Integrated pipeline solutions

by Jurgen Elbertse
HAk Industrial Services bv, Rhenen, Netherlands

Contents of this Paper:

Introduction

Key steps for an integrated pipeline solution system

Pipeline assessment

Data collection management

Defect assessment and remediation

Maintenance management

Advantages of an integrated pipeline solutions system for pipeline operators

The integrated pipeline solutions service package

Acknowledgement

Copyright 2001 Scientific Surveys Ltd. All rights reserved.

Pipeline Pigging and Integrity Monitoring Conference: Stavanger, 1999

Introduction
Recent technological advances have provided the operators of plants, terminals and offshore facilities several
different options to complete "In-line" inspection of pipelines and associated piping that makes up a vital
component of their overall operation. "In-line" inspection is a critical component of an overall system integrity
program.
Up until recently there werent any in-line inspection technologies that could be effectively utilized in plant,
terminal and offshore piping applications, due mainly to bend geometry and lack of appurtenances that would
economically allow the introduction and withdrawal of inspection vehicles.
As well, new regulatory pressures and environmental concerns are making the option of in-line inspection more
attractive as a vehicle to lower or control a corporations exposure level.
Apart from the problems associated with the selection of an inspection system or technology, many pipeline
operators are also faced with the fact that within their organization in-depth knowledge of (their own) pipelines
and knowledge about cleaning, inspection and rehabilitation is diminishing due to downsizing of maintenance and
inspection divisions. In many instances this does create problems in implementing a proper long term, costeffective, safe and easy to operate pipeline integrity management system.
This paper describes the philosophy behind the Integrated Pipeline Solutions concept, which is initiated by four
companies who have worked for decades in various disciplines in the pipeline (and plant/process) industry, and is
meant to solve the above mentioned problems for pipeline, plant and terminal operators.

Key steps for an integrated pipeline solution system

As the title already suggests, the philosophy is to provide the client with a total turn-key integrated solution
package which will help him to manage his pipeline systems, but without having to deal with multiple contractors.
This total solution concept is based on the following main items:

Pipeline Assessment

Data Collection Management

Defect Assessment and Remediation

Maintenance Management

Pipeline assessment
The first step in pipeline assessment is to identify the type of operation the client is running, and to determine
what his objectives are for both the short term and the long term. There are for example major differences in
operation between a main transport pipeline owner, and a tank terminal operator, despite the fact that their
inspection requirements could be similar.
The main questions are therefore Where are you today, and where do you want to be at the end of the program
Before one can tell where he wants to be at the end of the program, first all information has to be gathered on the
existing pipeline system. This involves checking companies records on system design, pipeline specifications and
operating procedures.

Copyright 2001 Scientific Surveys Ltd. All rights reserved.

Integrated pipeline solutions

Furthermore one has to verify Code Compliances such as local rules and regulations, imposed by Governmental
bodies. Specifically public safety and health/environmental play a major role in setting the bases for such rules
and regulations.
Last but not least, Risk Assessment is an important factor in pipeline assessment. In order to keep your companies
exposure at an acceptable level, one has to calculate the Probability versus the Consequences. In direct relation to
this the Risk Mitigation has to be determined as well and thus stop those elements that cause undesirable
consequences and exposure.

Data collection management

The bases of any system obviously is the gathering of data. This does not only involve inspection data, but also
the data as mentioned before. Such huge quantities of data can be difficult to maintain and assess and it is
therefore vital that a proper tool is installed. Such a tool can be an advanced GIS system allowing you to manage
your collected data.
For gathering the data itself a wide range of technologies is available . The most important ones are:

Inline-inspection systems

Cathodic Protection Systems

Caliper and bend Geometry Survey systems

External ultrasonic inspection systems

Leak detection Systems

Line locating and depth of cover survey systems

Coating inspection systems

GIS/GPS systems

The question to be asked when selecting a technology, or a range of technologies is: "What information do you
require, and how can it be most effectively obtained?".

Defect assessment and remediation

Once all the data is collected it has to be analyzed . As the analysis, or assessment is vital for the continuation of
the operation of pipeline systems, a number of programs have been developed by Governmental bodies and the
industry itself.

Copyright 2001 Scientific Surveys Ltd. All rights reserved.

Pipeline Pigging and Integrity Monitoring Conference: Stavanger, 1999

Examples are, RSTRENG, SHELL92, and the standard MAOP according to ASME B31 G.
Based on these programs, it becomes clear (to a large extend) what remedial action has to be taken.
Such remedial actions may consist of:

Replace pipe sections

Rewrap external coating

Local repair by composite systems

Operational/procedurial changes

Any of these actions will again have to be properly documented.

Maintenance management
If the foregoing points have been executed, it is important that all information is gathered and stored and used to
implement a maintenance management program. To be more specific, a "preventive maintenance program"
With such a preventive maintenance program, the pipeline owner/operator will be able to manage his maintenance
for the full economic life in a much more cost-effective way then before due to the fact that all historical data has
been taken into account.
Under normal circumstances a preventive maintenance program comprises of the following elements:

Cathodic Protection Materials and Installation

Pipeline Protective Coatings

General Materials Selection

As support for such a program, again the various inspection techniques become important, and those will be have
to be defined under a Risk Based Inspection Program.
Such a risk based inspection program in general will try to achieve to reduce the number of inspections, using
historical date as discussed previously.
Also here applies, under normal circumstances such a program can already start with simple "over the line
surveys", supported by " intelligent pigging programs".
And with this new data one can adjust the maintenance programs when the outcome of the analysis of such data
would recommend this.

Copyright 2001 Scientific Surveys Ltd. All rights reserved.

Integrated pipeline solutions

Advantages of an integrated pipeline solutions system for

pipeline operators
As such is the information as stipulated on the previous chapters not new. The necessity of such programs is often
expressed by pipeline owners, but due to the downsizing of pipeline operating companies and the high level of
expertise and the diverse package of services required for implementing such systems , has limited the actual
operational implementation of such systems to only a small number of companies, or has led to implementation of
limited versions.
In order to overcome this hurdle, an alliance was formed which can implement these systems in various scenarios.
The first scenario is that the complete management of the pipelines is taken over by the alliance. This has grave
consequences in terms of liabilities , in is very much depending on local Rules and Regulations. However, it has
the major advantage that the pipeline owner literally hands over its pipelines to the alliance and pays a fee for
keeping the pipelines in the shape as is agreed upon in advance.
The selection of techniques is entirely the responsibility of the alliance, and will be sourced within the group of
companies who are part of the alliance.
He will therefore be able to stick to its core business and thus reduce its direct maintenance and operational costs.
Due to the fact that the alliance will not have to charge commission on the individual services, the total costs, if
compared to the same services, hired individually, or by one main contractor, will therefor be substantially lower.
Also the discussion of who is responsible for which activity is eliminated, as the alliance bares full responsibility
and liability.
The second, most common option is that in agreement with the pipeline operational and maintenance people a
total contract is put in place whereby the ultimate decision of which techniques are going to be used lies with the
pipeline operator, however the alliance will bring forward a number of options, including the various cost
calculations for both the short term and the long term.
Obviously the end responsibility for executing the work lies with the alliance, but the pipeline owner will retain
the end responsibility for the integrity of the pipelines.
It has been proven that with this concept savings up to 24 % have been achieved on
inspection/maintenance/rehabilitation and integrity management of pipelines.

The integrated pipeline solutions service package

It would be too much to discuss at length the various services which are normally required for the discussed
concept and weigh its advantages and disadvantages over other options.
The strength for the client is, that for almost every service an equal option within the alliance is available. This
competitiveness amongst the various companies will keep the prices sharp and the technique at a high level.
More important, due to sharing the knowledge of each company, it has become possible to jointly develop new
techniques for the industry at a much more cost effective basis then if each company would have to do this on its
owns, or buy technologies from other companies.

Copyright 2001 Scientific Surveys Ltd. All rights reserved.

Pipeline Pigging and Integrity Monitoring Conference: Stavanger, 1999

The service package now includes the following items:

INTELLIGENT PIGGING LEAK DETECTION

KALIPER SURVEYS DEFORMATION INSPECTIONS

C.P. SURVEYS LAUNCHER/RECEIVER BARRELS

TETHERED PIGGING INSPECTIONS DEPTH OF COVER SURVEYS

STRAIN CALCULATIONS COMMISSIONING

GEOGRAPHICAL INFORMATION SYSTEMS PIPELINE LOCATING DRYING PIG TRACKING

SERVICES

VARIABEL SPEED CONTROL PIGGING NITROGEN PURGING

CLOSE INTERVAL SURVEYS GLOBAL POSITIONING SYSTEMS

COATING SURVEY

RISK ASSESSMENT

HYDROSTATIC TESTING

CORROSION MONITORING

MECHANICAL DAMAGE PIGGING

PROJECT MANAGEMENT

PIPELINE MODIFICATIONS

CRACK DETECTION

PIPELINE CLEANING

PIPELINE REPAIRS

INERTIAL NAVIGATION SYSTEM

IN-SITU INTERNAL COATING APPLICATIONS

Acknowledgement
This paper is for a large part based on various presentations given by Thomas J. Walls, Manager Pipeline Services
Division of Corrpro Companies Inc. based in Houston Texas. However any errors, inconsistencies, and other
mistakes will have to blamed entirely to the author of this paper.

Copyright 2001 Scientific Surveys Ltd. All rights reserved.