Monitoring of Critical Metallic Assets in Oil and Gas Industry Using Ultrasonic Guided Waves

This chapter presents advancements in structural health monitoring (SHM) using ultrasonic guided waves (UGW) technology for metallic structures to support their integrity and maintenance management. The focus is on pipelines and storage tanks, which are critical assets in the Oil and Gas industry, whose operational conditions can greatly accelerate damage mechanisms. Conventional routine inspections are both costly and time consuming and affect the plant reliability and availability. These operational and economic disadvantages have led to development of SHM systems which can be permanently installed on these critical structures to provide information about developing damage and optimise maintenance planning and ensure structural integrity. These technology advancements enable inspection without interruption to operations, and generate diagnosis and prognosis data for condition-based maintenance, hence increasing safety and operational efficiency. The fundamentals, architecture and development of such SHM systems for pipes and above ground storage tanks are described here

Aboveground Storage Tank Floor Corrosion Condition Assessment

The floors of aboveground storage tanks remaina most difficult part of the vessel to inspect forcorrosion damage. Generally, this section of the tankis inaccessible from the outside for conventionalnondestructive testing (NDT) and the costs ofopening the vessel and preparing it for an internalinspection including cleaning, purging and loss ofproduction availability create a significant financialburden for the tank owner or operator. An advancedNDT method with the capability of assessing thecondition of the tank floor without opening thetank is acoustic emission (AE) monitoring1. The AEmethod requires installation of sensors on the outsidewall of the tank and monitors the floor passively forcorrosion damage and its extreme case of leakingat substantially lower cost. AE monitoring is afront-line inspection method that complements theinternal inspection techniques. When it is integratedas an input to a risk-based maintenance program, itprovides both an enhanced level of tank reliabilityand significant cost savings over time-basedperiodically scheduled internal inspections2,3. Thispaper provides an overview of the AE inspectionmethod as applied to tank-bottom plate conditionassessment, a brief description of its use in a riskbasedmaintenance program including a case studyof the practical use of AE monitoring for tankbottom inspection

Internal in-service inspection of petrochemical storage tank floors to detect underside corrosion with Non-Destructive Testing Robot

This research develops a new robotics technology for the in-service inspection of floor plates of the majority for the world’s petrochemical storage tanks. The new robotic system aims to decrease inspection cost, reduce human inspector exposure to chemical and hazard environment during the inspection and eliminate tank outage entirely if the floor is found to contain no corrosion. The research focus is on the design and development of a Non-Destructive Testing Robot (NDTBOT) prototype that uses active buoyancy control for its locomotion mechanism and uses NDT ultrasound to measure floor plate thickness as an indication of corrosion thinning. The NDTBOT hops from one location of the floor to another location to make ultrasound thickness measurements of a tank floor, thus avoiding issues of motion on a dirty tank floor (due to oil sludge). Also, a novel radio frequency (RF) data communication system is investigated and developed that can operate while submerged in oil. This system allows control commands to be sent to the NDTBOT by an operator outside the tank and NDT data to be recovered for analysis. To evaluate the performance of the NDTBOT making thickness measurement in the tank, three types of measurement techniques were used. First, the real thickness was measured using a Vernier caliper, the second method used a standard hand-held ultrasonic thickness measurement instrument and finally the in-service inspection thickness measurements were made with the NDTBOT operating in a water tank. The NDTBOT thickness measurements with an immersion ultrasound probe obtained more accurate results than hand-held contact ultrasonic testing. Petrochemical storage tank size varies from 20 to 200 meters in diameter, rapid corrosion inspection in such tanks with a swarm of robots requires that a number of NDTBOTs be deployed inside the tank to perform the NDT. Such deployment needs coordination and control work between the robots to send the NDT data to the NDT inspector. Therefore, an investigation and experimental radio frequency wireless transmission is done in order to compare different radio frequency communication. Simulation with commercial software CADFEKO is used to perform simulation of RF wave transmission in petroleum and vegetable oil with selected radio frequencies of 200 MHz, 300 MHz, and 433 MHz. The experimental work and simulation results give confidence. The RF communication in petroleum medium is feasible for both control of NDTBOTs inside the tank and NDT data transmission back to a technician’s console placed outside the tank

Structural Health Monitoring of Pipelines in Radioactive Environments Through Acoustic Sensing and Machine Learning

Structural health monitoring (SHM) comprises multiple methodologies for the detection and characterization of stress, damage, and aberrations in engineering structures and equipment. Although, standard commercial engineering operations may freely adopt new technology into everyday operations, the nuclear industry is slowed down by tight governmental regulations and extremely harsh environments. This work aims to investigate and evaluate different sensor systems for real-time structural health monitoring of piping systems and develop a novel machine learning model to detect anomalies from the sensor data. The novelty of the current work lies in the development of an LSTM-autoencoder neural network to automate anomaly detection on pipelines based on a fiber optic acoustic transducer sensor system. Results show that pipeline events and faults can be detected by the MLM developed, with a high degree of accuracy and low rate of false positives even in a noisy environment near pumps and machinery

Structural Health Monitoring of Large Structures Using Acoustic Emission-Case Histories

Acoustic emission (AE) techniques have successfully been used for assuring the structural integrity of large rocket motorcases since 1963 [...

A Magnetic Flux Leakage and Magnetostrictive Guided Wave Hybrid Transducer for Detecting Bridge Cables

Condition assessment of cables has gained considerable attention for the bridge safety. A magnetic flux leakage and magnetostrictive guided wave hybrid transducer is provided to inspect bridge cables. The similarities and differences between the two methods are investigated. The hybrid transducer for bridge cables consists of an aluminum framework, climbing modules, embedded magnetizers and a ribbon coil. The static axial magnetic field provided by the magnetizers meets the needs of the magnetic flux leakage testing and the magnetostrictive guided wave testing. The magnetizers also provide the attraction for the climbing modules. In the magnetic flux leakage testing for the free length of cable, the coil induces the axial leakage magnetic field. In the magnetostrictive guided wave testing for the anchorage zone, the coil provides a pulse high power variational magnetic field for generating guided waves; the coil induces the magnetic field variation for receiving guided waves. The experimental results show that the transducer with the corresponding inspection system could be applied to detect the broken wires in the free length and in the anchorage zone of bridge cables