually by the PIT operator. For this purpose the pipe inner and outer wall echo were used as a reference
to compensate for surface condition and transducer alignment.

Signal Height Threshold Gain

Stand-off echo 10% FSH 100% FSH

Wall thickness echo 10% FSH 100% FSH

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Object : 48” Loading line

5 LOCATION

5.1 Location
The 48” Loading line is located at the Map Ta Phut Tank Terminal, Map Ta Phut, Thailand.
The picture below shows a view of the inspection area.

See Enclosure 1.0 for a layout of the area.

5.2 Parameters
For this inspection the transit distance times for the inner profile were calibrated in mm crude oil.
Sound velocity in Crude Oil is V Crude Oil ≈ 1305 m/s.
The average standoff distance used during the inspection is 82.0 mm.
For the wall thickness measurements, transit distance times were calibrated in mm steel.
Sound velocity in steel is V steel ≈ 5950 m/s.

5.3 Data collection

All inspection data was recorded during the forward and reverse run of the Pipeline Inspection Tool. All
data of the U.T. –unit was stored on the hard disks of the computer.
This kind of data gathering allows detailed expanded views of particular areas of interest, by means of
monitoring and/or printing. It also allows on-site evaluation of the results and a first-hand reporting to the
client.

5.4 Data analysis

5.4.1 Onsite analysis

All recorded data of the pipeline was subject to a quick evaluation in order to check the quality of the data
that was recorded by the PIT system and to produce the site report. The purpose of the site report is to
inform the client of major indications that are visible in the data at first glance. The site report was
presented the day after the inspection and is included in this report; see Enclosure 7.0 Site Report.

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5.4.2 Homebased analyses

All recorded data was evaluated to produce the final report and enclosures.

Internal profile:
Internal profile readings are taken with all transducers.
From the standoff signals the following features can be observed:
Typical signature for the PIT tool passing weld penetrations
Internal corrosion defects
Signal pattern indicating wax layers/dirt
Signal pattern flanges
Signal pattern bends
Signal pattern dents
Signal pattern offtakes
Signal pattern reducers
Signal pattern low points/high points
Signal pattern of longitudinal welds

Wall thickness:
From the wall thickness signals the following features can be observed:
External corrosion defects
Signal pattern mill defects (inclusions, laminations)
Signal pattern external welds (attachments, sleeves, supports)
Actual wall thickness readings for each individual pipe section are taken from the stored computer data and
are available in Enclosure 2.0 List of Anomalies.
It should be noted that any imperfections in the plate material, such as inclusions/laminations, would show up
in the wall thickness measurements. An attempt has been made to discriminate between real metal loss
defects on the external surface and mill defects. Nevertheless, such indications may hamper the detection and
determination of external defects.

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Object : 48” Loading line

5.5 Result explanation

5.5.1 General
The inspection results of the 48” loading pipeline are presented in Enclosure 2.0 List of Anomalies.
The inspection data is also available on DVD Rom and can be visualized with the enclosed PIT-Viewer®
program. An additional manual explains the separate features of this program. The PIT-Viewer® manual is
supplemented with this report.

5.5.2 List of Anomalies

The List of Anomalies, Enclosure 2.0 contains all information of any feature detected during the inspection.
For example: the locations of welds, information regarding corrosion, deformations, inclusions and the
actual wall thickness of each pipe section. For this specific project, every weld has GPS information
(Latitude, Longitude and Altitude).

Part of the List of Anomalies

5.5.3 Graphical displays

With all information available from the collected data, graphical displays were created; see enclosure 3.0.
To present the best overview, the graphical displays show the full length covered by the inspection.
The graphical displays available in this report are:
Graphical display of Feature overview
Actual wall thickness/Location of defects
Percentage Ovality
Severity
MAOP/Calculated Burst Pressure

Example of one of the Graphical displays

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5.5.4 Data Sheets

From specific points of interest data sheets are compiled and presented in this report. See Enclosures 4.0
for the List of Data sheets and Enclosure 4.1 up to 4.3 for the actual data sheet of each point of interest.

5.5.5 Explanation of the result color plots

The top horizontal color area represents the stand-off measurements. To the right of this area, the vertical
color bar represents the stand-off colors with the corresponding stand-off values.
The second horizontal color area illustrates the wall thickness measurements.
To the right, the vertical color bar indicates the wall thickness with the corresponding color.
The bottom area of this color plot can be used for displaying B-Scans of tracks that are marked with the
horizontal cursors.
On the top of the horizontal color bar, distance information (from-to) is available.
On the bottom of the color plot information about the cursor position, transducer number, clock position
and actual SO (Stand-Off) and WT (Wall Thickness) values are displayed.
During inspection we obtained 960 measurements equidistantly divided over the circumference for 100%
coverage of the entire pipeline circumference.

CIRCUMFERENCE, 960 STAND-OFF MEASUREMENT

CURSOR FOR SELECTION OF
B-SCAN
CURSORS FOR SELECTION OF B-SCAN

CIRCUMFERENCE, 960
WALL THICKNESS MEASUREMENT

B-SCAN STAND-OFF

B-SCAN WALL THICKNESS

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Object : 48” Loading line

6 EXPLANATION OF M.A.O.P. CALCULATIONS

A total of 3 metal loss indications are detected in the pipeline, the calculation of the MAOP has been carried
out using ASME B31 G-2009 (original approach) with maximum depth and maximum length of each defect as
parameter.
The following general parameters, received from PTTGC, for this pipeline were used for the assessment:
Diameter : 48”
Pipe material : API 5L - X60
Yield strength : 60,000 Psi
Used design pressure (Pd) : 1,375 bar
Estimated Repair Factor (ERF) = Used design pressure/MAOP
The cross section of missing metal/corrosion has been modeled as: 2/3Ld - parabolic area approach for ASME
B31G Original (L= length and d = max. depth of corrosion)
For the purpose of the calculations, Applus RTD corrosion depth measurement resolution of 0.1 mm has been
extended to 0.5 mm and added to all maximum corrosion depth values in the defect set analyzed. This allows
performing calculations and assessment with conservative assumption of maximum corrosion depths. For each
defect, the actual wall thickness as close to the defect area as possible was used.
The design pressure can be calculated with the following formula:
Pd = 2t/D* SMYS* Fd
Pd : Local design pressure
t : Wall thickness most frequently measured in the line
D : Nominal outer diameter
SMYS : Specified minimum yield strength for the pipe steel
Fd : Design factor, for this case 0.72

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7 EXPLANATION OF GPS LOCATIONS

7.1 General
During the inspection an INS unit was attached to the inspection tool.
The INS unit recorded the tool movement through the pipeline. With the recorded data, GPS locations are
added to the features in the pipeline.

7.2 Results
The result of the GPS data acquisition is presented in the List of Anomalies. The latitude, longitude and the
altitude is provided for each weld.

7.3 Accuracy
The provided GPS locations are best estimates.
The final accuracy of the GPS locations is determined by the distance travelled and the provided GPS positions
of the start and end location.
The accuracy will increase with the accuracy of the start and end locations.

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8 RESULT DISCUSSION

8.1 General information

The actual inspection of the 48” Loading line was performed from the 29th of June, 2016 until the 4th of July,
2016.
During the inspection the pipeline was filled with Crude Oil.
The zero point for this inspection is the flange at the entrance of the pipeline.
The distance covered during this inspection is 17,746.52 m against 19,000 m inspection distance as per
service contract requirement; at this point the tool was not capable to drive forward.
The 48” pipeline is constructed out of longitudinal welded pipe sections.
The pipeline material is API 5L - X60.
The average pipe length is 12.49 m.
The actual wall thickness for the pipe sections is 19.2 mm.

8.2 Specific information

There were no pipe sections detected where the longitudinal weld is present at the bottom area,
between 5 and 7 o’clock.
There are 2 bends present in the pipeline immediately at the starting point of the inspection. The bends
are not visible in the inspection data due to the liquid level in the pipeline. The first bend is 90 degrees
downwards and the second bend is 90 degrees back to horizontal and 90 degrees to the right.
A total of 3 external metal loss indications are detected in the pipeline. The deepest metal loss is at
4,923.89 m with a depth of 2.2 mm and a RWT of 16.8 mm. This metal loss indication has been
detected during the 2009 inspection as well, which was below the reporting threshold.
No internal defects have been detected in the pipeline.
The worst ovality calculated is at 85.56 m with a percentage of 6.5%. An overview of the ovality and a
comparison between the 2016, 2011 and 2009 inspections can be found in Enclosure 2.0 List of
Anomalies.
A wheel has been detected in the pipeline, located at 6,496.27 m.
Seven “Low points” are present in the pipeline (trace of heavier liquid).
All recorded GPS information was implemented in the List of Anomalies.

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9 CONCLUSION

The 48” Loading line was clean enough to produce reliable inspection results.

During analysis 3 external metal loss indications have been detected.

No internal metal loss is present in the pipeline.

Ovality is present in this pipeline over the first 2,044.25 m.

Recommendations:
To monitor the condition and ovality of this pipeline, Applus RTD recommends performing a re- inspection
within 5 years’ time.

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LIST OF ENCLOSURES

1.0 General layout of the area

1.1 2016-266-001 Layout of inspection site
2.0 List of Anomalies
3.0 Graphs, General
4.0 List of Data sheets
4.1 Data sheet 1 - Ovality
4.2 Data sheet 2 – External metal loss
4.3 Data sheet 3 – Most severe ovality
5.0 2016-266-002 Transducer Arrangement
6.0 2016-266-003 Block Diagram
7.0 Site Report PTTGC 2016

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LIST OF ABBREVIATIONS

A : Electrical current
API : American Petroleum Institute
ASME : American Society of Mechanical Engineers
BP : Burst Pressure
CD : Compact Disc
dB : Decibel
DVD : Digital Video Disc
FSH : Full Screen Height
LCD : Liquid Crystal Display
LoA : List of Anomalies
MAOP : Maximum Allowable Operating Pressure
m : Meter
mm : Millimeter
MHz : Megahertz
m/sec : Meter per second
mm/sec : Millimeter per second
PCU : Pit Control Unit
PIT : Pipeline Inspection Tool
PLEM : Pipeline End Manifold
PSI : Pound per square inch
RiserPIT : Riser Pipeline inspection Tool
RPM : Revolutions per Minute
RWT : Remaining Wall Thickness
SF : Safety Factor
SO : Stand Off
V : Sound velocity
WT : Wall Thickness
UT : Ultrasonic Technique
˚C : Degrees Celsius

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