Oil and gas pipelines integrity and safety

W ile O IL AND GAS PIPELINES INTERNATIONAL ADVISORY BOARD Ihsan A l-T aie R & D C enter S audi A ram co D hahran S audi A rabia J M alcolm G ray M icroalloyed Steel Institute Inc H ouston, TX U SA G erh ard K n au f S alzgitter M annesm ann Forschung G m bH E uropean Pipeline Research G roup e.V D uisburg G erm any M inxu Lu U niversity o f Science and T echnology Beijing B eijing C hina A lan M urray Principia C onsulting C algary A lberta C anada John O ’Brien Chevron H ouston TX USA Bill Santos N O V A C hem icals C entre o f Applied Research C algary, A lberta C anada Joe Zhou T ransC anada PipeL ines Lim ited C algary, A lberta C anada OIL AND GAS PIPELINES Integrity and Safety Handbook E dited by R W I N S T O N R E V I E ĨRUỜNGOHHANG HA1VIẼIKAM TÀi LIỆU THƯ VIỆN W iley C o p y rig h t © 2015 by Jo h n W iley & S o n s, Inc A ll rig h ts re serv ed P u b lish e d b y John W iley & S o n s, Inc H o b o k e n , N ew Jerse y P ub lish ed sim u lta n eo u sly in C an a d a N o p a rt o f th is p u b lic a tio n m ay b e re p ro d u c e d , sto red in a re trie v a l systein, o r tra n sm itte d in a n y fo rm o r by a n y m e a n s, e le c tro n ic , m e c h an ic a l, p h o to c o p y in g , rec o rd in g , scan n in g , o r o th e rw ise, e x c e p t as p erm itted u n d e r S e c tio n 107 o r 108 o f the 1976 U n ite d S ta te s C o p y rig h t A ct, w ith o u t e ith e r the p rio r w ritten perm issio n o f the P u b lish er, o r a u th o riz a tio n th ro u g h p a y m e n t o f the ap p ro p riate p e r-c o p y fee to the C o p y rig h t C le a n c e C enter Inc., 222 R o se w o o d D riv e , D a n v ers, M A , (9 ) -8 0 , i'ax (9 ) -4 , o r o n the w eb at w w 'w copyright.com R e q u e s ts to th e P u b lish e r fo r p e rm issio n should be a d d re sse d to the P e rm issio n s D e p artm e n t, Jo h n W iley & S o n s, Inc., 111 R iver S treet, H o b o k e n , N J , (2 ) -6 1 , fax (2 ) -6 0 o r o n lin e at h ttp ://w w w w ile y c o m /g o /p e m ii.ssio n L im it o f L iab ility /D isc la iin e r o f W arra n ty : W h ile th e p u b lis h e r a n d a u th o r have used th e ir b est e ffo rts in p re p a rin g th is b o o k , th e y m ake no re p re sen ta tio n s o r w a rra n tie s w ith resp ect to th e acc u c y o r co m p le ten e ss o f th e c o n te n ts o f this b ook and sp ecifically d is c la im a n y im p lie d w a rra n tie s o f m erch an tab ility o r fitness fo r a p articu lar p u ip o se N o w a rra n ty m ay be cre ated o r e x te n d ed by sales re p re sen ta tiv e s o r w ritten sale s m a te ria ls T h e a d v ic e a n d strategies c o n ta in ed herein m ay n o t be su ita b le fo r y o u r situ atio n Y o u s h o u ld c o n su lt w ith a p ro fessio n al w h e re a p p ro p ria te N e ith e r the p u b lish e r n o r a u th o r shall be liable fo r any loss o f p ro fit o r any o th e r co m m e rc ial d a m a g e s , in c lu d in g but n ot lim ited to special, in c id e n ta l, c o n se q u e n tia l, o r o th e r dam ages F o r g en eral in fo rm atio n on o u r o th e r p ro d u c ts an d serv ice s o r fo r technical su p p o rt, please c o n ta c t o u r C u s to m e r C are D e p a rtm e n t w ith in the U nited S tates at (8 0 ) -2 , o u tsid e the U n ited S ta te s at (3 ) -3 9 o r fax (3 ) 72-4002 W iley also p u b lish es its b o o k s in a v a rie ty o f ele ctro n ic fo rm a ts S om e content that appears in p rin t m ay n ot be a v a ila b le in e le c tro n ic form ats F or m ore in fo n n a tio n ab o u t W iley p ro d u c ts, v isit o u r w eb site at w w w w ile y c o m Library o f Congress Cataloging-in-Puhlication Data applied fo r P rinted in th e U n ited S tates o f A m erica 10 CONTENTS PREFACE XXX) C O N T R IB U T O R S xxxiii PART I D ESIG N Pipeline Integrity M a n a g em en t S y stem s (P IM S ) Ray G oodfellow and Katherine Jonsson 1.1 1.2 Introduction Lessons L earned an d the E volution o f Pipeline Integrity 1.3 W hat Is a P IM S ? 1.4 R egulatory R equirem ents 1.5 C ore Structure and P IM S E lem ents 1.6 PIM S F unction M ap 1.7 Plan: Strategic and O perational 1.8 Do; E xecute 1.9 C heck: A ssurance and V erification 1.10 Act: M anagem ent R eview 1.11 C ulture 1.12 Sum m ary R eferences 8 10 10 11 11 11 SC A D A ; S up ervisory C on tro l and D ata A cq uisition 13 M ichael VanderZee, Doug Fisher, Gail Pawley, and Rumi M oham m ad 2.1 2.2 2.3 2.4 2.5 2.6 2.7 Introduction SC A D A C o m p u ter S ervers SC A D A C o m p u ter W orkstatio n s H ierarchy R untim e and C onfiguration D atabases Fault T olerance R edundancy 13 14 14 15 15 15 16 2.8 2.9 2.10 11 2.12 2.13 2.14 2.15 2.16 2.17 2.18 Alarm R ationalization, M anagem ent, and A nalysis Incident Review and Replay Data Q uality O perator L ogbook and Shift H andover Training SC A D A U ser P erm issions and A O Rs W eb C onnection SC A D A Security H um an Factors D esign in SC A D A System s SC A D A Standards Pipeline Industry A pplications 2.18.1 Leak D etection 2.18.2 Batch T racking 2.18.3 D ynam ic Pipeline H ighlight 2.19 C om m unication M edia 2.19.1 Cat5 D ata C able 2.19.2 L eased Line 2.19.3 M icrow ave 2.19.4 D ial-U p Line 2.19.5 O ptical Fiber 2.19.6 Satellite 2.20 C om m unications Infrastructure 2.21 C om m unications Integrity 2.22 RTU s and PLC s 2.23 D atabase 2.24 U ser-D elined P rogram s 2.25 RT U /PLC Integrity R eferences M aterial Selection for F racture C ontrol 16 17 17 18 19 19 19 20 20 21 21 22 22 22 22 22 22 23 23 23 23 23 24 24 25 25 25 26 27 William Tyson 3.1 3.2 3.3 3.4 O verview o f Fracture C ontrol T oughness R equirem ents: Initiation T oughness R equirem ents: Propagation T oughness M easurem ent 3.4.1 T oughness M easurem ent: Im pact T ests 3.4.2 T oughness M easurem ent: J, C T O D and C T O A 3.5 CuiTent Status R eferences S train -B ased D esign o f Pipelines 27 28 29 31 32 32 33 34 37 N ader Yoosef-Ghodsi 4.1 Introduction and Basic C oncepts 4.1.1 O verview of Strain-B ased D esign 4.1.2 D eterm inistic versus Probabilistic Design M ethods 4.1.3 Lim it States 4.1.4 D isplacem ent C ontrol versus Load C ontrol 4.1.5 Strain-B ased D esign A pplications Strain D em and 4.2.1 O verview 4.2.2 C hallenging E nvironm ents and Strain D em and 37 37 38 38 38 39 39 39 39 4.2.3 Strain Levels and A nalysis C onsiderations Strain Capacity 4.3.1 O verview 4.3.2 C om pressive Strain Capacity 4.3.3 Tensile Strain C apacity 4.4 Role o f Full-Scale and Curved W ide Plate Testing 4.5 Sum m ary References 39 41 41 42 43 45 46 46 Stress-B ased D esign o f P ipelines 49 4.3 Mavis Sika Okyere 5.1 5.2 5.3 5.4 5.5 5.6 5.7 Introduction Design Pressure 5.2.1 M axim um A llow able O perating Pressure 5.2.2 M axim um O perating Pressure 5.2.3 Surge Pressure 5.2.4 Test Pressure D esign Factor D ctem iination of C om ponents o f Stress 5.4.1 H oop and Radial Stresses 5.4.2 L ongitudinal Stress 5.4.3 Shear Stress 5.4.4 Equivalent Stress 5.4.5 Lim its o f C alculated Stress Fatigue 5.5.1 Fatigue Life 5.5.2 Fatigue Lim it 5.5.3 S - N C urve Expansion and Flexibility 5.6.1 Flexibility and Stress Intensification Factors CoiTosion A llow ance 5.7.1 Internal C orrosion A llow ance 5.7.2 External C orrosion A llow ance 5.7.3 Form ulas 5.8 Pipeline Stiffness 5.8.1 C alculation o f Pipeline Stiffness 5.8.2 C alculation o f Induced B ending M om ent 5.9 P ipeline Ovality 5.9.1 B razier Effect 5.9.2 O vality o f a Buried Pipeline 5.10 M inim um Pipe Bend Radius 5.10.1 M inim um Pipe B end Radius C alculation B ased on Concrete 5.10.2 M inim um Pipe Bend Radius C alculation Based on Steel 5.10.3 Installation C ondition 5.10.4 In-Service C ondition 5.11 Pipeline D esign for External Pressure 5.11.1 Buried Installation 5.11.2 A bove-G round or U nburied Installation 5.12 C heck for H ydrotest C onditions 5.13 Sum m ary R eferences 49 49 49 50 50 50 50 51 51 51 55 56 56 57 57 57 57 58 58 59 59 59 59 59 59 61 61 62 62 62 62 62 62 63 63 63 64 64 64 65 S p iral W elded Pipes for Shallow O ffshore A pplications 67 Aymcm Eltaher 6.1 6.2 6.3 Introduction Lim itations o f tiie Teciinology Feasibility C hallenges o f O ffshore A pplications 6.3.1 D esign C hallenges 6.3.2 Stress A nalysis C hallenges 6.3.3 M aterials and M anufacturing C hallenges 6.4 T ypical Pipe Properties 6.5 T echnology Q ualification 6.6 A dditional R esources 6.7 Sum m ary R eferences 67 68 68 68 68 69 70 70 71 71 71 R esid u al Stress in Pipelines 73 Paul Prevey and Douglas Hornhacli 1 Introduction 7.1.1 The N ature o f R esidual Stresses 7.1.2 S ources o f Residual Stresses 7.2 T he Influence o f Residual Stresses on Perform ance 7.2.1 F atigue 7.2.2 Stress C orrosion C racking 7.2.3 C orrosion Fatigue 7.2.4 Effects o f Cold W orking and M icroscopic Residual Stresses 7.3 Residual Stress M easurem ent 7.3.1 C enter Hole D rilling M ethod 7.3.2 Ring C ore M ethod 7.3.3 D iffraction M ethods 7.3.4 Synchrotron X -R ay and N eutron Diffraction: Full Stress T ensor D eterm ination 7.3.5 M agnetic B arkhausen N oise M ethod 7.4 C ontrol and A lteration o f R esidual Stresses 7.4.1 Shot Peening 7.4.2 R oller or Ball B urnishing and Low Plasticity B urnishing 7.4.3 L aser Shock Peening 7.4.4 T herm al Stress R elief 7.5 Case Studies o f the Effect o f R esidual Stress and Cold W ork 7.5.1 C ase Study 1: R estoration o f the Fatigue P erfom iance o f C orrosion and Fretting D am aged 4340 Steel 7.5.2 Case Study 2: M itigating SCC in Stainless Steel W eldm ents 7.5.3 C ase Study 3: M itigation of Sulfide Stress C racking in PI 10 Oil Field C ouplings 7.5.4 Case Study 4; Im proving C orrosion Fatigue P erfonnance and D am age T olerance o f 410 Stainle.ss Steel 7.5.5 Case Study 5: Im proving the Fatigue Perform ance o f D ow nhole T ubular C om ponents R eferences 73 73 74 76 77 78 78 78 79 80 80 81 84 84 86 86 86 87 87 87 88 91 91 93 95 96 ... anada Joe Zhou T ransC anada PipeL ines Lim ited C algary, A lberta C anada OIL AND GAS PIPELINES Integrity and Safety Handbook E dited by R W I N S T O N R E V I E ĨRUỜNGOHHANG HA1VIẼIKAM TÀi LIỆU... M anagem ent, and A nalysis Incident Review and Replay Data Q uality O perator L ogbook and Shift H andover Training SC A D A U ser P erm issions and A O Rs W eb C onnection SC A D A Security... ased D esign A pplications Strain D em and 4.2.1 O verview 4.2.2 C hallenging E nvironm ents and Strain D em and 37 37 38 38 38 39 39 39 39 4.2.3 Strain Levels and A nalysis C onsiderations Strain