Yaser Al-Qahtani

Pipeline Integrity Engineer

Saudi Aramco

© Copyright 2013, Saudi Aramco. All rights reserved.

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Objective

To share with you Saudi Aramco’s recent initiative to

establish Integrity Plans (IP) for each Pipeline

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Outline

Background

Challenges of Managing Pipelines Integrity

Integrity Management Approach

Integrity Plans: Stages

Integrity Plans: Areas for Improvement

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Background

SAFANIYA

JUBAIL
RAS TANURA
QATIF

DHAHRAN
MADINAH ABQAIQ

KHURAIS
YANBU’ RIYADH ‘UTHMANIYAH
HAWIYAH

RABIGH HARADH
HAWTAH
SHAYBAH

ABHA

JAZAN
4
 Background - Network at a Glance
Total Length = 20,074 km
<20” 22-46” >46”

Sizes 26% 48% 26%

Crude Gas Product & NGL

Service 37% 33% 30%

<20 Years 20-30 Year >30 Year

Age 40% 20% 40%

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Challenges of Managing Pipelines Integrity

Various interferences with community and environment

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Challenges of Managing Pipelines Integrity

Several integrity threats with different mechanisms

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Integrity Management Approach
Consensus Assessment

Isolated
ISU Risk
Corrosion Assessment
ISU CP
Simulation Corrosion
Isolated
Isolated Simulation Piping Assessment
Assessment

Piping Inspection

Inspection
Operation

Maintenance Operation

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Integrity Management Approach
Integrity Management Cycle

Establish Integrity

Design Material Construction

Feedback
Maintain Integrity
Condition Condition Integrity Risk
Monitoring Control Restoration Management

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Integrity Management Approach
Integrity Management Plans

Planning

Integrity Plan
Integrity Assessment

Mitigations

Feedback

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Integrity Management Plans
• Planning Stage
– Pipeline Selection based on: Planning
• Operational Criticality
• Integrity Condition
• Leaks History
Integrity Assessment
– Communication with SMEs
• Pipelines Specialists
– Int./Ext. Corrosion
• ISU Engineers Mitigations
• DMU
– Population Density Index
– Elevation Profile Feedback
• Area Operation Engineer
• CP/Inspection Foremen

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Integrity Management Plans
• Integrity Assessment
– HCA Assessment Planning
– OSI Records
– CP Potentials
Integrity Assessment
– ILI Findings
• Corrosion Alignment Sheets
Mitigations

Feedback

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Corrosion Alignment Sheets
• External Corrosion

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Corrosion Alignment Sheets
• Internal Corrosion

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Integrity Management Plans
• Mitigations
– Integrity Restoration Planning
• Repair Scope (NDE)
• Area Class Revision
• HCA Implications Integrity Assessment
– Integrity Control
• Corrosion Inhibition
Mitigations
• Biocide Treatment
• Cleaning Runs Frequency
– Integrity Monitoring Feedback
• ILI Runs

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Integrity Management Plans
Recommendations: Corrosion Related

• External Corrosion:
• Attending Low CP Potential
• Checking Joint Coating Type
• Internal Corrosion
• Reviewing Velocity Profile History (Potential
Bacterial Growth)
• Adjusting Cleaning Scraping Frequency
• Attending OSI Low Reading (FFP)
Integrity Management Plans
Recommendations: Repair Scope
Metal loss (%)

100
90 Immediate repair
80 Verification Digs
2013 Scope
70
HCA
60
50
40
30 KM1183
20 KM1187

10 KM1193
KM1186
1150 KM
1100

1110

1120

1130

1140

1160

1170

1180

1190

1200
Type of Repair Repair Category No of Joints Affected Metal loss ranges (%)

Immediate Repair (2012, issued already) A 10 (120.81 meters) 43-64%

Immediate Repair-Verification Digs (2012, issued already) A 8 (93.26 meters) 35-47%

Calendared Work (2013, to be issued) B 8 (97.37 meters) 26-34%

Repair Scope Prioritization:
 High Metal Loss
 High Consequence Areas
 CP
Integrity Management Plans
• Feedback:
– A report will be produced after one year Planning
to ensure compliance

Integrity Assessment

Mitigations

Feedback

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 PTSD Integrity Plan Workflow
DMU PSU IMU ISU A&TU
Plan the ILI Revalidation
Review Previous Integrity
Run
Plans, Rehab Projects, MRPs
and Issued Reports
Perform the ILI Run
Provide PDI
Issue the Immediate Repair Plans (classify into
30 and 90 days based on failure mode and ERF) To provide
and Conduct Run QA/QC Checks operating
philosophy

To gather and analyze

To provide condition related information
information (CP, Internal and external
on IC, EC, corrosion, inhibition, coating, Align ILI data(MFL, UT,
MOC To provide
etc. OSI, Simulation, etc.) EMAT, Geometry, etc.) pressure
and Previous Repair trends
Assess all gathered Information from LDS
and prepare Master IM Develop preliminary MRPs
document and IM Plan

PTSD SME’s Integrity Management Plan Review Workshop

(Validation, Rehabilitation schedules, etc.)

Upload MRPs into SAIF

Integrity Management Plans
• Area for Improvements
– Enhance Corrosion Assessment through the Implementation of
the Corrosion Management Framework
– Develop Dynamic Process for
• Performance Measurement: KPIs
• Implementing Robust Tracking System

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