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In the oil and gas industry, solid metal equipment such as pipelines, pressure vessels, heat exchangers and valves are susceptible to surface cracks and discontinuities attributed to cyclic loading, process environment and severe operating conditions. These anomalies affect the safety, structural functionality, reliability, integrity and life cycle of the equipment. They could lead to catastrophic incidents if not detected timely, evaluated, monitored and properly repaired.
Inspection of surface and near-surface indications has been always a challenge in the oil and gas industry due to the limitations of the commonly utilized conventional Nondestructive Testing (NDT) methods and their implementation difficulties such as surface preparation requirements, reliance on operator skills, slow deployment and inability to archive inspection data. Keeping pace with industrial revolution (IR) 4.0, Nondestructive testing (NDT) methods have been evolving to be digitized by automated data evaluation and visualization of inspection results while improving detection capability, decision making processes and speeding up the inspection activities. This paper will discuss and analyze the trials conducted to validate the capability of the new digital generation of Eddy Current Test (ECT); namely Eddy Current Array (ECA), based on comparisons made against alternate methods. The paper will also illustrate the principles, applications and benefits of ECA technology. ECA technology shows significant potential as a replacement for conventional NDT methods, i.e., Magnetic Particle Inspection (MPI) and Penetrant Testing (PT) that are used for the inspection of surface-breaking and near-surface indications including Environmental-Assisted Cracking.
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The continuous improvements in the Oil&Gas Industry to deal with reliability and maintainability objectives, higher operational reliability, improved safety, and emergency readiness for potential risk of unexpected events have led the Offshore Companies to be in the forefront of development of design and analysis methodology for integrity assessment and safety operation. The architecture of an integrated model targeting the major residual risks to the asset, new generations of internal and external inspection techniques, real-time monitoring sensors, material degradation prediction related to the actual and future operational conditions and machine learning methods are, as identified from the experiences of the authors, the new frontiers for the Pipeline Integrity Management. The advance in automation process to build pipeline digital twin, looking at new predictive and diagnosis tool by advanced FE models allows not only thinking defensively but also in taking an aggressive position toward safety and asset optimization. Plenty of attention was devoted to the 40 years of pipeline integrity assessment through which the engineering assessment takes advantage from inspection and operational data. Suite of services for an integrated solution including ad-hoc engineering and repair system readiness have been identified as the main pillars for best-in-class Operators. Case histories and integrated solution to ensure satisfactory performance and safety have been presented.