IBP1008_19

Paulo A. Martinez1, Rene Landstorfer 2,

Guilherme F. Góes3

Copyright 2019, Brazilian Petroleum, Gas and Biofuels Institute - IBP

This Technical Paper was prepared for presentation at the Rio Pipeline Conference and Exhibition 2019, held
between 03 and 05 of September, in Rio de Janeiro. This Technical Paper was selected for presentation by the
Technical Committee of the event according to the information contained in the final paper submitted by the
author(s). The organizers are not supposed to translate or correct the submitted papers. The material as it is
presented, does not necessarily represent Brazilian Petroleum, Gas and Biofuels Institute’ opinion, or that of its
Members or Representatives. Authors consent to the publication of this Technical Paper in the Rio Pipeline
Conference and Exhibition 2019.

Abstract

Leak detection for pipelines has ever since been a necessary and important issue for safety of
people, environment and the lines themselves.
As the industry is facing new challenges over the years like product theft on pipelines, also
the technologies for detecting and locating leaks or drilling spots have to evolve to match
these tasks.
With completely new developed electronics like amplifiers, data processing filters as well as
current high resolution sensors like hydrophones and pressure sensors. The tool has become
much more sensitive. The already very precise technology with a certified minimum leak rate
of 6.8 l/hr is now reliable enhanced. The instrumented pig is designed to work in explosive
atmospheres, having Zone 0 certification and can be used during normal operating of the
pipelines.
This paper will focus on a case study in the rainforest in Brazil. Due to the increasing problem
with illegal hot tapping or leaking points in areas with difficult access, the operators are
forced to find new detection technologies for solving these issues.
The presentation will give a short overview of challenges pipeline operators are facing
nowadays.

Keywords: Leak Detection. Instrumented Pig.

1. Introduction

The extensive and complex Brazilian pipelines network that transports oil and its high
value-added derivatives crossing from inhospitable regions to high densely populated areas,
bring constant challenges to the operators responsible for monitoring the integrity and
tightness of these assets. Leaks, accidental or otherwise, have serious consequences such as
damage to the environment and millions of product losses. Several leak detection technologies
for transport and transfer pipelines have been made available in the Brazilian market recently,
each presenting its advantages and disadvantages, some with very high implantation costs,
high operational complexity and others with low precision and high false alarm rates.

______________________________
1
Mechanical Engineer - ASP Serviços Industriais
2
Engineer – GOTTSBERG Leak Detection GmbH & Co. KG
3
Data Analyst – ASP Serviços Industriais
 Rio Pipeline Conference and Exhibition 2019

In this context, this paper describes a method of acoustic detection of leakage, which
proved as being extremely reliable, easy to operate and capable of identifying and locating
even the smallest leaks up to 6.8 liters per hour. Such small leak corresponds to a pinhole of
approximately 0.3 mm and it possibly resulting from slow degradation processes, which are
usually outside the coverage of conventional detection systems.
We specifically describe an intelligent inline detection tool that can be used during
normal operation conditions of the pipelines, repeatedly. The acoustic pig is based on an
acoustic measurement method using a multispectral frequency analysis of sound events, thus
allowing an accurate identification of the acoustic signature of leaks, clearly filtering the
signals with the recognition and classification of common transient patterns such as pumps,
valves, and highway, river crossings, among others.
Due to the ease of operation, both during the pig launching and in the automated data
processing, the system allows frequent and low cost monitoring of pipelines. The system can
easily be use to complement the existing permanent and online leak monitoring methods in
order to assure a consistent assessment of pipeline tightness in terms of accuracy, limits of
detection and reliability of results. In addition, the technology has been certifying as
replacement for a pressure test to verify the tightness of the pipeline.

2. Leak Detection System

The Acoustic Leak Detector Pig, shown in Figure 1, consists of a housed electronic
core with the sensors, a chassis and an odometer. The Leak Detector records and stores all
noises present inside the pipeline as the pig is travelling through the line propelled by the
product itself and under normal pipeline operation conditions. The Pig has an on-board
inertial measurement unit (IMU) to detect the angular acceleration when the tool is running
over weld joints and allowing localization of the anomalies. The combination of information
of the IMU, the odometers and virtual markers allows a precise determination of the leak
position. Some electronic markers can be conventionally arranged along the pipeline in order
to assure the location accuracy. The length of the pipeline does not matter as the localization
feature allows a statement about the exact pipe piece where the anomaly was found. This
leads to an accuracy of 2-3m after the first run.
The Acoustic Leak Detector Pig is explosion proof and the world´s only intelligent pig
that, thanks to its ATEX approval for Zone 0, can be use in any liquid pipeline, without
compromising operation. The detection capacity is up to 6.8 liters per hour at a pressure of
6bar, measured and certified by TÜV Nord.

Figure 1. Acoustic Leak Detector Pig

2
 Rio Pipeline Conference and Exhibition 2019

The Leak Detector is assembled on a standard Chassis, shown in figure 2, which

dimension vary according to the internal diameter of the pipeline to be inspected. This
constructive feature allows the use of a single Leak Detector for different pipelines diameters.
These turns the application of the System very flexible in pipelines of diameter from 4"up to
bigger than 50", in an ease and economical way. Rugged and high chemical resistant metal
construction, the chassis is design to generate as little noise as possible during the tool run and
yet, allows the Pig to be able to transpose short bend radius with up to 1.5D and subjected to a
pressure of up to 100 bar.

Figure 2. Chassis

The data collected by the leak detector will be evaluated through analysis software
after the run. All recorded noises, such as those generated by small leaks, leaks in valves or
dirt that generate some kind of sound, will be quickly process in a semi-automated way by the
system’s software. The audio information is converted into a graphical system.
The software divides all recorded noises into 128 channels using a Fast Fourier Transform
algorithm (FFT), allowing the recognition of the different acoustic signatures. A
simplification of signatures can be shown in figure 3.

Figure 3. Acoustic Signature

The data can still be easily projected and viewed Geographic Information System
(GIS), making it possible to obtain additional information on the location and identify

3
 Rio Pipeline Conference and Exhibition 2019

possible noise sources along the inspected pipeline. This also reduces the response time of
service staff maintaining the pipeline leak due to the mapping information.
Because it is so easy to use and does not affect operation, the tools can start a new run
when they just finished the last on if required by the operator. The only time the detector
needs to be out of the line is for data download after a run and for recharging every 250 hours
of runtime. Due to pipeline integrity regulation, some customers run their tools once a week
to ensure the tightness of the pipeline.

3. Case Study

In order to exemplify the application of the Leak Detection System, and how flexible
and accurate it can be, a description of an inspection done in a chemical company based in
Manaus, Brazil, is presented. In one of their sites, an 8” ethylene pipeline runs from the
company plant to the Refinery site, crossing both forest and residential area, was under
integrity evaluation for leak presence.

A quick solution for detection and precise localization of the leak was required. The approach
was to take one of carries in stock with simple modification to fulfill the requirements given
by the operator. A GLD 305 – 200 Carrier and the GLD 204 leak detector were provided,
which ensured a solution for the vertical section of the pipeline. The mobilization and
preparation of the tools only took a few days.

Figure 1: GLD 305 - 200 and GLD 204

The flow was regulated at 160 m³/h and around 200 mm³/h for the vertical section 100m
before the receiver trap. The pressure in line the was adjusted with >5bar to assure the
acoustic leak detection capability.
4
 Rio Pipeline Conference and Exhibition 2019

The leak detection run took 53 minutes without complication. The tool was in good condition
and the data was 100% evaluable. The data was quickly analyzed from a technician directly
after the run.

There were 7 deviated noises been found. Through the frequency analysis and with the help of
the girth weld detection and the GIS system. all origins of the noises could be clearly
identified.

Figure 2: GLD 710 with GIS implementation

There was “No leak signal” detected in the pipeline leading to a quick clearance for operation.
The mobilization to the next pipeline could been done immediately afterwards due to the
rechargeable battery inside.

Advantages of the system

 Verified through a performance analysis by TUEV Nord and by the TRFL 11.4 the
technology can be used to detect creeping leakages and can replace DD-tightness tests.
 Cost effective: in comparison to other leak detection technologies it is proved to be
affordable and reliable;
 Easy handling: the handling of the tool could be compared to the use of a normal
cleaning pig
 Nearly real-time analysis about tightness condition
 High location accuracy due to Girth weld detection and GIS systems without usage of
plenty of AGM´s
 The tool can be used in challenging pipelines with very low flow speed and bigger
inclines the tool is usable.

4. References

WITH, S. GOTTSBERG Leak Detection GmbH & Co. KG.

LANDSTORFER, R. GOTTSBERG Leak Detection GmbH & Co. KG