SmartScan™ effectively unlocks, for the first time, the multitude of valuable information lying inside previously unpiggable pipelines. Reliable, high-resolution inspection is no longer cost prohibitive or disruptive of service.

This collapsible in-line inspection (ILI) tool is the first generation in a whole family of advanced ILI tools based on SmartScan™ technology.

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.

SmartScan enters and exits with the assistance of our new chute that allows medium flow to continue regardless of the hot tap’s insertion point.

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.

Hot-tap launch/receive system (click on image to enlarge).

Examples of unpiggable pipeline scenarios that would benefit from SmartScan’s 1D launch capability (left: 26" x 20" transition, right: 36" x 30" transition with unbarred 36" tee).

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. Specialized multi-diameter brush tools, complete with magnets, have been designed as the final step in a multi-cleaning process.

High-density, multi-diameter Scraper Foam Pig with Transmitter (patent-pending).

Sequential pig runs are undertaken in a manner that minimizes 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.

Multi-diameter scraper tool.

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.)

Brush tool.

Caliper inspection
GE Energy's new generation multi-diameter, multi-channel caliper inspection tool is used to collect accurate high-resolution information about physical pipeline defects. These tools are ideal to determine instances of construction and third-party damage, pipeline ovality, buckles, ripples, and other diameter reductions, while accurately measuring pipe radius and bend angles. Caliper tools can be run successfully in a variety of liquid and gas media.

20” x 26” multi-channel caliper tool.

Our caliper tool can be propelled with product, pumped (i.e. water, air, nitrogen), or wire-lined. Details are analyzed 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.

Flow loop in Alvin, Texas with fittings painted blue.

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.

The loop originates as a 20” diameter pipeline and transitions to a 26” diameter pipeline. The following special fittings are present:

• 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.”

For more information, please contact:
Steve Biagiotti, PE
Unpiggable Solutions Product Manager
Steve.Biagiotti@.ge.com

To download SmartScan fact sheet, click here.

To download SmartScan magazine ad, click here.

SmartScan is a trademark of General Electric Company.