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Solutions

Bridging Pipeline Assessment to

Pipeline Rehabilitation
June 19-21, 2006
Bucharest
by Laurent Fabry
 What comes after ILI?

ILI Service (defect detection)

Fitness-For-Service (FFS) Assessments lead to new
Pipeline Safe Operating Pressure

Various FFS Guidelines:

-API 579
-Modified B31G (RSTRENG)
-B31.8 App. L
-DNV RP F101
-BS 7910

Pipeline Rehabilitation aim is to restore original operating

conditions
 Fitness-For-Service

Fitness-for-Service will:
9 Extend design life
9 Define Safe & Reliable Operation Parameters of Pipeline

BUT FFS leads to decrease of Safe Operating

Conditions

FFS is NOT meeting the Economic Return needs of Operators!

While Rehabilitation will:

9 Maximize your profit
9 While Reducing your risk factor
 TDW & Rehabilitation
Full Products and Services offering
New revised ASME
B31.4 to be released
 Hot Tap & Stopple
Line intervention without Shutdown
Cut-out & Replace:
The Principle : Welding, Drilling and Plugging of
Pipeline under Pressure
 Welding on Live Pipelines
Complete Integrity Management Solutions
Welder & Welding Procedure Specifications Qualification
Operating P/L parameters validation during welding
How to avoid Post Weld Heat Treatment?
Line analysis - pipe stresses at every location
Finite Element Analysis - stresses in the welds
Engineering Critical Assessment - maximum allowable stable
crack in field weld
NDT Procedures developed linked to ECA results
Job Supervision continuous monitoring
Field ancillary Services:
bypass & valve installation
Pipe Cold-cutting,
 FFP
Flow Chart

INTEGRATED APPROACH
from fitting design to installation

Methodology originally
developped by Advantica.
 Welding on Live Pipelines

Welding Procedure and Welder Qualification Preheating Preparation

Online Welding Continuous Monitoring

 Welding on Live Pipelines

Water

Heat sink capacity measurement: decay time to

cool down till 100C
 How to avoid PWHT?
Step 1: Extensive Line analysis

Line analysis:
Design by Formula

Allowable stresses as per:

-ASME B31.3-2002
-IGE/TD/12

Load case combinations:

Case 1 (hydrotest) L1 = WW+HP
Case 2 (operating) L2 = W+T1+P1
Case 3 (operating) L3 = W+T2+P1
Case 4 (occasional) L4= W+P1+F1
Case 5 (sustain) L5 = W+P1
Case 6 (exceptional) L6= L2 + L5
Case 7 (exceptional) L7= L3 + L5
Case 8 (exceptional) L8= L3 + L2
where : W= weight of pipe and fluid, WW= weight of pipe and water for hydrotest load, HP = hydropressure, T1 = max. temperature 80C, T2 = min. temperature -20C,
P1 = max. pressure, F1 = concentrated loads, valves and intervention equipment,
 How to avoid PWHT?
Step 2: FEA - Sustained Case Pressure Vectors
End Closure Diaphragms and Load Beams

Finite Element Analysis:

Boundary conditions of FEA Model include the stresses
Design by Analysis
from Line Analysis.
Element 395 - PARA PLATE Element 89869 - RIGID
Element 518 - PARA PLATE Property 5 - 100mm Steel Plate Nodes: 8
Property 5 - 100mm Steel Plate Material 1 - Line Pipe Element 101 - BEAM
Material 1 - Line Pipe Property 4 - Outlet Pipe Beam
Material 8 - Split Tee Steel Beams
Element 89870 - RIGID Nodes: 4 7 8
Nodes: 28868

28868 7

Element 103 - BEAM

Property 3 - Branch Pipe Beam Element 131 - PARA PLATE
Material 8 - Split Tee Steel Beams Property 5 - 100mm Steel Plate
Nodes: 2 10 Material 1 - Line Pipe
5
4
10
Element 105 - BEAM
Property 2 - Main Line Pipe
Material 7 - Line Steel Beams
Nodes: 11 12

Node 2
Element 89871 - RIGID 6 Coord( 0 ) = 0., 0., 0.
Nodes: 5 DefCS = 0 OutCS = 0

3
2
1 Element 317 - PARA PLATE
Property 5 - 100mm Steel Plate
123456
Material 1 - Line Pipe
Node 1 11
Coord( 0 ) = 0., 0., 0.
Element 107 - BEAM DefCS = 0 OutCS = 0
Property 2 - Main Line Pipe
Material 7 - Line Steel Beams
Nodes: 5 6
Node 3
Coord( 0 ) = 0., 0., 0.
Y DefCS = 0 OutCS = 0
12
Y

Z X Element 89868 - RIGID

Z X Nodes: 12

AK3d03b: TDW 36x24x24 IN 3-way Split Tee - Rev G

AK3d03b: TDW 36x24x24 IN 3-way Split Tee - Rev G
 How to avoid PWHT?
Step 2: FEA - Sustained Stress Contours and Spot Values

Finite Element Analysis:

Design by Analysis

Deflections Scale = 100

300.

Node 10278
280.
Sustained analysis, occasional.
Coord( 0 ) = 0., 798., -295.
DefCS = 0 OutCS = 0 260.
Total Translation = 0.202211
X Translation = 0.0193497
Y Translation = -0.0279292
Z Translation = -0.199336
240. Allowable stresses as per:
Solid Tresca Stress = 253.7
220.

Node 62361
Coord( 0 ) = -292.355, 472.688, -39.41551
DefCS = 0 OutCS = 0
Total Translation = 0.541535
200.
-ASME B31.3-2002
X Translation = 0.146109 180.
Y Translation = -0.390054
Z Translation = -0.346079 Node 5176

Node 64009
Solid Tresca Stress = 271.3423 Coord( 0 ) = 292.355, 472.688, -39.41551
DefCS = 0 OutCS = 0
Total Translation = 0.534672
X Translation = -0.121996
160.

140.
-IGE/TD/12
Coord( 0 ) = -700., 459.5, 0. Y Translation = -0.391814
DefCS = 0 OutCS = 0 Z Translation = -0.342743
Total Translation = 0.416004 Solid Tresca Stress = 270.7444 120.
X Translation = 0.0750263
Y Translation = -0.264615
Z Translation = -0.312104 100.
-PD5500
Solid Tresca Stress = 277.7729
Node 6833
80.
Coord( 0 ) = 700., 459.5, 0.
DefCS = 0 OutCS = 0
Total Translation = 0.413923 60.
X Translation = -0.0527261
Y Y Translation = -0.283517
Z Translation = -0.296935 40.
Solid Tresca Stress = 277.071

X 20.
Z
Output Set: Lc5: Sustained Loads
Deformed(1.59): Total Translation 0.
Contour: Solid Tresca Stress AK3d03b: TDW 36x24x24 IN 3-way Split Tee - Rev G
 How to avoid PWHT?
Step 2: FEA - Shakedown Envelope Stress Contours and Spot Values

Finite Element Analysis:

Design by Analysis

Deflections Scale = 100

300.

280.
Shakedown analysis.
Node 67343 260.
Coord( 0 ) = -29.85178, 799.7752, -293.4857
DefCS = 0 OutCS = 0
Solid Tresca Stress = 263.2745 240. Allowable stresses as per:
220.

200. -ASME VIII Div.2

Node 62361
Coord( 0 ) = -292.355, 472.688, -39.41551 180.
DefCS = 0 OutCS = 0
Solid Tresca Stress = 284.3081 Node 5176
Coord( 0 ) = 292.355, 472.688, -39.41551
DefCS = 0 OutCS = 0
160. -IGE/TD/12
Solid Tresca Stress = 279.0742
140.

Node 64009
Coord( 0 ) = -700., 459.5, 0.
Node 6833
Coord( 0 ) = 700., 459.5, 0.
120. -PD5500
DefCS = 0 OutCS = 0 DefCS = 0 OutCS = 0
Solid Tresca Stress = 297.1635 Solid Tresca Stress = 297.1635 100.

80.

60.
Y
40.

X 20.
Z

Output Set: 11 STRESS RANGE ENVELOPE 0.

Contour: Solid Tresca Stress AK3d03b: TDW 36x24x24 IN 3-way Split Tee - Rev G
 How to avoid PWHT?
Step 3: ECA - Engineering Critical Assessment
Girth Weld Stress Classification Lines

End 1 SCL P5
Welding Residual Stresses added as
Nodes: 93917 57351
Secondary Stresses

End 1 SCL P6
Nodes: 64009 57351

End 1 SCL P4
Nodes: 93885 93917

Critical crack size

End 1 SCL P3
Nodes: 64009 57355

2.5
Y End 1 SCL P2 End_1_W eld_Pla ne_6_Code _213-T
Nodes: 105472 93885 x x x Sta ge 1/ 1 a ssm -1 Hot Critica l Cra ck: - Crack : prob-1 Hot Kr v Lr
+ + + Sta ge 2/ 2 a ssm -2 Cold Critical Crack: - Cra ck : prob-2 Cold Kr v Lr
X End 1 SCL P1
Nodes: 93926 93917

Z 2 TDW 36x24x24" 3-WAY SPLIT TEE

AK3d03b: TDW 36x24x24 IN 3-way Split Tee - Rev G

1.5

1.53

R6 Code (British Energy Assessment of the 1.72

Kr

Integrity of Structures containing defects) 1

Toughness ratio

BS7910 (Guide to Assessing the Acceptability of 0.5

flaws in metallic structures)

0
0 0.25 0.5 0.75 1 1.25

Lr
Load ratio
 How to avoid PWHT?
Step 3: ECA - Summary of The Calculated Critical Defect Size

Case ECA R6- Critical Defect Size (mm)

Plane Geometr
No
y Code Girth Weld
End 1 (-X Axis) End 2 (+X Axis)
Hot Cold Hot Cold

1 1 215 8.4 7.43 7.96 7.88

2 2 215 >15.68 >15.68 >15.68 >15.68

3a 3 9 5 2.55 4.95 2.62

3b 3 25 (1) 10.8 3.16 10.6 3.27

4 4 9 10.9 10.8 10.9 10.8

5 5 25 (2) 7.93 3.99 7.85 4.03

6a 6 213 1.72 1.53 1.64 1.62

6b 6 214 (1) 1.87 1.63 1.77 1.74

1)Elliptical crack with assumed major axis 2c = 40 mm.

2)Elliptical crack with assumed major axis 2c = 65.4 mm = diagonal of the girth weld section.
 How to avoid PWHT?
Step 4: Field NDT Procedure

Defect Acceptance criteria

linked to ECA Results.
Finite Element Analysis
STOPPLE JOB
Finite Element Analysis
STOPPLE JOB
 Finite Element Analysis
STOPPLE JOB

T48x48R2a: Blue Stream Pipeline 48x48 inch Split Tee - Sustained and Fatigue

T48x48R2a: Blue Stream Pipeline 48x48 inch Split Tee - Sustained and Fatigue
 Finite Element Analysis
STOPPLE JOB Node 244055
Deflections Scale = 100 Coord( 0 ) = 1100., 612., 0.
400.
Solid Tresca Stress = 630.2892

375.

Node 56393
Coord( 0 ) = -1100., 612., 0.
350.
Solid Tresca Stress = 633.0879
325.

300.

275.

250.

225.

200.

175.

150.

125.

Node 189969 100.

Coord( 0 ) = 573.5039, 626.6573, 0.
Solid Tresca Stress = 363.4992
75.
Y
Node 111396
Coord( 0 ) = -573.5039, 626.6573, 0. 50.
X Solid Tresca Stress = 363.824

Z 25.
Output Set: Sust'ed Lower Soil 98.5 B
Deformed(2.524): Total Translation 0.
 900# Stoppling Equipment

Previous experiences:

Tapping Machines Pressure balanced:

- TM936, Transco (2001)
- TM2460, Transco (2000) NIGC
(2003) Gazprom (2005, 2006)
TDW sa (2006)
- Subsea 1000 TDW sa (2004)

Plugging Equipment:
- 30IN 900Lbs, Aramco (2005)
- 14, 18, 20, 24, 26 IN 900Lbs,
Colombia & Equador Gas (1998)
Torque test of TM
- 14IN Services job @ 2220psi (2005)
 HT& P Services

Extreme environments
 Recent job site experiences:

Various job sites

in Plants,
Refineries
 Recent job site experiences:
Deflections Scale = 100
Node 50663 400.
Coord( 0 ) = 546., 307., 0.
Solid Von Mises Stress = 456.8241
375.

350.

325.

300.

275.

250.

Node 10859 225.

Coord( 0 ) = -546., 307., 0.
Solid Von Mises Stress = 455.5996
200.

175.

150.

125.

100.

75.
Y
Node 41672
Coord( 0 ) = 269.5, 322., 1.61399E-4 50.
X Solid Von Mises Stress = 488.1349

Z Node 20595 25.

Coord( 0 ) = -269.5, 322., 1.61399E-4
Output Set: Sust'ed Lower Soil 265 B Solid Von Mises Stress = 487.8077
Deformed(1.479): Total Translation 0.
Contour: Solid Von Mises Stress T24x24R2a: Blue Stream Pipeline 24x24 inch Split Tee - Sustained and Fatigue

SAIPEM
Stopple Fitting design 24IN 290 bar
Compressor station, Russia 2004
 Recent job site experiences:

BP-STOLT, 36IN Forties line

Subsea job 100meter depth,
Northsea, 2004
 Recent job site experiences:

Intervention on GRP P/L

Duba Airport, 2001
 Recent design experiences:

SAIPEM Bouygues Offshore

Fitting design 375 bar
Water injection, Algeria 2002
 Recent design & testing experiences:

3IN up to 12IN Taps

ASME Class 1500Lbs Flange
1,000 F at 1,200 Psi

High Temperature Tapping

1000F, USA, 2003
 Recent design & testing experiences:

100% Seal
Double Block & Bleed
No elastomer
From 4IN up to 12IN

8IN High Temperature Plugging

1000F, USA, 2005
 Plugging Pig

TDWs Isolation Tool Service uses a

remote-operated, non-tethered,
autonomous, mechanical plugging pig
technology that can isolate pipelines up
to 6000 psig or higher for a variety of
applications.

Plugging Pig Applications:

VALVE REPAIR OR REPLACEMENT: (55%)
PIPELINE OR RISER REPAIR/INSTALLATION: (10%)
TIE INS: (10%)
PIPELINE OR PLATFORM ABANDONMENT: (5%)
SUBSEA PIPE LAYING: (20%)
+ Recently HYDROTESTING

See Plugging Pig Animation

Subsea2.exe
Welded Sleeves
 BLACK DIAMOND Composite Wrap

BLACK DIAMOND is a TDW

composite repair system that
permanently restores the
maximum allowable operating
pressure of corroded or
damaged pipelines.

BLACK DIAMOND is a
structural Wrap for non-leaking
pipes
 BLACK DIAMOND Composite Wrap

WHAT IS BLACK DIAMOND?

A Carbon/epoxy composite with bi-
directional structure
A Fast curing two-part epoxy resin
with high adhesive strength
It is Light weight and Stronger than
steel
It can contain high pressures with a
low profile.
It is compatible with carbon steel,
stainless steel, alloy steel piping.
 BLACK DIAMOND Composite Wrap

HOW DOES IT WORK? Carbon Cloth

(12K X 3K)

Filler material Primer epoxy with high

pipe (putty) adhesive strength

Composite sleeve works by sharing the hoop load carried by the pipe wall at
the location of the defect.
The defect area is filled with a high compressive strength filler (epoxy) to
ensure load transfer from the defect to the carbon sleeve
The load sharing between the pipe and the composite depends also directly
on the composite stiffness or hardness the stiffer the composite the better
the pipe reinforcement.
 BLACK DIAMOND Composite Wrap

Wrap on a 32" transmission line

This Wrap was installed within one hour !!

 BLACK DIAMOND Composite Wrap

Wrap on a line operating at 177C and 4 bar

 BLACK DIAMOND Composite Wrap

Composite Wraps prevent corrosion and provide

structural reinforcement at weld seams
 LEAK
LEAK REPAIR
REPAIR CLAMP
CLAMP
PIT HOLE LEAK REPAIR CLAMP
SLIP JOINT COUPLING
FLANGE REPAIR SPLIT ENCLOSURE
FLANGE REPAIR RING
 Performance today,
Anticipate for tomorrow.

Corrosion Monitoring Systems:

Pro-active Solutions vs Curative
Better understanding of corrosion mechanisms
Provide realistic input for preventative
measures
Evaluation of effectiveness of preventative
measures
Dynamic Monitoring System

P/L Fluid is drawn into a monitoring

piping,
Water separated, and corrosion rate
Measured.
 Pipeline Corrosion Monitoring

Internal Corrosion Direct Assessment:

Dynamic Monitoring System
Corrosion coupon
Galvanic Probe Probes can be flush or
retractables
Bacteria Probe
Linear Polarization
Corrosion rate assessment
Probes installation
Thank you for your attention.