New Transverse Flux Technology

For
On-Line Inspection

Chris F Yoxall
General Manager
ROSEN Australia Pty Ltd
A ROSEN Group Company
(Inspection services for pipelines and hydrocarbon production facilities)



Traditional inspection technology for On-Line Inspection of Pipelines has
difficulties detecting narrow longitudinal shaped defects. These types of
defects are usually too narrow to be detected by normal Ultrasonic
Technology or by Magnetic Flux Leakage Technology.

ROSEN has developed Transverse Flux Technology and this induces the
magnetic field in transverse direction, perpendicular to the longitudinal axis of
the pipeline.

Narrowly shaped longitudinal type defects are now clearly detected and can
be sized accurately.

This development is a step closer to the ultimate ability to detect and size all
possible pipeline defects economically.

ROSEN 16inch size (AFD) Axial Flaw Detection tool.




New Transverse Flux Technology
For
On-Line Inspection


Table of contents

1 Introduction

2 Which defects can hardly be detected presently and threaten the
pipeline integrity

3 Why can these longitudinally shaped defects not be detected by
traditional Ultrasonic technology or by Magnetic Flux Leakage
technology

4 Explain the virtues of the new Transverse Magnetic Flux Leakage
technology

5 Inspection results of ROSEN Axial Flaw Detection (AFD) tool

6 Conclusion





By Chris F Yoxall
General Manager
ROSEN Australia Pty Ltd
(A ROSEN group company)

At the occasion of the
Australia Pipeline Industry Association Convention

New Transverse Flux Technology For On-Line Inspection

1. Introduction

Traditional inspection technology for On-Line Inspection of Pipelines has
difficulties detecting narrow longitudinal shaped defects. These types of
defects are usually too narrow to be detected by normal Ultrasonic
Technology or by Magnetic Flux Leakage Technology.

This new Transverse Flux Technology induces the magnetic field in
transverse direction, perpendicular to the longitudinal axis of the pipeline.
Narrowly shaped longitudinal type defects are now clearly detected and can
be sized accurately.

The development of Transverse Flux Technology is a step closer to the
ultimate ability to detect and size all possible pipeline defects economically.
ROSEN applied Transverse Flux Technology commercially with great success
and we want to share this information as follows:

Which defects can hardly be detected presently and threaten the pipeline
integrity.

Why can these longitudinally shaped defects not be detected by traditional
Ultrasonic technology or by Magnetic Flux Leakage technology.

Explain the virtues of the new Transverse Magnetic Flux Leakage
technology.

Share the inspection results using our new Axial Flaw Detection (AFD)
tool.

Conclusions.
New Transverse Flux Technology For On-Line Inspection

2. Which defects can hardly be detected presently and
threaten the pipeline integrity

The type of defects consist of:
Long axial defects
Longitudinal seam weld defects
Cracks
Any of these longitudinal defects are particularly a threat to the integrity of the
pipeline for two reasons: they are in longitudinal direction and they are long.

The hoop stress in the pipeline wall is twice the longitudinal stress due to
internal pressure (neglecting external loads).

The full thickness pipe wall material around shorter corroded defects
compensate for the localized metal loss. This effect limits the risk of pipe wall
failure to a workable level.

Longer defects lack that compensating effect and the risk of pipe wall rupture
increases to beyond acceptable levels. Pipe wall rupture is usually the failure.
Pipe rupture has a very dangerous propagating effect in gas lines
particularly.


New Transverse Flux Technology For On-Line Inspection

2. Which defects can hardly be detected presently and
threaten the pipeline integrity (Continued)

Long axial defects

Examples of presently known long axial defects are so called channel type
corrosion and faulty coating application type corrosion.

Channel type corrosion is internal pipe wall surface corrosion in the bottom
part of the pipeline typically caused by aggressive components in liquid
pipelines operating at low flow velocity (< 0.8meters per second / < 3feet per
second).

Under these conditions, corrosion may generate long and narrow channels
along the internal surface of the 6 oclock position in the pipe bottom. These
can be as long as 3 meters and as narrow as 3 5 millimeters.

NOTE
Terminology on pipe wall defects:
Internal pipe wall surface defects
External pipe wall surface defects
Mid wall defects

Channel corrosion can hence be predicted when the conditions are right. It
starts usually at the lower areas just upstream of upwards inclines, exceeding
a 10% clime. Traditional Magnetic Flux Leakage inspection tools can indicate
this phenomenon as they can usually detect the beginning and the end of
these channels. These detected defects combined with the knowledge of the
right ingredients of this phenomenon (being: low flow, aggressive
components and low areas in the topographic profile of the pipeline routing)
can be further investigated by digging up an expected location.

Faulty coating application type corrosion may occur when coating is
wrinkling around the pipe, causing improper bonding. This can cause long and
narrow corrosion along these wrinkles at the external surface of the pipe wall.
These type of defects are usually found when the traditional Magnetic Flux
tool reports external pipe wall surface corrosion at random orientation around.
New Transverse Flux Technology For On-Line Inspection.

2. Which defects can hardly be detected presently and
threaten the pipeline integrity (Continued)

Longitudinal seam weld defects

These defects can be:
Long single defect in the middle of the seam weld
Many short defects near to the seam weld grouped together




Long single weld defects are most probably manufacturers faults that have
slipped through the QC system.

Being subject to pressure and temperature cycles, they may lead ultimately to
pipeline failures.

As such, they must be found and monitored/repaired.
New Transverse Flux Technology For On-Line Inspection

2. Which defects can hardly be detected presently and
threaten the pipeline integrity (Continued)



Improper bonding of the coating in the weld area can cause multiple defects in
the heat-affected zone. It is more often seen when the coating is a tape
wrapping application.
This is a progressing condition and must be found.

Cracks
Cracks are also limited to certain conditions only.
Fatigue cracking in dent areas




Fatigue cracking in corroded areas
Lack of bonding in welds
HIC cracking
SCC related circular or longitudinal cracking

In summary:
Long axial defects
Longitudinal seam weld defects
Cracks
Almost all of the above-mentioned defects can be either predicted or their
existence can be found (but not sized) by traditional inspection methods.
New Transverse Flux Technology For On-Line Inspection

3. Why can these longitudinally shaped defects not be
detected by traditional Ultrasonic technology or by
Magnetic Flux Leakage technology

The pipeline inspection industry has presently two main inspection methods;
Ultrasonic and Magnetic Flux Leakage. Both of these standard methods can
normally not detect defects with a long and narrow shape in longitudinal
direction reliably.

Pipeline inspection tools operating Ultrasonic technology lacks either the
resolution or the sensor diameter is too large to detect very narrow or small
defects. Ultrasonic technology can only be used in slow-speed pipelines
(>1.2meters per second) and in liquid pipelines.

ROSEN uses Magnetic Flux Leakage type technology. This technology is
applicable to all pipeline services without any major limitation. It detects all
defects as long as they generate a disturbance in the longitudinal induced
magnetic field. This is positively the case with defects from pitting corrosion as
small as 3mm of only 10% deep to any corrosions of larger and deeper size.

The reason, why these narrow longitudinal type defects are difficult to detect
with this MFL standard technology, is that the pipeline wall is magnetized in
longitudinal direction. Any defects in the longitudinal direction that are narrow
do not generate sufficient disturbance to the magnetic flux field to be noticed
positively.

This is particularly the case for straight cracks in true longitudinal direction.

As mentioned earlier, channel type corrosion may be concluded from deduced
information on the phenomenon knowledge and detection information.
New Transverse Flux Technology For On-Line Inspection

4. Explain the virtues of the new Transverse Magnetic Flux
Leakage technology

The Transverse Magnetic Flux Leakage technology is based on magnetizing
the pipe wall in circumferential direction rather than in the traditional
longitudinal direction. Narrow defects in longitudinal direction create a very
visible disturbance to the circumferential induced magnetic field. They are
now very easily detected and sized.



As in the longitudinal induced magnetic field tool, it can be seen that the effect
on the magnetic flux disturbance is about three bigger than the actual defect.
It is almost as if the defect is magnified. This is the result of very high
resolution in both directions. Initial development tests indicated the absolute
necessity for very high-resolution type technology.


New Transverse Flux Technology For On-Line Inspection

4. Explain the virtues of the new Transverse Magnetic Flux
Leakage technology (Continued)



Transverse Magnetic Flux Leakage (TMFL) Service is provided by:
Data collection tool (AFD) Axial Flaw Detection
Data processing
Reporting

Specifications data collection tool AFD:
Very high resolution, full 360 degrees circumferential sensor spacing 2.9 mm
(576 sensors for 16inch size tool)
Pipeline Products: Any
Max Pipeline Pressure: 15 MPa
Pipeline Temperature: 0 - 65C
Tool Velocity: 0.5 - 3.0 m/s
Minimum Pipeline Bend Radius: 1.5 D
Wall Thickness (for 16): 4 - 13 mm
Maximum Run time (for 16): 116 h
Maximum Inspection length (for 16): 280 km
Sensitive to find small dents.


Handling specifications for a 16inch size tool:
Tool Length: 2.77 m
Tool Weight: 400 kg
Transport Weight: 1,010 kg.
the circumference of the pipe. Dig up information confirms the wrinkle type
coating defects.

New Transverse Flux Technology For On-Line Inspection

4. Explain the virtues of the new Transverse Magnetic Flux
Leakage technology (Continued)

Data processing and evaluation
Processing and evaluation of recorded data are essential elements for
successful inspection services and require sophisticated software

Basic design requirement:
Inspection services must produce reliable and accurate information about the
defects location, type and size.

Important programs for enhancing the collected data:
(FEM) Finite Element Method calculations
Digital Mock up
New consolidated findings in materials technology

Equally important, it must be designed for possible future developments.

The service cannot yet be called a crack detection service, as we have no
proof presently that it can detect closed cracks reliably but we have
successfully detected cracks with a 0.1millimeter opening. The software is
capable of sizing also closed cracks and we will keep you up to date on the
developments in this field.

Reporting
Minimum detection level for Axial defects:
Length 25mm
Depth 20% of wall thickness
Width 0.1mm
Minimum detection level for other defects:
Pits and general corrosion 20% of wall thickness

(POD) Probability of Detection 90%

Sizing accuracy:
Length +/- 25mm
Depth +/- 15% of wall thickness
Width (narrow defects) +/- 0.2mm
Width (Pits, etc.) +/- 25mm.
New Transverse Flux Technology For On-Line Inspection

4. Explain the virtues of the new Transverse Magnetic Flux
Leakage technology (Continued)

In hard copy and in the client friendly software format of ROSOFT
ROSOFT for AFD is completely compatible and interchangeable with all
inspection services information:

Electronic Geometry Inspection

Corrosion Inspection

XYZ mapping services



New Transverse Flux Technology For On-Line Inspection
5. Inspection results of ROSEN Axial Flaw Detection (AFD)
tool

We have tested our equipment in pull tests and we have performed slightly
under 1,000kms of runs under commercial conditions successfully.

The reason why we were so instantly successful is that there is no significant
change in the inspection tool with the traditional Magnetic Flux Leakage
inspection tool other than the transverse placed magnet unit. This means that
running performance of the tool is similar to the traditional design. These
running conditions are very important for the performance quality of the
inspection. We drew a lot of experience from the 100,000 plus kilometers that
we run with the traditional longitudinal induced magnetic flux tools.

The pull tests are particularly interesting as they were compared with results
by High Resolution Traditional MFL tools.

The following pictures show achieved inspection results:



New Transverse Flux Technology For On-Line Inspection
5. Share the inspection results using our new Axial Flaw
Detection (AFD) tool (Continued)



AFD capability can be included on other inspection service tools (Traditional
MFL and XYZ Mapping Tools)

The decision to combine should be based on careful technical and
commercial considerations. Stand alone AFD service is usually the most
economical and practical solution after earlier inspections.
We have simulated a number of crack type defects, as they are most
interesting to the industry.

The following pages contain pictures of the inspection and sizing results of
those types of defects.

The top picture on each following page shows the line plot of the signal
strengths while the bottom picture is a color representation of the magnetic
flux level behavior.

New Transverse Flux Technology For On-Line Inspection.
5. Share the inspection results using our new Axial Flaw
Detection (AFD) tool (Continued)




New Transverse Flux Technology For On-Line Inspection
5. Share the inspection results using our new Axial Flaw
Detection (AFD) tool (Continued)



New Transverse Flux Technology For On-Line Inspection
5. Share the inspection results using our new Axial Flaw
Detection (AFD) tool (Continued)

When is it most practical to use TMFL?




New Transverse Flux Technology For On-Line Inspection

6. Conclusion

This transverse technology (TMFL) adds a very useful service to the available
standard technology of using longitudinal induced Magnetic Flux Leakage
(MFL) method.

The Axial Flaw Detection (AFD) service is an economic addition and could be
used in addition to the traditional inspection method but only however when it
is absolutely necessary.

This new technology is again a step closer to the ultimate ability to detect and
size all possible pipeline defects economically.



It further reduces the risk
of leaving un-detected
pipeline integrity threatening defects.