Types of Defects 73

TPI

Mill/Constr.
defects

Old AC corrosion lightning

joints 0.000 20.00 40.00 60.00 80.00 100.0 120.0 140.0
Distance (mm)
160.0 180.0 200.0 220.0 240.0 260.0 280.0 300.0 320.0
22.00

22.50

23.00

23.50

24.00

24.50

25.00

25.50

26.00

26.50
T
i
m 27.00
e
( 27.50

s
) 28.00

Landslid
28.50

29.00

29.50

30.00

30.50

31.00

31.50

e
32.00

32.50

Corrosion

Pipeline Operation and Maintenance | 10.4.2014 Weld defects

Integrity by Assessment of Defects 74

Ensure Integrity by Assessment of

Defects
Weld defects
Cracks
Gouges from External Damage
Metal Loss caused by Corrosion
Dents
(Puncture)

Pipeline Operation and Maintenance | 10.4.2014


Assessment Criteria defined in Company Standard
Company Standard
Basic Principles of Pipeline Integrity;
Rules and Procedures for Verification
of Technical Pipeline Integrity
75
Internal Company Standard
Basis for Assessment of Pipeline Integrity
Describes basic principles of pipeline
integrity
Describes methods and procedures for
assessment of pipeline condition
Describes type, extent and frequency of
testing and assessment
Contains assessment criteria and limit values
Describes possible mitigating measures.
Pipeline Operation and Maintenance | 10.4.2014
 Direct (Defect) Assessment Methods 76

Non-Destructive Testing and Evaluation of Defect Geometry

Pipeline Operation and Maintenance | 10.4.2014

 Direct (Defect) Assessment Methods 77

Defect Measurement Using OPTO-CAM (3D Scanning)

Corrosion damage
Photo
Measurement of corrosion
using light/laser scanning

Digital reproduction
(3D point cloud)

Calculation of stress
distribution in surface
using FEM
Pipeline Operation and Maintenance | 10.4.2014
 Direct (Defect) Assessment Methods 78

Finite Element Analysis Vibration

analysis
Unstable slopes
Eigenvalue

Bending
Corrosion feature
assessment
Buckling

Crack assessment
Pipeline Operation and Maintenance | 10.4.2014
 Direct (Defect) Assessment Methods 79

On-Site Material Analysis

Chemical analysis
Hardness test Spark spectrometry
UCI method

Micrograph at
surface
Pipeline Operation and Maintenance | 10.4.2014
 Direct (Defect) Assessment Methods 80

Monitoring Field Measurements

Vibrations
Strain

Pipeline Operation and Maintenance | 10.4.2014

 Online monitoring

Temperature-induced stress
winter

Vergleichsdehnung (m/m)
summer

100
200
300
400
500
600
700
800
900
1000

0
03.02.1999
24.02.1999
17.03.1999
07.04.1999
28.04.1999
19.05.1999
09.06.1999
30.06.1999
21.07.1999
11.08.1999
01.09.1999
Temp.(C)

22.09.1999
Evg ME 6.2
Evg ME 6.1

13.10.1999
03.11.1999
24.11.1999
15.12.1999

mining subsidence
Stress relief following 05.01.2000
26.01.2000
16.02.2000
08.03.2000
29.03.2000
19.04.2000
Datum

10.05.2000
31.05.2000
Evg 756 m/m S=1,5

21.06.2000
12.07.2000
02.08.2000
23.08.2000
13.09.2000
04.10.2000
25.10.2000
15.11.2000
06.12.2000
27.12.2000
17.01.2001
Pipeline Operation and Maintenance |
Trend in strain following stress relief

07.02.2001
28.02.2001
21.03.2001
max.958

11.04.2001
02.05.2001
23.05.2001
81

10.4.2014
0
5
10
15
20
25
30
35
40
45
50
Direct (Defect) Assessment Methods

Temperatur (C)
 82

PIA2 - Assessment of Old Joints

until 1954 from 1955

+
800
SigV_3 SigVd_2 SigGg3_3 SigGg3_3
700
600 Spannungsnachweis
N/mm

500 Istwerte=Betriebsbedingungen
400
300
200
100
0
0 500 1000
Leitungsmeter

Theoretical Load Real Behaviour

Usage factor = (type of joint, diameter, pressure, wall thickness, grade, )

Pipeline Operation and Maintenance | 10.4.2014

 Direct (Defect) Assessment Methods 83

Metallography in Defect Analysis

Brittle Ductile/brittle

Fibers

Microstructure
Analysis with
SEM and EDX
Failure analysis Pipeline Operation and Maintenance | 10.4.2014
 84

Excavation Procedure (Corrosion Investigation)

Decision for excavation of MFL pig run feature

GPS localisation of feature

Conduction of
intensive measurement at
feature position +/- 50 m

Excavation

Corrosion study
(considering soil type, soil chemistry, type of coating, coating
condition, corrosion products, pH at coating defect and
underneath coating, scale formation, CP operational
parameters etc.)

Pipeline Operation and Maintenance | 10.4.2014

 85

Contents
OGE at a Glance, OGE Pipelines in Germany
Integrated Management System
Pipeline Design & Safety Philosophy
Pipeline Integrity Management System
Corrosion Control
Hydrostatic and Tightness Testing
Inline Inspection Techniques
Defect and Failure Investigation
Troubleshooting & Repair-Techniques
Conclusions

Pipeline Operation and Maintenance | 10.4.2014

 Repair Techniques 86

Repair of Small Defects

Grinding, Welding Patches,

Welding

Securing of Old Joints

Welding sphericial caps

Repair of Severe Defects

Split sleeve, hot sleeve,

pipe replacement
Pipeline Operation and Maintenance | 10.4.2014
 87

X 80 Pipe

Repairing by Split Sleeve

Pipeline Operation and Maintenance | 10.4.2014

 88

T-Joint

Pipeline Operation and Maintenance | 10.4.2014

 T-Joint 89

Gas flow: 106 m/h

Same Good Behaviour of Welding X 70 and X 80 in Service

Pipeline Operation and Maintenance | 10.4.2014
 Hot Sleeve 90

Testing of New Repair Method (Hot Sleeve), Example

Numeric simulation indicates
insufficient safety level Hot sleeve

Data transmission
For online monitoring

Installation of
hot sleeve

Pipeline Operation and Maintenance | 10.4.2014

 91

Temporary Repair Methods

Low Internal Pressure

Type Ruhrgas

High Internal Pressure

Type Plidco

High Internal Pressure and Coated

Pipe
Type Manibs
Pipeline Operation and Maintenance | 10.4.2014
 92

Repair Techniques

Cutting Pipeline in Areas of Ground

Movement

Inliner in Pipeline

Pipeline Operation and Maintenance | 10.4.2014

 Special Repair Techniques 93

Closure of Filter Cracks at Repairing by

or Pigging traps Welds Grinding

Construction Repairing in Repairing in

with Screws Workshop Operation
Pipeline Operation and Maintenance | 10.4.2014
 Special Repair Techniques 94

Cracks at Thermografy Simulation and

Combustor in Operation Analysis

3-dimensional Repairing Pressure Testing of New

Construction in Workshop Combustor
Pipeline Operation and Maintenance | 10.4.2014
 95

Contents
OGE at a Glance, OGE Pipelines in Germany
Integrated Management System
Pipeline Design & Safety Philosophy
Pipeline Integrity Management System
Corrosion Control
Hydrostatic and Tightness Testing
Inline Inspection Techniques
Defect and Failure Investigation
Troubleshooting & Repair-Techniques
Conclusions

Pipeline Operation and Maintenance | 10.4.2014

 96

Conclusions
Different Pipeline Standards Existing at OGE

Pipelines became older but are fully operational

Operation of pipeline for much more than 90 years is possible

Expert KnowHow for maintenance is very important

Intelligent strategies for operation of old and new pipelines are available at OGE

The DVGW technical rules (and the referenced standards) provide the
framework for construction, operation and maintenance of approx. 12,000 km of
Transmission pipelines

Pipeline Operation and Maintenance | 10.4.2014