Remaining Life Assessment of ERW Flaws: A Case Study

2012 ◽  
Author(s):  
Pablo Cazenave ◽  
Samarth Tandon ◽  
Katina Tinacos ◽  
Ming Gao ◽  
David C. Katz ◽  
...  
Keyword(s):  
Low Frequency ◽  
Management Program ◽  
Life Assessment ◽  
Seam Weld ◽  
Natural Gas Pipelines ◽  
Integrity Management ◽  
Remaining Life Assessment ◽  
Welded Pipe ◽  
Weld Area

Recent failures in seam weld pipe have raised concerns within the pipeline industry over the integrity of such welded pipe. Low-Frequency (LF) Electric Resistance Welded (ERW) pipe manufactured prior to 1970, in particular, can be susceptible to failures caused by hook cracks, lack of fusion and other planar defects should the weld area exhibit low toughness. Integrity management regulations and Pipeline operators are evaluating potential methodologies to address and mitigate the LF-ERW seam weld threat. A program has been initiated at Williams Northwest Pipeline GP (NWPGP) to address the integrity management of its pre-70s ERW pipelines. In this case study, as part of an overall integrity management program, a hydrostatic test and fatigue analysis based methodology for addressing the LF-ERW seam weld threat is presented. The methodology was applied to 15 pre-1970’s natural gas pipelines. The results and findings are summarized in terms of the integrity threat mitigation and maintenance strategies.

Case Study: Non-Conventional Remaining Life Assessment of a Significant Dent in a Subsea Pipeline Scheduled for Decommissioning

2019 ◽  
Author(s):  
A. Brett ◽  
A. Russell
Keyword(s):  
Life Assessment ◽  
Remaining Life ◽  
Element Analysis ◽  
Oil Pipeline ◽  
The North ◽  
Pressure Spike ◽  
The North Sea ◽  
Specific Assessment ◽  
Remaining Life Assessment

Abstract An inline inspection of a subsea oil pipeline located in the North Sea identified a large top of line dent. The pipeline was scheduled for decommissioning within 3 years, however conventional fatigue assessment of the dent indicated that the pipeline could become unsafe before the scheduled decommissioning date. As the required remaining life could not be justified by conventional assessment, a review was completed to determine whether a case-specific assessment methodology could be developed to reduce the conservatism, while reliably demonstrating that the pipeline could be safely operated up until the planned decommissioning date. This review identified that the pipeline had a unique pressure history, which included a large one-off pressure spike that had occurred following detection of the dent. This raised the possibility of a pseudo-hydrotest type assessment to justify the required remaining life. This paper describes the non-conventional pseudo-hydrotest assessment that was undertaken for the dent to demonstrate acceptability, which used a combination of state of the art finite element analysis and fatigue crack growth assessment.

Case Study of “TIEAMM” Approach to Geohazard Identification, Characterization, and Mitigation

2020 ◽  
Author(s):  
Joshua Nasrallah ◽  
Bailey Theriault ◽  
Andreas Kammereck
Keyword(s):  
Management Program ◽  
Team Approach ◽  
Subject Matter Experts ◽  
Construction Work ◽  
Differential Movement ◽  
Integrity Management ◽  
Mitigation Design ◽  
The Right ◽  
Ongoing Monitoring

Abstract This study presents the implementation of a multidisciplinary team approach to geohazard identification, characterization, assessment, and mitigation \, that includes landslide subject matter experts (SMEs) in geotechnical and hydrotechnical engineering and geology and pipeline stress analysis with the pipeline owner/operator (Owner). This approach provided targeted and programmatic geohazard training, identification, exploration, assessment, mitigation, and monitoring, and hase been coin as the “TIEAMM” approach. The Owner worked with the geohazard SMEs to develop a system-wide geohazard pipeline integrity management program, including a phased geohazard assessment along the right-of-way, office and field-based training for the local operations staff, risk-based design mitigation approaches, on-site construction support, and continued monitoring. The landslide discussed in this study is used as an example to demonstrate the TIEAMM approach; this site was identified by local operations staff, documenting differential movement of approximately 15 feet between November 2018 and February 2019. A more detailed geological exploration and assessment as well as a pipeline strain assessment was completed. The work allowed for mitigation efforts and corresponding costs to be optimized. The mitigation design was flexible to address ongoing monitoring, and then field-fit to address site conditions observed during the construction work. The approach to geohazard management completed for this site provided the data and information needed to make informed decisions to support targeted optimization for the scope and scale of mitigation work, and thereby avoided over-conservative (and thereby overly-costly) mitigation efforts.

My Pipes Are Corroding! When Should I Repair? Getting the Answers You Need for Maintaining Pipeline Integrity

2015 ◽  
Author(s):  
Michael Turnquist
Keyword(s):  
Finite Element ◽  
Life Assessment ◽  
Metal Loss ◽  
Element Analysis ◽  
Element Mesh ◽  
Level 3 ◽  
External Corrosion ◽  
Remaining Life Assessment ◽  
Ultrasonic Thickness

This case study exhibits how groundbreaking inspection methodologies combined with innovative computational analysis practices demonstrate the value of conducting fitness-for-service (FFS) assessments on sectional piping. In this instance, a fitness-for-service assessment was performed on two sections of piping experiencing external corrosion at the pipe-to-elbow seam welds. A full external scan and spot ultrasonic thickness (UT) readings were used to create the corroded geometry and verify accurate measurement of the remaining thicknesses in various corroded locations. This allowed for the actual corroded profiles to be accurately modeled using finite element analysis (FEA). Complications were present when modeling the observed metal loss. Through the use of innovative finite element mesh generation practices, the actual measured corroded geometry was modeled without the need for over-conservative geometric simplification. A Level 3 FFS assessment was then performed in addition to a remaining life assessment based on observed corrosion rates. The result of this analysis was that the piping could remain in service for at least two additional years before needing repair.

Total Pipeline Integrity Management System Implemented for KOC Pipelines: A Case Study

2010 ◽  
Author(s):  
M. Robb Isaac ◽  
Saleh Al-Sulaiman ◽  
Monty R. Martin ◽  
Sandeep Sharma
Keyword(s):  
Management System ◽  
Significant Loss ◽  
Management Program ◽  
Initial Assessment ◽  
Pipeline System ◽  
Transit System ◽  
Integrity Assessment ◽  
Wide Range ◽  
Integrity Management

In early 2005, Kuwait Oil Company (KOC) initiated a Total Pipeline Integrity Management System (TPIMS) implementation in order to carry out a major integrity assessment of its operating facilities, equipment, buried plant piping and pipeline network and to establish a continuing integrity management program. KOC Transit System is a complex infrastructure consisting of over three hundred pipelines, thousands of wellhead flow lines, and consumer and offshore lines for which there was a significant loss of data when the facilities were destroyed during a military invasion in 1990. An initial pipeline system assessment identified issues and actions regarding condition of the pipelines, corridors, requirements on in-line inspection (ILI), documentation, RISK assessment, status of international code compliance, and overall state of the system. Following recommendations from that initial assessment led to the development of a long term strategy; the execution of which required the implementation of a comprehensive integrity management program. This case study discusses the results obtained after five years of implementation of TPIMS at KOC. It will demonstrate some of the complex components involved in managing the integrity of the Transit System that have been made possible through the implementation of the system. The general concept and structure of TPIMS will be described, and how it deals with the complexity of the KOC pipeline system. The system made it possible to integrate and manage data from various sources, by conducting integrity assessment using ILI, Direct Assessment and hydrostatic testing, as well as structure a comprehensive RISK & Decision Support mechanism. This is one of the world’s first implementations of this magnitude which encompasses such a wide range of services and variables; all being managed in a single environment and utilized by a multitude of users in different areas at KOC. The biggest challenge in a project of this scope is data management. Examples will be shown of the integration structure to illustrate the benefits of using a single comprehensive and versatile platform to manage system requirements; ultimately providing system reliability and improving overall operational efficiency.

The Role of Effective Collaboration in the Advancement of EMAT Inline Inspection Technology for Pipeline Integrity Management: A Case Study

2012 ◽  
Author(s):  
Jeff Sutherland ◽  
Stephan Tappert ◽  
Richard Kania ◽  
Karlheinz Kashammer ◽  
Jim Marr ◽  
...  
Keyword(s):  
Predictive Performance ◽  
Management Program ◽  
Lessons Learned ◽  
The Past ◽  
Ongoing Work ◽  
Integrity Management ◽  
Effective Collaboration ◽  
Major Pipeline

Over the past three years there has been increasing industry interest and profile regarding the role and pipeline integrity management potential of EMAT crack inspection technology in the Oil & Gas pipeline industry. This paper outlines the stages and results of the effective collaboration of a major pipeline operator and a service company to advance the true predictive performance of the EMATScan Gen III crack inspection technology. The paper will also summarize and provide examples of lessons-learned from this collaboration across all stages of EMAT based SCC integrity management program. The paper will similarly outline ongoing work in progress regarding the assessment of the ILI data relative to hydro-testing equivalency, detection of injurious defects and the related analysis and reporting improvements made over the past three years.

Advanced Engineering Critical Assessments of Seam Weld Features in Pressure Cycled Hazardous Liquid Pipelines

2008 ◽  
Author(s):  
Kevin Spencer ◽  
Wilson Santamaria ◽  
Jane Dawson ◽  
Hong Lu
Keyword(s):  
Management Plan ◽  
Appropriate Technology ◽  
Maintenance Planning ◽  
Seam Weld ◽  
Planning Decisions ◽  
Pipeline Segment ◽  
Integrity Management ◽  
Assessment Techniques ◽  
Future Growth

The performance of older ERW pipelines has raised concerns regarding their ability to reliably transport product to market. Low toughness or “dirty” steels combined with time dependent threats such as surface breaking defects, selective corrosion and hook cracks are especially of concern in hazardous liquid pipelines that are inevitably subject to cyclic loading, increasing both the probability and rate of crack growth. The existing methods of evaluating seam weld flaws by hydrostatically testing the pipeline or In-Line Inspection (ILI) with an appropriate technology are well established. Hydrostatic testing, whilst providing a quantified level of safety is often impracticable due to associated costs, logistics and the possibility of multiple failures during the test. ILI technologies have become more sophisticated and as a result can accurately detect and size both critical and sub-critical flaws within the pipeline. However, the vast amounts of data generated can often be daunting for a pipeline operator especially when tool tolerances and future growth are required to be accounted for. For either method, extensive knowledge of the benefits and disadvantages are required to assess which is the more appropriate for a particular pipeline segment. This paper will describe advances in the interpretation of seam weld flaws detected by ILI and how they can be applied to an Integrity Management Plan. Signal processing improvements, validated by in-field verifications have enabled detailed profiles of surface breaking defects at seam welds for ERW pipelines to be determined. Using these profiles along with established fracture and fatigue analysis methods allows for reductions in the unnecessary conservatism previously associated with the assessment of seam weld flaws detected by ILI. Combining these results with other available data, e.g. dig verifications, previous hydrostatic testing records, enables more realistic and better-informed integrity and maintenance planning decisions to be made. A real case study conducted in association with a pipeline operator is detailed in the paper and quantifies the benefits that can be realised by using these advanced assessment techniques, to safely and economically manage their assets going forward.

Ultrasonic NDE Technology Comparison for Measurement of Long Seam Weld Anomalies in Low Frequency Electric Resistance Welded Pipe

2018 ◽  
Author(s):  
Luis Torres ◽  
Matthew Fowler ◽  
Jason Bergman
Keyword(s):  
Ultrasonic Testing ◽  
Low Frequency ◽  
Management Approach ◽  
Electric Resistance ◽  
Seam Weld ◽  
Tool Performance ◽  
Ultrasonic Nde ◽  
Welded Pipe ◽  
Continuous Technology ◽  
Non Destructive

In the pipeline industry, a widely accepted methodology for integrity crack management involves running ultrasonic In-Line Inspection (ILI) technologies. After an ILI tool run is completed, the performance of the tool is typically validated by excavating the pipeline and conducting in-the-ditch investigations. Ultrasonic Non-Destructive Evaluation (NDE) techniques are used in the field to characterize and measure crack-like features. These in-the-ditch measurements are compared back to ILI results in order to validate tool performance and drive continuous technology improvements. Since validation of the ILI tool relies on NDE measurements, acquiring accurate and representative data in the field is a critical step in this integrity crack management approach. Achieving an accurate field inspection comes with its challenges, some of which relate to complex long seam weld conditions present in older vintage pipelines including: weld misalignment, weld trim issues, and dense populations of manufacturing anomalies. In order to better understand the challenges associated with complex long seam weld conditions, an evaluation and comparison of the performance of NDE technologies currently available was conducted. In this study, a portion of a Canadian pipeline with complex long seam weld conditions was cut-out and removed from service. Multiple NDE crack inspection technologies and methods from three different vendors were used to assess the condition of the long seam weld. Conventional Ultrasonic Testing (UT), Phased Array Ultrasonic Testing (PAUT), Time of Flight Diffraction (TOFD), and variations of Full Matrix Capture Ultrasonic Testing (FMCUT) were used to assess the long seam weld and their results were compared. The performance of all NDE technologies is baselined by comparing them with destructive examination of sections of the long seam weld. The newer NDE assessment methodologies were shown to be consistently more accurate in characterizing long seam features.

Use of Geometric In-Line Inspection (ILI) Intelligence Tools With the Inertial Module for Diagnosis and Management of Structural Integrity in Pipelines With Geohazards: Case Study

2015 ◽  
Author(s):  
Jon Freddy Hernández Sánchez ◽  
Carlos Antonio Vergara ◽  
Carlos Hidalgo
Keyword(s):  
Structural Integrity ◽  
Geographical Area ◽  
Management Program ◽  
Ground Movement ◽  
The Andes ◽  
Geological Diversity ◽  
Integrity Management ◽  
Unstable Slope ◽  
Intelligent Tools

Colombia is a country located in a geographical area with great geological diversity, where every day the effects of climate change increases the probability of the failure of buried pipelines due to the movement of land or the instability associated with them. That is why the use of geometric In Line Inspection (ILI) intelligent tools with the inertial module is important for the diagnosis of structural integrity of pipelines and is associated with an integrity management program due to the geotechnical threats present throughout its path. It decreases maintenance costs due to pump stoppage for unscheduled repairs, anticipating the solution, and mitigating and controlling deformations in the pipeline caused by geotechnical ground displacements. OCENSA-Pipeline Central SA (Colombia) has developed, through its experience, a program to manage integrity by determining the structural expense in specific sections due to displacement of the pipeline caused by ground movement through the use of the Geometric ILI tools and MFL inertial module. This paper specifically presents the use of the tool in decision-making based on OCENSA’s preset study limits for deformations in the elastic range and plastic building material of the pipeline. In 1997 OCENSA was among the first companies in Latin America to use Inertial Geo-positioning technology; today there are sectors which have been inspected with this technology as many as five times, in which pipe displacement of up to 5 meters has been found. The case study presented refers to a geographical point on the route of the pipeline located in the Andes, at the site of the movement known as the “La negra” ravine, near the town of Puente Nacional, where movements of the pipeline associated with geotechnically unstable slope conditions were detected by In line inspection (ILI) Geometric and inertial modules, beginning in 2004. Since that time, integrity management was conducted in order to reduce the chances pipeline failure will materialize in this area of geotechnical instability.

Integration of Multiple ILI Technologies for Robust Understanding of Unique Anomalies on a Pipeline

2020 ◽  
Author(s):  
Taylor Shie ◽  
Andrew Lutz ◽  
Paul Taverna
Keyword(s):  
Magnetic Flux ◽  
Crack Detection ◽  
Low Frequency ◽  
Management Program ◽  
Probability Of Detection ◽  
Magnetic Flux Leakage ◽  
Electric Resistance ◽  
Seamless Pipe ◽  
Integrity Management ◽  
Flux Leakage

Abstract Pipeline operators have many choices when selecting inline inspection (ILI) vendors and technologies. No single technology has a one hundred percent probability of detection, identification, and sizing for all anomaly types. Operators must match the threats on their system to the existing capabilities of the ILI technologies to achieve the goals defined by the company’s integrity management program. It is sometimes necessary to run multiple technologies to effectively assess all threats in a pipeline. Multiple technologies may be run during the same timeframe or they may be run at different times during the life of the pipeline to meet program goals. Shell Pipeline Company, LP (SPLC) has a pipeline that is comprised of low frequency electric resistance welded (LFERW) pipe from Youngstown Sheet and Tube, seamless pipe from National Tube, double submerged arc welded (DSAW) pipe from Kaiser, and high frequency electric resistance welded (HF-ERW) pipe. The LF-ERW pipe was installed in 1948 while the HF-ERW was installed during relatively recent replacement projects. The DSAW pipe was installed in 1952 with the seamless pipe being installed in both 1948 and 1952. From 2015 through 2018, SPLC executed an extensive integrity management program. This included: an axial magnetic flux leakage (AMFL) inspection, two circumferential magnetic flux leakage (CMFL) inspections, two deformation inspections, an electro-magnetic acoustic transducer (EMAT) inspection, an ultrasonic crack detection (UTCD) inspection, an ultrasonic wall measurement (UTWM) inspection, and a hydrotest. A dig campaign of nearly 100 excavations was completed as a result of these surveys. One of the focuses of the paper will be the comparison of EMAT to UTCD for Likely Cracks, Possible Cracks and Unlikely Cracks that have been field verified. This paper also shares some of the unique anomalies found through the dig campaign identifying the effectiveness of each technology and their combination for integrity purposes. The paper shows the benefits of combining ILI technologies to properly characterize, assess and mitigate reported anomalies and ensure there are no blind spots in the integrity management program. Case studies including dent with gouge (e.g. AMFL + Deformation), manufacturing, and cracking anomalies as well as the analytics of ILI versus field findings are presented and discussed in the paper. The paper concludes with the knowledge creation resulting from multiple ILI technology integration assisted with subject matter expert experience and analytics to provide a robust understanding of unique anomalies in pipelines.

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