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. WT Ir\lm) 14.3 12.7 9.5 8.7 7.1
Figure 1-7. Typical pipeline grade cost
could cause pipeline pressure to exceed the maximum design pressure set by the pipe
strength and wall thickness. Without surge-mitigating facilities the pipeline couId rupture,
resulting in environmental and mantenance implications.
Sudden valve closure n liquid pipclines (e.g., crude oil) may create a low- pressure
stuaton that in extreme cases can lead to vapor pockets in the lineo Snce the collapse of
vapor pockets can damage the pipeline, this condition has to be avoided.
PIPELINE PROTECTION
External Protection
Buried pipelines are subject to external corros ion caused by the action and composition of
the soils surrounding them. During the design stage, the available types of externa' coating
material and cathodic systems required to protect the pipeline from external corrosion are
18 Pipeline Design and Construction: A Practical Approach
evaluated. The coating and cathodic protection are chosen according to economics and
ability to pnoct the pipeline.
External coating is usually a plastie material that is wrapped or extruded onto the pipe
or fusion-bonded to the surface. Externa! coatings have to be designed to serve as a
corrosion banlcr and to resist damage during transportation, handling, and backfilling.
Therefore, in sorne cases corrosion protection coatings are combined with other external
coatings, such as insulation, rockshield, or concrete.
Internal Protect1oo
Fluids containing corrosive components such as salt water, hydrogen sulphide (H
2
S), or
carbon dioxide/monoxide can cause internal corrosion. Many of the internal corros ion
problems can be corrected in the design stage. This is done by proper design and
selection of materials appropriate for the fluid to be transported. An example is the
pipeline transportation of sour gas. The typcs of corrosion that can occur in sour gas
pipelines are:
Hydrogen-induced corrosion
Hydrogen-induced cracking
Sulphide stress cracking (hydrogen embrittlement)
Pitting corrosion
General corros ion
Erosion corros ion
Hydrogen-induced cracking such as blistcring has been observed in both low- and
high-yield-strength steels under both stressed and nonstressed conditions. Hydrogen
blistering and cracking results from the diftuson of atomic hydrogen, produced by the
corrosive eIcmcnts in a we! H2S environment, into the stecl, where it is absorbed in
laminations or nclusions in the pipe walL
The atomc hydrogen changes to nondiffusible molecular hydrogen, building up high
localized pressures that cause blisters or cracKs in Ihe pipe waUs. The design wilI set the
stage tor the protection of the pipe against such a failure by specfying the lmits on the
folIowing:
Quantites 01' eerium or other rare eartb metal s to spheroidize manganese sulphides
Leve! of sulphur content
Level 01' copper content (up to 0.3%) to reduce the hydrogen absorpton properties of
the slrel
The exact mechanism 01' sulphide stress cracking or hydrogen embrittlernent is not
c1earIy understood; however, it is generally agreed that it is influenced by three
environmental, metallurgical, and stress-related. Environmental factors include pH, H2S
concentration and temperature. Metallurgical variables inelude strength or hardness,
ductility, compositon, heat treatment, and microstructure. The susceptibility of a steel to
sulphide stress cracking ncreases with increasing hardness and stress and also with
decreasing pH level of Iiquids. Sulphide stress cracking is evidenced as a reduction in the
normal ductility and the embrittlement of steeL
A specification for the line pipe material developed at the design stage ensures that the
pIpe produced is suitable for the operating temperature that will be encountered and is not
Elements of Pipeline Design 19
::Ilsecptible to hydrogen-induced corrosion. Pitting corrosion results from chemical attack at
luw points where fluids settle and accumulate in the piping system. Sulphate-reducing
bacteria may also cause pitting corrosion.
General corros ion results from chemical attack and usually occurs on the upper half of
tlle pipe wall adjacent to low arcas where the pipe wall is altemately wet and dry. The use of
corrosion inhibtors has proven to be the only effectve method to mtigate intemal
curros ion in wet sour gas pipelines. On-stream piggng facilities are generalIy incorporated
inlo the design of the system to permit the removal of lquid accumulation on a schedule.
UIl::;tream pigging also improves the distributon of the corrosion inhbitors and is a
valuable aid in the mitigation of intemal corrosion.
Erosion corrosion results from impingement of fluids/chlorides on the pipe surface at
1 1 1 ! ~ h tlowing velocities. Piping is generally sized to limit flowing velocities below the
critical velocity at which corroson erosion will begn to occur. Critical velocity is defined
as the point at which velocity is a significant factor in the removal of inhibitor films or
corros ion products.
"'>1 PElI" r: F,.\ ffGRITY MONITORI NG
No matter how well pipelines are designed and protected, once in place they are
subjected to environmental abuse, extemal damage, coating disbondment, soil movementJ
jnstability (Wong et al. 1988) and third-party damage. Figure 1-7 ilIustrates an example
01' a type of damage recordcd on transmission lines in the United States (Crouch et al.
1(94).
The goal of any pipeline integrity program is to prevent structural integrity problems
'mm having a significant effect on public safety, the environment, or business operations
Chem.ical,
Baclelial
4.0%
..EnvironmenLaliy
" tm,en
[)
Malerials and
Consrrucon
OulSide Force.
~
Figure 1-8. Pipeline incidents related to line pipe
,
J
i
20 Pipeline Design and Construction: A Practical Approach
by identifying and petfonning the most efl'ective inspection, monitoring, and repair
activities.
Integrity Assessment Methods
There are several tcchniques available to assess lhe integrty ol' the pipeline once it's in
place. These are surnmanzed as l'ollows:
Visual inspccton
Oepth ol' cover survey
External nondestructive testing (NOT)
Radiography
Magnetic particle testing
Oye penetrant inspection
Ultrasonic inspection
Cathodic protection monitorng
Coatng disbondment and damage survey
Hydrostatc testing
Geometry in-line inspection (TU) tools
Calper pig
x, y, z geometry (inertial guidance) tool
Ultrasonic in-lne inspection tools
Conventional magnetic tlux
High-resolution magnetic flux (30)
Utilization of high-resolution tools facilitates an accurate prediction ol' external anei
internal corros ion areas (Grimes 1992).
Risk Assessments
Risk assessment is an integrity management tool and its purpose is to identify and quantify
the risks associated with pipeline operation. such that remedial action can be performed in a
timely manner. This is achieved through the ranking of potential rsk to safety, environment,
and operations.
Several risk assessment methods are used by the industry. The most common are
failure probability mcthods and ranking systems. The most approprate method depends
upon several l'actors, including system complexity, availabi!ity of historcal data, and rigor
required by the analyss (Trefanenko et al. 1992).
Pipeline integrity and management decisions are made much easier by the risk
assessment and prioritization process, which establishes a firm, documented basis for
determining expenditures and schedules (U rednicek et al. 1991).
Pipeline Repairs
Once an integrity assessment method establshes a requirement for pipeline repair, there are
severa! methods that are cornmonly used by the industry to restore pipeline integrty:
Local coating repairs
Coating rehabilitation
Sleeve repair
Cutout repairs
Elements of Pipeline Design 21
Use of each repair system depends on Ihe extent of damage or corrosion problem, but
repairs are carried out lo restore the integrity of the pipeline to assure its intended
operational capacity.
!\sante, B., Luk, w., and Lixing, M., J993, "Pipeline System Optimization: A Case Study of Quinghai Gas
Pipeline," Proc. 12th lnternatonal ASME OMAE Conference, Glasgow, Scotland, Volume V, Pipeline
Technology, pp. 385-393.
\SCE, 1975, Committee on Pipeline Planning, "Pipeline Design for Hydrocarbon Gases and Liquids:
Report of the Task Committee on Engineering Practice in the Design of Pipelines," New York, NY
Crouch, A. E., Bubenik, T. A., and Bames, 8., 1994, "Outlook on In-Line Inspection for Stress Corrosion
Cracking," Pipeline Pigging & Integrty Montorng Conference, Houston, TX.
'jrimes, K., 1992, "lnspection Technologies for a Wide Range of Pipeline Defects," Pipeline Pgging &
Inspectioll Tedmology Conference, Houston, TX.
t<atz, D.L, et al. 1959, Handbook of Gas Engneering, McGraw HiII Book Co., New York, NY.
.(ung, P., and Mohitpour M., 1987. "Non-Newtonian Liquid Pipeline Design and Simulation Using
Microcomputers," Prac. ETCE Conference, New Orleans, LA.. PD-Vol 3, pp. 73-18.
Lester, c.8., 1958, Hydraulics for Pipelines, Oilden Publishing Co., Houston, TX.
Mohitpour, M., 1977, "Sorne Technical and Economic Aspects of High Pressure, Long Distance, Large
Diameter Gas Transmission Pipelines." Prac. 16th AlRAPT Conference, University of Colorado,
Boulder, Colorado.
. , 1987, "A Guideline Manual for Design 01' Hydrogen Pipeline Systems," NOVA Internal Report,
Calgary, Alberta, Canada.
__._, 1991, "Tempcrature Computaton in Fluid Iransmission Pipelines," Prac. ASME ETCE
COllference, Volume 34, Pipeline Engineering, pp. 78- 84.
M., and Kung P., 1986, "Gas Pipeline Hydraulics Design and Simulation: A Microcomputer
Application," Proc. Conference Society for Computer Simulation (SCl), San Diego, CA.
Mohitpour, M., and McManus. M.. 1995, "Pipeline System Design, Construction and Operation
Rationalization," Prac. ASME 14th OMAE Conference, Copcnhagen, Denmark, VoL V, Pipeline
Tcchnology, pp. 459-467.
Moody, L. E, 1944, "Fricton Factors for Pipe Flow," Imnsaction ASME, 66, p. 671.
Stuchly, J. M., 1977, Elements of Pipeline Enginecring, Canuck Enginccring Ud., unpublishcd Training
Course \'1aterial.
Ircfenanko. B., Coutts, R.. Ronsky, D., and McManus, M., 1992, "Risk Assessment an Integrity
Managemcnt Tool," Pipeline Risk Assessment, Rehabilitaton and Repar Con(erence, Houston, TX.
Urednicek M., Coote. R. L, Coutts, R., 1991, "Risk Assessment and Inspection for Structural Integrity
Managcment," PiPeline Pigging & lnspection Technology Conference, Houston, IX.
Withers, V. R., and Mowll, R. T. L., 1982, "How to Predict Flow of Viscous Crude," Pipeline Industry.
Wong, F., Mohitpour, M., SL J. Price, J., Porter J., and Ieskey, W. F., 1988, "Pipeline Integrity Analysis and
Monitoring Systems Show Defomlation Behaviour," Praceedings o( the 7th Annual ASME-OMAE
Conference, Volume V, Houston, IX, pp. 1 158.