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Sample Corrosion Verfication Report - Final

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137 views

Sample Corrosion Verfication Report - Final

details

Uploaded by

Raja Hone
Copyright
© © All Rights Reserved
Available Formats
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Pipeline Corrosion and Coating

Inspection Report
Line ABC - 20

Verification Dig Project


An In-Line Inspection Run was conducted on Line to Assess the Integrity of Line ABC -20. A
verification dig project was conducted at Station 143+55 using 3D Structured Light to assess a
corrosion indication 10 D/S of the weld. This report includes a Pipeline Inspection Report, 3D
Analysis using Company Interaction Rules and a RSTRENG Analysis to determine the safe
operating pressure and mitigation for this defect.

Joe Pikas
VP of Pipeline Integrity

In-Line Inspection INTEGRITY PROJECT


Pipeline Corrosion and Coating Inspection Report
Line ABC -20

Dig # 1A

Pipeline Corrosion and Coating Inspection Report


Contents
(1) Location ..............................................................................................................................2
(2) Pipe.....................................................................................................................................2
(3) Reason for Inspection ...........................................................................................................2
(4) External Pipe Coating ...........................................................................................................2
(5) Coating Evaluation ...............................................................................................................2
(6) Environment ........................................................................................................................2
(7) Recoat .................................................................................................................................2
(8) Internal Coating ...................................................................................................................2
(9) Magnetic Particle Inspection .................................................................................................2
(10) Evidence ............................................................................................................................2
(11) Corrosion ...........................................................................................................................2
(12) Defect, Damage or Corrosion Measurement Table ...............................................................3
(13) Conclusions .......................................................................................................................4
Field Conclusions ....................................................................................................................4
B31G, Modified and RSTRENG Calculations ..............................................................................4
(14) Recommendations and Mitigation ........................................................................................4
Remarks: ...............................................................................................................................4

Graphs of Field Scans and Corrosion Pipeline Analysis Pages 5 and 6


Figure 1 Corrosion Scan
Figure 2 Corrosion Pipeline Analysis
Figure 3 - Zoomed in Pipeline Analysis
B31.G, Modified and RSTRENG Pages 7 & 8

Page 1

In-Line Inspection INTEGRITY PROJECT


Pipeline Corrosion and Coating Inspection Report
Line ABC -20

Dig # 1A

Pipeline Inspection Report


(1) Location

Project Name: ABC Line-20


Project #: 12345
Work Order #: 12345
Line #: Line ABC-20
Begin Mile Post #: 2.718
Begin Station #: 143+55
End Mile Post # : 2.801
End Station #: 143+90
City: Wichita Falls
County/Township: Wichita County
Location Ref: Dig 1A
GPS LAT: 33 57.862 N
Inspector Name
John Smith
Serial # of 3D 152049
and Company:
Technical Toolboxes
Unit:

Inspection Date:
1/10/14
Align Sheet #: TX ABC 20
Beg. Valve Section #: 20
End Valve Section #: 30
State: TX
GPS LONG: 098 15.990 W
Verification 1/10/14
Calibration Date:

Exposed Pipeline When an underground pipeline facility is exposed and reveals any corrosion, defect or damage, Operator Qualified personnel
shall complete inspection report. This for can also be used for any inspection of pipe, vessels, and other structures.
(2) Pipe

Pipe O.D.: 20
MAOP: 800 psi

Nominal W.T.: .212


Grade or SMYS: 42000

Actual W.T.: .235


Class #: 1

(3) Reason for Inspection

Leak: NO
Anode Installation: No
Test Lead Installation:
Tie-ins: NO
Anomaly Investigation:
YES
Foreign Pipeline Crossing:
Third Party Damage: None
Name of Third Party: N/A

NO
NO

Other:

(4) External Pipe Coating

The Exterior Pipe is?


Coal Tar Enamel: YES
Outer Wrap?
Concrete:
Remarks: Poor adhesion

Bare: N/A
Fusion Bonded Epoxy: N/A
Somastic: N/A
Tape:
Other:
N/A
Glass: Yes
Rock Shield:
N/A Other:

Asphalt Enamel: N/A


Asbestos Felt

(5) Coating Evaluation

Good:

Condition of Coating?
Fair:

Evidence of Soil Stress?

Poor: YES

NO

Comments:

(6) Environment

Environment?
Caliche: NO

Moisture Content?

Clay: YES
Other: N/A
Dry:

Loam: NO

Sand: NO
Gumbo: NO
Depth to Cover: 53 (in.)
Moist: YES
Wet:

Rock: NO
Above Ground:

(7) Recoat

Recoated after Inspection?


Full encirclement repair? N/A

YES
Coating Type: Epoxy
Begin Station #:
N/A
End Station #:

(8) Internal Coating

Internal Coating? (If Line Cut Open)

NO

Condition?

Good:

Coating Manufacturer:
Spot Repair?
Station #:

Fair:

Poor:

3M
143+60
143+70
Corrosion?

(9) Magnetic Particle Inspection

Magnetic Particle Inspection?

YES

Die Penetrant Test?

NO

(10) Evidence

Evidence of?
Corrosion: Yes
SCC: NO
Defect: NO
Damage: NO
If S.C.C or Corrosion is noted, complete Corrosion Sections 11-17 and MPIR-2. If Defect or Damage I noted, complete MPIR-2.
(11) Corrosion

(11) General Corrosion Information


Greater than 10%, complete Sheet 2: NO
Location: External: Yes
Length of Pit: 11
(inches)
Maximum Depth:
138
(mils)
Internal: N/A
(12) Cathodic Protection? Impressed: Yes
Galvanic: NO
(13) Pipe-to-Soil-Potentials at nearest point from Corroded Area?
Volts: -0.811
(14) pH of Soil? 6.0
(15) MIC TEST? NO
Test Results?
Positive:
Negative
Remarks:
(16) Soil
780
(OHM-CM)
(17) Corrosion is?
Active: Yes
Inactive: N/A

Resistivity?
Remarks:

Calcareous deposits found after sleeve was pulled at U/S Girth Weld. No SCC cracking found. There
was a combination of flash rust & rain produced yellow rust over 5 section of pipe.
Moisture found underneath line pipe coal tar enamel coating at corroded area. There was evidence of surface
contamination with pitting. Coating holiday found at 6:00 in a 15 x 15 area.

Page 2

In-Line Inspection INTEGRITY PROJECT


Pipeline Corrosion and Coating Inspection Report
Line ABC -20

Dig # 1A

Defect, Damage or Corrosion Measurement Section


1) Tabulate all dents, gouges, slivers, corrosion, S.C.C., etc.
2) Reference Point - beginning or ending Sta. No. should be correlated to a Girth Weld, Valve, Tee, Road, etc., as shown on
Alignment Sheet with a known Station Number. Recommend Girth Weld as a reference.
3) Solid in one dashed line to depict long seam. On seamless pipe, measurements are to e made from the 12: oclock position. If
pipe is vertical, substitute North for the 12: oclock position.
4) Defects such as dents, slivers, gouges, etc. shall be tabulated individually. Corrosion cracks and/or corrosion pitting closely
grouped may be tabulated as one defect.
5) Defect width and length will be measured along the girth and longitudinal axis respectively.

Measurement from:
Reference
Begin Sta. No:

Upstream Weld
Downstream Weld

Flow Direction:

143+55

End Sta. No.:

143+90
Counterclockwise

12:00
35
Length of Jt.

Clockwise

(12) Defect, Damage or Corrosion Measurement Table

Reference Location:
NO.

Type

Distance from
Referenced Sta. No.

Clock Position

Width
(inches)

Length
(inches)

Maximum
Depth (mils)

Number of Cracks
or Pits

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.

U/S Weld

10

4.921

10.906

138

Multiple

Repair Required:

Yes

Type of repair Required?

Composite Sleeve

Comments:
ASME B31.G and Modified B31.G failed the established 550 PSI MAOP. However, the Remaining Strength exceeded
the MAOP. Because this is an area for possible encroachment, a composite sleeve was recommended for permanent
repair.

Page 3

In-Line Inspection INTEGRITY PROJECT


Pipeline Corrosion and Coating Inspection Report
Line ABC -20

Dig # 1A

Conclusions and Recommendations


(13) Conclusions
Field Conclusions were as follows:

1.
2.
3.
4.
5.

Corrosion pitting was found underneath disbonded coating.


Corrosion pitting was approximately 11 L x 5 W and 138 mils deep.
Coating was disbonded in a 15 long by 10 wide patch.
Low pipe to electrolyte potentials were found at corroded area.
Population growth and encroachment near site were observed.

B31G, Modified and RSTRENG Calculations:

ASME B31.G and Modified B31.G failed the established 550 PSI MAOP.
Remaining Strength Calculations (Effective Area) found Safe Operating Pressure at 580 PSI and Safety Factor
at 1.45.
Other safety factors were used to make recommendations.

(14) Recommendations and Mitigation

Mitigation consists of Recoat, Repair, Replace, Reduce Pressure or Other i.e. Additional CP, Reduce Interference, etc.
Recoat
Repair:
Composite
Repair:
Reduce
Pressure:
Replace
Pipe:
Other:

Yes
Yes
No
No
Increase Rectifier
Output

Type of Coating: Epoxy


Type of Composite: Composite Reinforcement
% Reduction: N/A
Cylinder Length of N/A
Pipe:
Type of Mitigation: Additional CP to offset
low potentials

Manufacturer: 3M
Manufacturer: Clock Spring
New Operating N/A
Pressure:
Coating Type: N/A
Adequate CP
Potentials:

-1.15 Volts OFF

Remarks:

Because of encroachment and other issues, ABC manager elected to use a permanent composite sleeve to maintain the
integrity of the pipeline in this area.

Page 4

In-Line Inspection INTEGRITY PROJECT


Pipeline Corrosion and Coating Inspection Report
Line ABC -20

Dig # 1A

Figure 1: Corrosion Scan of 20 Diamter Pipe

Figure:2 Corrosion Analysis of 20 Diameter Pipe


Page 5

In-Line Inspection INTEGRITY PROJECT


Pipeline Corrosion and Coating Inspection Report
Line ABC -20

Dig # 1A

Figure 3: Zoomed In Area of Corrosion with 3D River Bottom Path


And 2 D Profile of Pitting

Notes:

ASME B31.G Interaction Rules Selected were 3D Longitundial and 3D Circumferential


Grid Size was slected
Convex Hull was selected outlining corrosion
Color graphing used with deepest in dark red

Page 6

Site: Line ABC - 20


Station: U/S Weld Sta 143+55

Date: 1/17/2014

P = 2StFT/D [psig] - Calculated Pressure

641.088

Established MAOP [psig]

550

Pipe Outside Diameter [in]

20.00

Effective Length [in]

10.57

Pipe Wall Thickness [in]

0.212

Effective Area [in]

0.743

SMYS [psi]

42,000

Max. Pit Depth [in]

0.138

Design Factor

0.72

Max.Depth/Wall Thickness

0.65

Total Length [in]

11.018

Effective Length: Start [in] 0.20

End [in]

10.77

RESULTS OF ANALYSIS:
METHOD
RSTRENG - Effective Area
RSTRENG - 0.85dL
ASME B31 G

Max. Safe Pressure [psig]


580
412
247

Burst Pressure [psig]


806
573
344

CORROSION PROFILE:

INNER EDGE OF PIPE WALL

CORROSION PROFILE

EFFECTIVE LENGTH
0

X-AXIS OUTER EDGE OF THE NON-CORRODED PIPE


PIT LENGTH [in]
4

PIT DEPTH [Mil]

-25
-50
-75
-100
-125
-150
-175
-200

Prepared By: Joe Pikas

Approved By:

10

11

Safety Factor
1.46
1.04
0.62

Site: Line ABC - 20


Station: U/S Weld Sta 143+55

Date: 1/17/2014

CORROSION MEASUREMENT:
Nr.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
46.

Increment [in]
0
0.197
0.453
0.571
0.886
1.063
1.26
1.732
1.969
2.067
2.343
2.736
2.756
3.11
3.346
3.524
3.917
4.232
4.291
4.508
4.803
5.236
5.492
5.669
5.768
6.24
6.476
6.535
6.752
7.087
7.421
7.539
7.795
8.248
8.406
8.72
8.76
9.154
9.488
9.646
9.862
10.236
10.433
10.551
10.768
11.018

Prepared By: Joe Pikas

Pit Depth [Mil]


0
63.322
52.799
63.938
63.082
87.385
69.799
56.635
78.323
61.26
54.164
64.552
63.013
79.456
76.132
68.773
81.693
90.363
102.799
80.912
51.721
39.04
53.507
79.178
65.697
76.728
109.844
109.941
60.624
58.154
77.492
84.281
67.404
59.257
71.739
70.923
72.246
52.127
84.314
86.425
47.282
57.236
137.614
129.263
93.354
0

Approved By:

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