Pressure Cycling Monitoring Helps Ensure the Integrity of Energy Pipelines

2010 ◽  
Author(s):  
Peter Song ◽  
Doug Lawrence ◽  
Sean Keane ◽  
Scott Ironside ◽  
Aaron Sutton
Keyword(s):  
Fatigue Life ◽  
Pipeline System ◽  
Outer Diameter ◽  
Operating Pressure ◽  
Potential Growth ◽  
Integrity Assessment ◽  
Pressure Cycling ◽  
Pressure Cycle ◽  
Primary Focus ◽  
Pump Stations

Liquids pipelines undergo pressure cycling as part of normal operations. The source of these fluctuations can be complex, but can include line start-stop during normal pipeline operations, batch pigs by-passing pump stations, product injection or delivery, and unexpected line shut-down events. One of the factors that govern potential growth of flaws by pressure cycle induced fatigue is operational pressure cycles. The severity of these pressure cycles can affect both the need and timing for an integrity assessment. A Pressure Cycling Monitoring (PCM) program was initiated at Enbridge Pipelines Inc. (Enbridge) to monitor the Pressure Cycling Severity (PCS) change with time during line operations. The PCM program has many purposes, but primary focus is to ensure the continued validity of the integrity assessment interval and for early identification of notable changes in operations resulting in fatigue damage. In conducting the PCM program, an estimated fatigue life based on one month or one quarter period of operations is plotted on the PCM graph. The estimated fatigue life is obtained by conducting fatigue analysis using Paris Law equation, a flaw with dimensions proportional to the pipe wall thickness and the outer diameter, and the operating pressure data queried from Enbridge SCADA system. This standardized estimated fatigue life calculation is a measure of the PCS. Trends in PCS overtime can potentially indicate the crack threat susceptibility the integrity assessment interval should be updated. Two examples observed on pipeline segments within Enbridge pipeline system are provided that show the PCS change over time. Conclusions are drawn for the PCM program thereafter.

Integrity Assessment of HP/HT Infield Pipelines: Experiences With a New Methodology Applied in the Norwegian Sea

2008 ◽  
Author(s):  
Birger Etterdal ◽  
Hroar Nes ◽  
Stig Olav Kvarme ◽  
Stian Svardal
Keyword(s):  
Hot Spot ◽  
Operating Conditions ◽  
Pipeline System ◽  
Operating Pressure ◽  
Assessment Methodology ◽  
Long Term Conditions ◽  
Norwegian Sea ◽  
Integrity Assessment ◽  
Analysis Models

The subsea pipeline development for the A˚sgard and Midgard fields in the Norwegian Sea has been challenging due to high operating pressure and temperature (HP/HT pipelines), uneven seabed conditions and the potential for trawl gear interference. A general experience from the first years of operation is that it is not easy to use design information as basis for an integrity assessment of the lines. This is mainly due to the complexity of the global buckling process and the significant load fluctuations applied to the lines. As a consequence of this, analysis models established during design may not represent the actual pipeline behaviour properly, and established design limits do not fit intermediate operational load conditions and configurations observed during surveys. StatoilHydro has developed an integrity assessment methodology where analysis models are calibrated according to the as-surveyed condition, and then exposed to operational cyclic loads in order to predict both intermediate long term conditions and a final design condition. In the assessment of long term fatigue accumulation, process parameters monitored during pipeline operation are used as input. The integrity condition of the HP/HT pipelines is assessed based on a staged approach, depending on the criticality of the considered failure mode. The first level is used for screening and initial ranking. At level two the risk of integrity failure is quantified based on general design criteria, covering relevant operating conditions and the most important input parameters. If the uncertainty related to the assessment of an individual hot-spot location is assumed too high, a detail level three assessment may be specified. The operating condition of the pipeline system is expressed as the risk of failure defined by a limited number of hot-spot locations. The risk matrix concept used for the HP/HT pipelines, provides for a consistent comparison between individual failure modes, between different locations and sections, and between different pipeline systems. StatoilHydro has worked in close cooperation with DNV to develop software tools required to implement this integrity assessment methodology. These tools are now used for integrity assessment and follow-up of all HP/HT pipelines operated by StatoilHydro in the Norwegian Sea. The objective of this paper is to show how the methodology is used in practice, discuss major results and findings, and give general recommendations with respect to operational integrity assessment of HP/HT pipelines.

Effect of Pressure Loading on Integrity Management

2008 ◽  
Author(s):  
Sanjay Tiku ◽  
Aaron Dinovitzer ◽  
Scott Ironside
Keyword(s):  
Fatigue Crack ◽  
Fatigue Crack Growth ◽  
Crack Growth ◽  
Operating Pressure ◽  
Integrity Assessment ◽  
Pipeline Segment ◽  
Pressure Cycle ◽  
Integrity Management ◽  
Pump Compressor ◽  
Life Predictions

Integrity assessment or life predictions for in-service pipelines are sensitive to the assumptions they rely upon. One significant source of uncertainty is the pipeline operating pressure data often captured and archived using a Supervisory Control and Data Acquisition (SCADA) system. SCADA systems may be programmed to collect and archive data differently from one pipeline to another and the resulting pressure records can be significantly different on the basis of the sampling techniques, data processing and the distance from pump and compressor stations. This paper illustrates some of the issues involved in pressure load characterization and is based upon work sponsored by the Pipeline Research Council International (PRCI). A series of sensitivity studies using fatigue crack growth calculations have been carried out to evaluate several factors that can influence crack stability and growth predictions that are often employed in pipeline integrity planning and repair programs. The results presented will highlight the issues related to performing integrity management based upon pump/compressor discharge or suction SCADA data to characterize the potential severity of pressure fluctuation or peak pressure dependent defects, illustrate the differences in fatigue crack growth rates along a pipeline segment and demonstrate the complexity of pressure cycle severity characterization, based upon distance from discharge, elevation, hydraulic gradient, for different sites along the pipeline route.

Improved Pipeline Dent Integrity Management

2016 ◽  
Author(s):  
Sanjay Tiku ◽  
Amin Eshraghi ◽  
Vlad Semiga ◽  
Luis Torres ◽  
Mark Piazza
Keyword(s):  
Numerical Simulation ◽  
Fatigue Life ◽  
Fatigue Testing ◽  
Assessment Model ◽  
Third Party ◽  
Operating Pressure ◽  
Integrity Assessment ◽  
Integrity Management ◽  
Further Development ◽  
Dent Depth

Pipeline dents can be developed from the pipe resting on rock, a third party machinery strike, rock strikes during backfilling, amongst other causes. The long-term integrity of a dented pipeline segment depends upon parameters including pipe geometry, indenter shape, dent depth, indenter support, secondary features, and pipeline operating pressure history at and following indentation. US DoT and other standards include dent repair and remediation criteria broadly based upon dent depth, dent location (top or bottom side), pressure cycling (liquid or gas), and dent interaction with secondary features (weld, corrosion, cracks). These criteria are simple and easily applied, however, they may not direct maintenance appropriately and be overly conservative or, in some cases, unconservative. Previous IPC papers have discussed the full-scale dent fatigue testing and dent modelling efforts to support integrity management criteria development by collecting material and structural response during dent formation and pressure loading. The present paper will present the results of this extensive dent structural and fatigue life numerical simulation program using a validated finite element (FE) analysis process. The paper describes the numerical simulation technique, as well as, the development of the novel engineering tool for integrity management, eliminating the need for numerical simulation of individual dent features to assess the relative integrity threat they pose. The development of the engineering tool presented in this paper considers the dent formation, re-rounding and through life response to pressure fluctuations to evaluate the fatigue life of dent features. The results of these analyses are used to develop fatigue life trends based on dent shape, restraint condition and operating pressure. These trends were used to develop models to predict dent relative severity and life based upon ILI inspection dent shape data for single peak dents. Dent shape has also been used to determine the restraint condition of a dent and its influence on the dent feature fatigue life. The tools were developed to address many of the uncertainties inherent in existing regulatory repair and remediation criteria. Current and future applications of the integrity assessment model are described along with recommendations for further development and testing to support pipeline integrity management, industry guidelines and standards. The results of this research will be of use in improving integrity management decisions and support further development of industry guides and standards. As such the information presented in this paper will be of interest to pipeline operators, integrity management specialists, in-line inspection (ILI) organizations and regulators. The recommendations presented in this paper may be used to influence the direction of pipeline standards in their direction in the disposition of dent features.

Fitness for Service of Dents Associated With Metal Loss due to Corrosion

2014 ◽  
Author(s):  
Hans Olav Heggen ◽  
Joe Bratton ◽  
David Kemp ◽  
Jun Liu ◽  
Jason Austin
Keyword(s):  
Fatigue Life ◽  
Stress Concentration ◽  
Maximum Stress ◽  
Dynamic Pressure ◽  
Equivalent Stress ◽  
Metal Loss ◽  
General Effect ◽  
Element Analysis ◽  
Pressure Cycling ◽  
Pressure Cycle

Current federal regulations in the U.S. require excavation of all dents associated with metal loss due to corrosion identified through in line inspection surveys. Once a dent has been found to be associated with metal loss through excavation, there is little guidance to determine the serviceability of the anomaly. Past research has provided methodologies to assess the fatigue life of plain dents, considering the shape of the dent, but there are no widely accepted assessment methodologies to predict the effect of associated metal loss due to corrosion on the fatigue life of dents. This paper focuses on the fitness for service of dents associated with metal loss, particularly corrosion in dents. Currently, fitness for service assessments of plain dents provide an estimated remaining life of a dent based on the geometry of the dent and current pressure cycling of the pipeline. Dynamic pressure cycling at each dent location is estimated using the upstream and downstream pressure cycle data, elevation, and distance along the pipe. The dynamic pressure cycle data at each dent is then converted into equivalent stress cycles based on the results of rainflow cycle counting. Finite element analysis (FEA) of a dent without metal loss and with metal loss is performed to compare the maximum stress concentration areas. The FEA program Abaqus is used with solid elements to model the dents. The differences between maximum stress concentration areas is compared for a matrix of extent of metal loss, and orientation of metal loss to analyze the general effect of metal loss and the interaction of metal loss in a dent. The stress concentration areas of dents without metal loss and with metal loss are then applied to current fatigue assessment methodologies provided in API 579 to analyze the effect of metal loss on the fatigue life of dents.

Improvement of Integrity Concepts for NPP Primary Circuit Piping

2008 ◽  
Author(s):  
Alexey Arzhaev ◽  
Sergey Butorin
Keyword(s):  
Carbon Steel ◽  
General Scheme ◽  
Primary Circuit ◽  
Feed Water ◽  
Outer Diameter ◽  
Intergranular Stress Corrosion ◽  
Methodology Development ◽  
Integrity Assessment ◽  
Piping Systems ◽  
Steel Piping

Operating NPPs license extension activities in Russia produced strong demand for safety improvement of plants build according to earlier standards. Installation of additional supports as pipe whip restraints is one of requirement in acting regulatory documentation which should be followed or compensated by appropriate measures like Leak Before Break (LBB) analyses and improvement of In-Service Inspection (ISI) and Leak Detecting System (LDS). Basic document for LBB concept application to Russian NPP piping is RD 95 10547-99. Its requirements correspond to classical LBB principles used in many countries in Europe, USA and Japan. In many real cases requirements of RD 95 10547-99 could not be applied to safety important NPP piping systems due to the presence of specific features of operational degradation due to some corrosion mechanisms: for example, erosion-corrosion (E-C) for carbon steel piping and intergranular stress corrosion cracking (IGSSC) for heat affected zones of austenitic piping weldments. For special case of RBMK piping with outer diameter 325 mm (potentially susceptible to IGSCC) special Break Preclusion Concept has been developed in Russia after IAEA Extrabudgetary Program in 2000–2002. Contrary to LBB Concept demanding for all four basic principles to be completely fulfilled BP Concept accepts some principles to be fulfilled in a balanced way with demonstration of monitored degradation effectively achieved in operation. Special BP Concept is being developed now to support integrity assessment of RBMK carbon steel steam and feed water piping potentially susceptible to E-C which requires another set of measures to demonstrate principle of controlled degradation in operation then in case of austenitic steel piping. General scheme of piping integrity analyses according to LBB and BP Concepts is discussed and examples of specific approaches to achieve controlled degradation are illustrated in paper. As result of LBB and BP Concepts application it is possible to substantiate reject of additional piping whip restraints implementation on-site. Examples of similar safety methodology development in other countries have been reported at IAEA Specialists Meeting on LBB in Kiev, Ukraine in November 2006.

Pipeline Instrumentation: The British Gas National Transmission System

1987 ◽  
Vol 20 (1) ◽  
pp. 18-25
Author(s):  
P Gilbert
Keyword(s):  
Distribution System ◽  
Transmission System ◽  
Process Conditions ◽  
Pipeline System ◽  
Operating Pressure ◽  
Distribution Grid ◽  
History Of Development ◽  
History Of ◽  
Instrument Engineer ◽  
Transmission And Distribution

The transmission and distribution system operated by British Gas plc is the largest integrated pipeline system in Europe. The whole system comprises a national transmission system which carries gas from five terminals to the twelve gas regions. Each region in turn carries the gas through a regional transmission system into a distribution grid and thence onto its customers. The national, regional and distribution system all present the instrument engineer with different technical challenges because of the way in which they have been built and are operated, however, it is simplest to characterise them by their process conditions. The operating pressure is highest in the national transmission system being up to 75 bar, in the regional transmission system the pressure is usually less than 37 bar, and in the distribution grid it is less than 7 bar. In general, the pipe diameters decrease from the national system downwards, and the measured flowrates are lowest in the distribution grids. This paper is concerned only with instrumentation on the national transmission system. The discussion will cover current technology which is typical of that being installed at present, and concentrates on the more commonly found instrumentation. The paper begins with a brief history of development of the national transmission system and a description of how it is operated. This is followed by a discussion on the application of computers to the control of unmanned installations. A section concerning the measurement of pressure and its application to the control of the system comes next. The main part of the paper contains an analysis of high accuracy flowmetering and the paper concludes with some comments on developments in instrumentation and their application to changing operation of the national transmission system.

Integrity Assessment of Non-Piggable Pipeline Through Direct Assessment

2013 ◽  
Author(s):  
Jai Prakash Sah ◽  
Mohammad Tanweer Akhter
Keyword(s):  
Hydrostatic Pressure ◽  
Natural Gas ◽  
Stress Corrosion ◽  
Health Assessment ◽  
Assessment Method ◽  
Pipeline System ◽  
Internal Corrosion ◽  
Integrity Assessment ◽  
Direct Assessment ◽  
External Corrosion

Managing the integrity of pipeline system is the primary goal of every pipeline operator. To ensure the integrity of pipeline system, its health assessment is very important and critical for ensuring safety of environment, human resources and its assets. In long term, managing pipeline integrity is an investment to asset protection which ultimately results in cost saving. Typically, the health assessment to managing the integrity of pipeline system is a function of operational experience and corporate philosophy. There is no single approach that can provide the best solution for all pipeline system. Only a comprehensive, systematic and integrated integrity management program provides the means to improve the safety of pipeline systems. Such programme provides the information for an operator to effectively allocate resources for appropriate prevention, detection and mitigation activities that will result in improved safety and a reduction in the number of incidents. Presently GAIL (INDIA) LTD. is operating & maintaining approximately 10,000Kms of natural gas/RLNG/LPG pipeline and HVJ Pipeline is the largest pipeline network of India which transports more than 50% of total gas being consumed in this country. HVJ pipeline system consists of more than 4500 Kms of pipeline having diameter range from 04” to 48”, which consist of piggable as well as non-piggable pipeline. Though, lengthwise non-piggable pipeline is very less but their importance cannot be ignored in to the totality because of their critical nature. Typically, pipeline with small length & connected to dispatch terminal are non-piggable and these pipelines are used to feed the gas to the consumer. Today pipeline industries are having three different types of inspection techniques available for inspection of the pipeline. 1. Inline inspection 2. Hydrostatic pressure testing 3. Direct assessment (DA) Inline inspection is possible only for piggable pipeline i.e. pipeline with facilities of pig launching & receiving and hydrostatic pressure testing is not possible for the pipeline under continuous operation. Thus we are left with direct assessment method to assess health of the non-piggable pipelines. Basically, direct assessment is a structured multi-step evaluation method to examine and identify the potential problem areas relating to internal corrosion, external corrosion, and stress corrosion cracking using ICDA (Internal Corrosion Direct Assessment), ECDA (External Corrosion Direct Assessment) and SCCDA (Stress Corrosion Direct Assessment). All the above DA is four steps iterative method & consist of following steps; a. Pre assessment b. Indirect assessment c. Direct assessment d. Post assessment Considering the importance of non-piggable pipeline, integrity assessment of following non piggable pipeline has done through direct assessment method. 1. 30 inch dia pipeline of length 0.6 km and handling 18.4 MMSCMD of natural gas 2. 18 inch dia pipeline of length 3.65 km and handling 4.0 MMSCMD of natural gas 3. 12 inch dia pipeline of length 2.08 km and handling 3.4 MMSCMD of natural gas In addition to ICDA, ECDA & SCCDA, Long Range Ultrasonic Thickness (LRUT-a guided wave technology) has also been carried out to detect the metal loss at excavated locations observed by ICDA & ECDA. Direct assessment survey for above pipelines has been conducted and based on the survey; high consequence areas have been identified. All the high consequence area has been excavated and inspected. No appreciable corrosion and thickness loss have observed at any area. However, pipeline segments have been identified which are most vulnerable and may have corrosion in future.

scholarly journals Fatigue Variability of Alloy 625 Thin-Tube Brazed Specimens

Metals ◽  
2021 ◽  
Vol 11 (8) ◽  
pp. 1162
Author(s):  
Seulbi Lee ◽  
Hanjong Kim ◽  
Seonghun Park ◽  
Yoon Suk Choi
Keyword(s):  
Fatigue Life ◽  
Heat Exchanger ◽  
Room Temperature ◽  
Metal Layer ◽  
Outer Diameter ◽  
Multiple Crack ◽  
Joint Failure ◽  
Alloy 625 ◽  
Thin Tube ◽  
Brazed Joint

As an advanced heat exchanger for aero-turbine applications, a tubular-type heat exchanger was developed. To ensure the optimum performance of the heat exchanger, it is necessary to assess the structural integrity of the tubes, considering the assembly processes such as brazing. In this study, fatigue tests at room temperature and 1000 K were performed for 0.135 mm-thick alloy 625 tubes (outer diameter of 1.5 mm), which were brazed to the grip of the fatigue specimen. The variability in fatigue life was investigated by analyzing the locations of the fatigue failure, fracture surfaces, and microstructures of the brazed joint and tube. At room temperature, the specimens failed near the brazed joint for high σmax values, while both brazed joint failure and tube side failure were observed for low σmax values. The largest variability in fatigue life under the same test conditions was found when one specimen failed in the brazed joint, while the other specimen failed in the middle of the tube. The specimen with brazed joint failure showed multiple crack initiations circumferentially near the surface of the filler metal layer and growth of cracks in the tube, resulting in a short fatigue life. At 1000 K, all the specimens exhibited failure in the middle of the tube. In this case, the short-life specimen showed crack initiation and growth along the grains with large through thickness in addition to multiple crack initiations at the carbides inside the tube. The results suggest that the variability in the fatigue life of the alloy 625 thin-tube brazed specimen is affected by the presence of the brazed joint, as well as the spatial distribution of the grain size and carbides.

Risk Assessment for Small Diameter Piping for Liquid Pipeline Facilities

2018 ◽  
Author(s):  
C. M. Refaul Ferdous ◽  
Amanda Kulhawy ◽  
Jessica Farrell ◽  
Chris Beaudin ◽  
Anthony Payoe ◽  
...  
Keyword(s):  
Risk Measure ◽  
Small Diameter ◽  
Pipeline System ◽  
System Description ◽  
Maintenance Program ◽  
Inspection And Maintenance ◽  
Pressure Transmitter ◽  
Integrity Risk ◽  
Main Station ◽  
Pump Stations

The Enbridge Liquids Pipeline system is comprised of a large number of facilities including storage terminals, pump stations, injection sites, and delivery sites. Given the vast amount of small diameter piping (SDP) within company Pipeline facilities, SDP represents a significant portion of total facility integrity risk. An event such as equipment failure or product release can cause significant business impacts, and adverse consequences to the environment and/or safety of operations personnel. A quantitative risk based approach is required in order to establish robust, risk-based plans and programs to maintain the integrity of these SDP sections. Small diameter piping lengths are relatively short. Consequently, it is impractical to use SDP length as a unit of likelihood and risk measure. Instead, the preferred methodology is to determine the total number of assemblies for each type of SDP. In support of this approach, an inventory of SDP sections throughout the system has been gathered. For illustrative purposes, an example of a small diameter section would be a pressure transmitter branch connection. The isolatable section that would be risk assessed would start from the surface of the main station piping connection and continue up to the transmitter. This paper presents the framework for likelihood and consequence assessment of SDP based on the system description above. This framework quantitatively estimates the risk of SDP failure and risk-ranks SDP sections in support of implementing and establishing a system wide Risk Based Inspection and Maintenance program for SDP.

Probabilistic Assessment of Minor Mechanical Damage

2006 ◽  
Author(s):  
Patrick H. Vieth ◽  
Clifford J. Maier ◽  
William V. Harper ◽  
Elden Johnson ◽  
Bhaskar Neogi ◽  
...  
Keyword(s):  
Risk Assessment ◽  
Mechanical Damage ◽  
Residual Deformation ◽  
Evaluation Process ◽  
Assessment Methods ◽  
Metal Loss ◽  
Probabilistic Assessment ◽  
Pipeline System ◽  
Pressure Cycle ◽  
Important Field

In-line inspection (ILI) of the Trans Alaska Pipeline System (TAPS) using high resolution metal loss tools indicated 77 locations with suspected minor mechanical damage features (MDF). The tools used are able to detect the presence of a suspected feature, and measure indented dimensions, but are insufficient to detect the presence of cracks or gouges needed to reliably assess feature severity based solely on the ILI data. Excavations of 42 sites deemed most severe provided important field data characterizing residual deformation dimensions, the occurrence of gouges or cracks, and allowing a reliable field assessment of defect severity. Upon completion of the excavations, 35 possible MDF locations remained unexcavated. An engineering evaluation was undertaken to assess whether or not these remaining minor MDF pose a threat that is significant enough to warrant excavation. Multiple assessment methods were utilized including deterministic, probabilistic, and risk assessment methods. The probabilistic assessment of 35 unexcavated MDFs was performed using PCFStat; or Pressure Cycle Fatigue Statistical Assessment, which uses Monte Carlo simulation to estimate remaining fatigue life. PCFStat performs 1,000’s of simulations for each case where the input parameters are randomly selected from expected distributions. Of particular importance is the fatigue environment of the location. The results of the probabilistic assessment were used to estimate the potential for failure of remaining MDFs. The results suggest that 25 of 35 unexpected damage features had a POF of less than 10−4 over the remaining expected pipeline life cycle and thus are unlikely to fail. Alyeska considered a combination of probabilistic, deterministic and risk assessment results to decide on the actual locations to be examined. The results of probabilistic analysis also were found to support the outcome of the operator’s risk-based evaluation process.

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