Changing the Game of Unpiggable Pipeline Integrity: The Petronas Ultra Long Range Acoustic Technology (ORCA™)

Abstract

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.