Based on EN 16348
Standardised Integrity Assessment
Company Standard
Basic Principles of Pipeline Integrity;
Rules and Procedures for Verification
of Technical Pipeline Integrity
25
 Internal Company Standard
 Basis for Assessment of Pipeline Integrity
 Describes basic principles of pipeline
integrity
 Describes methods and procedures for
assessment of pipeline condition
 Describes type, extent and frequency of
testing and assessment
 Contains assessment criteria and limit values
 Describes possible mitigating measures.
Pipeline Operation and Maintenance | 10.4.2014
 Integrity Risks 26

General Corrosion Milling defects

• Under shielding coatings  Material defects
• Due to insufficient cp  Inclusions
• Within casings  Laminations
• Under concrete saddles  Rolling defect
 Grindings

Geometrical Defects
Corrosion by Interference
 Expansions
 AC corrosion
 Dents
 DC stray current corrosion

Cracks Routing and Strain

 Stress corrosion cracking  Pipeline displacement
 …  Additional strain

Mechanical Damage Miscellaneous

(Third party interference)  Girth weld anomalies
 By trenching machines  Lightning puncture
 Drilling  …
 Dents
 …
Pipeline Operation and Maintenance | 10.4.2014
 Based on EN 16348 27

Pipeline Classification for Integrity Assessment

Pipeline Main Tool for

Pipeline Category I Pipeline Category III
Category II Integrity Assessment

Inline Inspection
(Intelligent Pigging)

Not piggable Piggable

Electrically welded (sections ≥ 20 km, > DN 200)
CP almost since Electrically welded
up to 1954 since 1955 CP since construction
construction

Not piggable
Gas or electrically welded
Intensive measurement
Old pipe joints Casing survey
Long operational period without CP

Not piggable
(e.g. sections < 20 km)
Electrically welded
Joint assessment (PIA2)
CP since construction Intensive measurement
Casing survey

1912 1958 1963 today

Year of construction
Pipeline Operation and Maintenance | 10.4.2014
 Based on EN 16348 28

Integrity Assessment Process

Pipeline category I Pipeline category II Pipeline category III
Sleeve sockets Not piggable piggable
1912 – 1958 BJ 1959 - today 1963 - today

Schadenszahl pro Jahr & 100 km

1,8

1,6

Priorisation and determination

1,4

1,2

1,0

0,8

0,6

of assessment method
0,4

0,2

0,0

Ltg 15 Ltg 7 Ltg 6 Ltg 1 Ltg 9 Ltg 5 Ltg 2

Hauptleitung inkl. Anschlüssen

 Sleeve sockets (PIA²)  Inline inspection

 Intensive measurement
 Assessm. of casing pipes  High voltage assessment

Assessment and detail assessment

(corrosion protection, materials)

Measures
(Repair, securing, refurbishment, replacement)

Verification of Pipeline Integrity

(Documentation, definition of expiry date)
Pipeline Operation and Maintenance | 10.4.2014
 Integrity Assessment Tools
29

Integrity Measures and Intervals

Integrity Measure or Element Interval Reference
As-built documentation once G 463
Pressure test / stress test once G 463
Verification of CP effectiveness (e.g. by intensive measurement) once GW 10
Check of pressure safeguarding every four years G 495
CP remote monitoring every two months GW 10
Check of CP, off-potential measurements every three years GW 10
Check of AC interference situation every five years GW 10
Depending on
Pipeline monitoring and maintenance (incl. tightness testing) G 466-1
pipeline routing
Valve functional testing annual G 466-1
acc. to integrity G 466-1,
Integrity assessment
strategy (15 – 25 y) RN 210-001
acc. to ILI strategy G 466-1,
Inline inspection
(15 – 25 y) RN 210-001
Assessment of old joints typically once RN 210-001
Strategy in the case of previous damage Case-by-case …
Excavation, NDT, check for corrosion, ... Case-by-case …
Pipeline Operation and Maintenance | 10.4.2014
 30

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

Pipeline Operation and Maintenance | 10.4.2014

 DVGW
Integrity G … Tools
Assessment 31

CP-Tools/Methods and Intervals

CP-Tool / Method Example Reference Interval
Verification of cp effectiveness e.g. Intensive measurement GW 10 once
CP remote monitoring GW 16 2 month
Off-potantial measurement at
GW 10 3 years
selected test stations
CP survey measurements
GW 10, AfK 1 3 years
at casings
Review and check of AC
AfK 3, GL 718-079 5 years
interference situation
Intensive measurement Integrity assessment G 466-1, RN 210-001 15 – 25 years 1
Location of defects within
RN 268-022 (TVB)
warranty period
Intesive fault detection Case by case
AC corrosion assessment AfK 11

Verification of ILI features G 466-1, RN 210-001

Verification of cp effectiveness GW 10
Mobile cp probe Case by case
Integrity assessment G 466-1, RN 210-001

1) Depending on condition of pipeline

Pipeline Operation and Maintenance | 10.4.2014
 EN 12954, DVGW GW 12 32

Corrosion Protection of Burried Pipelines

Transformer/ Decoupling
Rectifier device
Test post

+ -
Power
supply
Anode (+)

Negative
drain (-)
Coke Groundbed Reference Coating
electrode defect
Test coupon
Cathodic Protection (CP) Earthing
strip
Coated pipeline
Protective current
Passive Corrosion Protection

Burried pipelines are protected against corrosion by a combination of

electrochemical protection (cathodic corrosion protection) and an electrically insulating
coating (passive corrosion protection).
Pipeline Operation and Maintenance | 10.4.2014
 EN 12954, DVGW GW 12 33

Prerequesites for Installation of CP (EN 12954, GW12)

 Electrical separation from grounded installations
(e.g. Metering- and compressor stations, grounding systems, e-valves)
 Use of unsulating couplings or flanges

 Longitudinal electrical conductivity

 fullfilled for continuously welded pipelines

 Electrically insulating coating

 factory and field coating of all installations

Pipeline Operation and Maintenance | 10.4.2014

 34

Typical Corrosion Risks on Pipelines

Corrosion under disbonded coatings Corrosion due to insufficient CP

Corrosion within
casings

Corrosion under concrete saddles AC corrosion

Pipeline Operation and Maintenance | 10.4.2014
 DVGW GW 12, GW 10, … 35

Quality Assurance by Corrosion Protection Measurements

 Coating insulation test (at construction stage)

 Drainage test (at construction stage)
 Intensive defect detection survey (within warranty period)
 Intensive measurement survey (existing pipelines)

 Main objective is to prevent coating defects

Pipeline Operation and Maintenance | 10.4.2014

 AfK No. 10  DVGW GW 27, EN 13509 36

Intensive Measurement (CIPS + DCVG)

Reference electrode
Potential measurement
V
Uon , Uoff

Voltage
gradient V
measurement
V
Uon, Uoff e.g. 5 m

e.g. >10m
Cable
connection

CP protected, coated pipeline

Coating defect

Pipeline Operation and Maintenance | 10.4.2014

 AfK No 1  DVGW GW 20 37

Assessment of Casings (Resistance Comparison Method)

Coating defect Transformer/

Rectifier
Casing pipe Product pipe

Pipeline

Rmi > Ra,min  CP is effecitve

(AfK Recommendation No. 1)
Rmi < Ra,min  Assessment not possible

Rmi = Calculated spread resistance of Ra,min = Spread resistance of a

coating defects within the casing pipe coating defect that can just be
protected

Pipeline Operation and Maintenance | 10.4.2014

 Integrity  DVGW GW 22
AfK No. 3 Assessment Tools 38

High-Voltage Interference

High-voltage power line

high voltage line

UAC Coating
coating fault defect UAC
with AC
(AC-voltage) corrosion
corrosion

JAC
JAC

IAC Pipeline
steel pipeline

coating
Voltage UAC

Voltage UAC

max. touch voltage

Calculated Calculated
voltage without voltage with
grounding systems grounding systems
AC corrosion
Pipeline Operation and Maintenance | 10.4.2014
 Development of a Third Party Interference
Beyond
Detection DVGW
System GW …Safety
 Additional

„Hazard“ „Protection“
New approach for pipeline protection
against external damage

TPI detection by CP measurement technique

Benefit:
 Real-time identification of a damage
(liability)
 Increased level of safety
 Potential for optimisation of survey cycles

TGL
 Beyond DVGW GW … 40

The Idea

Pipeline Operation and Maintenance | 10.4.2014

 Beyond DVGW GW … 41

The Idea

Pipeline Operation and Maintenance | 10.4.2014

 42

Test-
Realtest 11.03.2009, Test Scenario post

TestPipeline DN 300, Length 12 m

Gaspipeline
DN 1200
PN 100

Pipeline Operation and Maintenance | 10.4.2014

 Beyond DVGW GW … 43

Real Test

Minidigger

Test Pipeline before Backfilling

22 tonPipeline
Chain Operation and Maintenance |
Dredger 10.4.2014
 Beyond DVGW GW … 44

Real Tests

Test 2 Test 4

Pipeline Operation and Maintenance | 10.4.2014

 45

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

Pipeline Operation and Maintenance | 10.4.2014

 Stress Test
DVGW G 463 46

Stress Test = Hydrostatic Test close to yield strength to identify and

eliminate pipe with serious defects, e.g. weld defects, out of spec
material; but no minor defects (VDTÜV Working sheet No. 1060)

Rt0.5 = 1.6 MOP

Internal pressure

Pressure test at min. 1.3 MOP

MOP

Time Pipeline Operation and Maintenance | 10.4.2014

 DVGW G 463 47

Mill Defects found by Stress Test (at / after Construction)

Inclusion & Lamination Overlapping from

Plate rolling
Pipeline Operation and Maintenance | 10.4.2014
 DVGW G 463 48

Cracks & Gouges found by Stress Test (Rehabilitation)

SCC External Interference

Fatigue Crack Girth Weld Defects

Pipeline Operation and Maintenance | 10.4.2014