Managing Cracks and Seam Weld Anomalies on Pipelines

 

Various forms of cracks or crack-like indications are known to be present on pipelines, which could become a safety concern to their safe operation. The most typical forms of cracking and its derivatives are environment-, manufacturing- or operations-related, such as stress corrosion cracking, corrosion fatigue cracking, hydrogen-induced cracking, hook cracking, and seam-weld anomalies (such as those related to ERW/flash-welded pipe).

 

This course will provide an integrated, data-driven approach for addressing these forms of cracking and seam-weld anomalies. It covers in greater depth the formation of these types of anomalies and the conditions that drive their growth until they become unstable, leading to leaks or ruptures. The appropriate assessment methods such as ILI crack tools, pressure-testing and direct assessments will be presented as well as traditional and current engineering approaches for establishing crack severity and determining future integrity.

Course Program

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1. Material Behavior and Engineering Fracture Mechanics

• Fracture of metals. Brittle and ductile fracture behavior. Engineering mechanics of crack formation and growth. What factors drive the formation and growth of cracks on pipelines?
• Engineering equations that govern stresses around a crack

2. Characteristics and Behavior of Cracks Found on Pipelines

• What are the various forms of cracks and seam-weld related anomalies typically found on pipelines? Description of SCC or corrosion fatigue, hydrogen-induced, hook cracks, seam-weld anomalies: lack of fusion, cold welds, stitching,
• Are material inclusions, laminations and roll-in slug/scab cracks or not?

3. Evaluating Crack Severity

• What are significant cracks on pipelines? Review of US and Canadian guidelines.
• When do cracks become a safety threat to the pipeline?
• Selecting an appropriate failure criterion
• Evaluating methods for determining crack severity:
  
  • NG-18 Equation derived: KAPA, PAFFC
    
  • Failure Assessment Diagram derived: API-579, BS-7910
    
  • CorLAS
    
• Determining the severity of cracks expected to fail at MAOP and at a Safety Factor x MAOP (such as 1.39 MAOP or 110% SMYS)
  
• Elements of an O&M procedure for addressing crack severity. What are the guidelines in your O&M procedure with respect to addressing the severity of cracking?

4. Regulations & Recommended Practices

• Review of current U.S. and Canadian regulations and guidelines for addressing cracks and seam weld anomalies
  
• Review of current industry standards and recommended practices related to addressing cracking and seam weld anomalies

5. Appropriate Crack Assessments

• Factors to consider when deciding the most appropriate assessment method or methods for a particular pipelines segment. When do these assessment methods complement each other to enhance existing remediation program?
• Hydrostatic Testing, In-line Inspection and Direct Assessment
  

6. Non-Destructive Inspection (NDI)

• The integral role of In-ditch NDI in addressing cracking and SWAs
• Review of current NDI methods and technologies

7. Repairing Crack-like Features and Seam Weld Anomalies

• Review of appropriate repairs options in the industry: ASME, API, PRCI-PDAM, and applicable US and Canadian regulations
  
• Latest research and developments on repairing cracks and SWAs
  

8. Elements of Crack & Seam Weld Anomaly Management Strategies

• Know the pipeline material properties, historic pressure tests and operating conditions
  
• Know the type of cracking or SWA expected or found
  
• Integrity history of the pipeline
  
• Crack or SWA susceptibility and threat analysis
  
• Risk assessment approach
• Appropriate integrity assessments
• NDI protocols and characterization of cracks and SWAs
• Preventive & mitigative measures

 

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