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This paper was presented at the 10 Offshore Mediterranean Conference and Exhibition in Ravenna, Italy, March 23-25, 2011.
It was selected for presentation by OMC 2011 Programme Committee following review of information contained in the abstract
submitted by the author(s). The Paper as presented at OMC 2011 has not been reviewed by the Programme Committee.
ABSTRACT
Pipelines operators need to ensure that the safety level specified in the design phase is
maintained throughout the operating lifetime. The management of pipelines integrity is a
primary goal for pipeline operators, both from a technical and economical point of view.
This paper describes the pipeline integrity management approach adopted by Saipem
Energy Services (SES), an engineering consultant for offshore pipelines Companies.
The past experiences have proven that the cooperation between pipelines operators and
SES has given several benefits, like the continuous revision of inspection techniques and
frequencies in order to maintain or improve the results optimising the costs, the fast reaction
to inspection outcomes or to unexpected events through an accurate assessment of the
pipeline integrity, the capability to evaluate if maintenance or repair are necessary and
whether such remedial actions must be done immediately or can be postponed.
INTRODUCTION
Pipelines operators must manage their assets achieving the design safety level; at this
purpose an effective approach to Pipeline Integrity Management is an essential part of
successful operation.
Integrity is defined by DNV-RP-F116 as the submarine pipelines system ability to operate
safely and withstands the loads imposed during the pipeline lifecycle.
Pipeline Integrity Management (PIM) means ensuring that all the activities required to
maintain the pipeline integrity will be in place over the whole lifecycle, which includes design,
construction, commissioning, operation, maintenance and decommissioning. The Integrity
Management Process begins during the design phase and is carried out iteratively
throughout the design life until abandonment of the pipe.
An initial risk assessment has the purpose to identify the threats that may reduce pipeline
integrity (e.g. the presence of wet gas may lead to internal corrosion, whose consequence is
a metal loss damage) and to introduce different protective means at design stage.
At the end of construction and pre-commissioning, documentation shall be provided to define
the integrity status of the pipeline system, which has to be maintained during operation by
adequate inspection and maintenance activities.
When a pipeline system approaches the end of its design life and there is a need to operate
it for more years, an Integrity Management approach should be adopted to certify the lifetime
extension with reference to international codes and standards.
Risk Based
Inspection &
Monitoring
Planning
Inspection
Execution &
Database
Updating
Remedial
Actions &
Repair
Integrity
Assessment
Increasing Consequences
Consequences
Descriptive
Asset
(106 eur)
Pipeline Integrity
1. Extensive
> 10
2. Severe
1 - 10
3. Moderate
0.1 1
Damages (possible
propagation).
No gas release.
4. Minor
0.01 0.1
Local damages
No gas release.
Negligible
Remote
Unlikely
Likely
Frequent
MEDIUM
HIGH
Unacceptable Risk, reduction is required with additional mitigation measure or higher IM frequency.
10 years and it can include the first inspection after construction as well as the subsequent
ordinary inspections.
The development of an inspection and monitoring plan based on the risk assessment starts
with the identification of the inspections and monitoring typologies. For each threat the
applicable inspection and/or monitoring method is identified.
RBIMP considers the pipeline system between the battery limits including items as valves,
tees and other mechanical connections, pig traps, flanges, clamps anodes, coatings, etc.
The RBIMP activities cover external inspections (pipeline layouts, seabed configuration,
cathodic protection system, location and dimension of found areas of damage, etc.), internal
inspections (pipeline geometry condition, metal loss detection, route mapping and relevant
curvature/bending strain) and monitoring (inlet/outlet operating conditions, environment
conditions, valve position, etc.).
In addition to the typical inspection and monitoring activities, depending on the project
requirements, SES proposes and assists the pipeline operator in planning and establishment
of services as ship traffic monitoring based on AIS data (Automated Identification System).
Ship traffic monitoring is useful to identify and elude possible situations which could lead to
an emergency state. For instance, a prompt alert following the identification of anomalous
ship movements could avoid the interaction between dropped/dragged anchors and the
pipeline system or, in the worst case, reduce the response time after an accidental damage.
The final IM frequencies are the result of:
The system risk review result (i.e. risk level associated to the threat and the applicable
inspection and/or monitoring methods);
The integrity assessment after installation;
Pipeline operator specific general risk matrix;
Authority requirements.
Reviews could be considered and performed on the basis of:
The results from Inspection and Monitoring activities;
The results from any integrity assessment;
Possible interventions and repairs on the pipeline system;
Changes in operating conditions or any other changes affecting the threats;
Changes of risks levels;
Changes occurring in the authority requirements.
The update of the long term inspection plan and the risk assessment is performed at regular
intervals or when required due to inspection and monitoring activities results, threats
variations, integrity assessment results, changes in operating parameters.
As engineering consultant, SES gives assistance to pipeline operators in the preparation of
the documents relevant to RBIMP and the planned inspections (inspection plans, scope of
work for internal/external inspections, technical specification for internal/external inspections,
etc.). Other documentation under survey contractor responsibility (as procedures for internal
and external inspections) is carefully examined to verify the accordance with the pipeline
system requirements.
Modern standards, codes and recommended practices for Integrity Management of pipeline
systems are more and more recognizing the value of the risk based approach to the pipeline
inspection (the last approach demand coming from pipeline operator market).
The results obtained at the end of recent engineering projects prove that SES has fully
understood this market evolution and the engineering approach followed by SES has been
widely shared and appreciated.
5
The gathered data are both visual data (TV-cameras ROV mounted) and instrumental data
(dedicated equipment, ROV installed).
Internal Survey
affected by the feature. This operation might not involve extra cost and time if the required
survey equipment is already mounted on the ROV (usual condition) or if is present on board
(in case of required deep analysis on a damage).
Moreover, if any features (i.e. critical pipeline curvature, showed in Figure 4) needs to be
analysed in detail, SES personnel on board can contact the specialised office department for
accurate analyses. If required, additional investigations might be planned and executed with
little extra cost and short schedule delay.
INTEGRITY ASSESSMENT
The assessment of damage to the pipeline is an important task, since it allows operators to
determine whether the pipeline will be safe for the duration of its design life, or it will require a
reduction of operating conditions, or it must be repaired.
Inspection data acquired according to the Risk Based Inspection and Monitoring Plan shall
form the basis for any integrity assessment. When damage is observed, its dimensions shall
be quantified by a measurement system with adequate uncertainties.
If the damage is evaluated to be unacceptable, the information shall be included in an
updated risk assessment and the proper mitigation, intervention and repairs activities shall
be addressed.
Pipeline systems with unacceptable damage may be operated temporarily under actual
conditions or reduced operational conditions until the defect has been removed or repair has
been carried out. It must be documented that the pipeline safety level is maintained to
perform the inspection and repair activities.
The damage assessment should pay special attention to the risk of a sudden pipe failure. In
particular, the possibility of personal injury, for example during diver inspections, may require
the pressure to be reduced to a level which will not lead to pipe rupture. Following a repair,
system pressure test should be performed or waived according to design codes.
SES approach to integrity assessment is based on the identification of two categories of
investigation:
corrosion assessment covering internal and external corrosion;
mechanical assessment covering e.g. fatigue in freespan, displacement causing
overstress, third party damage causing extreme strains.
The assessment respect to internal and external corrosion requires the measurement of
residual pipe wall thickness along the line. The internal inspection using an intelligent pig with
adequate accuracy is highly recommended.
Once the defects depth and length have been measured, damage assessment can be
performed according to criteria and codes established in design phase. The most critical
defects will be identified and decision regarding pipeline safety can be provided; in case the
pipeline is judged not safe, a derating of the pipeline or a repair is required. A probabilistic
approach can be used to estimate pipeline failure probability, considering the measurement
uncertainties and assuming a proper corrosion rate for defect evolution.
Figure 5 shows the results of an internal inspection and an example to show how pipeline
failure probability increases over time.
Internal Inspection Data
1.E+00
70%
Metal Loss
60%
50%
40%
30%
20%
10%
1.E-01
Target for Safety Class High
1.E-02
1.E-03
1.E-04
1.E-05
1.E-06
0%
0
5000
10000
15000
20000
KP (m)
1.E-07
2010
2015
2020
2025
Year
2030
2035
Regarding mechanical assessment related to fatigue in free spans, SES reference for fatigue
life calculation is DNV-RP-F105. The inputs are free span length and depth and meteocean
data; if fatigue life is shorter than design life interventions are required. If data from previous
inspections are not available, assumptions have to be made on the year when the free span
has been generated and calculation on potential corrosion rate has to be performed.
External or internal inspection data can be elaborated by a smoothing process to obtain the
bending strain along the route and compare it with allowable value from reference codes.
The bending strains obtained by external survey data are affected by uncertainties due to the
inaccuracy of the pipeline profile and to the approximation introduced by the fitting tool used
to interpolate the survey data. For this reason, these strains have to be considered as
indicative values; more accurate results can be obtained by survey methodologies dedicated
for curvature measurements, e.g. by the internal geopig survey.
Field incidents may occur due to unexpected external loads applied to pipeline such as
fishing gear interaction, dropped objects, vessel interaction, collision of an iceberg, etc. This
may reduce the pipeline integrity and generate problems for the operation of the pipeline
over its design life. Potential pipeline damage include dent, gouge, dent and gouge, lateral
and upheaval buckling, etc Mechanical integrity assessment can be difficult because of the
many unknown parameters and pressing project schedule.
Damages must be correctly evaluated in order to make an appropriate decision for the future
service of the pipeline. A possible methodology includes the following phases:
Identification of failure modes and associated parameters;
Reconstruction of event;
Data collection;
Definition of analysis model: analytical or/and FEA;
Results evaluation and sensitivity studies;
Definition of a management plan for future service of the pipeline.
SES track record in integrity assessment includes pressure containment capacity evaluation
in presence of damage (dent, dent & gouge, etc), evaluation of pipeline status after anchor
dragging (see Figure 6) and buckling.
10
Operating
Conditions
- Flow rates
- Pressure
- Temperature
Pipeline Geometry
- Diameter,
- Steel wall
thickness
- Concrete
thickness
- Buckle Arrestors
- Valves location
P/L Configuration
- Curves
- Trenches and
other intervention
works
- Free spans
- Crossings
- Distance
between P/Ls
Hazards
- Ship Traffic
(anchor
interference and
drop objects)
- Fishing activities
- Environment
LOCAL FEATURES
- Pipeline configuration and
geometry combined with
requirements and constraints of
repair system
REPAIR TECHNOLOGIES
- Hyperbaric Welding (HW)
- Above Water Tie- in (AWT)
- Mechanical Connectors (MC)
- Repair Clamp (RC)
REPAIR STRATEGY
- Feasibility-Flexibility
- Schedule
- Technological Gap
CONCLUSIONS
Pipelines operators must manage their assets achieving the design safety level; at this
purpose an effective approach to Pipeline Integrity Management is an essential part of
successful operation.
Saipem Energy Services (SES) is an engineering consultant for offshore pipelines
companies able to provide Pipeline Integrity Management Services; SES approach follows
the four main steps addessed in DNV-RP-F116:
Step 1: Risk Based Inspection and Monitoring Planning;
Step 2: Inspection Execution and Database Updating;
Step 3: Integrity Assessment;
Step 4: Remedial Actions & Repair.
Each step can be addressed at design stage, and then the Integrity Management Process is
carried out iteratively throughout the pipeline design life.
The past experiences have proven that the cooperation between pipelines operators and
SES has given several benefits, like the continuous revision of inspection techniques and
frequencies, in order to maintain or improve the results optimising the costs, the fast reaction
to inspection outcomes or to unexpected events through an accurate assessment of the
pipeline integrity, the capability to evaluate if maintenance or repair are necessary and
whether such remedial actions must be done immediately or can be postponed.
REFERENCES
Det Norske Veritas, DNV-RP-F116, Integrity Management of Submarine Pipeline Systems,
2009.
Det Norske Veritas, DNV-OS-F101, Submarine Pipeline Systems, 2007.
Det Norske Veritas, DNV-RP-F101, Corroded Pipeline, 2004.
Det Norske Veritas, DNV-RP-F105, Free Spanning Pipelines, 2006.
ASME B31.8S, Managing System Integrity of Gas Pipelines, 2010.
ISO 17776, Petroleum and Natural Gas Industries - Offshore Production Installations Guidelines on Tools and Techniques for Identification and Assessment of Hazardous Events
2000.
Saipem Energy Services, Integrity Management Process for Nord Stream Pipelines
System, 2010.
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