direct assessment techniques for integrity management of ... · assessment • pipeline integrity...
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DIRECT ASSESSMENT TECHNIQUES FOR INTEGRITY MANAGEMENT OF UNDERGROUND
PETROLEUM PIPELINES
DET NORKE VERITAS (USA), Inc.Angel R. Kowalski John A. Beavers
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Outline
Pipeline Integrity• Pipeline Integrity Management• Integrity Assessment ToolsDirect Assessment• Pre-assessment• Indirect Inspection• Direct Examination• Post-assessmentSummary
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Pipeline Integrity• Pipeline Integrity Management• Differences between Natural Gas and Hazardous
Liquid Pipelines• Threats to Pipeline Integrity• Pipeline Integrity Assessment• Direct Assessment
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Pipeline Integrity Management (PIM)
• The Primary Goal of every Pipeline System Operator is to:– Provide safe and reliable delivery of the product to customers, without
adverse effects on employees, the public, customers, or the environment.
• An Effective Pipeline Integrity Management Program:– Provides information for an operator to effectively allocate resources
for an appropriate prevention, detection, and mitigation activities,– That will results in improved safety and a reduction in the number of
incidents
• Relates to a pipeline’s compliance with applicable regulations and standards
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US Pipelines Statistics
• The Department of Transportation, Office of Pipeline Safety post incident reports on their web page (http://primis.phmsa.dot.gov)– There are 321,000 miles gas transmission lines (onshore and
offshore)– There are 175,000 miles liquids pipelines (onshore and offshore)
• For the period 1/1/1991-12/31/2010:– 864 significant incidents (43 fatalities) onshore gas transmission– 2,681 significant incidents (40 fatalities) onshore liquid pipelines
• For the year 2010 (alone):– 52 significant incidents (10 fatalities) onshore gas transmission – 108 significant incidents (1 fatality) onshore liquid pipelines
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Hazardous Liquid Pipelines Onshore
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Gas Transmission Pipelines Onshore
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Hazardous Liquid and Gas Transmission PIM
• Process used to ensure continued operation safely and meeting all applicable regulations
• PIM takes into consideration all relevant codes, standards, and regulations
• Liquid hazardous pipelines:• Standard: API 1160• US Regulation: 49CFR195, Subpart F Paragraph
195.452• Gas transmission pipelines:
• Standard: ASME B31.8S• US Regulation: 49CFR192, Subpart O
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Pipeline Integrity Threats
• Gas Pipeline incidents data has been analyzed and classified by the Pipeline Research Committee International (PRCI) into 22 root causes.
• One of the 22 causes was reported by operators as “unknown” (no root cause or causes were identified).
• The remaining 21 threats have been grouped into (9) categories of related failure types, and
• Delineated by three time-related defects types
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Stable Threats
• Equipment– Gasket O-ring failure– Control/Relief
equipment malfunction
– Seal/pump packing failure
– Miscellaneous
• Manufacturing Related Defects- Defective pipe seam- Defective pipe
• Welding/Fabrication Related- Defective pipe girth weld- Defective fabrication weld- Wrinkle bend or buckle- Stripped threats/broken pipe/coupling
failure
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Time Independent Threats
• Third Party/Mechanical Damage– Damage inflicted by first,
second , or third parties– Previously damaged pipe
(such as dents and or gauges)
– Vandalism
• Incorrect Operations
�Weather related and outside force- Cold weather- Lightning- Heavy rains or floods- Earth movements
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Time Dependent Threats
• External Corrosion
• Internal corrosion
• Stress Corrosion Cracking
• Fatigue (not included)
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Pipeline Integrity Assessment
• Pipeline Integrity Assessment is a process that includes:
– Inspection of pipeline facilities,
– Evaluating the indications resulting from the inspections,
– Examining the pipe using a variety of techniques,
– Evaluating the results of the examination,
– Characterizing the evaluation by defect type and severity, and
– Determining the resulting integrity of the pipeline through analysis
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Pipeline Integrity Assessment Methods
• In-Line Inspection (Internal inspection)
• Pressure Test
• Direct Assessment
– ECDA
– ICDA – Dry Gas (DG), Liquid Petroleum (LP) and Wet Gas (WG)
– SCCDA
• Other Technology
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What is Direct Assessment?
• A method of assessing pipeline integrity.– Intended to be no less protective of public safety and
environment than ILI or Hydrotest.– SCCDA may not replace ILI or hydrotest in many cases
• From “direct examination.”– Bell hole inspections.
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Direct Assessment Process
• Utilize existing technologies in an integrated
approach intended to map corrosion defects
• Utilize prediction modeling to determine “like
and similar”
• Use results to safely manage the pipeline
system
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Direct Assessment Concept
• Technologies can be used as a diagnostic tool to assess pipeline integrity
• Defect growth models can be used to determine “safe” operating conditions and to determine re-assessment or inspection frequency
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Direct Assessment Methodology
• Pre-assessment– Assembly and review of pipeline data
• Indirect Inspection– Location of Indications / Severity Classification
• Direct examination– Excavation, inspection, defect assessment
• Post-assessment– Validation, prioritize repairs, re-assessment intervals
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Pre-assessment
�Data Collection:- Pipe
- Construction
- Corrosion Control
- Soil / Environment
- Operational
Pipe Grade: API 5L X65
Nominal Diameter: 16-inch
Wall Thickness: 0.288 inch
Year of Installation: 1941
Average Depth of Cover: 4 feet
Number of Steel Casings: 5
Cross-country pipeline
Pipe Coating: Coal Tar Enamel
Cathodic Protection: Impressed Current
Years without CP: 5
CP Records Available: Yes, since 1946Topography: Mainly flat
Soil: Miamiam-Pewamo Product: Natural Gas
Temperature: 80 F
Pressure: 850 psig
Leak: None
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Pre-assessment Data DG-ICDA Essential Data
CATEGORY DATA TO COLLECT
Operating history Change in gas flow direction, type of service, removed taps, year of installation, etc. Has the line ever been used previously for crude oil or other liquid products?
Defined length Length between inputs/outputs.
Elevation profile Topographical data (e.g., USGS data), including consideration of pipeline depth of cover. Take care in instrument selection that sufficient accuracy and precision may be achieved.
Features with inclination Roads, rivers, drains, valves, drips, etc.
Diameter and wall thickness Nominal pipe diameter and wall thickness.
Pressure Typical minimum and maximum operating pressures.
Flow rate Flow rates—maximum and minimum flow rates at minimum and maximum operating pressures for all inlets and outlets. Significant periods of low/ no flow.
Temperature For example, ambient soil temperature up to 54 ˚C (130 ˚F) at compressor discharge unless a special environment exists (e.g., river crossing, aerial pipeline).
Water vapor Information about water vapor dew point.
Inputs/outputs Must identify all locations of current and historic inputs and outputs to the pipeline.
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Pre-assessment Data DG-ICDA Essential Data
– cont’d.CATEGORY DATA TO COLLECT
Corrosion inhibitor Information about injection, chemical type, and dose.
Upsets Frequency, nature of upset (intermittent or chronic), volume if known, and nature of liquid.
Type of dehydration Is dehydration carried out using glycols (yes/no)?
Hydrotest information Past presence of water, hydrotest water quality data.
Repair/maintenance data Presence of solids, anomalies; pipe section repair and replacement; prior inspections; NDE data. Any cleaning pig locations, frequencies, and dates. Analytical data of all removed sludge, liquids when cleaning pigs were employed or from liquid separators, hydrators, etc. and the analysis performed to determine the chemical properties and corrosivity, including the presence of bacteria, of the removed products.
Leaks/failures Locations and nature of leaks/ failures.
Gas quality Gas and liquid analyses, and any bacteria testing results for the pipeline and on shipper and delivery laterals. Relationship of gas analyses to pipe location.
Corrosion monitoring Corrosion monitoring data including type of monitoring [e.g., coupons, electric resistance (ER)/linear polarization resistance (LPR) probes], dates and relationship of monitoring to pipe location, corrosion rate recorded/ calculated, and accuracy of data. Any available non-destructive inspection results.
Flow coatings Existence and location(s) of internal coatings.
Other internal corrosion data As defined by the pipeline operator.
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Pre-assessment Results
• Feasibility of methodology to evaluate the impact of IC, EC and SCC on the integrity of pipeline
• SCC: Prioritize potentially susceptible segments and help select sites for excavations on those segments
• IC-DG: define sections between gas inputs where possibility of water entering the system exists.
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Pre-assessment Results – cont.
• IC-LP: Identify any parameter related to liquid petroleum constituents, flow patterns, operating conditions, or mitigative actions that may affect the location of corrosion initiation, corrosion mechanism, or anticipated corrosion rate
• EC: – Define sections with similar corrosion history– Define indirect inspection tools
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Indirect InspectionsLine Location,
Station, Depth of Cover & Current
Attenuation
DCVG CIS GPS
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Flow Modeling Principles –DG-ICDA
Max = 3864 mscf/hr, Avg = 1473 mscf/hr, Min = 494 mscf/hr, Mode = 1449 mscf/hr
• Gas flow and gravity drive liquid downstream• No liquid holdup at any gas velocity
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Flow Modeling Principles DG-ICDA
• Gas flow drives liquid downstream• Gravity neutral• Liquid holdup only occurs with no gas flow
Zero Degree Inclination Angle (“completely” flat)
liquid
gas
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Flow Modeling Principles DG-ICDA
• Gas flow drives liquid downstream• Gravity drives liquid upstream• Holdup depends on inclination and gas
velocity
Positive Inclination Angle
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Critical Angle Versus VelocityZero to Vertical Inclination
0
5
10
15
20
25
30
35
40
45
50
- 5.0 10.0 15.0 20.0 25.0 30.0
Gas Velocity, ft/s
Incl
inat
ion
, deg
rees
Water Accumulates
Water Carries Through
GravityFlow
GravityFlow
8 inch pipe at 4.1 MPa (600 psi) and 15.5°C (60°F)
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DG-ICDA Example
• Example location showing where water may collect
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Indirect Inspections
0
100
200
300
400
500
600
700
800
233+60 234+60 235+60 236+60 237+60 238+60 239+60 240+60 241+60 242+60 243+60
Station
Ele
vati
on
(ft
)
-20
-15
-10
-5
0
5
10
15
20
25
30
35
40
Incl
inat
ion
An
gle
(d
egre
e)
Topograhical Map Elevation GPS Elevation Critical AngleTopographical Map Inclination Angle GPS Inclination Angle
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Data Alignment and Integration
Typical AC Current Attenuation Suvrey Result
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
0+0
0
10+
00
20+
00
30+
00
40+
00
50+
00
60+
00
70+
00
80+
00
90+
00
100+
00
110+
00
120+
00
130+
00
140+
00
150+
00
160+
00
170+
00
180+
00
190+
00
200+
00
210+
00
220+
00
230+
00
240+
00
250+
00
STATION (feet)
AC
Cur
ren
t (d
Bm
A)
Typical AC Current Attenuation Suvrey Result
0.00
0100
0.00
2575
0.00
0993
0.00
3257
0.00
0005
0.00
2973
0.00
024
8
0.00
314
8
0.00
1110
0.0
0931
7
0.0
000
75
0.00
4640
0.00
0213 0.
0021
81
0.00
0066
0.000000
0.002000
0.004000
0.006000
0.008000
0.010000
0.012000
0.014000
0.016000
0.018000
0.020000
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Survey Section
Cu
rren
t A
tte
nuat
ion
dB
mA
/ f
oot
PIPELINE A SECTION 01 CIS
-1.300
-1.200
-1.100
-1.000
-0.900
-0.800
-0.700
-0.600
-0.500
-0.400
1880
+00
1885
+00
1890
+00
1895
+00
1900
+00
1905
+00
1910
+00
1915
+00
1920
+00
1925
+00
1930
+00
Station
Pip
e to
So
il P
ote
nti
al V
olt
CS
E
On Off -0,85V -1.2V
Survey Direction
Firs
t Ave
Hw
y 2
-1.500
-1.300
-1.100
-0.900
-0.700
-0.500
-0.300
Pip
e to
So
il P
ote
nti
al. V
olt
CS
E
0
50
100
150
1097
2+00
1098
7+00
1100
2+00
1101
7+00
1103
2+00
1104
7+00
Station (feet)
Pip
e D
epth
of
Co
ver.
Inch
100
1,000
10,000
100,000
So
il R
esis
tivi
ty.
Oh
m-c
m
0
25
50
75
100
DC
VG
Ind
icat
ion
%IR
0
20
40
60
80
100
Cu
rren
t A
tten
uat
ion
dB
mA
PIPELINE A. SECTION 1 ALIGNED DATA PLOT
Survey Direction
LINE A Section 1 START OF DAY WAVEFORM STATION 00+67
-1.300
-1.250
-1.200
-1.150
-1.100
-1.050
-1.0000 1 2 3 4 5 6 7 8 9 10
Time (seconds)
Pip
e to
So
il P
ote
nti
al V
olt
(C
SE
)
LINE A SECTION 1 STATIONARY DATA LOG TEST STATION AT STATION 44+31
-1.400
-1.200
-1.000
-0.800
-0.600
-0.400
8:00
:00
9:00
:00
10:
00:0
0
11:
00:0
0
12:
00:0
0
13:
00:0
0
14:
00:0
0
15:
00:0
0
16:
00:0
0
17:
00:0
0
Time of the Day
Pip
e to
So
il P
ote
nti
al V
olt
(C
SE
)
On Off
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Direct Examination
Selection of Excavation Sites:
For SCCDA• Give higher priority to larger diameter pipe• Pipe with low fracture toughness or low tensile properties• Highest priority – Low frequency ERW seam weld pipe• Based on external coating – polyethylene tape higher• Prioritize older pipeline segmentsFor ECDA and ICDA• Prior corrosion history• Results of Indirect Inspection
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Topography, Soil TypeTopography:
Soil- Type- Profile- Drainage
Soil Samples- Obtain at least four samples from each dig site
- One at each end of the dig- One at 3:00 or 9:00 o'clock location near pipe
- Photograph soil samples and describe texture and color- Record any odors- Gray-black color and rotten egg smell usually indicate anoxic conditions- Tan color usually indicates oxic conditions
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Coating Evaluation• Coating Type: Asphalt, Coal Tar, FBE, Tape, Liquid Epoxy• Type of Damage: Wrinkles, holidays, cracks, blisters,
disbondment
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Pipe Surface Evaluation
• Pipe Surface Damage:– External Metal Loss:
• Type (morphology): General, localized, pitting, cracking• Measurements: Maximum depth, position, distance from reference point,
mapping, UT wall thicknessKey
= 1-50 = 51-100 = 101-200U/S -1' D/S 3'
A B C D E F G H I J K L M N O P Q R S T U V W X Y Z AA AB AC AD AE AF AG AH AI AJ AK AL AM AN AO AP AQ AR AS AT AU AV0 Degrees 1 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
2 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 13 10 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 03 0 0 0 0 0 0 0 0 0 23 0 0 0 0 0 0 0 0 0 0 0 0 0 0 10 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 04 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 05 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 72 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 06 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 07 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 08 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 09 0 0 0 0 0 0 0 0 0 0 21 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 32 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
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0 0 0 16 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0150 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
360 Degrees 151 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0
Ref GW47260
![Page 36: Direct Assessment Techniques for Integrity Management of ... · Assessment • Pipeline Integrity Assessment is a process that includes: – Inspection of pipeline facilities, –](https://reader035.vdocument.in/reader035/viewer/2022062613/614861372918e2056c22a673/html5/thumbnails/36.jpg)
Pipe Surface Evaluation• Pipe Surface Damage:
– Mechanical Damage:• Type: Dent, Gauge, Wrinkle, arc burn• Measurements: Maximum depth, position, distance from reference point,
mapping
![Page 37: Direct Assessment Techniques for Integrity Management of ... · Assessment • Pipeline Integrity Assessment is a process that includes: – Inspection of pipeline facilities, –](https://reader035.vdocument.in/reader035/viewer/2022062613/614861372918e2056c22a673/html5/thumbnails/37.jpg)
Post Assessment
• Analysis of data from Steps 1 to 3– Determine whether SCC mitigation is required– Calculate remaining strength (metal loss)– Define and prioritize remedial actions, if required– Conduct Root Cause Analysis– Define re-inspection interval– Evaluate effectiveness of DA approach– Feedback and continuous improvement
![Page 38: Direct Assessment Techniques for Integrity Management of ... · Assessment • Pipeline Integrity Assessment is a process that includes: – Inspection of pipeline facilities, –](https://reader035.vdocument.in/reader035/viewer/2022062613/614861372918e2056c22a673/html5/thumbnails/38.jpg)
DA Summary
• Pipeline Mechanical Integrity Assessment Methodology Similar to ILI and Hydrotesting
• 4-Step Process
• Indentifies areas where corrosion may have occurred or is occurring
• Prioritizes sites based on likelihood of ongoing corrosion and threat to the pipeline mechanical integrity
• Root cause analyses are conducted and mitigation plans are developed