April 2011

Pipeline Integrity

Ruptured However, pipelines risk

pipeline failing from time to time.
The consequences of a
catastrophic failure certainly
cost the operator additional
money through:

 Reparation
 Possible loss of product
 Environmental impact
 Public safety….

34’’ Crude oil pipeline was

burning (July 4, 2002)
Pipeline Failure Causes
The potential threats to pipeline
integrity can be classified into five or
six categories:

 General corrosion
(internal, external, pitting,…)
 Contact damage caused by third
party activities
(excavator tooth, anchor,...)
 Geotechnical failures
(landslides, floods, etc.)
 Stress Corrosion Cracking (SCC)
 Others
(material & equipment failure,
operator error, etc.)
3

Environmental impact

Flood of toxic mud 4

Uncontrolled Degradation
Piper Alpha

Uncontrolled Degradation

Pipeline burst
Uncontrolled Degradation

Corroded Pipe
Corroded Pipe

Corroded Pipe

The
concrete
coating

Weld Line

6 oclock
 Corroded Pipe

Pit Depth = Pit Depth =

1.0118 in Pit Depth = 0.0791 in
0.085 in
Flow Direction

Pit Depth =
Pit Depth = 0.0972 in
0.109 in

Pit Depth =
0.0811 in

Corroded Pipe

Microstructure of area near pitting hole position 1

at 6 o’clock. A Pipeline sub sea section.
Pipa diatas lumpur Sidoardjo
19 Maret 2007

20 Maret 2007

21 Maret 2007 15

14 Juni 2006 29 Juli 2006

 Citra
IKONOS
5 Jan 2008

Mud Volcano Profile

(Richard Davies, Durham Univ.)
Pipeline Integrity Management

The goal of a pipeline integrity management program is to prevent

integrity problems from producing a significant impact on public
safety, the environment, or business operations.

Ensure risks are

controlled
within acceptable limits

Pipeline integrity management consists of four-phase program:

● Pipeline assessment
● Inspection management
● Defect and repair assessment
● Rehabilitation and maintenance

19

Pipeline Integrity Management

• Aim :
Ensure risks are controlled
within acceptable limits Risk

RISK = PoF x CoF

Probability Consequence
Acceptable Limit :
– depends on legislation and corporate policy
– considers health, safety, environment, attitude of society and economic
realities
– Business interuption
Pipeline Integrity Management

Corrosion Natural Hazards

Internal Storm
External Impact on Population/Safety
Scour
Marine Growth
Operational Subsidence
System Impact on Environment
Human
Mechanical Failure
3rd Party Activity Construction Impact on Business
Accidental Material
Incidental Design
Malicious Structural

Pipeline Integrity Management Risk for Pipeline

Risk Ranking

Quantitative risk ranking

ANNUAL PROBABILITY OF
CAT
FAILURE
5 > 10-2 failure expected
-3 -2
4 10 - 10 high
-4 -3
3 10 to 10 medium
-5 -4
2 10 to 10 low
-5
1 < 10 virtually nil
Consequence Category A B C D E
Consequence of Failure

Contoh : Pipeline
 Risk Result

Control of Risk

• Risks can be controlled (managed) through:

– Inspection Identification of deterioration
– Monitoring & testing and reduction of uncertainty

– Planned repair works

– Prevention / preservation works Mitigation of failure mode
– Emergency preparedness and possible consequences

– Downgraded operations
– Appropriate design
Consideration of failure
- modes, possible
consequences, ease to test /
monitor and inspect
Control of Risk – Inspection RBI

• Time dependent failure modes

Limitations :
• ability of inspection method to identify degradation
• ability of inspection method to identify degradation rate prediction
• cannot prevent fast acting or time independent failures

Control requires:
- identification of the
degradation
- sufficient time to
implement remedial
action
- remedial action!

Control of Risk – Inspection

• Reduction of Uncertainty
- Control requires projection of future integrity
- Risk increases with time due to increasing uncertainty whether
degradation or instantaneous failure mode
- Inspection re-calibrates uncertainty levels

Limitations :
• ability of inspection method
to identify failure mode
• cannot prevent catastrophic
time independent failures (eg
rupture due to backhoe / ship
impact etc)
 RBI CONCEPT

Acceptance Criteria Client goals

Data evaluation and Information gathering

Updating & screening

Inspection Detailed Assessment

planning
PoF calculation
& execution
CoF assessment
Risk Evaluation
Inspection programs

Control of Risk - Monitoring &

Testing
Monitoring
– Produced fluids (pressure, temperature, flow-rate, composition)
• strength, corrosion, erosion, deposits in pipe bore
– Corrosion systems
• probes for fluid corosivity, impressed current load for external
corrosion)
– Human Geography
• location class, consequence of failure

Testing
Limitations
– Valve testing • does not capture all failure modes
• indirect measures of failure modes
– CP system operation
• mostly testing is not predictive
– Hydrostatic strength
Control of Risk - Planned Repairs

Planned Repairs

– Strength : cut-out and replacements, sleeves, wraps

– Coatings : paints, specialist coatings
– External loads : civil and mechanical works

Advantages
• usually cost effective for control of degradation modes

Limitations
• only mitigates slow acting inspect-able degradation
• reactive
• usually less cost effective than prevention

Control of Risk – Preservation/

Prevention
Preservation / Prevention

 Fluid conditioning Advantages

 Corrosion inhibition, chemical passivation, • can protect against some un-
external thermal blanketing inspectable failure modes
 Painting program • usually very cost effective
 Overstress protection
 Impact protection , dropped object protection
 Consequence limitation Limitations
 ROW patrolling • cannot mitigate all risks
• indirect - added value is less obvious
than for repair
• interfere with inspection based
degradation rates
Control of Risk –
Emergency Preparedness

Emergency procedures

Emergency repair systems

– availability of standard repair procedures, spare pipe, repair
clamps, qualified welding procedures, repair means.
Advantages
• can mitigate against some failure modes
that cannot be otherwise economically
or physically controlled

Limitations
• reactive not preventive
• only limits consequence of failure
• added value often underestimated

Control of Risk –
Downgraded Operations

Production restrictions

– Pressure de-rating (MAOP)

– Flow rate control for erosion, slug loads, debris
– Temperature control for thermal loading
– Cycling control for fatigue
Limitations
• cannot mitigate all risks
Advantages
• can be the most cost effective solution • relies on system operability at
particularly for ageing systems degraded condition
• system will continue to degrade
towards revised level
Control of Risk - Design
Appropriate Design

–Considers the CAPEX / OPEX balance over design life

• maintenance continues to be required
–Considers inspectability and repairability

Advantages Limitations
• most cost effective solution for • cannot mitigate risks unknown at
controlling known risks design stage
• cannot take advantage of new
technologies

Pipeline Integrity Management

Design

Feedback
Pipeline
Risk Data

Other
Downgraded Emergency Planned Monitoring undetectable
Preservation Inspect & testing
Operation Preparedness Repair degradation
mechanisms

Analysis
Pipeline Inspection
Based Management

Design Inspection cycle

Feedback
Pipeline
Risk
Data

Other
Downgraded Emergency Planned Monitoring undetectable
Operation Preparedness
Preservation Inspect & testing degradation
Repair
mechanisms

Analysis

Thank You