Post on 20-Jul-2020
PICA (California Office)3445 Kashiwa StreetTorrance, CA 90505 1-800-661-0127
Kristopher Embry, Regional Managerkembry@picacorp.comc. 412-999-4783
Who is PICA/Russell NDE?
PICA is a U.S. based subsidiary to Russell NDE in:
➢ Los Angeles / San Antonio / New Orleans / Washington, D.C.
Experience: Over 30 years of R&D and condition assessment.
Leaders in the Industry: Our president, Dave Russell, was one of
the original founders of PPIC (50 yrs exp.). Our Operations
Manager, Ad Shatat, MA in Engineering Physics, is a leader in
adapting RFT for large diameter pipes (25 yrs exp.).
Standards: We have developed NDE standards for ASTM, ASME,
ASNT, EPRI and recently contributed to the AWWA/M77 Manual.
Develop / Manufacture / Deploy / Data Interpretation / Reports
Inspection Solutions
Prescreening:
Free Swimming
Visual:
CCTV & Laser
NDE:
Electromagnetic
Inspection Solutions
Prescreening:
Free Swimming
Pre-Screening Inspection – RECON+
<<<<<<<<2.3”>>>>>>>
Sensors On-Board
• Hydrophone (leak detection)
• Pressure
• Magnetometer
• XYZ (accelerometer and IMU)
• Temperature (not reportable)
Gross Wall Anomalies
RECON+ - Leak Detection
The hydrophone identifies and quantifies a leak’s signature (amplitude
and frequency) and localizes it by combining all sensor data.
RECON+ - Leak Detection
Recent project example: 4.5 miles between access points.
RECON+ - Pressure Log
RECON+ - Pressure Log
RECON+ - Magnetic Log
RECON+ - Magnetic Log
RECON+ gross defect results compared to MFL results
RECON+ - Geolocation (X, Y, Z)
• Accelerometer and Gyroscope on board measure Pitch & Yaw Deflections without need for above ground markers. This is correlated to known locations of construction fittings and client As-built information
• More accurate when mounted on a soft foam pig.
RECON+ - Extraction
Extraction plans and devices
RECON+ - Advantages
Simple!
Fast!
Flexible!
Disruptive!
Inspection Solutions
Visual:
CCTV and Laser
Visual and Laser Scans
• Dedicated potable water equipment.
Visual and Laser Scans
• Laser Profilometry (Triangulation with CCTV)
• Lidar (Ranging)
Visual and Laser Scans
• Spalled liner identification/measurement
• Identify/measurement of ovality and deflection
Inspection Solutions
NDE/NDT:
Electromagnetics
Lines of Magnetic Flux
Field disturbances due to
PipeCrossSection
Probe Travel Direction
local wall loss
Near FieldZone
TransitionZone
RemoteFieldZone
Pipe
Exciter
Energy Flow Path
Receiver
Liner
NDE - Electromagnetic Basics
Where wall is thinner the signal arrives faster and is larger in amplitude
+V
-V
Sig
nal
Am
pli
tud
e [
Vo
lts]
Time →
Exciter Output
Flaw Signal
Signal
Nom Signal
Electromagnetic RFT – Basis of Measurement
22
Electromagnetic Remote Field
SeeSnake Line of Tools
3” to 78” ID Capable
PICA’s NDE - Electromagnetics
Electromagnetic tools were developed to condition assess metallic pipelines and assets.
Two Methods of Data Collection
In-Line Tools External Tools
3”-78” Capable Tools >6” Capable Tools
Typical ‘SeeSnake’ Tool
1. Tethered (dual and single tether)
2. Free Swimming
3. Manned Entry
Types of Tool Deployments
Tethered
Single Tether Connection to Tool
Double Tether Connection to
Tool (at each end)
Range: 6,000’
Maximum bends 270 degrees
Tethered Tool Deployments
Single Tether Inspection
Hydrant Launch Tethered
Single Tether Connection to Tool
Range: 6,000’
Maximum bends 270 degrees
Untethered or ‘Free Swimming’
Full Bore Access Required
No Maximum bends (no capstan effect)
Launch Assembly Required
Range: 20+ Miles
Monitored by on-grade TPM
Untethered Inspection
Typical Pig Launch Assembly
Manned Entry
Tool is pushed/pulled by tech
Often works in conjunction with
tethered deployment
Manned Tool Deployments
Pre-Cleaning – Non-Contact
This pipe is clean enough to inspect!
Ensure Success – Test Disc
Aluminum Body with fingers at tool circumference.
High Resolution Data• Scans every 1/10” over entire
circumference
0.253-inch nominal
0.253-inch nominal
0.222-inch nominal
High Resolution Results
Primary Area at 1982.6:
6”x5” corrosion
area
100% Wall Loss.
Secondary Area:
1” diameter
100% Wall Loss.
6-inches upstream
of the large
corrosion patch
Accuracy Determined
36
• Industry Standard Unity Plot
compares the RFT predicted depth
(vertical axis) to the known or
measured (dig verification UT) depth
(horizontal axis).
• Depth tolerances are +/-20% with
85% confidence, which is comparable
to oil & gas inspection technologies.
• Data in the graph on the right is based
on data for defects at or above the
TOD.
• Defects below the TOD (2” dia x 25%)
are still detected.
External EM RFT ‘Bracelet’ Probe
External EM Validation
Validate findings on-site with a UT gauge.
External Probe Results
How Can PICA Help?
Actionable Data:
Repair? Replace? Where?
Pre-Screening:
Narrow down the areas of concern.
Higher Accuracy:
Locate AND size defects
Family owned, small business.
We’re a SBA standard/SBE.
We are client centric.
We are data diligent.
Case Study – Mount Pleasant, SC
Background:
Mount Pleasant, SC (suburb of Charleston)
Services 70,000 people
~458 miles of wastewater pipe
Average Capacity of 6.35 MGD
Case Study – Mount Pleasant, SC
4,200 feet of DI. Section 1: 2,940; Section 2: 1,35516” DIP: Class 50; .34” WT2 – 45 degree bends; 2 – 22.5 degree bends
Client assumed areas with past failures were in poor condition. Better access was found upstream at Pit 1 in an area with no previous failures, thus that scope was added.
Past Failures
No Past Failures
Case Study – Mount Pleasant, SC
Estimated Replacement Cost: $4 million
Criticality: 25-30% of WW flow runs through this line
Case Study – Mount Pleasant, SC
Case Study – Mount Pleasant, SC
Start – 0 ft End– 4,200 ft550 ft 2,940 ft
Re
mai
nin
g W
all %
The vast majority of defects were found upstream near brackish water at the creek, but had exhibited no past failures.
Case Study – Mount Pleasant, SC
Through-hole indication at 42.12 feet (from start) at the 6:00 position (bottom of pipe)
Case Study – Mount Pleasant, SC
Case Study – Mount Pleasant, SC
Results:
Client replaced first 550 feet and upsized the last 2,000 feet
Cost: $1.5 million
Deferred cost: $2.5 million
Provided a better planning horizon
“So far, in the two condition assessment projects that we have used the SeeSnake, we
have spent less than 5% of the pipe replacement cost using this technology. In
return we have saved at least 65% of the pipe replacement cost by only replacing
and rehabilitating those sections of the pipe that really needed it.”
David Niesse, Engineering Manager, Mount Pleasant Waterworks.
Kris Embry, Regional Manager
e. kembry@picacorp.com
c. 412-999-4783
“Good Decisions Start with Good Information!”
Thank you!
Recent Video – Vallecitos WD, CA
Link to Article/Video Online:https://www.waternewsnetwork.com/new-inspection-tool-aids-vallecitos-pipeline-assessments/
Appendix – Additional Information
Remote Field Testing Characteristics:
RFT is a non-contact technique that relies on time varying EM fields.
RFT technology is thus not limited to collecting a single parameter of information (Amplitude) but additionally collects a time differential element which is used in enhancing the depth calibration of defects.
RFT technology has been in commercial use since the late 1980’s
RFT Technology has been validated by such organizations as the EPA, EPRI, Battelle, and AWWARF.
Industry standards for applying the technology are in place (e.g. ASTM Standard Practice E-2096-00)
Will locate and quantify amount (depth) of missing metal.
Can see through internal liners & deposits.
Sensitive only to the metallic components of the pipe.
Equally sensitive to external or internal corrosion.
Cylinder Information Provided by PICA Inspection Tools
For every defect above the Threshold of Detection:
- Depth
- Length
Upon request, PICA will calculate the safe operating (or
rupture) pressure for the steel shell using either modified
B31G (also known as RSTRENG) or DNV-RP-F101.
Stresses working on the pipe (cylinder).
Inspection speeds of 15ft/min (ideal) up to 60ft/min (maximum).
Defect depth measurements within +/-20%.
Reporting of the axial (in 0.1ft) and circumferential location of wall loss indications.
The tools measure the deflection angle of mitered bends in the line, and distinguish if the bends are up/down (+/- 3 degree pitch) or left/right (+/- 5 degree yaw).
Flagging of pipes with stress loading.
Defects can be sorted on depth or B31G burst pressure calculations.
References back to AGM (grade location sensor) locations within 0.3%.
Inspection Numbers
Inspection Tool Launch – 24”
Typical Stuffing Box Installed
Modular to facilitate introduction through Manholes.
PICA’s PCCP Tools
36” – 48” Tool
RAFT: High Res EM In-Line
Inspection Tool
RECON+ - Extraction
RECON+ - Extraction
Wire breaks are important for the understanding the
structural integrity/strength of PCCP.
Cylinders are important as a water barrier.
If the cylinder is compromised, it could corrode the wires
and is arguably a pre-cursor to wire breaks.
PICA’s remote field tool will also detects both wire breaks
and corrosion defects
PCCP – Wire Breaks and Cylinder
No Calibration Pipe Available
Use a close representative pipe sample to confirm tool is
sensitive to wall loss.
Estimate optimal tool settings based on representative pipe.
Perform a mathematical calibration and utilize histogram.
Calibration Process
Calibration Pipe Available?
Scan the cal pipe for a baseline.
After baselining, machine defects into the pipe.
Examples: Simplest Defect Morphology for depth sizing:
Six 25.4mm diameter, round, flat bottom holes (Depths: 20%, 40%, 50%, 60%, 80%, 100%)
Simplest Defect Morphology for volumetric sizing and determining Threshold of Detection: (Through Hole Diameters-THD) [25.4mm, 19.1mm, 12.7mm, 6.4mm, 4.8mm, 3.2mm, 1.6mm]
Scan the machined cal pipe for optimal accuracy.
No Pipe available?
Use close representative pipe sample.
Perform a mathematical calibration and utilize histogram.
24-inch Calibration Example
EMIT: High Res EM In-Line Inspection Tool
48” – 78” Tool
PICA’s PCCP Tools
Flexible and modular.
PICA’s PCCP Tools
EMIT: High Res EM In-Line Inspection Tool
Full Bore Access
All of our EM tools =<36” require full bore
access.
All PICA tools can pass through bends.
Butterfly and Plug valves must be removed or
avoided.
Butterfly valves in dewatered pipes, if large
enough, can be passed manually by a crew and
tool (rebuilt in pipe).
Access Requirements
Ongoing R&D – PCCP Inspection
Field Wire Break Detection
10+ broken wires in body of pipe.
Cylinder Failure with Intact Wires
On-Going R&D