Inline Inspection from an Operator’s Point of View

Strategic Insights, Volume VII, Issue 1 (February 2008)

Strategic Insights is a bi-monthly electronic journal produced by the Center for Contemporary
Conflict at the Naval Postgraduate School in Monterey, California. The views expressed here are
those of the author(s) and do not necessarily represent the views of NPS, the Department of
Defense, or the U.S. Government.

Abstract

E.ON Ruhrgas operates a gas transmission network with a length of more than 11,300 km.
Following a review of existing pigging results in 2003, the criteria for intelligent pipeline pigging
were revised based on experience from previous pig runs. It was found that inline inspection is an
efficient tool for monitoring the integrity of high-pressure gas pipelines, thus helping to ensure
safe and reliable operations.

Based on the results found, E.ON Ruhrgas decided to use inline inspection to examine all
piggable pipelines greater approx. 20 km in the E.ON Ruhrgas pipeline grid over a period of
approx. five to seven years. The good technical condition of the pipelines allows E.ON Ruhrgas to
organize the pig runs mainly based on economic and strategic criteria.

The results of current inspections are an important input to the company's pipeline integrity
management system (PIMS) for piggable pipelines. The necessary pipeline measures can be
planned and implemented in an economic manner thanks to the very good quality of the magnetic
flux leakage (MFL) results. Also, it is possible to prepare an electronic pipeline log based on the
data obtained from the pig runs. Excavation costs can be brought down if the geographic
locations of pipeline components and detected features are known and the geographic data can
serve as a basis for the GIS system and pipeline surveillance by air.

Long-term cooperation with a selected pipeline pigging company makes it possible to exploit
synergies and organize an ambitious pigging program in an economic and efficient manner.

Introduction

E.ON Ruhrgas is one of the leading gas companies of Europe. The company buys natural gas
from domestic and foreign sources and sells it to distribution companies, industrial customers and
power stations in Germany as well as to customers in neighboring countries. E.ON Ruhrgas
operates a gas supply network that is more than 11,300 km long. The total compressor capacity
installed is 908 MW and the storage capacity amounts to 5.1 billion cubic meters. The company's
main task is to ensure secure and continuous gas supplies to its customers in line with their
patterns of demand. This requires an efficient and sound pipeline system that is maintained and
operated based on technical and economic criteria. In a first step, the condition of the pipeline
needs to be evaluated to ensure an economic approach. One way of doing this is intelligent
pigging. The paper describes why E.ON Ruhrgas decided to use this method and how it is
applied.

Inline Inspection Concept

The pipelines of E.ON Ruhrgas built after 1962 are generally considered to be suitable for pigging
based on the current state of the art. Newly built pipelines are usually inspected by a caliper pig
and subjected to hydrostatic testing and even stress testing in most cases to detect and remedy
major fabrication and/or construction defects. The pipelines are provided with cathodic protection
on the day of commissioning. During the first three years of operation, intensive measurements
are made to check the pipelines for coating holidays and proper functioning of the cathodic
protection system. The pipelines are also surveyed (walking surveys, mobile surveys,
surveillance by air) as stipulated under the regulations applicable[1].

E.ON Ruhrgas and the relevant project companies introduced intelligent pigging in 1996. In 2003,
all results obtained for the approx. 2,600 km of pipe inspected were reviewed with the objective of
establishing a predictable pattern that helps the company to say when pig runs are necessary. It
was found that metal loss can occur despite a cathodic protection system that functions properly:

• In casing pipes where the protective current does not reach the product pipe.
• Under disbonded coating where the coating has separated from the pipe and prevents
the protective current from reaching the pipe, allowing conditions to develop that
accelerate corrosion rates (water, oxygen).
• Under anti-buoyancy concrete saddles where the protective current does not reach the
pipe.
• At locations where pipelines have been damaged by third parties or where the pipeline
operator failed to detect construction defects during or directly after the construction
period and metal loss did not occur until several years later.

It was also found that stress testing is not a criterion in favour of or against intelligent pigging
because the mechanisms mentioned above do not show until corrosion has reached a certain
stage or because the defects have possibly not yet existed when the stress test was made as, for
example, in the event of third party interference or hidden construction defects. Any such
corrosive damage can only be detected by intelligent pigging.

Based on the inspection results obtained for the period from 1996 to 2003, E.ON Ruhrgas
therefore decided to apply the intelligent pigging method for inspecting its transmission network in
line with the current state of the art and economic criteria. The condition assessment program
was to start with pipelines greater approx. 20 km. Of course, the program also covers shorter
pipelines where special circumstances indicate inspection priorities.

Pigging Program of E.ON Ruhrgas

In 2004, E.ON Ruhrgas introduced a pigging program for the inspection of approx. 5,000 km of its
pipelines. The pipelines have diameters from DN 200 to DN 1,200, pressure stages from 67.5
MOP to 100 MOP and lengths from 8 km to 240 km. The pipelines also include some dual-
diameter lines (e.g. 28“/32“, 36“/40“, 40“/44“, 42“/48“) and three 32“/36“/40“ multi-diameter lines
that are particularly challenging for the gas supplier and pipeline integrity company in terms of pig
availability and pig run organization. Figure 1 shows the pipeline lengths that E.ON Ruhrgas
inspected by intelligent pigging in the period from 1996 to 2006.
Figure 1: Annual Pipeline Lengths Inspected by Intelligent Pigging

As is obvious from the figure, the annual length of pipeline inspected was as high as 1,080 km in
2004 when the new pigging program was introduced. The average length of approx. 325 km valid
for the period from 1996 to 2003 has increased to approx. 840 km today.

In practice it was found that the pipeline length that can be inspected in a year is limited by two
factors. First, not more than approximately 15 pipeline sections can be tested for their integrity in
a year. Second, the time and organization input required for inspecting very long pipelines limits
the total length that can be examined in a year to approx. 1,100 km. Another important factor is
the complex nature of the pipeline system to be inspected or the number of invalid runs to be
expected. In 2005, the pipeline length inspected by pigging was therefore only 690 km because,
among other things, the integrity program included the very challenging dual- and multi-diameter
pipelines.

Thanks to the overall good condition of its pipelines, E.ON Ruhrgas is free to organize its integrity
program mainly based on economic criteria. Immediate line pigging jobs are not necessary at this
point of time.

Organization of Pig Runs and Line Pigging

Pigging Services

The E.ON Ruhrgas pipelines to be inspected are natural gas pipelines which usually carry dry
natural gas. Sometimes the lines also contain unwanted material such as pipe dust, construction
debris, welding electrodes, particularly after re-routing measures, or small quantities of
condensate. The pipelines must therefore be cleaned with a magnetic cleaning pig to prepare for
inline inspection. Brushes are not used as deposits on the inner pipe walls are not to be expected.
The cleaning pig is fitted with a caliper plate to determine and document whether the inspection
tool can safely pass through the pipeline. Experience from the past few years has confirmed that
one or two cleaning pig runs are sufficient in preparation for intelligent pigging.
After the cleaning pig, a caliper pig is sent through the line. The results of the caliper pig run are
only analyzed to the extent necessary for confirming that the passage through the pipeline is free.
A full analysis of the results may be necessary if the intelligent pig detects dents or ovalities in the
line.

Basically three types of pigs are currently used for intelligent pigging: MFL inspection tools,
ultrasonic inspection tools or electromagnetic acoustic transducers (EMATs). They are available
in diverse designs and in combination with mapping and caliper modules. The tools are selected
depending on their suitability for use in gas lines and the defects expected. The main pipeline
defects expected are metal loss, weld anomalies, dents and manufacturing defects. Both MFL
tools and ultrasonic tools are tools suitable for this purpose.

E.ON Ruhrgas uses MFL inspection tools as ultrasonic pig inspection in a gas pipeline requires
liquid batches. This would cause problems with respect to the pig run and operation of the gas
line. The EMAT is a crack detection tool suitable for use in gas pipelines. But E.ON Ruhrgas has
used the EMAT only for test purposes so far as the EMAT development status still needs some
input and cracks are not defects that occur frequently.

Another additional valuable service that can be performed together with pigging is mapping. For
this purpose, a mapping module with a gyrocompass is usually connected to the intelligent pig.
Above-ground markers (AGMs) are provided along the line at defined distances (e.g. max. 2 km).
They are installed on top of the pipeline and their positions are recorded. As the pig travels
through the pipeline, an AGM detects its magnetic field and stores its traveling time to the
relevant AGM. Using the information of the inertial measurement unit installed in the pig, the
exact position of each weld, valve, branch or other component as well as of each feature detected
is subsequently calculated. Based on the information obtained, an electronic log book is prepared
for the pipeline inspected. It is not possible in any other way to prepare such an electronic log
book with the same information density and at the same costs. The operator benefits from this
information in manifold ways.

The mapping information:

• serves to establish or consolidate a GIS system;

Tendering

Tendering is based on the POF specifications[3] that are expanded to include company-specific
requirements (e.g. the E.ON Ruhrgas safety requirements). The E.ON Ruhrgas specifications
contain the pipeline questionnaires for the lines to be inspected. The specifications also list in
detail the responsibilities of the contractor and of E.ON Ruhrgas based on the condition
assessment plan of a pipeline inspection company. The approach ensures that the
responsibilities for pig transportation and cleaning and the provision of auxiliary facilities are
clearly defined. The specifications also define in detail the accuracy and format requirements for
the mapping data as the POF requirements are not very specific in this respect.

E.ON Ruhrgas specifies the deadlines, contents and formats for the preliminary and final reports
to be submitted by the pipeline inspection company. These elements are essential to ensure
prompt processing of the inspection results at E.ON Ruhrgas. For example, the preliminary report
must contain information about the AGMs triggered during the pig run as this information is
important with respect to the mapping accuracy that can be achieved later. Early information
about problems allows the company to take prompt action. The format specified for the pig run
reports and mapping data is based on an E.ON Ruhrgas-specific format that is compatible with
the in-house PIMS and allows the large data volumes to be entered to the company's Electronic
Data Management System (EDMS).

The pipeline inspection companies are requested to quote their prices separately for the cleaning
pig and intelligent pig (mobilization, MFL inspection, mapping, report). The terms quoted for the
cleaning pig should be flexible as the number of pig runs required may vary.

The entire pipeline inspection package negotiated by E.ON Ruhrgas for the period from 2004
covers approx. 5,000 km of pipelines. The services were quoted and negotiated as optional items.
As a result, E.ON Ruhrgas is free to buy inspection services on an annual basis without having to
re-negotiate prices. At the same time, E.ON Ruhrgas has a reliable planning basis for the period
for which the price terms are valid.

Planning and Line Pigging

As network utilization is constantly increasing, it has become more and more important to have a
detailed and consistent integrity program plan. E.ON Ruhrgas therefore appointed a person from
the company's Pipeline Technology Centre of Competence as project manager. He heads the
pipeline integrity project team and manages all measures centrally. He receives the operations-
specific information he needs from the engineers on site who are operationally responsible for the
pig runs to be made in their operations areas. The project team of E.ON Ruhrgas is rounded off
by experts from the in-house Materials and Corrosion Technology Centre of Competence, staff
from the Operations, Dispatching and Purchasing Departments and from PLEdoc, a mapping and
documentation service provider.

The organizational approach is to use own staff for higher-value services and award contracts to
pipeline integrity companies or other sub-contractors for work that can reasonably and
economically be performed externally. External services include the design and provision of
cleaning pigs, transportation and cleaning of pigs, insertion of pigs into the launch trap and
removal of pigs from the receiver trap as well as assistance with pig tracking. E.ON Ruhrgas uses
its own staff for all services for which it is responsible as the operator pursuant to the German
Energy Industry Act[4] and the High-Pressure Gas Pipeline Regulation[5], e.g. launching of the
pig from the trap.

The pipelines to be inspected by pigging in a year are agreed internally in the autumn of the
preceding year. The Dispatching Centre examines the flow situation to be expected and
determines the time windows available for the pig runs. E.ON Ruhrgas then plans the pig runs
based on the time windows specified, keeping the number of mobilizations to a minimum. Equal-
diameter pipelines are therefore inspected together in one mobilization period. The time schedule
determined is then promptly agreed with the pigging service contractor to ensure early booking
and availability of the pigs required.

The necessary measures are organized in such a way that equal-diameter sections are first
cleaned and then inspected by caliper and intelligent pigs. This approach ensures minimum on-
site time for both the pigs and the service staff whose number varies depending on which type of
pig is used. Other factors influencing the time schedule are other operational measures that need
to be taken into account and, above all, pig availability. Planning must also take into consideration
preparatory measures on the pipeline, for example, welding or flanging on of pig traps.

The AGMs for the mapping pig run are installed in line with defined criteria. Courses are provided
for staff from the Operations Department to train them in pig tracking, AGM handling and safety
issues relevant to line pigging. E.ON Ruhrgas organizes on-site visits together with the pipeline
integrity company to examine the conditions on site. Pipeline books and a list of geographic
information are also made available. Sufficient space for inserting the pig in and removing it from
the trap, suitable workshops and washing stations as well as the locations and adequate
dimensions of pig traps are of particular importance in this context.

A couple of days before the pig run takes place, E.ON Ruhrgas works out a detailed pipeline
shut-off report for the inspection planned. The report includes all necessary switching measures
for the pipeline grid, responsibilities, persons involved as well as a pig tracking plan. The pig run
is made by the person responsible for the pigging measure (operations engineer) pursuant to
Guideline GL 273-501[6]. The operations engineer is supported by staff from the Operations
Department and employees of the pipeline integrity company. The pig run is documented in a
report that includes, among other things, the time schedule, liquids and solids removed as well as
any features detected.

Figure 2: Processing of Pig Run Results at E.ON Ruhrgas

Figure 2 describes how the pig run results are processed. The preliminary report is to be
submitted within five days from the date on which the intelligent pig run was made. E.ON Ruhrgas
checks the report for complete MFL data, the number of AGMs triggered and any significant
pipeline flaws that may require immediate action. The final report is to be submitted within two
months from the date on which the intelligent pig run was made. It is evaluated internally by the
Cathodic Protection and Materials Technology Departments using existing information from the
Operations Department and the general history of the pipeline. The MFL data are entered to a
special software program and ranked for further processing based on cathodic protection and
strength aspects. Following further automatic and manual processing, the following features are
evaluated:

• Reduced wall thicknesses in the base material and weld area,

In the next step, the E.ON Ruhrgas expert departments discuss the results with the Operations
Department. The measures recommended are summarized in a list that is appended to the
internal pipeline integrity report. The remedial action agreed is taken within a defined period of
time and certified by an expert, if required.

Integration in PIMS

The entire pigging process starting with the selection of the pipelines to be inspected is controlled
and documented by the PIMS (Pipeline Integrity Management System)[7] of E.ON Ruhrgas. The
PIMS is a tool that links technical, management and organization information (Figure 3).

Figure 3: Definition and Characteristics of PIMS

The system defines the condition assessment processes and sub-process interaction and links
the data processed. Technical pipeline integrity is confirmed based on the expert knowledge of
the Pipeline Technology Centre of Competence and Operations Department. For this purpose,
the processes mirror measures in the fields of operational monitoring and maintenance, cathodic
protection, material and strength analyses as well as measures to assess current pipeline
conditions, e.g. by means of intelligent pigging. Data and information integrity is ensured by
including the relevant process parameters in the RuhrgasGIS geographical information system,
the EDMS and the SAP PM.

The system makes it possible to describe the condition of specific pipelines or classes of
pipelines for reports to the company's management or work on future strategies.

Experience

Project Implementation and Technology

The project of inspecting an average length of approximately 870 km of natural gas pipelines
annually over the past three years and cooperation with a selected pipeline integrity company
were handled very efficiently by the project team. Some weak points were identified when the
project started but they were eliminated by appropriate action. At first, a special focus was on
responsibilities and interaction between the pipeline integrity company and the E.ON Ruhrgas
project team. It was soon found that established contacts and recurring procedures in planning,
project implementation and analysis of the results obtained were great advantages.
Communication between the project team members and the pipeline integrity company as well as
communication among the staff of the pipeline integrity company was not satisfactory in the
beginning. The situation improved when regular meetings of the project team members and
management meetings were introduced to discuss technical innovations and organizational
issues in addition to the project under way.

Also, a customer communication platform was introduced that was essential in ensuring efficient
communication between E.ON Ruhrgas and the pipeline integrity company. The customer
communication platform is an Internet-based software application that allows the project team
members to communicate by e-mail and access project-relevant information. It also serves as a
common project server and describes the project status. An automatic function for monitoring
dates makes it possible to directly remind project members of their tasks via e-mail. The
messages can be escalated, if required, to ensure that critical tasks remain in the focus.

When the difficulties encountered during project implementation were analyzed, it was found that
in 2004, the first project year, problems occurred with the MFL fleet. The problems were caused
by defective charging devices or safety valves, deficient data storage or electrostatic charging.
The cleaning and caliper pig runs, on the other hand, did not involve any problems. In 2005, the
inspection program included very challenging dual- and multi-diameter pipelines. The success
rate of the MFL runs was excellent in that year while the caliper and mapping pig inspections
required additional input. In 2006, E.ON Ruhrgas and the pipeline integrity company benefited
from the experience gained in the previous years and implemented the integrity program without
any problems.

All in all, it can be said that initial difficulties were solved efficiently by appropriate measures so
that the ambitious goals set for the project in terms of costs, quality, time schedule and safety
standards were fully achieved. Appropriate measures included organizational adjustments of the
project management at the pipeline integrity company, improved spare parts inventories,
pressure testing of pig trap components and stringent quality checks. Also, an important factor
that contributed to the project's success was the enormous flexibility of all persons involved.

Caliper and MFL Results

Experience over the past three years has confirmed that the use of caliper pigs is fully justified.
The MFL pig sometimes detects dents in the pipeline without specifying dimensions. It is an
economic approach in these cases to have the caliper pig runs analyzed and have a closer look
at the dents mentioned in the MFL report. Often, the strength characteristics of the relevant
pipeline sections are good so that costly confirmation digs and examinations on site can be
avoided.

The quality of the defect data listed in the MFL reports is very high. In many cases defects listed
were found immediately when the line was excavated and uncovered and the defect dimensions
determined by the pig were fully confirmed. The E.ON Ruhrgas Operations Department and
Pipeline Technology Centre of Competence therefore consider intelligent pigging a very valuable
inspection method.

Quality of Mapping Data

The original accuracy requirement E.ON Ruhrgas specified for pipeline position mapping was +/-
0.5 m for a three-dimensional coordinate. The AGM reference points were to be mapped with an
accuracy of at least 0.1 m and the distance between AGMs was to be limited to 2 km. But it
became obvious in practice that the requirement specified could not be met with the current state
of the art. Today, an accuracy of +/- 1m is usually specified for a three-dimensional coordinate
with a confidence level of 90 percent and an AGM spacing of, for example, 1 km.
E.ON Ruhrgas reviewed the mapping accuracy of a pig run made in 2003 based on reference
points mapped after the pig run was made. Figure 4 shows the cumulated measurement
deviations (only position, two-dimensional) determined as the differential between the coordinate
from the pig run report and the coordinate measured on site.

Figure 4: Cumulative Frequency of Reference Points [%] vs. Measurement Deviation in 2-D

For approximately 40 percent of the coordinates examined, the measurement deviation is less
than 0.5 m. As the percentage of coordinates examined increases in a linear fashion, the
measurement deviation reaches 1.0 to 1.5 m for 100 percent of the coordinates examined. The
measurement deviations would even be higher for three-dimensional coordinates.

Many technical optimizations were made and the pig run itself was optimized. Today, the pipeline
integrity company commissioned by E.ON Ruhrgas delivers an average position accuracy of
approx. 1 m (two-dimensional) with an AGM distance of not more than 2 km. This means, the
accuracy requirements for the location of defects in the field or for proper operation of the
CHARM system are met.
It is not possible to determine the covering layer above a pipeline with the measurement
accuracies achievable today. Theoretically, the coverage is determined by deducting the vertical
coordinate of the inline inspection tool from the vertical coordinate of the ground level (determined,
for example, by air surveys). But the measurement deviations described above can lead to very
erroneous results. For example, a sufficiently covered pipeline with a real cover of 1 m could be
interpreted as having no cover at all if the measurement deviation is approx. 1.5 m.

The current mapping accuracy for inspections of E.ON Ruhrgas pipelines has been achieved
thanks to technical innovations and improvements in program planning and implementation. For
example, new AGMs were introduced in 2006. The time drift is considerably lower than for the
previous model. This helps to significantly reduce, in particular, axial measurement deviations.
Also, AGM sensitivity to the magnetic field of the pig was improved considerably so that the
number of non-triggered AGMs is now negligible. In the past, measurement deviations were often
high because many AGMs were not triggered and, as a result, the number of reference points
was low. Other measures taken to minimize measurement deviations include photo-
documentation of AGM locations, training of staff to improve AGM handling, introduction of rules
to determine optimum AGM position or reduced AGM distances where possible.
Conclusion

Intelligent pigging is a valuable inspection method also for pipelines that were directly provided
with cathodic protection when they were commissioned. The method complements quality
assurance during construction, stress testing, caliper pig inspection, intensive surveys and
operational monitoring. The inspection results serve as an important basis for the company's
PIMS. The necessary pipeline measures can be planned and implemented in an economic
manner thanks to the very good quality of the MFL results. Also, it is possible to prepare an
electronic pipeline log based on the data obtained from the pig runs. Excavation cost can be
brought down if the geographic positions of pipeline components and detected features are
known and the geographic data can serve as a basis for the GIS system and pipeline surveillance
by air. Long-term cooperation with a selected pipeline integrity company makes it possible to
exploit synergies and organize an ambitious pigging program in an economic and efficient
manner.

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References

1. G 466 - Gasleitungen aus Stahlrohren für einen Betriebsdruck größer als 5 bar—
Instandhaltung; DVGW Code of Practice, April 2002.

2. Zirnig, W., Kordulla, K., Ulbricht, M.; Erdgas hat einen optischen Fingerabdruck; 3R
International 44, Book 11 (2005), 620-624.

3. "Pipeline Operators Forum, Specifications and Requirements for Intelligent Pig Inspection of
Pipelines," Version 3.2 (January 2005).

4. "Second Law Amending the Energy Industry Act," Federal Gazette, 2005.

5. High-Pressure Gas Pipeline Regulation (GasHL-VO), 1997.

6. GL 273-501, Funktions-, Reinigungs- und Inspektionsmolchung, 2006.

7. Linke, G., Michel, R., Steiner, M., Theilmeier-Aldehoff, H.-W.; "Das Pipeline Integrity
Management System" der E.ON Ruhrgas AG, 3R International 45, Book 7 (2006).