Recent / Featured R&D Projects

This project will provide a major update to the alternative girth weld defect acceptance criteria. The focus of the project will be in two primary areas: a) To update the alternative defect acceptance criteria to address the immediate need of pipeline construction in the USA, typically with pipeline longitudinal strains less than 0.5%; and b) To develop alternative defect acceptance criteria for ultrahigh strength pipelines (e.g., X100) in geotechnically challenging environments, such as arctic areas and deep water offshore. Update Appendix A of API Standard 1104 for girth weld defect acceptance criteria as specified in Federal regulations (49 CFR, Parts 192 and 195), to reflect the increased use of mechanized welding and automated ultrasonic testing in new pipeline construction.

The project will develop a working model to allow industry to predict the overall benefits of hydrotests. Such a prediction will be made with a consideration of various characteristics of a pipeline including the type of operation, stage of cracking, environmental susceptibility, steel metallurgy, and operation history. When hydrotesting is necessary, the model will help operators select the best parameters that would generate the most effective crack remediation.

JENTEK will adapt Meandering Winding Magnetometer (MWM)-Array technology and use JENTEK multi-variate inverse methods to deliver hybrid MWM-Array/MFL methods for ILI applications. For detection/sizing of internal/external corrosion, mechanical damage and SCC, with matching funds from Chevron, we will develop solutions for conventional pigs and platforms for unpiggable lines. We will also address concerns for pipelines with internal liners and coatings. Pigging platform providers will also provide matching funds.

The primary objective of this project is to advance the PIGPEN technology to pre-production status by completing development of advanced algorithms, field testing in a range of pre-production scenarios and developing practical procedures for deploying and utilizing the technology. This effort will address PHMSA's and Industry's need to develop technology that will monitor encroachment and prevent damage while construction equipment is digging and/or boring.

Working in collaboration with industrial sponsors, EWI proposes to: (1) extend the previous AUT work to develop a methodology for quantification of AUT systems, (2) enhance and quantify AUT image capture capabilities, (3) benchmark the performance of multiple AUT systems using blind trials approach, (4) implement the methodology in field tests using realistic operating conditions, and (5) incorporate project results into Reliability Based Design and Assessment (RBDA) standards.

The overall objectives of the research are as follows:

• Develop an automated welding system for use on in-service pipelines;
• Implement a real-time adaptive control system to ensure reliable welding conditions;
• Evaluate system performance by performing laboratory trials; and
• Validate the system and gain regulatory approval by qualification of procedures, complying with recognized industry standards, and performing field trials.

Project is to support efforts towards the development and application of procedures for welding on in-service pipelines using alternate welding processes.

This two-year research program is proposed to: (1) Experimentally determine the role of high strength magnetization during frequent pigging on the possibility of hydrogen damage in thick-walled, high-strength steels, both in base metal and the heat affected zone of welds [HAZ]; and (2) Determine the hydrogen damage mechanisms through polarization studies.

This study will identify the different disposal options available for pipelines abandonded or removed from the Gulf of Mexico. The options will be assessed with regard to feasibility, safety and cost, and compared in a manner that will assist the industry to make risk-based decisions regarding the proper disposal of subsea pipelines.

The project will conduct a technology assessment to determine the requirements for a new remote-field eddy current (RFEC) testing system.

Test system at a suburban road construction site to show feasibility and identify potentate issues

TTI has provided in detail a description of the work task, time line and identified six different quantifiable metrics to measure the performance of the test sensors.

Validation of the newly available direct assessment methodologies for both external corrosion and stress-corrosion cracking; development of improved modules for assisting operators with controlling the parameters that cause stress-corrosion cracking; approaches for improving the integrity of systems with wrinklebends and buckles; and a viable approach to running fracture that should help operators minimize its consequences when ruptures occur.

To develop a repair tool kit that will assist pipeline operators in determining available repair methods while defining anomalies in seam welds.

To develop proper guidance on the use of existing failure criteria for corroded linepipe operating in the ductile/brittle transition regime.

Investigate the development of new sensors and instrumentation that could work with currently available MFL in-line inspection tools to detect external coating disbondment. Much like the bore diameter sensor and inertial guidance systems that are being added to MFL tools, these sensors would not add substantial cost or complexity to a normal MFL survey. Moreover, coating assessment during in-line inspection will help pipeline owners assess the general health of the coating protecting their pipeline system.

The goal of this project is to apply laser ultrasonics for monitoring the integrity of girth welds in real time, using a measurement sensor that is mounted in tandem with the weld head. This project is consolidated with a parallel project on the development of hybrid laser arc welding for girth weld production.

The purpose of this research is to conduct a baseline study of alternative ILI vehicles that might be able to negotiate unpiggable pipelines.

To establish the potential for fatigue failure from corrosion, particularly under the loading conditions experienced by oil pipelines, and the implications for corrosion assessment.

The objective of the project is to enhance and evaluate a portable, cost effective, and reliable direct-assessment tool capable of detecting metal loss, pits, and cracks in ferrous pipes that does not require the removal of pipe coatings, and has the ability to be used through keyhole and traditional excavations.

The program objective is to improve and/or validate the butt fusion process by developing novel analytical solutions and new test approaches to ensure the safe long-term performance of polyethylene (PE) butt fusion joints.

This will be accomplished through comprehensive testing and evaluation of combined effects of circumferential stresses and other in-service stresses acting on buried in-service PE joints. Additionally, the program will provide for an in-depth evaluation of the state-of-the-art NDE technologies to determine the most suitable or most promising technology to apply or recommend for further development.

The objective of the proposed effort is to apply the proven technologies of laser ultrasonics and finite difference simulation toward the development of a tool that can provide the ability to map the SCC colonies accurately and provide spatially precise 3-dimentional data, and to develop an application that can do so in an efficient manner in the field.

Develop quantitative measures that determine which of the current corrosion assessment criteria are valid to assess corrosion defect severity and determine failure pressure.

To extend present guidance for assessing corrosion metal loss defects to material grades from X70 to X100.

The objective of Phase I is to formulate a preliminary assessment of whether Integran's knowledge of tubing repair can be applied to the large-diameter gas transmission pipe geometries and failure scenarios that are of specific interest to the DoT.

Project will analyze and develop pipeline repair plans and capabilities for spool piece repair and leak clamps for deepwater (1000+ ft) pipelines in he Gulf of Mexico.

To define the detection and sizing capabilities of current state-of-the-art phased-array technique for non-destructive inspection of electrofusion and saddle lap-joints in polyethylene gas distribution pipelines. Additional tasks include the development of an optimized phased-array procedure and determination of the performance of the technique and proposed improvements.

This proposed effort will support identification and demonstration of External Corrosion Direct Assessment (ECDA) technologies for demanding pipeline situations (cased and non-cased crossings, pipe with shielded coatings, segments with stray currents or interferences from other pipelines). The deliverable will be a published procedure (best practice) for ECDA that allows the identification of ECDA techniques for each situation. The results will be fed into industry standards and recommended practices (e.g., ASME and NACE) to assure the fastest possible implementation.

The objective of the proposed project (part of a three project Consolidated Program) is to develop a segmented Magnetic Flux Leakage (MFL) sensor and respective module for integration in a robotic platform (TIGRE; being developed through a parallel project, which is part of this Consolidated Program) that will allow the inspection of presently unpiggable transmission pipelines. The sensor will cover only a portion of the pipe's internal surface but should be able to provide the same level of sensitivity and accuracy as a state of the art MFL sensor used in smart pigs. Through multiple passes of the pipe, or through rotation and translation of the sensor down the pipe, the entire surface of the pipe will be inspected.

The development of the "Soft Crack Arrestor" validated design procedure will allow this device to be used for a wide variety of natural gas and liquid CO2‚ pipeline projects. This device will reduce the risk associated with catastrophic fracture of large-diameter natural gas or liquid CO2‚ pipelines.

The objective of the proposed project (part of a three project Consolidated R&D Program) is to develop a robotic platform (TIGRE) that will allow the inspection of presently unpiggable transmission pipelines. The platform, which is based on a locomotor developed for another robotic application in gas pipelines (Explorer; developed for visual inspection of distribution mains), will be able to propel itself independently of flow conditions, and will be able to negotiate all obstacles encountered in a pipeline, such as mitered bends and plug valves. The robot will be powered by batteries, which will have the capability of being recharged during operation by extracting energy from the gas flow. The operator will have live control of the robot using two-way through-the-pipe wireless communication, thus eliminating the need for any tether. The platform will be equipped with a segmented MFL sensor, also able to negotiate all pipeline obstacles, for NDE of the pipeline. The sensor will be developed through a parallel project, which is part of this Consolidated Program.

The project aims to understand how Fuel Grade Ethanol and other ethanol-rich products might be transported via pipelines.

The objectives of this program are to develop easy to implement methods based on sound physical principles to estimate (i) external corrosion rates, especially in CP shielded areas and (ii) internal corrosion rates by considering pipeline-relevant factors for gas and liquid lines. The inputs to these models will be information obtained by pipeline companies during direct assessment or other base-line integrity assessment process. A further objective is to validate these methods using a combination of field and laboratory data.

The goal of this project is to develop and demonstrate a tool that enables operators to make judicious decisions about repairs and re-inspections with regard to pipeline segments affected by SCC. One expected result is a solution that integrates the latest developments in non-destructive evaluation technology and provides a comprehensive, field ready, tool to evaluate, assess and determine repair requirements for SCC.

The work proposed here will establish the capability of the dual magnetic field MFL technology to detect mechanical damage and discriminate between critical and benign anomalies. This project will entail building a dual magnetization MFL tool and testing in an operating pipeline.

The objective of the proposed project is to develop heat-affected zone hardness acceptance criteria that can be used to evaluate welds during the qualification of procedures for welding onto in-service pipelines.

To develop an ICDA method applicable to pipelines transporting liquid petroleum products (e.g., crude oil, fuels) so that liquid pipeline operators can utilize DA for integrity verification.

The overall objective is to gain fundamental understanding of factors affecting weld properties and utilizing that understanding to guide the selection of welding processes and the development and qualification of welding procedures for the production of high quality welds in high strength X100 line pipe. Weld quality will be considered in the context of productivity and other practical constraints.

SwRI recently completed a PHMSA project on Modeling Reassessment Intervals and is conducting a PRCI project on Internal Corrosion and has identified the needs, consistent with the current PHMSA BAA, for developing guidelines for more reliably predicting field corrosion growth rates. The main objectives of the proposed work are: (1) Improving the current existing internal corrosion rate model for wet gas pipelines and further verifying the model using field corrosion growth rate data, (2) Developing a thin-film internal corrosion model to predict corrosion rates in dry gas pipelines with gas quality upsets, and verifying the model using field corrosion growth rate data, and (3) Using the existing external corrosion model to predict external corrosion rates with including the effect of CO2 permeation from soil into a disbonded region through a holiday and through the coating itself.

The objective of this proposed project is to develop a crack growth rate (CGR) model for pipeline operators to use to: a) Identify locations that should be given a high priority for assessment of stress corrosion cracking (SCC), and b) Determine the re-assessment and re-inspection intervals. The outcome of this project will be a tool to predict where SCC is most likely to occur, to prevent SCC failures, to ensure continued reliable pipeline operation, and to protect public safety. This project will help to achieve the pipeline operators' goal of zero failures by SCC.

The main objective of the proposed research is to leverage a free-swimming acoustic leak detection tool that is currently used in the water pipeline industry and further develop the device for application in oil product pipelines and evaluate its potential for natural gas pipelines. The target is to develop a device capable of detecting very small leaks (< 1 gpm) and further develop a software program to provide on-site evaluation of results to the end user. The goal is to have a commercially available device within a 24 month project duration.

The objective of the Differential Impedance Obstacle Device project is to develop a tool that can be coupled with a pipeline drill rig to detect pipeline obstacles in the drill path. The final deliverable is a device that can be commercialized. GTI will conduct a series of in-ground tests to prove that the DIOD can detect obstacles of at least three different materials (plastic, ceramic and metal) in at least three different soil materials (loam, sandy soil, and third type of soil) and demonstrate that the sensor is robust enough to withstand HDD conditions.

This purpose of this research is to detect all underground utilities, including plastic pipelines.

The Pipeline Safety Research and Development project with the Government and pipeline operators will investigate current perspective on the practices, techniques, and technologies that can reduce the threat of third-party mechanical damage, and to codify those findings into an ASME Standard.

The objective of this project is to couple in-service measurements with predictive tools to determine the maximum safe operating pressure and Code margins of safety based on direct measurements of the strains in pipelines that have suffered mechanical damage, or have been subjected to bending, either intentionally in construction or unintentionally from the effects of ground movement.

An examination of numerous coated pipeline segments is proposed, with characterization of the properties and microstructural features of both disbonded and well bonded regions on each segment received. The intent of the project is to answer a simple question that nobody in the industry can truthfully answer: what really causes a pipeline coating to disbond and fail?

The project addressees ECD Assessments for cased crossings, severity ranking of indirect inspection indications and potential measurements on pavement. Specifically, the project will identify assessment technologies for shorted, electrolytically-coupled and electrolytically isolated conditions of cased crossings; to better define severity-ranking classification criteria for data and to develop procedures for recording pipe-to-soil potential and CDVG measurements on pipelines under paving.

The project addressees ECD Assessments for cased crossings, severity ranking of indirect inspection indications and potential measurements on pavement. Specifically, the project will identify assessment technologies for shorted, electrolytically-coupled and electrolytically isolated conditions of cased crossings; to better define severity-ranking classification criteria for data and to develop procedures for recording pipe-to-soil potential and CDVG measurements on pipelines under paving.

There are two primary objectives of the proposed research: The first objective of the proposed research is to complement ECDA protocol by including assessment of threats posed by alternating current and excessive cathodic protection. The second objective of the proposed research is to establish the limitations to applicability to the ECDA indirect assessment techniques under stray current conditions.

The Colorado School of Mines (CSM), in association with the National Institute of Standards & Technology (NIST), proposes a three-year research program to measure the effect of concentration and temperature of ethanol in fuel blends on microbiological and caustic corrosion of high strength steels used in handling and transportation. The project will also determine tested solutions for identified corrosion problems while transporting ethanol-fuel blends.

Categorize ethanol blends into three categories: blends that can be transported in existing pipelines without significant modification of the system and operations (Category 1), blends that require significant modifications (Category 2), and blends that cannot be transported in existing pipelines, but could be moved in specially designed systems (Category 3).Develop data necessary to make engineering assessments of the feasibility of transporting fuel-grade ethanol (FGE) and FGE blends in existing pipelines in a batching or dedicated mode.

Determine the stress corrosion cracking susceptibility of steels in ethanol from different sources.Develop an understanding of the factors that cause source to source to variation in the potency of ethanol towards corrosion/SCC.Identify parameters that can be used to determine the degree of potency of a given source of ethanol in causing SCC for transportability decisions.

The aim of the proposed work is to improve the performance of multi-layer coatings through an understanding of the factors that affect the level of residual stress in the coating and the consequences for coating disbondment. This improved understanding is expected to (1) lead to the identification of improved methodologies for surface preparation and coating application, (2) enable the evaluation of construction or in-service damage on the long-term integrity of the pipeline and, consequently, (3) result in a greater acceptance by the North American pipeline industry for the use of these inherently safer, advanced coating systems

The main objective is to deveolp a new fault tree model that will estimate hit frequency due to third-party excavation based on pipeline condition and prevention practices. In addition to the evalutaion of prevention effectiveness, this model can be used to facilitate the selection of the most cost-effective prevention methods, and to evaluate risk and reliability of existing or new pipelines.

The objective of this project is to quantify the merits of modifications to existing construction practices and emerging practices related to pipeline padding.

The purpose of this research is to develop better technologies for detecting degradation in buried, unpiggable, pipelines.

The objective of the proposed program is to extend EMAT technology to address two areas of direct assessment and inspection of installed pipelines. One area is the full body inspection of tar coated pipelines for corrosion damage with a minimum of excavation. The other is the measurement of residual stress and plastic strain in pipelines that have been bent or otherwise displaced by movement of the surrounding earth or instability in the soil under pipe supports. Particular emphasis will be placed on non-piggable lines and the use of instrumentation that is suitable for field operation by inspection service providers.

The objective of the proposed project is to develop a method for qualification of fiber reinforced composite repairs while simultaneously evaluating the products that are currently available for operators. There is no existing standard for the application and use of composite repairs and field trials are limited to the existing conditions during the repair. In addition, a lack of published data increases the risk for improper installation and use of composite repairs under inappropriate conditions, such as exceedingly wet soils, over-protection with cathodic protection systems, and pipelines susceptible to mechanical damage. Thus a guideline for appropriate use, proper preparation, and compatible conditions must be developed. The end result would be a "buyer's guide" for operators and a reference manual providing data concerning appropriate usage, application, and conditions for the use of composite repair patches.

The overall objective is to determine the limitations/resolution of typically used modern aboveground ECDA techniques with respect to locating holidays and disbondments in the common coatings with varying spatial relationships and geometrical configuration, and to create an extensive test site which enables a wider array of variables to be investigated.

• To determine the effect of electrode drying and arc length on weld metal chemistry, mechanical properties and hydrogen cracking susceptibility.
• To determine the effect of electrode re-hydration on weld metal chemistry, mechanical properties and hydrogen cracking susceptibility.
• To develop practical guidelines on how to prevent hydrogen cracking in welds deposited using cellulosic covered electrodes.

This project will demonstrate the use of modified MFL ILI tools to inspect mechanical damage, cracks, wrinkles and corrosion.

This research project will address the non-metallic issues associated with use and conversion of existing pipelines for ethanol/biofuel transport, as well as develop low-cost options for new non-metallic pipelines. Evaluating effects of ethanol/biofuel blends on non-metallic pipeline components and relevant pipe lining applications are included for existing pipelines. For new pipelines, GTI will research new materials as potential low cost alternatives to specially designed metallic pipelines.

A solid basis for the development of an instrument to provide in-situ measurement of pipeline coatings properties. The measured properties being selected as they pertain to coating fitness for service and for use as guidelines for assisting ultrasonic inspection.

The proposed program has the objectives to make the first major improvements to the most commonly analysis for ductile fracture arrest toughness requirements for gas pipeline applications, as well as to develop experimental data that could be used for validation of more fundamental analyses in the future.

The objective of this project is to develop, demonstrate and commercialize a system that utilizes GPS technology to allow one-call centers and utility companies to ensure that excavation activity does not encroach upon underground facilities. The developed systems will be demonstrated in a pilot program with Virginia Utility Protection Services and NiSource to assess the costs, benefits and feasibility of the system. Trimble and Metrotech are commercial partners for this program.

The primary objective is to develop guidelines that 1) improve prioritization of CIS indications, and 2) create more uniform CIS data interpretation. There is a need to establish an understanding of the CIS profile data beyond the existing interpretation of the off-potential values (in/out of compliance).

We are proposing to develop a set of quantitative guidelines for predicting where and when SCC might be an integrity threat for gas and liquid hydrocarbon pipelines. These guidelines would complement other methodologies, such as the NACE RP0204, ASME B31.8S, and the CEPA Recommended Practices. These guidelines are aimed at improving the industry's ability to locate SCC in the field where the in-ditch protocols detailed in NACE RP0204 would be followed. In addition, the quantitative nature of the proposed guidelines would allow more-informed estimation of the re-inspection interval for repeat DA procedures.

ITT is extending its ANGEL (Airborne Natural Gas Emission Lidar) technology to the detection of small hazardous liquid and refined product leaks. The ANGEL system is designed to remotely detect, quantify, and map small plumes of methane and ethane, the principle constituents of natural gas. In addition to the hardware and software systems, ITT has developed expertise in the spectroscopy, modeling, and empirical/physical testing and validation of airborne dispersed hazardous vapors. These tests have yielded preliminary results that indicate the detection of vapors from hazardous liquids is possible with minimal changes to the existing ANGEL system.

The objective of the proposed research is to develop a set of guidelines for operators, which would enable the users to determine the limiting cathodic protection potentials for a given steel metallurgy and coating type and thickness to mitigate possible hydrogen-induced damage and coating disbondment and/or blistering.

Upon successful completion this project could result in developing an effective application of scanning Meandering Winding Magnetometer (MWM) sensor and Interdigitated Electrode Dielectrometer (IDED) arrays for rapid, in-situ imaging and assessment of several conditions of interest for pipeline life management. The scanning arrays will provide rapid detection and imaging of Stress Corrosion Cracking (SCC) in metallic pipelines and improved manufacturing quality control and in-situ condition assessment of coatings. Integration of these capabilities in a life management framework will provide pipeline owners/operators with new tools to reduce life cycle costs and improve safety margins.

The proposed project is aimed at producing a high-aplitude guided wave that allows inspection of a significantly longer length of pipeline than is presently achievable, based on the magneto-strictive sensor (MsS) guided-wave technology.

This project will systematically apply human factors research and development techniques in meeting two objectives. First, the study will establish an understanding of those human factors that adversely affect the safety, reliability, and efficiency of pipeline monitoring and control operations. Second, guidelines will be developed that can be used by industry to identify human factors problem areas in their operations and develop continuous improvement strategies to improve the effectiveness of pipeline monitoring and control operations.

The objective of this program is to take lessons learned from the lab and input from industry sponsors to develop, test, and validate a "field ready" Hybrid Laser Arc Welding (HLAW) system for full circumferential girth welding of large diameter (NPS30 and above) high strength pipelines.

The project aims to develop innovative hybrid Yb-Fiber Laser and GMAW process and technologies for pipeline girth welding and to demonstrate the system under field conditions. ID root pass welding with GMAW will be the baseline with external hybrid root pass welding techniques developed for variations of laser power and root face thickness since this combination has the greatest potential to meet existing pipeline integrity requirements and facilitate the use of new and existing Yb-Fiber Laser GMAW hot and fill pass techniques. Advanced automation will be used to improve and develop root and fill pass processes, and for attainment of mechanical property requirements.

In a consortium project offered for match requirements via a Group Sponsor Project (GSP) that is about to start at EWI, an integrated LBW/GMAW system based on a commercial bug and track system will be built, and will be used in this project to develop hybrid LBW/GMAW parameters for girth welds in X100 pipe.

To reduce premature coating failures of in-field welded and coated pipeline sections/appurtenances. GTI/EWI will survey/summarize current in-field welding/coating practices and interactions and develop protocols to improve welding-coating coordination. GTI/EWI and partners will weld and coat test sections using the existing and improved protocols and validate improvements with accelerated corrosion/coating tests. A set of clear/concise recommendations will be submitted for incorporation into consensus guides and recommended practices (NACE/SSPC/AWS/API/AGA).

Determine limits of automated ultrasonic testing for cross-country gas transmission pipelines. There are uncertainties in defect detection and sizing using the current zonal discrimination.

This contract covers two separate projects. The first (Project No 138: "Managing the Integrity of Early Pipelines") will develop a quantitative basis for evaluating the significance of specific time-dependent threats, as the basis to determine the effectiveness of mitigative measures proposed in a given IMP. The objective of the second project (this project) is to add soils data to the previously developed external corrosion direct assessment (ECDA) datasets and methodology.

The objective of the proposed project is to expand an ongoing industry project to develop inspection technology for an automated butt fusion inspection instrument to a technology that will inspect any heat fusion or electro-fusion joint such as socket, saddle, elbow, tee, and service line joints.

The goal of this development is to improve corrosion anomaly depth sizing of magnetic flux leakage (MFL) tools by adding phased array Guided-Wave Ultrasonic (GWUT) inspection technology. This addresses Research Area 3 as defined in the solicitation.

Anticipated Results:

The proposed flaw inspection approach is novel by itself and is right on the target for the underground pipeline Transporation infrastructure. There are about 160 pipeline companies in the United States, operating over 285,000 miles of pipe. The proposed system combines the latest development in sensor technology with most recent theories in signal processing to detect mechanical failures and hence will provide valuable information that could save costs for the crude, petroleum and natural gas transportation industry. It will also help to make pipeline structures safe. The system has low computation burden and hence is suitable for real-time applications. Automatic tools for dignosis will also be very useful for other structural integrity approaches, We expect the market for such a system to be in the 50 million range.

In this program, the Colorado School of Mines and the National Institute of Standards and Technology - Boulder will collaborate in the development of non-destructive technology for weld inspection, assessment, and repair in high strength pipeline steels and their weldments. Advanced sensors will allow the pipe integrity to be frequently or continuously monitored to assure pipeline safety and environmental protection. The research would be further advanced by the characterization of hydrogen in pipeline steel weldments. The characterization of hydrogen content and behavior in high strength steel weldments is timely and important with the introduction of new higher strength steels (e.g. X100, which have higher susceptibility to hydrogen damage) in the pipeline industry.

To develop an infrasonic gas pipeline evaluation network that uses low frequency seismic/acoustic (0.1 to 100 Hz) sensor technology to proactively detect and warn of unauthorized activity near underground gas pipelines before damage occurs.

Physical Sciences, Inc (PSI) has successfully developed under a SBIR phase I program the Infrasonic Gas Pipeline Evaluation Network (PIGPEN) system that detects and warns of third-party damage before it occurs. PIGPEN uses low frequency seismic/acoustic sensor technology to proactively detect and warn of unauthorized activity near underground gas pipelines before damage occurs, thereby preventing third party damage and subsequent pipeline leaks or failure. Under the SBIR phase I work PSI successfully demonstrated the basic feasibility of the concept, and will transition the technology from its current proof-of-concept stage to a pre-commercial prototype in phase II.

1. Demonstrate a PIGPEN sensor that meets the performance requirements of a third-party damage early warring system.
2. Demonstrate threat identification and threat location algorithms as an enabling technology for a third-party damage early warning system.
3. Develop a PIGPEN prototype system that forms a basis for a commercially viable project that meets both the performance and market requirements of a third-party damage early warning system.
4. Transition the PIGPEN technology to a commercialization partner.

The objective of the proposed program is to design, develop and test an Experimental Prototype (EP) sensor, advancing the Infrasonic-Frequency Seismic Sensor System (aka PIGPEN) technology to a point where the system is ready for advanced engineering and pre-commercial design and prototyping. Using an independent consultant (to be determined), all issues related to soil geophysics (and in particular signal wave velocity) will be examined and interpreted for the proposed design and EP. Also, as a result of utility, sponsor and cosponsor review, additional tasks will be determined.

Phase I work will focus on development and evaluation of the proposed integrated approach for the metal loss detection in a representative mock-up, including the theoretical analysis of SH wave scattering from a "cup" shape or ellipsoid surface dent in a pipe with 3D BEM, SH EMAT sensor design and fabrication, and metal loss detection and characterization using the nonlinear split-spectrum filter and PCA-LVQ algorithms.

The project aims to develop innovative welding processes and technologies for single-sided pipeline girth welding. Root pass welding techniques will be emphasized since they have the greatest potential to improve pipeline integrity and facilitate the use of new and existing GMAW fill pass techniques. Advanced automation techniques will be used to improve weld quality, process control, seam tracking, and robustness.

This project will build upon previous successful development of a sensor system for gas pipelines that is capable of locating areas of water accumulation, determining the corrosivity of any found liquids, is low cost, and can be operated in both piggable and non-piggable pipelines and extend it to liquids pipelines. This methodology would compliment the LP-ICDA and traditional ILI methods but would provide a direct measure of corrosivity/corrosion rate (an improvement upon LP-ICDA) and would be low cost and could be used in unpiggable pipelines (potential improvements over traditional ILI methods).

The proposed project seeks to develop and validate a method to assess the integrity of pipelines with respect to internal corrosion by identifying and prioritizing locations of corrosion damage. The final product will be applicable to both dry and wet gas lines, including those lines that cannot be inspected using inline inspection (ILI) tools.

Develop a method to use with ICDA to detect water in non-piggable lines. This method will be low cost and will entail introduction of small, wireless sensors capable of detecting water inside pipelines that flow with the gas stream.

In addition to the protection of oil and gas pipelines, the proposed sensor network could be used to monitor leaks in water pipes for commercial or local civil infrastructure or used to detect leaks in chemical or manufacturing plants where potentially hazardous materials are transferred during normal processing operations.

This project will be an evaluation of existing in-line inspection tools for detecting, discriminating, and characterizing mechanical damage. The main benefit is to help industry manage the threat of delayed mechanical damage and document the relative value of existing technology versus additional technology, such as the proposed dual field technique, in characterizing mechanical damage and discriminating defects from benign anomalies.

The new technology will provide the pipeline owner with substantially more information to support excavation and repair decisions. Most importantly, a disbond can be detected and repaired before corrosion or stress-corrosion cracking have set in, or have reached a level detectable by pigging. MEIS technology could be widely integrated into the offerings of commercial pipeline inspection firms.

JENTEK will deliver new capability for inspection from outside pipelines, without coating/insulation removal. The goal is reliable/rapid imaging of external/internal corrosion, mechanical damage, and SCC. With matching funds from Chevron, we will first adapt Meandering Winding Magnetometer (MWM)-Array technology for external damage, using high frequency methods. This includes integrated field demonstrations within twenty-four months. Solution for internal corrosion will transition later, using lower frequency methods.

This contract covers two separate projects. This project will develop a quantitative basis for evaluating the significance of specific time-dependent threats, as the basis to determine the effectiveness of mitigative measures proposed in a given IMP. The objective of the second project is to add soils data to the previously developed external corrosion direct assessment (ECDA) datasets and methodology. (See Project 118, "Improvements to the External Corrosion Direct Assessment Methodology by Incorporating Soils Data")

This research will address mechanical damage ILI through the use of smaller/simpler MFL tools.

The objective of the proposed research is to provide critical standard test methods and data for improving pipeline integrity and speeding the evaluation of new pipeline designs or in-service failures. This objective will be approached by a combination of the following work:

• Develop axial orientation fatigue data for comparison with the girth data,
• Evaluate the effects of hydrogen on pipe fatigue and fracture properties,
• Extend CTOA work to include girth direction data, effects of dynamic rates on CTOA, and modeling of CTOA,
• Examine fracture surfaces to document and evaluate failure mechanisms,
• Provide baseline data and method to define yield strength of high strength pipeline steels and their welds, and
• Transfer knowledge and data to codes and standards bodies.

The development of a test methodology which addresses the application of rehabilitation and repair coatings on wet surfaces is proposed. The method will encompass the extremes of wet surface coating application, namely a continuously wet and cold surface.

The objective of the research proposed is to review potential LNG release scenarios in storage terminals and from LNG ships, and augment exiting analytical/computer models or develop new ones for different types and sizes (a spectrum) of LNG fires by properly considering important phenomena that have effects on the fire characteristics and the hazards they pose. A second objective is to develop protocols for using these models in performing a risk assessment of LNG transport in ships or storage in terminals. Additional objective is to provide mathematical tools with which to make Regulatory assessments or LNG terminal siting decisions.

Develop a field operable monitoring system to determine the conditions under which steel pipelines or other equipment may be susceptible to SCC. Install the monitoring system and conduct studies over an extended period of time. Develop guidelines for decision making from monitoring and other laboratory information.

Includes the following: 1. To brainstorm and review a set of new solutions to the SCR TDZ problem; 2. To select high-value solutions based on high-level comparative assessment; 3. To address analysis, design, material, fabrication, installation, and cost issues in evaluation of solutions; 4. To implement technology qualification and approval process, and identify need for testing and detailed analysis necessary to enable near-term application of TDZ solutions; 5. To demonstrate and quantify the benefits from application of selected TDZ solutions to SCR and floater case studies in different regions and water depths.

The NoPig Pipeline Inspection System has been developed for detecting metal loss anomalies on small diameter non-piggable pipelines from above ground.

Delayed failures of mechanically damaged pipelines can occur unexpectedly and with serious consequences due to time-dependent fracture mechanisms, such as fatigue, as illustrated by the catastrophic failure in Bellingham, WA. The objective of this proposed research is to derive fatigue life related defect severity criteria for pressurized pipelines containing gouged dents using the nonlinear harmonic (NLH) method for detecting surface strain anomalies left in the pipe after gouging. The work will involve gouging pressurized pipes and performing full-scale cyclic pressure tests to failure while periodically inspecting the pipes using NLH sensors. The proposed work will be co-funded by the Pipeline Research Council International (PRCI), with in-kind funding being provided by Tuboscope Pipeline Services who will develop software for implementing the derived NLH-based defect severity criteria in in-line inspection (ILI) equipment.

The major objectives of this program are as follows:

The work is to develop a phase sensitive technology that could detect coating disbondment on steel pipe from above ground, thus locating potential corrosion failure points. The system would consist of two components, a stationary signal generator that is attached to a test point and a detector that is carried along the pipeline. Sinusoidal or pulse excitation signals may be used. A wireless link between the generator and the detector provides accurate synchronization. An abrupt change of signal phase is expected at the disbondment.

This R&D program will offer a low-cost solution to early detect leaks and reduce environmental damage.

This Phase I project will provide us with the necessary background and technical results to proceed with the development of a transitionable multi-mode guided wave piping inspection system. The advanced capabilities of the final commercial product will make it cost-efficient, robust and easy-to-use. The proposed multi-mode pipe inspection system has commercial applications not only for the DOT, but also for the DOD, the DOE, and other commercial industries (e.g. -- drinking water and sewage systems, ship building companies, oil and gas companies, and chemical, petrochemical, and pharmaceutical companies).

The objective of the proposed project is to expand the electronic version of the PRCI Pipeline Repair Manual by (1) adding guidelines for assessing the need for repair and (2) incorporating guidance developed for the European repair manual. The results of this work will be produced as an expert software system for pipeline defect assessment and repair.

The purpose of this research is to develop and commercialize economical, reliable locatable magnetic plastic polyethylene pipe material.

This project will address large scale ground movement events related to landslides, long term slope movement and ground subsidence. The objective of the proposed effort will develop recommendations on engineering practices with respect to the assessment of these large scale ground movement geohazards, and guidance to define appropriate and sufficient pipeline design and operational measures for the mitigation of large scale ground displacement effects on buried pipelines.

The objective of the PHMSA protocols is the verification of a process or an action with the associated documentation. In many cases these processes require contribution from personnel in both the office and the field and as such, PIPe-MAS as a web based application will fully support the user IMP while providing a direct response to any PHMSA auditors' requirement.

GTI plans to develop Guidance on analytical criteria necessary for the introduction of biogas, a new and interchangeable fuel from dairy waste, wastewater treatment, landfills facilities, into existing pipeline networks, in order to assess quality, safety, and compatibility with existing supplies and pipeline delivery infrastructure.

The primary objective is to provide a simple tool to optimize determination of integrity reassessment intervals by more accurately predicting external corrosion rates that are 1) representative of a specific pipeline segment, 2) include distribution of corrosion rates as a function of location and time (allowing prediction of time-to-first-failure). Secondary objectives include 1) putting recently reported NIST data into a context that can be used by pipeline operators and 2) including the ability to allow reduction of predicted corrosion rate based on close-interval-survey and/or other data.

The primary objective of the proposed research is to determine the failure risks and threats to plastic gas pipes by conducting failure analyses including a root-cause analysis to identify defects that lead to failure initiation and growth and prioritizing the risks and threats using risk assessment techniques and to identify an inspection technology to mitigate plastic pipe failures, risks and threats.

One of the leading causes of pipeline failures is corrosion. Current inspection techniques for corrosion may require the pipeline to be shutdown during inspection resulting in loss of revenue. The team of Acellent, ConocoPhillips, BP and Stanford University proposes to develop a Real-time Active Pipeline Integrity Detection (RAPID) system for the detection of corrosion, erosion and associated damage in pipeline structures using a network of distributed built-in sensors. The overall goals will be to reduce structural inspection costs and avoid unplanned pipeline failure.

To develop simplified guidance to assess corrosion metal loss defects in pipelines that are subjected to external loadings in service. Ongoing analytical work is developing simplified rules and methods to account for the effects of secondary loads on the behavior of corroded pipelines, avoiding the need to resort to complex numerical analysis using non-linear finite element analysis (FEA). Extension of this analytical work to address the full range of combined pressure/secondary loading and pipe/defect geometries, and validation of the simplified rules by conducting selected full-scale tests will provide the necessary information on which to base modifications to extend the current guidance beyond pressure-only loading. This work will also address buckling.

Develop next generation tensile strain limit models and strain-based design procedures. This project is part of a Consolidated Program. See also Project No 200.

The project addressees ECD Assessments for cased crossings, severity ranking of indirect inspection indications and potential measurements on pavement. Specifically, the project will identify assessment technologies for shorted, electrolytically-coupled and electrolytically isolated conditions of cased crossings; to better define severity-ranking classification criteria for data and to develop procedures for recording pipe-to-soil potential and CDVG measurements on pipelines under paving.

To manufacture a Stage 2 phased array wheel probe for ILI detection of stress corrosion cracking (SCC). Specifically, to build a smaller wheel probe that can be utilized as-built for In-Line Inspections.

Project will identify emerging technologies, technology gaps, and monitoring techniques; develop SCR validations approach and integrity management methodology; and provide an industry forum for sharing of technology. More specifically to: 1. Develop a systematic method for the integrity management of SCR field systems; 2. Develop an approach to validation of design methods and key assumptions; 3. Provide a framework for structured record-keeping; 4. Develop a method for remaining life/life assessment; 5. Identify and describe current best for SCR integrity monitoring; and 6. Identify technology gaps and emerging technologies for SCR integrity monitoring.

The major objective of the proposed project is to develop design and assessment guidelines for pipelines that may experience high strains in service. This effort draws its basis from a previously concluded project which laid the groundwork to begin the framework of these guidelines (see: Project 101, PHMSA DTRS56-00-X-0035). The guidelines will include:

• Recommended pipeline material specifications to minimize strain localization (soft HAZ)
• Recommended welding specifications to minimize strain localization at pipeline girth welds
• Descriptions of the range of cases where combinations of operating pressure, strain localization, and high strain affect pipeline performance.

The objective of Phase I is to demonstrate that the mature nanotechnology-based structural crack repair concept can be adapted for application as an in-field pipeline repair tool. This will be accomplished by establishing the overall technical and economic feasibility via proof-of-concept degraded pipe plating, repair integrity characterization, preliminary burst testing, and a first-pass cost analysis.

The primary objective of the project is to establish a detailed experimental database to support the development and validation of improved burst and fatigue strength models for assessing the interaction of mechanical damage with secondary features (gouges, corrosion, and welds). The use of this data to develop and validate mechanistic models will produce reliable tools to assess a wide range of mechanical damage forms, thereby increasing safety, reducing unnecessary maintenance, and supporting the improvement of pipeline standards and codes of practice.

The US Department of Transportation (DOT), Pipeline and Hazardous Materials Safety Administration (PHMSA), has a requirement to provide technical expertise as it implements its program of research and standardization activities, focusing on pipeline materials, inspection processes, and measures of materials performance and reliability to support PHMSA efforts to maintain and ensure the integrity of natural gas and hazardous liquid pipelines. The Pipeline Infrastructure Protection to Enhance Safety and Security Act (H.R. 3609) provides NIST and PHMSA with an opportunity for increased coordination and collaboration on natural gas and hazardous liquid pipeline facility research, development, demonstration and standardization.

The US Department of Transportation (DOT), Pipeline and Hazardous Materials Safety Administration (PHMSA), has a requirement to provide technical expertise as it implements its program of research and standardization activities, focusing on pipeline materials, inspection processes, and measures of materials performance and reliability to support PHMSA efforts to maintain and ensure the integrity of natural gas and hazardous liquid pipelines. The Pipeline Infrastructure Protection to Enhance Safety and Security Act (H.R. 3609) provides NIST and PHMSA with an opportunity for increased coordination and collaboration on natural gas and hazardous liquid pipeline facility research, development, demonstration and standardization.

To establish the effectiveness of cathodic protection in mitigating stress corrosion cracking (without causing hydrogen damage) for a range of high-strength pipeline steels from X-70 to X-120, and to assess the effects of overprotection and underprotection.

The primary objective of the proposed project is to develop, test and independently assess the commercial viability of a pre-commercial pipe and joint imaging system. Through this project, this product will be further developed, tested and demonstrated to prospective commercial partners that it can locate pipes and cast iron joints in all types of soils, including some of the most difficult soils for imaging; clay soils. As an added feature, this product will locate with accuracy both the horizontal AND vertical position of the pipe or underground facility and it will distinguish pipes from other underground clutter in dense environments that are typical of suburban or urban areas.

The Pipeline Safety Research and Development project will provide for understanding, identification, and characterization of the MFL signals arising from the geometric and residual stress components to enhance the reliability of employing MFL tools for mechanical damage detection.

• Provide guidelines on linepipe steel properties essential to specific designs.
• Provide guidelines and recommended practices for assessment of strength and toughness of weld metal and HAZ regions that are essential to girth weld integrity.
• Develop and work toward codifying test procedures that are consistent with the requirements of the property specifications.
• Develop and validate assessment procedures that can take essential material property data and predict weld performance.

The proposed program will be comprised of four phases: Feasibility, Application Development, Testing, and Commercialization to be completed over a period of three years. The use of available Unmanned Aerial Vehicles (UAVs) and Unmanned Underwater Vehicles (UUVs) and automotive sensor technologies will allow the team to rapidly converge on a cost effective system solution to conduct aerial surveillance for right of way monitoring and leak detection. Electricore is confident that a Consolidated Program will maximize the results received through the investment by government and industry.

The proposed program will be comprised of four phases: Feasibility, Application Development, Testing, and Commercialization to be completed over a period of three years. The use of available Unmanned Aerial Vehicles (UAVs) and Unmanned Underwater Vehicles (UUVs) and automotive sensor technologies will allow the team to rapidly converge on a cost effective system solution to conduct aerial surveillance for right of way monitoring and leak detection. Electricore is confident that a Consolidated Program will maximize the results received through the investment by government and industry.

The project objectives can be summarized as follows:

*Obtain high quality experimental data to allow the effects of the most important parameters on the tensile strain capacity of pressurized pipes to be determined;

*Using the experimental data, and building on previous work, determine the accuracy of existing models (FEA and other engineering models) to predict full-scale results, make initial modifications to improve model accuracy and identify requirements for next generation model developments;

*Prepare initial recommended procedures, for design and material testing, for establishing project-specific, tensile strain limits for pipelines designed using strain-based design methods; and

The objective of the proposed (individual) project is to further validate and develop a product that can be used as a screening tool to detect external and internal corrosion and coating defects in gas pipes (with diameters from 2" to 60"). It is particularly useful where traditional DA or inspection technologies cannot be used. Propagation distances are claimed to be on the order of 50 – 100' in each direction from the transducer ring but distances vary based on pipe geometry, coating, content and presence of pipe appurtenances such as valves, tees, etc.

The ability to discriminate flaws that do and do not affect pipeline integrity is important for low stress pipelines which are subject to new DOT pipeline integrity management regulations. Current federal regulations do not provide guidance on the need to repair mechanical damage to low stress pipelines. The objective of this research is to demonstrate that flaw acceptance criteria normally applied to high stress pipelines are overly conservative and may be relaxed for low stress pipelines.

• To test a large set of girth welds produced under realistic conditions by a state of the art high productivity GMAW system.
• To demonstrate the effect of material variability between pipes, between heats and between pipe manufacturers.
• To validate current and proposed new weld defect assessment methods against the performance of a large set of welds made under field production conditions.

The objective is to estimate corrosion growth-rates, reduce assessment costs, and improve the selection of reassessment intervals of pipelines and increase their safety. This will be achieved by: (1) perform field tests and demonstrations using LPR and ER technologies, (2) correlate results with weight-loss of buried coupons, (3) evaluate soil parameters that affect corrosion, and (4) incorporate the measurements into a database and program that improves corrosion-rate estimates.

This verification project is to quantify the predictability of direct assessment standard processes to accurately predict coating damage, by integrating facility and historical inspection records, recent remote voltage, and current or magnetic inspections.

The object of this project is to support current efforts towards the development of a Guidance Note for Fillet Welded Connections to pipelines.