Details

Oil and Gas Pipelines

Integrity and Safety Handbook
1. Aufl.

von: R. Winston Revie
177,99 €
Verlag:	Wiley
Format:	PDF
Veröffentl.:	01.04.2015
ISBN/EAN:	9781119019190
Sprache:	englisch
Anzahl Seiten:	864

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Titelbeschreibung

A comprehensive and detailed reference guide on the integrity and safety of oil and gas pipelines, both onshore and offshore <ul> <li>Covers a wide variety of topics, including design, pipe manufacture, pipeline welding, human factors, residual stresses, mechanical damage, fracture and corrosion, protection, inspection and monitoring, pipeline cleaning, direct assessment, repair, risk management, and abandonment</li> <li>Links modern and vintage practices to help integrity engineers better understand their system and apply up-to-date technology to older infrastructure</li> <li>Includes case histories with examples of solutions to complex problems related to pipeline integrity</li> <li>Includes chapters on stress-based and strain-based design, the latter being a novel type of design that has only recently been investigated by designer firms and regulators</li> <li>Provides information to help those who are responsible to establish procedures for ensuring pipeline integrity and safety</li> </ul>

Inhaltsverzeichnis

Preface xxxi Contributors xxxiii Part I Design 1 Pipeline Integrity Management Systems (PIMS) 3 Ray Goodfellow and Katherine Jonsson 1.1 Introduction 3 1.2 Lessons Learned and the Evolution of Pipeline Integrity 4 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 8 1.7 Plan: Strategic and Operational 8 1.8 Do: Execute 9 1.9 Check: Assurance and Verification 10 1.10 Act: Management Review 10 1.11 Culture 11 1.12 Summary 11 References 11 2 SCADA: Supervisory Control and Data Acquisition 13 Michael VanderZee, Doug Fisher, Gail Powley, and Rumi Mohammad 2.1 Introduction 13 2.2 SCADA Computer Servers 14 2.3 SCADA Computer Workstations 14 References 26 3 Material Selection for Fracture Control 27 William Tyson 3.1 Overview of Fracture Control 27 3.2 Toughness Requirements: Initiation 28 References 34 4 Strain-Based Design of Pipelines 37 Nader Yoosef-Ghodsi 4.1 Introduction and Basic Concepts 37 4.1.1 Overview of Strain-Based Design 37 4.5 Summary 46 References 46 5 Stress-Based Design of Pipelines 49 Mavis Sika Okyere 5.1 Introduction 49 5.2 Design Pressure 49 5.13 Summary 64 References 65 6 Spiral Welded Pipes for Shallow Offshore Applications 67 Ayman Eltaher 6.1 Introduction 67 6.2 Limitations of the Technology Feasibility 68 6.3 Challenges of Offshore Applications 68 6.3.1 Design Challenges 68 6.3.2 Stress Analysis Challenges 68 6.3.3 Materials and Manufacturing Challenges 69 6.4 Typical Pipe Properties 70 6.5 Technology Qualification 70 6.6 Additional Resources 71 6.7 Summary 71 References 71 7 Residual Stress in Pipelines 73 Paul Prevéy and Douglas Hornbach 7.1 Introduction 73 7.1.1 The Nature of Residual Stresses 73 7.1.2 Sources of Residual Stresses 74 7.2 The Influence of Residual Stresses on Performance 76 7.2.1 Fatigue 77 7.2.2 Stress Corrosion Cracking 78 References 96 8 Pipeline/Soil Interaction Modeling in Support of Pipeline Engineering Design and Integrity 99 Shawn Kenny and Paul Jukes 8.1 Introduction 99 8.2 Site Characterization and Geotechnical Engineering in Relation to Pipeline System Response Analysis 101 8.2.1 Overview 101 8.2.2 Pipeline Routing 102 Acknowledgments 130 References 130 9 Human Factors 143 Lorna Harron 9.1 Introduction 143 9.2 What Is “Human Factors”? 143 9.3 Life Cycle Approach to Human Factors 143 9.9 Summary 154 References 155 Bibliography 155 Part II Manufacture, Fabrication, and Construction 10 Microstructure and Texture Development in Pipeline Steels 159 Roumen H. Petrov, John J. Jonas, Leo A.I. Kestens, and J. Malcolm Gray 10.1 Introduction 159 10.2 Short History of Pipeline Steel Development 160 10.5 Summary 182 Acknowledgments 183 References 183 11 Pipe Manufacture—Introduction 187 Gerhard Knauf and Axel Kulgemeyer 11.1 Pipe Manufacturing Background 187 11.2 Current Trends in Line Pipe Manufacturing 187 References 188 12 Pipe Manufacture—Longitudinal Submerged Arc Welded Large Diameter Pipe 189 Christoph Kalwa 12.1 Introduction 189 12.2 Manufacturing Process 189 12.3 Quality Control Procedures 191 12.4 Range of Grades and Dimensions 192 12.5 Typical Fields of Application 192 13 Pipe Manufacture—Spiral Pipe 195 Franz Martin Knoop 13.1 Manufacturing Process 195 13.2 Quality Control Procedures 198 13.3 Range of Grades and Dimensions 198 13.4 Typical Fields of Applicability 200 References 201 14 Pipe Manufacture—ERW Pipe 203 Holger Brauer and Hendrik Löbbe 14.1 Introduction 203 14.2 Manufacturing Process 203 14.3 Quality Control Procedures 204 14.3.1 Welding Line 205 14.3.2 Finishing Line 206 14.3.3 Destructive Material Testing 208 14.4 Range of Grades and Dimensions 208 14.5 Typical Fields of Applicability 208 References 209 15 Pipe Manufacture—Seamless Tube and Pipe 211 Rolf Kümmerling and Klaus Kraemer 15.1 The Rolling Process 211 15.1.1 Introduction and History 211 15.1.2 Cross Rolling Technology 212 15.1.3 Pilger Rolling 213 15.1.4 Plug Rolling 215 15.1.5 Mandrel Rolling 216 15.1.6 Forging 218 15.1.7 Size Rolling and Stretch Reducing 218 15.2 Further Processing 219 15.2.1 Heat Treatment 219 15.2.2 Quality and In-Process Checks 221 15.2.3 Finishing Lines 221 References 222 16 Major Standards for Line Pipe Manufacturing and Testing 223 Gerhard Knauf and Axel Kulgemeyer 16.1 API SPEC 5L/ISO 3183 223 16.2 CSA Z662-11: Oil and Gas Pipeline Systems 223 References 224 17 Design of Steels for Large Diameter Sour Service Pipelines 225 Nobuyuki Ishikawa 17.1 Introduction 225 17.2 Hydrogen-Induced Cracking of Linepipe Steel and Evaluation Method 225 17.2.1 Hydrogen-Induced Cracking in Full-Scale Test 225 17.2.2 Standardized Laboratory Evaluation Method for HIC 227 17.2.3 Mechanisms of Hydrogen-Induced Cracking 227 17.3 Material Design of Linepipe Steel for Sour Service 228 17.3.1 Effect of Nonmetallic Inclusions 228 17.3.2 Effect of Center Segregation 229 17.3.3 Effect of Plate Manufacturing Condition 229 References 230 18 Pipeline Welding from the Perspective of Safety and Integrity 233 David Dorling and James Gianetto 18.1 Introduction 233 18.2 Construction Welding Applications 234 18.2.1 Double-Joint Welding 234 18.2.2 Mainline Welding 234 18.2.3 Tie-In and Repair Welding 236 18.3 Nondestructive Inspection and Flaw Assessment 237 18.4 Welding Procedure and Welder Qualification 239 18.4.1 Welding Codes and Standards 239 18.4.2 Welding Procedures 239 18.4.3 Welding Procedure Specification 239 18.4.4 Procedure Qualification Record 240 18.4.5 Qualification of Welders 240 18.5 Hydrogen Control in Welds and the Prevention of Hydrogen-Assisted Cracking 240 18.6 Important Considerations for Qualifying Welding Procedures to a Strain-Based Design 242 18.7 Welding on In-Service Pipelines 243 18.8 Pipeline Incidents Arising from Welding Defects and Recent Industry and Regulatory Preventative Action 245 Appendix 18.A: Abbreviations Used in This Chapter 247 Appendix 18.B: Regulations, Codes, and Standards 247 References 248 19 The Effect of Installation on Offshore Pipeline Integrity 253 Robert O’Grady 19.1 Introduction 253 19.2 Installation Methods and Pipeline Behaviour During Installation 253 19.2.1 Pipeline Installation Loading and Failure Modes 253 19.2.2 S-Lay Method 254 19.2.3 J-Lay Method 256 19.2.4 Reel-Lay Method 256 19.3 Critical Factors Governing Installation 257 19.3.1 Vessel Restrictions 257 19.3.2 Pipeline Integrity Criteria 257 19.4 Installation Analysis and Design Methodologies 259 19.4.1 Global Installation Analysis 259 19.4.2 Methodologies 259 19.5 Monitoring the Installation Process Offshore 261 19.5.1 Monitoring Process and Remedial Action 261 19.5.2 Monitoring Analysis Software 261 19.6 Implications of Deeper Water on Installation 261 19.6.1 Increased Tension and Potential for Local Buckling 261 19.6.2 Plastic Strains 262 19.6.3 Prolonged Fatigue Exposure 262 19.6.4 Design Implications 262 Reference 262 Bibliography 262 Part III Threats to Integrity and Safety 20 External Corrosion of Pipelines in Soil 267 Homero Castaneda and Omar Rosas 20.1 Introduction 267 20.2 Background 267 References 273 21 Telluric Influence on Pipelines 275 David H. Boteler and Larisa Trichtchenko 21.1 Introduction 275 21.2 Review of the Existing Knowledge on Pipeline-Telluric Interference 275 21.3 Geomagnetic Sources of Telluric Activity 276 21.4 Earth Resistivity Influence on Telluric Activity 278 21.5 Pipeline Response to Telluric Electric Fields 278 21.6 Telluric Hazard Assessment 279 21.6.1 Geomagnetic Activity 279 21.6.2 Earth Conductivity Structure 280 21.6.3 Pipeline Response 280 21.7 Mitigation/Compensation of Telluric Effects 281 21.8 Knowledge Gaps/Open Questions 283 21.9 Summary 283 Acknowledgments 285 References 285 22 Mechanical Damage in Pipelines: A Review of the Methods and Improvements in Characterization, Evaluation, and Mitigation 289 Ming Gao and Ravi Krishnamurthy 22.1 Introduction 289 22.2 Current Status of In-Line Inspection (ILI) Technologies for Mechanical Damage Characterization 290 References 322 23 Progression of Pitting Corrosion and Structural Reliability of Welded Steel Pipelines 327 Robert E. Melchers 23.1 Introduction 327 23.2 Asset Management and Prediction 328 23.3 Pitting 328 Acknowledgments 339 References 339 24 Sulfide Stress Cracking 343 Russell D. Kane 24.1 Introduction 343 24.2 What Is Sulfide Stress Cracking? 343 References 351 25 Stress Corrosion Cracking of Steel Equipment in Ethanol Service 353 Russell D. Kane 25.1 Introduction 353 25.2 Factors Affecting Susceptibility to Ethanol SCC 353 References 360 Bibliography of Additional eSCC Papers 361 26 AC Corrosion 363 Lars Vendelbo Nielsen 26.1 Introduction 363 26.2 Basic Understanding 363 26.2.1 The Spread Resistance 365 26.2.2 The Effect of AC on DC Polarization 368 26.2.3 The Vicious Circle of AC Corrosion—Mechanistic Approach 370 26.3 AC Corrosion Risk Assessment and Management 373 26.3.1 Criteria 373 26.3.2 Current Criteria 373 26.3.3 Mitigation Measures 374 26.3.4 Monitoring and Management 379 References 382 Bibliography 382 27 Microbiologically Influenced Corrosion 387 Brenda J. Little and Jason S. Lee 27.1 Introduction 387 27.2 Requirements for Microbial Growth 388 27.6 Conclusions 395 Acknowledgments 395 References 395 28 Erosion–Corrosion in Oil and Gas Pipelines 399 Siamack A. Shirazi, Brenton S. McLaury, John R. Shadley, Kenneth P. Roberts, Edmund F. Rybicki, Hernan E. Rincon, Shokrollah Hassani, Faisal M. Al-Mutahar, and Gusai H. Al-Aithan 28.1 Introduction 399 28.2 Solid Particle Erosion 401 28.7 Summary and Conclusions 419 Acknowledgments 419 References 419 29 Black Powder in Gas Transmission Pipelines 423 Abdelmounam M. Sherik 29.1 Introduction 423 29.2 Internal Corrosion of Gas Transmission Pipelines 425 29.9 Summary 434 Acknowledgments 435 References 435 Part IV Protection 30 External Coatings 439 Doug Waslen 30.1 Introduction and Background 439 30.2 Coating Performance 439 Reference 446 31 Thermoplastic Liners for Oilfield Pipelines 447 Jim Mason 31.1 Introduction 447 31.2 Codes and Standards 447 References 454 32 Cathodic Protection 457 Sarah Leeds and John Leeds 32.1 Introduction 457 32.2 Historical Foundation of Cathodic Protection 457 References 482 Part V Inspection and Monitoring 33 Direct Assessment 487 John A. Beavers, Lynsay A. Bensman, and Angel R. Kowalski 33.1 Introduction 487 33.2 External Corrosion DA (ECDA) 488 References 493 34 Internal Corrosion Monitoring Using Coupons and ER Probes 495 Daniel E. Powell 34.1 Introduction—Corrosion Monitoring Using Coupons and ER Probes 495 34.1.1 Corrosion—A Definition 496 References 513 35 In-Line Inspection (ILI) (“Intelligent Pigging”) 515 Neb I. Uzelac 35.1 Introduction 515 35.2 Place of ILI in Pipeline Integrity Management 515 References 535 Bibliography: Journals, Conferences and Other Sources with ILI Related Content 535 36 Eddy Current Testing in Pipeline Inspection 537 Konrad Reber 36.1 Standard Eddy Current Testing 537 36.1.1 Introduction 537 36.1.2 How Eddy Current Testing (ECT) Works 537 References 542 37 Unpiggable Pipelines 545 Tom Steinvoorte 37.1 Introduction 545 37.1.1 What Is an Unpiggable Pipeline? 545 References 554 Bibliography: Sources of Additional Information 555 38 In-the-Ditch Pipeline Inspection 557 Greg Zinter 38.1 Overview 557 38.2 Introduction to Nondestructive Examination of Pipelines 557 38.12 Summary 568 Acknowledgments 568 Reference 569 Bibliography 569 39 Ultrasonic Monitoring of Pipeline Wall Thickness with Autonomous, Wireless Sensor Networks 571 Frederic Cegla and Jon Allin 39.1 Introduction 571 39.2 The Physics of Ultrasonic Thickness Gauging 571 39.6 Summary 576 Acknowledgments 577 References 577 40 Flaw Assessment 579 Ted L. Anderson 40.1 Overview 579 40.1.1 Why Are Flaws Detrimental? 579 References 586 41 Integrity Management of Pipeline Facilities 587 Keith G. Leewis 41.1 Overview 587 41.2 Outline 588 41.3 Scoping a Facilities Integrity Plan 588 Part VI Maintenance, Repair, Replacement, And Abandonment 42 Pipeline Cleaning 601 Randy L. Roberts 42.1 Introduction 601 42.2 Contaminates 601 42.3 Progressive Pigging 602 42.10 Summary 607 References 607 43 Managing an Aging Pipeline Infrastructure 609 Brian N. Leis 43.1 Introduction 609 43.2 Background 609 Acknowledgments 633 References 633 44 Pipeline Repair Using Full-Encirclement Repair Sleeves 635 William A. Bruce and John Kiefner 44.1 Introduction 635 44.2 Background 635 44.3 Full-Encirclement Steel Sleeves 636 44.6 Summary and Conclusions 654 References 654 45 Pipeline Repair 657 Robert Smyth and Buddy Powers 45.1 Introduction 657 45.2 Background 657 45.3 Safety 657 References 664 46 Pipeline Oil Spill Cleanup 665 Merv Fingas 46.1 Oil Spills and Pipelines: An Overview 665 46.1.1 How Often Do Spills Occur? 665 46.1.2 Pipelines 666 References 687 47 Pipeline Abandonment 689 Alan Pentney and Dean Carnes 47.1 What Is Pipeline Abandonment? 689 47.2 Abandonment Planning 689 References 696 Part VII Risk Management 48 Risk Management of Pipelines 699 Lynne C. Kaley and Kathleen O. Powers 48.1 Overview 699 48.1.1 Risk-Based Inspection for Pipelines 699 48.1.2 Scope 700 48.1.3 Risk Analysis 700 48.1.4 The RBI Approach 702 48.1.5 Risk Reduction and Inspection Planning 703 48.5.1 Summary 724 48.5.2 Ten Criteria for Selecting the Most Appropriate Level of RBI 724 48.5.3 Justifying Costs 725 References 726 49 Offshore Pipeline Risk, Corrosion, and Integrity Management 727 Binder Singh and Ben Poblete 49.1 Introduction 727 49.2 Challenges, Lessons, and Solutions 728 49.3 Life Cycle 733 49.7 Summary: Recommendations and Future Strategies 755 Acknowledgments 755 References 755 Bibliography 756 Part VIII Case Histories 50 Buckling of Pipelines under Repair Sleeves: A Case Study— Analysis of the Problem and Cost-Effective Solutions 761 Arnold L. Lewis ii 50.1 Introduction 761 50.1.1 Statement of the Buckle/Collapse Problem 762 50.1.2 Observations 762 50.3 Summary 767 Acknowledgment 767 References 767 51 In-Line Inspection on an Unprecedented Scale 769 Stephan Brockhaus, Hubert Lindner, Tom Steinvoorte, Holger Hennerkes, and Ljiljana Djapic-Oosterkamp 51.1 Introduction 769 51.2 Challenging Design and Operating Conditions 769 51.3 Combined Technologies for Reliable Inspection Results 769 51.7 Summary 775 References 775 52 Deepwater, High-Pressure and Multidiameter Pipelines—A Challenging In-Line Inspection Project 777 Hubert Lindner 52.1 Introduction 777 52.2 Project Requirements 777 52.7 Summary 783 References 783 Glossary Part 1: Abbreviations 785 Part 2: Selected Terms 791 Index 793

Autorenportrait

R. Winston Revie retired from the CANMET Materials Technology Laboratory, Ottawa, Canada, in 2011, after 33 years as a scientist, project leader, and program manager for pipeline technology. He is a Past President of the Metallurgical Society of the Canadian Institute of Mining, Metallurgy and Petroleum, a Past President of the NACE Foundation of Canada, and a Past Director of NACE International. He received the Distinguished Technical Achievement Award of NACE International in 2004 and has received Fellow honors from CIM (1999), NACE International (1999), ASM International (2003), and The Electrochemical Society (2012) among other awards for his work. He has authored or co-authored more than 100 reference papers and technical reports and was the editor of Uhlig's Corrosion Handbook, 2nd and 3rd editions (Wiley, 2000 and 2011), and he co-authored the 3rd and 4th editions of Corrosion and Corrosion Control (Wiley, 1985 and 2008).

Back cover copy

A comprehensive and detailed reference guide on the integrity and safety of oil and gas pipelines Oil and gas pipeline transport is used to supply energy to power our industries, fuel our cars, and heat and cool our homes. While an extensive pipeline network is an efficient and safe method of transporting petroleum and other products, several hazards and incidents, such as gas leaks and oil spills, have raised environmental and social concerns. Oil and Gas Pipelines: Integrity and Safety Handbook discusses the factors that affect the integrity of new and aging pipelines, public safety, and environmental protection. It covers the reliability of pipelines as affected by factors throughout the pipeline lifetime, ranging from design, manufacture, and welding to operation, inspection, monitoring, maintenance, and repair. Through contributions from leading experts in diverse fields, Oil and Gas Pipelines: Integrity and Safety Handbook features: <ul> <li>52 peer-reviewed chapters on the integrity and safety of production and transmission pipelines, onshore and offshore</li> </ul> <ul> <li>Chapters on both stress-based and strain-based design, the latter being a novel type of design that has only recently been investigated by designer firms and regulators</li> <li>Detailed discussion of many critical issues, including mechanical damage, residual stresses, erosion-corrosion, pitting corrosion, microbiologically influenced corrosion, telluric effects, direct assessment, human factors, flaw assessment, integrity management of pipeline facilities, pipeline cleaning, black powder, oil spill cleanup, repair, abandonment, and risk management</li> <li>Links between modern and vintage practices to help integrity engineers better understand their system and apply up-to-date technology to older infrastructure</li> </ul> Additional chapters examine in-line inspection, in-the-ditch inspection, and internal corrosion monitoring. The book closes with several case histories with practical examples of solutions to complex problems related to pipeline integrity. The evolution of the pipeline industry has experienced many recent developments as a result of engineering advances, new standards and regulations, and environmental requirements. The breadth and depth of coverage of this Handbook make this new book a valuable source of information for all those concerned with pipeline technology.