PIPELINE INTEGRITY and EXTENDING the PIPELINE LIFECYCLE A presentation for the Business Review Webinar series Bryan Melan Senior Pipeline Engineer Marathon Oil UK Ltd.
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PIPELINE INTEGRITY andEXTENDING the PIPELINE
LIFECYCLEA presentation for the Business Review Webinar series
Bryan Melan
Senior Pipeline Engineer
Marathon Oil UK Ltd.
TODAY’S AGENDA
Defining the Pipeline Lifecycle
What is the meaning of ‘Design Life’?
‘Age’ and ‘Ageing’ as an Essential Performance Indicator of Pipeline Integrity
Pipeline ‘Ageing’ and its variety of issues
The ‘nuts and bolts’ of Pipeline Lifecycle extension
Why Pipeline Lifecycle Extensions?
10 February 2011
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Pipeline Lifecycle
After DNV RP-F116, Table 3-2
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What is Design Life?
• ISO 13623:2000: Design life is the period of time selected for the purpose ofverifying that a replaceable or permanent component is suitable for theanticipated period of service
• BS PD 8010: time period for which a pipeline is to be used for its intendedpurpose with planned integrity management.
• DNV-OS-F101:2007: Design life is the initially planned time period from initialinstallation or use until permanent decommissioning of the equipment or system.The original design life may be extended after a re-qualification.
• ASME 31.8:2003: (does not define a design life, but uses design life and servicelife as dimensional limits for design with respect to cyclic loading and cathodicprotection systems.)
• ASME 31.4:2006: Design life is a period of time used in design calculationsselected for the purpose of verifying that a replaceable or permanent componentis suitable for the anticipated period of service. Design life does not pertain to thelife of the pipeline system because a properly maintained and protected pipelinesystem can provide liquid transportation indefinitely.
Pipeline Design Life Definitions
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Essential Performance Indicators of PipelineIntegrity Coating History and CP performance
Product quality history
Pipe and girth weld toughness
History of 3rd party encroachments
Pipe weld seam performance
Welding Inspection history
NDE Testing history
What about Age ?
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Age as an Essential Performance Indicator
‘Oil Pipeline Characteristics and Risk Factors:
Illustrations from the Decade of Construction’ by Kiefner and Trench(2001)
“Age – the number of years a pipeline has been in service – is an unreliableindicator of the condition of a pipeline system. A better first indicator is thetechnologies that are represented in the manufacture and construction of thesystem when it was first placed in service. Even the decade of originalconstruction, however, is only a first indicator. Also critical to a pipeline'scondition are the renovation, inspection, and maintenance practices that havebeen applied since construction.”
“Pipeline systems constructed in any decade can provide safe and reliableperformance with the application of the newest testing and monitoringtechniques, and with an appropriate program of assessment and mitigation asrequired.”
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AGEING
Ageing is not about how old your equipment is; it is about its condition, andhow that is changing over time.
The effect whereby a component suffers some form of deterioration and damage (usually, butnot necessarily, associated with time in service) with an increasing likelihood of failure. Thereis often insufficient information and knowledge available to know the extent to which thispossibility exists.
The significance of deterioration and damage relates to the potential effect on the equipment’sfunctionality, availability, reliability and safety. Just because an item of equipment is old doesnot necessarily mean that it is significantly deteriorating and damaged. All types of equipmentcan be susceptible to ageing mechanisms.
There are many examples of very old plant remaining fully fit for purpose andnewer plant showing evidence of accelerated or early ageing due to corrosion,fatigue, erosion failures etc.
Source: UK HSE RR509
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AGEING
Source: UK HSE RR509
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Pipeline Life Cycle Ageing
Why Pipelines Age – It isn't All Corrosion & It isn't All Physical! High cycling rate of extreme temperatures, pressures loads or flexing; History of operating at the limit, or beyond, original design envelope; Use of aggressive chemicals and fluid properties (corrosive or abrasive) Aggressive environmental conditions Encroachments Critical parts of the pipeline difficult to access or inspect externally Limited or no internal inspection undertaken; internal conditions inhibit
data collection History of poor recordkeeping, maintenanceand inspection Associated control equipment that is obsolescent &no longer supported by the manufacturer or supplier.
COMPLACENCY
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Pipeline Life Cycle Ageing
Evidence of ageing Frequent or recurring defects and failures, or increasing trends of
unplanned maintenance, repair work, and breakdowns;
Signs of ageing e.g. cracking, corrosion, creep, etc.
Loss of records – construction, testing, inspection, maintenance
Reduction in pipeline safe operating limits or temporary isolation or down-rating due to deterioration or discovery of defects
Increase in frequency of inspection and testing regimes for pipelinesystems, associated equipment and protective devices
Reduced reliability and standard in performance
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Pipeline Life Cycle Ageing
Situations where ageing is not being identified Gaps in management interfaces between operators
Internal organisation gaps; e.g. pipelines and topsides
Equipment not in maintenance management system.
Records and findings from inspections not being kept and reviewed
Findings from pipeline tests and inspections not used to check/modifytesting protocols
Inadequate recording and use of operational performance data
Gaps in maintenance and corrosion management routines
Historical data lost during operatorship transfers
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Pipeline Life Cycle Ageing
Internal issues occur mainly due to corrosion and can arise dueto deposits and water lying in the pipeline: Current fluids not consistent with the original design
Changing operation conditions:– Increasing water cuts– Sludge, wax and misc. deposits building-up– Change in Flow rates, decreasing or increasing– Erosion concerns with increasing flow rates– Water hold-up in low flow rates– Sulfate-Reducing Bacteria developing
Operational maintenance pigging may need to be increased
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Pipeline Life Cycle Ageing
External damage can occur due to: Third-party interaction, utilities crossings, anchors, dropped objects etc.
Cathodic protection systems failing
Coating failures due to faulty application or damage from earth movementor other forces
Failures of Attachments – corrosion or material failures of tees and stubs,dead legs
Air/soil/water interface - inadequate protection from corrosion and erosion
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Pipeline Life Cycle Ageing
Topsides or Above ground Equipment & Valves Maintenance needs frequently reviewed and remedial works carried out
Emergency shutdown valve test trending may indicate a change is required
Valves for isolation purposes which are passing may require changeout
Pig launchers/door closure mechanisms wear out
Changes in operating practice e.g. isolation standards require double blockand bleed
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Knowledge is Power !
There is no substitute for inspection GVI, CVI, Intelligent pigging, ROV, Close Interval, DCVG
Corrosion models may predict indicative corrosion rates but cannot predict exactlywhere localised corrosion may be occurring.
Preservation of records and documentation is essential Inspections can fill in gaps of lost data
Awareness of Changes External to
Organisation Changes in legislation have an impact
Changes in Codes and Standards have an impact
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Pipeline Life Extension Analysis – the ‘nuts &bolts’1. Identify past deviations from Original Design Basis
2. Evaluate current integrity
3. Evaluate integrity for extended use - Define future needs
How much life is left under current conditions?
How can I get ‘X’ more years of life?
4. Anticipate changes to system
New tie-ins
Product conversion
Reuse within another pipeline system
Extension of life of producing asset
Pipeline Life Extension Analysis – the ‘nuts &bolts’4. Time-dependent flaw analyses
Corrosion growth assessment and predictions
Fatigue assessment and predictions
5. NORSOK and ISO standards to provide guidance
6. Business case justification – cost of required upgrades
NORSOK STANDARD Y-002Edition 1, December 2010
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Life extension for transportation systems
Pipeline Life Extension – the business case
There is always an alternative to pipeline life extension (such asinstalling a replacement pipeline) and a business case will berequired to determine the most suitable option. This wouldcompare the cost of the mitigation necessary to achieve thedesired life extension against the cost of a new pipeline.
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Why Pipeline Life Cycle Extension? Regulatory Compliance – obviously
Regulators will have specific requirements regarding the elements of a Life ExtensionAnalysis
Other industries with long term outlooks already address ageing issues as amatter of normal business – e.g. Nuclear, Aviation, Pharmaceutical
Commercial Demands and Opportunities: Future projections for continued oil and gas exploration & production using existing
infrastructure Future consumer energy demand for natural gas and refined petroleum products will
continue well into foreseeable future Emerging energy technology developments can deploy existing infrastructure; e.g. CO2
sequestration; potential for hydrogen fuels
Life Extension projects are likely to be a significant feature to ensure cost-effective utilisation of existing ageing infrastructure to meet these demands Also to evaluate the potential for uprating design pressure and flow rates
The challenge is to ensure effective management of ageing infrastructure toensure that, as a minimum, the original standards are maintained
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Conclusions
Ageing has little to do with chronological age Don’t throw away a valuable cash-generating asset
Pipeline Life Extension – bottom line - is a business case
Pipeline Life Extension is a multi-component evaluation: currentintegrity & future integrity – and the cost to get from now tothe future
Pipeline Integrity Management is the common denominatorand needs to be continuous throughout the pipeline lifecycle
Knowledge is critical to successfully getting the most out ofasset life!
References Maximising Pipeline Structural Integrity and Prolonging Pipeline Life Cycle
Bryan Melan - Oil & Gas Pipeline Integrity Management and Maintenance Forum,London, 22 – 24 February 2010Offshore Pipelines: Life Management & Fitness for Purpose
Offshore Pipelines: Life Management & Fitness for Purpose Blaire McKay - Offshore Pipelines: Life Management & Fitness for Purpose; Institute
of Mechanical Engineers Conference, Aberdeen, 25 November 2010
A Regulatory View on Ageing and Life Extension of UK Pipelines Douglas Souden - Offshore Pipelines: Life Management & Fitness for Purpose;
Institute of Mechanical Engineers Conference, Aberdeen, 25 November 2010
Plant Ageing: Management of equipment containing hazardous fluids orpressure Research Report RR509 - HSE Books 2006
Oil Pipeline Characteristics and Risk Factors: Illustrations from the Decade ofConstruction John F Kiefner and Cheryl J Trench – American Petroleum Institute 2001
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THANK YOU FOR YOUR ATTENTION!!
Bryan P Melan, PEMarathon Oil UK Ltd.Aberdeen, Scotland
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