bsi Remote UT Monitoring drives rapid roi & risk reduction
Situation: A major interstate gas pipeline with gathering & processing operations was starting up a wellhead in a remote location in Pennsylvania that required ATV transportation to access the piping for integrity monitoring. The concern was erosion-corrosion which is a complicated and expensive problem. Wear rates are known to be uneven and are dependent on product size and density, sand and fluid impingement velocities and angles, and component geometry. This affects pipe intersections, injection points, elbows and reducers. Current practice requires the dispatching of personnel to the remote locations in order to conduct inspections of these assets using a variety of non-destructive inspection techniques. The problem is that those inspections only provide give a one-time snapshot of component the health and they are costly. Any piping failures have high safety and environmental consequences risks. The need was great to improve component maintenance, replacement planning, predict costs, and prevent pipeline failures and the catastrophes that follow.
Solution: The KERR team recognized the problem proposed a continuous monitoring system designed to establish erosion-corrosion profiles, and predict wear-corrosion rates. Berkeley Springs Instruments LLC (BSI) automated online integrity monitoring system for precise and consistent wall thickness monitoring of facility piping and pipelines. The Eagle Array and system can be configured for any diameter, while in operation and under pressure. It is nonintrusive and can be removed or reattached without any interruption of plant operations. The Eagle Array can be viewed as a smart digital health monitoring system that is capable of operating below ground, submerged and in harsh environments. The product also provides the user with a host of environmental monitoring options such as corrosion, vibration/seismic, temperature/humidity and potential third party intrusion alerts. Real time alarming and text-messaging is provided when mechanical health thresholds are reached. Data is transmitted via a mesh network to the Internet through cellular or Wi-Fi.
Results: BSI value proposition was a win-win for the client who recognized improvements in safety performance, reduced overall costs and greater reduction of environmental risk. BSI significantly reduced the risk of the client’s well-head piping failure by providing real time information about the condition of the asset and a projection of its condition into the future. The information can be audited, exported and available 24/7 without dispatching or exposing personnel to risky operational conditions or remote locations. All data is analyzed and formatted per American Petroleum Institute (API) guidelines. Additional benefits include reduced labor and associated overhead costs. Continual and automated monitoring is a critical factor in prevention of the next catastrophe.
East Coast Utility Avoided Costly Line Shut Down
Situation: An East Coast Gas distribution utility had a dilemma on their hands. A major local highway needed to be widened and one of their main 12″ PE Lines was right in the way. The traditional method of relocating a PE Line would have used large hydraulic squeeze tools and would have required multiple fittings, and very large excavations to fit the tools and complete the work. In one area, the squeeze tools could not have even been used because of the proximity of the work area to butt fusion joints.
Solution: Kerr Engineered Sales presented the TD Williamson Large Diameter PE Hot Tapping and Plugging System to the Distribution Company and they chose to use this method to complete their relocation. Several 12″ Stops were performed using traditional Top Entry SHORTSTOPP PE Fittings, and the Bottom out Bypass Tee Fittings.
Results: The work was completed in a safe and timely manner without the lines being taken out of service.
catalytic Pipeline Heater improves performance
Situation: A major East Coast Gas Transmission company called Kerr about a couple of stations where their existing heater equipment was failing. The problems resulted in how our new improved technology would adapt to the environment and provide safe and reliable service. At one of the stations the heater that was previously in service was located outside and had to transfer the heat over 25 feet. This made it very inefficient and costly to operation.
Solution: With the help from Kerr and Bruest Catalytic we provided a very simple, safe, and efficient heater that was installed inside the building. This was only made possible with the fact that the heater is rated for Class 1 DIV 2 and can be put in a hazardous location.
Results: The performance of the heater has led to reduced maintenance time, reduced operating costs from reduction in fuel Consumption) and a simplified operating system.
COMPRESSOR STATION PERFORMANCE IMPROVEMENT
Situation: A major eastern energy company was using foam pigs infrequently and improperly to pig lines into a compressor station. The station ended up flooding with liquid which cost over $500k to repair, clean and restart.
Solution: When the Kerr team was called in, they immediately recognized the problem and source. The compressor station needed a different design of pigs, closures, pig signals and closure door. Education and comprehensive training would be critical for proper process, maintenance and safety. Kerr worked closely with the energy company on the plans, selection of pigs, quotes and recommendations for TDW equipment. The training sessions included three days of hands-on pig runs in the field.
Results: With consistent, efficient pigging the compressor station has run maintenance free over six months. The TDW pigs were run 75 times. A maintenance plan is in place and the technicians know how to avoid future problems.
Plant Shutdown Avoided at Manufacturing Plant
Situation: A New England high tech manufacturing plant that had a chilled water piping system was running under capacity which was restricting the output of the plant. A 12″ line was being run through a 8 meter/line causing a problem in the flow rate, due to a flow restriction. Shutting down the plant to fix the equipment would have cost $1Million/day.
Solutions: The Kerr team proposed solutions that enabled removing the flow restriction while keeping the system on line. TDW Services served as project managers and provided welding services. Extensive training from Kerr provided the necessary education and assurance about the process, field assessment work, job reviews, and field follow up.
Results: The plant’s system successfully stayed in service throughout the project. It was delivered on time and within the budget, avoiding expensive shut downs which would have cost approximately $2 -5 Million.
Environmental Crisis Averted – NYC Waste Water
Situation: A major NYC sewage pumping station had a dilemma of how to replace a broken pump without shutting their system down. Government restrictions would not allow the station to open the bypass valves and freeflow the sewage into a major river. The company had to find another way to meet critical environmental restrictions.
Solution: The Kerr sales team intervened with a proven solution to this very difficult and highly charged problem that had the potential to escalate into an environmental crisis. The solution included having the plant install new valves and a pump, all while keeping the plant in normal operation. Kerr provided consultation, comprehensive education from TDW Services, job site assistance, and follow up.
Results: The cost-effective equipment package and solutions were quickly orchestrated to avert a very serious and ethical challenge for the company.