Keeping pace with the industry digital transformation accelerated by the 2020 pandemic, PETRONAS sees the opportunities of sustaining the forward momentum of its Pipeline Integrity Management System (PIMS) digitalization deployment as it becomes more deeply integrated in day-to-day operation. After two years of utilizing digital PIMS, the platform services have matured, and PETRONAS is able to reap the benefits of having a centralized digital platform for pipeline related information. The aspiration for the pipeline digital PIMS is to give near real-time insight of overall pipeline condition and risk, and for operators to perform proactive actions to eliminate downtime by identifying early warnings of failure. The immediate value of digital PIMS implementation was having the legacy data being contextualized and transformed into structured data, which is the backbones for descriptive, predictive and prescriptive big data analytics. The platform was devised as such that integration with Enterprise application for data ingestion was made easier. As of to-date, digital PIMS is able to pull and push data to PETRONAS Enterprise Resource Planning tool, geographic information system (GIS) supported software, as well as operational monitoring real-time data through Supervisory Control and Data Acquisition (SCADA) system. In addition to conventional deterministic fitness for service analytics modules, the platform is also currently integrated with analytics modules, primarily for onshore and offshore pipeline threats such as internal corrosion, free span, geohazard and damage from third party. By implementing predictive analytics approach to assess pipeline threats, it will assist stakeholders and operators in optimizing inspection campaign and rectification, thus ultimately reduce OPEX throughout pipeline remaining lifecycle.
This technology is created and developed by exploring and utilizing the capability of the passive acoustic-based which design intended to detect corrosion at unpiggable onshore pipeline without major modification or disrupting the operation. ORCA™ technology consists of the capabilities and functionalities to perform analysis and assessment utilizing real-time and historical data to detect the corrosion behavior over the period. If these corrosions are injurious in nature, further response either immediate or schedule can be executed to prevent pipeline failure. The passive, low acoustic-based sensor installed at 2 ends of the pipeline which communicate through Data Acquisition System (DAQ) which subsequently transmit data via public mobile network linking through virtual private network, wide area network which transferred data storage to the digital server. A specialized analysis software capable of performing data pre-processing, cleansing, AE features identification & sizing with Deep Learning capability & post processing with determination of risk and integrity to facilitate system real time capability are also discussed in this technical paper. Acoustic Emission transducers installed between the test section and software to collect and filter the data. The technology has been deployed on one Feed Condensate pipeline back in 2020/21 with continuous data collection. Higher accuracy was achieved comparing against latest intelligent pigging (IP) data. The validation has been conducted by using Mean Absolute Error (MAE) method and API 1163 matrix and this higher accuracy level has been obtained through the maturity of deep learning in adapting with the environmental and process conditions. ORCA™ has been approved for replication on PETRONAS 18 nos. of onshore unpiggable pipelines from 2022-2026. The positive value creation is estimated for long term application by 20% OPEX reduction over the life cycle. The technology will help to eliminate the occurrence of pipeline failure due to improper integrity management. In conclusion, ORCA™ will change the way of managing the integrity of unpigable pipeline as previously ICDA & ECDA approached has been used in estimating the integrity condition of the pipeline.
In PETRONAS, there are on-going initiatives at petrochemical plants, gas processing plants, Upstream's well engineering and retail business in pursuing the digitilisation in line with the Industrial Revolution (IR) 4. The aim of the initiatives is basically to improve the efficiency of critical processes thus at the end will reduce overall cost and improve production margin and revenue/profitability. This paper will present the initiative of PETRONAS' Pipeline fraternity consisting of pipeline experts, managers and engineers in the development of intelligent and integrated pipeline integrity management system. The system is designed to have minimal people intervention as data will be automatically uploaded by Inspection & Maintenance (I & M) vendors and field technicians through interface software and utilising artificial intelligence/ machine learning for descriptive, predictive and prescriptive analytics. It is envisaged that by having the system, critical decision-making pertaining to integrity, safety and reliability of pipeline system could be done in ‘split seconds’ extending the asset's life and eliminating unwanted incidents i.e. leak/rupture. Furthermore, standardisation of pipeline risk and integrity software/tools among Operating PETRONAS Units (OPU)/regions will provide cost savings in the long term compared to current practice of having off-the-shelf software/tools. Integration of relevant corporate software/tools and the intended software/ tools will further provide cost savings in terms of database management and enhanced efficiency. There are few other initiatives running in parallel with the i-PIMS i.e. using advanced acoustic emission technology to detect corrosion anomalies using new developed sensors and also establishing algorithms/analytics for corrosion's growth, location and position throughout pipeline length; formation of dynamic free spanning for offshore pipeline; and predicting/monitoring 3rd party impact occurrence. Development of pipeline predictive analytics is to gain significant improvement in PIMS for better integrity status verification, faster decision making and optimization for I&M activities. The overall outcome/results/algorithms will be integrated into i-PIMS as part of final assessment. It is PETRONAS' aspiration that eventually, descriptive analytic of i-PIMS i.e. critical pipeline integrity performance indicators and critical processes can eventually able to be accessed via mobile apps which will be a ‘pace-setter’ in overall pipeline integrity management scheme i.e. ‘effectively managing pipeline at fingertips’.
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