Reparacion y Rehabilitacion Tuberias 01-10.pdf

Reparación y Rehabilitación de Tuberías de Transporte de Hidrocarburos
parte 1/2

1. REPAIR
r:
PIPELINEREPAIRANOREHABILITATION
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2. ·50yearsofprovenoil&gassuppliesintheworld.
-Inrnanycasesoil&gasIieldinfrastructureisattheendofitsdesign
lifebuttheystillhave25oreven50yearsofproductionleft.
•AgoodexampleisRussia'spipelineinfrastructure-20%ofitsoil
andgassystemisnearingtheendofitsdesignlife.In15yearstime,
50%willbeattheendofitsdesignlife.
·Over50%ofthe1,000,000kmUSAoilandgaspipelinesystemis
over40yearsoId.
I-Many1,000s'ofkm oflinesarebeingreplaced,repairedor
rehabilitatedintheUSAeveryyear.TheUSDepartmentof
Transportationestirnatesthat80,000kmofpipelineswillrequire
rehabilitationinthenext10years.
·Sorneoperatorsarealreadyreplacingtheirpipelinesforthe3rdtime.
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3. STAGE1
InspectionlDetection
STAGE2
ResponsetoDetection
PROJECT
RepairandRehabilitationis
NOTaboutinspection,isNOT
about'defectassessment'...
itisaengineeringexercise
thatneedswideranging
engineeringskills.
"._:
STAGE3
AssessmentofDefects
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STAGE4
Repair/Rehabilitate
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4. ·1:
-D·
·DRIVERS-Manyrepairorrehabilitationprojectsarenotdrivenbythechoiceof
repairorrehabilitationmethod;Theyaredrivenbyeconomics,urgencyor
engineeringconsiderations. (:
·COST-Forexample,thecostoftherepairclampforadamagedoffshorepipelineisnegligible
comparedtothecostofthevesselthathastobehiredtoinstalltherepair.
Furtherexample;itmaybecostbeneficialtoreplace, ratherthanrehabilitate, apipeline-anew,
larger,moreefficientpipelinecangivelowerwholelifecoststhananageing,small, inefficientline,
albeitrehabilitated.
·URGENCY-Acatastrophicfailure(peopleorenvironmental)hassuchadevastating effectonPR,
etc.,thattheleastofacompany'sworriesisthetypeofrepair/rehabilitation.Costtopublicimage,
lostrevenueandcleanupcostsarekeyconsiderations.
·ENGINEERINGThe'engineering'associatedwithanyworkonapipelinemaybethe
crucialconsideration.Forexample,anoffshorelinethathaslostitscoating,andisfloating,
oranonshorelinethatistobeliftedoutofatrenchandrecoatedlive.
APPROACH-Pipelinerehabilitationissimilartopipelineconstruction/overhaul
(i.e.retrieval/trenching,sectionrehabilitation,backfill,inspection,etc.),and
requiresthesameengineeringapproach.
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5. 80
70
'-60
ro
~50
--
~40
--o
g30
~
Y720
10
O
160km, 914mmline
Landlines
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6. Reair&Rehabilitation-Strate
I
DEFINEREPAIR/REHABANDMONITORING
STRATEGY
Assesslikelyrepair/rehab
methodsforeachlocation
·,1. 'Y
Pre-investin
toolsfor
repair/rehab
I
Setupstandbyrepairl
rehabtoolstorage
facility
........
....
~
I
Buildupdatabaseof
pipelinetechnical
data&repair/rehab
data
I
Pre-qualifycontractorstorepairor
rehabsubseaandonshorepipelines
Definedefect
assessment
approachand
criteriaforeach
pipeline
Definecondition
monitoringstrategy
I
Appoint
inspection
contractor
Setupresponseteamand
repair/rehabco-ordination
team
Write ....'..
repair/rehab .l
..
manualand ...:
.'.
procedures .': ~
~~X~· ~...~~~
.--_____._I ----.
Write
repair/rehab
specifications
Ensureaccessto
pipelinealonqroute
Defineenvironmental
&hazardresponse
Write
responseplan
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7. ,'.l¡.
,'
TiteprojectmanagementprincipIesused00newpipelinesshouldbeappliedto
pipelinerehabilitation:
0-ProjectConcept(GoalStatement)
0-ProjectStudyandDefinition(PlanofExecution)
0-Pre-Construction(AwardContract)
0-Construction(Tumover)
0-Ongoingoperations(Inspection&maintenance)
Projectmanagementwillco-ordinatemanydifferentservices,includinginspections,
protectionsurvey,coatingsselection,etc..Problemsmayinclude:
0-scopeofprojectdifficulttodefineasmanyuncertaintiesexist(e.g.locationofcorrosion)
0-:dealingwitholderpipeline,whosedesign,drawings-etc.,maybedifficultto
locate/prove
D~{projectsareoften'fast-tracked'duetooperationalpressures
O-afienonalivepipelinewithadditionalsafetyrisks
D-.,~akeupandremovalofexistingcoatingmaybedisposalproblem
,..a,
0-etc.!
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8. OAMAGE/OETERIORATION REPORTEO
f············
I
,
A_
l
Reducepressure?
"
I
Colleetdata1
1
Defeet Assessloeationof
Assessment, damage,define
ded definerepairor aeeess
b
.'.
. rehab. requirements
'.
····teq\!~rements ..
..
jt
.
.....~-'.
Seleet
......•......................... ~
repair/rehab
method
I
~....""...........
.....
Carryout
repair/rehab,
inspeetionand
reinstatement
Reeommen
repair/reha
methods
Repair/Rehab
toolson
standby
.)1..Mobiliseeo-
ordination and
planningteam
I
Decideaetionto
limit
environmental
.damage&hazards
"~ I
Organise
aeeessand
eonsents
I
Mobilisetask
forcefor
repair/rehab&
damagelimitation
".
..-
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9. PRELIMINARYSTRATEGICPOSITION
1Damagelocation,excavationandmarking
2Preliminarydamagesurvey
3Exposure&stabilisationofdamagesite
4Coatingremoval/pipecleaning
5Detailedinspectionofdamage
6Damageassessment&reporting
FINALSTRATEGICDECISIONS/COSTMODELLING
7Repair/rehabilitationrnethoddecision
8Equipmentfabrication&proctirement.
9Repair/rehabprocedurepre-qualificationtests
10Repair/rehabdamage
llInspectionanddocumentation
12Sitereinstatement/protection
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10. ,A
1ReducePressure
(:
•reducepressuretosafelevelandplanpressurereductionsforrepair/rehab.
2CriticalInformation
•Establishcriticalinformationforengineeringassessment
3EngineeringDefectAssessment
•Carryoutengineeringdefectassessment.Notethat'defects'arenotalwaysmetalloss.
Other'defects'couldbestructural,e.g.lossofsupport,buckles,etc..
4LocationAssessment
•Assessmentofdamagelocationtodefineaccessrequirementsandavailablerepairand
rehabilitationmethods:
5RepairlRehabilitationMethod
•Selectmosteffectiverepairorrehabilitationmethod
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11. 3CarryoutEngineeringCritical(Defect)Assessment
•Urgencyoftherepair&analysisdependsupon
-defectseverity:location,depth,length,orientation,and
...financial/strategicvalueofpipeline
-threattoenvironment&PR
-regulatory/legal/insuranceconsiderations
-failure/furtherfailuresconsequences
,,
;,..,..
•Notall'defects'arepipewalldefects.Sornewillbe
.structural-anomalies (e.g.bucklesorunsupportedspans)
thatwillrequiredesign/structuralanalysis
•Useengineeringassessrnentforrepair/no-repairdecision.
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12. ResonsetoDiscoverinDefects
EngineeringCriticalAssessments(ECAs)
.Establishanyaccepteddefectassessmentmethodswithclientandregulatory
authority.
IIEstablish'level'ofassessment:
.Simpleworkmanship
.Conservative'code'calculation
BDetailed'fitnessforpurpose'assessment
.•Probabilisticassessment('limitstate'calculation)
.RiskAssessment
.Other-e.g.fullscaletesting.
•Ensuredefectassessmentisconductedbyexperts,andaqualityassured
reportisproduced,withuncertaintiesandconservatismshighlighted,and
consequencesoffailurerecognised.
•Alwaysobtainthreeprices!
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13. .1'
..¡.
••
&,; .:
,
.Usuallyverylimiteddatatoworkon-thisisthemajorconsideration.
•Oftenhighlypricedandnaive(simplisticapproachforcomplexproblem).
•Staffconductingthemareusuallyspecialistswithoutanyengineeringsupport,or
knowledgeofspecificpipeline,i.e.theywillassessthedefect,ratherthanthe
pipeline.
IIUsually'distant'report,deliveredtoclientwithno'ownership'.
•Usuallythereportdoesnotaddresstheclient'smainproblem-howcan1continue
tooperaternypipelinesafelyandcosteffectivelyforthewholedesignlife?
.Solution? :;
.GiveaveryclearandfocusedScopeofWork,~ anddonotasksolelyfora
,'defectassessrnent',anddonotgiveanywiderworkscopetospecialistswithout
¡assurances.
c..Ensurethatconsultantworkscloselywithyou,andappreciatesyourpipelines,
designsandoperationalproblems.
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14. 4LocationAssessmenttodefineaccessrequirementsand
availablerepair/rehabilitationmethods:
(:
•PlatformTopsides
•OffshoreRiser
•DeeperWaterDepthZone(>50m)
•IntermediateWaterDepthZone(20-50m)
•ShallowWaterDepthZone(<20m)
•Inter-tidalzone
•Inshorezone
•Onshore
•ValveStations/Piggingfacilities/Terminals
•RoadIRiverCrossings
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15. .,y,',,"....
.,.
5SelectmosteffectiveRepair/RehabilitatioDMethod:
•Grinding
•WeldMetalDeposition
•FullCircumferentialSleeves
•CompositeReinforcementSleeves
•MechanicalClamps
•PipeSectionorPipelineReplacement
~.
•UpgradingCathodicProtection
•ExternalCoatings/lntemalLiners
•Combinedinspections/repairs/rehabilitation
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16. --- -
'Grindin
Repairbyhandfilingorl}owergrindingmaybeusedif:
•stressconcentrationatdefectorimperfectionisremoved
~alldamagedorexcessivelyhardmaterialisremoved
•thepressurecanyingcapacityofthepipeisnotreduced.
Criteria:
•operatingpressurelevelisreducedto80%ofrecentlydemonstrated
highestoperatingpressure
•IimitsofmetalremovaIfornon-indenteddefectscanbesetby
engineeringcriticalassessment(ECA).
•grindingofindenteddefectsiscomplexandnotrecommendedwhen
thelineispressurised.
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17. osition
•Advantages:
•Simpleanddirectapplicationofadditionalwallthickness.
•Canbeusefuiwheresleevesarenotpossible-atfittingsandbends-or
whereaccessisdifficult.
•Concems
•ECAcanusualIyshowitisnotneeded.
•Possibleblow-outorpenetrationofpipe(bum-through):
•penetrationdependsonwallthickness,weldheatinputandremovalof
heatbyflowoffluidinsidepipe.
•Possiblelossofintegrityofpipefollowingrepair:
•staticstrengthandfatiguestrengthmustberestored.
•significantdiscontinuitiesmustnotbeintroduced,includinghydrogen
crackingintheHAZ(heataffectedzone).
•canbedifficulttoQA.
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18. TYPESOFWELDED SLEEVE
"""'f
•TypeA-noweldingtopipert(reinforcementonly)
•TypeB-weldedtopipe (pressurecontainment)
•Half-sole (variantofTypeA)
•Stand-offShell (pressurecontainrnent)
•EpoxyFilledSleeve (usedontypeA,canuseonB)
SLEEVECONFIGURATION
•Buttinghalveswithlongitudinalweld
•Overlappinghalves (TypeAonly,butnotrecornmended)
•Circumferencialfilletweldforpressurecontainment(notTypeA)
•Stand-Offsleeve (nearbends/fittings)
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19. Seamweld
(detailbelow)
Fillet
weld
/
NobackingBackingst(ip·&·. Backingstrip-
strip.reliefgroóvenoreliefgroove
.PREFERREb
Overlapping
sidestrip
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