pipeline inspection - The Hydrographic Society UK

PIPELINE INSPECTION
Clive Anderson
Stolt Offshore
1
Agenda:
•Why Inspect
•Regulations
•The IMR Cycle
•What is a pipeline
•Inspection Methods
•Data Acquisition
•Data Processing
•Reporting
•The Future
•Conclusions
•Questions
The agenda for today’s presentation.
2
Why
Inspect ?
•This is the famous pipeline inspection expert Sherlock Holmes checking a
marble pillar for signs of corrosion!
•Notice his dress, this is what passed for PPE in Victorian times!
3
Why Inspect?
•Car = Major asset, £10K’s
•You want to keep it in condition
•Retains value & operates well
•Maintenance = servicing
•Inspection = MOT
•MOTè Fit for purpose
•MOTè Road Tax & Insurance
If not maintained it’s:
•Unreliable
•Not fit for purpose
•Fails the MOT
•Worth nothing
•Costs you money
•SORN & £1000 fine
•Delays you: walk or bus.
•Society (Government) recognises that cars must be fit for purpose &
drivers have duty of care to the public
•Hence there are Acts & Statutory Instruments to ensure this happens.
•For cars this means: MOT, Insurance & Road Tax.
4
Why Inspect?:
Huge downside if not in good condition:
•Major Asset worth £10 - £100M’s
•Contents may stop flowing or leak out!
•Owners have a vested interest to...
–Environmental clean up
–Maintain pipeline in efficient condition.
–Business Interruption
–Duty of care: environment & marine users
–X £1M’s DTI / HSE Fines
•It will retain it’s value, less depreciation
–X £10M’s lost production - daily
•Sold on to next field owner / operator
–X £???M’s Law suits, Litigation
•Just like you & your car
•Pipeline operator has a vested interest in keeping the line in good
condition.
•If the don’t the contents may stop flowing or even leek out!
•Just as the government has lawful MOT regulations for cars.
•So they have lawful regulations - statutory instruments - for pipelines.
•The MOT is actually the “Fitness for Purpose Assessment”, the FPA
5
Regulations
To ensure pipelines are maintained:
•Pipelines Safety Regulations, 1996.
=Statutory Instrument 1996/825
–Obligatory to keep lines in good condition.
–Must Inspect, Maintain & R epair.
–“ Fit for
Purpose Assessment” = MOT
–The pipeline is then insurable
–Just like your car
•The Ten Commandments, an early example of regulations.
•The rules governing inspection are the Pipeline Safety Regulations.
•Compulsory to keep pipelines in good condition.
•You must service them, like your car.
•That is you Inspect, Maintain & Repair them.
•The MOT for pipelines is the Fitness for Purpose Assessment.
6
Pipelines Safety Regulations
Up to 1996:
•
•
•
•
•
•
Various regulations
E.g. SI 1513
Complex
Ambiguous
Prescriptive
Open to interpretation
Post 1996:
• Pipeline Safety Regulations
•
•
•
•
•
= SI 1996 / 825
Aligned with HSWA
Simple
Goal setting: Clause 13
“The operator shall insure that
a pipeline is maintained in an
efficient state, in efficient
working order and in good
repair.”
• PSR facilitated:
– Risk Based Inspection
– Cost savings & efficiency
– Innovative systems
•Up to 1996 there were various regulations including SI 1513.
•They were very prescriptive, open to interpretation and not working well.
•Regulations were revised and consolidated resulting in PSR - SI 1996/825
•Written so that it was aligned with the Health & Safety at Work Act 1974.
•This brought with it a shift from prescriptive to goal setting legislation.
•The crux of the PSR legislation is Clause 13 - a “one-liner”, 21 words.
•The legislation sets goals: I.e. prove the pipeline is in good condition.
•Owners have responsibility to put systems in place to achieve that.
•The new regulations enabled a move to Risk Based Inspection.
•Freed inspection contractors to provide solutions, systems, technology, and
to innovate.
7
ABCDEFGH?JKL?NOPQ?STUVWXYZ
The IMR Cycle
•
•
•
RBI
IMR (Repair)
IMR (Routine)
8
•RBI: Risk Based Inspection
•
An inspection regime such that you are confident the asset will be
in the same condition at the next inspection interval.
•
Permits flexibility & efficiency, cost effective solutions.
•
Allocate inspection effort where it is most effective & required.
•
Explore alternative survey methods / strategies
•
Permits new technology & innovation
•
Customised IMR for each asset.
•
Based on risk assessment, trend analysis & experience
•This is one definition of a Risk Based Inspection - quite succinct, good.
•The move to RBI, facilitated by the Pipeline Safety Regulations 1996, was
liberating.
•It allowed the Operators, Integrity Managers and the survey / inspection
contractors to develop suitable, cost effective & efficient, techniques and
systems.
•Importantly:- a Customised Inspection & Maintenance Routine means you
don’t have to inspect every component of the asset infrastructure every time.
9
IMR: Inspection & Maintenance Routine.
Customised for each “asset”
Sets out for each asset:
•
Cover asset infrastructure:
-
Wellheads
Platforms
Risers
SSIV’s
Pipelines
Umbilicals
Cables
Landfalls
•Risks & probability
•Pipeline anomaly criteria
•
•
Links & nodes
Surface & subsea
•Types of inspection (Controls)
+ Recommended:
•Interval - each inspection type
•Interval - each asset component
= planned inspection schedule.
They can be revised:
•Through trend analysis.
•Life cycle: new - mature - old
(dead or even re-incarnated!)
•Change of use
•IMR = document, customised for each particular asset.
•Describes all the infrastructure of an asset
•Notice - logical sets of structures - logical to use different inspection
techniques.
•To create the IMR each component of the asset is risk assessed.
•Maximum conditions are set above which they are anomalous.
•The IMR is designed, based on:
-RBI philosophy
-Engineering - predicted deterioration of components
-Experience & Common sense.
10
Operators:
•Accountable
•PSR Clause 13
•Manage Budget
•£££’s & ITT
PSR
RBI
FPA
ir
pa
Re
Ma
int
en
an
ce
Inspection
Maintenance
& Repair
Inspection
Integrity Management Consultants:
•Analysis & Assessment
•Recommendations
•Fit for Purpose?
Survey & Inspection Contractors:
•Gather data
•Report
•Solution providers
Visual representation of how regulations & parties involved in IMR interact.
•Survey & Inspection Contractors survey & report pipeline conditions.
•Reporting according to condition & anomaly limits: anomalies.
•IMC’s assess the results & advise on pipeline condition.
•They issue the “Fitness for Purpose Assessment”
•Operators are accountable for pipeline integrity per Clause 13 of PSR 1996.
•Operators manage the cycle in the light of the recommendations.
•They set budgets for Inspection and invite bids to conduct Maintenance &
Repair work as it is needed.
•Finally, we need someone to police the whole system and that is……
•The Health & Safety Executive inspectors = Traffic Warden.
•Seen here slapping an improvement notice on an Oil Exec’s car.
•Their experts will visit & audit IMC’s & operators and audit FPA’s.
•If they find things are not in order, they will issue an Improvement Notice.
•And they keep everyone on their ………..Toes.
•This is a closed loop - epitomises much of what happens in IMR.
•It is commonly called the IMR cycle
11
THE IMR CYCLE
Maintenance
& Repair
Maintenance
& Repair
Year 1
Anomalies
Start
IMR
Schedule
Assess
Report
GI
Year 1
Anomalies
Workscope
Inspection
Review
Schedule
Assess
Report
GI
Year 2
Inspection
Anomalies &
Monitor Items
Data
Workscope
Data
Year on Year: GI Survey
2 Year Inspection Cycle - GI
•Consult the IMR
•Develop workscope, conduct inspection, acquire data.
•Assess data onboard the vessel.
•Determine anomalies (damage & conditions which threaten integrity)
•Report from the vessel (7 - 14 days)
•IMC’s then assess the data & make recommendations
•= Closed cycle
•Information from year 1 is carried into Year 2
•IMR Schedule plus year 1 findings determine Year 2 workscope.
•Reviewed & adjusted by IMC’s / Operators.
•Survey & Inspect - gather data.
•Determine anomalies & monitor items
•Monitor items = anomalies that are no longer anomalous but need
monitored
•Report from the vessel (7 - 14 days)
•IMC’s then assess the data & make recommendations
•= Closed cycle
12
THE IMR CYCLE
Maintenance
& Repair
Maintenance
& Repair
Year 1 GI
Anomalies
Start
IMR
Schedule
Assess
Report
GI
Year 1
Anomalies
Workscope
Inspection
Review
Schedule
Assess
Report
GVI
Year 1
Inspection
Anomalies &
Monitor Items
Data
Workscope
Data
1 Year Cycle: GI then GVI Survey
1 Year Inspection Cycle - 2 Surveys, GI & GVI.
•Consult the IMR for GVI inspection requirements
•IMR Schedule plus year 1 GI findings determine year 1 GVI workscope.
•Written by inspection contractor.
•Reviewed & adjusted by IMC’s / Operators.
•Survey & Inspect - gather data.
•Assess data onboard the vessel.
•Determine anomalies & monitor items
•Report from the vessel (7 - 14 days)
•IMC’s then assess the data & make recommendations
•= Closed cycle
•Build up database of pipeline conditions that are assessed.
•Subsequent inspections: planned based on IMR schedule & historic data
13
Day 1
Day 2
Day 3
Day 4
Day 5
Day 6
Day 7
Day 8
Day 9
Day 10
Day 11
Day 12
Day 13
Day 14
Day 15
Day 16
Day 17
Day 18
Day 19
Day 20
Day 21
Day 22
Day 23
Day 24
Day 25
Day 26
Day 27
Day 28
Day 29
Day 30
Day 31
Day 32
Day 33
Day 34
Day 35
There are various cycles & feedback loops in the IMR cycle:
•Yearly
–By Inspection type
–Between inspection types.
When you are out inspecting, there is the daily cycle.
Which looks like this.
14
On Groundhog Day the people of Seaway Petrel consult Punxsutawney.
If he sees a shadow that means another 2 weeks of survey……………….
•= Groundhog day.
•Inspection can be a little bit repetitive………..
•But, inspection being inspection, there is always something that comes
along that is interesting.
15
UXO
•This certainly broke the daily cycle!
•This is a “UXO” anomaly, an unexploded object.
•A 3000 pound air dropped mine.
•Dropped sometime in the 1960’s.
•When we find one of these we:
–DO NOT touch it…..!
–Photograph it.
–Call the Royal Navy bomb squad.
–Make it stable - if it isn’t - we sand bagged this one.
–Stay on site until Navy or a guard boat comes out.
–If we’re lucky we see the explosion.
•There are some more UXO slides later.
•Other interesting thingss:
–Usually find 1 or 2 of towed sidescan & pinger fish each year.
–A coffin - assumed a burial at sea.
–Plenty of marine life: lobsters, big monkfish etc.
16
What is a Pipeline?
In its simplest form a pipeline comprises:
• Risers
• Spoolpiece
• Sealines
• Landfall
There are analogies to human anatomy:
• Pumping oil = heart
• SSIV = valves
• Pipeline = arteries
• Umbilicals = nerves
– electro - hydraulic umbilcals
– fibre optic cables (optical nerve)
•The oilfield is not dissimilar to the human body
•It’s lifeblood is the flow of oil and / or gas through pipelines.
•Burst or clogged arteries are unhealthy as are burst or clogged pipelines.
•An SSIV is a subsea isolation valve, an automatic stop valve.
•They were made compulsory after Piper Alpha, 6/7/88.
•167 people lost their lives then.
•There is no better reason than that to inspect, maintain & repair.
•Safety is paramount.
17
Riser:
Connects platform
to sealine via a
spoolpiece
Sealine (purple):
The export pipeline connects riser /
spoolpiece to processing facilities ashore
Landfall:
The part of the
export pipeline in
the inshore zone
•Here is a diagram of a very simple pipeline system.
•It shows the 3 main sections of a pipeline.
•In reality oil & gas infrastructure is much more complex.
•“Pipeline” is a misnomer, we inspect linear & point features of
infrastructure.
•There are many different types of point and linear features.
18
RISERS
Risers can degrade rapidly due to
•
•
•
•
•
•
Instability
Current
Wave Action
Corrosion - electrical & chemical
Wave Action / Movement
Impact
Inspection options:
•
•
•
•
Above sea level - RATS
Splash Zone - RATS / divers
Subsea - DP Vessel & ROV’s
Subsea - Platform based ROV’s
•The pipeline is at its most vulnerable in the splash zone.
•Subjected to alternative wet & dry cycles at different intervals.
•Tidal cycle (12 hour - diurnal) and wave cycle (seconds).
•Above the splash zone it is impacted by salty air.
•And also subjected to sunlight & temperature cycles & wind action.
•Which are the enemies of paint and the allies of corrosion.
•Riser is very susceptible to impact by supply vessel.
We also see the Rope Access Technicians at work.
•They inspect, clean, repair, maintain and lift heavy objects
•Usually to be found swinging from platforms or vertical cliff faces.
•It must be great when your job is your hobby!
•RAT inspection & intervention teams are an innovation:
–Safer than scaffolding - offshore scaffold operations are very dangerous.
–Quicker, more efficient
–They can get into places scaffolding can’t
–Cost effective solution.
19
SEALINES
North Sea:
• 20,000+km “pipeline”
• = Linear features
- Pipelines: gas & oil & water
- Umbilicals - electric, hydraulic,
chemical elements.
- Cables - electrical & fibre optic
- Multifunction pipeline bundles
At risk from:
• Anchors & Trawl gear
• Instability
• Current & Wave Action
• Corrosion - electrical & chemical
• Upheaval Buckling (expansion)
• Munitions
Survey Platforms:
– Vessel, usually “DP”
– Plus ROV’s
– Eyeball & Workclass
Main Types of Inspection :
• GI = Acoustic sensors
• GVI = Visual sensors
•There are thousands of km’s of pipeline in the north sea.
•Carry varying products, including water - injected for enhanced recovery.
•Some are still operating, efficiently & safely, beyond original lifecycle.
•Some 30+ years old, still operating due to over-engineering & good IMR.
•These are the main risks to which they are exposed.
•Unlike a car, you can’t wheel pipelines into a garage for inspection / MOT.
•You have to go out & look at them somehow.
•You need survey & sensor platforms: vessels & remotely operated vehicles.
•Usually the vessel will have “DP” capability, I.e. Dynamic Positioning.
•This permits “follow-sub” mode: I.e. “station-keeping” on the moving
ROV.
•It also facilitates a means of positioning the ROV.
•Sensors are mounted on the ROV which substitute for your eyes and ears.
•Knowing vessel & ROV position & attitude lets you position the sensors.
•Sensor data is then “added” to give you positioned pipeline condition data.
20
LANDFALLS
•
•
•
=
TOB to @ 3km offshore.
Through the inter-tidal zone.
Buried, rock-dumped or in conduit.
Protected
At Risk From
• Anchors & Trawl gear
• Munitions
• Very Strong Currents
• Wave Action - to seabed
• Erosion / Deposition
• Beach activities
• Corrosion - chemical & electrical
Survey Platform:
– Shank’s Pony
– Inshore survey vessel
Sensors:
• RTK back pack
• Radio-detection tools
• Innovation:- Divining rods
• RTK, SVS, SBP, SSS
• Divers, Mini ROV
• CP (Trailing wire / snake)
•This is a professional landfall survey team, working very hard.
•PPE = work boots & sun-block!
•A pleasant way to spend a month in summer.
•Landfall is often defined as from top of beach to @ 3km offshore.
•The 3km offshore is not a hard and fast rule.
•In the southern north sea it’s the sort of safe distance that you can
comfortably bring a large vessel into the beach.
•Given that you are going to do an inshore survey with a suitable inshore
vessel then why risk the large offshore vessel to unnecessary risk, hence
3km.
•In some places a large vessel can get within 10’s of metres of the shoreline.
21
•Inshore, the effects of tidal forces are amplified by shallow water effects.
•Strong currents, erosion & deposition, long shore drift, high energy zone.
•Shallow water means waves impact on seabed: churning it up.
•It is not unusual to see 2 metres of seabed erosion between yearly surveys.
•Various cycles: diurnal tides, seasonal - winter storms, yearly.
•Currents: example here of Bacton, this shows 1.2ms = 2.3 knots.
•They can be a lot stronger than that, e.g Shetland - 7 knots in places.
•Surveyed once a year.
•What would you find if you:
–Monitored daily?
–Or before & after a storm.
–What impact will coastal defence policies have on east coast landfalls?
22
•A few examples of pipeline landfalls.
•LHS: landfall somewhere sunny, a perfect survey / inspection location.
•Top & Middle RHS: Landfall Shetland.
•We use divers at these locations due to local seabed topography & kelp.
•Acoustic methods can’t get through the kelp.
•Bottom RHS: Landfall somewhere with no Working at Height policy.
•You would not get away with this in the north sea = safety is paramount!
23
Survey / Inspection Methods
•This was probably taken in the 19th century sometime, somewhere.
•Maybe on the railroads in the wild west of America.
•The clothes may look daft to us but it is obvious that they are wearing work
clothes fit for their activity, I.e. PPE, good for them.
•The instrument on the left is an astroblade.
•Today that would be an intergalactic, in line, roller skates or a rocket
powered skateboard.
•The tripod, table & telescope on the right is what was called a “Plane
Table”.
•Based on tacheometry, it is a fast method for conducting detailed survey.
•The present day equivalent would be the Total Station or RTK backpack.
•In the next few slides we’ll look at the main inspection modes: GI & GVI.
• GI = General Imaging = side scan sonar, acoustic inspection
•GVI = General Visual Imaging = cameras = visual inspection
•Plus the types of sensors utilised for each type of survey
24
Inspection Methods
Inspection
Survey Platform
Type / Method
Component
Notes / Restrictions
RATS
Platform based
Visual - cameras
NDT techniques
Riser
Down to splash zone
Weather
Diver
Platform or
DP vessel based
Visual - cameras
NDT techniques
Riser
Pipeline
Point structures
Landfalls
Landfall GI
Inshore survey vessel
Hull mounted
Accoustic
Depth, Current
Weather, Sea state
HSE
Inshore only
Pipelines
CP snake
Weather, tides
Seastate @ 1m
Fishing gear
Oil platform or
DP survey vessel
3 X Eyeball ROV’s
Visual – cameras
NDT techniques
FMD
Legs
Structural members
Weather
Sea state @ 2m
Risers
Current, Visibility
Pipeline GI
Survey vessel
ROTV
Towed SSS
Accoustic
Pipelines
Seafloor structures only
Cannot stop
Structures
Current restrictions
Seastate @ 2m
DP survey vessel
WROV
DP follow sub
Riser
Current restrictions
Pipeline GVI
Visual – cameras
CP
Pipeline
Structures
Visibility
Seastate @ 4.5 – 5 m
Structural GVI
This table summarises the common types of survey we have conducted
historically.
•GI = General Imaging inspection = side scan sonar
•GVI = General Visual imaging = cameras
•NDT = Non Destructive Testing
•FMD = Flooded Member Detection
•CP = Cathodic Protection:
–A zinc anode is attached to the structure.
–It corrodes = oxidation, loss of electrodes = sacrificial anode.
–Structure protected by small electric current.
–CP inspection tool is basically a current meter.
–Proximity & contact tools determine milli-volts
–Determines the status of the CP system: is it working
Certain methods require a vessel with Dynamic Positioning capability:
•To keep station next to structures or relatively over a moving vehicle
•To position the subsea survey platform (ROV / Diver) & sensors
25
Inspection Methods
SENSOR PLATFORMS
INSPECTION TYPE
GI
GVI
Combined
Platform:
ROTV
OBS ROV
WROV
Survey Vessel:
ü
Accoustic only
Visual
r
ü
üü
Sensors:
DP
ü
ü
Visual &
Accoustic
DGPS
ü
ü plus XP
ü plus XP
Poor tracking
Seapath
r
Gyrocompass
ü
MRU
r
ü
ü
ü
ü
ü
ü
WROV
WROV
OBS ROV
OBS ROV
Sensor Platforms:
ROTV
Historically - single mode GI or GVI inspection cruises:
•GI - Spring - general inspection X sidescan
•GVI - Summer - detailed inspection X camera
Fast ROV “GI”:
•Facilitated by WROV & DP vessel combination
•Increased SSS target accuracy < +/- 5m
•Can stop & conduct GVI on detected damage
•Can intervene if necessary
•Multi-tasked cruises with GI & GVI capability
Fluxgate compass
ü
ü
ü
Bathy
r/ü
ü
ü
ü
ü
ü
ü
ü
ü
Gyrocompass
r
r
MRU
r
r
SSS
ü
r
OAS
r
r
Altimeter
r/ü
r/ü
ü
Cameras
r
1 maybe 2
3+
Lighting
r
ü
Scanning Profilers
r
r
ü
ü
Swathe Bathy /
Profiling
r
r
ü
CP Contact
r
CP Continuous
r
ü
ü
ü
ü
Overside
N/A
ROV mounted
r
1-limited
2-multi
function
Responder
CTD
Manipulators
•GI: towed SSS survey, fish or ROTV, low tech, DP not necessary.
–Fast method of amassing general information about pipeline condition.
–Looking for spans, exposures, movement, large anomalies / damage.
–No detail on localised anomalies: cracks, bare metal
–Conducted at start of year - results used to plan GVI workscope.
•GVI: ROV sensor platform positioned by HiPAP / transponder system.
–Visual camera inspection plus accoustic sensors.
–Looking for detailed damage to pipelines & structures.
–Conducted in summer using information from the GI.
•The advent of fast ROV’s, Solo I & Solo II, along with custom built ROV
survey vessels led to the fast ROV GI survey: speeds up to 8 km/hour.
–Importantly, the ROV / DP vessel combination lets you slow down & stop.
–I.e. you can conduct both inspection types on the same cruise.
–As long as you carry the correct sensors.
–Surveys have started to merge into combination GI / GVI inspections.
–Though still generally planned as GI & GVI.
26
SURVEY PLATFORMS
Seaway Petrel - Hi-Tech
RRS Ernest Shackleton
Humber Surveyor
Old Survey Vessel
“Survey Platform” = what you deploy your Sensor Platform from = vessel
Seaway Petrel:
MV Humber Surveyor:
•State of the art ROVSV, built 2003.
•Originally Firth of Forth Passenger Ferry
•Dual Independent HiPAP 500 DP
•Catamaran - operated by ABP
•Fast RO: GI at @ 8kmh.
•Humber Estuary Survey vessel
•Solo II survey WROV
•Utilised for inshore survey - landfalls
•Internal ROV hangar
•Hull mounted sensors
•Custom built Hydrolift launch facility
•Also carries Eyeball ROV
•Operations in sea state of 4.5m+
RRS Ernest Shackleton:
Old Survey Vessel:
•Antarctic Research Vessel
•Converted fishing vessel.
•Ice breaker
•ROTV survey vessel
•2005 GI / GVI cruise platform
•Superceded by FAST ROV solution
27
SENSOR PLATFORMS
Solo II WROV New Tech.
SeaEye Lynx
Solo II WROV New Tech.
ROTV - Old Tech.
“Sensor platforms” = vehicle you deploy your sensors on..
Solo 2 WROV:
Solo 2 Workclass Survey ROV:
•Stolt Offshore
•Good view of camera booms
•Custom built GI & GVI fast WROV
•EM3000 mounts
•Weighs @ 6 tonnes
•Stills cameras.
•GI speed to @ 8kmh
•Obstacle avoidance sonar
•Inspection & Intervention capability.
•Camera booms, cameras & lights
•No manipulators - not installed.
Lynx:
ROTV:
•Observation ROV
•Steerable frame with SSS transducers
•1 forward looking camera
•Superceded by Fast WROV solution
•Probably another camera on it.
•Using Seaway Petrel & Solo II.
•Manipulator - limited intervention
28
Combination GI / GVI Inspection Spread
Solo II Sensors:
•Responder - position via HiPAP
•Gyrocompass - heading
•MRU - pitch & roll
•Bathy Unit - depth below sea level
•Altimeter - height over seabed
•Pipetracker - track pipe & DOB
•Profilers / Swathe - cross profiles
•CP - Field gradient & potential
•GI SSS Systems - accoustic
•GVI Camera Systems - visual
•This is now the combination of survey & sensor platforms we conduct
inspection with, whether for GI or GVI.
•Someone, somewhere, at sometime during the survey is going to ask us to
undertake GI when we are conducting GVI or vice versa.
•So we equip the vessel & ROV to accommodate both modes.
29
Petrel Online Survey
Petrel Online ROV
•This is the online ROV & Survey room on the Seaway Petrel
•The ROVERS always get the plushest chairs.
•A busy place when inspecting
LHS: Online ROV:
•L to R:
•Co-pilot, pilot, inspection engineer seats.
•ROV systems PC’s & monitors
–Power management
–System status, power, thrust etc.
•Video: 2 X 3 VCR banks - hot swap
•Pipe-tracker control
•Obstacle Avoidance Sonar (OAS)
•ROV camera monitors
RHS: Online survey station:
•DGPS:
–GPS receivers, Multifix 4
–Decoders / demodulators
•NaviPac: positioning
•NaviScan: sensor data logging
•Helmsmans PC
•PC’s & surface control units for:
–Profiler, E.g. TriTech
–Swathe. E.g. EM3000
–Bathy / Altimeter
–Coda
–Analogue & digital video control
–Video encoders - digital video
•ROV camera monitors: port, centre, starboard
30
Data Acquisition
The future of acquisition & processing?
31
Acquisition
Process
• Log sensor data
• Log position & attitude data
•
Event & QC data (SSS / Video)
•
•
•
•
•
•
•
•
•
•
•
•
•
•
•
Capture anomaly images
Smooth position & bathy
Smooth & event X-profiles
Smooth long profiles
Smooth & event pipetracker
Apply tides
Merge events & position
QC events
Export PRISM Files
QC PRISM Files
Assign anomalies
Assign monitor items
Export Report Data
Collate Reports
IDC of Reports
System
= Network – NAS / RAID Unix
= NaviPac / NaviScan - Unix Servers
= SSS – Coda
= Video – Seamap / Visualsoft
= Image grabs - Offline
= Seamap – Offline
= Seamap – Offline
= Seamap – Offline
= Seamap – Offline
= Seamap / PolPred - Offline
= Seamap – Offline
= Seamap – Offline
= Seamap – Offline
= PRISM – Offline
= PRISM – Offline
= PRISM – Offline
= PRISM - Offline
= Word – Offline
= C.Doc, onshore
=
Acquisition
=
Processing & Interpretation
=
Reporting
First part of a process:
•
•
•
•
•
Acquisition
Processing
Interpretation
Assessment
Reporting
Acquisition is the first part of a sequence of parallel and sequential
processes that form the A-P-I-A-R .
This table is a simplified version of the sequence.
32
Acquisition - Sensors
Basics (very):
• Transducers = underwater speakers & microphones.
•
•
•
Sound pulses emitted, reflected & multiple return pulses timed.
2 way travel time & speed of sound in water known.
Distances to reflectors calculated:- sets of data points.
•
•
•
Referenced to sensor electrical centre
Sensors referenced on survey platforms via offsets
Vessel (DGPS) & ROV (HiPAP) position known
+
=
=
Platform attitude: heading & orientation data
Geospatial data set referenced by time (GPS 1 PPS signal)
Fixed in XYZ framework: geodetic reference system
•
•
•
Echo-sounder
Side Scan Sonar
Sub-Bottom Profiler
•
•
•
Scanning Sonars
Scanning Profilers
Multibeam-swathe bathy
•
Multibeam-profilers
Towed SSS
Hull mounted
Echo-sounder
Swathe bathy
Towed SBP
These are the basics of acoustic inspection detection / positioning in none
too technical terms.
The import points are that:
•sensors collect discreet patterns of points / data
•These can be positioned, absolutely, through positioning of sensors &
survey platforms.
•As long as they are synchronised.
33
Acquisition - Position Determination
Platform /System / Sensor
Survey Vessel
DGPS Systems
1. GPS Antenna Position
+ Vessel Gyrocompass
+ MRU5
+
Vessel offsets
2. HiPAP CRP position
+ Vessel Gyrocompass
+ MRU5
+ HiPAP 500 range, vertical
& horizontal angles
ROV
3. ROV responder position
+ ROV Gyrocompass
+ ROV MRU5
+ ROV Offsets to survey
sensors (SSS)
4. ROV Sensor positions
+ ROV Gyrocompass
+ SSS Altimeter
+ SSS slant target ranges
Measures:
=
Determines:
XYZ position
= 1. GPS antenna position
= Vessel bearing
= Vessel pitch & roll
= XYZ separation
GPS Ae. – HiPAP CRP
= 2. HiPAP CRP position
= Vessel bearing
= Vessel pitch & roll
= XYZ separation
HiPAP CRP – responder
= 3. ROV position
(Responder)
= ROV bearing
= ROV pitch & roll
= XYZ separation
ROV - ROV sensors
=
=
=
Bearing to SSS target
SSS – seabed height
SSS – target slant range
Origin for HiPAP
XYZ measurement
The common link to
position ROV sensors
= 4. ROV Sensor positions
(SSS Port / Starboard)
The common link to
position SSS targets
= 5. SSS target positions
This is a more quantitative & qualitative version of the previous slide.
The point is that everything must be linked:
•Physically
•By time synchronisation
•By measurement
If this is in place the system becomes automated and massive data sets can
be recorded.
If you don’t achieve this, or miss something the data can be useless.
34
Acquisition: Position & Sensor Data
CODA Waterfall
Displays
ROV
SSS
Trigger
VGA
Port
SIU4
I/FBox
Vessel
Sensors
Vessel
Position
Heading
Pitch & Roll
HiPAP XYZ
Position
Easting /
Northing
Offsets
CTD
Trigger
Starboard
ROV
Sensors
Starboard
Port
Digital
SSS
Data
Ultra 120
Thermal Printer
SSS
Data
Depth,
Altitude
Heading
Pitch & Roll
Annotation
Online CODA
Fix, position, KP, time, gyro,
depth, altitude, pitch & roll
Log CODA Data
Online NaviPac / Naviscan
Log Data NaviPac / NaviScan
Original Logged Data: SSS (Coda), Position & Sensor (ROV / Vessel)
Network / Server:
Working files: Coda Tag (Event) Files, Seamap, PRISM Files, Import / Export
This is a schematic diagram showing the acquisition of data & information
during GI SSS inspection.
There are 2 elements of the system:
•Positioning & attitude data
•Sensor data
All acquired raw data is logged on networked mass data storage (NAS /
RAID) and backed up to tape.
35
Data
Processing
This is what you can end up with if you don’t get data processing right!
36
Processing
Original Logged Data: SSS (Coda), Position & Sensor (ROV / Vessel)
Network / Server:
Working files: Coda Tag (Event) Files, Seamap, PRISM Files, Import / Export
CODA Event Tag Files
Offline
Eventing
Offline
Event QC
Seamap
Processing
Import
Tag Files
Smooth Nav.
Apply Tides
Import Coda
Event File
CODA
(Geophysicists)
Seamap Processing
Merge CODA
Nav & bathy
Export
Event File
QC
Event File
SEAMAP (PolPred)
(Senior Data Processor)
SSS Image
Capture
SEAMAP
(Senior Surveyor)
Assign
MI No's.
Export PRISM File
PRISM File
C/W Anom & MI's
Geophysicists
Seamap Processing
MI
List
Anom Span Span
List
Anoms List
Condition
Summaries
Reports Co-ordinator
QC
PRISM Files
Senior Surveyor
Aquisition
Summaries
Collate
Asset Reports
Asset
Reports
Asset
Reports
APA
PRISM
Files
Determine
MI's
PRISM Files,
Images & Reports
Reports Co-ordinator
Onshore
Customer
Comment
Assign
Anomalies
IDC
Span
Analysis
Assessed
Anomalies & MI's
QC'd
Assessments
APA Onshore
QC'd
PRISM
Clean
DataSet
PRISM
Files
PRISM Network
Once the data is logged it has to be processed.
This involves:
•Eventing: SSS data & video data.
–Done digitally
–Data is replayed and the records are marked with electronic event tags.
•Smoothing of ROV position data
•Smoothing & eventing of X-profile data (GVI)
•Apply tides & smooth depth data (bathy / altimeter)
•Merge data sets by time stamp / event:
–Events
–Position
–X-profiles
–Bathy
•This is done using copies of the raw data, never work on original data.
•Raw data is regularly backed up to tape or other mass storage medium.
37
Step Process / Description
LF
From
SSS Data Eventing
1
Completed Tag / event Coda files
Log file
Geo's
2
QC Coda Tag / event files
1
SGeo
3
Merge QC'd Coda Tag / Events files
2
SGeo
4
Transfer QC'd Coda Tag / Events files
3
SGeo
Nav Data Processing
5
Smooth Position
Log file
SDP
6
Smooth bathy
Log file
SDP
7
Create tide files
Create file
SS
8
Apply tides
7
SDP
Coda Data Merge / Event QC
9
Import Coda Tag / event files
4
SDP
10
Merge Coda with smoothed Nav. & bathy
9
SDP
11
Export Seamap event file
10
SDP
12
QC Seamap event file
11
SS
Assign Anomalies & MI's
13
Determine all anomalous events (excluding spans)
12
SS
14
Span list to APA (all spans)
13
SS
15
Anomalous span list from APA
14
APA
16
Assign anomaly No's to events & spans
15
SS
17
Anomaly list to APA & SGeo (numbered, with spans)
16
SS
18
Determine MI's (numbered), List from APA
17
APA
19
Add MI numbers & details to Seamap Event file
18
SS
PRISM Export & QC
20
Export PRISM files
19
SDP
21
QC (1st pass) PRISM files
20
SDP
22
Amend Seamap events & re-export PRISM file
21
SS / SDP
23
QC PRISM File: PRISM & Excel QC
22
RC
24
Amend PRISM file per results of Excel QC
23
RC / SDP
Compile 2005 GI PRISM Dataset
25
Capture SSS anomaly images
17
SGeo
26
SSS anomaly images to image directory
25
SGeo
27
Generate PRISM anomaly file (Anom's & MI's)
19
SDP
28
Cross check PRISM files / dataset for completeness
27
RC
Collate 2005 GI Asset Reports
29
KP Limits / work completed tables
CSA
SS / SGeo
30
Asset condition & anomaly summaries.
CSA
SGeo
31
Data acquisition summaries
CSA
SS
32
Weather Log
CSA
Sec
33
Results (Anomaly & MI tables) section 4
CSA
RC
34
Write, edit & check asset report
29 – 33
RC
Asset Report Check & Transmittal
35
1st Pass QC check asset reports
34
WSR
36
Apply report corrections
35
RC
37
Email QC'd asset report to onshore co-ordinator
35
RC
38
Email QC'd PRISM data to onshore co-ordinator
28
RC
To
Timescale
SGeo
----SDP
ASAP
ASAP
ASAP
12 hours
----SDP
---
ASAP
ASAP
ASAP
12 hours
----SS
---
1 hour
1 hour
1 hour
2 hours
--APA
SS
--APA & SGeo
SS
SDP
2 hours
1 hour
1 hour
2 hours
1 hour
24 hours
3 hours
----RC
--RC
1 hour
Instant
2 hours
1 hour
2 hours
RC
RC
RC
---
Ongoing
Ongoing
1 hour
2 hours
RC
RC
RC
RC
RC
RC
24 hours
24 hours
24 hours
24 hours
7 days
7 days
RC
RC
RC Onshore
RC Onshore
12 hours
12 hours
Instant
Instant
•This does not have to be read in detail.
•This is a SSS survey internal deliverables process list
•There are 38 internal deliverable in this list.
•It’s here to indicate why:
–Everything must be time-synchronised.
–The survey process must have structure.
–Everyone involved must be very clear of their deliverables
–Everyone must know where & who they are getting data from
–Everyone must know where & who they sending their data to.
•This is all set out in the procedures.
38
Reporting
These are the reports co-ordinators.
39
Reporting - Deliverables
Deadlines:
•
Anomalies threatening integrity: immediate
•
Significant features - 24hrs - daily call
From asset completion:
•
•
–
Anomalies - 7 days
Survey report - 4 weeks, including:
PRISM Files
–
–
“Complete” Reports
“Single Pager”
To achieve these goals the reporting process must:
•
•
•
Automate repetitive tasks
Be fully auditable
Be systematic - no repetition
•
•
Conduct QA & QC
Have a clearly defined structure from the start
•Any pipeline condition that may have an immediate threat on asset
integrity must be reported immediately.
•Every day there is a daily conference call - ship to shore - to discuss the last
24 hours summary findings (after safety issues discussed).
•We work to a 4 week deliverables schedule for reporting: I.e. for delivering
a final, QC’d, collated report & QC’d PRISM files.
•The acquisition, processing & interpretation process delivers listings at an
early stage in the sequence. Because of this we provide simple listings as
early as we can. Hence the 7 day anomaly deliverable.
40
PRISM - Pipelines
•PRISM files are the main deliverable.
•PRISM = Pipeline Reporting Inspection System Multimedia.
•It is an interactive computer graphic representation of the pipeline.
•Evented pipeline conditions are indicated by suitable symbols.
•(Looks like some creative eventing here - fish, seahorse, toucan)
•An anomalous event is indicated by a red number.
•A monitor item is indicated by a negative - blue number.
•PRISM contains all of the pertinent data from the inspection.
•The slide shows the PRISM pipeline data sheet.
•Linked to the pipeline data are:
–Anomaly reports
–Inspection datasheets
–Profiles: long profiles & individual X profiles
–Photographs
–FHR’s - First hand reports
–Images: side scan data & video images.
–SSS & Video clipes
•PRISM is a database with flexible user defined reporting.
41
PRISM - Anomalies
•This is an example of anomaly data available through the pipeline data
sheet
•RHS: Pictures of the anomaly
•LHS: Engineering assessment of the anomaly with recommendations.
42
PRISM - Self Configurable Reports
•PRISM is very flexible in its reporting output.
•The report control box - RHS is used to configure reports.
•KP limits to narrow the search / report
•Can look at:
–1 pipeline, 1 year
–1 pipeline, many years
–Multiple pipelines
–Select individual data: anomaly types / conditions
43
PRISM - Position Comparisons
•This is a PRISM pipeline plan position screen.
•The graphic shows 3 sequential years pipeline data.
44
PRISM - Structures
•This is the PRISM structural data sheet.
•Structural anomalies are represented on drawings by numbered hot spots.
•A linked set of drawings at various scales & component levels allows you
to drill down into more & more detail.
•Linked with the anomaly hot spots are anomaly datasheets, reports, pictures
etc.
45
PRISM Structures - Drill Down
•Example of the 1st level of drill down.
•The red numbers are the hot spots where you drill down further.
•Diagrams plus data boxes at the bottom of the screen.
46
DV SDLT
Tape Drive
Eyeball ROV
Camera
Video Overlay In
VisualSoft
DVR
VisualSoft Offline
Archive
DV SDLT
Tape Drive
CP to Video
Eyeball ROV
Gyro, Bathy/Alt,
Camera, CP
ROV Monitor
Port
ROV Monitor
Centre
ROV Monitor
S'board
Digiboard
Video out
From Workclass ROV
Camera's (direct)
Port
Centre
Starboard
Starboard
Video overlay in
Centre
Port
VisualSoft Offline
Review
DV RAID
Port Video
Digital Video
1GB Switch
Eyeball video
Online
Video - Starboard
COE PC
(Video Grabb)
COE PC
Offshore Manager
Communications
Bridge
OffshoreManager
Client Office
Online
Solo I
Eyeball
Offline
Clearcomms
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Microphine
Centre
DVD Writer
Eyeball ROV
PC
Internal Phone
Yes
Yes
Yes
Yes
Yes
Yes
Yes
VSAT
Optional
Yes
Yes
Yes
(Share)
---Yes
Port
CP to Video
Quad Camera Monitors:
(3 Solo & 1 Eyeball Camera's)
Bridge, Offline, Client Office,
Offshore Manager
UHF
Existing
---Yes
-------------
Starboard
Centre Video Starboard Video
VisualSoft Online
Port Camera
UPS
Key
Systems
VisualSoft Online VisualSoft Online
Centre Camera Starboard Camera
Online Video
1GB Switch
Portable USB
Storage (X 4)
Video
Control
NaviPac
Telegram
KVM
Video - Centre
3 Way Switch
Mouse
Keyboard
COE PC
Client
Video - Port
COE PC
Sec. / MSO
Printer
Single Sheet
Scanner
Video
Control
Client Office - Fax
COE NAS Box
CP from Solo I
DP / Video Review
Printer
Keyboard
COE Server
Mouse
COE PC Online
(Surv Tech - APA / CP)
Multi-feed
Scanner
Spare UNIX server
Senior Surveyor
COE PC
COE PC
COE PC
COE PC
Offline (DP / Spare) Offline (Tech Rep.) Offline (Insp Eng)
Survey
1GB Switch
CODA
1GB SWITCH
Senior DP
CP Contractor PC
Online
CP from Eyeball
Photocopier
Video
Control
Survey
1GB Switch
Coda Waterfall Displays:
Online, Offline, Solo I,
Client Office,
Offshore Manager
APA PC
Online
Printer
Keyboard
Mouse
Main UNIX server
NaviPac
Telegram
UPS
Key
Systems
Survey RAID
Survey SDLT
Tape Drive
Survey Container
CODA Offline
PI No.2
CODA Offline
PI No.1
Coda DA
Online (Spare)
Coda DA
Online
Ultra
Thermal
Printer
From ROV
SSS Transducers
Via Ethernet Bottle
Wet / Dry Lab's
Solo I Control
Client Office
Obs ROV Control
Offshore Manager
COE PC
Online
UPS
Key
Systems
Helmsman
Online
Helmsmans Displays:
Bridge: Fore & Aft,
Online, Offline, Solo I,
Eyeball, Client Office,
Offshore Manager
(VGA via CAT5)
Ultra
Thermal
Printer
NaviScan
Online
NaviPac
Online
Digiboards
Digiboard
Solo ROV
Gyro, MRU, Bathy/Alt,
Pipetracker, Profilers,
EM3000, CP
3 X DGPS, HiPAP,
Seapath, Gyro,
MRU, 1-PPS, CTD
•We have looked at data acquisition, processing and reporting.
•This is the survey spread for the combined 2005 GI / GVI Cruise.
•It is a schematic diagram of the systems required for:
–Data acquisition
–Interpretation & processing
–Reporting:
•Survey Platform: RRS Ernest Shackleton
•Sensor Platforms: WROV = Solo II & Lynx.
•120 days multi-function operations including:
–GI pipeline inspection
–GVI pipeline inspection
–CP Inspection
–Seabed structures spot dives
–Platform & riser inspection
–Platform 500m zone debris surveys
–Pipeline route corridor surveys
–Out of straightness survey
47
Some
Examples:
•Anomalies
•Data
C/O
The Reporters
No comment!
48
Sonar Image Pipeline Movement
•Sonar image - pipeline movement.
•Pipes can move by the action of currents
•They also expand & contract - moving much like a snake.
•The ridges are where sediment has built up beside the pipe before it has
moved.
Note:
•displaced & intact stabilisation - mattresses.
•Fully exposed V buried pipeline
49
Processed Position Pipeline Movement
•This is the plotted position of the pipeline in the last sonar image.
•The top line is the original position of the pipeline “as-laid”
•The bottom line is where it has moved to.
•This was quite an impressive example of movement & the operator took
immediate action to conduct remedial stabilisation work on the line.
50
A sample digital SSS image.
A & D shadows of where pipeline enters the structure - not anomalous.
B - pipeline
C - some snatch on the record - where there has been some pull on the fish
or survey platform.
51
Sonar Image Upheaval Buckle
•This upheaval buckle was detected during a GI - acoustic SSS survey.
•This is classic SSS image of an upheaval buckle - it pokes you in the eye.
•It screams “anomaly” - we were ecstatic when we discovered it.
•As the GI survey platforms were DP survey Vessel & WROV it was
possible to stop and conduct GVI - visual inspection.
•The client took immediate remedial action - rock dumping.
52
GVI of Upheaval Buckle:
Top left:
ROV on seabed
Looking under pipeline.
Estimated height 4 metres.
•These are video grabs of the same upheaval buckle.
•Based on GI & GVI inspection & first hand reporting the client was able to
take immediate action to remedy this anomaly.
53
Port, centre & starboard & suitable lighting & suitable camera angles.
E.g. Where there are spans you would back light with 1 camera to silhouette
the bottom of the pipe - cameras pointing inwards..
E.g. Movement - you would position cameras to look ahead to see sediment
ridge build up - this can be 2 to 3 metres away from the pipe & you may
miss it on if cameras are looking inward.
54
Cross Profiling
Where a pipe is layed in a trench you may have to raise the profilers to see
over the spoil heap to the natural seabed.
55
CP Inspection Data
•This is a sample of CP data.
•It’s a black art.
•It’s obvious where the CP (Cathodic Protection) anomalies are though.
•CP values: contact & continuous are available in the CP data box on the
PRISM pipeline data sheets.
56
Examples of damage:
•Top left: pipeline slipping through weightcoat.
•Top right: anchor damage - 20” pipeline, dragged 450 metres offline.
•Bottom left: anchor under 4 inch line - resulted in immediate remedial
action.
•Weightcoat loss around joint / weld - monitor.
57
•Close up of UXO shown earlier - air dropped mine.
•The tether is the silk parachute cord.
58
•And again, same UXO.
59
•Another UXO.
•Which ones the bomb & which ones the pipeline?
•Answer on last slide plus one!
60
•Close up of the last UXO c/w scale - 10 centimetre divisions..
61
(Back to) The Future
•
PRISM on Internet (rolled out 2004)
•
Live data to client PC via internet - video & SSS?
•
Digital cameras to supercede analogue - when?
•
= Another magnitude of data storage?
•
Laser profilers?
•
Move full reporting process onshore?
•
Get rid of paper report?
•
Greater emphasis on data rather than report.
•
Digital cameras & software: new imaging techniques
•
AUV’s for GI survey?
•
Coastal defense policy - consequences of erosion?
•
Intelligent infrastructure: build in inspection?
62
Conclusions
•
Pipeline inspection is a mature business but
continues to embrace new technology.
•
Management of change: adapting to new systems.
•
Digital age has almost eclipsed the analogue age.
•
Days of pure GI / GVI cruises gone: the multi task GI
/ GVI cruise is here.
•
Client (in the office) is getting closer & closer to live
raw data.
•
Control of multiple surveys through one contractor
produces consistent results
•
Inspection / survey must be fun!
63
? NSPECT ? ON,
MA ?
NTENANCE
& REPA ? R
•To continue on the “Catchphrase” / pictorial pun theme.
•Here is the last offering.
•= “We are the eyes in Inspection, Maintenance and Repair.”
64
No difficult
ones!
Any
Questions????????????????????????????????????????????????????????
65