Congratulations to the 2023 APGA Innovation shortlist!

PipeServ

View the full presentation here: Crude Line DN450 – VIC (1)

Another Problem Solved by PipeServ Location: Victoria, Australia Application: Pipeline Lifting & Inspection

PipeServ was asked to assist in plans to lift a DN450 crude oil pipeline to allow for pipe inspection and the replacement of several pipe support materials.

This pipeline was within a rail easement with very limited access for any vehicle and near impossible to access with a crane. Add to this the uneven ground, the height of the pipeline off the ground, and the difficulty was increasingly challenging.

PipeServ was able to assist the inspection company by supplying the Ovolifts Multi-Jack tools to engineer a safe lifting solution. This providing the required clearance between the pipe and the pipe support whilst the pipeline is in-service.

Engineering recommended that the pipe also be lifted at the adjacent supports and reduce the pipe stress. Three tools were used, allowing for a controlled pipeline lift. With the tools securely locked in position, the inspection team was able to complete their works.

Major benefits experienced were:

• A controlled pipe lift from a remote position.
• Ease of manual handling (1-2 person lift).
• Able to use tools on various pipe supports.
• Speed of installation.
• Significant cost savings.

PSSS

View the full presentation here: APGA Innovation Award Proposal 2023

PSSS + Axis Machines Pte Ltd
Axis Machines Pte Ltd is a newcomer to the portable machine manufacturing market. Behind it though there are 80+ years of specific industry knowledge through Managing Director and owner Alan Thompson and his R&D team. Based in Singapore, they are in an ideal location for efficient and cost-effective component production whilst maintaining only the highest level of quality in both components and workmanship.

The Axis AF842 Flange Facing Machine
The Axis AF842 represents the pinnacle of machining technology, meticulously designed to meet the unique demands of our industry. This proposal provides a comprehensive overview of the Axis AF842, highlighting its innovative features and how it stands to revolutionize ‘in-field’ machining here in Australia and globally.

What Are Flange Facers?

Flanged joints are integral to any petrochemical production plants, oil wells, pipelines, and power generation plants. Although the factory flanges come with a machined gramophone finish this can become damaged or scratched. When this occurs the flange will need to be replaced or re-machined in situ. The gramophone finish is a spiral path across the face of the flange. This spiral path allows for the gasket to be compressed into these grooves providing an effective seal. Even after a flange has been in service, corrosion can make its way inside the joint compromising its integrity. When a flange is in need of refacing, the Axis flange faces can be installed in the bore of the flange or mounted to the outside of the flange. The flange machine will rotate the facing arm across the face first machining off any imperfections, corrosion, or scratches. Once these are removed, the facer returns to machine the gramophone finish.

• Material
  • The Axis AF842 is designed to be: Portable, Lightweight, Yet versatile enough to handle challenging flange materials, including Inconel. Its core components are constructed from high grade 7-series aluminum alloy, offering the strength of steel while maintaining a lightweight profile, making it ideal for on-site operations.
• Facing Arm
  • A unique feature of the AF842 and other new age Axis Machines is the facing arm is engineered for adaptability. It can extend to reach flanges of varying sizes and retract to accommodate smaller flanges. Additionally, its design allows for maneuverability in tight and confined spaces, ensuring it can access even the most challenging locations. No other comparable machine allows this.
• Tool Post
  • The tool post is a marvel of precision engineering, traversing across the facing arm on precision ground V rails. These rails are polished, hardened, and generously sized to ensure stability. The carriage that slides along these rails is crafted from graphite-impregnated Ally Bronze, providing low friction and Self-lubrication without the need for oil or grease.
    The tool post can swivel and cut in 360 degrees, allowing for versatile machining operations, including the creation of immaculate 1.6mmsurface finishes for RTJ grooves.
• Drive Hub
  • The Axis AF842 is powered by an internal air motor, ingeniously housed within the drive hub, ensuring a low profile, suitable for tight workspaces. The air motor employs a unique planetary gear system, balancing the inertia of the facing arm for smooth and consistent transmission. This design is particularly advantageous when machining flanges in vertical positions, countering the effects of gravity.
• Counterbalance
  • A standout feature of the Axis AF842and its sister machines, is its Modula counterbalance system, consisting of1kg blocks and a 6kg block, mirroring the weight of the tool post.
    These counterbalance blocks are precisely positioned to match the extension or retraction of the facing arm. This dynamic counterbalance ensures smooth, load-free swing of the arm, maintaining constant RPM and uniform cuts for a flawless surface finish.
• Gearbox
  • The machine’s gearbox offers a range of federates, enabling the creation of diverse surface finishes. With six available feed rates, the tool can automatically feed inward and outward along the facing arm, accommodating various joint types and gaskets.
• Base
  • The Axis AF842 is equipped with three bases to cover a wide range of bore sizes. Each base is secured to the flange via eight adjustable legs that extend outward. These heavy-duty, high-tensile extension legs include large extension bolts and mounting feet designed to grip the bore of the flange. Four of these feet facilitate machine centralization, ensuring precise leveling, while the remaining four provide stability and support once the machine is positioned correctly.

ROSEN

See the Full presentation here: ROSEN-Group_APGA_Innovation_Award_Application_RoMat-DMG_Service_Presentation

ADVANCED PIPELINE DIAGNOSTICS ROMAT DMG SERVICE

THE CHALLENGE – WHAT ARE HARD SPOTS IN PIPELINES?

Areas on the pipe surface with a hardness level higher than that of the surrounding metal are referred to as hard spots.

• Hard spots generally occur during manufacturing processes
• Heating/cooling i.e. heat treatment, welding HAZ ]) creating volumetric internal /external hard spots
• Welding processes creating hard spots on the pipe body or near to long seam position
• Hard spots are vulnerable to cracking

OUR SOLUTION – ROMAT DMG

• ILI service using a well established axial magnetic flux leakage ( technology combined with eddy current technology in a dual magnetization approach
• Accurate and precise detection, classification and sizing of hard spots along the entire pipeline
• Deliverable of information on
  • Hard spot dimensions
  • Base hardness of the pipe body
  • Absolute hardness of hard spots
• Depending on the location and on the type of hard spot different ILI approaches are available.
• Inspection in accordance with API 1163
• Reliable data as a basis for a comprehensive integrity approach considering feature prioritization, susceptibility, verification and response strategies.

Dual m magnetization (DMG) utilizes standard magnetic flux technology (MFL):

• Conventional MFL magnetizes on a high level (high mag) to saturate a pipeline with a magnetic field to be independent from microstructure changes.
• DMG magnetizes on a low-level low mag) to detect microstructure changes.

ROMAT DMG COMBINED WITH OTHER TECHNOLOGIES

The combination of modular inspection technologies on a single tool leads to increased operational efficiency.

• Increased accuracy of inspection data leads to more comprehensive and reliable integrity assessments.
• High resolution detection and sizing of:
  • Hard spot anomalies
  • Metal loss features, e.g. general corrosion or pitting
  • Pipe grade
  • Geometry features, e.g. dents, wrinkles, bending strain, dent stress or dents with re rounding.

Additionally, the mapping data is determined.

YOUR BENEFITS

• Accurate and precise detection, classification and sizing of hard spots along the entire pipeline for timely identification of potential future threats and extension of the asset’s lifecycle
• Differentiation between different types of hard spots
• Market leading ILI technology ensures most reliable data on the market
• Maximizing cost efficiency by combining MFL and eddy current (EC) technologies to identify the most common threats in one run (metal loss, pipe grade, mapping and hard spots)
• Comprehensive service package from threat identification to ILI execution and data evaluation to interpretation of results and integrity management implications
• Inspection in accordance with the latest regulations, such as API 1163

• APGA Innovation awards submissions open on the 31 March 2023.
• Entry into the APGA Innovation Award is restricted to registered exhibitors only.
• Exhibitors will be invited to enter the 2023 APGA Innovation Awards once they open in July 2023.
• Only one entry is permitted per exhibitor.
• Submissions close on 1 September 2023.
• The selected judges on the APGA Innovation Awards selection panel will shortlist the five best entries based off the information provided at the time of submission.
• The top 5 entries will be given an opportunity to produce a five-minute video that will be broadcast at the APGA Convention and Exhibition on Monday 16 October 2023.
• Those same top 5 entries will be shortlisted on the Convention App, which will open for delegates to vote for the best innovation for 2023. Voting will close at morning tea on Tuesday 17 October 2023.
• Winners will be announced at the Gala dinner on Tuesday 17 October 2023.

During the course of the 2023 Convention and Exhibition the Convention App will open for delegates to vote for their favourite and most preferred innovation.

More information will become available during the course of the Convention. Make sure to download you Convention App to participate.

Winners of our 2022 innovation award, Aquip Systems Pty Ltd, have certainly put their innovation into use. Not only did it win at this year’s APGA Convention, but it is already demonstrating its use across multiple industry pipelines, from oil and gas to water and mining.

Well done to our winners, we are looking forward to your next submission in the 2023 innovation awards.

Extract of the winning entries submission

Pipers® technology provides operators full insight in their pipeline assets under all conditions allowing them to make informed decisions − keeping their pipelines safe and efficient.

INGU’s Pipers® technology is the most efficient and economical pipeline inspection solution to achieve Net Zero and ESG compliance for the oil, gas and water pipeline infrastructure. The patented self-serve approach gives full control to the pipeline operator and is designed to actively monitor changes in pipeline condition. By combining inline leak detection, deposit surveys, and wall condition monitoring, the Pipers® technology provides operators full insight in all pipeline assets under all conditions allowing them to make well informed decisions to keep their pipelines safe and efficient.

The self-serve system uses free floating, tennis ball-sized, micro sensor technology that is designed to work under operational conditions, which translates into 100per cent uptime and the ability to take action where and when needed. Pipers® data is highly repeatable making it ideal for monitoring for changes in pipeline condition, keeping operators on top of leaks, deposits and wall condition.

Currently deployed in multiple Industry Pipelines – oil and gas, Mining, Water / Companies – Rio Tinto, WaterCorp, Chevron, BHP, Water Councils Australia wide