STRESS-CORROSION IN TRUNK PIPELINES:

CURRENT STATUS AND SAFE OPERATION FORECAST

V.V. Kharionovsky (Gazprom VNIIGAZ),
V.N. Lisin, E.A.Spiridovich, A.F. Puzhailo (DOAO “Giprogaztsentr”)

1 Introduction
Stress-corrosion is a factor that shapes the operational status of the trunk pipelines.
Being a complex and ambiguous phenomenon underlain by various environmental
conditions, stress state, structure and metal-specific properties, stress-corrosion is known as
one of the most dangerous types of damages affecting pipes (Figure. 1).

SCC
Longitudinal SCC

Lateral SCC

Figure 1. Factor set determining initiation and propagation of stress-corrosion in gas

pipelines

According to recent findings, apart from linear part of trunk pipelines, underground
flowlines (compressor stations process pipelines) are also affected by stress-corrosion.
In-pipe inspection is somewhat difficult to conduct on compressor station flowlines as
soon as the pigs can not be run, therefore specific corrosion control and pipeline
maintenance methods need to be developed.
These days, OAO Gazpom is implementing a plan package to mitigate risks of
failures due to stress-corrosion. The root causes of stress-corrosion have been detected; a
pipeline maintenance methods have been adopted (including methods of inspection,
evaluation of strength properties and scope of repair); a pipeline re-insulation program has
been launched (under this program a large variety of coatings have been developed to
ensure reliable corrosion-proof operation of pipelines).

2 Focus Areas
Due to the efforts of OAO Gazpom, its subsidiaries, specialised and research
organisations, operating reliability of gas transport objects is managed to maintain at the
stable level and prevent avalanche increase of failures. The distinctive progress has been
made in the lots of organisational and engineering issues associated with mitigation of
stress-corrosion risk. At the moment, the major causes and conditions of stress-corrosion are
identified and the strategy of maintenance service is developed for gas pipelines which are
the subject of corrosion. This technique includes different diagnostic methods and
technologies, strength assessment and repair of trunk pipelines exposed to SCC (Figure 2).
Number of identified and repaired SCC defects is growing with the increase of maintenance
overhaul; the production models of scanners able to detect SCC defects during re-insulation
are developed along with the methods of SCC defects welding-up and maintenance of pipes
with SCC defects by couplings.

Progressing of non-destructive inspection facilities

Flaw detecting scanners

Working out methods and technologies for

repair of pipes with SCC defects

Figure 2. Maintenance of trunk gas pipelines exposed to SCC

Evolution of the gas mains failure occurrences caused by SCC (Figure 3) in OAO
Gazpom shows that the number of them tends to decrease due to the package plan
implemented by OAO Gazpom, its subsidiaries, specialised and research organisations. The
stable trend of reducing the pipelines accidents caused by SCC has emerged during the last
10 years, for the first time after the year 2004.
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Figure 3. Statistics of SCC-caused failures of trunk gas pipelines in OAO Gazpom during
1991-2008

The positive trends are observed in the dynamics of the amount of SCC defects,
which are registered in the sections of the repeated in-line inspections (Figure 4). On the
Figure 4 one can clearly see the decrease of SCC defects number registered by the
repeated in-line inspections (ILI). This goes to prove that it is not a significant growth of
existing SCC defects in the most sections of gas mains. A similar trend is generally observed
in the overall dynamics (of primary and repeated inspections) to identify SCC defects

100
Reduced defects amount

90

80

70

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50

40

30

20
Sections with 3 ILI
10
0 Sections with 2 ILI
1
2
3
ILI number

Figure 4. Comparison of the number of observed SCC defects while the repeated inspections

Pipeline protection projects may focus on the following areas:

- regular inspections of trunk pipelines by running “Spetsneftegaz” magnetic flaw
detectors that are capable of detecting the longitudinal cracks;
- development of production models of scanners to detect flaws during re-insulation;
 - development of regulations for inspecting and evaluating severity of stress-
corrosion defects;
- research projects focusing on analysis of stress-corrosion in compressor stations
flowlines;
- development of repair methods involving welding, application of pipe couplings, or
removal of damaged sections.

Evaluation of stress-corrosion on the compressor station flowlines

Started in 2005-2008, re-insulation activities showed the high relevance of SCC
challenge on the process pipelines of the compressor stations (CS). Opposite to
assumptions, the pipelines of I and B classes occurred to be exposed to stress-corrosion
among the others (Figure 5). The situation is worse in comparison with the linear trunk
pipeline portions because the CS flowlines are still not available for in-line inspection whilst
the consequences of the CS accidents may be incomparably greater. What is more, the
existing regulations don't consider the possibility of pipes repair on the sections of I and B
classes. The issue of SCC on the process pipelines of CS should be expanded.

Figure 5. State of SCC issue on the process pipelines of CS

During 2006-2008 and till now the comprehensive repair of the process
communications has been conducted on 75 CS compressor sections with total length of
more than 90 km of flowlines. The examples of detected defects are presented along with
their parameters on Figure 6.
• Max length of SCC zone — all the pipe (up to 11m)
• Max width — up to the half round of pipe (mostly on the ground part)
• Max depth of cracks — up to 5 mm
• Most of SCC zones include the area of thermal impact near the welding
joint (pipelines Du 720, Du 1020 and Du 1420 mm)

Figure 6. The main features of detected SCC defects of CS processing pipelines

One may state that processes evident now due to SCC on the CS processing
communications are the same as on the linear trunk pipeline portions 10-15 years ago. The
SCC defects were detected as a result of examination in the pipes with diameter 720, 1020,
1220 and 1420 mm. For the listed pipes SCC defects occurs at wall thickness from 9 to 23.3
mm, it confirms that SCC process can occur on the heavy walled pipes of I and B classes.
So, it is evident today that that SCC defects occurrence on the CS flowline is not a random
event. Obviously, the fact of detection of SCC defects on the CS flowline shows that the
extent of SCC on the gas transportation facilities is really much more considerable than it
was previously expected.

3. Research Methods
3.1.Comprehensive research.
Pipeline sections potentially vulnerable to stress-corrosion are detected by
implementing a set of services that identify favorable stress-corrosion conditions and drivers
stimulating its propagation. The set of services includes analysis of design and operation
documentation, field studies, and data processing. The algorithm of services is shown on the
following flowchart (Figure 7). The flow chart includes design stage measures that help
mitigate stress-corrosion risks by selecting the appropriate route sections. During the
operation stage the in-pipe inspection and coating inspection data is used.
 Figure 7 Potentially vulnerable sections distribution flow chart.

Based on the result of research general drivers are identified – a stress state,
insulation status, soil corrosion activity, ground water occurrence, that are evaluated by using
weight metrics.
On the next stage a severity level is evaluated, and the framework for the next
inspection is provided.

3.2. Detecting potentially vulnerable sections of compressor station flowlines.

As soon as inspection of process flowlines provides certain challenges, an individual
method was required for detecting potentially vulnerable sections and ranging compressor
stations based on the priority of inspection and technical maintenance. The method suggests
doing the following:
detect potentially vulnerable sections;
evaluate stress-corrosion defects in sampling pits;
evaluate operational reliability of the flowlines;
provide forecast of the stress-corrosion state.
This methodology is shown on the following flow chart, fig. 8. The main challenge with
the compressor station flowlines is that its underground sections need to be uncovered first
(the pits should be made) so that the inspection could be carried out. Then the workflow
follows the research algorithm specified under para 3.1.

Interpretation of design, construction, and operational specifications for

compressors\boosters process flowlines

Data card

Inspection plan

Inspection of pipelines to detect potentially vulnerable pipeline sections

Detecting magnetic Detecting flaws and

Stress-state
signatures by remote defects by in-pipe
evaluation
sensing inspection

Assessment of Identifying sections

Evaluation of
ground water subject to cyclic
insulation status
occurrence wetting

Evaluation of soil Lithology

corrosion activity evaluation

Processing of inspection results and calculation of integral SCC risk index

Scheduling inspection of pipelines in pits to

detect potentially vulnerable sections

Inspection of pipelines in pits

Conclusion on SCC database

technical status

Figure 8 The workflow of identification of potentially vulnerable sections and inspection of

compressors process flowlines in pits.

3.3. Repair methods

Based on the inspection results, the following repair methods to remove stress-
corrosion defects were developed:
* crack grinding and a follow-up welding repair technique;
* application of pipe couplings;
* removal of a damaged section.
The applicable technique is selected based on the flaw severity and the priority status
of a pipeline. Fig. 9 shows the repair technique selection algorithm for process flowlines of a
compressor station that are deemed to be top priority facilities of a trunk pipeline. The flow
chart shows a number of selection scenarios that vary depending on the crack depth and
length, physical properties of a pipe metal, and the degree of stress-state.

Setting initial metrics:

category of compressor station process flowline;
pipe metrics (diameter Dн, wall thickness δ) and pressure p;
physical material properties (KIC, σв, σт);
real defect size (
, Lр, Wр)
coupling workload, ∆p

Repair method applicability check: controlled grinding for I & В pipelines.

Rk ≤ [Rg] Controlled grinding repair

yes
method
dр ≤ [d]

no

Repair method applicability check: pipeline couplings

Rc ≤ [Rg]
yes
Lр ≤ [Lм]
Application of pipeline couplings
Rт ≤ 1

no

Repair method applicability check: controlled grinding and application of pipeline

couplings for I pipelines.

Rм ≤ [Rg]
yes Controlled grinding and application of pipeline
Lр ≤ [Lм] couplings
Rk ≤ 1

no

Removal of sections in I & B pipelines

Figure 9 Selection of a method to repair pipes with crack-like defects

4. Providing a stress state forecast for a pipeline sections

During the last years the significant amount of researches was carried out to develop
the new methodological approaches of detection of pipeline sections, which are potentially
vulnerable to stress-corrosion; pipes of gas mains were ranked by their vulnerability to SCC
etc. Figure 10 presents the methodological approach for scheduling the next in-line
inspection on the trunk gas pipelines sections exposed to SCC. This approach is
implemented in the Gazprom 2-2.3-095-2007 «Guidelines for diagnostic examination of
linear portion of the trunk gas pipelines» standard statement document. Timing for the next
in-line inspection of trunk gas pipelines is defined on the base of evaluation of the expected
increase of detected defects number; statistic processing of ILI results are used for this
purpose. This figure shows also predicted dependence of mean time between trunk gas
pipeline failures on the amount of the maintenance works after the in-line inspection.

Evaluating current status

of pipeline sections
Processing results of in-pipe inspection Maintenance
Identifying flaw distribution parameters costs
Defect propagation
forecast for a
f( d ) Distribution pipeline section
parameter σo σ(t)

n =356 Time
m=123 Expected number of Flaw depth 53
distribution after Maintenance
faulty pipes (before maintenance
The number of pipes
inspection), n that require maintenance

σo Effective number of
faulty pipes detected
d =d/ d during inspection, m Next in-pipe
inspection date
Flaw depth and time
distribution before
Inspection costs maintenance recommendations

Figure 10 The stress-state forecast for a trunk pipeline section provided on the basis of in-
pipe inspection results and definition of the scope of repair

The surface technique for stress-corrosion diagnostics has got a practical application.
It is based on the design and as-built documentation and was developed in “Giprogaztsentr”
research institute. The prediction methodology for identification of potentially vulnerable
stress-corrosion sections was developed on the base of this technique (see Figure 11).
Scheme shows that it is possible to detect the sections with the probable stress-corrosion on
the base of soil conditions analysis, hydrogeological data, design and construction solutions
and take appropriate actions on the design stage.

Hydrogeology data — areas Indications of SCC

of pipes cyclic wetting vulnerability
III-IV class section
Ph – soil
Film insulation

Potentially vulnerable PVS lists for SCC forecast with

sections (PVS) enterprises map-making

Operational planning and Long-term planning

optimization of in-line Design preventive maintenance;
inspection Diagnostics;
Repairs
Figure 11. Prediction technique for identification of potentially vulnerable stress-corrosion
sections
 The new technology recently developed in VNIIGAZ Ltd. is rather prospective for
identification of pipe steels vulnerability to SCC. This technology is based on the laboratory
tests of the model x-shaped samples and allow to simulate cracking process in the short
time (Figure 12). The technology implemented in Gazprom 2-5.1-148-2007 «Test methods
for steel and welded joints for stress-corrosion cracking” document allows to estimate the
influence of forces of metallurgic and engineering nature that are responsible for SCC
occurrence. According to this technique the vulnerability to SCC of number of Russian and
imported pipes is evaluated. Figure 13 presents the results of stress cracking resistance
examination of 6 pipe types that was conducted together with «JFE STEEL
CORPORATION» (Japan). Figure 13 shows that the examination allowed to rank the pipes
by their vulnerability to stress-corrosion and detect the correlation between structure and
strength of the steel and vulnerability to cracking.

X-shaped samples
Samples cracking while testing

Testing for SCC with biaxial loading

Figure 12. The new techniques of pipe steels examination for resistivity to SCC
 Figure 13. The results of evaluation of resistance to SCC for pipe steels.
Investigation of VNIIGAZ-JFE (Japan)

At present, the most part of scientific and engineering problems related to the applied
components of the SCC challenge are solved as a part of yearly R&D Programs of OAO
Gazprom.
For the last three years VNIIGAZ Ltd. has developed five regulatory documents
(Figure 14) relating to SCC effect in diagnostics, strength calculation, testing and
improvement of repair methods.

Temporary instruction for

identification of stress-corrosion
vulnerable sections and technical
diagnostics of gas flowlines on
compressor stations

Temporary instruction for rejection

and repair of gas flowlines on
compressor stations

Technology of classification of
SCC defects that are subject to
repair with pipe couplings on the
gas pipelines sections of the first
and B classes

Figure 14. Regulatory documents considering SCC effect.

 5. Conclusion
In Russia a well-established comprehensive system is implemented that enables detect,
repair and provide forecast for stress-state defects propagation and applicable methods of
repair.
The scope of stress-corrosion field research is required to include the following:
- the study of impact of pipe structure and factory defects on physical
properties of the pipes, stress cracking resistance, and operational reliability.
- development of methodical framework and tools enabling control of physical
and chemical environment metrics that stimulate stress-corrosion, general, and sub-
coating corrosion during pipeline construction and operation.