Complex Crack Detection in an Above-ground Pipeline

An oil and gas exploration, development and production company required assistance verifying field anomalies on its 24" above ground pipeline. 

The customer was in the process of a multi-year thermal development program as this project is a thermal in situ operation that produces > 50,000 barrels per day. As the line transports hot fluid it experiences large temperature changes. It is well isolated and includes a high number of bends to allow expansion. Deposits appear in the form of bitumen, which in its natural state is too viscous to flow. When bitumen is too deep (> 80 m) to economically mine, steam is injected to warm it. This reduces the viscosity and allows it to be pumped through surface wells. 

Field investigations of this line identified cracking features. The presence of such features determined a possibility that some features located within bends had exhibited axial/circumferentialAn event that occurs or is measured along the circumference of a pipeline. It implies the direction or orientation that is perpendicular to the longitudinal axi… cracking with complex angles. Because of this, time was now a main concern for all consecutive actions. A streamlined repair schedule was required to bring this line back into service as soon as possible. 

This would be the first completed inspectionThe systematic process of visually examining, testing, or monitoring pipeline components to assess their condition, integrity, and compliance with regulatory re… for the line, which has been operational for six years and would form a starting point for ongoing integrity management. Although no previous projects were completed for this customer, NDT Global was chosen based on a reputation for customer service, accuracy and quality data analysisThe evaluation process of extracting insights, patterns, and valuable information from the data collected during pipeline operations, inspections, or monitoring…. 

Streamlined repair program:  A streamlined repair program was introduced based on reliable ILI reports. This enabled the customer to prioritize maintenance, repairs and resources, while having a starting point for ongoing integrityThe capability of a pipeline to perform its intended function safely and reliably throughout its life. It includes a range of factors, including the structural … management of this asset. 

Tight schedules:  The entire project from inquiry to delivery of final reports occurred within 80 days. The reporting timelines were extremely tight with the first preliminary report delivered within 7 days of receipt of the tool, and the final reports were delivered within 30 days. 

Detailed results:  NDT Global provided 53 circumferentially-oriented and 52 axially-oriented features from the final analysis phase. Additionally, through customized analysis targeting features outside of tool reporting tolerances, specifically in areas of the bends, another 348 potential sloping crackA fracture or discontinuity in the wall of a pipeline, where the material is separated or broken, potentially compromising the integrity and safety of the pipel… like indications were identified. Of the combined axial, circumferentialAn event that occurs or is measured along the circumference of a pipeline. It implies the direction or orientation that is perpendicular to the longitudinal axi… and potentially sloping indications, 119 were investigated to determine the accuracy and reliability of the inspectionThe systematic process of visually examining, testing, or monitoring pipeline components to assess their condition, integrity, and compliance with regulatory re… data as well as to complete the integrity management programA documented set of policies, processes, and procedures implemented by operators to ensure the safe, reliable, and efficient operation of pipelines throughout t… on this system and bring it back into operation.