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Page 1: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally
Page 2: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

Abstract of Papers:-

PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly

aged offshore pipelines principally for oil and gas evacuation in Sarawak Malaysia. By

implementing an integrated approach to pipeline integrity management comprising

rigorous inspections, fitness for service assessments and risk assessments; a risk based

asset integrity management programme has been developed which has enabled PCSB

to prioritize and optimize pipeline integrity management with the objective of

reducing incidents of pipeline failures and at the same time achieve life extension.

The predominant integrity threat for the pipeline assets has been microbial influence

corrosion (MIC). The integrity management programme implemented has enabled

PCSB SKO to assess the pipeline asset risks to MIC as well as prioritize and optimize the

internal corrosion mitigation programme.

Page 3: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

An Integrated Approach to Managing the Integrity of Offshore Pipelines.

Mohamed Amin Abdullah

Head of Sarawak Operations

PETRONAS Carigali Sdn Bhd

7th APCE, 11th October 2011, Kuala Lumpur

Page 4: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

Overview of PETRONAS Carigali Sarawak Operations (SKO) and its

Pipeline System

Primary Integrity Threats and Pipeline Condition Assessment

Strategy.

MIC Prediction

Integrity Management Approach - Detection and Mitigation Strategy

A Case Study

Summary and Conclusion

Page 5: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

Source: Regional pipeline data

PCSB Sarawak Operation (SKO) involves in

managing predominantly aging pipeline assets

SKO Pipelines (1477km , 172 nos.)

Size

(in dia.)Up to 36

Age

(years)

< 20 20-30 > 30

47 58 67

Page 6: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

PCSB Sarawak Operations operates about 1500 km of offshore pipelines

connected to Crude Oil Terminals in Miri and Bintulu

SKO Gas Customers

Helang Layang

B12B11

Laila

D21 D30

D18

Temana

D28

J4

D35

D16

Bayan

Hasnah

Lembuk

Sikau

Siwa

Fairley Baram

D51D5D26

D41

D12

D2

S. Acis

Singa Laut

Patricia

Sompotan

Serunai

Geduk

N. AcisE2

Gambang

Sapih

W. Lutong

Tukau

Bokor

Betty

ASAM PAYA

Fatimah

Merak

Beryl BaroniaBaram

Bakau

Mawar

Lemai

BINTULU

MCOT

MIRI

LUTONG

D34

MLNG

MLNG-TIGA

BCOT

Not to scale

MLNG DUA

TK/SI

F6

F13

E8

Sh. ClasticsE6

F28

E4

F23SW

E11R-C

E11R-B

E11R-AE11

JintanSerai

F23Cili Padi

M3M5G7

M4

F29

F12

F11F14

F9

Lada Hitam

Selasih

B.Sawi

Bijan

Bunga Pelaga

M1

F27F22

Saderi

Bokor South

Tukau Timur

Bakau Deep

Bario

J1

J5

J32

J2

K5

Tenggiri Marine

A21

A23

K4

BentaraBalai

J12Yu

C13

C2

Selar Marine

Jerong Marine

OBO

COB

COB

SarawakBrunei

SKO Crude Customers

ABF SMDS MLNG

Crude Oil Group (COG)

PC4

Kumang

PCPP – SK305 Block

Dana

Page 7: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

CPIMS Enhancement

Corrosion Management

(product / process

monitoring, cleaning, inhi

bition / biociding)

Internal Inspection

External Inspection

Contingency material &

repair

Pipeline/facility

Rejuvenation and

replacement

Page 8: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

What is MIC?

Microbial Influenced Corrosion (MIC): a

modified form of localised corrosion that

is enhanced by bacteria activity.

In crude oil and water injection pipelines,

Sulphate Reducing Bacteria (SRB) is a

primary source.

Growth and activity requires:

- Water

- An energy source (e.g. Light)

- A carbon source (e.g. CO2)

- An electron donor (e.g. organic /

inorganic substrate)

- An electron acceptor (e.g. SO4-, O2)

J Healy et all. Development of appropriate inspection and maintenance options to mitigate microbial induced corrosion (MIC) in offshore oil pipelines. 4th Annual Middle East Pipeline Integrity Management Summit, Abu Dhabi, 23-24 February 2009

Page 9: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

Primary Threats are internal corrosion (sub-sea

pipelines) and external corrosion (risers)

Primary cause of internal corrosion attributed to MIC

This paper is focused on internal corrosion.

Page 10: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

Typically the corrosion pits due

to MIC tend to be small (8 – 15

mm in diameter) and

hemispherical in shape.

Occurrence along pipeline can

be random (low points, areas

of low or stagnant flow) where

“biofilms” could be established

Recent experience of corrosion

rates (unmitigated) due to MIC

are in the range 0.5 to 6 mm/yr.

Premature pipeline failures

recorded (as early as 4 years

after installation)

SKO experienced very high corrosion rates

including failures due to MIC

ILI data showing Corrosion Growth

Rates of 0.5 to 3mm/yr

J Healy et all. Development of appropriate inspection and maintenance options to mitigate microbial induced corrosion (MIC) in offshore oil pipelines. 4th Annual Middle East Pipeline Integrity Management Summit, Abu Dhabi, 23-24 February 2009

Page 11: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

Concentration of localised pits at the bottom of pipeline is

a typical pattern of MIC from internal Inspection (IP)

Page 12: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

MIC associated with deep pitting and high corrosion growth rates – major implication on safe operation and remaining life prediction.

MIC on older assets (>25 years old) – experienced change in operations parameter, contamination of well and processing facilities.

Such assets traditionally designed for CO2 (sweet) corrosion with no cleaning & biocide treatment facilities.

Once established, MIC is difficult to control (no easy access to treat deep pits by cleaning and biocide dosing)

Low flow rates also a major issue in achieving effective cleaning / water removal and biocide treatment.

Page 13: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

Structured approach to assess the MIC susceptibility

• Risk Assessment to prioritise high risk / criticalpipelines.

• Inspection & condition assessment.

• Integrity (FFS) Assessment / Root Cause Diagnosis

• Mitigation Strategy – to include feedback to enableeffectiveness of the Corrosion Management Plan(CMP) to be monitored and adjusted as appropriate.

• Pipeline Rejuvenation

Page 14: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

MIC Prediction using monitored data has enabled quick

identification of affected pipelines for “treatment”

Sampling / Monitoring conducted for several of the field.

Relationship between available nutrients, bacteria counts,

other operational data and perceived risk established.

Key issues identified:

No water separation offshore

Water injection and well contamination

Recommendation for control / mitigation

BiDi OP brush tool + biocide.

Monitoring and condition assessment including

Inspection frequencies (IP & UT).

Page 15: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

SKO Wide Risk Assessment is used to rank and

prioritize the pipelines for “treatment”

• Risk Assessment to prioritise high risk / critical pipelines.

• In-line Inspection to quantify the pipeline condition, risk level and extent of damage.

• Based on inspection data, evidence to diagnose (or otherwise) whether MIC is present

• Integrity (FFS) Assessment to define long term remedial and Corrosion Mitigation Strategy

• Rejuvenation to provide facilities for full CMP implementation.

Page 16: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

• Options:

– In-line inspection along length of the pipeline

– UT inspection at local “high” risk areas?

• Techniques:

– Conventional in-line Ultrasonic's (UT) or Magnetic Flux Leakage (MFL)

– Tethered UT

– Localised subsea external UT

Page 17: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

• Based on inspection data, evidence to diagnose whether MIC is present

• Immediate repair / investigation priorities is scheduled

• Based on available pipeline information, Corrosion Growth Rates can be estimated

• Operating conditions– Monitoring information – Corrosion modelling– Detailed comparison of

inspection data,

• Future repair priorities can be defined, together with revised Corrosion Management Plan (CMP).

Inspection 1

Inspection 2 Growth of Existing

Features

Growth of “New”

Feature

Inspection 1

Inspection 2 Growth of Existing

Features

Growth of “New”

Feature

Page 18: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

A Case Study : 18” Crude Oil Pipeline.

• 18” x 55km crude oil line with a design life of 30 years

• In service since 1983 (19 years at time of first inspection 2002)

• Transport crude oil, water cut 17%, pH 6.86, CO2 1.27 mole%

• No inhibitor / biocide applied.

• Operational cleaning & water removal with Bi-Di tool conducted

monthly

• MIC Risk Assessment indicated HIGH risk level.

• First in-line inspection conducted in 2002 and repeat inspection

conducted in 2007 using IP and Calliper tools.

• Survey of Cathodic Protection system indicated that the pipeline was

adequately protected subsea.

Page 19: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

IP result and its interpretation is used to

determine major internal corrosion threat.

• Re-inspection in 2007,

indicated significant increase

in internal corrosion features

(from 3,944 in 2002 to 26,276

in 2007) Deepest Feature

46%.

• Indicative of severe internal

corrosion activity over the 5

year inspection interval.

• 159 external features

reported, deepest 49%

located in the riser.

• Corrosion in riser associated

with transition from neoprene

riser coating to topside glass-

flake coating Distribution on internal corrosion features

49% @ 55,074.84m159External Corrosion Features

26,276 46% @ 28,699.84m

Deepest Feature

(%wt)

Internal Corrosion Features

49% @ 55,074.84m159External Corrosion Features

26,276 46% @ 28,699.84m

Deepest Feature

(%wt)

Internal Corrosion Features

Page 20: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

• Significant and extensive corrosion reported at the

bottom of the line

• Although, sweet corrosion in the water phase has

contributed to the reported corrosion features but in

the current conditions (water cut, CO2) the expected

corrosion growth rate would be relatively low.

• MIC is suspected to have contributed to the

observed pitting in the line over the inspection

interval of 2002 to 2007.

Page 21: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

FFS Assessment established the immediate

integrity and future inspection/maintenance plan

• FFS conducted using DNV RP-F101 Part B. Allowance for tool

tolerance included.

• All reported corrosion features found acceptable for Operation at

maximum allowable operating pressure (MAOP).

Page 22: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

FFS Assessment established the future Inspection

and Maintenance Plan for the pipeline

• Based on determined corrosion

growth rates, 7 features were

predicted to require

investigation / repair within 4

years.

• Immediate Bi-Di cleaning and

inhibitor / biocide dosing was

recommended to addressed

MIC activity.

• Continued monitoring for MIC

activity, to determine

effectiveness of revised CMP.

• Re-inspection interval

proposed at 3 - 4 years, subject

to status of MIC control activity.

• Cost benefit analysis required

to justify upgrades to CMP and

repairs / reinspection strategy

versus pipeline replacement

SRB Trending

10

100

1000

10000

100000

1000000

Ju

l-0

7

Au

g-0

7

Se

p-0

7

Oct-

07

No

v-0

7

De

c-0

7

Ja

n-0

8

Fe

b-0

8

Ma

r-0

8

Ap

r-0

8

Ma

y-0

8

Ju

n-0

8

Ju

l-0

8

Au

g-0

8

Se

p-0

8

Oct-

08

No

v-0

8

De

c-0

8

Ja

n-0

9

Fe

b-0

9

Ma

r-0

9

Date

SR

B C

ou

nt

(ce

lls

/ml)

M MH H Inlet Outlet

Example of MIC Monitoring / trending

47.67

52.44 52.44 52.44 52.44 52.44

40

45

50

55

60

21-

Sep-

09

22-

Sep-

09

23-

Sep-

09

24-

Sep-

09

25-

Sep-

09

26-

Sep-

09

27-

Sep-

09

Dosage (

PP

M )

Date

Actual Dosage Of Corrosion Inhibitor Onsite Based on Water Production WLP-A (PL 339)

Recommended Dosage

(+15%)

from recommended

dosage(-15%)

fromrecommended

dosage

Page 23: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

• MIC is a modified form of localised corrosion that is enhanced by the action of bacteria.

SKO have implemented a structured approach to identify and manage the risk of MIC, including:

SKO Wide Risk Assessment

Inspection and condition assessment

Integrity (FFS) Assessment

Development of appropriate mitigation actions including rejuvenation and replacement where required.

The approach adopted by SKO has enabled MIC to be managed effectively. This has enable SKO to implement an asset wide Pipeline Rejuvenation Program since 2009.

Page 24: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

“Unless a man undertakes more than

he possibly can do, he will never do

all that he can”.

Henry Drummond

Page 25: Abstract of Papers:- - Malaysian Gas · PDF fileAbstract of Papers:-PETRONAS Carigali Sdn Bhd, Sarawak Operations (PCSB SKO) operates predominantly aged offshore pipelines principally

25

ThankYou

End of presentation


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