1. INTELLEGENT PIGGING
I. P. Survey of
14’’ Crude Oil Pipeline (756 Kms)
from PS5 to BPS

2. Pipeline Overview
16” line
14” line

3. Pipeline System
• Duliajan-Guwahati, 16"dia : 401 Km
• Guwahati-Barauni, 14" Dia : 756 Km
Total, M/Line = 1157 Km
• Duliajan-Digboi, 8"dia : 35 Km
• Badulipar-Numaligarh, 16" Dia : 13.5 Km
• Numaligarh-Siliguri, 16" Dia : 600 Km
(Under Construction)

4. Pipeline System
• Injecting Pump Station : 4 Nos.
• Booster Pump Station : 6 Nos.
• Terminal Station : 4 Nos.
• Repeater Station : 17 Nos.
• Maintenance Base : 3 Nos.
• Pumping Units : 51 Nos.
• Generating Units : 21 Nos.
• Gen. Sets at Repeater : 45 Nos.

5. What is pigging ?
Pigging can be defined as running a specially designed tool in a pipeline to
get a better performance of the pipeline in a way that can not be achieved in
any other way.
Why pig pipelines ?
A better performance for pipelines means :
* Lower installation cost
* Lower energy requirement for moving the product
* Lower maintenance cost
* More efficient separation of product batches
* Longer pipeline lifetime
The following are the various areas (stages) in which pigging can be
considered :
CONSTRUCTION :
* Removal of construction debris (Soil, sand and mill scale in gas line
feeding to power plants.)
* Test water filling and removal (Air pocket at high points)
* Drying of the pipelines before commissioning. (Swab pig, industrial alcohol
drying)

6. COMMISSIONING :
* Introduction of pipeline products leading up to the process point.
MAINTENANCE :
* Pipeline cleaning (removal of aggressive debris from product so that corrosion is
minimized.
* Pipeline Inspection.
OPERATION :
* Pipeline cleaning (removal of obstruction debris for maintaining designed flow
area, wax)
* Paraffin, asphaltenes, liquid built-up in gasline.
* Batch pumping of different products.
REPARING :
* Product evacuation and re-introduction.
CONSTRUCTION :
* Product evacuation

7. The types of defects that threatens the pipeline’s integrity :
> Corrosion at the internal pipe wall surface
* Wet sour medium (H2S) attack * CO2 attack
* Bacterial attack * Salt water
> Corrosion at the external pipe wall surface
* Incidental coating damage during construction
* Incorrect pipeline coating material
* Incorrect pipeline coating application
> Cracks on the inside pipeline surface
* SCC (Stress Corrosion Cracking)
> Inside pipe wall defect due to manufacturing faults
* Lamination * Inclusion
> Weld defects
* Cracks in the weld * Cracks in heat affected zone
* Improper welding
> Mechanical damage to the pipe wall
* Gouge * Dents
* Buckles * Wrinkles
* Ovality

8. Pipeline Cleaning Tools And Accessories
Pipelines - no matter what they transport, should have clean
inner surface. A clean inner surface insures good operating
conditions resulting efficient pipelines with lower operating cost.
Types of Cleaning Tools :
 Disc Type – The disc type tool is ideal for dewatering, batching
applications, commissioning and for general cleaning activities.
Standard configurations have bi-directional capability and high
cleaning performance.
 Cup Type – It moves uni-directional. This tool type is recommended
to be one of the first tools in the cleaning program, specially in cases
where pipeline has not been cleaned for a long period.
These Rosen cleaning tools can be fitted with transmitters to
ensure tool tracking, if needed.
Pig Accessories – Brush (Metallic) , Magnets, Transmitters, Sealing
Disc, Gauging plate etc.

9. WHY IPS ?
• It is said that the strength of a chain is equal to its
weakest link.
• To minimize the risk of operating a petroleum pipeline, it
is required to have a detailed knowledge about the
structural integrity, the information about the pipe wall
condition.
• Only a few meters of the pipeline is visible & can be
inspected from outside.
• IPS (Intelligent Pigging Survey) tool is a NDT tool,
designed to check the health and integrity of a pipeline to
enhance the safety & efficiency of a pipeline.
• CDP is a kind of IPS tool to detect & size the metal loss
features of a pipeline.

10. Cleaning before Inspection
Important - Why ?
A clean inner pipe surface is a pre condition for high
quality in-line inspection results. Inefficient cleaning
may affects inspection survey performance -
b) Mechanical failure of the CDP. E.g. Jamming odometer
wheels
c) Lift off of the magnetizing Brushes, Loss of magnetic
strength.
d) Lift off of the sensors, limiting detection with magnetic
flux leakage.
e) Accumulation of metallic debris disturbing the sensors.

11. PIGGABLE
A pipeline system consist of
two parts: OD(mm) 355.6 355.6 355.6
2. Pipeline
3. Pig Traps
Thickness
OIL’s pipeline has variable 7.92 9.52 11.91
(mm)
ID due to three thickness
with constant OD. It requires
cleaning/guiding discs of ID(mm) 339.76 336.56 331.76
different diameter.

12. PIGGING TRAPS
• The ROSEN designs compact MFL tools for specific
projects to work with the existing traps. The length of the
tool depends on the diameter of the pipeline to
accommodate the components. The size reduces with
the increase in the diameter of the pipeline.
• Receiving Trap strainer may have to be removed before
receiving the CDP to avoid damage of the sophisticated
sensors.
• Trap design is important for arresting debris/wax and to
regulate the pig pushing force.
• Launching Trap should accommodate the pig in such a
way that pressure equalization can be done properly to
avoid accidental collision of the pig with the gate valve.

13. INTELLIGENT PIGGING SURVEY OF 14”
PIPELINE FROM BARAUNI PS TO PS5
TYPE OF INSPECTION : Corrosion Detection pigging based
on magnetic flux leakage method
NUMBER OF SECTION : 15 no, Average Length of 50km each
TOTAL LENGTH : 756 Km from BPS to PS5
PROJECT CONTRACTOR: Rosen Europe B.V.,The Netherlands.
PERIOD OF OUR VISIT : 19.06.2007 to 26.06.2007
PROJECT MANAGER : Jeroen Dirven

14. At Oldenzaal,The Netherlands
During the visit to Rosen Europe B.V. at Netherlands, we covered
the following areas by way of presentations, plant & facility visits and by
open discussion with the project manager & software engineer at Oldenzaal.
• Introductory presentation about the company and it’s activities.
• Latest technology adopted for in-line inspection and pipeline integrity
management.
• Presentation on CDP and it’s components, benefits and limitations.
• Visit to the workshop, carrying out repairing and maintenance jobs on
various types of in-line inspection tools received from fields.
• Visit to storage facilities, pig storage and spare parts storage area.
• Presentation on Rosoft software used for handling database collected
from in-line inspection.
• Discussion and question-answer session.

15. Rosen Training & Research Center
(RTRC), Germany
• Repeat presentation about the company.
• Presentation on different types of in-line inspection tools and its
accessories.
• Visit to Production Line; Manufacturing Units (Metallic parts).
• Visit to Polyurethane and Plastic component Manufacturing Units.
• Visit to full scale test facility area and simulation of Pull-through test
with CDP.
• Visit to data storage device section meant for testing and preparing
the devices for in-line inspection tools
• Visit to equipment testing lab & facility section for tool calibration.
• Visit to electronic component & circuit board designing , testing and
developing section of the company.
• Visit to see the CDP and actual accessories and components to be
used in IP survey of OIL pipeline.
• Visit to data analysis and interpretation section

16. SPIDER NOSE PIG :
To clean the forehead of the pig during pigging, to reduce the back
pressure. The spider nose creates turbulence and avoids
accumulation of debris and wax in front of the tool.

17. DESCALING PIG:
- used to clean the hard scale from inner surface of the
pipe wall.

18. PIG YARD
Bi-Di high performance cleaning pigs

19. In-line Metal loss Inspection
CDP (Corrosion Detection Pig)
• The basic element of the metal loss survey is the high-resolution
Magnetic Flux Leakage (MFL) technology.
• The pipe wall is magnetized axially to saturation level using the very
latest permanent magnets.
• High magnetization levels are necessary to differentiate corrosion
from other pipeline features such as hard spots, stress and strain
variations and to minimize the effects of permanent magnetization
and velocity.
• In a pipeline with no flaws, the magnetic flux travels undisturbed
through the walls.
• Internal and external metal loss due to corrosion that turns steel into
non-ferromagnetic iron oxide and magnetic flux “leaks” out of the
pipeline and is recorded by its sensors.
• Mechanical damage can be detected because the magnetic
properties of steel are changed locally due to plastic deformation.
• High magnetization levels of >10 kA/m ensure the validity of the
results.

20. MFL Inspection Tool (CDP)
The CDP is a high-resolution MFL inspection tool utilizing
longitudinal pipe magnetization, and it is optimized to detect and
accurately measure pipeline anomalies such as corrosion, gouging,
construction features, pipe mill defects and others.

21. Corrosion Detection Pig

23. PARTS OF CDP
Magnet Unit:
To achieve the required magnetization level in both straight pipes with varying
thickness and bends – the tool is equipped with multiple spring supported permanent
magnet units mounted on the central body.
Sensor Unit:
Spring loaded sensor units prevent vibration and maintains the parallel guiding along
the pipe wall in bends and internal diameter changes etc. Field sensors (25x8=200
nos) measure the actual magnetic field strength in the pipe wall and the flux leakage
at the anomalies.
Odometer Unit:
Odometer wheels measure the distance covered during an inspection. It has various
applications:
– To derive the location of anomalies and pipeline features
– To evaluate the dynamic performance of the MFL tool
Computer Unit:
The on-board computer is used to process and store all recorded pipeline data as
well as the speed and the acceleration of the tool. It can withstand temperature up to
65 degree C.

24. CDP Tool Components
Magnetic Unit
Odometer
Sensor
Power supply Unit Computer and data
recorder Unit
On/Off Switch
Universal Joint

25. Pipeline Data Logger (PDL)
Rosen’s pipeline Data Logger can record
data for pipelines up to 500 km or pig runs of
more than 30 days.
Key Benefits :
• Bolts onto any cleaning tool.
• Fast-response sensors recording high-
resolution data.
• Supplied with user-friendly operational and
graphic software.
Time-Based Recorded Profiles :
• Temperature profile.
• Absolute and deferential pressure profile.
• Three axis acceleration profile (also providing
for inclination and rotation of the pig).

26. ITX Transmitter
ITX transmitters are new generation of Rosen
pig transmitters having compact design with higher
signal range (up to 23 meters), longer operating
time (more than 500 Hrs) and improved handling
and safety features.
Key Benefits :
• Easy replacement of batteries.
• On/Off switch without dynamic seal.
• Max. pressure 200 bar. On/Off Switch
• Max. operating temperature 85 ºC.
• Bolts onto any cleaning and ILI tool.
• Operating time up to 500 Hrs.
• Signal Range up to 23 mts.
• Applicable in all media due to stainless
steel housing.
ITX Transmitters

27. Above Ground Marker – BM6
Benchmarker System

28. Above Ground Marker – BM5
(CDP)
Benchmarker Systems

29. Marker Magnet
20×10×5 cm3
Wt. = 2 Kg
Benchmarker System

30. Picture 18
High Quality Inspections
High Level
low Level

31. High Quality Inspections
Importance of high magnetization level
Identical Anomalies seen at different magnetization levels
18.2 KA/m Magnetization 7.6 KA/m Magnetization

32. Pull-Through Test
(simulation run of CDP)
At RTRC, Germany, Pull-Through test area was shown to us
having facilities to carry out simulation runs for in-line inspection
tools on the test pieces having length of 30 meter and diameter from
8” to 56”. We also observed a test piece of 30 meter length,
vertically standing to carry out simulation test on straight vertical
pipeline. All these test pieces were having a predefined artificially
created defects to carry out calibration on in-line inspection tools for
certification.
In our presence, a sample simulation run was carried out with
a 12” CDP tool on a 30 m pipeline test piece to show the calibration
process.
After this test we were taken to calibration and certification
section and were shown the process of data downloading. It was
informed that all in-line inspection tools are calibrated and certified
at this centre before sending to the working site.

33. Rosoft Data Management For
In-line Inspection of a Pipeline
This pipeline based software suit consists of the following components :
1.1 Rosoft for pipelines – It gives digital information on all the data recorded during the
survey and on all the reported results of the inspected pipeline.
1.1.1 Rosoft maps – Rosoft map publishes the pipeline trajectory, characteristics and
height profile to perform location based analysis.
1.1.2 Rosoft 3D pipe – It presents a 3 – dimensional virtual view of the pipeline
including features, locations and characteristic.
1.2 Rosoft Risk Management – It identifies pipe sections most at risk using assessment
criteria to develop integration and control measures to minimize susceptibility from
active threats.
1.3 Administration – It assists installing, removing and managing pipeline data.
1.3.1 Line Manager – The line manager is a task which assist installing, selecting and
removing pipeline data.
1.3.2 Backup Manager – The backup manager provides an integrated backup and restore
system along with the ability to store intermediate results
1.3.3 Security – It administrates different user right levels of Rosoft users.
1.4 Data services (ETL) – ETL module is used to extract, transform and upload Rosoft data
to SPDW (Standardized Pipeline Data Warehouse).

34. Other In-line Inspection Tools
 Extended Geometry Tool (RoGeo-Xt) – RoGeo-Xt tool is
based on an innovative hybrid concept. It combines a
traditional mechanical caliper arm with an electronic distance
measurement system thereby optimizing measurement
accuracy and –providing 100 % circumferential coverage. It
consists of two sensor units which are connected to each
other : a touch less sensor is integrated inside the sensor
head and a position sensor monitoring the mechanical
position of mthe sensor arm attached at the bottom. Since the
non-contact electronic sensor compliments data obtained
from caliper arm so even sharp transition on the internal
surface is recorded accurately.
 Axial Flaw Detection Tool (AFD) – The AFD tool also
uses high resolution MFL technology and induces a magnetic
field perpendicular to the pipeline’s longitudinal axis. On the
basis of disturbances in magnetic field, seam welds, their
position in circumferential direction and seam weld flaws can
be accurately detected.

35.  EMAT Crack Detection & Coating Disbondment Tool -
This tool is based on an electromagnetic-acoustic conversion
resulting from the application of an eddy current within a static
magnetic field. The Lorentz force and Magnetostriction
generated thereby lead to an interaction between the EMAT
tool and the metal surface. This interaction in turn produces
an acoustic wave within the material. Crack features such as
stress corrosion cracking and other individual cracks like
fatigue cracks disturbs the guided waves and produce echo.
On the basis of the detection and measurement of the echo,
the features and condition of the pipe wall can be accurately
inferred.
 Robotic Pipe Scanner (RPS) – The basic principle of
RPS metal loss survey is also based on High resolution MFL
method. The semi-automatic mechanism of RPS system is
able to clear and bypass pipeline supports and it is useful
where traditional methods (ILI) cannot be used.

36.  Automatic Coiled Tubing Integrity Monitoring (ACIM) –
The failure of on/off shore coiled tubing are significant in
terms of non-availability of services and operational
losses (financial). The Rosen ACIM tool detects critical defects
(metal loss, corrosion) using MFL technology. It performs real-
time measurements of the coiled tubing condition and the
measured data and report can be read and analyzed with the
Rosen software. Based on these results, an operator can take
appropriate corrective action in time to avoid unwarranted failure
of the tubing.
 Electronic Geometry Tool (EGP) – It has a fully computerized
measuring system designed to inspect the internal geometry of
the pipelines ( such as bends, ovalities, dents etc.) and to locate
hidden third party damage to confirm a free passage for any
other tool. All possible obstructions are indicated, located and
sized by this tool in most cost effective way. The unique touch
less measuring system of EGP ensures a full circumferential
coverage of the pipe wall due to overlapping sensors and allows
bi-directional operation of the equipment. The measurement
principle is based on multi-channel eddy current technology.

37.  XYZ Mapping Tool – XYZ mapping is a new
service in range of Rosen inspection activities.
It has been developed for identification of 3-
dimensional geographical pipeline coordinates
by an inertial navigation unit which is a
combination of accelerometer and gyroscope.
MFL sensors and geometry measurement
system with touchless eddy current technology
are also incorporated for the detection
geometrical anomalies and accurate weld
detection
 Tank Bottom Inspection Tool (TBIT) –
Rosens Tank Bottom inspection tool forms an
essential part of tank integrity and risk
management as required by the new
government standards. It is a self contained
battery operated unit requiring no cable for
inspection of tank bottom plate by using MFL
floor scanners.It has a very high inspection
capacity, short inspection period and can
inspect both lined and coated bottom floors.

38. Rosen Combo ILI Technology
Tools
Units available for combination : Possible Combinations with CDP as
central body :
Speed Control Unit
XYZ Mapping Unit CDP
Extended Geometry incl. XYZ Mapping
CDP
CDP
CDP
CDP
Other tool combinations :
High-resolution Geometry Unit (XGP) (including XYZ Mapping) in
combination with different high resolution metal loss inspection tools are –
> Axial Flaw Detection (AFD) + XGP (incl. XYZ)
> Corrosion Detection (CDP) + XGP (incl. XYZ)
> XGP (incl. XYZ)