- Table of Contents
1/ Calibration is the key to successful in-line diagnostics.
The essence of this stage is to determine the minimum cross-sectional area of the inspected pipeline section by passing a caliber pig through it.
The main functions and purpose
of caliber pigs:
► Pipeline cleaning: Caliber pigs help to remove deposits such as wax formations, rust, dirt and other contaminants from the pipeline system that can impede the normal flow of the pipeline (oil, gas, water, etc.). This is important to maintain optimum performance and prevent blockages.
► Checking pipeline diameter and shape: They allow calibration by checking whether the internal diameter of the pipe has changed and detecting deformations such as dents, stretches, constrictions and other anomalies that may occur over time due to external influences or wear and tear.
► Prevent sediment buildup: Regular cleaning with the pigs will prevent the pipeline from becoming clogged with sediment and contaminants, helping to maintain optimum flow capacity and reduce the risk of breakdowns.
How do caliber scrapers work?
There are several steps in the process of using the caliber pigs:
► Preparation for cleaning: Before using the pigs, the pipeline is cleaned of large contaminants. This is important so that the pig can pass through the pipe unobstructed and perform its task effectively.
Inserting the pig into the pipeline: The caliber pig is placed into the pipeline where it can be moved using pressure or a special device to propel it.
► Cleaning and measuring: As the pig moves through the pipe, its brushes or other elements clean the inside surface and a metal plate detects any deviations in diameter or damage.
Advantages of using caliber scrapers
► Maintaining optimal performance:
Regular use of the pigs helps to keep the pipeline in good condition, preventing the accumulation of contaminants and improving the flow of substances.
► Ease of use:
Pigs are easy to insert into the pipeline and can operate effectively in a variety of conditions, making them suitable for use in all types of pipeline systems.
► Saving on repairs
Regular cleaning and calibration with the pigs avoids large expenditures on major repairs or replacement of pipelines.
► Increased safety:
Cleaning pipelines of accumulated deposits and identifying potential defects increases the overall safety of system operation.
- Operating characteristics:Diameter of calibration disks: 0.85 and 0.9 outside diameter of the pipeline
Minimum turning radius of the pipeline: 1.5 pipe outside diameter
Minimum passable diameter: 0.7 pipe outside diameter
Operating speed range: 0.5 - 4 m/s
Maximum medium pressure: 12 MPa
2/ The oil and gas pipeline cleaning procedure is an integral part of pipeline system maintenance
Why is oil and gas pipeline cleaning necessary?
► Pipeline cleaning: Caliber pigs help to remove deposits such as wax formations, rust, dirt and other contaminants from the pipeline system that can impede the normal flow of the pipeline (oil, gas, water, etc.). This is important to maintain optimum performance and prevent blockages.
► Checking pipeline diameter and shape: They allow calibration by checking whether the internal diameter of the pipe has changed and detecting deformations such as dents, stretches, constrictions and other anomalies that may occur over time due to external influences or wear and tear.
► Prevent sediment buildup: Regular cleaning with the pigs will prevent the pipeline from becoming clogged with sediment and contaminants, helping to maintain optimum flow capacity and reduce the risk of breakdowns.
How do caliber scrapers work?
There are several steps in the process of using the caliber pigs:
► Preparation for cleaning: Before using the pigs, the pipeline is cleaned of large contaminants. This is important so that the pig can pass through the pipe unobstructed and perform its task effectively.
Inserting the pig into the pipeline: The caliber pig is placed into the pipeline where it can be moved using pressure or a special device to propel it.
► Cleaning and measuring: As the pig moves through the pipe, its brushes or other elements clean the inside surface and a metal plate detects any deviations in diameter or damage.
Why is oil and gas pipeline cleaning necessary?
► Maintaining optimal flow capacity:
Clogs and deposits in pipes can significantly reduce the flow capacity of the pipeline, resulting in reduced efficiency of the entire system. Cleaning eliminates these problems.
► Prevent corrosion and damage:
Deposits such as water, paraffin, soot and other substances can accelerate corrosion processes. Cleaning helps extend the life of pipelines and prevent damage.
► Improved safety:
Clogs and accumulated deposits can lead to internal pressure and rupture of the pipeline. Cleaning prevents these risks, increasing operational safety.
► Improved quality of transported substances:
Particularly important for oil and gas pipelines, where accumulated sediments can contaminate oil or gas, reducing its quality and potentially affecting further processing.
► Reduced energy costs:
When a pipeline becomes clogged, the resistance to flow increases, requiring more energy to pump. Cleaning helps reduce these additional costs.
- Operating characteristics:Minimum pipeline turning radius:
1.5 outside diameter of the pipeline (for equipment with a diameter of 200-550 mm)
2.5 outside diameter of the pipeline (for equipment over 550 mm diameter)
Minimum passable diameter: 0.85 pipe outside diameter
Operating speed range: 0.5 - 4 m/s
Optimum travel speed: 2 - 3 m/s
Maximum medium pressure: 12 MPa
3/ Profilimetry - the key to successful diagnosis
With Profilimer, we offer services to identify, localize and assess the size of dents, ovals, corrugations and constrictions that result from external mechanical impacts, as well as changes caused by ground movement in pipeline locations.
► In addition, the curvature of the pipeline centerline is monitored to determine the parameters and location of areas with steep bends that may prevent magnetic flaw detectors from passing through. The parameters of bends, oblique joints and elastic-plastic bends of pipes are also checked.
► Cross-sectional shape inspection is performed by measuring the internal diameter of the pipe using lever sensors, while simultaneously recording the current distance for accurate positioning of abnormal sections.
► The centerline curvature control is based on the use of an inertial module and an odometer, which measure changes in the orientation of the pipeline centerline while recording the current distance.
The data obtained in the process of profilemetry allows to identify defects in pipe geometry and make a decision on the possibility of their inspection by flaw detectors.
- Operating characteristics:Minimum pipeline turning radius: 1.5 outside diameter of the pipeline
Minimum passable diameter: 0.7 pipe outside diameter
Operating speed range: 0.5 - 4.0 m/sec.
Optimum travel speed: 2.0 - 3.0 m/sec.
Maximum medium pressure: 12 MPa”
4/ In-line longitudinal magnetization diagnostics (MFL)
*corrosion defects (general corrosion, cavern, ulcer, transverse groove)
*mechanical defects of transverse orientation
*transverse metallurgical defects
*transverse stress-corrosion cracks
*defects of annular (assembly) welds.
This method is based on measuring the changes in the magnetic field inside the pipe that occur due to the presence of defects in the metal.
When is an MFL service necessary?
► During routine inspections: To assess the condition of the pipeline and prevent possible accidents or leaks.
► After repair or maintenance: To check the quality of rehabilitated sections and to detect hidden damage.
► Before repairs or upgrades: For detailed diagnostics to determine exactly which sections of the pipelines need repair.
► In case of emergencies: When damage to the pipeline is likely to occur, such as after exposure to external factors or natural disasters.
► For residual life assessment: To understand how long the pipeline can still be safely operated without risk of accidents.
How does it work?
► During the diagnostic process, the pipeline is supplied with a magnetic field and sensors detect variations in the magnetic flux caused by defects such as corrosion or cracks. These variations are analyzed to pinpoint the exact location and type of defect.
► MFL diagnostics is an efficient and cost-effective method for assessing the condition of pipeline systems and ensuring their safe operation.
Benefits of the service to the client:
► Accident prevention:
MFL diagnostics allows timely detection of defects that could lead to leaks, explosions or environmental contamination, which significantly reduces the risk of accidents.
► Saving on repairs and maintenance:
Detecting and localizing defects at an early stage can prevent costly overhauls or complete replacement of pipeline sections.
► Extended pipeline life:
Timely diagnostics helps to promptly repair damage, which helps to extend the service life of the pipeline system.
► Improved safety:
MFL diagnostics ensure that the pipeline is in good condition, reducing the likelihood of catastrophic damage and threats to human life.
► Reduced cost of operation:
Regular diagnostics can reduce overall operating costs by preventing major repairs and accidents.
► Regulatory compliance
In many countries, regular MFL inspections are required to meet safety standards, thus avoiding fines and non-compliance.
- Operating characteristics:Minimum turning radius of the pipeline: 1.5 pipe outside diameter
Minimum passable diameter: 0.7 pipe outside diameter
Operating speed range: 0.5 - 4.0 m/sec.
Optimum travel speed: 2.0 - 3.0 m/sec.
Maximum medium pressure: 12 MPa
5/ Transverse magnetization in-line diagnostics (TFI)
When is a TFI service needed?
► For regular inspections and condition monitoring of pipelines: To detect corrosion, cracks and other defects that may affect the safety and performance of the system.
► For preventive inspections: To prevent accidents and pipeline deterioration, which helps avoid costly repairs and downtime.
► Before and after pipeline reconstruction or modernization: To check the quality of work performed and the condition of the pipeline before or after repair measures.
► In emergency situations: When mechanical damage or corrosion is suspected after natural disasters, earthquakes, earthquake, earth swelling or other factors affecting the pipeline.
► For inspection during the construction or installation phase of pipelines: To confirm the quality of welds and other critical areas of the pipeline.
How does TFI diagnostics work?
► The diagnostic process involves creating a transverse magnetic field that passes through the pipe walls. When defects appear in the pipe metal, this affects the magnetic field. Using special sensors, changes in the magnetic flux are recorded, allowing defects to be accurately localized and their size estimated.
► TFI diagnostics is a reliable and effective way to assess the condition of pipelines, which helps to ensure the long-term and safe operation of systems, preventing accidents and minimizing operational risks.
Benefits to your company:
► High accuracy in defect detection:
TFI diagnostics can accurately detect defects even in complex pipeline sections such as welds or bending points that are difficult to diagnose by other methods.
► Reducing the risk of accidents and leaks:
Prompt defect detection helps prevent accidents, gas or oil leaks, which reduces the risk of environmental disasters and increased remediation costs.
► Saving on pipeline repair and replacement:
Regular use of TFI diagnostics helps detect defects early, preventing the need for expensive overhauls and complete system repairs.
► Extending the life of pipelines:
Continuous monitoring of pipelines with TFI helps in timely repair of defects, which extends the life of the system and reduces the likelihood of pipeline failure.
►Improved safety:
TFI diagnostics help ensure safe pipeline operation by eliminating hazards to workers and the environment, which is especially important for high-hazard facilities.
►Reduced operating costs:
Early diagnosis allows for timely defect repair, which reduces unscheduled repairs, equipment downtime, and emergencies.
► Compliance with regulatory standards:
In many countries, pipeline diagnostics using magnetization techniques (including TFI) is mandatory to meet environmental and technical and economic standards.
- Operating characteristics:Minimum pipeline turning radius: 1.5 outside diameter of the pipeline
Minimum passable diameter: 0.7 pipe outside diameter
Operating speed range: 0.5 - 4.0 m/sec.
Optimum travel speed: 2.0 - 3.0 m/sec.
Maximum medium pressure: 12 MPa”
6/ Intratube ultrasonic diagnostics
Using an ultrasonic sensor, a map of the defect is captured, which allows the most accurate assessment of the hazard level, taking into account its profile.
► Reliable assessment of defects is necessary to ensure the required safety of the pipeline system on the one hand, and on the other hand - to achieve it at minimum labor and material costs. Ultrasonic flaw detector has high accuracy of defects geometric parameters, angular position of features and distance traveled.”
