INTERNAL CORROSION DIRECT ASSESSMENT

(ICDA)
Document Name: AGCL_AE_ICDA_PrA_Report_4inch_Gas_Line-6_01
Document No.: 01 Rev: 0

ICDA PRE-ASSESSMENT REPORT

4” AGCL TIPAM OFFTAKE POINT TO PANBARI NATURAL
GAS PIPELINE
LINE-6

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Revision Index

Rev Date Description Prepared By: Reviewed By: Approved By:

Dr. Carlos A. Palacios T
NACE Internal Corrosion
25-May- Ashish Khera, P.Eng.
0 For review Jayan Tundaliya Specialist#24333,
2022 NACE (ID#283890)
Bidyut B. Baniah, C.Eng., IEI
(ID#1618075)
Allied Engineers

Rev No. Description Date

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Disclaimer Notice: This Report including any recommendations made by the Contractor relating to the pipeline has been
prepared by the Contractor to his best knowledge and belief. All recommendations are made in good faith and are a reliable
expert opinion of Contractor, according to common practice prevailing in the pipeline industry. The Report or measures
based on it will not constitute a warranty of the quality, capacity, safety or fitness for purpose of the pipeline.

Table of Contents
1. INTRODUCTION............................................................................................................
1.1 PIPELINE HISTORY........................................................................................................
2. DATA COLLECTION......................................................................................................11
2.1 PIPELINE CHARACTERISTICS........................................................................................12
2.2 LIQUID ANALYSIS - ICDA.............................................................................................14
2.3 GAS ANALYSIS - ICDA..................................................................................................15
2.4 SOLIDS ANALYSIS - ICDA.............................................................................................16
2.5 CHEMICAL TREATMENT – ICDA...................................................................................16
2.6 OPERATING HISTORY - ICDA.......................................................................................17
2.7 OTHER RELEVANT / IMPORTANT INFORMATION........................................................21
3. IDENTIFICATION OF WG-ICDA REGIONS......................................................................22
4. WET GAS – INTERNAL CORROSION DIRECT ASSESSMENT (WG-ICDA) FEASIBILITY
ASSESSMENT.........................................................................................................................24

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List of Tables

Table 1: List of Margherita Gas Grid............................................................................................7

Table 1: Pipeline Data for 4” Gas Pipeline..................................................................................12
Table 3: Gas Analysis of product conducted by HOEC dated 21.06.2021 as provided by AGCL
....................................................................................................................................................15
Table 4: Operating History.........................................................................................................17
Table 5: Hydrotesting pressure testing record conducted in January 2004..............................20
Table 6: Other Relevant Information.........................................................................................21
Table 7: Flow and Corrosion Modelling Scenarios based on Average Operating Flowrates.....25

List of Figures

Figure 1: General Schematic of Line#6 (4” Tipam Offtake Point to Panbari)...............................6

Figure 2: Site photograph of Upstream Point Facility..................................................................8
Figure 3: Site Photograph of Downstream Point Facility.............................................................9
Figure 4: 12” Tap-in to subject Pipeline.....................................................................................10
Figure 5: 8” Tap-in with drain-point to subject Pipeline............................................................10
Figure 6: ICDA Region Identification..........................................................................................22
Figure 7: ICDA Region-1 for Year 1995 to 2021..........................................................................23
Figure 8: ICDA Region-2 for Year 2021 to 2022..........................................................................23

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1. INTRODUCTION
Direct Assessment (DA) is a methodology that is used to evaluate the integrity of
pipelines due to the time dependent threats of external corrosion, internal corrosion,
and stress corrosion cracking.

Assam Gas Company Limited (AGCL) has engaged Allied Engineers (AE) to perform
Internal Corrosion Direct Assessment (ICDA), External Corrosion Direct Assessment
(ECDA) and Stress Corrosion Cracking Direct Assessment (SCCDA) for the two (2)
pipelines located in the State of Assam in line with the NACE International Standards
for DA.

This Pre-Assessment Report compiles the data collected for the purpose of conducting
ICDA. For the time-dependent threat of internal corrosion, the Wet Gas Internal
Corrosion Direct Assessment (NACE-WG-ICDA) methodology is applicable to pipelines
that are normally carrying wet gas.

WG-ICDA methodology is described in terms of a four-step Process: (1) Pre-

Assessment (PrA), (2) Indirect Inspection (IDi), (3) Detailed Examination (DEx), and (4)
Post Assessment (PoA). The WG-ICDA method provides the greatest benefit for
pipelines that cannot be in-line inspected; however, the method is not limited to un-
piggable pipelines. Several successful ICDA programs have been performed for
piggable lines too, with or without historic ILI data. NACE ICDA Standards also
encourage ICDA for piggable lines as per below:

“WG-ICDA methodology may also serve or assist those cases in which ILI may have
been performed or is contemplated to demonstrate the reliability of the WG-ICDA
process. It may also be used for optimizing the selection/justification or prioritization
of pipelines that are subjected to ILI.”

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The WG-ICDA methodology is performed to assess the pipelines’ integrity for the
threat of internal corrosion. Whereas External Corrosion Direct Assessment (ECDA)
methodology is used to assess the threat of external corrosion. Whilst Stress
Corrosion Cracking Direct Assessment (SCCDA) methodology is utilized to assess the
threat of Stress Corrosion Cracking.
The application of these three (3) methodologies simultaneously provides great
advantage to the Asset Owner.

This report contains the Pre-Assessment conducted for the 4” Gas pipeline (Line#6)
from Tipam Offtake to Panbari as illustrated in below schematic (Figure-1).

Figure 1: General Schematic of Line#6 (4” Tipam Offtake Point to Panbari)

.

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1.1 PIPELINE HISTORY

Below Table-1 tabulates the list of Margherita Gas Grid consumers that require regular
supply of natural gas for their tea factories. To meet the requirement, OIL India
Limited Provided supply through two (2) locations, one (1) at Digboi Tiniali and
another at Tipam T.E.
For the remaining requirement, AGCL Commissioned a 4” pipeline from Tipam T.E. to
Panbari with length of approx. 8.235 Km in the year 1995 (Shown in Figure-1).
Below Figure-2&3 illustrates the Upstream and Downstream facilities of 4” Subject
pipeline.
Before the commissioning of the subject AGCL pipeline, gas was being supplied by OIL
India Limited (OIL) via their 12” (Duliajan) Pipeline.
Post-commissioning of the 4” Subject pipeline, a tap-in was made at Tipam PRS 4” tap-
in through a 12” OIL line (as illustrated in Figure-4) to supply the product to
consumers.
However, due to increasing the no of customers in the year 2021 – an additional tap-in
was made through the draining facility to the subject 4” subject pipeline from the
another AGCL’s 8” Digboi Tininali to Kusijan Pipeline which is shown in below Figure-5.
As a result, the subject pipeline carries the gas from source of HOEC (Hindustan OIL
Exploration Company) since 2021. Post 2021, the 12” OIL tap-in line valve is closed and
not in use. It is to be noted that AGCL does not own or operate any kind of Separator,
Knock Out Drum (KOD) or Scrubber. Any and all kinds of primary natural gas
processing is conducted at HOEC end prior to supply of product to AGCL.

Table 1: List of Margherita Gas Grid

S. No List of Margherita Gas Grid

1 Tipam T.E.
2 Powai T.E.
3 Margherita T.E.
4 Namdang T.E.
5 Dirak T.E.
6 Khatangpani T.E.
7 Pengeri T.E.
8 Sengunbari T.E.

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Figure 2: Site photograph of Upstream (Tipam Offtake) Point Facility

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Figure 3: Site Photograph of Downstream (Panbari PRS) Point Facility

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Figure 4: 4” Tap-in to subject pipeline from OIL’s 12” Duliajan Pipeline

Figure 5: 4” Tap-in from 8” Line with drain-point to subject pipeline at Tipam Offtake
Point

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2. DATA COLLECTION
In compliance with NACE SP0110-2018 for Wet Gas Internal Corrosion Direct
Assessment (WG-ICDA) - execution of the Pre-Assessment step for ICDA includes
following activities:

 Collection, Integration, and analysis of pipeline data.

 Assessment of ICDA feasibility.
 Identify pipeline segments, pipeline regions.

To collect all essential data and obtain as much information as possible, AE

commenced a site visit with AGCL for data collection, data integration and data
analysis of the subject line. This was initiated on 1 st April 2022. Although, data
collection based on AE’s ICDA Pre-Assessment Protocol have continuously being
exchanged with AGCL via email. The Pre-Assessment data / observations / results for
the subject pipelines’ operations are described in this report to the best of AE’s
understanding.

The data to be used for the Indirect Inspection Step that includes flow and locations of
most probable internal corrosion simulations is presented in the sections that follow.

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2.1 PIPELINE CHARACTERISTICS

The pipeline data as per below Table-1 was collected during the site visit which will be
utilized during the Indirect Inspection step.

Table 2: Pipeline Data for 4” Gas Pipeline

S. No. Item Value
Pipeline Description
1 Pipe Grade API 5L Gr. B
2 WT (mm) 6.4 mm
3 Commissioning Year 10.08.1995
4 Pipeline Length Total: 8.253 km
5 Diameter, inch 4”
6 Weld Type SMAW
7 Material Composition of Pipe Carbon Steel
8 Geometries Not Applicable
9 Presence of Elbows None
2 nos. Tap-in’s &
10 Presence of Tees
4 nos. Tap-out’s
11 Presence of Expansions None
12 Presence of Reductions None
13 Microstructure Normalized as per Pipeline Grade
14 Insulation No
15 External Coating Coal Tar Enamel (CTE)
16 Internal Coating Present No
Pipeline Operations Data
17 Fluid Temperature (°C) - Min 20
18 Fluid Temperature (°C) - Max 35
Fluid Temperature (°C) – Operating To
19 27
be used for Flow Modelling
20 Fluid Pressure (kg/cm²) – Min 6
21 Fluid Pressure (kg/cm²) – Max 10
Fluid Pressure (kg/cm²) – Operating –
22 6-10
To be used for Flow Modelling
Site activity by AE as part of the IDi (2 nd
stage) of this program is ongoing.
23 Elevation Profile
Elevation will be included in 2nd stage report
i.e., IDI stage.
Description and location (chainage) of
24  
any accessories such as:
  a. Locations of Valves, Clamps, 2 tap-in’s at Tipam Offtake (Refer Figures 4
Supports, Taps, Mechanical Couplings, and 5) &
Expansion Joints, Cast iron 4 Tap-out’s (Refer Figure 6)
components, Tie-ins, and Isolating

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Joints
One (1) Drain Point before Tipam Offtake
  b. Sampling point
(Refer Figure-5)
  c. Pressure Gauge (kg/cm²) Yes
  d. Temperature Gauge (oC) Yes
Liquid (Condensate from Gas) Flow
25 Not Applicable
Rate (kL/hr) – Min
Liquid (Condensate from Gas Flow Not Applicable
26
Rate (kL/hr) – Max
Liquid (Condensate from Gas Flow Not Applicable
27 Rate (kL/hr) – Operating

28 Density of Gas @ 15 °C (gm/cm3) See Table 3

29 Kinematic Viscosity of Gas Not Applicable
Gas – Condensation from Water Vapor
30 Water Flow Rate (kL/hr)
Saturated
No. of Product Tank? Presence of Not Applicable
31
water in storage tank?
32 If 'Yes' for item 31; Volume? Not Applicable
If 'Yes' for both items 31 & 32, for
tank bottom water - Lead Acetate Not Applicable
33
Paper based Sulphide Test
conducted? Result?
34 Flow Rate of Gas – Min
35 Flow Rate of Gas – Max Average Inlet Flow – 15739.00 SCMD – This
36 Flow Rate of Gas – Operating Flow Rate to be used for Flow Modelling
Ambient Air Temperature (°C) –
37 Winter Temperature worse case used 10 winter to 39 summer
for Flow Modelling.
38 Gas Chromatography Yes – Table 3
39 Ambient Water Temperature (°C) Not Applicable
40 Ambient Soil Temperature (°C) 24 winter to 35 summer
41 Condensate API Not Applicable
42 Gas Oil Ratio (GOR) None as the product is Gas

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2.2 LIQUID ANALYSIS - ICDA

The presence of water can be driven by water vapor condensation or formation water
carried over from draining facility at upstream drain point situated at Tipam Offtake
before supplying to the subject pipeline.

AE with AGCL visited the drain point for the collection of water at the upstream end.
No water sample was obtained for the purpose of testing.

In-line with AE’s protocol for high specification Direct Assessment (DA), AE attempted
to collect a representative water sample to run water chemistry analyses as well as
microbiology tests at the drain point location – highlighted by the yellow-colored
circle as shown in above Figure-5.

In the absence of any representative water from the subject pipeline, if or when
required based on AE’s SME judgement during the Internal Corrosion Predictive
Modeling (ICPM) stage.

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2.3 GAS ANALYSIS - ICDA

As informed by AGCL, prior to 2021 gas was being supplied through the subject
pipeline from the source of OIL. Post 2021 gas is being supplied through the source of
HOEC (Hindustan OIL Exploration Company).

Table-3 below tabulates the gas analysis provided by HOEC to AGCL and OIL to AGCL
for the product flowing through the subject pipeline for the year 1995 to 2021 from
OIL Source and from 2021 onwards HOEC source to obtain a broad idea of the type of
product flowing through the subject pipeline.

Table 3: Gas Analysis of product conducted by HOEC dated 21.06.2021 as provided by

AGCL
Gas Component HOEC Source OIL Source
Carbon Dioxide (mol %) 0.171 0.07

Hydrogen Sulphide (mol %) Not reported Not reported

Oxygen (mol %) 0.0 0.0

Methane (C1) (mol %) 90.96 98.66

Ethane (C2) (mol %) 4.69 0.72

Propane (C3) (mol %) 2.07 0.28

i-Butane (mol %) 0.45 0.04

n-Butane (mol %) 0.65 0.06

i-Pentane (mol %) 0.24 0.02

n-Pentane (mol %) 0.19 0.01

Hexane + (n-C6) (mol %) 0.53 0.08

Up to Decane + (n-C10) (mol %) Not reported
Not reported
available?
Nitrogen (mol %) 0.05 0.06

Gas Density Kg/m3 0.7808 0.6934

Specific Gravity of Gas Not available 0.5657

Moisture Content (Lbs/MMSCFT) Not available Not available

1
This is the worse case for corrosion. This value will be used for the Corrosion Modelling.

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2.4 SOLIDS ANALYSIS - ICDA

As informed by AGCL, solids are not present in the gas pipeline. Post Detailed / Direct
Examination – AE IC SME will make a call if solids hold-up is required to be performed
as part of the Post Assessment (4th and final stage of the Program). This will however
be made on assumptions, which will clearly be stated as allowed by NACE
International.

2.5 CHEMICAL TREATMENT – ICDA

As informed by AGCL, there is no chemical treatment applied to the fluids within the
subject pipeline.

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2.6 OPERATING HISTORY - ICDA

The pipeline operating historic data was collected as per below Table-4 which will be
utilized during the Indirect Inspection step.

Table 4: Operating History

S. No. Item Value
Period of Activity (days / per month) -
1 Continuous
FLOW ON
Period of Inactivity (days / per month) -
2 None
FLOW OFF
Period of Abnormal Activity (spill over /
3 None
contamination)
4 Period of Change of Flow Direction None
5 Period of different services None
6 Period of Upsets None
7 Period of Tap-offs None
8 Any evidence of MIC No
Are bacteriological samples collected
9 No
and enumerated?
10 Has any biocide been utilized? No
11 Cleaning Pigging performed? No
12 If 'Yes' to item 11 - interval for pigging Not Applicable
13 If 'Yes' to item 11 - type of pig used Not Applicable
14 If 'Yes' to item 11 - muck received Not Applicable
15 If 'Yes' to item 14 - quantity of muck Not Applicable
16 If 'Yes' to item 14 - analysis of muck Not Applicable
If 'Yes' to item 16 - testing of sludge Not Applicable
17
deposits
18 If 'Yes' to item 16 - testing of hydrates Not Applicable
19 If 'Yes' to item 16 - testing of emulsions Not Applicable
20 Maintenance Shut Down Taken Yes, at the time of Hydrotesting
21 If 'Yes' to item 20 - interval & duration 24 hrs.
Past occurrence of flow induced
22 vibrations and or fluid hammer Not experienced
(pressure surges)
23 In-Line Inspection performed No
Any NDT (UT, RT, VT, MPI etc.)
24 None
inspection performed
If at any point of time of the operating
history the pipeline was cut open -
25 No
information / data / photographs on the
internal condition of the pipe available

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26 Specification of Product Available – Table 3

Before 2021 source: OIL India LTD.
27 Product supplied through After 2021: HOEC (Hindustan OIL Exploration
Company)
28 Historical Data pertaining to:  
a. Crude Oil Assay (API gravity, specific
  Not Appliable
gravity, TAN, Viscosity, Density etc.)
  b. SARA Analysis Not Appliable
  c. BS&W Analysis (% mass) Not Appliable
d. BS&W cloud and pour point in case of Not Appliable
 
paraffinic crude oils
  e. Sulfur Content (% mass) Not Appliable
  f. Acidic Sulfur Compounds Not Appliable
  g. Natural occurring fatty acids Not Appliable
  h. Wettability Not Appliable
  i. Emulsions Not Appliable
  j. Water oil dispersion Not Appliable
Will be included in the Indirect Inspection
  k. Elevation profile
report
l. Features with inclinations (road/ Will be included in the Indirect Inspection
 
river / valves etc.) report
  m. Location and nature of leaks / failure None
  n. Type of anomalies repaired Not Applicable
  o. Pipe section repair or replacement None
  p. Repaired using Not Applicable
q. Any NDE based analysis on repair
  None
location
Yes, Last was performed in the year 2004
with water.

As informed by AGCL, Hydrotesting had to be

performed due to Statutory requirement
  r. Hydrotest performed every eight (8) years. Prior to 2004, no
records are available.

No leaks were found during Hydrotest in

2004.

r. i. If 'Yes' to item 'r' - information

  Unknown
regarding water used for the purpose
r. ii. If 'Yes' to item 'r' - information
  Refer below Table-5
regarding hydrotest pressure
  r. iii. If 'Yes' to item 'r' - hydrotest report Refer below Table-5
  s. De-rating history None
  t. Presence of H2S detected in on-field No

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storage tanks (ppm)

u. Sludge present in product tank, m 3,
  Not Applicable
any tests performed on the sludge
v. Water present in product tank, m 3,
  Not Applicable
any bottom thief tests performed

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Table 5: Hydrotesting pressure testing record conducted in January 2004

TIME GAUGE PRESSURE (Kg/cm2) DEAD WT. TESTER. (Kg/cm2) TEMP. (0C)
9 AM 25 25.3 19
10 AM 25 25.3 20
11 AM 25 25.3 22
12 PM 25 25.3 24
1 PM 25.5 25.3 24
2 PM 25.5 25.3 24
3 PM 25.5 25.3 23
4 PM 25.5 25.3 21
5 PM 25.5 25.3 17
6 PM 25.5 25.3 15
7 PM 25.3 25.25 14
8 PM 25.3 25.25 14
9 PM 25.2 25.2 13.5
10 PM 25.1 25.15 13
11 PM 25 25.1 12
12 AM 25 25.05 12
1 AM 25 25 12
2 AM 25 25 12
3 AM 25 25 11
4 AM 25 25 11
5 AM 25 24.9 11
6 AM 25 24.9 11
7 AM 24.8 24.9 12
8 AM 24.9 24.9 16
9 AM 24.95 25.1 19

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2.7 OTHER RELEVANT / IMPORTANT INFORMATION

Table 6: Other Relevant Information

S. No. Item
AGCL has mentioned there are no history of water accumulation. However, AE will
assume one scenario with gas carrying water vapor saturated and a second scenario
 1
with gas carrying a quantity of 0.065 BBLS of free water/day with gas flowing for half of
the life of the pipeline for each scenario.
As informed by AGCL, due to the lack of the flow data AE IC SME will simulate the
2 pipeline based on the current year provided data i.e., year 2020-2021 by considering all
the tap-outs are working on the continuous basis since commissioning.

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3. IDENTIFICATION OF WG-ICDA REGIONS

As per the Clause no. 3.5. of NACE WG-ICDA standard (NACE SP0110-2018) and as
per SME judgement the selected WG-ICDA region are reflected in Figure 6 and further
Figure-7 below illustrate the respective scenario based on the data and the
operational parameters provided by AGCL.

Figure 6: ICDA Region Identification

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Figure 7: ICDA scenario-1 from Year 1995 to 2022

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4. WET GAS – INTERNAL CORROSION DIRECT ASSESSMENT (WG-

ICDA) FEASIBILITY ASSESSMENT
Based on the data provided and the analysis of it by the Subject Matter Experts (SME),
the feasibility to perform WG-ICDA is confirmed, and it is as follows:

Based on the flow rates provided by AGCL, AE has decided to model the pipeline with
the following one (1) Scenario based on the average operating flowrates. Table-7
below shows the scenario for the water vapor saturated gas.

FLOW and CORROSION MODELLING

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Table 7: Flow and Corrosion Modelling Scenarios based on Average Operating Flowrates

Free water
Inlet / Carbon Moisture
Period Consumed Oxygen (lbs/day) –
Regio Remaining Dioxide H2S Content
Scenario Flowrate (O2 ) AE IC SME
n Flow (CO2 )* (ppm) (Lbs/
(SCMD) (mol %) Assumptio
(SCMD) (mol %) mmcft)*
From To n

Water
Not Vapor
0.17
R-1 1995 2022 15169.42 569.58 0.00 Reporte Not Reported Saturated
d and 0.065
lbs/day
Water
Vapor
Not
Saturated
R-2 1995 2022 14750.63 418.79 0.17 0.00 Reporte Not Reported
and 0.065
d
lbs/day0.06
5 lbs/day
Scenario-
Water
1
Vapor
Not
Saturated
R-3 1995 2022 12340.53 2410.10 0.17 0.00 Reporte Not Reported
and 0.065
d
lbs/day0.06
5 lbs/day
Water
Vapor
Not
Saturated
R-4 1995 2022 0 12340.53 0.17 0.00 Reporte Not Reported
and 0.065
d
lbs/day0.06
5 lbs/day

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26