API 1163 Verification and Validation Workshop

Day 1 & 2
8am-5pm PT

This course is for engineers responsible for verifying and validating ILI inspections of pipeline systems in accordance with the new 3rd edition of API Standard 1163 “In-line Inspection Systems Qualification.” API 1163 provides requirements for qualification of in-line inspection systems used in gas and hazardous liquid pipelines. The standard is incorporated by reference into PHMSA regulations 49CFR192 and 195, and the 3rd edition is expected to be incorporated after PHMSA’s review.

API 1163, 3rd edition, expands and makes mandatory requirements that pipeline operators both verify and validate ILI performance as part of a pipeline integrity management program:

Verify: Ensure compliance with appropriate plans, procedures, and processes and that inspection conditions are consistent with those used to establish the performance specification(s) for the inspection system being used. A verified inspection should meet the performance specification(s).

Validate: Ensure that the reported ILI results are consistent with the performance specification(s). A validated inspection is one that the pipeline operator considers consistent with the performance specification(s) and suitable for use in managing the integrity of a pipeline.

The course will teach students practical techniques for verifying and validating a metal loss ILI in accordance with API 1163, 3rd edition. The course includes and provides instructions on the use of an API 1163, 3rd edition, spreadsheet recently released by PRCI to validate ILI results. Exercises conducted during the course will ensure students understand how to use the software, and they will help students build and maintain the skills needed to successfully apply API 1163, 3rd edition. The skills used for metal loss inspection program can also be applied to crack-detection and other inspections programs.

COURSE OBJECTIVES

At the completion of this course, students will be able to:

Understand ILI essential variables in API 1163, 3rd edition, and how ILI service provider’s performance specifications are formulated
Verify that an ILI has been successfully conducted in accordance with API 1163, 3rd edition
- Establish the basis for verifying the inspection before the inspection is conducted
- Evaluate the conditions under which the ILI was conducted to ensure they are consistent with the ILI performance specification
- Review preliminary (field) ILI results regarding data quality and consistency requirements
- Accept the ILI data on site after evaluating and reviewing the ILI conditions and preliminary results.
Validate ILI accuracies in accordance with API 1163, 3rd edition
- Establish the basis for validating the inspection before the inspection is conducted
- Define the number of field measurements needed to validate the inspection based
- Validate an inspection to API 1163, 3rd edition, Level 1, 2, or 3
- Accept the ILI results after evaluating the ILI results as given in the inspection report and/or data spreadsheet
Understand the role uncertainty plays in using ILI results

PREREQUISITE KNOWLEDGE

Entering this course, you should have a basic understanding of what in-line inspection (ILI) entails

How ILI tools are selected, prepared, and used to inspect pipelines for anomalies that could threaten integrity
How basic inspection technologies work – caliper, MFL, ultrasonic wall thickness, ultrasonic crack detection, and EMATs
What typical ILI data, reports, and spreadsheets look like
Field methods of measuring anomalies versus what has been reported by the ILI

CONTINUING EDUCATION UNITS

Upon completion of the course, participants will be awarded 1.4 CEUs.

COURSE DOCUMENTATION

Complete course presentation material will be available as a PDF download prior to the course.

INSTRUCTORS

Matt Ellinger is a Principal Engineer within DNV’s Integrity Solutions & Compliance department in Columbus, Ohio. Matt has over 17 years of industry experience with a focus on ILI projects.

Greg Morris is a Principal Engineer in the Incident Investigation section at DNV in Columbus. He joined DNV in 2019 with 27 years of experience in pipeline integrity management support, failure investigation, risk assessment, material specifications, and training.

SYLLABUS

Day 1

1. Introduction and Background
a. ILI Basics
b. API 1163 Development
c. Regulatory Requirements
d. Key Definitions and Terms of Reference
2. Performance Specifications – Section 6 of API 1163, 3rd edition
a. Concept of Essential ILI Variables – what’s important for each technology, ranges of applicability, etc.
b. Requirements on ILI service providers when preparing a Performance Specification
c. Basis for Performance Specifications
d. Reporting Requirements
e. Role of Continuous Improvement, QA/QC, etc.
f. Reading and Understanding Performance Specifications (case study examples)
3. ILI Acceptance Introduction and Overview
a. On-site verification – Section 7 of API 1163, 3rd edition
b. Accuracy validation – Section 8 of API 1163, 3rd edition
4. Field data collection
a. Purposes of field data collection relative to API 1163, 3rd edition
b. Data quality and data integrity
c. Measurements
5. Verification under API 1163, 3rd edition
a. Verification tasks
b. Examples and case studies
c. What happens after on-site verification

DAY 2

6. Validation under API 1163, 3rd edition
a. Introduction and basic requirements
b. Evaluating PODs and POIs
c. Collecting sample data from a population
d. Level 1 validations
e. Level 2 validations
f. Level 3 validations
g. Level 2 versus Level 3 validations
h. API 1163, 3rd edition validation software
7. Using Validation Results in Integrity Decisions
a. Validating performance specifications versus estimating actual performance
b. Accounting for uncertainties in burst pressure calculations
c. Accounting for uncertainties in remaining life calculations
d. Relationship between calculated remaining lives and reassessment intervals
e. Regulatory acceptance

Assessing Cracks & Long Seam Weld Anomalies

Day 1 & 2
8am-5pm PT

WHY YOU SHOULD ATTEND

Various forms of cracks and long seam weld anomalies are known to be present in pipelines, which can become a safety concern over the operational life of the pipeline. The most typical forms for cracking are environmentally assisted, manufacturing related and operational driven. This course will cover in greater depth the formation of cracking and seam weld defects and the conditions that drive their growth until they become unstable, leading to leaks or ruptures.

WHAT YOU WILL LEARN

Led by Sergio Limon, this 2-day, in-person course is designed for pipeline engineers and managers. You will learn the basics of how and why cracks and seam weld anomalies form and how to effectively assess them. This will include hands-on demonstration and discussion of pipeline samples with cracking and seam weld defects. Appropriate assessment methods such as ILI tools and pressure testing will be discussed as well as traditional and current engineering methods for determining their severity for response and remediation. In-ditch Non-destructive Examination (NDE) methods and technologies will also be covered and demonstrated with actual pipeline samples. Each attendee will receive a complimentary Excel based crack assessment calculator which will be demonstrated in class using practical case studies.

WHO SHOULD ATTEND

Pipeline engineers, managers and service professionals who are involved with the operation, maintenance, inspection and repair of pipelines.

COURSE REQUIREMENTS

It will be necessary to bring a laptop to this course.

COURSE DOCUMENTATION

Complete course presentation material will be available as a PDF download prior to the course.

CONTINUING EDUCATION UNITS

Upon completion of the course, participants will be eligible to receive 1.4 Continuing Education Units.

INSTRUCTOR

Sergio Limón is a Sr. Engineering Advisor with Blade Energy Partners responsible for developing, implementing, and executing strategic integrity management programs for gas and liquids pipelines, as well as performing fracture mechanics based structural evaluations, fatigue assessments and failure analyses. Sergio has worked in the oil & gas pipeline industry for more than 22 years with emphasis on pipeline integrity threat analysis and response. He was employed for 10 years with a large owner and operator of natural gas transportation pipelines where he led for six years the Asset Integrity group for the western division responsible for the analysis, response, and remediation of integrity threats. Sergio holds B Sc. and M Sc. degrees in Mechanical Engineering with emphasis in fracture mechanics and materials from the University of Utah.

COURSE SYLLABUS

DAY 1

Characteristics and Behavior of Cracks and Long Seam Weld Anomalies in Pipelines
- A review of line pipe making, with emphasis on vintage ERW, Flash and Direct Current Welded pipelines
- The formation and growth of
  - Environmentally Assisted Cracking: SCC axial & circumferential, hydrogen induced cracking, corrosion fatigue cracking, sulfide stress cracking, and selective seam corrosion
  - Manufacturing Related Imperfections: lack of fusion, cold welds, stitching, and hook crack-like features
  - Operationally Driven Cracking: fatigue cracks
- Difference between cracks and long seam weld anomalies
- PHMSA requirements for evaluating pipelines with cracks and seam weld defects
  - Old and new regulations in Parts 192 and 195
- Review of current industry standards and recommended practices related to addressing cracking and seam weld integrity
  - ASME B31.8S and API 1176 and 1160
- Hands-on demonstration of pipeline samples with cracks and seam weld defects

Foundations of Engineering Fracture Mechanics
- The fracture process of pipelines with cracks or seam weld anomalies
  - Fracture initiation, stable propagation, and fracture arrest or final fracture
- Fracture behavior: brittle, ductile and mix-mode
- Basic principles underlining Liner Elastic and Elastic-Plastic Fracture Mechanics and their applications to pipelines
- The concept of Stress Intensity Factor describing the relationship of failure stress as a function of crack size and material properties
- Fracture toughness testing
  - Impact Charpy V-Notch and its relation to Ductile-to-Brittle transition curve
  - Fracture mechanics-based toughness testing: Kc, Jc, CTOD and J-R crack growth resistance curve
  - Correlation of CVN to K, J and CTOD

Performing Failure Pressure Calculations
- What to look for in any engineering method for determining the failure pressure of pipelines in the presence of cracks or seam weld anomalies
- Review of the following engineering methods: NG-18 Equation, Newman-Raju Equation, CorLAS, API 579-1/ASME FFS-1, and PRCI MAT-8
  - Review of published studies comparing the accuracy of these methods
  - Which one is more accurate or conservative?
- Effects of fracture toughness on failure pressure predictions
- In class demonstration of an Excel failure stress analysis calculator
- A review of crack prioritization and severity rankings by ASME and CEPA
- Crack length interlinking conditions of neighboring crack features by CEPA and API 579
- SCC growth estimation and industry reported growth rates

DAY 2

Performing Fatigue Crack Growth Analysis
- Common concepts in fatigue analysis and stages of fatigue and fatigue life
- Steps for performing a fatigue crack growth analysis and remaining life calculation
  - Setting initial cracks sizes, evaluating cyclic pressure data, choosing material properties, selecting a fatigue crack growth model and deciding on one the termination point of the fatigue analysis (failure condition)
- Review of fatigue crack growth models: Paris-Erdogan, Walker, Forman, NASGRO and choosing an appropriate set of C & m fatigue parameters
- Simplifying variable amplitude cyclic pressure data by means of the rainflow counting methods (ASTM E1049) and assessing the severity of cyclic pressures
- Performing sensitivity analysis of the final calculated fatigue life
- The use of safety factor on the predicted final fatigue life
- In class demonstration of case studies and the analysis of cyclic pressures

Integrity Assessments for Addressing Cracks and Long Seam Weld Anomalies
- Factors to consider when evaluating and deciding on assessment methods
- Hydrostatic Testing: setting up appropriate pressure test targets, hold times, the role of spike testing and determination of appropriate re-test intervals
- In-line Inspection: description of the UT, EMAT and C-MFL technologies, their performance, industry experience, and development of response criteria
- Direct Assessment methods: review and applicability of NACE SP0204 for SCCDA and CSA Z662 & CEPA Condition Monitoring for SCC

In-Ditch Non-Destructive Evaluation (NDE)
- Pipeline coating removal and surface preparation techniques
- Review of most widely used NDE methods and technologies
  - Magnetic particle inspection
  - Conventional UT shearwave
  - Phased array UT (PAUT)
  - Total Focusing Method (TFM)
  - Inverse Wave Field Extrapolation (IWEX)
  - Eddy Current-based
  - Including emerging technologies
- NDE personnel qualifications, what should they be for pipeline applications?
- Present an NDE protocol framework for field evaluations and characterization of cracks and long seam weld anomalies
- Hands-on demonstration of various NDE methods and technologies commonly used for crack and seam weld detection and sizing
- Review of repairs options in the industry: ASME B31.8 & B31.4 and PRCI Repair Manual

Pipeline Defects Repair Workshop

Day 1 & 2
8am-5pm PT

OVERVIEW

Imperfections and defects may be found in pipelines associated with the inherent steel making process, line pipe manufacturing, pipeline construction or introduced during its operation. Not all imperfections and defects are injurious to the safe operation of pipelines and established engineering methods exist for performing engineering assessments to make such determination. Those defects that are injurious require repair. The operator must then choose from a wide selection of repair methods considering regulations, industry guidance, repair effectiveness, and practical details.

OBJECTIVES

To demonstrate existing and new Repair technologies and their application for specific defects uncovered during the defect assessment and NDE phases of pipeline rehabilitation.

COURSE DOCUMENTATION

Complete course presentation material will be available as a PDF download prior to the course.

CONTINUING EDUCATION UNITS

Upon completion of the course, participants will be eligible to receive 1.4 Continuing Education Units.

WHY YOU SHOULD ATTEND

This course will cover assessment methods and repair options for the most common pipeline imperfections and defects. PHMSA repair regulations and industry Codes ASME B31.8 and B31.4 associated with pipeline repairs will be discussed. The course will address pre-NDE activities, field NDE defect evaluation, engineering assessment, repair criteria, repair selection and installation. Hands-on NDE and repair installation demonstration are part of the workshop.

WHAT YOU WILL LEARN

Led by Sergio Limon and Mike Rosenfeld, you will learn:

How common defects form in pipelines and the mechanisms that can make them grow
Non-destructive evaluation methods and technologies, and hands-on demonstration of their applications
Engineering methods and models for assessing the severity of defects
Criteria in PHMSA regulations and ASME codes for determining injurious defects that need remediation
Definitions of temporary and permanent repairs
Pipeline pressure reduction guidelines prior to and during defect evaluation and repair
Repair methods: buffing/grinding, Type B and A metallic sleeves, compression sleeves, composite sleeves, mechanical bolt-on clamps, and emerging repair sleeve systems
Hands-on demonstration of most common repair systems

WHO SHOULD ATTEND

The course is intended for practicing pipeline professionals who are involved with the field defect evaluation, engineering assessment, and onsite repair preparation and installation activities; these include pipeline engineers and operators, bell hole support specialists, excavation inspectors, NDE service providers, repair manufacturers, ILI analysts and field support team.

COURSE SYLLABUS

DAY 1

8:00am – Introductions

Pressure Reduction Guidelines and pre-NDE Activities (Sergio)

Pipeline pressure reductions
Coating removal techniques and pipeline surface preparation

Non-Destructive Evaluation Methods (Sergio)

Common definitions of defect assessments and in-ditch evaluation
Magnetic Particle Inspection (MPI), pit gages and laser surface profilometry
UT shear-wave and phased array, Eddy current probes, IWEX, TFM, and CT

Common Pipeline Repair Systems (Mike)

Definitions of temporary and permanent repairs: PHMSA and ASME
Buffing/grinding, Type B and A metallic sleeves, compression sleeves, composite sleeves: e-glass and carbon fiber
Mechanical bolt-on clamps, and hybrid repair sleeve systems

Repairing Corrosion (Mike)

Formation of internal and external general corrosion and pitting corrosion and what can make them grow
Corrosion defects that require repair and allowable repair options

12:00-1:00pm – Lunch Break

Repairing Cracks (Sergio)

Formation of stress corrosion cracking, hydrogen induced cracking, and fatigue cracks and mechanisms that can make them grow
Cracks that require repair and allowable repair options
Demonstration of NDE Methods
Hands on demonstration of pipe surface preparation and defect characterization

Demonstration of NDE Methods

Hands on demonstration of pipe surface preparation and defect characterization

5:00pm – End of Day 1

DAY 2

8:00am – Course resumes

Repairing Gouges and Grooves (Mike)

Source of gouges and grooves in pipelines and what can make them grow
Defects that require repair and the allowable repair options

Repairing Seam Weld Defects (Sergio)

Formation of lack of fusion, cold welds, hook-like defects and stitching and what can make them grow
Sean weld defects that require repair and the allowable repair options

Repairing Seam Weld Corrosion (Mike)

Formation of selective seam weld corrosion (SSWC) and what can make them grow
SSWC defects that require repair and the allowable repair options

Repairing Plain Dents and Dents with Damage (Sergio)

Formation of dents and dents with gouges, cracks, or corrosion and what can make them grow
Dents that require repair and the allowable repair options

Repairing Wrinkle, Buckles and Ripples (Mike)

Formation of wrinkle bend, buckles, and ripples
Wrinkle bend, buckles and ripples that require repair and the allowable repair options

12:00-1:00pm – Lunch Break

Repairing Grith Weld Defects (Mike)

Formation of cracking and volumetric defects initiate in girth welds and what can make them grow
Girth weld defects that require repair and the allowable repair options

Repairing Hard Spots, Laminations, Blisters (Sergio)

Formation of cracking and volumetric defects initiate in girth welds and what can make them grow
Girth weld defects that require repair and the allowable repair options

Demonstration of Repair Systems Installation

Class attendees will witness the preparation and installation of most common repair systems: composite sleeves, metallic sleeves, bolt-on, and grinding/buffing

5:00pm – End of Workshop

ABOUT THE INSTRUCTORS

Sergio Limón is a Sr. Engineering Advisor with Blade Energy Partners responsible for developing, implementing, and executing strategic integrity management programs for gas and liquids pipelines, as well as performing fracture mechanics based structural evaluations, fatigue assessments and failure analyses. Sergio has worked in the oil & gas pipeline industry for more than 22 years with emphasis on pipeline integrity threat analysis and response. He was employed for 10 years with a large owner and operator of natural gas transportation pipelines where he led for six years the Asset Integrity group for the western division responsible for the analysis, response, and remediation of integrity threats. Sergio holds B Sc. and M Sc. degrees in Mechanical Engineering with emphasis in fracture mechanics and materials from the University of Utah.

Michael J. Rosenfeld, PE – RSI Pipeline Solutions LLC, is an experienced consultant in pipeline fitness for service, pipeline integrity, pipeline design and construction, causes of pipeline failures, pipeline regulations and standards, and related matters. He has performed numerous pipeline failure investigations and root cause failure analyses; research funded by the pipeline industry on the effects of mechanical damage, fatigue, pipeline integrity threat interactions, and methods to determine the probable grade of undocumented pipe materials; engineering analyses of a broad range of design, operations, or integrity matters for numerous pipeline operators; and provided expert support in litigation. He chairs the Subgroup on Design, Materials, and Construction of the ASME B31.8 Gas Transmission and Distribution Piping Committee and serves on other ASME piping standards development committees. Mr. Rosenfeld has authored or co-authored over 100 published articles or public presentations, is an ASME Fellow, and is a Professional Engineer registered in the State of Ohio. He earned a Bachelor of Science in Engineering from the University of Michigan (1979) and a Master of Engineering from Carnegie-Mellon University (1981).

Payment

Payment by check, credit card or bank transfer is due in full prior to the start of the event.

Cancellations/substitutions

Cancellations received on or before 15 days prior to the event will be refunded less a $200 fee to cover pre-event costs incurred. ($50 if the registration fee was less than $200.) Cancellations received on or after 14 days prior to the event are non-refundable. Substitutions may be made at any time; if you wish to transfer to another course or conference at another time, a 50% credit will be applied for fees already paid.

Confirmation will be made in writing as soon as possible upon receipt of payment. This confirmation will be sent to the address given on the registration form, unless otherwise required.

The organizers reserve the right to cancel any event due to insufficient enrollment. In this event fees will be refunded in full. However, the organizers assume no liability for travel or any expenses other than fees paid.

Hydrostatic Testing of Pipelines

Day 1 & 2
8am-5pm PT

This course is designed for pipeline personnel in engineering, integrity management, operations, and regulatory compliance roles. This course will cover a wide range of topics related to hydrostatic testing of pipelines for gas and hazardous liquid service for both in-service and new construction according to CFR 49 Parts 192 and 195.

COURSE OBJECTIVES

To provide attendees with necessary information for planning and conducting a successful hydrostatic test, whether it’s for initial service or retesting existing lines. Planning will cover review of integrity prior to testing through evaluation of test results. The course will focus on testing with water but testing with other medium will be discussed.

CONTINUING EDUCATION UNITS

On completion of the course, participants will be awarded 1.4 CEUs.

WHO SHOULD ATTEND

The course is intended to cover the technical aspects of planning and conducting a hydrotest. It is designed for engineers, project managers, integrity management, and operation personnel to prepare for testing. The following topics will be covered:

Pipeline integrity review
Water source identification, disposal, and permitting
Leak detection
Risk assessment and contingency planning
Calculations for test pressures according to 49 CFR 195
Assessment of test results, including methods of analyzing pressure discrepancies
Test scheduling
Documentation for regulatory review

INSTRUCTOR

Gary Zunkel, PE, is an independent consultant specializing in pipeline integrity, based in Ames, IA. Prior to establishing his consultancy, he was Senior Engineer of Pipeline Integrity with BlueFin in New Iberia, LA. He has been involved in the oil and gas industry for over 30 years with the last 10 years focusing on pipeline integrity management. He has been involved with over 200 pipeline tests; planning, managing, executing, and reviewing. In recent years, he has planned and conducted multiple, simultaneous tests on large diameter in-service pipelines for integrity verification.

SYLLABUS

1. Establishing Test Requirements

Purpose of the test
- Evaluate integrity of the pipeline
- Confirm integrity program
Establishing pressure requirements
- Federal regulatory requirements
  - Liquid – 49 CFR 195
  - Gas – 49 – CFR 192
- Pressure parameters based upon MOP/MAOP requirements
- Strength Test
- Leak Test
- Spike Test
Segment Isolation
- Headers & End Caps
- Valves
  - Gel Isolation

2. Conducting a Safe Test

Risks of potential energy
- Compressed gas
- Compressed liquid
Protecting the public
Managing test safety
- Immediate area
- Equipment
Communication prior to and during a test

3. Preliminary planning

Pipeline evaluation
- Historical records evaluation
  - Repairs
  - Previous test records
  - Integrity records
Equipment pressure ratings
Elevation profile
Water sources
Water crossings
Exposed pipe

4. Test Schedule

Preliminary Scheduling
- Water source & landing
- Outage
- Permitting
- Pipeline rehabilitation
- Notifications
Test Setup
- Site preparation
- Line Isolation
- Line fill
Test Sequence
- Stabilization
- Pressurization
- Test time
- Depressurization
Water movement & discharge
Restoring a line to service

5. Water as a test medium

Source
- Permits
- Volumes
- setup
Discharge
- Permits
- Treatment
Volume requirements and calculations

6. Other test medium

Liquid hydrocarbon
Natural gas
Nitrogen
Air
Applications
- Requirements
- Changes in test planning
- Instrumentation

7. Leak Detection

Dye
Gas
Acoustic pressure
Section isolation
- Valves
- Freeze plugs
- Test headers/caps

8. Test Documentation

Graphs
Calibration certificates
Drawings
Elevation profile
Test procedure
Summary of results
Explanation/calculations of pressure changes
- Test pressure interpretation
- Temperature effects on pressure
- Air entrapment
- Examples of test results and interpretation
Pressure Volume (PV) Plot
- Creation of a PV Plot
- Offset Line
- Interpretation of a PV Plot
Test log
OQ documentation
- Historical records evaluation
  - Repairs
  - Previous test records

9. Managing water movement

Fill rate
Purging prior to line fill
Dewatering
- Product
- Air
Drying
- Explanation of terminology
  - Penetration depth
  - Dew point and temperature
Air lock
Contamination
Contingency
- Drain up calculations
- Refill/Retest planning
Discharge
- Rates
- Discharge structure
- Treatment of contaminated product
Pigging
- Types
- Multiple pigs in the line
- Launching receiving
- Bypassing a station
- Tracking

10. Instrumentation

Types – Pressure & Temperature
- Bourdon Tube (Pressure & Temperature)
- Bi-metallic (Temperature)
- Resistance Temperature Detector (RTD)
- Quartz electronic
Accuracy vs. Repeatability
Calibration
Pressure measurement
- Deadweight – Mechanical/Electronic
- Gauges
- Recorders
Temperature
- Thermometer
- Recorders
  - Quantity
  - Placement
  - Type
Volume measurement
- Stroke counter
- Flow meter

11. Data Interpretation & calculations

Pipeline evaluation
- Historical records evaluation
  - Repairs
  - Previous test records

12. Test Failure

Rupture
Leak
Pressure reversal
Equipment failure
Location of failure
Repairs
Retesting

13. Contingency Planning

Repair materials
- Sleeves
- Replacement Pipe
- Stopples
Emergency Response
- Public relations
- Notifications
- Cleanup and remediation
Retesting
- Venting & refill

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