The SmartScan fleet offers a level of flexibility and collapsibility never seen before in ILI technology, with enhanced bend-passing capabilities and video pre-inspection systems. They are shorter than conventional tools and can be deployed using existing launch and receive traps or injected into the line using a new hot-tap procedure.

Pipeline access through a hot-tap fitting

For pipelines without existing inspection access traps, GE developed an innovative new hot-tap launching/receiving system (patent pending). The system is specially designed to provide a full-bore hot-tap and a 45° fitting connecting a temporary launcher/receiver to the pipeline.

Using this system, SmartScan tools can be launched through a hydraulic chute that is permanently affixed over an equal bore, angled penetration in the pipe. Using this assembly, ILI can be conducted without the need, design time, or expense of conventional launch and receive facilities. Hot-tap launch systems can be installed and pressure tested in a matter of days, leading to completed inspections of an unpiggable system within days of the cleaning operations.

The hot-tap fixture remains as part of the pipeline, providing easy access for continuing inspection and cleaning requirements. SmartScan can transverse pipe sections between restricted valves - while a modified application enables valve bypass for continuous inspection over longer distances.

In order to conserve space at inspection sites, the launch system was designed with a 1D bend for tool entry, and the tools can accommodate a 1D bend in the smallest launch/receive diameter. These specifications are advantageous for pipeline sections without existing traps or the space to install temporary/permanent traps.

Cleaning

Many of the industry's unpiggable pipelines have been in service and uninspected for 50 years or more - so it is impossible to know whether debris remains from construction or what amount of residue has collected during the line's operating lifetime. Therefore, one of the greatest challenges rests in assuring that the line is clean enough to allow both tool passage and high-quality data collection.

It is critical to address the cleaning issue as early as possible in the project. Progressive mechanical cleaning is the most straightforward, lowest cost approach, while chemical cleaning may be needed depending on the nature and volume of the material in the line.

The cleaning process begins with a series of poly pigs, followed by various brush and scraper pigs. Specialised multi-diameter brush tools, complete with magnets, have been designed as the final step in a multi-cleaning process.

Sequential pig runs are undertaken in a manner that minimises the risk of blocking the pipeline, while ensuring that the line is cleaned to a level necessary for successful ILI data collection. For pipelines that have little or no previous pigging history, an undersized soft density poly pig is run first. Manufactured from 5lb/cu.ft soft-density foam and undersized to the internal pipeline bore, the pig has less resistance in negotiating any obstructions or pipeline features. This first pig simply shows whether or not it will be possible for an inspection tool to traverse the pipeline from launcher to receiver. The poly pigs are designed so they will not lodge in the pipeline - even with extreme bore-reductions, the pigs will either squeeze through or break apart, making them the ideal, low-risk method of determining a line's passability. After the poly pig, the first enhanced cleaning vehicle is a flexible cup pig fitted with shaped discs.

The discs have three cut-outs which reduce contact with wax and allow a large amount of bypass through the disc. Various sizes of discs are provided, and the vehicles can be configured to suit the application required.

The magnetic brush cleaner is run next. This pig is fitted with specially designed large surface area magnets which are capable of attracting and removing items of debris which have a ferrous content (e.g. welding rods, spacers, corrosion product, etc.)

Our caliper tool can be propelled with product, pumped (i.e. water, air, nitrogen), or wire-lined. Details are analysed and information related to minimum ID, restriction locations, minimum bend radius, minimum ID within bends, and distance between bends can be provided in the field 24 to 48 hours following the inspection. This allows for an immediate overview of pipeline condition as well as verifying passage for subsequent inspection tool runs.

Test-loop facilities

As part of the multi-million-dollar development of this technology, a full-scale test loop was created to validate the new cleaning, caliper and MFL tool technologies.

This facility assures operators of the tool's ability to negotiate troublesome fittings such as diameter reductions and difficult tee orientations. To date more than 200 representatives of over 40 companies have witnessed the successful movement of our tools through the complicated flow loop.

• 45° hot-tap entry launch system that includes an integral 20" 1D 90° bend
• 20" x 20" unbarred tee
• Two 20" out-of-plane 1.5D 90° elbows
• A 20" x 26" concentric reducer
• Two 26" out-of-plane 1.5D 90° elbows

Unique piping challenges are also tested here. For example, one project involved a multi-diameter pipeline that started as 24", reduced to 18" and returned to 24". The design team modeled a 24" x 18" x 24" configuration to confirm the collapsibility of the tool, and then ran it through the test loop with an 18" spool piece as a final confirmation. The 20" x 24" SmartScan tool (which launches through an effective hot-tap opening of 17.1") easily passed the test.

Access to this live flow loop gives inspection teams insight regarding potential passage issues before inspection - therefore presenting opportunities to improve inspection success rates and avoid costly in-field difficulties.

In-field success

The first SmartScan inspection ran successfully in January 2005 for El Paso Pipeline Group, using conventional traps to launch and receive the tool, and many more inspections are planned for 2005 using this new technology.

SmartScan's ability to obtain high-quality metal-loss data will help give pipeline operators significantly more confidence in the safety and integrity of their assets - and will quickly make the term "unpiggable pipeline" as outdated as the "cordless phone."

To download SmartScan fact sheet, click here.

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