14.pipeline Integrity Management External

Asset Management Services
Pipeline Integrity Management Services

Germanischer Lloyd Service/Product Description
Contents
Service Description and Values Generated
Detailed Method Statement
External Corrosion Management
Fitness for Service Assessments
Geotechnics and Ground Movement
In-Line Inspection Services
Integrity Management System Audits
Investigation of Pipeline Incidents
TD/1 Surveys (Affirmation of MOP for
Onshore Pipelines)
Pipeline Uprating
Welding Technology Services
Grouted Tee
Internal Corrosion Management
Case Studies and Examples
Investigation of AC Interference Problem
on High Pressure Pipeline
Guidance on SCC Risks on a Pipeline
Operators Network
Coating and Backfill Interaction
CP Decision Support Tool
Dent Assessment on a 30 Oil Pipeline
Advances in Interaction Rules for Corrosion
Defects in Pipeline Using FE Analysis and
Full Scale Testing
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Pipeline Integrity Management
Services
Service Title: Asset Management Services
Lead Practice: GL Asset Management (UK)
Germanischer Lloyd Service/Product Description
2
Service Description
and Values Generated:
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SERVICE DESCRIPTION
Case Studies and Examples
Fracture Mechanics Assessment of a Defective Pig
Trap
Fatigue Assessment of Dented Pipeline
Metallic Gas and Water Mains Affected by Ground
Movement
Pipeline Affected by Collapse of Quarry Face
Deep Basement Construction - Large Diameter
Cast Iron Gas Main Affected by Ground Movement
Effect of Slope Instability of High Pressure Pipeline
In-Line Inspection Vehicle Development
In-Line Inspection Data Analysis
In-Line Inspection Scheduling
Review of Operations and Maintenance Practice
China Joint Venture LNG Pipeline
Investigation of Pipeline Incidents
TD/1 Surveys
Pipeline Uprating
Design and Qualification of Repair Procedures for
Bellows Attachment Welding
Grouted Tee
TM
Weldability Testing of 48 Diameter X80 Europipe
Production
Corrosion Control of a Sour Gas Pipeline
Naphtha Pipeline Integrity Management Study
Sour Export Pipeline Study
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Germanischer Lloyd (GL) offers a complete pipeline
integrity service and many variations to the basic service
are possible. Clients may wish a complete PIMS to be
provided for them, an audit/review of their existing
system or anything in between these two.
GLs incident investigation service is just one part of a
complete integrity package that GL can supply to process
plant operators and Gas and Oil producers. This is one of
GLs strengths and can generate a considerable amount of
revenue.
This service is primarily aimed at clients whose pipelines
are designed and operated to IGE/TD/1. It can however
be promoted as a best practice offering for all onshore
gas pipelines operating in populated areas. The actual
detailed implementation could be adapted to suit other
pipeline codes e.g. ASME 31.8.
National and international oil and gas (and water?)
pipeline owners and operators.
Oil and gas majors with new assets or joint ventures.
Small scale operators with limited experience in pipeline
integrity management.
Oil, gas, and water pipeline owners and operators.
Pipeline contractors and consulting firms.
Major Gas/Oil operators in the Middle East and North
Africa.
Gas operators in the UK.
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DETAILED METHOD STATEMENT
a. External Corrosion Management
The coating choice and the method by which the pipeline coating is
applied will dictate the long term protection afforded to a pipeline.
As with the coating system, the design, operation and monitoring of
the cathodic protection system will also have an impact on the
in-service performance of the pipeline.
Control, mitigation and management of corrosion anomalies such as
AC and DC corrosion, MIC and SCC will safeguard the integrity of a
pipeline and extend intervals between inspections and ultimately its
service life.
Coating Selection
The generic choice of a pipeline coating system will significantly
influence the protection it affords during, handling, construction,
commissioning and service. Small-scale laboratory evaluation is
generally performed to rank and select materials prior to their
full-scale application. This process evaluates the coatings physical,
chemical and mechanical properties with reference to those properties
that are essential for successful in-service performance. The factors
during application that influence the long term performance of a
coating system e.g. surface preparation, application temperature and
time at temperature must be fully appreciated in order to optimise
performance. GL has significant experience of coating selection and
small and large scale evaluation programme generated over the last
40 years.
Coating Application
A technical audit is often required at the coating application facility,
prior to large scale production coating, to establish whether the plant
is capable of controlling the parameters required to achieve the
ultimate properties of a pipeline coating, and that operatives are
suitably trained to operate this equipment. The technical audit should
review the following:
Facilities for storage of uncoated and coated pipes
Contamination assessment and cleaning prior to coating
Surface preparation
Chemical pretreatment
Coating application/curing
Testing and inspection
Coating protection for storage and transport
GL has been providing technical audits in coating application facilities
for a range of customers over many years.
Procedure Qualification Testing
In order to confirm that a coating applicator is competent to apply the
specified coating material, procedure qualification trials must be
conducted. The purpose of the procedure qualification trial is to
establish that the coating applicator is capable of applying the coating
material in accordance with the coating specification and produce a
coating which is capable of passing the performance criteria required
by the specification. In general, testing will evaluate the following
properties of the coating.
Adhesion
Cure/Hardness
Impact resistance
Flexibility
Water soak resistance
Cathodic disbonding resistance
Strain polarisation resistance
Once procedure qualification testing has been successfully performed
production coating can commence.
GL instigated the requirements for procedure qualification testing
prior to production coatings, and have been active in performing
qualification testing of a range of coating materials applied to
linepipe, fittings and field joints.
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Coating Condition Assessment
As part of the pipeline commissioning process, it is necessary to
perform a coating condition assessment to minimise any coating
damage which may have been sustained during the pipeline
construction activities. Any coating damage found must be excavated
and repaired. Two techniques are employed to locate coating damage
on buried pipelines viz. the Pearson technique and a technique
referred to as Direct Current Voltage Gradient (DCVG) measurement.
The purpose of these surveys is to locate coating damage that may be
associated with mechanical damage to the pipe. Location and repair
of coating damage will minimise the current requirement from the
cathodic protection system.
GL has developed detailed work procedures for the various survey
techniques and has been active in their application.
Management Procedures for Cathodic Protection of Pipelines
To ensure a high level of safety and reliability in operation, it is
essential that buried steel pipework associated with transmission and
distribution systems is designed, installed and commissioned to
withstand the potentially harmful effects of corrosion and that
corrosion control systems employed are monitored to ensure
continued effectiveness. The procedures used for the management
of cathodic protection systems should encompass the requirements
for design, construction, installation, validation and monitoring.
Design
Before undertaking the design of a cathodic protection system,
detailed information on the plant to be protected will be required.
This will normally involve a site survey to determine the factors (e.g.
soil type and resistivity) relating to the overall corrosion control
programme. The design will take account of the route plan, pipe
parameters, coating types, the requirement for insulation
joints/flanges, proximity to power lines etc. An important choice in
terms of the design is whether a sacrificial or impressed system is
required.
Protection Criteria
Any cathodic protection system must meet the protection criteria
specified by the company or international standards being adopted.
In general, the following criteria apply when measured against a
copper/copper sulphate reference electrode:
A polarised pipe to soil potential more negative than
minus 850mV
A polarised pipe to soil potential more negative than
minus 950mV where sulphur reducing bacteria is known
to be present
An ON potential more negative than minus 1250mV
Following successful commissioning of the cathodic protection system
the following checks will be required.
Electrical isolation of the carrier pipe and sleeves to be
confirmed
The operation of insulation joints and flanges to be
checked
That the CP criteria referred to above is being met
In order to establish that the cathodic protection system is operating
in compliance with company or international cathodic protection
codes, validation of the system is required. This is achieved by
measuring the output parameters (voltage and current) of the TRs
along the pipeline route, the On and instant off potentials at test
posts, and by performing close interval potential surveys.
Routine Monitoring
Routine coating condition and CP monitoring is required to confirm
that the cathodic protection system is operating in compliance with
the codes. As well as monitoring pipe to soil potentials etc.,
interaction testing to mitigate the effects on third party pipelines will
be required along with checks for interference from AC (overhead
power lines) and DC (traction systems) electrical sources.
GL has been involved in developing policy and procedures for CP de-
sign, validation and monitoring.
Review, Mitigation and Management of Corrosion Anomalies
Stray DC Corrosion
Stray DC current can have a significant effect on pipelines in areas of
coating damage. The main source of this interference is from DC
electric transit systems that run close-by the buried structure. In most
DC transit systems, the power (load current) to operate the 'train' is fed
via an overhead feeder connected to the positive pole of the DC
supply. This load current is returned to the negative pole of the DC
supply via the tracks. Unfortunately, as the tracks are laid at ground
level, complete insulation from earth is unlikely and therefore some of
the load current may take an earth path back to the DC supply.
Pipelines close to a DC system constitute a good return path for a
portion of this current. If a pipe offers a less resistant path, the current
will travel along it, creating an anodic area where the current
dissipates. DC corrosion is usually characterised by localised deep
pitting.
Most codes and recommended practices related to CP monitoring
and control should require interaction testing to be performed in stray
current areas and appropriate action to be taken to mitigate the
problem. On-line inspection or direct assessment in areas of coating
damage will confirm the effectiveness of the action taken.
DC Influences
When a cathodic protection system is sited near other buried
neighbouring structures or services, corrosion may occur to one or
other of these due to interference. DC current, applied to cathodically
protect a pipeline can be picked up by these buried structures. Where
this current is dissipated at coating defects, the structure may
experience corrosion. DC current interference may also occur as a
consequence of DC traction systems.
Most codes and recommended practices related to CP monitoring
and control require interaction testing to be performed in stray
current areas and appropriate action to be taken to mitigate the
problem. On-line inspection or direct assessment in areas of coating
damage will confirm the effectiveness of this action.
CP Shielding
An electrically isolating object e.g. a rock or stone, in contact, or in
close proximity to a pipe can cause electrical shielding. This form of
shielding can prevent the CP current reaching open coating defects.
Electrical shielding is also a concern under disbonded coatings.
On-line inspection will identify metal loss that may result as a
consequence of CP shielding.
AC Corrosion
AC currents, most commonly induced onto buried structures by
overhead power lines or traction systems, may result in AC corrosion.
Although there appears to be no consensus concerning the
mechanism of AC corrosion, it is reasoned that it is caused by the
irreversibility of the corrosion reaction. The corrosion features that
result are generally localised, hemi-spherical and crater like and have
a smooth surface. AC corrosion rates can be as high as 2 mm/year.
The requirement to routinely monitor AC voltage and current should
be incorporated into the various codes and recommended practices.
If a problem is found to exist, various means of mitigating this can be
instigated. Metal loss due to AC corrosion will be detected through
On-line inspection or direct assessment in areas of coating damage.
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Microbially Induced Corrosion (MIC)
Corrosion induced by the activity of bacteria, most generally in
anaerobic environments, is characterised by large craters, striations
running parallel to the longitudinal pipe axis, the presence of sulphate
and sulphide compounds and a smell of hydrogen sulphide.
MIC corrosion rates are reported to occur between 0.2 and 0.7
mm/year, and to develop preferentially in anaerobic, wet and boggy
soils. External MIC has been reported on bitumen/asphalt coated
pipelines and those coated with PE (tapes and HSSs) having
bituminous-based mastics.
Metal loss due to MIC will be detected through On-line inspection.
Pipelines that are coated with asphalt/bitumen, and tapes or HSSs
employing bitumen-based adhesives will be at greatest risk.
Stress Corrosion Cracking (SCC)
Stress corrosion cracking is a form of "environmentally assisted
cracking" where the surrounding environment, the pipe material and
stress act together to reduce the strength or load carrying capacity of
a pipe. Two types of SCC are known and are referred to as high pH
and near-neutral pH SCC.
High pH SCC occurs in a relatively narrow cathodic potential range
(-600 to -830 mV ref. Cu/CuSO4), in the presence of a carbonate/
bicarbonate environment and at a pH greater than 9. High pH SCC is
typically experienced downstream of compressor stations (where the
pipe temperature is elevated) and is associated with disbonded or
damaged coatings. In the cathodic potential range and environment
required for high pH SCC, a protective film forms on the metal
surface. If the pipe is subjected to plastic strain, this protective film will
crack and create the opportunity for SCC to occur. Stress corrosion
cracks will continue to grow only if the rate of plastic deformation
occurs more quickly than the rate at which the protective film
re-forms. High pH SCC occurs intergranularly.
Although the mechanism of near neutral SCC is not fully understood,
it is thought to involve metal dissolution and the ingress of hydrogen
into the steel, the hydrogen facilitates crack growth by promoting
reduced ductility in the steel. Cracks are probably initiated at corrosion
pits on the steel surface containing a localised environment with a
pH low enough to produce atomic hydrogen. The low pH solution is
produced by dissolution of CO2 in the groundwater. Some of the
atomic hydrogen enters the steel, degrading the mechanical
properties locally so that cracks can initiate or grow. The plastic stress
level necessary to produce cracking may not be related entirely to
fracturing the embrittled steel. It may also contribute to rupturing the
protective film, allowing hydrogen to reach and penetrate the steel.
Near neutral SCC occurs primarily transgranularly.
On-line inspection with tools employing ultrasonic or transverse
magnetic flux leakage principles may be successful in detecting SCC.
Lines should be targeted which have been protected with CTE, asphalt
and tapes applied over mechanically cleaned surfaces.
GL has significant experience of all of the corrosion anomalies that
can threaten the integrity of a pipeline system. GL has provided
consultancy to a range of customers who have wished to confirm that
a particular corrosion mechanism is occurring on their pipeline and
how to mitigate/manage the problem.
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AC Corrosion
b. Fitness for Service Assessments
GL consultants have extensive experience and knowledge in
conducting comprehensive fitness for service assessments of pipelines
using stress analysis techniques, defect assessment and fracture
mechanics assessment methods. This capability has been applied in
assessing a wide variety of different types of defects and damage
types (including: arc strike, general and pitting corrosion, cracks and
spalling, smooth and kinked dents, gouges, smooth dents plus
cracks/spalling/gouges, and stress corrosion cracking), and can be
tailored to provide damage assessment procedures in line with
individual company requirements.
We have excellent knowledge of the UK Pressure Systems Safety
Regulations, 2000 (PSSR) and relevant US Code of Federal Regulations
(e.g. CFR 192 and 195). We also have a very good understanding of
the capabilities of in-line inspection (ILI) tools, to interpret the results
from inspections and to then undertake defect assessments.
GL routinely undertakes assessments of damaged transmission
pipelines for an international clientele of asset owners / operators
worldwide. We have in-depth knowledge and experience in the use
of industry recognised assessment methods such as:
ASME B31G
API 579
RSTRENG
DNV RPF101
BS7910
For any fitness for service assessment, information is required on the
input parameters. These include:
Original equipment design data
Operational and maintenance history
Expected future service
Information specific to the assessment such as defect
sizes, stress state, location of flaws, and material
properties such as tensile strength and fracture
toughness
Fitness for Service can then be demonstrated using methods such as
stress analysis, defect assessment and fracture mechanics approaches.
These are described as follows:
Stress Analysis
Fitness for Service can be demonstrated using higher level assessment
methods such as FEA. GL can undertake work ranging from the stress
analysis of individual structural components such as branch
connections, hot tap tees, threaded well bore casing strings and
damaged (corroded or dented) pipelines. GL consultants have the
capabilities to undertake advanced non-linear, static/dynamic analysis,
vibration, thermal and fatigue analyses. We use these capabilities to
undertake fitness-for-service assessments of pressure systems and in
conjunction with full scale testing facilities to develop defect
assessment methods for pipelines. GL uses an extensive range of FE
and associated software tools that are mounted on both SUN Unix
network and PC based Windows system. The software tools we use
include:
ABAQUS (Standard and Explicit) FE analysis program
MSC/PATRAN and ABAQUS CAE FE pre-and post-processor
programs
PC based software such as MathCad and MATLAB
In addition to the above, our consultants can write customised
programs, user subroutines, etc. in order to overcome the limitations
in proprietary software. Areas of expertise include:
Linear and non-linear analysis. Where necessary,
non-linear effects can be included in the analysis; this can
be through the modelling of non-linear material
behaviour, geometric non-linearity and contact
Buckling, postbuckling and collapse analysis of pipelines
Soil structure interaction
Steady state and transient heat transfer analysis
Fatigue and fracture mechanics; cracked body analysis
Design by analysis
Windows is a trademark of Microsoft
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corporation
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Defect Assessment
Defect assessment is a deterministic approach used to assess the
integrity and fitness for service of defects found on pipelines. Defects
are features which affect the structural integrity and may be located
on the surface of the pipe wall or actually inside the material of the
pipe. There are numerous codes that can be used to assess defects
and are summarised in documents such as the Pipeline Defect
Assessment Manual used for pipelines, which our consultants fully
understand the best methods to use. We have in-depth knowledge
and experience in the use of industry recognised assessment methods
such as:
ASME B31G
API 579
RSTRENG
DNV RPF101
BS7910
Sources for defect data include pipeline intelligent inspection tools or
other NDT methods. Using in-house expertise, appropriate assessment
methods can then be chosen and applied to demonstrate
fitness-for-service in order to satisfy regulatory requirements and
operators integrity management strategy.
Damage assessment capabilities include the following types of
defects:
i) Manufacturing Damage,
Manufacturing features are often a discontinuity in the
geometry of the pipe or shell such as a reduction in wall
thickness or in the material itself.
ii) Construction Damage,
Construction defects may include girth weld defects or
seam weld defects caused by lack of fill or misalignment
and in the most severe case cracking. Also, other forms of
damage may occur such as indentation damage,
corrosion at the girth weld, or even damage to the
external coating.
iii)3rd Party Interference,
3rd party damage is often the most severe form of
damage resulting in failure of the pipe or requiring
immediate repair. Often this involves mechanical damage
such as a gouge resulting in metal loss of the pipe wall,
or distortion of the pipe wall such as a dent.
iv)Operational Damage.
Defects arising from operational usage include external
corrosion caused by damaged or disbonded coating
where the Cathodic Protection System is not effective.
Also internal corrosion caused by water in the product,
and even other forms of corrosion namely Sweet
Corrosion and Sour Corrosion may occur in pipelines.
GL has developed methods for the assessment of
corrosion defects in pipelines through a combination of
finite element analysis and full scale burst testing. These
methods have been included in guidance documents
such as the British Standard BS7910. GL is continuing to
develop methods for assessing the integrity of corroded
pipelines for Pipeline Research Council International.
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Fracture Mechanics
BS7910 and similar codes such as the UK nuclear industry code R6
and API 579, carry out fracture assessments using the Failure
Assessment Diagram (FAD). This provides a graphical method for
assessing the proximity of a loaded structure containing a defect to
failure by fracture and plastic collapse mechanisms. Proximity to
fracture is characterised by the fracture ratio parameter Kr and
proximity to plastic collapse is characterised by the parameter Lr. A
loaded structure can therefore be represented as an assessment point
on the FAD following calculation of Lr and Kr.
This approach is used in levels 1 to 3 of BS7910 to determine the
acceptability of cracks by plotting a point on the diagram. When
deciding which level to use, this depends on the input data available
and conservatism required. These levels can be summarised as:
Level 1 is a simplified assessment method when there is
limited data on material properties,
Level 2 is the normal assessment route, and
Level 3 is based on a ductile tearing resistance analysis.
Using the fracture mechanics approach, our consultants can
determine whether a defect is SAFE or UNSAFE based on the Failure
Assessment Diagram. Finally, using the fatigue assessment approaches
described in BS7910, we can then determine the remaining fatigue
life and future integrity of the structure if subjected to cyclic loading.
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c. Geotechnics and Ground Movement
The safe and adequate performance of pipelines and piping at
installations under conditions of external loading is achieved by:
Quantification of pipeline loads and supports by
characterising the inherent variability in the geological
environment to specified confidence levels.
Ensuring compliance with relevant codes and standards.
Fitness-for-purpose assessments that recognise limit
states relevant to the applied loads with appropriate levels
of safety.
Estimates of probabilities of failure and system reliability
for uncontrolled geological hazards such as landslip
events.
Geotechnical Aspects
Pipelines sustain loads from a range of sources covering engineering
activities such as earthworks and other surface construction,
tunnelling, transient live loads on road and rail networks and also
construction and mining plant, and subsidence events due to mining
for example. Natural hazards include landslides, earthquakes, natural
subsidence, and erosion and exposure typically around water courses
leading to spanning and potentially hydraulic loading.
We have expertise to investigate and interpret all forms of ground
loading and geological hazards, and quantify instability, movement
and load transfer to pipeline structures.
Pipeline Integrity Aspects
The performance of a pipeline depends on the imposed loads, ground
support and the pipeline structural response. We deal with this by
identifying and quantifying ground loading processes, soil/pipe
interactions and pipeline performance capabilities.
Pipeline integrity is assessed through well-established principles
including ground investigations, material testing, structural
calculations using pipe stress analysis software and pipeline
monitoring.
The results of integrity assessments are evaluated based on relevant
performance limits. The findings may warrant monitoring, protection,
or replacement works. We have experience in the specification,
installation, data collection and interpretation for indirect and direct
methods of monitoring. Satisfactory monitoring of pipeline
performance is typically achieved by a combination of the
measurement of existing stress levels, recording changes in pipeline
strains and geotechnical instrumentation or topographic surveying as
appropriate.
d. In-Line Inspection Services
While there is rarely a standard method for work in this field, we
would naturally begin by working with the customer to understand
precisely what is required from a project. Then we would select the
right specialists from our team of scientists and engineers, including
people who have extensive long-term experience in the area of ILI and
have worked on product development and exploitation for specialist
ILI vendors.
For any work that involves making use of ILI data that has already
been collected we gather pipeline and inspection information. Where
uncertainties exist in the data - for example, with regard to actual
material properties (as distinct from material specifications) and
inspection errors - these can be accounted for in a probabilistic limit
state assessment using the techniques of structural reliability analysis.
If there are questions about interpretation of ILI results (see Case Study n)
then we would resolve these by examining recorded data, as
available, to form an independent opinion on the interpretation.
e. Integrity Management System Audits
In general an audit or review of a Pipeline Integrity Management
System will begin with a Gap Analysis. This entails a thorough review
of the Operators activities, including the following:
Compliance with national legislation and local
requirements
Integrity threats and mitigations in place
- Onshore mechanical damage, corrosion, ground
movement etc
- Offshore mechanical damage, stress/fatigue type
material failures, internal and external corrosion etc
Quantitative risk assessments undertaken
Engineering documentation
Pipeline records and fault data
Quality, health, safety and environmental issues
Pipeline operations and maintenance
- Work scheduling
- Record keeping
- Routine and non routine activities
- Pipeline cleaning
Internal pipeline inspection - ILI
External pipeline inspection
- Onshore - above groundsurveys etc
- Offshore - ROV surveys etc
Modification and repair process
Emergency management
Defect assessment and repair methods
Training and competency of staff
Safe control of operations
Continuous improvement processes in place
The Pipeline Integrity Management System under review can then be
assessed for compliance with prevailing regulations and compared to
international best practice. Recommendations can be made to the
Operator as to how they can improve their processes and systems.
Generally in such a project there will be a Phase 2 which comprises
gap closure actions. Depending on the results from the gap analysis
this might entail a complete overhaul of an Operators Engineering
Documentation System or it may involve some rationalisation and
repackaging to ensure that the PIMS is clear and coherent.
Typical Onshore Pipeline Damage/Failure Data
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f. Investigation of Pipeline Incidents
The majority of incidents on pipelines usually involve some form of
mechanical damage being caused to the outside of the pipe surface.
In some cases, corrosion may also be the cause of a pipeline failure.
In both scenarios, if the damage or corrosion is extensive, this may
cause the process fluid to escape.
Incidents involving surface damage to the pipeline where no process
fluid has escaped are usually easier to investigate and assess. Typically,
this type of assessment involves using a range of mechanical
measuring systems to map out the damaged area, non destructive
testing examinations such as ultrasonics, magnetic particle inspection
and/or dye penetrants to detect for defects and cracking in the
damaged area, a photographic survey and if required, cuttings of the
pipe material are taken for analysis to confirm the grade of pipe
material. At the end of the onsite investigation, GL will produce a
technical report on the findings from the onsite inspections and will
make a number of recommendations to enable the pipeline to be put
back into service.
If the damage or corrosion has caused a through wall hole and
process fluid has escaped, then the operator will usually have to
shutdown the pipeline and fit an emergency wraparound clamp to
contain the leak. GL have been involved in a number of these types
of incidents and provided support to the client that required a number
of GL consultant engineers covering a range of disciplines to produce
a solution. In the majority of cases, through wall leaks have been
repaired using a specially fabricated wraparound fitting, called an
epoxy repair sleeve. No welding is required with this type of fitting
and can be fitted in approximately half the time and at a fraction of
the cost when compared to a welded fitting.
g. TD/1 Surveys (Affirmation of MOP for Onshore Pipelines)
A full survey of the pipeline route must be carried out in order to
determine the extent of developments. This can be undertaken by a
line walk or by means of aerial photography or video. Measurement
of population density is based on this survey and the method of
calculating this is described in IGE/TD/1.
Infringements from changes in proximities, population density or
traffic density identified from the survey should be evaluated as soon
as possible by means of a quantitative risk assessment (QRA). Any
measures identified by the QRA which are viewed as reasonably
practicable in reducing the risk should subsequently be
implemented.
In addition to the proximity review the following issues are also
subject to review:
Materials & fittings
Road crossings
Valve maintenance
Hydrostatic testing
Rail crossings
Ground movement
Annual & 5 year MOP records
Watercourse crossings
Pipeline damage history
Fatigue life
Exposed crossings
Pipeline leakage history
Weld quality
Other crossings
Actual pipe details
In addition to all of the above items, pipeline strip maps,
photographs, pressure system drawings and other relevant data are
used to produce a Fitness for Purpose Report of the pipeline under
review. This report will recommend a suitable Maximum Operating
Pressure for the pipeline. The report will include areas of non
compliance where remedial work is required before the MOP can be
applied.
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Town gas service
(manufactured & reformed)
Sleeves
Environmental issues
Depth of cover
Impact protection
Records
Building proximity distances
Cathodic protection
Abandoned sections
Population density (type
R&S areas)
Condition monitoring
Offtakes & spurlines
LA planning proposals
h. Pipeline Uprating
The general approach is:
Collation of all relevant design, construction and
operation data for the pipeline
Assessment of the pipeline at the proposed up-rated
pressure in accordance with the up-rating
recommendations contained in the pipeline operating
code. Where major design non-compliance is identified,
then a detailed fitness-for-purpose assessment is carried
out to determine whether it is acceptable or not
Where a pipeline infringes surrounding infrastructure
then established risk analysis techniques are used to
assess both individual and societal risks. Where the risks
are demonstrated to be clearly within the pipeline
operators acceptance criteria, then they are deemed
acceptable
In all cases where the pipeline design factor at an
infringement exceed 0.72 then potential risk reduction
measures are considered and the safety benefits are
evaluated in accordance with the As Low As Reasonably
Practical (ALARP) principle
All required modifications are identified and then required
detail designs are prepared and the modifications are
implemented
The pipeline is revalidated using in-line inspection
techniques and all necessary repairs are then identified
and implemented
Following satisfactory completion of modifications and
repairs, the pipeline pressure is raised to the up-rated
Maximum Allowable Operating Pressure (MAOP)
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i. Welding Technology Services
GL staff have been involved, in many cases, in the development and
qualification testing of procedures and consumables for the
construction of pipelines, process plant and ancillary high pressure
equipment. GL carries out weldability studies on all candidate linepipe
and components used in the UK National Grid Transmission system in
accordance with the requirements of National Grid specification
T/SP/MPQ/1. For line pipe this involves the production of a full scale
girth weld under simulated field conditions, to an approved
procedure and including such factors as lifting and manipulation to
simulate movement of the line-up clamps following deposition of the
hot pass.
Additionally repair special procedures are tested and qualified before
being putting into service.
Welding consultancy services are also required when new or difficult
materials are involved, such as those employed for high temperature
or sour service environments and include materials such as Inconel,
duplex stainless steels or linepipe clad with these materials. In these
cases very specific welding procedure specifications are drawn up and
initial production welding is carried out under the supervision of
GL expert staff.
GL also carries out welding prequalification of high pressure
components produced by new suppliers, and an investigation of the
welding procedures and consumables employed by candidate
companies is an integral part of this. Site visits are carried out and
supervision of component production ensures that they meet the
relevant requirements for specific companies and individual projects
and can be welded into the system without problems.
GL also supplies expert assistance in the selection and application of
methods for weld repair of pipelines, process plant and high pressure
equipment. This is supplemented by expertise in inspection which
ensures that defective areas are professionally repaired and returned
to service in fully reliable condition.
j. Grouted Tee
The Grouted Tee involves placing two half shells around the pipe and
bolting them together. The shells, with a specified wall thickness,
have a similar material grade to the parent pipe. The shells are sized
to allow a generous gap between the bore of the shells and the
outside diameter of the parent pipe. This annular gap is filled with
grout, when cured this transfers additional structural loading in the
pipe to the tee shell.
Pressure containment is achieved via the "saddle" seal, which is
positioned next to the opening of the main pipe. The sealing
specification is unusual and demanding. The primary function
accommodates large variations in the annular gap between pipe and
shell. It also has to cope with a grit blasted surface preparation,
which is equivalent to SIS 05-59-00 Sa 2.5 finish. It also needs to
withstand elevated temperatures during the drilling operation.
Moreover, the saddle seal has been designed to be independent of the
quality of the grout and on its own should maintain the integrity of
the pressure containment.
15
k. Internal Corrosion Management
GLs approach to corrosion management is to consider the fluids,
materials and safety aspects as an integrated whole. In most respects
the transported fluids dictate the materials and corrosion control
methods used for pipelines while occasionally the materials
technology available will shape the feasible transportation options.
Ultimately the objective is to produce a pipeline with an acceptable
risk of failure. Thus, all these aspects have to be addressed when
considering internal corrosion management.
The production of a corrosion management system would generally
involve the following stages:
1. Gather process data e.g. temperatures, pressures and
fluid compositions during both normal operation and
upset conditions
2. Consider the pipeline safety risk assessment in order to:
Identify major hazards
Identify HAZOP actions related to corrosion and
materials
Determine acceptable level of risk
3. Conduct corrosion risk assessment including:
Calculation of internal corrosion rates
Assessment of stress corrosion cracking threat
Assessment of erosion threat
4. Produce corrosion management scheme
Select materials (corrosion resistant alloys or carbon
steel with corrosion allowance)
Select corrosion control methods (e.g. inhibition,
coatings)
Select corrosion monitoring methods and locations
Produce corrosion data management strategy and
select tools
Devise suitable key performance indicators (KPI) for
corrosion management
Document change procedure for revising scheme if
process parameters are altered (e.g. after uprating)
Produce pipeline corrosion management
guide/manual
5. Feed back the corrosion management activities into the
pipeline safety case and risk assessment as mitigating
factors
Corrosion inhibitor selection is an important aspect of internal
corrosion management for pipelines. The figure below shows the
work flow commonly used when GL undertakes inhibitor selection for
pipelines:
16
17
CASE STUDIES
a. Investigation of AC Interference Problem on High Pressure
Pipeline
Date: 2003
Customer: Shell UK Ltd
Savings: Prevention of pipeline rupture
Issue:
The client had experienced up to 40% loss in pipe wall thickness on
a high pressure ethylene pipeline within 3 4 years of commissioning.
It was initially thought that the metal loss was due to microbially
influenced corrosion (MIC).
Methodology and Results:
The pipeline was coated with a fusion bonded epoxy mainline
coating, which does not support the proliferation of bacteria required
for MIC to occur. The pipeline was observed to be running in parallel
with a high voltage power line for distances in excess of 1 km and
high AC potentials and current densities were recorded on the line.
Features specific to AC corrosion were noted during direct
examination including:
Hardening of the soil adjacent to corrosion features
Smooth, hemispherical metal loss features
Significant build up of calcite salts within corrosion
feature
Confirmation of the corrosion mechanism, which was occurring at a
rate of 1.3mm/year allowed more regular ILI to be scheduled and
mitigating action to be taken.
Savings:
Confirmation of the corrosion mechanism allowed a pipeline rupture
to be avoided along with the associated loss of gas and supply to the
customer.
b. Guidance on SCC Risks on a Pipeline Operators Network
Date: 2006
Customer: Major Pipeline Operating Company
Savings: Preventing pipeline rupture due to SCC
Issue:
The client requested GL to review the mechanisms by which near
neutral and high pH SCC occur on pipelines and to prepare
procedures for management of SCC risk.
Methodology & Results:
Stress corrosion cracking is a form of "environmentally assisted
cracking" where the surrounding environment, the pipe material and
stress act together to reduce the strength or load carrying capacity of
a pipe. Two types of SCC are known and are referred to as high pH
and near-neutral pH SCC.
GL reviewed the mechanisms by which SCC occur on a pipeline and
assessed the probability of near neutral and high pH SCC initiating
on the clients pipeline network. Where a risk was perceived to be
present, guidance was produced on the actual risk SCC poses to a
pipelines integrity, the timeframe in which remedial action would
need be taken, the conditions under which pipelines could remain in
service, the methods of establishing the extent of SCC and how the
SCC risk could be managed and controlled in the future.
Savings:
The work allowed the client to identify and target areas at highest
risk by better understanding the factors that contribute to SCC. The
procedures developed by GL have allowed the client to modify
conditions thereby minimising risk and maximising the timeframe in
which remedial action can be undertaken.
18
CASE STUDIES
c. Coating and Backfill Interaction
Date: 2006
Customer: BP Exploration and Operating Company Limited
Savings: Eliminating the requirement for selective padding
Issue:
The client was constructing a pipeline in a remote, environmentally
sensitive region of the World, where the importation of selective
material for bedding and padding of the pipeline was not practicable.
As a consequence, the only means of providing suitable bedding and
padding material was to process indigenous spoil, on site, by a
method of crushing and screening. The number of crushing and
screening units required to would have a major impact on
construction costs. The aim of this project was to identify the
maximum particle size of bedding and padding that could be
accommodated during backfilling, commissioning and service.
Pipeline construction often involves the importation of significant
amounts of selective backfill to prevent mechanical damage of the
external coating during construction and operation. Importation of
backfill is extremely expensive, may be impractical in the more remote
regions of the world and may present problems in environmentally
sensitive areas.
By understanding the links between geotechnical ground analysis,
trench excavation equipment and performance and backfill materials,
it was possible to identify appropriate external pipe coatings for
particular ground conditions. In addition, it was also possible to
reduce the amount of imported backfill or the processing
requirements to match the mechanical resistance of the coating.
The data generated during this project enabled an algorithm/decision
making chart to be developed which allowed the operator to compare
pipeline coating/backfill options based on technical and financial
considerations.
Savings:
This work resulted in a significant reduction in construction costs by
minimising the number of crushing and screening units required on
site. There was also a significant reduction in the environmental
impact of having to import selective bedding and padding materials
onto site.
Backfilling
19
CASE STUDIES
d. CP Decision Support Tool
Date: 2008
Customer: Major Pipeline Operating Company
Savings: Compliance with the regulatory authority
Issue:
The client operated a number of pipelines that did not comply with
the minimum criteria for CP. The regulatory authority was aware of the
problem and placed a requirement on the client to demonstrate how
they were going to prioritise pipelines for remedial action.
GL developed a software programme to allow the prioritisation of
non-compliant pipelines/pipeline sections, based on the integrity
threat that being under protected posed.
The programme utilised information that was readily available from
the original pipeline design data, from coating and CP surveys, from
in-line inspections and from adhoc exploratory excavations on the
pipeline. The algorithms used within the programme considered the
likely failure mode (rupture or leak) that might result from being
unprotected, the timescale in which failure might occur (based on the
date when CP was first lost, the pipe wall thickness and the likely
corrosion rate) and safely and economic considerations.
The output of the programme was a priority ranking and a timescale
for remedial action.
Savings:
The CP decision support tool was accepted by the regulatory authority
as a transparent means of prioritising remedial action, thereby
preventing improvement notices being issued to the operator.
Development of the tool kick started the process of revalidating
non-compliant pipelines.
e. Dent Assessment on a 30 Oil Pipeline
Date: 2007
Customer: Middle East Operator
Savings: Savings were made due to potential loss of
containment and system shutdown
Issue:
A major Middle Eastern Operator had requested GL to undertake an
initial assessment of the integrity of a 30 diameter subsea main oil
pipeline, which had sustained dent damage. The operator had
indicated that several in-line inspection tools had been damaged due
to the restriction in the pipe cross section. The dent was located on
the top of the pipe, and in close proximity to the seam weld. The
operator therefore provided GL with a damage survey report which
included a map of the dent shape, identification of the peak dent
depth, and results of a visual inspection and magnetic particle
inspection of the damage area on the outer pipe surface.
The purpose of the work was to provide the operator with an initial
assessment of the severity of the dent damage in relation to the
ability of the pipeline to operate at its original design capacity and
continue to be inspected using in-line inspection tools. Assessment
was undertaken based on the guidance given in the Pipeline Defect
Assessment Manual (PDAM) and background documentation to
PDAM. Using information taken from full scale burst and fatigue test
data from vessels and ring specimens in PDAM, the data showed that
both the static strength and fatigue performance of a pipe with a
dented weld could be significantly reduced. With the information
available and the uncertainty surrounding the quality of the material
(pipe and weld) and the possibility of additional welding defects and
damage associated with the inspection tool, the recommendation
was that the damage should be repaired or replaced.
Savings:
Following recommendations for repair and the implications of any
future pressure increases, savings were made due to potential loss of
containment and system shutdown.
f. Advances in Interaction Rules for Corrosion Defects in
Pipelines Using FE Analysis and Full Scale Testing
Date: 2007
Customer: PRCI
Savings: Considerably improving the accuracy of pipeline defect
assessment and thereby helping to reduce operating
costs for pipeline operators by improving repair criteria.
Issue:
There still remain a number of limitations in the existing methods for
assessing corrosion damage in pipelines (ASME B31.G, RSTRENG,
API579, BS7910). GL has been undertaking a large programme of
work on behalf of Pipeline Research Council International, Inc. (PRCI)
to develop methods for:
Assessing interaction of corrosion defects
Assessing corrosion defects in pipelines of low toughness
Assessing pipelines subject to significant external loading
Assessing corroded pipelines subject to cyclic loading
Extending assessment methods for pipelines constructed
from higher strength steels
Corrosion metal loss is one of the major damage mechanisms in oil and
gas transmission pipelines. The pipeline industry widely uses the ASME
B31G and the RSTRENG methods for assessing the remaining strength
of corroded pipelines. These methods were developed using an early
fracture mechanics relationship for the toughness- independent failure
of pressurised pipes and were empirically calibrated against a database
of around 80 full-scale burst tests for thin wall pipes, dominated by
pipes of material grades B and X52.
GL recently undertook a comprehensive review on behalf of Pipeline
Research Council International, Inc. (PRCI) of the existing and
emerging methods for assessing corroded pipelines. This review
identified that the existing criteria used by the pipeline industry to
assess interaction of metal loss defects is based on limited
experimental data and has not been adequately validated. Existing
practice within the pipeline industry is to assume that defect clusters
interact when they are spaced six wall thicknesses (6t) from each
other. The development of new criteria for defect grouping and
interaction would considerably improve the accuracy of pipeline
defect assessment and thereby help to reduce operating costs for
pipeline operators. GL undertook a comprehensive non-linear FE
study and full scale burst testing program to develop new guidance
for interaction of metal loss defects in pipelines. It was concluded
from this work that the 6t criterion used at present can be over
conservative, particularly when assessing interaction of small pit like
corrosion defects. The output of this work will be included in a defect
assessment guidance document for the pipeline industry.
Non-Linear Finite Element Models of Pipelines with Corrosion Damage
Savings:
Savings were made due to improvements in the accuracy of pipeline
defect assessment, which thereby helps to reduce operating costs for
pipeline operators through significant improvements in repair criteria.
20
CASE STUDIES
21
CASE STUDIES
g. Fracture Mechanics Assessment of a Defective Pig Trap
Date: 2007
Customer: United Utilities
Savings: Cost of temporary pig trap and system downtime
due to installation
Issue:
GL were required to conduct a detailed assessment of a reported crack
indication found on the closure casting of a pig trap located at an
AGI facility in the UK. Following defect measurement in February
2007, this was recorded at approximately 3-4 mm. A number of pig
runs were then subsequently conducted. The defect was then
re-measured and reported to have a maximum depth of 5.3 mm.
Measurements suggested that the defect had therefore grown since
the pigging runs were conducted in 2007. The operator of the site
facility intended to conduct further pig runs in February 2008 and
hence required an assessment to determine whether the defect was
safe for the intended pig runs.
The approach that GL used was based on a BS7910 level 2a fracture
mechanics assessment. Using fracture mechanics calculations and use
of the FAD (Failure Assessment Diagram), the aim was to determine
whether the current size of crack was safe under the current design
conditions and safe for the intended pig runs. Finally using a BS7910
fatigue assessment of the crack, fatigue calculations were then
conducted to determine the remaining fatigue life of the reported
defect and whether further pressure cycles can be tolerated due to
the intended pig runs. The fatigue assessment results showed that
the defective area was likely to endure a large number of cycles before
failure. Consequently it was concluded that the defect would endure
sufficient further pressure cycles to conduct the intended pigging
runs.
Savings:
Ultimately the operator would have had to install a temporary pig
trap to conduct the required pigging runs. Following this, the
temporary trap would have been removed and a new trap installed in
its place resulting in costly delays and system downtime. By
conducting a fracture mechanics assessment, GL have saved the client
costs associated with installing a temporary pig, inspection delays and
system downtime.
h. Fatigue Assessment of Dented Pipeline
Date: 2006
Customer: UK Operator
Savings: The fatigue assessment confirmed the remaining
fatigue life of the reported dents, pending
confirmation that no further defects were present,
was acceptable for the design life of the pipeline.
Issue:
The UK operator had requested GL to undertake a fatigue assessment
of two smooth dents found on one of their pipelines. The dents were
inspected during a calliper survey undertaken by T D Williamson, and
were reported as being no greater than 3% of the pipe diameter in
depth. The dents were originally discovered in 1995 and the operator
suspected they had been there since pipeline commissioning.
The assessment method used was developed by GL and is
recommended for Industry use by EPRG. The results from the
assessment were also supported by a series of full-scale fatigue tests
on dented linepipe undertaken for National Grid. Fatigue life of the
pipeline dents, initially assuming an unconstrained plain dent was
then calculated using the method recommended for use by the EPRG.
Results of the assessment showed that for smooth and defect free
dents, the fatigue life was in excess of the design life of the pipeline.
However, recommendations were made to confirm that no additional
defects were present such as internal or external surface cracking.
Savings:
This fatigue assessment confirmed the remaining fatigue life of the
reported dents, pending confirmation that no further defects were
present, was acceptable for the design life of the pipeline. The result
was that savings were made by the operator through unnecessary
repairs.
22
CASE STUDIES
23
CASE STUDIES
i. Metallic Gas and Water Mains Affected by Ground
Movement
Date: 2007
Customer: UK Gas and Water Distribution Company
Savings: Specification of pipeline protection
Issue:
A new high speed rail link in the UK involved the construction of
approximately 19km of twin bore tunnel below east London. The civil
engineering work took place in the vicinity of a network of utility
services. A total of 261 metallic gas and water distribution mains
require an integrity assessment due to the potential ground
movement from the tunnel construction. Of these mains units there
were approximately 73 that cross existing bridge structures located
within the influence zone above the tunnel. If overstressing due to
the tunnelling occurred, diversion or protection of the mains would
be required.
The work has involved the selection of geometric and material
parameters for mains units, the selection of dimension and level
values for individual bridge structures and tunnelling geometries, the
calculation of ground and structure movements, the structural
analysis of mains response to loading and restraints, and the checking
of calculated stress increments and joint disturbance levels against
acceptance limits.
Soil load transfer assumptions were considered over a range in order
to embrace the uncertainty over actual ground conditions around the
mains unit. This permits the sensitivity of piping response to be
quantified and reduced uncertainty.
Benefits:
Many of the mains had demonstrated that overstressing due to the
tunnelling is very unlikely to occur, therefore can be left in place and
avoid expensive diversion or unnecessary protection.
Schematic showing pipeline level, bridge
dimensions and tunnel details
PIPELINE model for a cast iron main crosses a bridge structure
showing applied ground movements due to twin tunnel
j. Pipeline Affected by Collapse of Quarry Face
Date: 2006
Customer: UK Gas Transmission Company
Savings: Improved pipeline integrity
Issue:
An 18 steel pipeline located on the boundary of a sand and gravel
pit became exposed by the collapse of a quarry face. The pipeline was
constructed prior to the requirement for 100% inspection of girth
welds and therefore could be at risk of tensile fracture when subjected
to increased longitudinal tensile stresses. The operator required an
investigation into the nature of the loading on the pipeline and the
identification of measures to maintain the pipeline integrity.
Immediate action was taken to stabilise the slope by designing and
constructing a buttress embankment against the quarry face.
Excavations onto the pipeline indicated the presence of voids and
lateral and vertical deflections consistent with failure of the quarry
face. Pipeline profile measurements were carried out to establish the
stress state and welds were inspected and repaired where necessary.
The pipeline curvatures indicated yield magnitude stresses had
developed. A de-stressing operation was undertaken involving
uncovering and lifting the pipeline to reduce the pipeline stresses and
restore the as-laid profile. The stress relief was closely monitored by
fitting strain gauges to the pipeline and these demonstrated that the
ground movement loads were successfully reduced. Detailed
reinstatement guidance was specified in order to provide sufficient
support to the pipeline in the new position.
Benefits:
Rapid reaction to a site incident averted the development of a
potentially dangerous leak failure. A coordinated investigation and
remediation exercise confirmed the condition of the pipeline and
enabled appropriate remedial measures to be taken to ensure the
pipeline operated within safe limits.
24
CASE STUDIES
A section of pipe being supported by airbags to relieve soil loading
A section of the exposed pipeline,
showing the horizontal bending
25
CASE STUDIES
k. Deep Basement Construction Large Diameter Cast Iron
Gas Main Affected by Ground Movement
Date: 2006
Customer: UK Gas Distribution Company
Savings: Appropriate pipeline protection
Issue:
A hotel development in Central London involved the construction of
a 12-storey block with four basement levels. The basement
construction involved excavation to a depth of 20m and the
installation of a segmental diaphragm wall of 33 panels with total
width of 44m and up to 29m below ground level.
Two large diameter cast iron low pressure gas distribution mains are
within the site boundary and the closest gas main is only 4m from
the diaphragm wall.
Ground movement and surface loading associated with the hotel
construction may cause some disturbance to the gas mains. This level
of disturbance need to be assessed in order to confirm that the gas
mains would continue to operate within safe limits.
As part of the integrity evaluation, a condition assessment on the two
mains was carried out. Two trial pits were excavated on site to
establish the exact location of the mains, to obtain samples of the pipe
backfill materials for laboratory testing, and to carry out a condition
and support assessment on the mains. Although the mains were laid
circa 1880 and corroded externally, they were still in an acceptable
condition. Their remaining metal thickness was never less than 75%
of the British Standard manufacturing minimum thickness value.
The structural analysis has been performed using GL in-house pipeline
stress analysis programs PIPELINE and SURFLOAD. Both short term
and long term ground movement from the basement excavation,
together with construction traffic loading have been considered.
The integrity assessment shows that ground movements caused by
the basement construction raised the stress level in the mains and
caused the joints to articulate. Stress levels in the mains were also
increased due to the effects of construction traffic. However, the
amounts were within acceptance limits.
Benefits:
The integrity assessment shows that, with appropriate temporary
protection at the ground surface, the gas mains can be operated
safely during and after the basement construction. This resulted in
significant cost saving in unnecessary protective measures and
possible diversion.
Surface corrosion of the 24 Gas Main
24 Gas Main 36 Gas Main
l. Effect of Slope Instability on High Pressure Pipeline
Date: 2006
Customer: UK gas Transmission Company
Savings: Improved pipeline monitoring
Issue:
A 24 diameter pipeline is known to be routed through an area prone
to natural slope instability in West Yorkshire. Two slope failures have
affected the pipeline in recent years resulting in two phases of pipeline
construction to avoid active areas of movement. The operator
required a fitness-for-purpose assessment of the current pipeline
configuration to determine whether it has adequate performance for
potential future slope failures.
The pipe shown in this photograph sprang out of line when cut
The slope was examined to identify landslip dimensions and
movements that would represent design ground movement levels for
the fitness-for-purpose assessment. In addition to confirming the pipe
had adequate strength and toughness, curved wide plate testing was
commissioned to determine the strain capacity of field girth welds.
Performance limits were selected based on tensile strain capacity, axial
buckling due to overload and lateral buckling due to the maximum
movement capacity. The structural analysis considered the beam and
ring performance of the pipeline subject to a range of landslide
geometries and used thermal strain measurements to guide the
selection of appropriate longitudinal fixity conditions.
The structural calculations of the pipeline behaviour from slope
instability identified that the critical performance limit was buckling
from movement overload. The level of slope movement was identified
to exceed 2m and the development is progressive allowing sufficient
time for intervention activities to take place.
Aerial photograph showing the pipeline route, the region of landslip
and the surrounding area
Benefits:
The assessment identified that, with appropriate monitoring and
surveillance activities, the pipeline is fit-for-purpose. The outcome of
the work avoided the need for costly upgrading or diversion work and
the need for widespread slope stabilisation measures.
26
CASE STUDIES
27
CASE STUDIES
m. In-Line Inspection Vehicle Development
Date: 2007
Customer: China Pipeline Operator
Savings: Improved inspection
A team of consultants worked with the China Petroleum Pipeline
Inspection Technologies company to design and build a new
high-resolution magnetic flux leakage (MFL) ILI system. This project
started from a blank sheet of paper with the aim of delivering a
state-of the-art inspection system having outstanding performance
for inspection range, maximum pipeline flow speed, detection
sensitivity and defect discrimination. Work covered all aspects of
hardware and software, including development and coding of
algorithms for automated data analysis. Following an intensive
two-year programme of work, which included substantial periods
spent in China with the customer and their local contractors, the new
ILI system was shown in trials in live gas transmission pipelines to
meet all of its specified requirements.
n. In-Line Inspection Data Analysis
Date: 2007
Savings: Avoidance of excavations
An operator had conducted two ILI operations on the same pipeline
segment; one inspection used a calliper tool to identify denting while
the other was conducted using high-resolution MFL for metal loss
detection. The calliper inspection reported a number of dents,
including two of sufficient magnitude to require excavation and repair
according to the operators standards. However, the locations of these
two dents were such that excavations would have been extremely
disruptive and expensive. GL were approached by the operator to give
an opinion on whether the relevant calliper signals were, in fact, due
to dents.
GL specialists examined both the low-resolution (single channel)
calliper record and flux signals from the MFL tool. Having performed
a careful correlation of the two records it was possible to conclude
that the two dent responses were actually caused by (a) a protruding
weldolet fitting and (b) bore reduction at an unusually heavy-walled
forged bend. The operator was thus able to avoid digging at either
dent location.
o. In-Line Inspection Scheduling
Date: 2007
Savings: Optimised inspection schedule
A major operator of high pressure pipelines required a method for
scheduling ILI that would maintain consistent reliability with respect
to the corrosion threat.
GL applied their expertise in the field of structural reliability analysis to
take information from the most recent in-line inspection and model
the development of reported metal loss over time, allowing absolute
failure probabilities to be calculated for any time after the inspection.
Our approach to this problem uses statistical and probabilistic
techniques to represent uncertainties in pipe dimensions and material
properties, defect dimensions and corrosion growth rates. GL
proprietary software then applies these uncertainties with appropriate
limit state functions to quantify the time-dependent likelihood of
failure for an ILI segment. Thus, the date of next inspection can be
chosen so as to keep this failure probability below any required
threshold.
p. Review of Operations and Maintenance Practice
Date: 2006
Customer: Middle East Pipeline Operator
Savings: Pipeline integrity management strategy
A gas transmission company were operating a small network in the
UAE. As part of a major growth strategy they were constructing a
new gas import pipeline and taking over responsibility for part of an
existing gas network.
The operator contracted GL to undertake a study of their current
Operations and Maintenance practices as well as those in use for the
network they were about to take over. GL undertook a gap analysis
and compared the findings against best practice used by other world
class operators. The next step was to consolidate practices, processes
and documentation from the existing and new networks into a
coherent Pipeline Integrity Management Strategy.
The gap closure actions entailed the production of a complete
Engineering Documentation System to allow the successful adoption
and integration of the new network into the existing company asset
base. The PIMS was designed so that it can be readily adapted and
updated as required in the future.
28
CASE STUDIES
29
CASE STUDIES
q. China Joint Venture LNG Pipeline
Date: 2006
Customer: International Pipeline Operator
Savings: Developed pipeline integrity strategy
A major oil and gas pipeline operator is working in partnership with
a locally owned enterprise in China to export gas through a
transmission pipeline from an LNG receiving terminal. GL was
contracted by the oil major to undertake a review of the Pipeline
Integrity Management System in place to see that it was adequate.
The review covered the following issues:
Management strategy
Pipelines operations and maintenance management
Emergency management
Data management
Engineering documentation
Following an in-country visit to gather information and interview
operational staff, GL subsequently prepared a report and a
presentation for the joint venture company management. This
provided a PIMS strategy and process diagrams to provide the client
with a road map towards achieving best practice.
r. Investigation of Pipeline Incidents
Date: Ongoing
Customer: UK Gas Supplier
Savings: Incident report compliance
Over the past 12 years, GL have been contracted to a major UK gas
supplier to provide an incident consultancy service for both their high
pressure and low pressure gas distribution systems. Various incidents
have occurred over the intervening years and have involved both
pipeline corrosion and mechanical damage to the pipeline. The
incidents have ranged from minor to severe, but have all been dealt
with quickly and efficiently by GLs team of specialist incident
consultants.
GL have also performed a number of investigations involving incidents
on process plant. This area of work whilst smaller than pipeline
incidents is growing in size. GL have investigated process plant
incidents both the within UK and abroad for a number of major
energy companies.
s. T/D1 Surveys
Date: 2007 - 2011
Customer: National Grid
Savings: Re-affirms M.O.P
GL have recently commenced a contract to survey approx 50 pipeline
sections per year over a 4 year period for the largest gas pipeline
operator in the UK (approx 12,000km in total). GL were well placed
to win this work having extensive previous experience of delivering
this service in various parts of the UK, including East Anglia, North
London, Wales and West, South of England and Scotland. GL also
developed the Maintenance Procedure (T/PM/MAINT/5) upon which
the detailed aspects of the survey are based.
The TD/1 resurvey begins with the existing TD/1 Report (undertaken
4 years previously). A data gathering phase reviewing all the items
listed above then commences. A major aspect of this is pipeline faults,
modifications and repairs experienced in the intervening period. In
parallel with this an infrastructure survey will commence using aerial
photographs. A close comparison is carried out between the new
photographs and those from the previous survey. From this, new
developments and potential encroachments are identified. These are
later confirmed via on site surveys. Any changes to area type (e.g. type
R area becoming type S) can then be assessed. If necessary pipeline
Quantitative Risk Assessments can also be undertaken.
The final deliverable for the client is a TD/1 Report in line with IGE/TD/1
and T/PM/MAINT/5. This report gives the client the information they
require to allow them to re-affirm the Maximum Operating Pressure
for the pipeline section in question for the next 4 years.
t. Pipeline Uprating
Date: 2004
Customer: Transco
Savings: Avoids new construction
Transco successfully uprated >1000km of pipeline
utilising systems and methods developed by GL
GL worked with Transco in developing the systems and
methods
GL has incorporated previous learning points within cur-
rent methodology
GL, as principal contractor, has successfully uprated
375km of pipeline for Transco when GL executed all
works from feasibility study, through assessment and site
remedials, to pressure-raise
GL has worked via other principle contractors to provide
complete uprate safety justifications for Transco
GL offer modular up-rating work packages that cover an
entire project or any discreet part thereof
30
CASE STUDIES
31
CASE STUDIES
u. Design and Qualification of Repair Procedures for Bellows
Attachment Welding
Date: 2008
Customer: Pipeline Operator
Savings: Improved welding procedure
A GL report on the bellows connection concluded that the bellows on
the pipeline required a weld repair to be undertaken on the cracked
fillet welds. The bellows configuration is shown in Figure A of that
report, reproduced below:
Consequently, according to British Standard BS 6990, prior to welding
onto the live pipeline, it is necessary to qualify a procedure, simulating
the cooling effect of the gas which complicates the qualification. The
qualification set-up should simulate actual flow conditions.
The weld procedure (below) has been developed to minimise the risk
of lamellar tearing. For weld procedure qualification, plate material
representing the nearest equivalent currently available material is
used.
Proposed weld procedure for the repair. Qualification of this
procedure is in progress.
Weld Repair instructions:
Weld repairs to cracked fillet welds in bellows unit to be
carried out after qualification of the attached weld repair
procedure and following decommissioning and purging
of pipeline 2.
Ensure all necessary risk assessments and safety checks
have been undertaken and procedures are followed,
including safe control of operations (non routine
operation) and entry into confined spaces.
Prior to repair, determine chemical analysis of carrier pipe
and box material by on-site material sampling of the
carrier pipe and restraining box material in accordance
with T/PM/Q/10 (ref clause 12 and appendix B). Report
results to GL for assessment.
Remove the two fillet weld cracks in bellows 2 by grinding
in accordance with T/PM/P/11 appendix F.
Confirm defect removal by visual inspection and MPI.
Check carrier pipe for defects by UT & MPI below
intended area of weld repair prior to welding.
Perform weld repair in accordance with attached
procedure: WPS/A/Tinsley/01FR (subject to qualification).
Completed repair welds to be subjected to visual
inspection and MPI.
Cracking located in bellows attachment fillet welds.
v. Grouted Tee
Date: Ongoing
Customer: Various
Savings: Avoids welding and pipeline decommissioning
National Grid Transmission Above 7 bar
National Grid Distribution below 7 bar
BP (Forties 36 pipeline) Approved for high spiked crude
oil application
Tullow Oil Class 600 56 bar
Ineos Chlor (Runcorn former ICI plant)
Laing Above 55 bar system
Murphy below 7 bar
BG International thin wall applications
Comgas (Sao Paulo, Brazil) CLASS 600 17 & 35 bar ring
mains.
Phoenix Natural Gas (Belfast, N Ireland) (1 operation -
One Grouted Tee installation)
Edison Welding Institute (Columbus, USA) Stainless
Steel and Titanium flow lines
34
CASE STUDIES
36 x 36 - Feeder 7 - July 2003
35
CASE STUDIES
National Grid - Marsworth Pressure Reduction
Date of Installation:
Pipeline Diameter:
Pipeline Material:
Pipeline Wall Thickness:
Operating Pressure:
Size of Tee installed:
BGI / ComGas - Sao Paulo, Brazil
Pipeline Diameter:
Pipeline Material:
Operating Pressure:
Bishop Auckland Test Loop
Pipeline Diameter:
Pipeline Material:
Operating Pressure:
National Grid - Feeder #7 Transmission pipeline
Pipeline Diameter:
Pipeline Material:
Operating Pressure:
Tullow Oil - Bacton, United Kingdom
Pipeline Diameter:
Pipeline Material:
Operating Pressure:
Duration of Installation:
Client name & contact No.
Installation of 4 high pressure double branch Grouted Tee fittings
for flow isolation, stopple operation. o 4 bypass connections
October 2004
12
Steel (API 5L Grade X42)
7.9 mm
34.5 bar
12 Equal Tee (Class 300) Double branch
Two Grouted Tees were installed, one either side of an existing block valve.
The installations were used to create a full-bore bypass around the block valve.
October 2003
20
4.5 mm
31 bar
20 Equal Tee (Class 300)
Controlled pipeline loop at GLs test facility at Bishop Auckland
October 2000
24
12.5 mm
58 bar
One CLASS600 Grouted Tee was installed onto Transcos transmission
pipeline to allow for a new pipeline tie-in.
June 2003
36
15.9 mm
75 bar
Two Grouted Tees were installed linking two incoming offshore pipelines. The Grouted Tee was
considered because of Tullow Oils polices of zero hot work, except during a plant shut down.
August 2004
20 & 24
API 5L Grade X52
20mm & 24mm
56 ar
18 off 20 & 18 off 24 (Class 600)
15 hours per Grouted Tee plus Grout curing
Michael Webster 01263 725084
w. Weldability Testing of 48 Diameter X80 Europipe Production
Date: 2007
Customer: National Grid (Milford Haven extension)
Savings: Approved procedures and manufacturing
Weldability testing entails the production of a full-scale girth weld
between two 12m pipe joints under field conditions and including
the manipulation of the partially-completed weld to simulate the
removal and movement of the line-up clamp. Following production of
the complete girth weld, the joint is subjected to X-ray inspection and
must pass required codes (T/SP/P/2 or API 1104 requirements) and is
then subjected to a full suite of mechanical tests. Following
satisfactory results from these investigations, the welding procedure
and the linepipe manufacturing route are qualified for supply to
National Grid.
x. Corrosion Control of a Sour Gas Pipeline
Date: 2006
Customer: North Africa Offshore Operator
Savings: Identified corrosion inhibitor
Description:
A major operator produced sour gas and condensate from a field located
in the Mediterranean. The field infrastructure consists of a number of
platforms to dehydrate the produced fluids, which are then transported
to the onshore gas processing plant via a multiphase pipeline.
Issues:
The processing plant on the platforms and the multiphase pipeline
were manufactured in carbon steel. Corrosion protection is required
and this is provided by corrosion inhibitor injection. The inhibitor in
use was dosed at high rate to ensure sufficient protection resulting in
a high cost of treatment.
Application:
GL carried out a chemicals selection programme with the aim of
identifying a corrosion inhibitor treatment providing the optimum
balance between dose rate, cost and environmental impact. The
programme included a review of vendor-supplied data, corrosion
inhibitor performance evaluation in laboratory autoclave tests, (under
representative conditions) and field trials.
Results:
A suitable inhibitor meeting the performance criteria was identified.
Dosing was optimised and the following benefits were delivered:
50% reduction in the chemical unit price
Improved corrosion inhibition performance
33% reduction in the chemical dose rate
Lower environmental impact
Increased plant integrity
Increased corrosion awareness (improved corrosion
management strategy)
32
CASE STUDIES
Girth welding of 48 X80 pipe
during weldability testing
Simulation lifting of 48 joint after
hot pass deposition.
Sample welding procedure
qualification record from the
48 X80 trials, showing joint
design, consumables, pre-heat
requirements, pass sequence
and other details.
33
CASE STUDIES
y. Naphtha Pipeline Integrity Management Study
Date: 2005
Customer: Far East Offshore Operator
Savings: Corrosion management
Background:
GL was contacted by a gas company operating in the Far East to offer
recommendations for corrosion management of a naphtha subsea
pipeline. A recent in-line inspection revealed that the pipeline had
undergone internal corrosion (equating to 10-25% metal loss). As the
pipeline was required to operate for a further 20 years, GL was asked
to devise a cost-effective lifetime integrity management strategy.
Solution:
GL applied its broad knowledge and experience in failure
investigation and pipeline corrosion management to determine the
reason for internal corrosion and identify the most cost-effective
integrity management solution. GL applied risk based
lifecycle-costing methods to compare the viable reconditioning
strategies. We also delivered an implementation plan and corrosion
monitoring strategy to demonstrate long-term effectiveness.
Benefits:
GL demonstrated that both corrosion inhibition and in-situ coating
would allow a 20-year life for the pipeline. However, based on upon
NPV cost and ease of implementation, corrosion inhibition was the
preferred option. NPV for inhibition over 20 years was only one third
of the coating NPV costs. GL also demonstrated that the in-situ coat-
ing option would require complex project management in order to ac-
complish the work between naphtha shipments.
z. Sour Export Pipeline Study
Date: 2006
Customer: Major Oil Production Company
Savings: Materials and evaluation
Background:
A new ultra sour oil field was to be developed in the environmentally
sensitive Caspian sea. It was thus vital that the oil export pipelines did
not suffer any leaks during operation to avoid pollution damage. One
member of the joint venture suggested the use of corrosion resistant
alloy pipelines to avoid any risk of leaks, however this would involve
costs of $2 billion just for the alloy so another solution was needed.
The oil company asked GL to consider the materials and
corrosion control options for the pipeline.
Solution:
GL evaluated the corrosivity of the produced fluids by
considering the acid gas composition, water content, pressures and
temperatures. These parameters were used for sour gas corrosion
modelling using both industry standard methods (e.g. DeWaard and
Milliams) and software specifically developed by GL (PrCSM). Sour
cracking mechanisms such as sulphide stress cracking and
hydrogen induced cracking were also considered in the study. The
results of the modelling and an economic study were used to
compare various materials options for the pipeline. The options were:
Sour resistant carbon steel with corrosion inhibition
Nickel alloy lined pipe
Nickel alloy clad pipe
Solid nickel alloy pipe
Results and Benefits:
The study showed that sour resistant carbon steel with corrosion
inhibition could be used for the sour oil export lines with an
acceptable risk of failure. The small quantities of water present within
the pipelines allowed corrosion inhibition to reduce corrosion rates
and the cracking risk to a minimal value.
Germanischer Lloyd does not warrant or assume any kind of liability for the
up-to-date nature, accuracy, completeness or quality of the information provided.
Liability claims against Germanischer Lloyd arising out of or in connection with
material or non-material loss or damage caused by the use or non-use of information
provided, including the use of incorrect or incomplete information, are excluded
unless such loss or damage is caused by the proven wilful misconduct or grossly
negligent conduct of Germanischer Lloyd.
All offers are subject to alteration and are non-binding. Germanischer Lloyd expressly
reserves the right without notice to change, supplement or delete parts of the pages
or the entire offer or to stop the publication temporarily or definitively.
Germanischer Lloyd
Industrial Services GmbH
Oil and Gas
Steinhft 9
20459 Hamburg, Germany
Phone +49 40 36149-7700
Fax +49 40 36149-1781
glis@gl-group.com
www.gl-group.com/glis
Issue no.001 15.05.2008
Asset Management Services
Plant Integrity Management Services
Pipeline Integrity Management Services
Production Optimisation (Includes RAM
and Gas Processing)
Dynamic and Steady State Simulation
Rotating Equipment Performance &
Condition Monitoring including
Emissions Reporting
Gas Quality and Interchangeability

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