BP Pipeline Management

Risk assessment, operation experience

and lessons learned

Per Olav Gartland, John Berget and Bente Herfjord

FORCE Technology Norway AS
and
Inge J. Mland and Alf Inge Lyse
BP Norway

PTIL seminar on pipeline integrity 9. December 2009

 Pipeline Integrity Management

to ensure the technical integrity of the pipeline, i.e.:

to operate w ithin acceptable safety margins and
optimised economy throughout the lifetime

avoid failures and incidents

re-qualification and life extension of old pipelines
optimize life cycle cost (LCC)

PTIL seminar on pipeline integrity 9. December 2009

BP Norway PIM Strategy

Risk Assessment
Evaluate internal/external condition
Identify critical parameters and accept criteria (KPI s)
Monitoring
Corrosion monitoring
Critical process parameters (KPI`)
Free span, burial, CP etc.
Status Reporting (quarterly)
Inspection
Internal and external inspection plans
Detail inspection planning (scope, inspection method/practical arrangements etc.)
Inspection (ILI, ROV)
Evaluate inspection results/finding & take actions
Maintenance activities
Cleaning (pig)
General maintenance of valves and pig receivers and launcher.

INSPECTION & CORROSION MANAGEMENT

Update plan

Control
Risk Monitoring Implement Execute Monitoring Evaluate
PTIL seminar on pipeline integrity 9. December Actions Follow up
Assessment Inspection plan workscope Inspection Findings2009
BPs Engineering Technical Practice ETPs

PR 43 Pipeline ETP Rationale and Philosophy

GP 43- 17 Pipeline Risk Management
GIS 43-213 Pipeline Spanning (DNV RP F105)
GP 43-23 Offshore Facilities for Pipelines
GP 43-24 GIS and Mapping
GP 43-26 Offshore Surveys
GP 43-36 Pipeline Protection
GP 43-37 Control Systems for Pipelines
GP 43-39 Measurement and Sampling on Pipelines
GP 43-48 Pipeline Operations Organisation Setup
GP 43- 49 Pipeline Integrity Management Systems (PIMS)
GP 43-50 Pigging, Pig Launchers, and Receivers
GP 43-51 Maintenance and Reliability
GP 43- 52 Inspection and Integrity Assessment of Pipelines
GP 43-53 Pipeline Intervention and Repair

PTIL seminar on pipeline integrity 9. December 2009

Risk Assesment
Failure Mechanisms during Operation

INTERNAL Load effects EXTERNAL Load effects

Corrosion caused by Corrosion

CO2 / HAc CP system malfunction
H2S Coating quality
Bacteria (deposit) Bacteria
HISC
Erosion caused by Ground movements
particle (sand) Earth quake
Soil movements
3rd party damage
Impact (anchoring etc.)
Sabotage
Mechanical defects
Fatigue
Vibration
RISK = Probability (PoF) x Consequence (CoF)
PTIL seminar on pipeline integrity 9. December 2009
Internal Risk Assessment

Quantitative assessment based on:

Corrosion features from In-line Inspection (ILI)
CorPos-AD pipeline corrosion model
CO2 (Norsok M-506), HAc, H2S, erosion
Additional models (Cassandra) to be implemented
Model combined with ILI data
Qualitative assessment
Bacteria corrosion

Integrity check based on DnV RP-F101

Remaining Lifetime Estimation
Time to next inspection
Monitoring program parameters and associated critical values

PTIL seminar on pipeline integrity 9. December 2009

CorPos-AD, overview

Graphs Reports

Flow modeling
Import inspection data
OLGA

CorPos-AD
Import monitoring data Corrosion modeling

Combine corrosion model

Import chemical injection data
and monitoring/inspection

Database
Import production data
Risk analysis and
Safety Check

PTIL seminar on pipeline integrity 9. December 2009

Case 1: Hod 12 Multiphase pipeline

PTIL seminar on pipeline integrity 9. December 2009

 Case 1: Hod multiphase pipeline ILI

12 Hod multiphase pipeline (CS)

Operation from 1990
ILI 1993, 1994, 1995, 1998, 2004, 2009
Corr. Inhibitor injection 1993

Hod
12.0
Inspection data
MFL UT
Corrosion depth (mm)

10.0

8.0

6.0

4.0

2.0

0.0
mai.90 jan.93 okt.95 jul.98 apr.01 jan.04 okt.06 jul.09 apr.12
Time

PTIL seminar on pipeline integrity 9. December 2009

Case 1: CorPos-AD analysis of Hod multiphase pipeline

CorPos-AD analysis based

on:
Production data
1.4
Inhibitor injection data CR (1991-1993)
CR (1993-1998)
1.2
CR-profile obtained for 4 CR (1998-2000)
CR (2001-2008)
time periods

Corrosion rate [mm/ year]

1

Max corroded depth vs 0.8

time from integration 0.6

0.4

0.2

0
0 2000 4000 6000 8000 10000 12000 14000
KP [m]

PTIL seminar on pipeline integrity 9. December 2009

Case 1: CorPos-AD analysis of Hod multiphase pipeline

Hod
12.0
Inspection data
Corrosion depth (mm)

10.0 Corpos-AD analysis 2009

8.0

6.0

4.0

2.0

0.0
mai.90 jan.93 okt.95 jul.98 apr.01 jan.04 okt.06 jul.09 apr.12
Time

PTIL seminar on pipeline integrity 9. December 2009

 Case 1: Hod Multiphase pipeline CorPos-AD Risk
Assessment

Critical pit depth according to ILI data from 2008

DnV RP-F101
Design lifetime = 7
years (2015)
Risk status at end of
design life = OK
Estimated remaining
lifetime > 50 years
Future ILI frequency 5
years
Blue lines: Pit growth model prediction from 2008 to 2015

Zone 1- Pit growth prediction

PTIL seminar on pipeline integrity 9. December 2009
Case 1: Major challenges

Wax deposits in pipeline

UT pig data more sensitive
to residual wax than MFL
pig data
MFL and UT data have
different accuracy and
resolution
Modification of pig hardware
and software over time
makes it difficult to evaluate
time evolution of corrosion
features (e.g. to extract
corrosion rates)

PTIL seminar on pipeline integrity 9. December 2009

Case 1: Hod Multiphase - Corrosion Monitoring

Quarterly status reporting:

PTIL seminar on pipeline integrity 9. December 2009

Case 2: Ula - Ekofisk 20 oil export pipeline

10 Cod Gas Export Ula

(Decommisioned)
Length: 26.4 km 8 Tambar Production Flowline
(Decommisioned) Total length 170 km
Length: 16 km
Ula/Gyda
Wye
Cod
Assembly 10 Spool from Tambar to UGIP
Length: 60 m

Tambar

20 Gyda Oil Export Pipeline

Length: 24.8 km

Gyda

20 UTS Pipeline
Length: 70 km from Ekofisk to Ula
13 km from Ula to Y Assembly

Ekofisk 2/4 J

36 Ekofisk to Teeside

PTIL seminar on pipeline integrity 9. December 2009

20 UT pig Launching..

PTIL seminar on pipeline integrity 9. December 2009

Case 2: Ula - Ekofisk 20 oil export pipeline

Production start in 1986

Time of inspection Method Findings

1997 MFL No findings

2004 MFL Pitting with depth up to 6.9 mm

before Y-connection
2006 UT Pitting with depth up to 4.4 mm
before Y-connection

2006 ILI

PTIL seminar on pipeline integrity 9. December 2009

Case 2: Ula - Ekofisk 20 oil export pipeline

Low production rates

Increased water holdup
Dilution of inhibitor

Changes leading to improved corrosion control

Increased inhibitor injection rates CorPos/OLGA analysis

Increased frequency of cleaning pig runs
30
Increased frequency of intelligent pig runs Before Y-connection
25
After Y-connection
Increased production rate (Tambar)
Max water holdup (%)
20

15

10

0
1992 1994 1996 1998 2000 2002 2004
Year

PTIL seminar on pipeline integrity 9. December 2009

Case 2: Ula - Ekofisk 20 oil export pipeline

Quarterly status reporting:

PTIL seminar on pipeline integrity 9. December 2009

Lessons Learned (1)

Proper cleaning of pipelines prior to inspection is very important

to ensure good / reliable and comparable inspection data.

Good planning and coordination of the operation is important to

ensure effective utilization of expensive rental equipment
(cleaning pigs and inspection tools)

Dimension control by gauge plate

Hook devices both in front and back of the cleaning/ inspection

pigs to ease the pig launch and retrieval from pig launcher /
receiver.

PTIL seminar on pipeline integrity 9. December 2009

Lessons learned (2)

Data on corrosion rates (CR) required for lifetime estimation

ILI data strongly dependent on method (MFL, UT) and
method development Difficult to obtain corrosion
rates from ILI data
No corrosion monitoring units on pipelines.
Probes top-side not relevant for the entire pipeline.
Good experience from using CR data obtained from CorPos-
AD model, adjusted to fit ILI data if required
Low production rates may lead to water accumulation and poor
inhibitor performance in oil export lines with low water content
(1-2 %) High frequency of cleaning pigs required

PTIL seminar on pipeline integrity 9. December 2009

Major challenges in the future

Internal
MIC (Microbial Influenced Corrosion)

External
How determine anode depletion for buried pipelines?
How to inspect for HISC risk of CRA pipelines?

PTIL seminar on pipeline integrity 9. December 2009