Corrosion Management Challenges of

Non-piggable Pipelines,
Sections & Dead Legs

Rajdeep Dutta
Lead Integrity Engineer & CP Specialist
Asset Integrity (Downstream), Technical Services
DOLPHIN ENERGY LIMITED
Abu Dhabi (U.A.E.)
 Why some pipelines are non-piggable?

Roughly 1/3 of the global pipelines are unpiggable

because of a variety of issues:
• Grade, type of welds, length, internal diameter (multi-
diameter), elevation profile, restrictions, bends,
ovalities, valves, unbarred tees
• Launchers and receivers mal function
• Pipeline cleanliness issues
• Aggressiveness of the product, flow rate, pressure,
temperature
• Inter connectors, branches, by-pass not in pig path
• Design error, dead legs

No. 2

Dolphin Presentation Template 01

20 September
2014
 Non-piggable Sections and Dead Legs

• Eventhough main pipeline is piggable, but most of the

inter connectors, branches, by-pass are not in pig path
• Design error may create dead legs
• Some sections are no longer in use, but connected
with live system
• These sections are may be used rarely and not in
operational priority, but these ‘weak’ links post major
threat to overall system integrity

No. 3

Dolphin Presentation Template 01

20 September
2014
 Non-piggable Sections and Dead Legs

No. 4

Dolphin Presentation Template 01

20 September
2014
 What are the risks?

• Many of these non-piggable pipelines do not have a

corrosion control strategy and the technical integrity
of most is unknown.
• This has been identified as providing a high integrity
risk to operating companies with respect to loss of
production, high cost of failure/degradation and high
failure safety risk.
• As part of the technical integrity drive and risk
management strategy, a need was identified to
develop the strategy to assure the integrity of non-
piggable pipelines.

No. 5

Dolphin Presentation Template 01

20 September
2014
 Integrity Assessment Methods

• Hydrostatic Pressure Testing

• External MFL Survey

• Long Range Ultrasonic Thickness (LRUT)

• Corrosion Direct Assessment

No. 6

Dolphin Presentation Template 01

20 September
2014
 Pressure Testing Method Limitations

• The pipeline must be taken out of service

• Only the critical flaws leading to failure at the time of
testing are identified; sub-critical flaws are not
identified
• A large volume of water must be used and then
disposed of in accordance with environmental
regulations
• Introduction of water into the pipelines creates a
corrosion risk; the pipeline must be dried before it can
be returned to service
• Pressure testing is destructive

No. 7

Dolphin Presentation Template 01

20 September
2014
 External MFL Method

No. 8

Dolphin Presentation Template 01

20 September
2014
 External MFL Method Limitations

• This method can not be applied economically for

buried pipeline
• Only aboveground pipelines and sections can be
inspected
• It is time consuming and labor intensive
• Following sections of even above ground pipelines
can not be inspected:
 Pipe supports
 Any underground road crossing
 Section below a sleeve / clamp

No. 9

Dolphin Presentation Template 01

20 September
2014
 LRUT Inspection Technology

• Long Rage Ultrasonic Thickness (LRUT) inspection is

primarily a Non Destructive Test (NDT) where low
frequency ultrasonic waves are used to detect defects
and imperfections some distance away from the
ultrasonic source in a range of components.
• A typical application of LRUT is the detection of
corrosion and metal loss in pipes and pipelines. A set of
piezoelectric transducers sends the ultrasonic waves in
both directions along the length of the pipe. The same
transducers detect the return signal and identify how far
along the pipe the imperfections lay

No. 10

Dolphin Presentation Template 01

20 September
2014
 LRUT Inspection Technology

No. 11

Dolphin Presentation Template 01

20 September
2014
 LRUT Inspection Limitations

• Direct access and surface preparation are pre-requisites

of LRUT survey

• Typical longitudinal test range is +/- 30 m, ideally it can

go up to +/- 180 m

• Techno-economic for above ground pipelines, however

costly for buried pipeline, as it needs bell hole at every
60 m of the pipeline

No. 12

Dolphin Presentation Template 01

20 September
2014
 Applicability of Corrosion Direct Assessment

• Greater than 90% predictive capability for corrosion

hot spots for non-piggable pipelines

• Ability to establish root cause mechanism

• Ability to establish and utilize defect growth models to

establish safe operating conditions

• Ability to repair and mitigate defects before they lead

to failure

No. 13

Dolphin Presentation Template 01

20 September
2014
 Corrosion Direct Assessment Methodology

• ANSI/NACE SP0502-2008 (NACE International): “Pipeline External

Corrosion Direct Assessment Methodology”
• NACE SP0208-2008 (NACE International): “Internal Corrosion Direct
Assessment for Liquid Petroleum Pipelines”

No. 14

Dolphin Presentation Template 01

20 September
2014
Pre- Assessment
― Data collection
• Pipe related
• Construction related
• Soils/Environment
• Corrosion Protection
• Pipeline Operations
― CDA feasibility for pipeline
― CDA region identification
― Indirect inspection survey method selection
External Corrosion Inspections

Identify coating faults and areas where corrosion

activity may have or may be occurring

• ON/OFF Pipe to Soil Potential Survey (PSP)

• Close Interval Potential Survey (CIPS)
• DC Voltage Gradient Surveys (DCVG)
• HVAC Interference Surveys
• Soil Resistivity Survey
• Pipeline Location & Depth Survey (45° trolley)
CIPS & DCVG Surveys
Pipe to Soil Potential Graphs
Direct Examination Process

• Excavate and collect data where corrosion most likely

• Categorize indications
• Characterize coating and corrosion anomalies
• Establish corrosion severity for remaining strength
analysis
• Determine root-cause
• In-process evaluation, re-categorization, guidelines on
number of direct examinations
External Corrosion Direct Examinations

• Corrosion product data collection

• Corrosion product chemical tests

• Microbial tests (type & count)

• Identification of coating defects

• Mapping of corrosion defects

• Electronic mat / pencil impression

• Photographic documentation
Internal Corrosion Direct Examinations

• Ultrasonic Thickness Measurements

• Automated Ultrasonic Thickness Scanning

• Phased Array / Transverse Wave

• Magnetic Particle Examination

• Dye Penetrant Test

• Magnetic Tomography
Corrosion Direct Examinations
Dead Legs Corrosion Management

• Automated Ultrasonic
Thickness Scanning

• Corrosion Growth Tracking

• Pipeline BVS By-pass Line

Flushing

• Boroscope Inspection during

shutdown

• Additional reinforcement by
composite wrapping
POST ASSESSMENT & ANALYSIS

• CDA effectiveness

• Remaining Life Calculations

― ASME B31G
― RSTRENG
― DnV RP-F101

• Root cause determination

• Corrective action plan

• Reassessment interval
 Thank you !

Any question is welcome