technical

Ensuring pipeline integrity of an unpiggable pipeline: a case study of a project including line preparation, ILI, rehabilitation, and certification
By Manuel Valdes1, Neb Uzelac2, and Luis Snchez Graciano3
1 NDT Systems & Services de Mxico, Mexico City, Mexico 2 NDT Systems & Services (America) Inc., Houston, TX, USA 3 PEMEX, Mexico City, Mexico

A total integrated certified maintenance programme was conducted to rehabilitate, modernise, enhance, and bring up to the best industry standards, the process pipeline system in Madero City, Mexico. The programme consisted of running a multidiameter ultrasonic in-line inspection (ILI) tool to determine the current condition of the pipeline and provide input for a maintenance procedure, following which integrity assessment was conducted and every integrity-diminishing feature present on the system was repaired and, finally, the line was certified. Due to the complex nature of the pipeline construction dating from 1975, and the lack of maintenance, several special modifications and special activities were necessary to enable an advanced ILI survey in a traditionally unpiggable system. ILI was chosen because its data allows for optimization of immediate and future integrity assessments and hence establishes a basis for developing the most efficient rehabilitation programmes.

he system consists of a 28 km pipeline with diameters varying from 14 inch to 16 inch and back to 14 inch again. It is located on the coast of the Gulf of Mexico and its main purpose is to transport fuel oil from Madero City refinery to the Federal Thermoelectric Central plant in Altamira. The integrity analysis used to define the project development employs ASME, BS, and API codes and standards. The total maintenance approach was divided in the following main aspects: assessing pipeline suitability and conditioning, pipeline cleaning (mechanical and chemical), geometry inspection, ultrasonic ILI of wall thickness, pipeline mapping with an inertial navigation system tool, risk assessment, fitness for purpose assessment, rehabilitation, and certification. This article will elaborate on the details on the tasks, experiences, and results of this process which achieved total success in the projected benefits. The need to restore and improve the Madero Altamira pipeline systems capabilities pushed the development of a complex maintenance programme that would involve different stages to achieve the desired final condition of the pipeline. The programme was designed to include all the necessary activities and stages that had to be completed sequentially in order to complete the rehabilitation and allow for certification, the two goals of this project. Whereas the goal of the maintenance programme were rehabilitation and certification, each step in the succession of the process was significant as it set the stage for the next one. The pipeline system dealt with in this project distinguished itself by several conditions that required technical creativity and design fitness to solve the complex issues of the line.

Figure 1: Altamira Federal Electricity Commission Thermal Power Station.

Pipeline location
Madero City is located on the north Mexican shore of the Gulf of Mexico in the state of Tamaulipas. This city is well known for a major refinery, which supplies gasoline, crude oil, oil fuel, and other products to the northeast of the country. In Altamira, a municipality located to the north of Madero City as a part of the same urban area, there is the Federal Electricity Commission (CFE) thermal power station (Figure 1) which uses the fuel oil transported from Madero refinery to generate electricity for the NE of Mexico.

Pipeline system
The pipeline system connects the Madero refinery and the Altamira CFE station, being thus of great importance to the power generation of the country; its characteristics are listed in Table 1. The main obstacles that complicated the project were the facts that pipeline is a dual-diameter line, with 14 inch and 16 inch diameter sections, and that the line was constructed more than 30 years ago. The latter fact,

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along with the changing diameter, make the pipeline unpiggable, causing difficulties for the integrity assurance process, as using ILI is one of the fundamental tools to deliver input for the fitness-forpurpose (FFP) analysis. Operating conditions of the system make it susceptible to corrosion (internal and external), mechanical damage (dents and third-party damage), ground movements, and combined defects (those containing excessive stress concentrations).

Figure 3: Receiver trap construction. Besides this, there were also other crucial modifications to the line in order to facilitate and ensure that any pig would go through the 28 km line without a problem. The concept, construction, and operation of this pipeline date back to 30 years ago when pipeline inspection services were completely different from the current advanced tools that are available to diagnose and treat pipeline assets. These all-new technologies that are offered nowadays require a minimum of conditions to be met to enable inspection, compared to the large benefits that they deliver. The modifications performed to meet those conditions, as large as they seemed, provide a substantial increase in the level of applicable methods of pipeline integrity management, as this will now be a system operating at the highest maintenance standards where periodical review and integrity assurance are feasible.

Total integrated maintenance procedure

Based on FFP analysis geared to the final condition of the pipeline system as envisaged by the operator, the project stages were designed to reach the desired final condition and, as they were so versatile in scope, this resulted in a total integrated maintenance programme being developed. Once the initial pipeline integrity was assessed and the first phase of the FFP analysis was done, the next steps towards the realisation of the final system condition could be identified. These steps were: pipeline cleaning, geometry inspection, UT ILI for metal loss, pipeline mapping, risk assessment, rehabilitation, and certification.

Pipeline cleaning
The first stage defined in the maintenance programme was the cleaning of the line. Cleaning in itself is very important and necessary for establishing the flow of product, but it is also a necessary precondition for running ILI tools, as it removes debris (paraffin, chlorides, etc.) from the pipeline walls in preparation for any inspection. Pigging traps (launchers and receivers) were installed prior to cleaning to facilitate mechanical and chemical cleaning (see Figures 2 and 3). According to an integrated maintenance analysis which considered the operating pressure, operating temperature, and composition of the hydrocarbon mixture transported, it was necessary to apply chemical cleaning of the line to remove wax and other oil fuel residues that had reduced the internal diameter of the pipeline. Three chemical-cleaning runs at 0.7 km/hour using the oil fuel for pig propulsion were applied. The liquids and solids (paraffin and sand) were recovered in a production tank designated by the operator. Chemical gaps were injected, followed by tough polyurethane foam pigs. The chemical used was a mixture of dissolved surfactants in a biodegradable ester base, developed in order to avoid other dangerous products used today as pipeline cleaners.

Figure 2: Launch trap construction.

Initial assessment of the condition of the pipeline

The starting phase of the programme was to recognise the initial condition of the pipeline and plan activities that had to be done in the next stages. The results of the initial FFP analysis pointed to the main flaws and damage present in the pipeline, as well as the next steps in the maintenance programme and the difficulties of accomplishing them. The FFP analysis was conducted with the following four main interests in mind: Security of operation Securing supply Economical operation Regulatory compliance.

An engineering evaluation of the context and stresses applied to the line was conducted and it helped defining the activities that had to be done to make the pipeline a sustainable system with the proper conditions to meet the four main requirements aimed for by the FFP. Both the FFP and the engineering evaluation showed the necessity of using ILI as the most efficient method of assessing the condition of the pipeline as a prerequisite to structuring the proper maintenance. To enable ILI, the unpiggable pipeline system had to be reconditioned and made piggable. As the system was over 30 years old quite a few modifications had to be performed, most notably installation of launchers (Figure 2) at the start and receivers at the end of the pipeline (Figure 3).

Figure 4: Cleaning pig (left) and retrieving it after the run (right).

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This chemical has strong dispersing/solving proprieties designed to penetrate the oil, paraffin, and grease deposits; it is safer than traditional chemicals as it has a high boiling point, and is biodegradable. The configuration of the pipeline (with its 16 inch and 14 inch diameter sections) made the use of conical wire brush pigs necessary (see Figure 4), one for the 16 inch section and one for the 14 inch section. Cleaning the complete system took a total of over 11,000 litres of liquid chemical.

and appurtenances (such as valves), as well as severity of dents present in the line. Information about dents is important as it has to be taken into consideration in estimating the remaining strength of the pipe, but also because some of the dents might have had to be mitigated to allow for passage of heavier and more complex ILI tools. This initial direct information was important both to create a first virtual image of the pipeline and to help create the subsequent steps of the maintenance programme.

Dents
Based on the analysis from the results of the caliper tool and according to assessment codes ASME/ANSI B31G [1] and NRF-030PEMEX-2006 [2], there were no dents to be repaired at or near the welds.

Figure 5: Caliper tool run in the pipeline.

In-line inspection
Three different ILI technologies were applied during this project: Geometry survey with a caliper tool Mapping using an inertial navigation system (INS) tool for establishing the centreline of the pipeline Metal-loss inspection using an UT wall-thickness measurement tool for evaluating the metal-loss features present in the pipe. Specially-designed and configured ILI tools with the abovementioned technologies and with the capabilities of navigating and passing through the changes in diameter in these pipelines were used. The inspections made possible the collection of all data that were needed for fracture-mechanics analysis, together with the FFP procedure. The data were collected on the following features: Dents Corrosion (internal and external) Girth and longitudinal weld defects Material (fabrication) defects Construction defects Geometry inspection.

Figure 6: Mapping or centerline tool.

Pipeline mapping
Pipeline mapping was made possible by using an inertial navigation system tool, also called centreline tool (Figure 6). This tool provides information on the location of the centreline of the pipeline in global coordinates, and gives the operator a projection of their pipeline with its absolute geographical co-ordinates. As demonstrated in this project, knowing the space coordinates of every point on the pipeline and being able to tie inch all the data pertinent to the pipeline to those co-ordinates (for example detected corrosion defects, dents, etc.), makes locating the flaws for digging much easier and more reliable.

Since this was an unpiggable system with lack of maintenance, there was uncertainty about the internal condition of the line. This implied that one of the obligatory stages of this total integrated maintenance project would be the geometric inspection of the entire pipeline. Once the cleaning process was finished, the specially-designed caliper tools (Figure 5) did not have any problems in performing the survey of the system with an excellent effectiveness and data quality. The geometric inspection provided a clear picture of the internal diameter of the pipe and allowed visualisation of the inner wall conditions, as well as ensuring the passage ability for the other instrumented tools (the ILI tools) that would give further and specific information on the state of pipeline integrity. Besides giving reliable information on the pipeline by measuring diameter reductions, the caliper run also provided information on wall-thickness changes, locations of girth welds

Figure 7: UT wall thickness measurement tool.

Metal-loss inspection
The most important part of the ILI stage was the inspection for metal loss for which an UT wall-thickness measurement tool (Figure 7) was selected, as it provides the most accurate sizing of metal loss. The tool detects, locates, and sizes metal-loss features such as corrosion, gouging, and pitting for example, and is also capable of detecting and sizing mid-wall defects such as laminations, inclusions, and hydrogen inchduced cracking. The results provided by this inspection revealed the following features:

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Figure 8: External corrosion at 3,887.37 m from start of the pipeline.

External corrosion
In this project 1,793 corrosion anomalies (Figure 8) were detected on the external side of the pipe wall with different depths of metal loss (expressed as a percentage of the wall thickness): 20 per cent: 762 2 per cent to 40 per cent: 933 41 per cent to 60 per cent: 75 61 per cent to 80 per cent: 23 > 80 per cent: 0 There were no any anomalies of 80 per cent or deeper present in the line and, according to the average defects found, external corrosion in the line was graded as moderate to severe.

Internal corrosion
As a result of the ILI, 14 anomalies were located at the inner walls of the 28 km pipeline. These anomalies were metal loss due to internal corrosion and they were also classified by percentage of wall penetration: 20 per cent: 13 21 per cent to 40 per cent: 1 41 per cent to 60 per cent: 0 61 per cent to 80 per cent: 0 > 80 per cent: 0 There were no internal anomalies present above 40 per cent of the wall thickness and because of their severity average the internal corrosion was graded as light.

length, and pipe wall thickness. Using these criteria to evaluate the anomalies and code API 1160 [4], 18 external defects were found with an ERF higher or equal to unity that therefore must be considered for immediate repairs. Table 2 shows the anomalies with ERF 1 that were rehabilitated during this project. Also, based on these evaluation criteria, it was determined that there were no internal defects that had to be immediately repaired. Additionally, for the internal and external anomalies detected, it was possible to project ERF values to three, five, and eight years in the future, using operating parameters and conditions of the pipeline. Based on that, beside the anomalies selected for immediate repair mentioned above, another 19 external defects were forecast as candidates for repair in the next three to eight years, although none of the internal ones. Based on repair analysis of the pipeline features according to modified ASME B31G [1], the recommended repair method was sleeve type A. Whenever it was possible, a more complete rehabilitation was done, making pipe section changes or using pressurised sleeve procedures; in this case, however, the budget and the character of the anomalies themselves led to the decision that the type A sleeve was the appropriate method. In case where there was a small defect presenting some kind of filtration, sleeves of type B would have been used. The recommended repair procedures were based on and in compliance with Pemexs internal and international codes: ASME B31.4 (2002) [3] ASME B31.8 (2003) [5] ASME B31.8S (2004) [6] API 1160 (2001) [4] NRF-PEMEX-030-2006 [2]

Rehabilitation
Based on the maximum operating pressure (MOP) provided by the pipeline operator, a system was created to attend to the more severe anomalies using an estimated repair factor (ERF) according to codes NRF-030-PEMEX-2006 [2] ASME B31G [1], B31.4 [3], and modified B31G [1]. The ERF was calculated for each one of the 1,793 anomalies presented in the inspection results and all of the anomalies with factors equal or above unity were selected for repair. The ERF can be calculated from the expression: ERF = MOP/Pcalculated Where Pcalculated is the safe operating pressure in the pipe with the defect. The maximum safe operating pressure is calculated using the features of anomalies such as defect area, depth, axial

Figure 9: Sleeve principles.

Type A metal sleeve

This method consists of two halves of pipe carefully placed surrounding the outer wall of the pipeline over the area of interest and welded axially together (see Figure 9). A filler material is used between the sleeve and the pipe, usually an epoxy grout that prevents further growth of the defect. This kind of sleeve is convenient as there is no direct welding to the pipe, it is considered as permanent repair (internal corrosion being an exception), and is fairly simple to apply. Repair of some of the anomalies was quite challenging: examples of this are the flaws at the odometer marks of 11.194 km and 15.121 km, which were specially complicated given the configuration and context of the pipeline.

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Figure 12: Rehabilitation of anomaly at 15.121 m. Figure 10: Rehabilitation of anomaly at 11,194.27 m.

Conclusion
A total integrated certified-maintenance programme was designed and conducted on a 30-year old pipeline of extremely high importance to the economy of northern Mexico. The programme incorporated pipeline retrofitting to make the pipeline piggable, running a range of ILI tools, rehabilitating the line, and finally certifying it for further operation. The pipeline was brought into such a condition that integrity-management programmes according to the latest standards can be conducted in the future. In addition to the rehabilitation and extending the results of ILI, a cause analysis was made to determine the possible origins of the faults that had developed in the pipeline. This part of the integrity assessment will allow the pipeline operator to set parameters for preventive actions to be taken. Possible failures in coatings and cathodic protection systems were studied; for this, the efficiency of the anodes and current drainage were verified, along with the soil-pipe potential, and the efficiency of the installed and maintained cathodic-protection systems, as external corrosion is related to malfunction of the coating and cathodic-protection systems [7]. Other investigations were performed, in which the soil pH, the soil humidity percentage, and mechanical protection were analysed. As part of the preventive process, it is important continuously to review the external-corrosion progress and the cathodic-protection effectiveness. Measures were also taken at surface facilities to allow pig launching and retrieval with the same ease in the future. Finally, based on this total integrated programmes results, and due to the advanced external corrosion in some sections, a reinspection interval of five years from the time the project was finalised was recommended. Reinspection time may vary according to the further conditions of the pipeline, such as functioning and operating of preventive systems and soil and weather conditions.

Anomaly at 11.194 km
This anomaly was located at exactly the middle of a federal highway (see Figure 10) in the state of Tamaulipas. Performing a fast and accurate repair was vital to affect the state traffic as little as possible. Besides having to obtain a federal permission to excavate, organize a traffic detour, and deal with the substantial depth of burial of the pipeline, there was an additional difficulty to the repair: the raid flooding of the excavation site. With a great team and hours of uninterrupted work, the repair, from the start to the final coat of asphalt, was done in less than 36 hours.

Figure 11: Rehabilitation of anomaly at 15.121 km.

Anomaly at 15.121 km
This was a flaw that was especially difficult to repair as it was located directly underneath a railway line (Figure 11), which is the main supply and distribution means of transport for the nearby industries. One chemical plant, in particular, produces and consumes large quantities of gases that are transported in and out of the plant solely by this railway. To make sure the anomaly had been correctly located, a confirmation correlation of the nearest girth weld was made. This was made possible by the results of the mapping (centreline) tool which provides geographical coordinates for the entire pipeline, including locations of detected defects, and which can easily be confirmed using GPS location devices. The repair was demanding as it involved dismantling the railway lines, cutting the outer wall to reach the pipeline, mounting the sleeve (Figure 12), backfilling the excavation, and final restoration of the railway; all was performed at the fastest possible pace to allow the trains waiting on stand-by to resume their daily schedules as quickly as possible. In this case, reaching the pipeline also included cutting the first cover wall that had been constructed to protect the pipeline from ground movement and compression incurred when a train passes over the pipeline.

References
1. ANSI/ASME B31G-1991 (R2004), Manual for determining the remaining strength of corroded pipelines: a supplement to B31, Code for pressure piping. American Society of Mechanical Engineers, 1991. NRF-030-2006, Design, construction, inspection and maintenance of ground pipelines for hydrocarbons transport and collection. PEMEX Internal Regulations, 2006. ANSI/ASME B31.4-2006, Pipeline transportation systems for liquid hydrocarbons and other liquids. American Society of Mechanical Engineers, 2006. API Standard 1160, Managing system integrity for hazardous liquid pipelines. American Petroleum Institute, 2001.

2.

3.

4.

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5.

6. 7.

ANSI/ASME B31.8-2007, Gas transmission and distribution piping systems. American Society of Mechanical Engineers, 2007. ANSI/ASME B31.8S 2004, Managing system integrity of gas pipelines. American Society of Mechanical Engineers, 2004. NFR-047-2002, Design, inspection and maintenance of cathodic protection systems. PEMEX Internal Regulations, 2002.

System Characteristics Origin Destination Length Diameter Spec Grade Wall Thickness Fabrication Date First Operation Product Madero Refinery Altamira CFE Station 28,028 km (17,518 miles) 14-16 -14 API-STD-5L X-52 0.375 (9.525mm) 1975 1977 Oil Fuel

Table 1: System characteristics.

Table 2: Features selected for repair based on the ERF (Estimated Repair Factor).

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