CONTENTS

Cover

International Advisory Board

Title Page

Preface

Contributors

Part I: Design

Chapter 1: Pipeline Integrity Management Systems (PIMS)
1. 1.1 Introduction
2. 1.2 Lessons Learned and the Evolution of Pipeline Integrity
3. 1.3 What is a PIMS?
4. 1.4 Regulatory Requirements
5. 1.5 Core Structure and PIMS Elements
6. 1.6 PIMS Function Map
7. 1.7 Plan: Strategic and Operational
8. 1.8 Do: Execute
9. 1.9 Check: Assurance and Verification
10. 1.10 Act: Management Review
11. 1.11 Culture
12. 1.12 Summary
13. References
Chapter 2: SCADA: Supervisory Control and Data Acquisition
1. 2.1 Introduction
2. 2.2 SCADA Computer Servers
3. 2.3 SCADA Computer Workstations
4. 2.4 Hierarchy
5. 2.5 Runtime and Configuration Databases
6. 2.6 Fault Tolerance
7. 2.7 Redundancy
8. 2.8 Alarm Rationalization, Management, and Analysis
9. 2.9 Incident Review and Replay
10. 2.10 Data Quality
11. 2.11 Operator Logbook and Shift Handover
12. 2.12 Training
13. 2.13 SCADA User Permissions and AORs
14. 2.14 Web Connection
15. 2.15 SCADA Security
16. 2.16 Human Factors Design in SCADA Systems
17. 2.17 SCADA Standards
18. 2.18 Pipeline Industry Applications
19. 2.19 Communication Media
20. 2.20 Communications Infrastructure
21. 2.21 Communications Integrity
22. 2.22 RTUs and PLCs
23. 2.23 Database
24. 2.24 User-Defined Programs
25. 2.25 RTU/PLC Integrity
26. References
Chapter 3: Material Selection for Fracture Control
1. 3.1 Overview of Fracture Control
2. 3.2 Toughness Requirements: Initiation
3. 3.3 Toughness Requirements: Propagation
4. 3.4 Toughness Measurement
5. 3.5 Current Status
6. References
Chapter 4: Strain-Based Design of Pipelines
1. 4.1 Introduction and Basic Concepts
2. 4.2 Strain Demand
3. 4.3 Strain Capacity
4. 4.4 Role of Full-Scale and Curved Wide Plate Testing
5. 4.5 Summary
6. References
Chapter 5: Stress-Based Design of Pipelines
1. 5.1 Introduction
2. 5.2 Design Pressure
3. 5.3 Design Factor
4. 5.4 Determination of Components of Stress
5. 5.5 Fatigue
6. 5.6 Expansion and Flexibility
7. 5.7 Corrosion Allowance
8. 5.8 Pipeline Stiffness
9. 5.9 Pipeline Ovality
10. 5.10 Minimum Pipe Bend Radius
11. 5.11 Pipeline Design for External Pressure
12. 5.12 Check for Hydrotest Conditions
13. 5.13 Summary
14. References
Chapter 6: Spiral Welded Pipes for Shallow Offshore Applications
1. 6.1 Introduction
2. 6.2 Limitations of the Technology Feasibility
3. 6.3 Challenges of Offshore Applications
4. 6.4 Typical Pipe Properties
5. 6.5 Technology Qualification
6. 6.6 Additional Resources
7. 6.7 Summary
8. References
Chapter 7: Residual Stress in Pipelines
1. 7.1 Introduction
2. 7.2 The Influence of Residual Stresses on Performance
3. 7.3 Residual Stress Measurement
4. 7.4 Control and Alteration of Residual Stresses
5. 7.5 Case Studies of the Effect of Residual Stress and Cold Work
6. References
Chapter 8: Pipeline/Soil Interaction Modeling in Support of Pipeline Engineering Design and Integrity
1. 8.1 Introduction
2. 8.2 Site Characterization and Geotechnical Engineering in Relation to Pipeline System Response Analysis
3. 8.3 Pipeline/Soil Interaction Analysis and Design
4. Nomenclature
5. Acknowledgments
6. References
Chapter 9: Human Factors
1. 9.1 Introduction
2. 9.2 What is “Human Factors”?
3. 9.3 Life Cycle Approach to Human Factors
4. 9.4 Human Factors and Decision Making
5. 9.5 Application of Human Factors Guidance
6. 9.6 Heuristics and Biases in Decision Making
7. 9.7 Human Factors Contribution to Incidents in the Pipeline Industry
8. 9.8 Human Factors Life Cycle Revisited
9. 9.9 Summary
10. References
11. Bibliography

Part II: Manufacture, Fabrication, and Construction

Chapter 10: Microstructure and Texture Development in Pipeline Steels
1. 10.1 Introduction
2. 10.2 Short History of Pipeline Steel Development
3. 10.3 Texture Control in Pipeline Steels
4. 10.4 Effect of Texture on In-Plane Anisotropy
5. 10.5 Summary
6. Acknowledgments
7. References
Chapter 11: Pipe Manufacture—Introduction
1. 11.1 Pipe Manufacturing Background
2. 11.2 Current Trends in Line Pipe Manufacturing
3. References
Chapter 12: Pipe Manufacture—Longitudinal Submerged Arc Welded Large Diameter Pipe
1. 12.1 Introduction
2. 12.2 Manufacturing Process
3. 12.3 Quality Control Procedures
4. 12.4 Range of Grades and Dimensions
5. 12.5 Typical Fields of Application
Chapter 13: Pipe Manufacture—Spiral Pipe
1. 13.1 Manufacturing Process
2. 13.2 Quality Control Procedures
3. 13.3 Range of Grades and Dimensions
4. 13.4 Typical Fields of Applicability
5. References
Chapter 14: Pipe Manufacture—ERW Pipe
1. 14.1 Introduction
2. 14.2 Manufacturing Process
3. 14.3 Quality Control Procedures
4. 14.4 Range of Grades and Dimensions
5. 14.5 Typical Fields of Applicability
6. References
Chapter 15: Pipe Manufacture—Seamless Tube and Pipe
1. 15.1 The Rolling Process
2. 15.2 Further Processing
3. References
Chapter 16: Major Standards for Line Pipe Manufacturing and Testing
1. 16.1 API SPEC 5L/ISO 3183
2. 16.2 CSA Z662-11: Oil and Gas Pipeline Systems
3. 16.3 DNV-OS-F101-2012: Submarine Pipeline Systems
4. 16.4 ISO 15156-1:2009: Petroleum and Natural Gas Industries—Materials for Use in H2S-Containing Environments in Oil and Gas Production
5. 16.5 EFC Publication Number 16, Third Edition: Guidelines on Materials Requirements for Carbon and Low-Alloy Steels for H2S-Containing Environments in Oil and Gas Production
6. 16.6 Nace TM0284 and TM0177
7. 16.7 ISO 10893-11—2011 Non-Destructive Testing of Steel Tubes—Part 11: Automated Ultrasonic Testing of the Weld Seam of Welded Steel Tubes for the Detection of Longitudinal and/or Transverse Imperfections
8. References
Chapter 17: Design of Steels for Large Diameter Sour Service Pipelines
1. 17.1 Introduction
2. 17.2 Hydrogen-Induced Cracking of Linepipe Steel and Evaluation Method
3. 17.3 Material Design of Linepipe Steel for Sour Service
4. References
Chapter 18: Pipeline Welding From the Perspective of Safety and Integrity
1. 18.1 Introduction
2. 18.2 Construction Welding Applications
3. 18.3 Nondestructive Inspection and Flaw Assessment
4. 18.4 Welding Procedure and Welder Qualification
5. 18.5 Hydrogen Control in Welds and the Prevention of Hydrogen-Assisted Cracking
6. 18.6 Important Considerations for Qualifying Welding Procedures to a Strain-Based Design
7. 18.7 Welding on In-Service Pipelines
8. 18.8 Pipeline Incidents Arising From Welding Defects and Recent Industry and Regulatory Preventative Action
9. Appendix 18.A: Abbreviations Used in this Chapter
10. Appendix 18.B: Regulations, Codes, and Standards
11. References
Chapter 19: The Effect of Installation on Offshore Pipeline Integrity
1. 19.1 Introduction
2. 19.2 Installation Methods and Pipeline Behaviour During Installation
3. 19.3 Critical Factors Governing Installation
4. 19.4 Installation Analysis and Design Methodologies
5. 19.5 Monitoring the Installation Process Offshore
6. 19.6 Implications of Deeper Water on Installation
7. Reference
8. Bibliography

Part III: Threats to Integrity and Safety

Chapter 20: External Corrosion of Pipelines In Soil
1. 20.1 Introduction
2. 20.2 Background
3. 20.3 Critical Factors of Soil Corrosivity That Affect Pipelines
4. 20.4 Identifying Corrosive Environments
5. 20.5 Cathodic Protection and Stray Currents
6. References
Chapter 21: Telluric Influence on Pipelines
1. 21.1 Introduction
2. 21.2 Review of the Existing Knowledge on Pipeline-Telluric Interference
3. 21.3 Geomagnetic Sources of Telluric Activity
4. 21.4 Earth Resistivity Influence on Telluric Activity
5. 21.5 Pipeline Response to Telluric Electric Fields
6. 21.6 Telluric Hazard Assessment
7. 21.7 Mitigation/Compensation of Telluric Effects
8. 21.8 Knowledge Gaps/Open Questions
9. 21.9 Summary
10. Acknowledgments
11. References
Chapter 22: Mechanical Damage in Pipelines: A Review of the Methods and Improvements in Characterization, Evaluation, and Mitigation
1. 22.1 Introduction
2. Current Status of In-line Inspection (ILI) Technologies for Mechanical Damage Characterization [8,9]
3. 22.3 Improved Technologies for In-Ditch Mechanical Damage Characterization
4. 22.4 Assessment of the Severity of Mechanical Damage
5. 22.5 Mitigation and Repair
6. 22.6 Continuing Challenges
7. References
Chapter 23: Progression of Pitting Corrosion and Structural Reliability of Welded Steel Pipelines
1. 23.1 Introduction
2. 23.2 Asset Management and Prediction
3. 23.3 Pitting
4. 23.4 Model for Long-Term Growth In Pit Depth
5. 23.5 Factors Influencing Maximum Pit Depth Development
6. 23.6 Structural Reliability
7. 23.7 Extreme Value Analysis for Maximum Pit Depth
8. 23.8 Pitting At Welds
9. 23.9 Case Study—Water Injection Pipelines
10. 23.10 Concluding Remarks
11. Acknowledgments
12. References
Chapter 24: Sulfide Stress Cracking
1. 24.1 Introduction
2. 24.2 What Is Sulfide Stress Cracking?
3. 24.3 Basics of Sulfide Stress Cracking in Pipelines
4. 24.4 Comparison of Ssc to Other Sour Cracking Mechanisms
5. 24.5 Influence of Environmental Variables on SSC
6. 24.6 Influence of Metallurgical Variables on SSC in Steels
7. 24.7 Use of Corrosion-Resistant Alloys to Resist SSC
8. References
Chapter 25: Stress Corrosion Cracking of Steel Equipment in Ethanol Service
1. 25.1 Introduction
2. 25.2 Factors Affecting Susceptibility to Ethanol SCC
3. 25.3 Occurrences and Consequences of eSCC
4. 25.4 Guidelines for Identification, Mitigation, and Repair of eSCC
5. 25.5 Path Forward
6. References
7. Bibliography of Additional eSCC Papers
Chapter 26: AC Corrosion
1. 26.1 Introduction
2. 26.2 Basic Understanding
3. 26.3 AC Corrosion Risk Assessment and Management
4. References
5. Bibliography
Chapter 27: Microbiologically Influenced Corrosion
1. 27.1 Introduction
2. 27.2 Requirements for Microbial Growth
3. 27.3 Internal Corrosion
4. 27.4 Testing
5. 27.5 External Corrosion
6. 27.6 Conclusions
7. Acknowledgments
8. References
Chapter 28: Erosion–Corrosion in Oil and Gas Pipelines
1. 28.1 Introduction
2. 28.2 Solid Particle Erosion
3. 28.3 Erosion–Corrosion of Carbon Steel Piping in a CO2 Environment with Sand
4. 28.4 Erosion–Corrosion Modeling and Characterization of Iron Carbonate Erosivity
5. 28.5 Erosion–Corrosion of Corrosion-Resistant Alloys
6. 28.6 Chemical Inhibition of Erosion–Corrosion
7. 28.7 Summary and Conclusions
8. Acknowledgments
9. References
Chapter 29: Black Powder in Gas Transmission Pipelines
1. 29.1 Introduction
2. 29.2 Internal Corrosion of Gas Transmission Pipelines
3. 29.3 Analysis Techniques
4. 29.4 Composition and Sources of Black Powder
5. 29.5 Physical and Mechanical Properties
6. 29.6 Impacts on Operations
7. 29.7 Black Powder Management Methods
8. 29.8 Guidance on Handling and Disposal of Black Powder
9. 29.9 Summary
10. Acknowledgments
11. References

Part IV: Protection

Chapter 30: External Coatings
1. 30.1 Introduction and Background
2. 30.2 Coating Performance
3. 30.3 Product Testing
4. 30.4 Standards and Application Specification
5. 30.5 Field-Applied Coatings
6. 30.6 Coating Types and Application
7. Reference
Chapter 31: Thermoplastic Liners for Oilfield Pipelines
1. 31.1 Introduction
2. 31.2 Codes and Standards
3. 31.3 The Installation Process
4. 31.4 Important Mechanical Design Aspects
5. 31.5 Liner Materials
6. 31.6 Operating a Pipeline with a Liner
7. 31.7 Lined Pipeline Systems—Application Examples
8. References
Chapter 32: Cathodic Protection
1. 32.1 Introduction
2. 32.2 Historical Foundation of Cathodic Protection
3. 32.3 Fundamentals of Cathodic Protection
4. 32.4 How Cathodic Protection is Applied
5. 32.5 Design Principles of Cathodic Protection
6. 32.6 Protective Coatings and Cathodic Protection
7. 32.7 Monitoring Cathodic Protection Systems
8. 32.8 Cathodic Protection Criteria
9. References

Part V: Inspection and Monitoring

Chapter 33: Direct Assessment
1. 33.1 Introduction
2. 33.2 External Corrosion DA (ECDA)
3. 33.3 Stress Corrosion Cracking DA (SCCDA)
4. 33.4 Internal Corrosion DA (ICDA)
5. References
Chapter 34: Internal Corrosion Monitoring Using Coupons and ER Probes
1. 34.1 Introduction—Corrosion Monitoring Using Coupons and ER Probes
2. 34.2 Corrosion Coupons and Electrical Resistance Corrosion Probes
3. 34.3 Placing Corrosion Monitoring Coupons or Electronic Probes Within Pipelines
4. 34.4 Monitoring Results “Drive” Chemical Treatment and Maintenance Pigging Programs
5. 34.5 Relative Sensitivities of NDT Versus Internal Corrosion Monitoring Techniques
6. 34.6 Fluid Sample Analysis to Complement and Verify Monitoring Results
7. 34.7 Summary
8. 34.8 Definitions of Corrosion Monitoring Terms from NACE 3T199 [10]. © NACE International 1999
9. References
Chapter 35: In-Line Inspection (ILI) (“Intelligent Pigging”)
1. 35.1 Introduction
2. 35.2 Place of ILI in Pipeline Integrity Management
3. 35.3 Running ILI Tools
4. 35.4 Types of ILI Tools and their Purpose
5. 35.5 Utilizing ILI Data/Verification
6. 35.6 Integrating ILI Data
7. Appendix 35.A1: Sample Pipeline Inspection Questionnaire (Nonmandatory)
8. References
9. Bibliography: Journals, Conferences and Other Sources with ILI Related Content
Chapter 36: Eddy Current Testing in Pipeline Inspection
1. 36.1 Standard Eddy Current Testing
2. 36.2 Enhanced Eddy Current Testing
3. 36.3 Applications for Pipeline Inspection
4. References
Chapter 37: Unpiggable Pipelines
1. 37.1 Introduction
2. 37.2 Challenging Pipeline Inspection Approach
3. 37.3 Free Swimming ILI Tools for Challenging Pipeline Inspections
4. 37.4 Self-Propelled Inspection Solutions
5. References
6. Bibliography: Sources of Additional Information
Chapter 38: In-The-Ditch Pipeline Inspection
1. 38.1 Overview
2. 38.2 Introduction to Nondestructive Examination of Pipelines
3. 38.3 NDE and A Pipeline Integrity Program
4. 38.4 Pipeline Coatings
5. 38.5 Types of Anomalies
6. 38.6 NDE Measurement Technologies
7. 38.7 Excavation Package
8. 38.8 Data Collection
9. 38.9 Conducting in-the-Ditch Assessment
10. 38.10 Data Management
11. 38.11 Recent Technological Developments
12. 38.12 Summary
13. Acknowledgments
14. Reference
15. Bibliography
Chapter 39: Ultrasonic Monitoring of Pipeline Wall Thickness with Autonomous, Wireless Sensor Networks
1. 39.1 Introduction
2. 39.2 The Physics of Ultrasonic Thickness Gauging
3. 39.3 Autonomous Sensor and Network Considerations
4. 39.4 Test Results
5. 39.5 Applications
6. 39.6 Summary
7. Acknowledgments
8. References
Chapter 40: Flaw Assessment
1. 40.1 Overview
2. 40.2 Assessing Metal Loss
3. 40.3 Crack Assessment
4. 40.4 Dents
5. References
Chapter 41: Integrity Management of Pipeline Facilities
1. 41.1 Overview
2. 41.2 Outline
3. 41.3 Scoping a Facilities Integrity Plan
4. 41.4 Specific Facility Threats
5. 41.5 Facility Safety Consequences
6. 41.6 Building a Facility Integrity Plan
7. 41.7 Integrity Assurance
8. Bibliography: Essential Reading

Part VI: Maintenance, Repair, Replacement, and Abandonment

Chapter 42: Pipeline Cleaning
1. 42.1 Introduction
2. 42.2 Contaminates
3. 42.3 Progressive Pigging
4. 42.4 Pig Types
5. 42.5 Durometer [5]
6. 42.6 Mechanical and Liquid (Chemical) Cleaning
7. 42.7 On-Line or Off-Line
8. 42.8 Cleaning a Pipeline
9. 42.9 How Clean Do I Need to Be?
10. 42.10 Summary
11. References
Chapter 43: Managing an Aging Pipeline Infrastructure
1. 43.1 Introduction
2. 43.2 Background
3. 43.3 Evolution of Line Pipe Steel, Pipe Making, and Pipeline Construction
4. 43.4 Pipeline System Expansion and the Implications for “Older” Pipelines
5. 43.5 The Evolution of Pipeline Codes and Standards, and Regulations
6. 43.6 Some Unique Aspects of Early and Vintage Pipelines
7. 43.7 Management Approach and Challenges
8. 43.8 Closure
9. Acknowledgments
10. References
Chapter 44: Pipeline Repair Using Full-Encirclement Repair Sleeves
1. 44.1 Introduction
2. 44.2 Background
3. 44.3 Full-Encirclement Steel Sleeves
4. 44.4 Comparison of Steel Sleeves and Fiber Reinforced Composite Repairs
5. 44.5 Welding Onto An In-Service Pipeline
6. 44.6 Summary and Conclusions
7. References
Chapter 45: Pipeline Repair
1. 45.1 Introduction
2. 45.2 Background
3. 45.3 Safety
4. 45.4 Protocols
5. 45.5 Pipe Replacement
6. 45.6 Grinding/Sanding
7. 45.7 Full-Encirclement Steel Sleeves
8. 45.8 Epoxy-Filled Shells
9. 45.9 Steel Compression Sleeves
10. 45.10 Composite Reinforcement Sleeves
11. 45.11 Hot Tapping
12. 45.12 Direct Deposition Welding
13. 45.13 Temporary Repair
14. 45.14 Temporary Repairs of Leaks
15. 45.15 Applicability to Various Defect Types
16. References
Chapter 46: Pipeline Oil Spill Cleanup
1. 46.1 Oil Spills and Pipelines: An Overview
2. 46.2 Response to Oil Spills
3. 46.3 Types of Oil and Their Properties
4. 46.4 Behavior of Oil in the Environment
5. 46.5 Analysis, Detection, and Remote Sensing of oil Spills
6. 46.6 Containment on Water
7. 46.7 Oil Recovery on Water
8. 46.8 Separation, Pumping, Decontamination, and Disposal
9. 46.9 Spill-Treating Agents
10. 46.10 In Situ Burning
11. 46.11 Shoreline Cleanup and Restoration
12. 46.12 Oil Spills on Land
13. References
Chapter 47: Pipeline Abandonment
1. 47.1 What is Pipeline Abandonment?
2. 47.2 Abandonment Planning
3. 47.3 Procedures for Abandoning Pipelines and Related Facilities
4. 47.4 Post-Abandonment Physical Issues
5. 47.5 Post-Abandonment Care
6. References

Part VII: Risk Management

Chapter 48: Risk Management of Pipelines
1. 48.1 Overview
2. 48.2 Qualitative and Quantitative RBI Approaches
3. 48.3 Development of Inspection Programs
4. 48.4 Putting RBI Into Practice
5. References
6. Bibliography
Chapter 49: Offshore Pipeline Risk, Corrosion, and Integrity Management
1. 49.1 Introduction
2. 49.2 Challenges, Lessons, and Solutions
3. 49.3 Life Cycle
4. 49.4 Case Histories
5. 49.5 Codes, Standards, Recommended Practices, and Regulations
6. 49.6 Corrosion Risk Analysis, Inspection, and Monitoring Methodologies
7. 49.7 Summary: Recommendations and Future Strategies
8. Acknowledgments
9. References
10. Bibliography

Part VIII: Case Histories

Chapter 50: Buckling of Pipelines Under Repair Sleeves: A Case Study—Analysis of the Problem and Cost-Effective Solutions
1. 50.1 Introduction
2. 50.2 Study Conclusions
3. 50.3 Summary
4. Acknowledgment
5. References
Chapter 51: In-Line Inspection on an Unprecedented Scale
1. 51.1 Introduction
2. 51.2 Challenging Design and Operating Conditions
3. 51.3 Combined Technologies for Reliable Inspection Results
4. 51.4 Overcoming the Multi-Diameter Challenge
5. 51.5 Overcoming the Challenge of High Product Flow Velocity in the Pipeline
6. 51.6 Overcoming the Distance Challenge: Tool Wear During the Longest Continuous Inspection Run Ever Conducted
7. 51.7 Summary
8. References
Chapter 52: Deepwater, High-Pressure and Multidiameter Pipelines—a Challenging In-Line Inspection Project
1. 52.1 Introduction
2. 52.2 Project Requirements
3. 52.3 Project Planning
4. 52.4 Tool Design
5. 52.5 Testing
6. 52.6 Gauging and Inspection Runs
7. 52.7 Summary
8. References

Glossary

Part 1: Abbreviations
Part 2: Selected Terms

Index

End User License Agreement

List of Tables

Table 2.1

Table 2.2

Table 4.1

Table 5.1

Table 5.2

Table 5.3

Table 5.4

Table 5.5

Table 9.1

Table 9.2

Table 9.3

Table 9.4

Table 9.5

Table 9.6

Table 9.7

Table 9.8

Table 9.9

Table 9.10

Table 9.11

Table 9.12

Table 9.13

Table 10.1

Table 10.2

Table 10.3

Table 14.1

Table 20.1

Table 20.2

Table 20.3

Table 22.1

Table 22.2

Table 22.3

Table 22.4

Table 22.5

Table 22.6

Table 22.7

Table 22.8

Table 22.9

Table 22.10

Table 22.11

Table 22.12

Table 22.13

Table 22.14

Table 22.15

Table 22.16

Table 23.1

Table 23.2

Table 24.1

Table 24.2

Table 25.1

Table 28.1

Table 28.2

Table 28.3

Table 29.1

Table 29.2

Table 29.3

Table 29.4

Table 32.1

Table 32.2

Table 32.3

Table 32.4

Table 32.5

Table 32.6

Table 32.7

Table 32.8

Table 33.1

Table 34.1

Table 34.2

Table 38.1

Table 39.1

Table 40.1

Table 41.1

Table 42.1

Table 43.1

Table 44.1

Table 45.1

Table 46.1

Table 46.2

Table 46.3

Table 46.4

Table 46.5

Table 46.6

Table 46.7

Table 46.8

Table 47.1

Table 48.1

Table 48.2

Table 48.3

Table 48.4

Table 48.5

Table 48.6

Table 48.7

Table 48.8

Table 48.9

Table 48.10

Table 48.11

Table 48.12

Table 48.13

Table 49.1

Table 49.2

Table 49.3

Table 49.4

List of Illustrations

Figure 1.1

Figure 1.2

Figure 1.3

Figure 1.4

Figure 1.5

Figure 1.6

Figure 1.7

Figure 3.1

Figure 3.2

Figure 3.3

Figure 3.4

Figure 3.5

Figure 5.1

Figure 5.2

Figure 5.3

Figure 6.1

Figure 6.2

Figure 6.3

Figure 7.1

Figure 7.2

Figure 7.3

Figure 7.4

Figure 7.5

Figure 7.6

Figure 7.7

Figure 7.8

Figure 7.9

Figure 7.10

Figure 7.11

Figure 7.12

Figure 7.13

Figure 7.14

Figure 7.15

Figure 7.16

Figure 7.17

Figure 7.18

Figure 7.19

Figure 7.20

Figure 7.21

Figure 7.22

Figure 7.23

Figure 7.24

Figure 7.25

Figure 7.26

Figure 7.27

Figure 7.28

Figure 7.29

Figure 7.30

Figure 7.31

Figure 7.32

Figure 7.33

Figure 7.34

Figure 8.1

Figure 8.2

Figure 8.3

Figure 8.4

Figure 8.5

Figure 8.6

Figure 8.7

Figure 8.8

Figure 8.9

Figure 8.10

Figure 8.11

Figure 8.12

Figure 8.13

Figure 8.14

Figure 8.15

Figure 8.16

Figure 8.17

Figure 8.18

Figure 8.19

Figure 8.20

Figure 9.1

Figure 9.2

Figure 10.1

Figure 10.2

Figure 10.3

Figure 10.4

Figure 10.5

Figure 10.6

Figure 10.7

Figure 10.8

Figure 10.9

Figure 10.10

Figure 10.11

Figure 10.12

Figure 10.13

Figure 10.14

Figure 10.15

Figure 10.16

Figure 10.17

Figure 10.18

Figure 10.19

Figure 10.20

Figure 10.21

Figure 10.22

Figure 10.23

Figure 10.24

Figure 10.25

Figure 10.26

Figure 10.27

Figure 10.28

Figure 10.29

Figure 10.30

Figure 10.31

Figure 10.32

Figure 10.33

Figure 10.34

Figure 10.35

Figure 10.36

Figure 10.37

Figure 10.38

Figure 12.1

Figure 12.2

Figure 12.3

Figure 12.4

Figure 12.5

Figure 13.1

Figure 13.2

Figure 13.3

Figure 13.4

Figure 13.5

Figure 13.6

Figure 14.1

Figure 14.2

Figure 14.3

Figure 14.4

Figure 14.5

Figure 14.6

Figure 14.7

Figure 14.8

Figure 14.9

Figure 14.10

Figure 14.11

Figure 14.12

Figure 14.13

Figure 15.1

Figure 15.2

Figure 15.3

Figure 15.4

Figure 15.5

Figure 15.6

Figure 15.7

Figure 15.8

Figure 15.9

Figure 15.10

Figure 15.11

Figure 15.12

Figure 15.13

Figure 15.14

Figure 15.15

Figure 15.16

Figure 15.17

Figure 15.18

Figure 15.19

Figure 15.20

Figure 17.1

Figure 17.2

Figure 17.3

Figure 17.4

Figure 17.5

Figure 17.6

Figure 17.7

Figure 17.8

Figure 17.9

Figure 17.10

Figure 17.11

Figure 19.1

Figure 19.2

Figure 19.3

Figure 19.4

Figure 20.1

Figure 20.2

Figure 20.3

Figure 20.4

Figure 20.5

Figure 20.6

Figure 20.7

Figure 20.8

Figure 21.1

Figure 21.2

Figure 21.3

Figure 21.4

Figure 21.5

Figure 21.6

Figure 21.7

Figure 21.8

Figure 21.9

Figure 21.10

Figure 21.11

Figure 21.12

Figure 21.13

Figure 22.1

Figure 22.2

Figure 22.3

Figure 22.4

Figure 22.5

Figure 22.6

Figure 22.7

Figure 22.8

Figure 22.9

Figure 22.10

Figure 22.11

Figure 22.12

Figure 22.13

Figure 22.14

Figure 22.15

Figure 22.16

Figure 22.17

Figure 22.18

Figure 22.19

Figure 22.20

Figure 22.21

Figure 23.1

Figure 23.2

Figure 23.3

Figure 23.4

Figure 23.5

Figure 23.6

Figure 23.7

Figure 23.8

Figure 23.9

Figure 23.10

Figure 23.11

Figure 23.12

Figure 23.13

Figure 23.14

Figure 23.15

Figure 23.16

Figure 24.1

Figure 24.2

Figure 24.3

Figure 24.4

Figure 24.5

Figure 24.6

Figure 24.7

Figure 24.8

Figure 25.1

Figure 25.2

Figure 25.3

Figure 25.4

Figure 25.5

Figure 25.6

Figure 25.7

Figure 26.1

Figure 26.2

Figure 26.3

Figure 26.4

Figure 26.5

Figure 26.6

Figure 26.7

Figure 26.8

Figure 26.9

Figure 26.10

Figure 26.11

Figure 26.12

Figure 26.13

Figure 26.14

Figure 26.15

Figure 26.16

Figure 26.17

Figure 26.18

Figure 26.19

Figure 26.20

Figure 26.21

Figure 26.22

Figure 26.23

Figure 26.24

Figure 26.25

Figure 27.1

Figure 28.1

Figure 28.2

Figure 28.3

Figure 28.4

Figure 28.5

Figure 28.6

Figure 28.7

Figure 28.8

Figure 28.9

Figure 28.10

Figure 28.11

Figure 28.12

Figure 28.13

Figure 28.14

Figure 28.15

Figure 28.16

Figure 28.17

Figure 28.18

Figure 28.19

Figure 28.20

Figure 28.21

Figure 28.22

Figure 28.23

Figure 28.24

Figure 28.25

Figure 28.26

Figure 28.27

Figure 28.28

Figure 28.29

Figure 29.1

Figure 29.2

Figure 29.3

Figure 29.4

Figure 29.5

Figure 29.6

Figure 29.7

Figure 30.1

Figure 30.2

Figure 30.3

Figure 30.4

Figure 30.5

Figure 30.6

Figure 30.7

Figure 30.8

Figure 30.9

Figure 30.10

Figure 30.11

Figure 30.12

Figure 31.1

Figure 31.2

Figure 32.1

Figure 32.2

Figure 32.3

Figure 32.4

Figure 32.5

Figure 32.6

Figure 32.7

Figure 32.8

Figure 32.9

Figure 32.10

Figure 32.11

Figure 32.12

Figure 32.13

Figure 32.14

Figure 32.15

Figure 32.16

Figure 32.17

Figure 33.1

Figure 33.2

Figure 33.3

Figure 34.1

Figure 34.2

Figure 34.3

Figure 34.4

Figure 34.5

Figure 34.6

Figure 34.7

Figure 34.8

Figure 34.9

Figure 34.10

Figure 34.11

Figure 34.12

Figure 34.13

Figure 34.14

Figure 34.15

Figure 35.1

Figure 35.2

Figure 35.3

Figure 35.4

Figure 35.5

Figure 35.6

Figure 35.7

Figure 35.8

Figure 35.9

Figure 35.10

Figure 35.11

Figure 35.12

Figure 35.13

Figure 35.14

Figure 35.15

Figure 35.16

Figure 35.17

Figure 35.18

Figure 35.19

Figure 35.A1

Figure 36.1

Figure 36.2

Figure 36.3

Figure 36.4

Figure 36.5

Figure 36.6

Figure 36.7

Figure 36.8

Figure 36.9

Figure 37.1

Figure 37.2

Figure 37.3

Figure 37.4

Figure 37.5

Figure 37.6

Figure 37.7

Figure 37.8

Figure 37.9

Figure 37.10

Figure 37.11

Figure 37.12

Figure 37.13

Figure 37.14

Figure 37.15

Figure 37.16

Figure 38.1

Figure 38.2

Figure 38.3

Figure 38.4

Figure 38.5

Figure 38.6

Figure 38.7

Figure 38.8

Figure 39.1

Figure 39.2

Figure 39.3

Figure 39.4

Figure 39.5

Figure 39.6

Figure 39.7

Figure 39.8

Figure 40.1

Figure 40.2

Figure 40.3

Figure 40.4

Figure 40.5

Figure 40.6

Figure 40.7

Figure 40.8

Figure 40.9

Figure 40.10

Figure 40.11

Figure 40.12

Figure 40.13

Figure 40.14

Figure 40.15

Figure 43.1

Figure 43.2

Figure 43.3

Figure 43.4

Figure 43.5

Figure 43.6

Figure 43.7

Figure 43.8

Figure 43.9

Figure 43.10

Figure 43.11

Figure 43.12

Figure 43.13

Figure 43.14

Figure 43.15

Figure 43.16

Figure 43.17

Figure 43.18

Figure 43.19

Figure 43.20

Figure 43.21

Figure 44.1

Figure 44.2

Figure 44.3

Figure 44.4

Figure 44.5

Figure 44.6

Figure 44.7

Figure 44.8

Figure 44.9

Figure 44.10

Figure 44.11

Figure 44.12

Figure 44.13

Figure 44.14

Figure 44.15

Figure 44.16

Figure 44.17

Figure 44.18

Figure 44.19

Figure 44.20

Figure 44.21

Figure 44.22

Figure 44.23

Figure 44.24

Figure 44.25

Figure 44.26

Figure 44.27

Figure 44.28

Figure 44.29

Figure 44.30

Figure 45.1

Figure 45.2

Figure 45.3

Figure 45.4

Figure 45.5

Figure 45.6

Figure 45.7

Figure 45.8

Figure 46.1

Figure 46.2

Figure 46.3

Figure 46.4

Figure 46.5

Figure 46.6

Figure 46.7

Figure 46.8

Figure 46.9

Figure 46.10

Figure 48.1

Figure 48.2

Figure 48.3

Figure 48.4

Figure 48.5

Figure 48.6

Figure 48.7

Figure 48.8

Figure 48.9

Figure 48.10

Figure 48.11

Figure 48.12

Figure 48.13

Figure 48.14

Figure 48.15

Figure 49.1

Figure 49.2

Figure 49.3

Figure 49.4

Figure 49.5

Figure 49.6

Figure 49.7

Figure 49.8

Figure 49.9

Figure 49.10

Figure 49.11

Figure 49.12

Figure 49.13

Figure 49.14

Figure 49.15

Figure 49.16

Figure 49.17

Figure 49.18

Figure 49.19

Figure 49.20

Figure 49.21

Figure 49.22

Figure 49.23

Figure 49.24

Figure 49.25

Figure 49.26

Figure 49.27

Figure 50.1

Figure 50.2

Figure 50.3

Figure 50.4

Figure 50.5

Figure 50.6

Figure 50.7

Figure 50.8

Figure 50.9

Figure 51.1

Figure 51.2

Figure 51.3

Figure 51.4

Figure 51.5

Figure 51.6

Figure 51.7

Figure 51.8

Figure 51.9

Figure 52.1

Figure 52.2

Figure 52.3

Figure 52.4

Figure 52.5

Figure 52.6

Figure 52.7

Figure 52.8

Figure 52.9

Figure 52.10

Figure 52.11

International Advisory Board

Ihsan Al-Taie

R&D Center

Saudi Aramco

Dhahran

Saudi Arabia

J. Malcolm Gray

Microalloyed Steel Institute Inc.

Houston, TX

USA

Gerhard Knauf

Salzgitter Mannesmann Forschung GmbH

European Pipeline Research Group e.V.

Duisburg

Germany

Minxu Lu

University of Science and Technology Beijing

Beijing

China

Alan Murray

Principia Consulting

Calgary, Alberta

Canada

John O'Brien

Chevron

Houston, TX

USA

Bill Santos

NOVA Chemicals Centre of Applied Research

Calgary, Alberta

Canada

Joe Zhou

TransCanada PipeLines Limited

Calgary, Alberta

Canada

Published by John Wiley & Sons, Inc., Hoboken, New Jersey

Published simultaneously in Canada

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Preface

The objective of preparing this Handbook was to make available, in one volume, essential scientific, engineering, and technical knowledge on integrity and safety of oil and gas pipelines. The aim was to help ensure the safe operation of pipeline networks that we depend on for reliability in service, deliverability of energy, protection of the environment, and safety of the public.

This book, containing 52 chapters, is divided into the following eight parts:

Part I:	Design
Part II:	Manufacture, Fabrication, and Construction
Part III:	Threats to Integrity and Safety
Part IV:	Protection
Part V:	Inspection and Monitoring
Part VI:	Maintenance, Repair, Replacement, and Abandonment
Part VII:	Risk Management
Part VIII:	Case Histories

The breadth of coverage will help make the book useful to engineers, scientists, technicians, and students from a wide range of disciplines. The depth of coverage is intended to meet the needs of those who require a high level of detail. In addition to the case histories presented in Part VIII, there are practical examples with solutions to problems and analytical discussion throughout the book. References to other books, journals, and standards that readers can consult for further information are listed

The 86 authors who have contributed the 52 chapters come from different sectors, industry, academia, and government, and from 14 countries, bringing diverse perspectives to pipeline integrity and a balance of practice and theory.

I would like to convey my thanks to the team of authors for contributing chapters in their areas of specialty. I would also like to highlight the contributions of the reviewers who, in anonymity, reviewed the draft chapters and provided their comments, suggestions, and recommendations for the authors, so as to enhance the quality of the chapters, documenting the current state of knowledge. In addition, the International Advisory Board provided helpful advice and guidance in the preparation of the Handbook.

I would like to thank Bob Esposito, Michael Leventhal, and the staff at John Wiley & Sons, Inc. for their encouragement. The concept for this book was developed in discussion with Bob Esposito about the Banff Workshops on managing pipeline integrity, which I organized over a period of nearly 20 years, beginning with the 1993 Workshop. These Workshops continue to be held biennially.

If this Handbook helps in the quest to achieve the objective that we all share of zero incidents—no incidents, in the world of engineering and business where “zero” means “zero” and “no” means “no”—then the efforts of the entire team who worked tirelessly in preparing it will have been rewarded.

R. Winston Revie

Ottawa, Ontario, Canada

Contributors

Gusai H. Al-Aithan, Saudi Aramco, Dhahran, Saudi Arabia

Jon Allin, Permasense Ltd., Horsham, UK

Faisal M. Al-Mutahar, Saudi Aramco, Dhahran, Saudi Arabia

Ted L. Anderson, Quest Integrity Group, LLC, Boulder, CO, USA

John A. Beavers, Det Norske Veritas (U.S.A.), Inc., Dublin, OH, USA

Lynsay A. Bensman, Det Norske Veritas (U.S.A.), Inc., Dublin, OH, USA

David H. Boteler, Earth Sciences Sector, Natural Resources Canada, Ottawa, Ontario, Canada

Holger Brauer, Salzgitter Mannesmann Line Pipe GmbH, Hamm, Germany

Stephan Brockhaus, ROSEN Technology & Research Center, Lingen, Germany

William A. Bruce, Det Norske Veritas (U.S.A.), Inc., Dublin, OH, USA

Dean Carnes, Canadian Natural Resources Ltd., Calgary, Alberta, Canada

Homero Castaneda, Chemical and Biomolecular Engineering Department, National Center for Research and Education in Corrosion and Materials Performance, The University of Akron, Akron, OH, USA

Frederic Cegla, Mechanical Engineering Department, Imperial College London, South Kensington, UK

Ljiljana Djapic-Oosterkamp, Statoil, Kårstø, Norway

David Dorling, Starco Engineering, Calgary, Alberta, Canada

Ayman Eltaher, MCS Kenny, Houston, TX, USA

Merv Fingas, Spill Science, Edmonton, Alberta, Canada

Doug Fisher, Willowglen Systems Inc., Edmonton, Alberta, Canada

Ming Gao, Blade Energy Partners, Houston, TX, USA

James Gianetto, CanmetMATERIALS, Natural Resources Canada, Hamilton, Ontario, Canada

Ray Goodfellow, IRISNDT – Engineering, Calgary, Alberta, Canada

J. Malcolm Gray, Microalloyed Steel Institute Inc., Houston, TX, USA

Lorna Harron, Enbridge Pipelines Inc., Edmonton, Alberta, Canada

Shokrollah Hassani, BP America Inc., Houston, TX, USA

Holger Hennerkes, ROSEN Headquarters, Stans, Switzerland

Douglas Hornbach, Lambda Technologies, Cincinnati, OH, USA

Nobuyuki Ishikawa, JFE Steel Corporation, Hiroshima, Japan

John J. Jonas, Department of Mining and Materials Engineering, McGill University, Montreal, Canada

Katherine Jonsson, IRISNDT – Engineering, Calgary, Alberta, Canada

Paul Jukes, Wood Group, Houston, TX, USA

Lynne C. Kaley, Trinity Bridge, LLC, Houston, TX, USA

Christoph Kalwa, EUROPIPE GmbH, Mülheim an der Ruhr, Germany

Russell D. Kane, iCorrosion LLC, Houston, TX, USA

Shawn Kenny, Memorial University, St. John's, Newfoundland, Canada; Carleton University, Ottawa, Ontario, Canada

Leo A.I. Kestens, Department of Materials Science and Engineering, Ghent University, Ghent, Belgium; Department of Materials Science and Engineering, Delft University of Technology, Delft, The Netherlands

John Kiefner, Kiefner and Associates, Inc., Worthington, OH, USA

Gerhard Knauf, Salzgitter Mannesmann Forschung GmbH, Duisburg, Germany

Franz Martin Knoop, Salzgitter Mannesmann Großrohr GmbH, Salzgitter, Germany

Angel R. Kowalski, Det Norske Veritas (U.S.A.), Inc., Dublin, OH, USA

Klaus Kraemer, Vallourec & Mannesmann Deutschland GmbH, Düsseldorf, Germany

Ravi Krishnamurthy, Blade Energy Partners, Houston, TX, USA

Axel Kulgemeyer, Salzgitter Mannesmann Forschung GmbH, Duisburg, Germany

Rolf Kümmerling, Vallourec & Mannesmann Deutschland GmbH, Düsseldorf, Germany

Jason S. Lee, Naval Research Laboratory, Stennis Space Center, Mississippi, USA

John Leeds, DC Voltage Gradient Technology & Supply Ltd., Wigan, UK

Sarah Leeds, DC Voltage Gradient Technology & Supply Ltd., Wigan, UK

Keith G. Leewis, Dynamic Risk Assessment Systems, Inc., Calgary, Alberta, Canada

Brian N. Leis, B N Leis Consultant, Inc., Worthington, OH, USA

Arnold L. Lewis II, Research and Development Center, Saudi Aramco, Dhahran,

Saudi Arabia

Hubert Lindner, ROSEN Technology & Research Center, Lingen, Germany

Brenda J. Little, Naval Research Laboratory, Stennis Space Center, Mississippi, USA

Hendrik Löbbe, Salzgitter Mannesmann Line Pipe GmbH, Hamm, Germany

Jim Mason, Mason Materials Development, LLC, Birdsboro, PA, USA

Brenton S. McLaury, Erosion/Corrosion Research Center, The University of Tulsa, Tulsa, OK, USA

Robert E. Melchers, Centre for Infrastructure Performance and Reliability, The University of Newcastle, Newcastle, NSW, Australia

Rumi Mohammad, Willowglen Systems Inc., Edmonton, Alberta, Canada

Lars Vendelbo Nielsen, MetriCorr ApS, Glostrup, Denmark

Mavis Sika Okyere, Bluecrest College, Kumasi, Ghana

Robert O'Grady, Wood Group Kenny, Galway, Ireland

Alan Pentney, National Energy Board of Canada, Calgary, Alberta, Canada

Roumen H. Petrov, Department of Materials Science and Engineering, Ghent University, Ghent, Belgium; Department of Materials Science and Engineering, Delft University of Technology, Delft, The Netherlands

Ben Poblete, ATKINS, Houston, TX, USA

Daniel E. Powell, Williams, Tulsa, OK, USA

Buddy Powers, Clock Spring Company L.P., Houston, TX, USA

Kathleen O. Powers, Trinity Bridge, LLC, Houston, TX, USA

Gail Powley, Willowglen Systems Inc., Edmonton, Alberta, Canada

Paul Prevéy, Lambda Technologies, Cincinnati, OH, USA

Konrad Reber, Innospection Germany GmbH, Stutensee, Germany

R. Winston Revie, Consultant, Ottawa, Ontario, Canada

Hernan E. Rincon, ConocoPhillips Company, Houston, TX, USA

Kenneth P. Roberts, Erosion/Corrosion Research Center, The University of Tulsa, Tulsa, OK, USA

Randy L. Roberts, N-SPEC Pipeline Services, Business Unit of Coastal Chemical Co., L.L.C./A Brenntag Company, Broussard, LA, USA

Omar Rosas, Chemical and Biomolecular Engineering Department, National Center for Research and Education in Corrosion and Materials Performance, The University of Akron, Akron, OH, USA

Edmund F. Rybicki, Erosion/Corrosion Research Center, The University of Tulsa, Tulsa, OK, USA

John R. Shadley, Erosion/Corrosion Research Center, The University of Tulsa, Tulsa, OK, USA

Abdelmounam M. Sherik, Research and Development Center, Saudi Aramco, Dhahran, Saudi Arabia

Siamack A. Shirazi, Erosion/Corrosion Research Center, The University of Tulsa, Tulsa, OK, USA

Binder Singh, Genesis-Technip USA Inc., Houston, TX, USA

Robert Smyth, Petroline Construction Group, Nisku, Alberta, Canada

Tom Steinvoorte, ROSEN Europe, Oldenzaal, The Netherlands

Larisa Trichtchenko, Earth Sciences Sector, Natural Resources Canada, Ottawa, Ontario, Canada

William Tyson, CanmetMATERIALS, Natural Resources Canada, Hamilton, Ontario, Canada

Neb I. Uzelac, Neb Uzelac Consulting Inc., Toronto, Ontario, Canada

Michael VanderZee, Willowglen Systems Inc., Edmonton, Alberta, Canada

Doug Waslen, Sherwood Park, Alberta, Canada

Nader Yoosef-Ghodsi, C-FER Technologies, Edmonton, Alberta, Canada

Greg Zinter, Applus RTD, Edmonton, Alberta, Canada

International Advisory Board

Oil and Gas Pipelines

Integrity and Safety Handbook

Preface

Contributors

Part I
Design