Managing the integrity of pipeline assets

Transcription

1 ROSEN Integrity Solutions Managing the integrity of pipeline assets

2 Pipeline Integrity Services ROSEN: Leading the way in integrity management The safe and efficient operation of major transmission pipe lines is an important issue for many stakeholders, including pipeline operators, landowners, regulatory bodies, national and local governments, and the general public. At ROSEN, we provide specialized engineering, integrity assessment and data management services that support operational decision-making. The key aims for pipeline operators are to reduce downtime due to unforeseen events define cost-effective inspection plans and inspection intervals avoid unnecessary repairs and interventions during standard operation extend asset life without compromising the principles of safe operation Cost New Construction Inspection Inspection Interval Repair Avoid Repairs/Interventions Operation Reduction of Downtime Downtime These objectives are influenced by a range of legal and financial factors, including compliance with legislation and company policies maximizing asset value and production targets operational life extension centralized approach for integrity management The ultimate driver for us is to help our customers balance these factors and make informed decisions to ensure that they meet their business targets while maintaining a safe and reliable asset base that does not harm the environment. Decommission Extension of Lifetime Time Schematical view of total spendings during pipeline service life Drivers and Policies: How ROSEN can help ensure compliance with industry regulations Codes and standards issued by regulatory bodies provide guidance to pipeline operators on how to maintain the integrity of their assets. ROSEN s product and service portfolio is aligned with core industry framework documents and codes. System definition and data gathering ROSEN supports its clients in reviewing and implementing their integrity programs down to the creation of integrityrelevant procedures and processes. Threat assessment Adopting both qualitative and quantitative approaches, we utilize the data and subject matter expertise of our engineers and our clients to determine the presence of potential threats along a pipeline route. Risk analysis and inspection strategy On the basis of an evaluation of potential threats and the likely consequences of specific failure events, ROSEN assists customers in implementing risk-reduction and mitigation measures. As part of this service, we determine the most cost-effective inspection strategy including the most appropriate technology for assessing the identified threats. Action plan execution In addition to our best-in-class in-line inspection services, ROSEN offers further inspection measures that help pipeline operators identify and verify threats. Examples are above-ground survey projects, geotechnical assessments as well as remote sensing projects. To optimize corrective measures based on inspection findings, ROSEN provides follow-up analysis such as fitness-for-service assessment and corrosion growth studies. System Definition Data Gathering Threat Assessment Risk Analysis and Evaluation Action Plan / Inspection Strategy Action Plan Execution Response to Findings Information Analysis Unified Integrity Management Process Response to findings ROSEN integrity specialists have extensive experience in selecting the most appropriate rehabilitation method for identified defects. In addition, we ensure that the right data are collected during field verifications. The information collected on site provides highly useful input for assessing the quality and reliability of inspection data and can additionally be used for further analysis. Information analysis ROSEN Business Consultants support the process of reconciling integrity aspects with commercial considerations. This reconciliation is achieved, for example, by connecting our integrity systems to SAP and Maximo, resulting in a centralized approach for the Pipeline Integrity Management System (PIMS). 2 3

3 Pipeline Engineering and Consultancy Services ROSEN integrity products and services Portfolio: What ROSEN can offer Engineering and consultancy services Based on our strategic partnership with MACAW Engineering, we provide the following integrity based services: ILI feature review and corrosion mechanism diagnosis Fitness For Purpose (FFP) assessment Future integrity management planning Corrosion Growth Assessment (CGA), including raw signal data comparison Remaining life assessment Risk assessments and Risk-Based Inspection (RBI) implementation Pipeline Integrity Management System (PIMS), including reviews and recommendations Materials and welding consultancy Failure investigation (including laboratory based services) Integrity software implementation services The ROSEN Asset Integrity Management Software (ROAIMS) for pipelines is recognized as one of the industry s best integrity management software suites. Utilizing ROAIMS, we perform the following activities with the final goal of creating auditable standards of integrity: Client-specific enterprise interfaces Client-specific algorithms for defect and risk assessment On-site and off-site data gathering and processing Data quality evaluation (QA/QC) Data management services Data services: from high consequence area evaluation to comparison of ILI data with as-built information, ROSEN performs various data analysis services. The analysis is typically conducted using a structured data model such as PODS. Geo-services: using GIS technology, we perform geotechnical threat and environmental change assessments; also pipeline movement is analyzed combining inertial mapping results from in-line inspections with satellite and aerial imagery. Risk Assessment Risk assessment involves identification and evaluation of threats, failure modes and potential consequences for pipelines. Based on methodologies customized to client system requirements, such risk assessment provides the clear direction and priorities required for the development and implementation of Integrity Management Plans (IMP). Ensuring compliance with the relevant safety, health, environmental protection and quality regulations, risk assessment and management aim at improving security of supply, maintaining safe operations, reducing risk to human health, and avoiding environmental damage. Key steps include: Holding client workshops to determine available data and risk model customization requirements Client system definition and segmentation Threat/hazard identification Threat susceptibility assessment Consequence analysis Risk result presentation as per client-specific requirements Prioritization of future integrity actions Immediate integrity assessment Immediate integrity assessment provides expert analysis of inspection findings and corrosion mechanisms to determine the current integrity of the pipeline (i.e., at the time of the last inspection). Key steps include: Summarizing feature distributions and identifying activity hot spots Characterization and diagnosis of reported corrosion Consideration of High Consequence Areas (HCAs) for activity prioritization Assessment of metal loss features in accordance with applicable international/regional codes Assessment of other features (e.g., dents) reported by the inspection Identification and prioritization of features requiring repair Utilizing our product ROAIMS for the analysis execution, the client decides whether results are provided in analog report or in a populated version of the software. Risk matrix is one of the main tools used to visualize assessment results. 4 5

4 Corrosion Growth Assessment Corrosion growth assessment documents changes between repeat inspections and on this basis estimates corrosion growth rates for input into FFP assessments. Key steps include Alignment of repeat inspection data by normalizing it to common reference points (e.g., girth welds). Automatic feature matching process, resulting in calculated corrosion growth rates between inspection intervals. Raw signal data comparison, to validate the calculated growth rates based on feature matching. Feature resizing (where required) of selected features conducted by data analysts to further validate corrosion growth rates. Matching of other reported features (e.g., dents) to determine possible pipeline damage between inspections. Future Integrity Planning On the basis of the findings of integrity and CGA assessments, future integrity planning makes recommendations for future corrosion prevention and control methods. It also provides the technical basis for defining repair and maintenance plans to ensure safe and cost-effective operation in future. Key steps include Reviewing available pipeline data (e.g., above ground surveys, CP data, excavation data, repair/rehabilitation data) and correlating it with inspection findings. Estimating future growth behavior of reported corrosion and its influence on the future integrity of the pipeline. Provision of the technical basis for defining repair and maintenance plans to ensure safe and cost-effective future operation. Making recommendations for optimum re-inspection intervals and the most appropriate inspection technology. Recommendations for modifications/improvements to current corrosion prevention and control measures. PIMS Process review and implementation A Pipeline Integrity Management System (PIMS) relies on a number of core elements such as people, procedures and methodologies, as well as data and software. To be effective, a PIMS must: Have clearly defined objectives and Key Performance Indicators (KPIs) Be supported by an effective staff organizational structure and training program Have good access to accurate and comprehensive pipeline data Be aligned with existing operational and maintenance procedures and practices Be supported by appropriate software enabling regular review of pipeline risks and outputs that fit client metric system; these reviews then form the basis for informed decisions to ensure safe and economic pipeline operation Be regularly updated to incorporate changes such as regulatory updates, technological improvements and modified pipeline threats As part of our service, we define procedures to enable effective interaction between all PIMS components. These procedures aim to achieve all integrity objectives and ensure that every single task performed is controlled, and validated and that it contributes to integrity. Based on broad experience in PIMS implementation for onshore and offshore assets worldwide, ROSEN defines customer-specific processes taking into account international guidelines and codes. Our consulting team consists of experienced individuals working in the fields of process safety, risk-informed decision-making and management system audit and evaluation. During the implementation of a PIMS, a specialized team evaluates existing integrity management systems and procedures as well as asset-specific information. On the basis of this evaluation, established processes are verified and measures recommended to continue achieving goals related to safety, integrity management, compliance and reliability. External corrosion is one of the primary threats to pipeline integrity 6 7

5 Pipeline Integrity software implementation services ROAIMS Implementation Integrating Asset Integrity Management Software into daily business processes is not a trivial task. Existing data sources, software packages, processes, procedures, and industry standards must all be considered to ensure proper integration. At ROSEN, we understand the importance of established processes and ensure that our system interfaces with, and acts as a complement to, the customer s existing IT landscape. To ensure smooth compatibility, the following services are provided as part of integrity software implementation: PIMS gap analysis and recommendations IT environment consultancy and enterprise integration ROAIMS software implementation and installation Client-specific enterprise interfaces (GIS, CMMS, DMS) Client-specific algorithm development, e.g., defect and risk assessment Data quality evaluation (QA/QC) Training that enables users to perform software-related tasks independently Hosted solutions Technical support ROAIMS Overview: Data & Integrity Management Modules ROAIMS is a modular software suite covering all components of an effective integrity program. Some of the key differentiators that make ROAIMS a leading industry product are: Integrity know-how: ROAIMS is designed in cooperation with leading engineers and operators for maximum practical application Global reach: functionalities reflect the needs of companies around the globe rather than a single legislative scenario Centralized approach: based on project work, ROAIMS offers critical analytical capabilities in a single product. Its modules cover all aspects of the daily work of integrity engineers, such as data alignment, corrosion comparison and risk analysis. Provider-independent inspection data management and analysis, including in-line inspections, above-ground surveys and offshore integrity measures GIS-enabled design: ROAIMS presents all records in a spatial context; fully integrated interfaces with pipeline GIS products available. Integration with existing business processes: tracking of integrity plan activities; compatible with the Computerized Maintenance Management Software (CMMS) system Proven and configurable risk model, can be accessed by the user at all times Local support: with access to resources in all major oil and gas hubs worldwide, ROSEN provides support well beyond the implementation phase 8 9

6 Pipeline Data Management Services Data Management Services ROSEN provides data services starting from the recreation of stationed pipeline centerlines to spill modeling as the basis for high consequence area analysis. Based on our vast experience with in-line inspection records we utilize this detailed source for comparisons with previous inspections and quality checks of as-built data. Examples of services are: High consequence area/class location analysis to determine which segments of an operator s transmission system are located within High Consequence Areas. In-line inspection data box-matching: independently of the inspection service provider used in the past, ROSEN aligns in-line inspection records and applies a configurable matching metric to identify potential change. The results are typically utilized for detailed integrity analysis and corrosion growth assessments and thus as a basis for prioritization and safety decisions. Pipeline as-built data validation: in-line inspections provide highly accurate information on wall thickness changes, casings, and installations, etc. ROSEN aligns and compares this data to a given centerline and identifies inconsistencies as a basis for potential route adjustments. Geo-services Geographical information plays a major role in assessing pipeline conditions. With pipeline right-of-ways often in unstable and potentially changing terrain, linear assets are prone to geotechnical hazards such as ground movement. ROSEN connects the physical parameters of the pipeline route with environmental factors to identify high-risk areas. For such GIS-enabled services we utilize various spatial datasets as well as results from inertially-enabled in-line inspections. ROSEN provides a range of GIS analysis and integration services, including: Remote sensing acquisition: through its international network, ROSEN transmits remote sensing data. In combination with an XYZ mapping survey, highresolution imagery provides excellent snapshots allowing identification of nearby construction activities. Environmental change assessment: to help clients understand external influences on their assets, ROSEN offers a range of environmental analyses and indicators to determine potential impact. Geotechnical assessment: a GIS-based service for pipeline operators to determine geotechnical risk to pipeline assets. Pipeline movement assessment: evaluation of pipeline displacement based on XYZ mapping data collected in the course of a single or consecutive inspections

7 Integrated Asset integrity Services Full-Circle Support ROAIMS Support Provided by trusted industry experts, ROSEN s integrity portfolio covers most needs arising in connection with the execution of an integrity program. System Definition Integrity Program Review Implementation, Training, Support Software Product Definition GIS Integration Rather than in isolation, ROSEN offers its services as a complete integrity package. Clients typically involve ROSEN integrity engineers in their day-to-day work, thereby benefiting from ROSEN s expertise gained in projects worldwide. Data Gathering Risk Model Updates Alignment & Integration Geo-Services Assessment Code Implementation Pipeline Data Services Hosting Services Typical long-term involvements include: Data gathering and integration: ROSEN data experts collect and align data for critical major integrity records, either remotely or on site. Risk analysis: integrity engineers implement the anticipated risk model together with the operator and take ownership of feeding and running the required algorithms. Results are discussed with the operator s integrity team and action plans are defined. Post inspection assessments: together with MACAW, ROSEN provides advice on immediate, medium and long-term maintenance and repair activities, even if the existing asset data was obtained through other service providers or inspection methods. Information updates: records are maintained from any in-field activities. These records are very valuable for future integrity analysis. ROSEN data experts make sure information is linked and aligned to the right components, so that future assessments can leverage it to their benefit. Threat Assessment Risk Analysis and Evaluation Action Plan Inspection Strategy Design Action Plan Execution Response to Findings Conduct Risk Assessment Development of IM/MTN Strategy Risk Reduction and Mitigation Inspection Strategy (Tech / Timing) Cleaning XYZ Mapping Geometry Inspection Metal Loss Inspection Crack Inspection Field Verifications Repair Selection / Recommendation Aboveground Surveys FFP Assessments Corrosion Growth Assessments Bending Strain / Movement Repair Optimization Pipeline Repair Replacement ROSEN and MACAW have long-term master service agreements with major operators who very successfully apply this integrity model. We ensure that our engineers who are either remotely or locally assigned meet the highest expectations, as trust and credibility are the cornerstones of such agreements. Information Analysis Certification Verification Feedback Record Updates 12 13

8 Project Experience Offshore assignment in Europe This project involved a client who operates more than 1200 kilometers of offshore and 20 kilometers of onshore pipelines. As part of the project, ROSEN implemented ROAIMS for pipelines including some critical interfaces to CMMS and other systems. The assignment also required digitization of analog integrity records. Key client benefits: PIMS implementation resulting in a centralized system for all integrity related matters Development of customized algorithms to ensure compatibility with client-specific methodologies Custom interfaces (ESRI, ArcGIS, MS SharePoint, IBM Maximo) to ensure full digital process support On-site data integration of pipeline records and connected offshore data structure making analog data interpretable for further use in automated assessments. Onshore corrosion growth assessment in Australia As part of this project, a corrosion growth study was conducted for a 28" onshore crude oil pipeline with known external corrosion issues which had previously resulted in leaks. The scope of the study allowed for corrosion cause diagnosis and assessment of corrosion growth between one recent in-line inspection and data from two earlier inspections. On the basis of automatic feature comparison supported with extensive manual raw signal evaluation, the client was provided with sectional corrosion growth rate distributions along the entire line. Key client benefits: Confirmation of areas of active corrosion and quantification of growth rates to enable targeted repairs Definition of a cost-effective pipeline rehabilitation strategy (repair and recoating) As a result of the project, the client avoided costly replacement of whole sections of the pipeline. Onshore pipelines and terminal assignment in Mexico Project involved a long-term service contract for the provision of Integrity Management (IM) services for 14 onshore terminals and 174 associated pipelines. As part of this assignment, the following services were performed: provision of data management tools including risk assessment models, definition of integrity management plans, evaluation of ILI results, performance of data analysis and assessment, and above-ground survey services. Key client benefits: On-Site and back-office data collection Development of baseline risk assessment and action plan including transitioning the company to a new Integrity Management approach Action plan execution to manage risks across all assets Inspection of critical assets both with in-line inspection as well as external devices Monitoring defined Key Performance Indicators (KPI) Audit the effectiveness of the information management program Ageing offshore assets in the North Sea (UK) With many assets nearing or having reached the end of their design life and internal corrosion posing an active threat, the client required integrity-based services to determine whether assets could be kept in active service. Key client benefits: Risk-based assessment of topsides, pipelines and terminals Provision of corrosion risk assessments and corrosion management plans Expert advice on materials selection and welding procedures Advice on future inspection needs Recommendations for extending asset life 14 15

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