Documenti di Didattica
Documenti di Professioni
Documenti di Cultura
14059.PLI.COR.PRG
Rev. 0
March 1998
0
REV.
Emission
DESCRIPTION
CORM
CORM
CORM
March 98
COMP.
VERIF.
APPR.
DATE
Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
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14059.PLI.COR.PRG
Rev.0
March 1998
Sheet 2
FOREWORD
Rev. 0
No. Sheets 28
March 1998
Emission
Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
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14059.PLI.COR.PRG
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Sheet 3
CONTENT
1
GENERAL
1.1
1.2
1.2.1
1.2.2
1.2.3
1.2.4
Scope
Normative references
European normative references
Normative references of ISO, IEC and national organizations
Normative references of other organizations
Internal normative references
1.3
Definitions
2.1
2.2
3.1
3.2
3.3
3.4
4.1
4.2
4.3
4.3.1
4.3.2
4.3.3
Corrosion morphology
Fluid type
Pipe geometry
Diameter
Curves
Pipeline thickness
4.4
4.5
4.6
4.7
5.1
5.2
Results
Interpretation of results
Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
14059.PLI.COR.PRG
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Sheet 4
6.1
6.2
6.2.1
6.2.2
6.3
6.3.1
6.3.2
6.4
GUIDELINES
FEASIBILITY
7.1
Verification criteria
DOCUMENTATION
FOR
THE
VERIFICATION
OF
INSPECTION
Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
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Sheet 5
GENERAL
1.1
Scope
This document provides criteria for intelligent pig inspections of carbon and low
alloy steel pipelines for liquid and gas hydrocarbons, with particular attention to
the aspects related to corrosion, internal and external.
In this document, as intelligent pig is intended a device of any kind able to move
freely inside a pipeline pushed by the transported fluid, suitable to execute
measurements of thickness loss due to corrosion and to detect existing defects of
the pipe. This document does not cover the so called cable-operated intelligent
pigs or, in general, other methods for the internal inspection of pipelines.
The aims of this document are the followings:
to identify the scope of the inspection;
to illustrate the features of various types of available devices and their
advantages and drawbacks;
to provide guidelines to select the type of instrument related with the scope of
the inspection;
to provide guidelines for the planning of inspections with intelligent pigs.
Furthermore, requirements for the inspectionability of pipelines are mentioned.
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Sheet 6
1.2
Normative references
1.2.1
1.2.2
1.2.3
1.2.4
ASME B31.4
ASME B31.8
EFC N 16
NACE MR0175
NACE RP0175
NACE RP0775
for
Liquid
Metallic
06805.SLI.OFF.SPC.
02555.VAR.COR.PRG.
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Sheet 7
1.3
Definitions
Chloride Stress Corrosion Cracking - CSCC
Formation of cracks caused by stress corrosion in a water and chloride ions
containing environments (02555.VAR.COR.PRG).
Corrosion
Physicochemical interaction between a metal and its environment that results in
changes in the properties of the metal and which may often lead to impairment of
the function of the metal, the environment, or the technical system of which these
form a part (ISO 8044).
Corrosion product
Substance formed as a result of corrosion (ISO 8044).
Corrosivity
Ability of an environment to cause corrosion in a given corrosion system (ISO
8044).
Corrosivity class
It is an attribute conventionally assigned to each type of fluid in order to point out
the most significant corrosivity features. For the fluid designated: liquid
hydrocarbons and multiphase (I.L.), gas hydrocarbons and gas with condensates
(I.G.), the corrosivity classes are defined as follows (02555.VAR.COR.PRG):
N.
non containing CO2 and H2S
C.
containing CO2
S.
containing H2S
CS.
containing CO2 and H2S.
Crevice Corrosion
Corrosion associated with, and taking place in, or immediately around, a narrow
aperture or clearance (ISO 8044).
Defects
Defects include: geometric anomalies of the pipe, with a purely mechanical origin
or pre-existent (for instance indents, folds, ovalities); geometric anomalies or
porosities associated with welds, damages to the pipe caused by corrosion (for
instance losses of metal); cracks.
Dummy tool
A device that simulates, for dimensions and mechanical features, an intelligent pig.
Before inspection, it is launched with the following scopes:
to verify the feasibility of the inspection;
to clean the pipe from deposits or corrosion products that could interfere with
the measurement.
Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
14059.PLI.COR.PRG
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Sheet 8
Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
14059.PLI.COR.PRG
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Sheet 9
Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
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Sheet 10
2.1
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2.2
Corrosion monitoring
In the present document, corrosion monitoring is intended as the intelligent pig
inspection of a pipeline in order to estimate the average corrosion rate.
The most significant application of corrosion monitoring with intelligent pig
inspection regards the case of new pipelines transporting a corrosive fluid, in order
to assess, in the early operating steps, that the methods adopted to mitigate
corrosion are really suitable.
The corrosion monitoring with intelligent pig requires at least two subsequent
inspections:
a first inspection, to be performed just after the pipe has been laid, or during the
early operating phases, establishes the reference inspection;
subsequent inspections, conducted after a period of time variable from case to
case, usually not less than one year, allow, by means of a comparison with the
reference inspection, to determine the average corrosion rate in the positions
where defects have been found.
The monitoring of corrosion requires instruments able to detect small thickness
losses due to corrosion and with a good level of measurements repeatability ( 0.5
mm for the measurement of thickness losses) so that it is possible to use the results
of at least two inspections conducted in different times to evaluate the average rate
of corrosion in the period.
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Sheet 12
3.1
3.2
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Magnetic flux pigs are divided in high and low performance pigs. The main
differentiating factor is the ability of high performance magnetic flux pigs to
distinguish between external and internal defects. In order to do this, probes for the
detection of internal defects employ the eddy current technology or Hall effect
probes. The latter, by measuring the absolute value of magnetic fields (while the
traditional method measures the flux gradient), allow also the measurement of the
average residual thickness.
Magnetic flux pigs may be used without distinction for pipelines transporting oil or
gas.
Generally, they detect localised corrosion attacks better than uniform ones.
Magnetic flux pigs have a low ability to detect, and to correctly evaluate the
dimensions of defects situated by or near (up to a few centimetres) girth welds and
curves.
They are presently available for pipes with a diameter greater or equal to 6 (152
mm) and are compatible with curves whose minimum radius is 3 times the external
diameter of the pipe.
3.3
Ultrasonic Pigs
Ultrasonic pigs are instruments equipped with ultrasonic transducers positioned at
a fixed distance from the wall of the pipe. The transducers emit sonic impulses
perpendicular to the pipe walls that are reflected partially by the inner wall and
partially by the external wall. The measurement of the time interval between the
two sound echoes allows to go back directly, with good repeatability and high
reliability, to the measure of the thickness. However, the two echoes cannot be
distinguished if the residual thickness is too small or the thickness of the pipe is less
than a limit value. Actually with these devices it is possible to inspect pipes with a
thickness greater than 4 mm and smaller than 50 mm.
Ultrasonic pigs need, in order to work, the presence of a liquid phase between the
transducers and the wall of the pipe. With regard to this it should be noticed that
the presence of deposits (for example paraffin) hinders the acquisition of readings.
This imposes that:
in case of pipelines transporting gas, the pigs has to be launched inside a liquid
slug;
before conducting an inspection an accurate cleaning of the pipeline has to be
carried out.
Presently, they offer the chance to evaluate, besides conventional defects like
thickness losses, also internal defects of the material like lamination cracks,
provided they exceed a minimum dimension (20 mm).
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14059.PLI.COR.PRG
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Sheet 14
Devices are available on the market for pipelines with a diameter greater or equal
to 6 (152 mm), compatible with curves whose minimum radius is 3 times the
external diameter of the pipe.
3.4
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4.1
Corrosion morphology
Corrosion forms may be divided into the following fundamental types, according to
the attack morphology:
General corrosion: it occurs on the whole surface of the metal in contact with the
environment; it can be uniform, with a generalised and regular loss of metal on the
exposed surface, or non uniform, with corrosion penetration varying from area to
area.
The following classes may be used to express the penetration rate of general
corrosion forms (internal normative reference 02555.VAR.COR.PRG):
negligible:
< 50
m/y
low:
< 50 100
m/y
moderate:
100 500
m/y
severe:
500 1000 m/y
very severe:
> 1000
m/y
This classification, applicable to evaluate the corrosion rate expected during the
design or observed on operating structures, is different from the one proposed by
NACE RP0775. The latter, more conservative, is oriented at the evaluation of
corrosion as measured by monitoring systems, particularly by weight loss coupons.
Localised corrosion: it occurs on a limited portion of surface exposed to the
environment. The morphology of localised corrosion changes considerably,
depending on material and environment. The entity of damage does not depend on
the total quantity of oxidised metal.
Ultrasonic pigs are suitable to detect general corrosion attacks. Magnetic flux pigs,
on the contrary, are more sensitive to localised defects.
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Fluid type
Ultrasonic pigs need the presence of a liquid phase to allow an adequate contact
between the probe and the metallic wall. Therefore, the launch of pigs into
pipelines transporting gas or multiphase systems has to be conducted within a
liquid slug.
If water is employed as circulation liquid for the pig, possible corrosive effects of
the water shall be adequately prevented, for example by treating it with corrosion
inhibitors or by having the inspection followed by circulation of a slug of corrosion
inhibitor.
In case of H2S containing fluids (sour conditions), all metallic components of the
pig shall comply with the requirements of NACE MR0175.
4.3
Pipe geometry
The pipeline geometry shall be carefully considered in order to avoid block risk of
the intelligent pig inside.
The most important parameter to be taken into account are:
the diameter and its internal variations;
curves, with special regard to their angular width and radius of curvature;
the pipe wall thickness.
4.3.1
Diameter
Pipelines with a diameter between 3 (76 mm) and 6 (152 mm) can be inspected
only with eddy current pigs.
Pipelines with a diameter greater than 6 (152 mm) can be inspected with every
type of intelligent pigs.
The uniformity of the pipelines internal diameter shall be carefully considered.
Another important factor are the discontinuities in correspondence of welds.
The Contractor shall verify, in each occasion, the feasibility of the inspection in
connection with the extent and the type of restrictions existing along the pipeline.
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4.3.2
Curves
Generally it is possible to inspect pipelines whose curves have a radius greater
than 3 times the external diameter and angular width smaller than 90.
For pipelines with curves of a smaller radius, the inspection can be conducted with
suitably modified devices. The Contractor shall verify, in this cases, the feasibility
of the inspection..
4.3.3
Pipeline thickness
Selection among various types of available intelligent pigs depends on the wall
thickness of the pipeline to inspect.
It is possible to employ eddy current pigs with pipelines whose thickness is
between 3.2 and 7.1 mm.
It is possible to employ magnetic flux pigs with pipelines whose thickness is below
a limit value, depending on the pipe diameter. Generally, with diameters greater
than 16 (400 mm) the limit thickness of the pipe is 20 mm; with diameter smaller
than 16 (400 mm) it is calculated with the following relationship:
Th_max = D/20
where:
Th_max: maximum inspectionable thickness with a magnetic flux pig, in mm
D:
nominal diameter of the pipe, in mm
It is possible to employ ultrasonic pigs with pipes whose thickness is between 4
and 50 mm.
4.4
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Pipeline location
High precision and sensitivity are recommended for the inspection of sealines. For
buried pipelines, the selection of the inspection method is primarily based on
economic criteria and therefore the preferred options are those one that minimise
the inspection costs and the subsequent verification through sample excavations.
4.6
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Sheet 19
4.7
Parameter
Purpose of the
inspection
integrity
assessment
(monitoring)
ultrasounds
eddy current
monitoring
(integrity
assessment)
integrity
assessment
Corrosion
morphology
general
localised (general)
general
(localised)
general
Defects detection
internal
internal/external
internal/external
(residual
thickness)
all
all
all1
all
Max. temperature
50 C
50 C
50 C
40 C
Min. temperature
4 C
4 C
4 C
Max. pressure
150 bar
150 bar
120 bar
50 bar
Min. diameter
152 mm (6)
152 mm (6)
152 mm (6)
76 mm (3)
Max. thickness
20 mm
20 mm
min. 4 mm
min. 3.2 mm
D/Th > 20
D/Th > 20
max. 40 mm
max. 7.1 mm
1 m/s
1 m/s
1 m/s
0.25 m/s
Minimum speed
0.3 m/s
0.3 m/s
0.8 m/s
Maximum speed
3 m/s
3 m/s
2 m/s
Min. curvature
radius
3D
3D
3D
1.5 D
90
90
90
95
Required cleaning
medium
medium
high
medium
Type of
measurement
intrusive
intrusive
intrusive
intrusive
direct
indirect
Fluid type
Recommended
speed
indirect
indirect
The launch of a liquid slug is required in the case of gas
Legend:
D = External diameter
Th = Thickness
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Sheet 20
5.1
Results
The Contractor is responsible to issue the data collected in the inspection in the
form of a file stored on a magnetic computer support (floppy disk or equivalent).
The Contractor is also responsible for the supplying of a document that gathers and
highlights:
all data regarding the inspection;
all detected anomalies;
the distinction between the signals related to normal features of the pipe or its
fittings (welds, joints, flanges, valves) and the ones related to corrosion defects
detected in the inspection;
the statistical distribution of corrosion defects with respect to their depth;
the statistical distribution of corrosion defects with respect to their length;
the statistical distribution of the number of corrosion defects for linear kilometre
of pipe;
the interpretation of results with the information of the confidence intervals for
the results obtained.
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5.2
Interpretation of results
The interpretation of results is performed by the Contractor, using appropriate data
processing software.
Defects shall be ordered according to their depth relatively to the thickness of the
pipe.
The classification is made by grouping together the defects for depth intervals.
Usually a number of four damage classes are considered, whose limits are defined
case by case, according to the depth distribution of detected defects. An example
of definition of damage classes follows:
class
1
qualitative damage
evaluation
low
thickness reduction
percentage
< 20
moderate
20 - 40
severe
40 -60
very severe
> 60
In any case, the Customer reserves the right to ask further or different
classifications.
Data regarding subsequent inspections of the same pipeline shall be properly filed
with easy accessibility.
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Sheet 22
6.1
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6.2
6.2.1
Evaluation parameters
The decision to conduct the inspection requires the acquisition of the following
data.
6.2.1.1
Pipeline data
They include:
pipeline age;
residual life;
features of the pipeline material: chemical composition; mechanical properties;
welding procedures; non destructive tests results;
compliance with references normative and with design data;
corrosion mitigation methods.
The historical review of the operating phases of the pipeline shall be conducted,
with particular attention to:
evolution of operative parameters (temperature and pressure);
changes intervened in the flow rates;
changes intervened in the fluid composition, particularly in the water phase flow
rate and in the chemical composition (CO2 and H2S molar fractions in the gas
phase, chemical composition of the water phase);
corrosion events occurred;
possible pipe inactivity periods and measures adopted to control corrosion.
6.2.1.2
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6.2.1.3
6.2.1.4
6.2.2
Criteria
Some of the main aspects to consider when trying to identify the priorities of
inspection operations are reported, as guidelines, here below.
Pipelines operating from more than 10 years; they are in conditions in which
corrosion defects, that grow continuously in time, could reach critical
dimensions.
Offshore pipelines. The costs for offshore repair operation are usually very high.
Pipelines for the transportation of corrosive or untreated fluids.
Offshore pipelines located near risk areas for the environment or the population.
Large size pipelines with significant flow rates.
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Sheet 25
6.3
6.3.1
Evaluation parameters
Evaluation parameters are the same reported for the integrity control.
The analysis is targeted at aspects concerning internal corrosion, while usually
external corrosion has no a significant role in the decision about performing the
inspection.
6.3.2
Criteria
For new pipelines, the execution of a preliminary inspection at the beginning of
operations shall be evaluated during the design phase of the pipeline.
The execution of a preliminary inspection is recommended in the following cases:
Offshore pipelines for transportation of untreated fluids - non stabilised oil; wet
gas; multiphase systems - from platform to treatment plant, every time the
internal corrosivity is expected to be severe or very severe.
Onshore pipelines for transportation of untreated fluids - non stabilised oil; wet
gas or multiphase systems from production wells - to treatment plant, operating
in contact with fluids whose corrosivity is severe or very severe or with a high
corrosion probability and located near risk areas for the environment or the
population.
Subsequent inspections shall be performed after a period of 1 to 5 years, in
connection with the features of the pipe and the corrosivity of the fluids.
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Sheet 26
6.4
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14059.PLI.COR.PRG
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Sheet 27
GUIDELINES
FEASIBILITY
FOR
THE
VERIFICATION
OF
INSPECTION
Scope of this chapter is to provide, even to non experts, general criteria useful for
the execution of the feasibility verification of an inspection with intelligent pig,
prior to that one conducted by the Contractor. Only general guidelines are referred
to here below without carrying out a detailed analysis of single activities.
It is task and responsibility of the Contractor to conduct, in every case, an accurate
control of all the problems connected to the execution of the corrosion inspection
with intelligent pig.
For the procedures of execution of the intelligent pig inspection, see the internal
normative references 06806.PLI.MEC.SPC and 06805.SLI.OFF.SPC.
7.1
Verification criteria
The verification of the feasibility of the inspection shall be carried out considering
the guidelines and the requirements mentioned in Chapter 4.
As for operating conditions see Paragraph 4.7.
As for the features of the pipeline and its fittings, the pipeline can be inspected with
the following characteristics:
internal diameter uniformity, as showed in paragraph 4.3.1;
curves as showed in paragraph 4.3.2;
valves with an internal diameter equal to that of the pipe;
T connections with a diameter smaller than 75% of the nominal diameter for
pipes up to 30 (762 mm) and T connections with a diameter smaller than 50%
of the nominal diameter for pipes with a diameter greater than 30 (762 mm).
Otherwise, T connections with guide bars;
fittings that do not obstruct the passage of the pig in the pipe.
Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.
14059.PLI.COR.PRG
Rev.0
March 1998
Sheet 28
DOCUMENTATION
As for the results of the inspection are concerned, the Contractor shall provide the
following documentation:
file of measurement data as shown in Chapter 5.1;
printout of the results as shown in Chapter 5.1.
Il presente documento RISERVATO ed di propriet dell'AGIP. Esso non sar mostrato a Terzi n sar utilizzato per scopi diversi da quelli per i quali stato inviato.
This document is CONFIDENTIAL and the sole property of AGIP. It shall neither be shown to third parties nor used for purposes other than those for which it has been sent.