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Distance (mm)
0.000 20.00 40.00 60.00 80.00 100.0 120.0 140.0 160.0 180.0 200.0 220.0 240.0 260.0 280.0 300.0 320.0
Time (µs)
22.00
22.50
23.00
23.50
24.00
24.50
25.00
25.50
26.00
26.50
27.00
27.50
28.00
28.50
29.00
29.50
30.00
30.50
31.00
31.50
32.00
32.50
Mill/Constr.
defects
TPI
Landslid
e
Weld defects
Corrosion
AC corrosion Old
joints
Types of Defects
lightning
73
Pipeline Operation and Maintenance | 10.4.2014
Integrity by Assessment of Defects
Ensure Integrity by Assessment of
Defects
Weld defects
Cracks
Gouges from External Damage
Metal Loss caused by Corrosion
Dents
(Puncture)
74
Pipeline Operation and Maintenance | 10.4.2014
Assessment Criteria defined in Company Standard
Pipeline Operation and Maintenance | 10.4.2014
75
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.
Company Standard
Basic Principles of Pipeline Integrity;
Rules and Procedures for Verification
of Technical Pipeline Integrity
Non-Destructive Testing and Evaluation of Defect Geometry
Direct (Defect) Assessment Methods 76
Pipeline Operation and Maintenance | 10.4.2014
Defect Measurement Using OPTO-CAM (3D Scanning)
Corrosion damage
Photo Measurement of corrosion
using light/laser scanning
Digital reproduction
(3D point cloud)
Calculation of stress
distribution in surface
using FEM
Direct (Defect) Assessment Methods 77
Pipeline Operation and Maintenance | 10.4.2014
Finite Element Analysis
Unstable slopes
Bending
Buckling
Corrosion feature
assessment
Eigenvalue
Crack assessment
Vibration
analysis
Direct (Defect) Assessment Methods 78
Pipeline Operation and Maintenance | 10.4.2014
On-Site Material Analysis
Hardness test
UCI method
Chemical analysis
Spark spectrometry
Micrograph at
surface
Direct (Defect) Assessment Methods 79
Pipeline Operation and Maintenance | 10.4.2014
Monitoring – Field Measurements
Vibrations
Strain
Direct (Defect) Assessment Methods 80
Pipeline Operation and Maintenance | 10.4.2014
Online monitoring
max.958
0
100
200
300
400
500
600
700
800
900
1000
03.0
2.1
999
24.0
2.1
999
17.0
3.1
999
07.0
4.1
999
28.0
4.1
999
19.0
5.1
999
09.0
6.1
999
30.0
6.1
999
21.0
7.1
999
11.0
8.1
999
01.0
9.1
999
22.0
9.1
999
13.1
0.1
999
03.1
1.1
999
24.1
1.1
999
15.1
2.1
999
05.0
1.2
000
26.0
1.2
000
16.0
2.2
000
08.0
3.2
000
29.0
3.2
000
19.0
4.2
000
10.0
5.2
000
31.0
5.2
000
21.0
6.2
000
12.0
7.2
000
02.0
8.2
000
23.0
8.2
000
13.0
9.2
000
04.1
0.2
000
25.1
0.2
000
15.1
1.2
000
06.1
2.2
000
27.1
2.2
000
17.0
1.2
001
07.0
2.2
001
28.0
2.2
001
21.0
3.2
001
11.0
4.2
001
02.0
5.2
001
23.0
5.2
001
Datum
Verg
leic
hsd
eh
nu
ng
(µ
m/m
)
0
5
10
15
20
25
30
35
40
45
50
Tem
pera
tur
(°C
)
Evg ME 6.1
Evg ME 6.2
Temp.(°C)
Evg 756 µm/m S=1,5
Trend in strain following stress relief
Temperature-induced stress
Stress relief following
mining subsidence
winter
summer
Direct (Defect) Assessment Methods 81
Pipeline Operation and Maintenance | 10.4.2014
PIA2 - Assessment of Old Joints
Pipeline Operation and Maintenance | 10.4.2014
82
Spannungsnachweis
Istwerte=Betriebsbedingungen
0
100
200
300
400
500
600
700
800
0 500 1000Leitungsmeter
N/m
m²
SigV_3 SigVd_2 SigGg3_3 SigGg3_3
until 1954 from 1955
+
Usage factor = (type of joint, diameter, pressure, wall thickness, grade, …)
Theoretical Load Real Behaviour
Metallography in Defect Analysis
Pipeline Operation and Maintenance | 10.4.2014
83
Brittle
Analysis with
SEM and EDX
Failure analysis
Ductile/brittle
Fibers
Microstructure
Direct (Defect) Assessment Methods
Excavation Procedure (Corrosion Investigation)
Decision for excavation of MFL pig run feature
GPS localisation of feature
Conduction of
intensive measurement at
feature position +/- 50 m
Excavation
Corrosion study
(considering soil type, soil chemistry, type of coating, coating
condition, corrosion products, pH at coating defect and
underneath coating, scale formation, CP operational
parameters etc.)
84
Pipeline Operation and Maintenance | 10.4.2014
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
85
Repair Techniques
Repair of Small Defects
Grinding, Welding Patches,
Welding
Securing of Old Joints
Welding sphericial caps
Repair of Severe Defects
Split sleeve, hot sleeve,
pipe replacement
86
Pipeline Operation and Maintenance | 10.4.2014
Gas flow: 106 m³/h
Same Good Behaviour of Welding X 70 and X 80 in Service
T-Joint 89
Pipeline Operation and Maintenance | 10.4.2014
Testing of New Repair Method (“Hot Sleeve“), Example
Numeric simulation indicates
insufficient safety level “Hot sleeve”
Installation of
“hot sleeve”
Data transmission
For online monitoring
Hot Sleeve 90
Pipeline Operation and Maintenance | 10.4.2014
Low Internal Pressure
Type „Ruhrgas“
High Internal Pressure
Type „Plidco“
High Internal Pressure and Coated
Pipe
Type „Manibs“
Temporary Repair Methods
Pipeline Operation and Maintenance | 10.4.2014
91
Cutting Pipeline in Areas of Ground
Movement
Inliner in Pipeline
Repair Techniques
Pipeline Operation and Maintenance | 10.4.2014
92
Closure of Filter
or Pigging traps
Construction
with Screws
Repairing in
Workshop
Cracks at
Welds
Repairing by
Grinding
Repairing in
Operation
Special Repair Techniques 93
Pipeline Operation and Maintenance | 10.4.2014
Simulation and
Analysis Thermografy
in Operation
3-dimensional
Construction
Cracks at
Combustor
Repairing
in Workshop
Pressure Testing of New
Combustor
94
Pipeline Operation and Maintenance | 10.4.2014
Special Repair Techniques
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
95
Conclusions
Different Pipeline Standards Existing at OGE
Pipelines became older but are fully operational
Operation of pipeline for much more than 90 years is possible
Expert KnowHow for maintenance is very important
Intelligent strategies for operation of old and new pipelines are available at OGE
The DVGW technical rules (and the referenced standards) provide the
framework for construction, operation and maintenance of approx. 12,000 km of
Transmission pipelines
96
Pipeline Operation and Maintenance | 10.4.2014