Pipeline Integrity Ensuring Safety from Start to Finish
Pipeline Construction and Testing
Pipelines are critical infrastructure for transporting liquids and gases long distances. Before any pipeline is put into operation, careful construction and testing procedures are followed to guarantee integrity. Once the pipeline route is determined based on engineering studies, heavy equipment is used to clear the right-of-way and dig the trench. Sections of pipe are welded together before lowering into the trench. Non-destructive testing such as x-ray or ultrasonic testing ensures no defects are present in the welds that could lead to leaks or breaks over time. Hydrostatic testing involves pumping water or air through the pipeline at high pressure, usually 1.5 times the maximum operating pressure, to check for any leaks from faulty construction or weaknesses in the pipe material. Any issues discovered during construction and testing are reworked before the pipeline is deemed ready for service.
Coatings and Corrosion Protection
The external Pipeline Integrity coating provides the first line of defense against corrosion that can weaken pipelines over decades of service. Three-layer polyethylene or polyurethane coatings are commonly applied followed by backfilling once testing is complete. Cathodic protection helps slow corrosion even further. This involves connecting the pipeline to either an impressed current or sacrificial anode grounding system that prevents corrosion by making the pipeline cathode. Pipeline coatings and cathodic protection are monitored and repaired as needed to maintain corrosion protection for the life of the asset. Internal coatings also protect against internal corrosion for some product types.
Get more insights on - Pipeline Integrity
Aerial and Ground Patrols
Regular aerial and ground patrols are essential for pipeline operators to monitor rights-of-way and identify any indications of leaks, third party damage, or ground movements and soil erosion that could impact the structural integrity of aboveground facilities or buried pipelines if left unaddressed. Any issues observed are investigated and remediated prior to becoming safety or environmental risks. Aerial patrols usually occur quarterly with the use of infrared cameras able to detect hydrocarbon emissions not visible to the naked eye. More frequent ground or vehicle patrols supplement aerial monitoring for harder to access areas or terrain.
External Corrosion Direct Assessment
External corrosion direct assessment (ECDA) is a method used to evaluate pipe integrity and detect unprotected areas vulnerable to corrosion issues. ECDA leverages non-intrusive technology tools together with physical inspection. In-line inspection tools such as magnetic flux leakage or ultrasonic devices are run inside pipelines to check for metal loss from corrosion. Direct examination excavates and visually inspects areas suspected to have corrosion indicated by in-line inspection results or other factors. Soil samples are analyzed for properties that accelerate corrosion risk to pipelines. ECDA helps operators prioritize and dig areas most in need of corrosion rehabilitation to address before any safety issues arise.
Internal Inspection Tools
Internal inspection tools provide critical information about the condition of the pipeline internal surface where corrosion or mechanical damage cannot be directly observed. Tools known as smart pigs are run through pipelines using product flow or pumping. Typical inspection technologies include ultrasonic testing, magnetic flux leakage, and geometry tools. Ultrasonic tools “see” through the pipe wall to measure remaining wall thickness and detect corrosion, dents, scratches and other abnormalities. Magnetic tools sense changes in the pipe wall magnetic field to pinpoint metal loss erosion areas. Geometry pigs provide diameter and ovality measurements to find denting or other mechanical damage. Inspection data enables pipeline operators to prioritize repairs and remediation work to protect safety and reliability.
Pipeline Pressure Management
Careful pressure management during both normal operations and pressure testing/startup activities is a core aspect of pipeline integrity. Sustained pressure spike events pose risks for mechanical damage via fatigue. Operators implement pressure control protocols, install automated pressure control equipment such as relief valves tied to Supervisory Control and Data Acquisition (SCADA) systems, and institute procedures for safely changing pipeline pressures during commissioning, startup or planned maintenance activities. Pressure tests on pipeline sections and at pump stations check for leaks before returning facilities or line segments to operational service. Management of Pressure Transients either created by operations or third-party excavations near buried lines is also necessary for continued integrity.
Repair and Remediation
When in-line inspection, integrity assessments or surveillance identifies sections of pipeline in need of repair, prompt remediation is scheduled. Common fixes for external corrosion include coating repair, application of additional external protection such as wraps, and installation of new impressed current deep anode ground beds. Patches, sleeves or pipe replacement excavates and repairs lengths with severe metal loss. Mechanical damage like dents are repaired by induction, compression or cut-out replacement. Pipelines may also undergo hydrotesting after repair to validate the work before resuming service. Continuous pipeline integrity management ensures repair and remediation are prioritized to address issues proactively before compromising safety or environmental performance.
Personnel Training
All individuals with pipeline safety responsibilities receive thorough initial and ongoing training tailored to their role. This includes operations, maintenance and emergency response personnel as well as contractors and excavators. Training encompasses classroom and field components and ensures full understanding of pipeline risks, integrity management programs, operating/maintenance procedures, emergency response protocols, damage prevention requirements and other key competencies. Regular drills keep response skills sharp. When new inspection or assessment technologies arise, personnel are updated to properly utilize and act on the resulting integrity data. A skilled and knowledgeable workforce is fundamental for maintaining pipeline integrity from design and construction through the full service lifetime.
Monitoring and Continuous Improvement
Not resting on past success, pipeline operators pursue monitoring and data analysis to continuously strengthen integrity programs. Performance metrics track leading and lagging indicators of protection success or areas
Unlock More Insights—Explore the Report in the Language You Prefer
About Author:
Ravina Pandya, Content Writer, has a strong foothold in the market research industry. She specializes in writing well-researched articles from different industries, including food and beverages, information and technology, healthcare, chemical and materials, etc. (https://www.linkedin.com/in/ravina-pandya-1a3984191)