Risk Assessment of Subsea Pipelines

Inspection Maintenance and Repair of Deepwater Pipelines
DNV RP-F113 Deep and Ultra-deepwater Pipelines Conference 27 - 28 September 2011, Novotel Paris Les Halles Inspection Maintenance and Repair of Deepwater Pipelines
Ian Nash
Introduction
Requirements for pipeline inspection: what, when and how Pipeline maintenance and routine inspection Pipeline damage during installation and operation in deepwater, causes and effects Understanding the risks and potential need for repair Repair systems & tools
Deep and Ultra-deepwater Pipelines Conference 27 - 28 September 2011, Novotel Paris Les Halles
Ian Nash
Requirements for pipeline inspection: what, when and how
Ian Nash
Typical Characteristics of Deepwater Pipelines

Water depths are beyond diver limits and all activity (IMR) is remote Wall thickness are typically high } Materials, Welding, buckling Operating pressures are typically very high or very low
Ambient external pressures are high, commonly similar to internal operational pressures } Coating and Insulation Degradation
High levels of Insulation are commonly required } Insulation Degradation
All inspection, maintenance and Waters are typically cold approx 4C6C } CP, Flow Assurance, Materials
Pipelines tend not to be protected by a concrete coating } Damage
Geohazards can be significant } Spanning, Buckling, Damage, Bend Stability, Turbitity and Debris flows Slugging within produced fluids is common } Spanning, Fatigue Greater tolerances Survey inaccuracy, installation accuracy Metocean and environmental conditions tend to be benign } Stability Seabed mobility is less dominant } Scour, Spanning
repair is performed remotely
Corrosion coatings tend to be of very high quality } Corrosion, Damage

Deep and Ultra-deepwater Pipelines Conference 27 - 28 September 2011, Novotel Paris Les Halles Inspection Maintenance and Repair of Deepwater Pipelines
Ian Nash
BASELINE SURVEY
The ongoing assessment of inspection findings will involve comparison of data with that recorded during previous inspection campaigns. This will allow trends to be extrapolated and judgments made regarding the urgency of remedial action. This process necessarily commences with the acquisition of the measurement of internally and externally taken values at the commencement of pipeline service, known as a Baseline Survey.
Ian Nash
INSPECTION STRATEGY (Monitoring)

Planned inspection campaigns are an integral part of the IMR strategy, the purpose of the inspections being: to monitor pipeline system integrity over time monitor the impact of the subsea and production environments on the pipeline. Understanding and confirming design assumptions
Routine inspections may indicate a requirement for more specific investigations involving detailed or specialist techniques.
The normal physical inspection tasks undertaken on the Deepwater Pipelines can be split into locations internal and external to the pipeline. Internal and External locations are typically periodically inspected by Pigging and Remote Vehicle methods respectively. Permanent monitoring methods also exist and are becoming more commonplace.
Ian Nash
INSPECTION STRATEGY (Understanding the Design)

It is essential that in developing an inspection regime that the deign is understood and must include interaction with the designers: deepwater lateral buckling and walking issues will have been solved with reference to the anticipatedpipeline operation response. Is that what really happened? If your system is anticipated to have multiple start up and shut down scenarios you will need to understand what the designers anticipated happening and how to monitor it. there may be need to reconfirm what has actually happened once the pipeline is in operation.
Ian Nash
INSPECTION METHODS
Location Method Technique
Magnetic Flux Ultrasonic Pigging Internal Visual Calliper Geometry (XYZ) Corrosion Probe/Spool Sand Probe Visual Geometry XYZ Inspection ROV Burial Acoustic CP Probe Weld Scanner Tomography Scanning Side Scan Visual AUV Geometry (XYZ) Sidescan Permanent Monitoring
Defects
Spanning/Burial Corrosion Dents Gouges leak CP Failure Coating Damage Hydrate Movement Buckle Vibration Cracking Fatigue Protection Integrity (mattresses/ Rock/Covers)
Permanent Monitoring
External
Vibration Strain
Ian Nash
INSPECTION DEFECT MATRIX

Defect Spanning/ Burial/ Scour
Movement
Protection Integrity
CP Failure
Corrosion
Vibration
Pigging
Internal Permanent Monitoring
ROV External AUV Permanent Monitoring
Magnetic Flux Ultrasonic Visual Calliper Geometry (XYZ) Corrosion Probe Sand Probe Visual Acoustic CP Probe Weld Scanner Tomography Side Scan Visual Acoustic Sidescan Vibration Strain
leak
Location
Method
Technique
Cracking 9
Coating Damage
Hydrate
Erosion
Gouges
Ian Nash
Buckle
Dents
Risk Based Inspection Concept

Identify Threats/Hazards to Pipeline Assess Inspection History
DNV RP-F116 (Sec H1) The risk assessment comprises the following main tasks;
Susceptibility to Threat Likelihood of Failure
Failure Mode Remaining Life or Inspection Grade
a) Establish equipment scope b) Identify threats
Consequence of Failure
c) Data gathering
d) Data quality review e) Estimate probability of failure (PoF) f) Estimate consequences of failure (CoF) g) Determine risk h) Identify risk mitigating measures i) All equipment threats have considered j) Determine aggregated risk k) Planning of inspection, monitoring and testing activities
Risk Factor
Risk OK?
Mitigation Measure to reduce susceptibility
Inspection Scheme
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Targeted Inspections
Design Dossier Defect Type1 Code Requirements
Defect Type 3 Defect Type 4 Review design Review previous inspections Defect Type 5 Defect Type 6 Prepare & Perform Targeted Inspection
Determine most likely location
Record Results No Defect observed? Yes Assess Defect & Determine Correction
Stop
Inspection Records
Defect selected
Defect Type 2
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Deepwater Pig Inspection
Pig Inspection of offshore pipelines tends to look for internal problems. Generally running pigs in offshore pipelines is very similar to running in onshore lines, after the wall thickness and higher pressures are taken in to consideration. The most favoured inspection methods are either ultrasonic or magnetic flux inspection. Magnetic flux is limited by magnet strength, ie get enough magnetism in the wall of the pipe to enable good results to be obtained. Ultrasonic can inspect very thick wall pipe but Ultrasonic's have to be run in a liquid medium. The main difference between offshore and onshore is the length of run between pig traps, as Offshore pipelines tend not to have intermediate compression stations with conveniently located pig traps. The pig must not get stuck in the pipeline as retrieving it will be much more expensive than from an onshore pipeline. The pig must stay alive and recording data (battery duration may be an issue)
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Ian Nash
Deepwater ROV Inspection
Traditionally, external inspection, of deepwater pipelines is performed using work ROVs deployed from DP ROV support vessels. These vessels are expensive, and they may not be available when they are needed most. In deep waters, ROVs become heavy to handle from these vessels, because of long umbilicals; and they become prone to breakdowns. ROV inspections of long transmission lines can be very slow and may take many months to complete end to end Weather downtime is also an issue for ROV support vessels when working in harsh and hostile environments
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Ian Nash
AUV based Inspection

AUV-based Inspection in deepwater fields may provide dramatic improvements in cost, performance, safety and reliability.
Large DPII vessels with high-end ROV spreads would no longer be required for simple inspection.
AUVs have demonstrated solid performance requiring simple autonomy for missions such as bathymetric survey and high resolution sonar imaging
AUVs can be deployed from small utility vessels, be capable of operations in higher seas, without the operational limitations and equipment hazards imposed by umbilical and tether management systems.
In the future AUVs would become field resident, residing in the subsea field for periods of months.
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Pipeline routine inspection and maintenance
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Optimisation of Routine/Scheduled Inspection
An optimum IMR plan aims to strike an appropriate balance between the following objectives: maximising the availability of the pipeline system during its operating life by maintaining and preserving its integrity, thus maximising revenue; minimising inspection, intervention and rectification measures through the life of the pipeline system, thus minimising through-life IMR related costs. reducing to as low as is reasonably practicable all risks to people, the environment and assets, in accordance with legislative, societal and business requirements, thus minimising the costs of failures.
When and What do we inspect?
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Ian Nash
Optimisation of Routine Inspection Measures

The typical variation of failure rate in an operating system with time, takes the shape of the classic 'bath-tub' curve, and can be divided into three phases: Phase 1, early failures or damage, due to defects in materials, incorrect installation, incorrect operation, unexpected environmental effects (Scouring etc) Phase 2, random failures or damage, due to earthquakes, impacts (dropped objects, fishing, anchors), etc Phase 3, wear out failures or damage, due to corrosion, fatigue, internal erosion, anode depletion, coating breakdown etc
Phase 3 Phase 1
Failure rate
Phase 2
Time
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Ian Nash
Code Requirements DNV OS-F101

1. Define equipment scope ( i.e. All equipment that can lead to a failure) (DNVOS-F101, Sec. 11, D304) 2. For each equipment, identify all threats which can lead to a failure (DNV-OSF101, Sec. 11, D201) 3. For each threat; estimate risk (DNV-OS-F101, Sec. 11, D202) Consequence of failure (CoF) Probability of failure (PoF) Inspection, monitoring and testing (IMT) (DNV-OS-F101, Sec. 11, D103) Mitigation, intervention and repair (MIR) (DNV-OS-F101, Sec. 11, D700) Integrity assessment (IA) (DNV-OS-F101, Sec. 11, D600)
Propose plans for:
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Inspection Planning
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Inspection Planning
APPENDIX G EXAMPLE - RISK ASSESSMENT AND IM PLANNING
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Example Process from RP-F116

Inspection Interval
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Example Process from RP-F116

Schedule Planning
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Years Const As-Built Survey Baseline Survey Phase 1 "Early Failure"
Type of Inspection
Phase 21) "Random Failure"
Phase 33) "Wear-Out Failure"
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
Intelligent Pig
Visual including CP and Side Scan Towed Acoustic Side Scan Sonar 2) Targeted Special Events ? ? ?
1) Reduction in annual inspection applies to remote subsea pipelines only 2) Acoustic side scan sonar is not always cost effective especially in deepwater or where there are strong currents. An ROV survey with reduced scope could be considered 3) the third phase may not occur within normal project lifetimes, i.e. the Phase 2 (plateau phase) extends for several decades with well designed, operated and maintained facilities.
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Pipeline Maintenance
Preventive maintenance Because of the high cost and potential delays associated with intervention, preventive maintenance should be eliminated at the design stage, wherever possible. Routine maintenance Routine maintenance tasks are required where the elimination of specific intervention is uneconomic or technically problematic. Normally such maintenance would be undertaken during repair activity, or combined with planned inspection campaigns. Corrective Maintenance Intervention to rectify breakdown or degradation (Corrective Maintenance) is referred to as Repair. Normally Subsea Facilities shall possess sufficient reliability to ensure availability throughout the field life. Subsea equipment that is susceptible to failure should be designed to minimize the effort/cost required for replacement of the failed assembly.
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Pipeline damage during installation and operation in deepwater, causes and effects
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Installation Damage Scenarios

The potential causes and effects of damage during installation Phase of the pipeline(s) are summarized as follows:
3rd Party Objects
Ships Material and Construction Defects
Dropped
from
Installation Tension failure Station Keeping Geohazards Slope Stability Route Features Rock Outcrops, Cement Soil, Shell and Coral Banks. Pockmarks
Damage to pipeline geometry and/or pipe wall: Gouges, Grooves and Notches. Dents Wet and Dry Buckles. Overstressing or Excessive Bending. Fatigue Damage. Bend Pull Out
Coating Damage (Corrosion and Weight
coating): Lost & Damaged weight coating Damaged corrosion coating Lost & Damaged insulation coating Anode Damage: Lost anode Disconnected anode
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Ian Nash
Operational Damage Scenarios

The potential causes of damage during operational Phase of the pipeline(s) are summarized as follows:
3rd Party Trawling Anchoring Objects Dropped Geohazards Earthquakes Seismic Fault movement Submarine Landslides Mass Gravity Flows Turbidity Currents Sub-marine Volcanoes Liquefaction Tsunamis Route Features Rock Outcrops, Cement Soil, Shell and
Environmantal Wind, Waves and Currents Scour Seabed Morphodynamics

Ships Ship sinking Ship Grounding Shipwrecks and Debris Material and Construction Defects Sabotage Military Action
from
Coral Banks. Shallow Gas and Seepage of Gas and Fluids Pockmarks Mud Diapirs and Mud Volcanoes Slope Instability Mass Movements
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Operational Damage Scenarios (effects)

The effect of damage that could occur during the operational phase of the pipeline(s) are summarized as follows:
Damage to pipeline geometry and/or Coating Damage (Corrosion and Weight
pipe wall: Rupture. Internal Corrosion. External Corrosion. Pinhole Leak. Gouges, Grooves and Notches. Cracks and Fracture Propagation. Dents and Buckles. Overstressing or Excessive Bending. Fatigue Damage.
coating): Lost & Damaged weight coating Damaged corrosion coating Lost & Damaged insulation coating Anode Damage: Lost anode Disconnected anode Over consumption Anode pasivity Hydrate Formation: Pinhole Leak. Lost & Damaged insulation coating Incorrect operation
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Ian Nash
Based on the damage scenarios and risk assessment it is clear that: The pipeline installation contractor should have fully developed procedures and all necessary equipment mobilised and ready for implementation in the event of dry or wet buckles, prior to the start of deepwater pipelay operations.
The operator should have fully developed procedures and all necessary
equipment ready for implementation prior to the start of operations, to cater for the following scenarios:

Hydrate formation. Localised damage (i.e. dent or pinhole leak). Local Rupture. Rupture over extensive pipeline length.
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Understanding the risks and potential need for repair
MEIDP Example
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MEIDP Example (3500m WD)
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Intervention Zones
Based on this preliminary information, the route has been divided into five different intervention requirement zones. 1) Shallow Water Zone (0 to 150m WD) 2) Continental Slope Zone (150m to 2500m WD) 3) Deep Water Section (2500m to 3500m WD) 4) Remote Seamount Section (300m to 3000m WD) 5) Indus Fan Section (2500m to 3000m WD)
Slope
North Murray Ridge Dalrymple Trough South Murray Ridge
Abyssal Plain
Slope
Rise
Rise
Abyssal Plain
Qualhat Seamou nt
Middle Indus Fan
Upper Indus Fan
Abyssal Plain
Shelf
4 3
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Ian Nash
Typical QRA for Deepwater Pipelines
MEIDP QRA Risk Contributors and % contribution Ship sinking (40.24%) Objects dropped from ships (19.91%) Ship grounding (14.07%) Material and construction defects (11.17%) External corrosion (10.62%) Anchoring (3.23%) Internal corrosion (0.63%) Trawling (0.12%)
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Ian Nash
Typical QRA for Deepwater Pipelines
6.00E-03 3.00E-03 5.00E-03 2.50E-03
4.00E-03 2.00E-03
1.50E-03 3.00E-03 1.00E-03 2.00E-03 5.00E-04 1.00E-03 0.00E+00 0.00E+00
Most likely location for Intervention is the deepest water
Material and construction defects External corrosion Material and construction defects Internal corrosion External corrosion ShipInternal grounding corrosion ShipDropped sinking objects Dropped objects Anchoring Anchoring Trawling Trawling
Abys sal Plain North Murray Ridge Dalrym ple Trough South Murray Ridge
R is e Sl o p e
Rise
Abyssal Plain
Qualhat Seamou nt
Middle Indus Fan
Upper Indus Fan
Abyssal Plain
Shelf
Sl o p e
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Repair systems & tools
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Help is at Hand
This Recommended Practice (RP) is intended to provide criteria and guidelines for the qualification of fittings and systems used for pipeline subsea repair and/or modifications and tie-ins.
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Why Tooling is Needed

Equipment DP Support Vessel Pipelay Vessel Purpose Platform from which to operate ROVs and conduct repair operations. Working platform in the event that an extensive section of damaged pipeline has to be relaid/replaced. Flooding/Dewatering/Drying Various purposes including: Spread Pressure equalisation prior to cutting (flooding). Coupling for intelligent pigging (flooding). Removal of water (dewatering). Drying prior to returning to service to minimise water content and risk of hydrates. Seabed Dredging/Levelling Exposure of the pipeline, if locally trenched or buried, to allow for survey Equipment and/or repair operations. Pipeline Lifting Frames Elevation of pipeline off the seabed in the vicinity of any repair, for the purpose of improving access for repair equipment and operations. Subsea Measurement Tool Performance of measurements between pipeline ends for accurate spool piece and connector assembly. Pipeline Cutting Tool Cutting of pipeline (and coatings) to allow removal of any damaged sections.
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Ian Nash
Why Tooling is Needed

Equipment Pipeline Coating Removal Tool External Weld Bead Removal Tool End Preparation Tool Pipeline Recovery Tool Pipeline Repair Clamp Subsea Pipeline Connectors Replacement Spool piece Hydrate Blockage Removal Spread Purpose Removal of external pipeline coatings in the vicinity of any section that has been cut (by the Pipeline Cutting Tool). Required in the event that the Pipeline Recovery Tool grips the pipeline on its external steel surface. Removal of external longitudinal weld seam (SAW linepipe) to prevent interference on connector seal. Machining of the end face of the pipeline to prevent interference on connector seal. Tool connected to the end of the cut pipeline to allow recovery to surface. Designed to allow the pipeline be dewatered and isolated prior to recovery. Permanent clamp installed around the pipeline in the vicinity of minor damage (i.e. dent) for the purpose of ensuring the structural integrity of the pipeline without the need for cutting out and replacing an entire section of pipe. Connector assembly and modular system used for the installation and connection of a new section of pipeline. New section of pipeline used to replace area of damage. Accidental ingress of moisture into the pipeline can cause formation of a hydrate plug. Hydrate removal is possible by various passive methods but may ultimately require a deepwater hot-tap operation at actual location of the hydrate where the spread taps a hole into the pipeline and injects hydrate removal chemicals.
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Ian Nash
Summary of Inspection for Deepwater Pipelines
Intelligent pigging is the primary form of internal inspection ROV are the primary tool for performing external inspection
The development of AUVs for flypast inspections may give benefits deepwater by
isolating the vehicle from surface influences RP116)
Risk Based methods have been established for determining Inspection regimes (DnV
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Ian Nash
Summary of Repair for Deepwater Pipelines

Installation Phase
Damage scenarios during installations and operation pose differing levels of risk.
The most significant potential damage scenarios during the installation phase are
dry and wet buckles.
The technology and methodologies required for rectification of installation phase
damage (i.e. buckles) are a direct extension of techniques used for similar events in shallow water, and currently exists with installation contractors and specialist equipment suppliers.
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Ian Nash
Summary of Repair for Deepwater Pipelines

Operational Phase
Several potential damage scenarios exist during the operational phase. The most
significant are where a damaged section of pipeline needs to be reinforced, replaced or cleared of a hydrate blockage. Where a replacement pipeline section is required, the length could vary significantly depending on the nature of the event causing the damage (a few meters to several kilometres in the event of a geohazard (i.e. slope instability). There is a wide range of qualified or nearly qualified equipment for the subsea repair, both currently available and under continual development. The equipment exists both as individual components (equipment, tools and fittings) and full systems. Some repair systems are owned and operated on a club basis, by a group or consortia of pipeline operators. The clubs at present operate in specific geographical locations. The need to access the pipeline at both ends for the purpose of re-commissioning (i.e. flooding, cleaning, dewatering, etc.), is inherent in many of the repair scenarios. Access facilities and the provision of adequate space for equipment (particularly dewatering) are significant.
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Ian Nash
References
I Nash & P Roberts OPT 2011, MEIDP The Deepwater Gas Route to India, February
23-24, I Nash & P Roberts DUDPC 2011, Case Study: MEIDP Installation, intervention and Repair, Sept 27-28 Peritus International, 18001.01-REP-IIDP-Y-0014 MEIDP, Emergency Pipeline Repair Systems, Aug 2011 Peritus International, 18001.01-REP-IIDP-Y-0007 MEIDP Quantified Risk Assessment Update, Dec 2010 Dan McLeod, Emerging Capabilities for Autonomous Inspection Repair and Maintenance, OCEANS 2010 (ART) DNV RP-F116 Integrity Management of Submarine Pipeline Systems DNV RP-F113 Subsea Pipeline Repair
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Ian Nash

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Inspection Maintenance and Repair of Deepwater Pipelines

Inspection Maintenance and Repair of Deepwater Pipelines

Requirements for pipeline inspection: what, when and how

Inspection Maintenance and Repair of Deepwater Pipelines

Typical Characteristics of Deepwater Pipelines

repair is performed remotely

Corrosion coatings tend to be of very high quality } Corrosion, Damage

Inspection Maintenance and Repair of Deepwater Pipelines

INSPECTION STRATEGY (Monitoring)

Inspection Maintenance and Repair of Deepwater Pipelines

INSPECTION STRATEGY (Understanding the Design)

Inspection Maintenance and Repair of Deepwater Pipelines

Inspection Maintenance and Repair of Deepwater Pipelines

INSPECTION DEFECT MATRIX

ROV External AUV Permanent Monitoring

Risk Based Inspection Concept

Susceptibility to Threat Likelihood of Failure

Failure Mode Remaining Life or Inspection Grade

a) Establish equipment scope b) Identify threats

Mitigation Measure to reduce susceptibility

Inspection Maintenance and Repair of Deepwater Pipelines

Determine most likely location

Inspection Maintenance and Repair of Deepwater Pipelines

Deepwater Pig Inspection

Deepwater ROV Inspection

Inspection Maintenance and Repair of Deepwater Pipelines

AUV based Inspection

Inspection Maintenance and Repair of Deepwater Pipelines

Pipeline routine inspection and maintenance

Inspection Maintenance and Repair of Deepwater Pipelines

Optimisation of Routine/Scheduled Inspection

When and What do we inspect?

Inspection Maintenance and Repair of Deepwater Pipelines

Optimisation of Routine Inspection Measures

Inspection Maintenance and Repair of Deepwater Pipelines

Code Requirements DNV OS-F101

Propose plans for:

Inspection Maintenance and Repair of Deepwater Pipelines

Inspection Maintenance and Repair of Deepwater Pipelines

Inspection Maintenance and Repair of Deepwater Pipelines

Example Process from RP-F116

Inspection Maintenance and Repair of Deepwater Pipelines

Example Process from RP-F116

Inspection Maintenance and Repair of Deepwater Pipelines

Years Const As-Built Survey Baseline Survey Phase 1 "Early Failure"

Phase 21) "Random Failure"

Phase 33) "Wear-Out Failure"

Inspection Maintenance and Repair of Deepwater Pipelines

Installation Damage Scenarios

Ships Material and Construction Defects

Coating Damage (Corrosion and Weight

Operational Damage Scenarios

Environmantal Wind, Waves and Currents Scour Seabed Morphodynamics

Inspection Maintenance and Repair of Deepwater Pipelines

Operational Damage Scenarios (effects)

Inspection Maintenance and Repair of Deepwater Pipelines

Inspection Maintenance and Repair of Deepwater Pipelines

Understanding the risks and potential need for repair

Inspection Maintenance and Repair of Deepwater Pipelines

MEIDP Example (3500m WD)

Inspection Maintenance and Repair of Deepwater Pipelines

North Murray Ridge Dalrymple Trough South Murray Ridge

Middle Indus Fan

Upper Indus Fan