Asset Management Services

Plant Integrity Management Services

Germanischer Lloyd Service/Product Description

Germanischer Lloyd Service/Product Description

Plant Integrity Management Services

Service Title: Lead Practice: Asset Management Services GL Asset Management (UK)

Contents
Page 3 Service Description and Values Generated Pages 4 - 12 Detailed Method Statement a: Plant Integrity Management System Audits b: Corrosion Management c: Material Defect and Component Failure Investigation d: Fitness for Service Assessment e: Written Schemes of Examination f: Coatings Services g: Welding Services h: Risk Based Inspection i: Pipework Vibration Services

Pages 12 - 22 Case Studies and Examples a: Corrosion Management of LNG Storage Facilities b: Integrity Management Review c: Fracture of Thermowell d: Failure of Impulse Pipework Compression Fitting e: Fitness-for-Purpose Assessment of Pressure Vessels f: Fracture Mechanics Assessment of a Defective Pig Trap g: Defect Assessment of Corroded Pipework h: Review of Integrity Management Framework i: Safety Management Audit j: Fitness for Service Assessment k: Repair of Amine Stripper l: Investigation of Coating Failure on Oil Storage Tank

SERVICE DESCRIPTION

Service Description and Values Generated:

Pages 23 - 32 Case Studies and Examples m: Corrosion Management Study n: Weldability Testing of 48 Diameter X80 Europipe Production o: Design and Qualification of Repair Procedures for Bellows Attachment Welding p: Evaluation of RBI Software q: T-OCR Risk Based Inspection r: Investigation of Double Block and Bleed Valve Vibration at a Gas Processing Facility s: Long Term Monitoring of Pipework Vibration at Gas Compressor Stations t: Assessment of Risk of Pipework Failure Due to Vibration During Offshore Plant Uprating u: Vibration Screening at an Onshore Gas Terminal Germanischer Lloyd (GL) provides a range of Plant Integrity Management services to assist Operators in managing their assets in a safe and efficient manner, as well as complying with all prevailing regulations and legislation. GL are able to tailor their services to meet client needs and can generally provide support & solutions to a range of Integrity Management problems. Supporting each of the core services are experts with many years experience in integrity management.

DETAILED METHOD STATEMENT

a. Plant Integrity Management System Audits In general, an audit or review of an Integrity Management System will begin with a Gap Analysis. This entails a thorough review of the Operators activities from corporate policy and organisation through to company procedures and work instructions, including the following: Compliance with requirements national legislation and local

b. Corrosion Management GLs approach to corrosion management is to consider the process, materials and safety aspects as an integrated whole. In most respects the process dictates the materials and corrosion control methods used on plant while occasionally the materials technology available will shape the feasible process solutions. Ultimately, the objective is to produce a system that assures the safety of plant operations. Thus, all have to be addressed when considering corrosion management. The production of a corrosion management system would generally involve the following stages: 1. Gather process data e.g. temperatures, pressures and fluid compositions during both normal operation and upset conditions

Integrity threats and mitigations in place Onshore mechanical damage, corrosion, ground movement etc Offshore mechanical damage, stress/fatigue type material failures, internal and external corrosion etc

Quantitative risk assessments undertaken Engineering documentation Plant records and fault data Quality, health, safety and environmental issues Plant Operations and Maintenance Work scheduling Record keeping Routine and non routine activities

2. Consider the safety risk assessment in order to: Identify pressurised systems Identify major hazards Identify HAZOP actions related to corrosion and materials

3. Conduct corrosion risk assessment including: Calculation of internal corrosion rates Assessment of stress corrosion cracking threat Assessment of erosion threat Assessment of external corrosion including under insulation

Plant Inspection Modification and repair process Emergency management Defect assessment and repair methods Training and competency of staff Safe control of operations Continuous improvement processes in place

The Integrity Management System under review can then be assessed for compliance with prevailing regulations and compared to international best practice. Recommendations can be made to the Operator as to how they can improve their processes and systems. Generally in such a project there will be a Phase 2 which comprises gap closure actions. Depending on the results from the gap analysis this might entail a complete overhaul of an Operators Engineering Documentation System or it may involve some rationalisation and repackaging to ensure that the IMS is clear and coherent.

DETAILED METHOD STATEMENT

4. Produce corrosion management scheme Select materials (corrosion resistant alloys or carbon steel with corrosion allowance) Select corrosion control methods (e.g. inhibition, coatings, cathodic protection) Select corrosion monitoring methods and locations Produce corrosion data management strategy and select tools Devise suitable key performance indicators (KPI) for corrosion management Document change procedure for revising scheme if process parameters are altered (e.g. after debottlenecking) Produce plant/field corrosion management guide/ manual

c. Material Defect and Component Failure Investigation GLs approach to failure investigations is not only to use state of the art methods to determine the immediate cause of the failure, but also to identify the root cause and propose solutions for eliminating the problem in future. There are many reasons why a material defect or failure may arise; for example:Incorrect materials selection, Materials quality issues, Fabrication issues, Operating conditions outside original design parameters, Environmental factors, Maintenance and protection issues, Human and procedural factors,

5. Feed back the corrosion management activities into the field safety case and risk assessment as mitigating factors

Third party damage.

The scope of a failure investigation depends upon the nature of the failure and also upon the results obtained as the investigation proceeds. An important first step is to ensure the failure is preserved for future examination, particularly where this may be used as evidence for litigation purposes. This may involve visits to site to assist in identifying, examining and collecting all relevant material, and stabilising and protecting as necessary for transport to the laboratory. In the event of a dynamic failure, such as an explosion resulting in extensive damage, this may be a difficult and arduous task as the majority of the failures evident will be effect and not necessarily directly relevant to identifying the cause. In these circumstances detailed photography is essential before any material is removed from the site of the failure. It is also important to talk to site personnel to establish the circumstances surrounding the failure and operating conditions at the time. Where the failure involves a defect in a component or structure it is important that NDT (Non Destructive Testing) is carried out to determine the extent of the failure and any associated damage prior to extraction for detailed analysis. GL NDT experts offer a range of techniques, both on-site and in the laboratory, including: magnetic particle inspection (MPI), dye penetrant testing (DP), manual ultrasonic testing (MUT), alternating current potential drop (ACPD), and mechanical measurements. For characterising the defect or failure a metallurgical examination and materials testing programme is carried out.

DETAILED METHOD STATEMENT

A metallurgical examination of a defect or failure would typically include:Visual examination by eye and using a stereo optical microscope Detailed fractography using a scanning electron microsope (SEM) Surface compositional analysis by semi-quantitative X-ray energy dispersive micro-analysis (EDX) in the SEM Preparation of weld sections for macro-examination and hardness surveys Preparation of mounted and polished sections for microstructural analysis and to confirm crack path

d. Fitness for Service Assessment GL routinely undertakes assessments of damaged pressure vessels and pressure systems for an international clientele of asset owners/ operators worldwide. We have in-depth knowledge and experience in the use of industry recognised assessment methods such as: API 579 RSTRENG DNV RPF101 BS7910 ASME VIII PD5500

Materials testing, to establish compliance with relevant standards and to generate mechanical property data for supporting engineering analysis assessments, would typically involve:Chemical composition Tensile testing (e.g. yield strength, ultimate tensile strength, elongation etc, and specific tests for threaded fasteners) Hardness testing Charpy impact testing Fracture mechanics testing (such as CTOD and J-integral)

BS EN13445

GL therefore have the capability to assess the integrity of pipework and pressure vessels and routinely use advanced numerical techniques such as the finite element (FE) method and pipe stress analysis to undertake fitness for service assessments. We have excellent knowledge of the UK Pressure Systems Safety Regulations, 2000 (PSSR) and relevant US Code of Federal Regulations (e.g. CFR 192 and 195). For any fitness-for-purpose assessment, assumptions are required on the input parameters. These assumptions include: Original equipment design data

The output from the metallurgical analysis and materials testing programme would offer the customer an opinion on the mode and likely cause of failure, and an understanding of the contribution of material related factors. It is usual to complement the metallurgical examination and materials testing programmes with an engineering analysis to identify and understand the contribution of mechanical factors. Depending upon the nature and scope of the investigation further analysis may be carried out to understand the wider implications of the failure and to ensure that recommendations for preventing further failures are implemented, for example:Detailed fracture mechanics analysis to determine safe operating parameters Fitness for purpose assessments Remaining life analysis Review and update of operating procedures Review of asset integrity and inspection programmes (such as RBI)

Operational and maintenance history Expected future service Information specific to the assessment such as defect sizes, stress state, location of flaws, and material properties such as tensile strength and fracture toughness. Fitness for Service can be demonstrated using methods such as stress analysis, defects assessment and fracture mechanics approaches. These are described as follows:

DETAILED METHOD STATEMENT

Stress Analysis Fitness for service can be demonstrated using higher level assessment methods such as FE (Finite Element Analysis). GL can undertake work ranging from the stress analysis of individual structural components such as pressure vessel nozzles, full pressure vessel models to complete piping systems. GL consultants have the capabilities to undertake advanced non-linear, static/dynamic analysis, vibration, thermal and fatigue analyses. We use these capabilities to undertake fitness-for-service assessments of pressure systems and in conjunction with full scale testing facilities to develop defect assessment methods for pipelines and pressure vessels. GL uses an extensive range of FE and associated software tools that are mounted on both SUN Unix network and PC based Windows system. The software tools we use include: ABAQUS (Standard and Explicit) FE analysis program MSC/PATRAN and ABAQUS CAE FE pre and post processor programs PC based software such as MathCad and MATLAB In addition to the above, our consultants can write customised programs, user subroutines, etc. in order to overcome the limitations in proprietary software. Areas of expertise include; Linear and non-linear analysis. Where necessary, non-linear effects can be included in the analysis; this can be through the modelling of non-linear material behaviour, geometric non-linearity and contact Buckling, postbuckling and collapse analysis of pipelines Soil structure interaction Steady state and transient heat transfer analysis Fatigue and fracture mechanics; cracked body analysis Design by analysis

Defect Assessment Defect assessment is a deterministic approach used to assess the integrity and fitness for service of defects found on pressure vessels or piping. Defects are features that affect the structural integrity of vessels, pipelines or piping, and may be located on the surface of the pipe wall or actually inside the material of the pipe or shell. There are numerous codes that can be used to assess defects and are summarised in documents such as the Pipeline Defect Assessment Manual used for pipelines, which our consultants understand the best methods to use. In addition, GL has experience in conducting assessments to API 579 and BS 7910 used for pressure vessels and piping. Sources for defect data include NDT methods. Using in-house expertise, appropriate assessment methods can then be chosen and applied to demonstrate fitness-for-service in order to satisfy regulatory requirements and operators integrity management strategy. Damage assessment capabilities include the following; i) Manufacturing Damage, Manufacturing features are often a discontinuity in the geometry of the pipe or shell such as a reduction in wall thickness or in the material itself. ii) Construction Damage, Construction defects may include girth weld defects or seam weld defects caused by lack of fill or misalignment, and in the most severe case, cracking. Also, other forms of damage may occur such as indentation damage, corrosion at the girth weld, or even damage to the external coating. iii) 3rd party interference, 3rd party damage is often the most severe form of damage resulting in failure of the pipe or requiring immediate repair. Often this involves mechanical damage such as a gouge resulting in metal loss of the pipe wall, or distortion of the pipe wall such as a dent. iv) Operational damage. Defects arising from operational usage include external corrosion caused by damaged or disbonded coating where the Cathodic Protection System is not effective. Also internal corrosion caused by water in the product, and even other forms of corrosion namely Sweet Corrosion and Sour Corrosion may occur in pipelines.

Windows is a trademark of MicrosoftTM corporation

DETAILED METHOD STATEMENT

Fracture Mechanics BS7910 and similar codes such as the UK nuclear industry code R6 and API 579, carry out fracture assessments using the Failure Assessment Diagram (FAD). This provides a graphical method for assessing the proximity of a loaded structure containing a defect to failure by fracture and plastic collapse mechanisms. Proximity to fracture is characterised by the fracture ratio parameter Kr and proximity to plastic collapse is characterised by the parameter Lr. A loaded structure can therefore be represented as an assessment point on the FAD following calculation of Lr and Kr. This diagram is used in levels 1 to 3 of BS7910 to determine the acceptability of cracks by plotting a point on the diagram. When deciding which level to use, this depends on the input data available and conservatism required. These levels can be summarised as; Level 1 is a simplified assessment method when there is limited data on material properties Level 2 is the normal assessment route Level 3 is based a ductile tearing resistance analysis

e. Written Schemes of Examination The Written Schemes of Examination (WSoEs) will be logically structured to allow for effective monitoring and control and will show individual pressure systems within each of the major systems. The components that require periodic inspection in order to ensure continued fitness for purpose will be identified. The WSoE will ensure that all components within the plant are sufficiently inspected to ensure that any defects are detected at an early stage to prevent inoperability of the asset. Such inspections may not be limited to pressure containing components, but may also include access ladders, gantries, foundations, whose failure may limit the operability of the plant or equipment. The WSoE will be structured in such a way that will allow the User to determine the future inspection requirements for at least a 5-year period, however, it is more likely that future inspection requirements for circa 10 years will be attained. The items of equipment covered will generally cover the following: Pressure vessels, drums, tanks etc. Heat exchangers

Using the fracture mechanics approach our consultants can determine whether a defect is SAFE or UNSAFE based on the Failure Assessment Diagram. Using the fatigue assessment approaches described in BS7910, we can then determine the remaining fatigue life and future integrity of the structure if subjected to cyclic loading.

Compressors Filters Onshore pipelines Offshore pipelines Relief valves Pressure safety valves Fire systems components Compressed air and nitrogen systems

DETAILED METHOD STATEMENT

The WSoEs will be developed by:Reviewing existing documentation pertaining to design, manufacture, construction, testing, modifications and repairs, past inspection reports, etc. and plant operation records. Establishing safe operating limits and their protective devices. Identifying individual pressure systems. Developing examination specifications from each component group. Identifying examination frequencies on fixed time intervals for major items of equipment based upon industry practices, GL experience and information as supplied from the Client. Liaising with the system User.

GL will nominate competent, technical engineers, with long term experience in compiling WSoEs for major gas transporters, to undertake this work. The WSoEs will be generated on Microsoft Word and Excel and be provided on CDs and hard copy. The WSoEs will be based on UK best practice and will not include any other national requirements, unless otherwise stated. The WSoE will be submitted to the Independent Competent Person for review and/or approval.

The WSoEs will typically include :Safe Operating Limits. Equipment to be inspected. Identification references of each item of equipment. Nature and type of inspection required (visual, NDT etc.) Functional testing requirements for protective devices. Preparatory work required prior to inspection. Frequency of inspection. Detailed written inspection procedures for each item of equipment, based on current inspection methodologies, based upon the generic examination specifications. Competencies/qualifications required by inspectors. Standard report formats for recording examinations. Identification of applicable international / national codes, specs, procedures etc. Applicability and adaptability to utilise the most up to date inspection techniques for the examination of plant in the most cost effective manner.

DETAILED METHOD STATEMENT

f. Coatings Services Many factors dictate the protection being afforded to plant and equipment and these must be considered when selecting paint and coating systems for providing corrosion, erosion and chemical resistance. Long term corrosion protection will generally require: 1. Identification of appropriate coating systems Identify substrate type, method of preparation, operating temperature, requirements for insulation, contents being processed or stored etc 2. Small-scale performance evaluation to ensure long-term protection at the new construction and maintenance stage Application, accelerated performance assessment corrosion testing,

g. Welding Services GL staff have been involved, in many cases, in the development and qualification testing of procedures and consumables for the construction of pipelines, process plant and ancillary high pressure equipment. GL carries out weldability studies on all candidate linepipe and components used in the UK National Transmission system in accordance with the requirements of National Grid specification T/SP/MPQ/1. For line pipe this involves the production of a full scale girth weld under simulated field conditions, to an approved procedure and including such factors as lifting and manipulation to simulate movement of the line-up clamps following deposition of the hot pass. Additionally, repair special procedures are tested and qualified before being putting into service. Welding consultancy services are also required when new or difficult materials are involved, such as those employed for high temperature or sour service environments and include materials such as Inconel, duplex stainless steels or linepipe clad with these materials. In these cases very specific welding procedure specifications are drawn up and initial production welding is carried out under the supervision of GL expert staff. GL also carries out welding prequalification of high pressure components produced by new suppliers, and an investigation of the welding procedures and consumables employed by candidate companies is an integral part of this. Site visits are carried out and supervision of component production ensures that they meet the relevant requirements for specific companies and individual projects and can be welded into the system without problems. GL also supplies expert assistance in the selection and application of methods for weld repair of pipelines, process plant and high pressure equipment. This is supplemented by expertise in inspection which ensures that defective areas are professionally repaired and returned to service in fully reliable condition.

3. Development of coating application specifications for new construction and maintenance Surface preparation, application, inspection and testing 4. Coating survey and technical audits to ensure successful application and compatibility with existing systems

GL has been involved in material selection, testing, specification development and quality control issues to ensure long term protection of plant and equipment. Where inappropriate coating systems have been specified, or coatings have been applied incorrectly, GL offer a consultancy service to help confirm the cause of failure. Laboratory test programmes help establish the mechanism of failure, and to apportion blame where litigation is a likely outcome.

h. Risk Based Inspection The main objectives of the RBI is to derive an inspection strategy that ensures the maintenance of integrity of the plant. To establish a minimised vessel inspection programme in accordance with regulations To optimise the inspection strategy for equipment including the testing and maintenance of relief valves To establish integrity management procedures for LNG pipework To reduce, and where possible, eliminate the need for full vessel isolation and entry by utilising borescopic inspection techniques

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DETAILED METHOD STATEMENT

The RBI methodology combines expert judgement and probabilistic modelling. RBI software is used for the execution of criticality assessments and generation of inspection plans. The methodology includes procedures to define process fluids and systemise process streams. Within any process stream there may be changes in pressure and/or temperature of the contained fluid. A system is defined as being that part of a process stream at similar temperature and pressure; such changes may give rise to different corrosion regimes, or a different fluid state. Systemisation of sites is carried out using the latest version hard copies of the piping & instrumentation diagrams (P&IDs). As part of the RBI process, a qualitative assessment is carried out by relevant members the RBI Project Team. This procedure uses process system information, in combination with the materials and contained fluid properties to allocate specific operational consequence ratings relating to standby, financial and location impact. This is also used to highlight any particular areas of concern with respect to equipment deterioration.

A Plant Integrity Review (PIR) is then undertaken. The PIR re-evaluates criticality assessments by examining process history, operating conditions and past inspection results. The initial risk assessment is reviewed and verified against actual plant experience. This is an essential step as it provides an opportunity for the degradation mechanisms calculated by the software to be verified, by the expert panel and any additional failure mechanisms to be added. Changes to equipment criticality and confidence factors arising from the PIR will produce changes to the recommended inspection frequencies/tasks. PIR meetings should be formally recorded, using the appropriate PIR decision record template, with details of the key decisions made and persons present. The competent should either be present at the PIR or receive a detailed report of any changes that are proposed, their reasons and the effect on periodicity for equipment covered by PSSR. Any changes that are made to the Written Schemes of Examination (WSoE) should then be either made by the competent person or certified by the competent person before they can take effect and job plans can be altered.

i. Pipework Vibration Servicves GL offers a broad range of vibration measurement and analysis services with specialist skills and knowledge in the following areas to determine and manage the risk of vibration-induced fatigue failure of process pipework: Troubleshooting service to resolve vibration related problems Detailed screening of main pipe and small bore connections Vibration measurement and assessment Provision of advice and design guidance Following data entry, an initial criticality (risk) assessment is carried out using the current equipment design and process information. This will generate an initial relative risk (or criticality rating) for each item of equipment in the database, based on the probability and consequence. The RBI software includes a module program that can be used to develop detailed inspection plans. Although the RBI will determine the recommended frequency of inspection, it cannot assign an inspection method. This must be manually selected from a list of methods. The RBI project team is responsible for populating the database with recommended inspection methods for each interim inspection task. However, these may be amended by site once the RBI system is fully operational, depending on the views of site engineers, inspectors and the competent person. Identification and development of optimum solutions

Substantial experience has been gained in the investigation of pipework vibration problems on process plant, including mechanical and flow-related sources, and structural and acoustic transmission of vibration. This knowledge, coupled with an extensive range of experimental and theoretical techniques which can be employed, enable a thorough investigation to be carried out. Any failure investigation can also draw on the substantial expertise in the company regarding integrity issues on pipelines, pipework components, rotating machinery, pressure vessels and other structures. In the event of a vibration related failure or identification of a problem, GL are able to provide a timely response, depending on the urgency of the request for support.

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DETAILED METHOD STATEMENT

As part of a plant integrity management programme for onshore and offshore assets, it is essential to manage the risk of potential vibration problems on piping systems and small bore tubing. This can be achieved through a structured screening methodology which aims to quickly identify pipework at risk, assess the relative risk, and prioritise effort on plant areas of most concern. GL have been active in developing strategies for reducing the threat of vibration related failures in order to target potential problems and demonstrate legislative compliance, resulting in a significant reduction in the risk of failure at many sites. Typically a study of this type would cover the main pipework and small bore connections through the following: Visual survey Basic vibration measurements Assessment of risk of failure

GL has also developed a measurement, data acquisition and analysis system that performs long term monitoring of a large number of sensors over extended periods, for investigation of intermittent but significant pipework vibration problems associated with compression facilities and process plant. Subsequent analysis of the data provides in-depth understanding of the operators specific vibration problems to enable the implementation of a cost-effective solution. Following collection of the measurement data from a site, vibration and fatigue assessment techniques are used, which have been developed and independently validated to assess dynamic stress and vibration on all aspects of pipework systems. Acceptance criteria have been derived from BS 7608 (Fatigue design and assessment of steel structures) for a range of common welded pipework and instrument stabbing connections and used extensively in site surveys and assessments. Finite element modelling is used in support of assessment and analysis activities, with detailed studies allowing pipe wall vibration modes and stress concentration effects to be investigated in depth. To reduce the risk of failures occurring to acceptably low levels, GL is able to provide advice on all aspects of pipework design related to dynamic behaviour, building on the experience gained in resolving vibration related pipeline integrity issues. This advice can be applied at any stage of a plants design, construction and operation. For example, specifications can be written for input to the design of an installation, design reviews can be carried out, and/or an as-built review of new or existing plant can be undertaken to identify areas of concern. Guidance can be provided on areas such as the following: Main pipework configuration

The screening programme aims to identify issues from the site survey requiring immediate action, such as ineffective supports, poorly supported pipework and vulnerable small bore connections. Subsequent investigations, if required, can then focus on the highest risk areas which might include assessment of vulnerable connections, monitoring of transient vibration events, and monitoring of plant over an extended period to assess the behaviour over a full range of operating conditions. This assessment methodology is consistent with the process industry best practice, and has been used by operators to successfully demonstrate to the UK HSE that appropriate steps have been taken to manage the issue of pipework vibration on their assets. An additional benefit of this type of project is an increased awareness of vibration issues for operational staff. This helps to avoid these problems becoming significant in the future, through recognition of problems at an early stage, and implementation of best practice for any maintenance and replacement activities. GL offers extensive experience of vibration surveys and on-site measurements on operating plant pipework. Methodologies and assessment methods have been developed for measuring and assessing dynamic stress and vibration on all aspects of pipework systems. Intrinsically safe instrumentation has been designed specifically for these applications, allowing vibration measurements to be carried out in hazardous areas using a combination of strain gauges and accelerometers as required. This includes a friction strain gauge for small bore pipework which was developed and patented by GL, and which can be easily and rapidly installed to achieve accurate dynamic strain measurement on most pipe sizes without the need for significant surface preparation.

Pipework supports Small bore connections Impulse pipework Valve selection Thermowells

Subsequent to the identification of pipework vibration problems, and building on an increased understanding of the cause of the problem from any on-site investigation, GLs expertise is well placed to make recommendations on the need for remedial measures to reduce the risk of failures occurring. A variety of solutions to reduce the risk of vibration-related failures are typically proposed for the clients consideration, taking into account issues of cost, effectiveness, ease of implementation, operational restrictions and safety, depending on the nature of the problem and site under investigation. Solutions can range from redesign and modification of pipework and connections, and improvement of pipework supports, to identification of preferred operating regimes and recommendations for investigation of plant performance, and development of design guidance documentation for future projects.

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CASE STUDIES

a. Corrosion Management of LNG Storage Facilities

Date: Customer: Savings:

Ongoing National Grid Improved corrosion management

GL has provided direct support and guidance for corrosion management initiatives at five separate sites within the UK. In recent years, this support has focused on the development of best-practice corrosion management policies and guidelines. GL assisted with the initial implementation of these guidelines by raising the profile of corrosion issues in LNG processes, and by promoting a corrosion awareness culture across the business. Specific areas of support have included: Fabric maintenance Management and interpretation of site surveys to determine requirements for maintenance painting and insulation replacement. Definition of site-specific workscopes for ongoing fabric maintenance. Corrosion Management Policy Drafting of policy to reflect best-practice approach to corrosion control and monitoring. Identification and definition of specific tasks to enable integration with maintenance management system. Cooling Water Treatments Review of cooling water systems and chemical treatment service provision at all sites. Identified shortfalls in operational systems, recommendations for improved monitoring and opportunities for rationalisation of service contracts. LNG Vaporiser Life Extension Conducted studies at two sites to confirm fitness-for-service of direct-fired vaporiser units and identify operations and maintenance to achieve required life extension.

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CASE STUDIES

b. Integrity Management Review

Date: Customer: Savings:

2006 UK North Sea Oil Gas Operating Company Improved systems integrity

GL was requested to carry out a review of integrity management procedures relating to pressure systems, pipelines and subsea equipment ahead of an internal audit of the client company management systems. As part of this review GL was asked to consider the suitability of the following: Organisational relationships for delivery of effective integrity management Corrosion risk assessments used as a basis for integrity management planning The methods and frequency of inspection Inspection records of lead integrity management contractor The interpretation and analysis of inspection data Review feedback process from inspection findings into future inspection programmes The impact of general fabric maintenance procedures on integrity management

The review of documentation was followed by a number of interviews with key staff within the client organisation and the lead integrity management contractor. The objective of the interviews was to address a series of questions that were developed based on the relevant policies/procedures and integrity management best-practice within the oil and gas industry. It was found that the integrity management systems for pressure systems, subsea and pipelines were well structured and were, in general, providing highly effective services. Although there had been a number of relatively recent changes in terms of both staff and supporting guidelines/procedures, it was considered that these were largely positive and should strengthen the understanding and control of integrity management issues in the near future. The most pressing issue to be addressed concerned the fatigue of topside process plant. It was considered that the existing risk based inspection (RBI) plan could not be expected to manage this problem. Although it was felt that the RBI process could assist with, through criticality assessments, the targeting of equipment a separate strategy was required to manage the problem effectively. Further actions were recommended in the following areas: Management of corrosion under insulation (CUI)

To carry out the review effectively, GL requested access to a number of client and integrity management contractor documents, including: Integrity Management Policy Pressure Systems Integrity Management System Subsea and Pipeline Integrity Management (Draft) Fabric Maintenance Philosophy Pressure Systems Integrity Review Procedure Monitoring, Inspection and Mitigation Procedures Written Schemes of Examination (for relevant assets)

Incorporation of piping systems from vendor skids into inspection plans Consideration of performance targets or key performance indicators for the Integrity Management Policy Clarification of the terms of engagement between the client and lead integrity management contractor Consideration of weld corrosion in risk assessments

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CASE STUDIES

c. Fracture of Thermowell

d. Failure of Impulse Pipework Compression Fitting

Date: Customer: Savings:

2005 Transmission Pipeline Operator Improved use of thermowells

Date: Customer: Savings:

2005 Compressor Station Operator Improved installation specifications

GL were asked to investigate the failure of a stainless steel thermowell which had been located in a dry gas transmission pipeline. A circumferential crack was found at the base of the thermowell. A metallurgical examination determined that the crack was consistent with low stress, high cycle fatigue crack propagation. An assessment of the process conditions indicated that the fracture was caused by flow induced vibration produced by vortex shedding around the thermowell.

GL were asked to investigate the failure of a compression fitting on a section of impulse pipework at a compressor station. The failure of the fitting had caused the shutdown of the compressor unit. A metallurgical examination determined that the failure was due to three circumferential low stress, high cycle fatigue cracks which had initiated on the outer surface of the pipe at the point of contact with the back ferrule of the compression fitting. The root cause of the problem was identified as inadequate support provided to the impulse pipework. GL suggested an improved support arrangement and, as part of a larger programme of work, GL monitored the vibration of the impulse pipework to ensure that the new support arrangements were sufficient to prevent any future failure of this pipework.

Fracture highlighted using dye penetrant As a result of this failure the customer reviewed the use of thermowells across its whole network. GL assisted by providing further guidance on the susceptibility of thermowells to vortex shedding, and by identifying appropriate alternatives. Failed impulse pipework

Above scanning electron microscope images of crack surface. Left low magnification, transgranular separation and feathery appearance typical of austenitic stainless steel low stress high cycle fatigue failures. Right high magnification, fine striations, a characteristic feature of low stress high cycle fatigue crack propagation.

Circumferential fracture

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CASE STUDIES

e. Fitness-For-Purpose Assessment of Pressure Vessels

Date: Customer: Savings:

2007 Centrica Cost savings to the client through a reduced frequency for repair/replacement, reduced system downtime, and life extension of high-pressure storage assets.

Issue: Fracture mechanics-based fitness for purpose (FFP) assessment methods, such as those described in BS 7910, R6 and API 579 have undergone rapid developments over the past 30 years. The FFS (Fitness For Service) methodology has developed into a powerful tool that enables the analyst to assess the significance of flaws in welded structures. Although comprehensive and applicable to a wide range of engineering components, the methods contained within these guidance documents are conservative. Furthermore, the methods can be limited by, for example, the availability of stress intensity factor and reference stress solutions for specific geometries. One such limiting geometry is the nozzle, in particular the nozzle attachment welds, which is a common feature on high-pressure gas storage systems. In the UK, operators must follow legislation given in the Pressure Systems Safety Regulations (PSSR), which provides a regime with the aim of ensuring the safety of pressure systems. One of the regulations requires that high-pressure gas storage systems must be subject to periodic inspections followed by a FFS assessment to ensure the integrity of the system.

Pressure Vessel Nozzle

Methodology & Results: To ensure compliance with the requirements of the PSSR, GL has developed an in-house procedure that enables an FFS assessment to be undertaken for a flaw in a nozzle weld. This procedure was developed to reduce the conservatism inherent in the assessment procedures given in BS7910 while still maintaining an acceptable level of safety. Using a combination of Finite Element analysis and fracture mechanics techniques, a full FFS of pressure vessels was completed.

Savings: This has resulted in substantial cost savings to the client through a reduced frequency for repair/replacement, reduced system downtime, and life extension of high-pressure storage assets.

Finite Element Analysis of Pressure Vessel Nozzles

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CASE STUDIES

f. Fracture Mechanics Assessment of a Defective Pig Trap

Date: Customer: Savings:

2007 United Utilities Cost of temporary pig trap and system downtime due to installation

Issue: GL were required to conduct a detailed assessment of a reported crack indication found on the closure casting of a pig trap located at an AGI facility in the UK. Following defect measurement in February 2007, this was recorded at approximately 3-4 mm. A number of pig runs were then subsequently conducted. The defect was then re-measured and reported to have a maximum depth of 5.3 mm. Measurements suggested that the defect had therefore grown since the pigging runs were conducted in 2007. The operator of the site facility intended to conduct further pig runs in February 2008 and hence required an assessment to determine whether the defect was safe for the intended pig runs.

Methodology & Results: The approach that GL used was based on a BS7910 level 2a fracture mechanics assessment. Using fracture mechanics calculations and use of the FAD (Failure Assessment Diagram), the aim was to determine whether the current size of crack was safe under the current design conditions and safe for the intended pig runs. Finally using a BS7910 fatigue assessment of the crack, fatigue calculations were then conducted to determine the remaining fatigue life of the reported defect and whether further pressure cycles can be tolerated due to the intended pig runs. The fatigue assessment results showed that the defective area was likely to endure a large number of cycles before failure. Consequently it was concluded that the defect would endure sufficient further pressure cycles to conduct the intended pigging runs.

Savings: Ultimately, the operator would have had to install a temporary pig trap to conduct the required pigging runs. Following this, the temporary trap would have been removed and a new trap installed in its place resulting in costly delays and system downtime. By conducting a fracture mechanics assessment, GL have saved the client costs associated with installing a temporary pig, inspection delays and system downtime.

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CASE STUDIES

g. Defect Assessment of Corroded Pipework

Date: Customer: Savings:

2004 ADMA-OPCO Savings due to potential loss of containment and system shutdown

Issue: ADMA-OPCO identified areas of general corrosion on the inlet pipework to separators on one of their platforms. The corrosion had occurred where clamps were fitted around vertically orientated 12 pipework, just above the girth weld that connects the pipework to 90 elbows. ADMA-OPCO requested that GL undertake an assessment of the defective area.

Methodology & Results: Four assessment methodologies were used for the assessment, B31G, RSTRENG, LPC-1 and API 579 Level 1. Predicted failure pressures and safe operating pressures were calculated using the B31G, RSTRENG and LPC-1 assessment methodologies. Results showed that all failure pressures were well in excess of the design pressure, however the safe operating pressures calculated using the B31G and RSTRENG methodologies were considered to be unacceptable. In addition, the defect area was assessed to the general and local metal loss Level 1 procedures of API 579. The defects had been found to be unacceptable. These assessment results formed part of an overall opinion regarding the safety of the reported defect.

Savings: Savings were made due to potential loss of containment and system shutdown.

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CASE STUDIES

h. Review of Integrity Management Framework

i. Safety Management Audit

Date: Customer: Savings:

2007 Middle East Oil Producer Improved integrity management

Date: Customer: Savings:

2006 UK LNG Terminal Operator Improved safety management system

A major operating company in the UAE were keen to ensure that their recently implemented Integrity Management Framework was delivering what was intended. GL undertook a gap analysis of the current operating philosophy against the IMF, and reported on where we felt the organisation was in relation to the IMF as well as benchmarking where we determined the IMF was in relation to international best practice. This project covered:Pipelines Pressure Equipment Critical Safety Systems Rotating Equipment Structure Civils Electrical Equipment Lifting Equipment Wells

A UK LNG Terminal operator were expanding their storage capacity. Before they were able to commission the new phase, it was imperative that a complete safety audit was undertaken to ensure that all processes currently in place were operating correctly. GL sent in a team of specialists in their field to undertake this review. Interviews were undertaken with a cross section of staff, documents were reviewed, and site inspections were undertaken to ensure that the practice matched the document trail. The benefit to the client was that they were able to ensure that all deficiencies were actioned and lessons learned before the expansion was commissioned.

Once the gap analysis had been undertaken, a detailed list of deficiencies was prepared, and suggested improvements identified to bring the operations up to the desired level.

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CASE STUDIES

j. Fitness for Service Assessment

Date: Customer: Savings:

2007 BG Tunisia Improved monitoring and compliance

Issue: Regulatory conditions state that all pressure systems need to be inspected to ensure they are fit for purpose, and examination schedules needed to be produced. Therefore the client required an inspection schedule to be developed to make sure their assets are fit for purpose and operating within the design specifications.

Methodology & Results: By working closely with the client and by taking reference from Pressure Systems Safety Regulations, the contents of the WSoEs were agreed upon. An up to date inspection scheme was produced, scheduling inspection work to be carried out during the plant shutdown period. Inspections were identified with inspection dates and times organised and a contingency for remedial work allocated. A list of required inspection qualifications was produced and from this a list of qualified engineering staff was assembled. A Competent Person was assigned to define roles under the UK legislation that the staff would take.

Savings: From the construction of the WSoEs an extensive inspection of the clients assets were produced. The inspection identified areas of remedial work that were required and helped setup monitoring programmes on assets that were at greatest risk of failure. The Written Scheme of Examination also provides the client with a means to demonstrate compliance with the Pressure Systems Safety Regulations 2004.

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CASE STUDIES

k. Repair of Amine Stripper

Date: Customer: Savings:

2006 BG Hannibal Gas Processing facility Failure of processing vessel and plant shut down

Issue: The client had experienced up to 40% loss in wall thickness on an amine stripper due to corrosion.

Methodology and Results: The use of a coating system to isolate the vessel wall from the corrosive environment inside the amine strippers was considered to be the most cost effective solution. GL reviewed the properties of a range of different generic coatings systems to identify a material that would be compatible with the operating conditions within the amine stripper. Having identified a suitable material, a technical review of the proposed coating specification was performed and technical assistance provided during the on-site coating application process.

Savings: Through wall corrosion failure and the requirement to shutdown the plant to facilitate a vessel repair. The estimated cost of a shutdown was 500,000/day.

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CASE STUDIES

l. Investigation of Coating Failure on Oil Storage Tank

Date: Customer: Savings:

2006 Major Exploration and Operating Company Prevention of large-scale coating failure

Issue: The customer was experiencing cracking and disbonding of the coating system applied to the external surfaces of a crude oil storage tank. The customer required GL to establish the mechanism of breakdown and to recommend methods of reparation.

Methodology and Results: GL visited site to investigate the scale and nature of the failure. A laboratory programme of work was initiated to reproduce the coating failure under controlled conditions and to establish the failure mechanism systems for reparation of the failed coating were recommended and an application procedure prepared.

Savings: This work identified the mechanism of coating failure and helped to prevent similar failures occurring in the future.

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CASE STUDIES

m. Corrosion Management Study

Date: Customer: Savings:

2006 National Grid Development of a robust corrosion management policy to maximise asset life

Issue: The client wanted to establish a robust corrosion management plan for the above ground installations that were an integral part of the high pressure gas transmission system.

Methodology & Results: GL performed a review of the customers corrosion management policy with a view to quantifying how much should be invested on inspection and maintenance for corrosion control purposes. The review included: Inspection and maintenance policy Future maintenance requirements to reflect best industry practice The current inspection frequencies and those frequencies required to maintain plant and equipment fit-for-purpose

A series of site visits were conducted to obtain an overview of the current condition of the corrosion control systems, the general requirements for maintenance painting and to identify and quantify areas which would require regular inspection and maintenance.

Savings: Reduced unscheduled reductions and outages due to corrosion related issues. Reduced repair cost. Maximisation of asset life.

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CASE STUDIES

n. Weldability Testing of 48 Diameter X80 Europipe Production

Date: Customer: Savings:

2007 National Grid (Milford Haven extension) Approved procedures of manufacturing

Weldability testing entails the production of a full-scale girth weld between two 12m pipe joints under field conditions and including the manipulation of the partially-completed weld to simulate the removal and movement of the line-up clamp. Following production of the complete girth weld, the joint is subjected to X-ray inspection and must pass required codes (T/SP/P/2 or API 1104 requirements) and is then subjected to a full suite of mechanical tests. Following satisfactory results from these investigations, the welding procedure and the linepipe manufacturing route are qualified for supply to National Grid.

Girth welding of 48 X80 pipe during weldability testing

Simulation lifting of 48 joint after hot pass deposition.

Sample welding procedure qualification record from the 48 X80 trials, showing joint design, consumables, pre-heat requirements, pass sequence and other details.

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CASE STUDIES

o. Design and Qualification of Repair Procedures for Bellows Attachment Welding Date: Customer: Savings: 2008 Pipeline Operator Improved welding procedure

A GL report on the bellows connection concluded that the bellows on the pipeline required a weld repair to be undertaken on the cracked fillet welds. The bellows configuration is shown in Figure A of that report, reproduced below:

Proposed weld procedure for the repair. Qualification of this procedure is in progress. Weld Repair instructions: Weld repairs to cracked fillet welds in bellows unit to be carried out after qualification of the attached weld repair procedure and following decommissioning and purging of pipeline 2. Ensure all necessary risk assessments and safety checks have been undertaken and procedures are followed, including safe control of operations (non routine operation) and entry into confined spaces. Prior to repair, determine chemical analysis of carrier pipe and box material by on-site material sampling of the carrier pipe and restraining box material in accordance with T/PM/Q/10 (ref clause 12 and appendix B). Report results to GL for assessment. Remove the two fillet weld cracks in bellows 2 by grinding in accordance with T/PM/P/11 appendix F. Confirm defect removal by visual inspection and MPI. Check carrier pipe for defects by UT & MPI below intended area of weld repair prior to welding. Perform weld repair in accordance with attached procedure: WPS/A/Tinsley/01FR (subject to qualification). Completed repair welds to be subjected to visual inspection and MPI.
Cracking located in bellows attachment fillet welds.

Consequently, according to British Standard BS 6990, prior to welding onto the live pipeline, it is necessary to qualify a procedure, simulating the cooling effect of the gas which complicates the qualification. The qualification set-up should simulate actual flow conditions. The weld procedure has been developed to minimise the risk of lamellar tearing. For weld procedure qualification, plate material representing the nearest equivalent currently available material is used.

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CASE STUDIES

p. Evaluation of RBI Softaware

Date: Customer: Savings:

2007 Major Gas Operator Company time understanding the issues with different RBI software packages

Issue: The client was in the process of evaluating bidders for provision of integrity management software (IMS) oriented risk based inspection management of pressure systems, pipelines and structure of the Miskar Assets. Five software products were evaluated: Tishuk T-OCA, DNV Orbit, Lloyds Capstone, Aver Kvarner Coabis and Credosoft Credo Pro. The client required a third party overview of the RBI systems embedded in the software and to determine the merits of the five different RBI systems.

Methodology & Results: From GL experience with RBI systems, an evaluation of the RBI software was produced. The main factors GLs experienced personnel believed to be important in determining an effective RBI system are: Determine whether the RBI is qualitative, quantitative, semi-quantitative or combination of both Evaluate how the software derive Probability of Failure (PoF) Evaluate how the software derives Consequence of Failure (CoF) and whether important consequence attributes have been captured Degradation mechanisms in the assessment and comparison with degradation mechanism in country Post RBI analysis activities (e.g. Inspection planning)

Savings: An impartial third party review of software was obtained, denoting the merits and drawbacks to each system. Allows GLs experienced personnel to put forward the best system that meets the requirements of the client, so that the investment into the system produces the best result. Also saves personnel time in trialling all the software and producing an evaluation of each.

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CASE STUDIES

q. T-OCR Risk Based Inspection

Date: Customer: Savings:

2005 Major Natural Gas Company Reduced equipment downtime and costs due to failures

Issue: The client expressed an interest in adopting a risk based inspection (RBI) scheme for integrity management of its offshore and onshore process plant. A feasibility study was required to determine the practicalities, outline implementation costs and potential benefits of applying RBI.

Savings: Main saving is on the company time and finances on determining the benefits and viability of implementing an RBI approach. Also identifies to the client the long term benefits of a RBI approach, as shown below: Reduced equipment downtime and costs due to failures

Methodology & Results: The initial part of the study included a review of the current integrity management systems. This was followed by an assessment of the feasibility and requirements for the application of RBI. The final part of the study comprised two RBI pilot studies centring on known areas of concern on the specific plants. The key results from this study were as follows: A feasibility of applying (risk based inspection) RBI to the facilities produced A review of existing approaches to integrity management, and any modification required to accommodate the RBI approach were identified Potential benefits of applying RBI to its facilities identified, including improvements in equipment reliability and cost reductions from optimisation of inspection planning and deployment

Reduced requirement for items to be taken offline to be inspected Focusing of inspection resources on key corrosion and materials degradation issues

The report also includes recommendations for implementation of RBI, including support required and a breakdown of likely resources requirements.

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CASE STUDIES

r. Investigation of Double Block and Bleed Valve Vibration at a Gas Processing Facility Date: Customer: Savings: 2004 Onshore Operator, Kazakhstan Management of the risk of failures reduce the occurrence of failures and the associated costs of plant shutdown and remedial work

Issue: During the commissioning and early operational life of a large gas processing facility, failures were experienced of a significant number of small bore connections across the plant. This was determined to be due to the poor design of these connections. Replacing all these fittings would have been extremely costly, and a programme of bracing of the large double block and bleed valves was therefore undertaken. However, it was not known how effective this bracing was in reducing the dynamic stresses to acceptable levels.

Methodology & Results: GL undertook a study across the processing plant to characterise the vibration of the small bore connections with large mass double block and bleed valves. Dynamic stress measurements were taken on a selection of connections, including a range of different designs and bracing arrangements. This knowledge was used to develop a screening method which could be used by Client staff to assess all the connections on the plant to implement a prioritised replacement plan.

Savings: Management of the risk of failure of these connections reduced the occurrence of failures, and the associated costs of plant shutdown and remedial work.

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CASE STUDIES

s. Long Term Monitoring of Pipework Vibration at Gas Compressor Stations Date: Customer: Savings: 2003 to 2008 UK Onshore Operator Detailed understanding of the risk of pipework vibration problems across operating range of compression plant

Issue: Earlier work programmes had carried out an initial assessment of small bore connections at compressor stations, from which a large programme of replacement and removal had been instigated. However, some pipework vibration problems were known to occur at operating conditions that were experienced only occasionally and had not been assessed.

Methodology & Results: GL developed a data acquisition and analysis system that would perform long term monitoring of a large number of sensors over extended periods. To date this has been installed on nine of the twenty-six UK compressor stations for a period of at least three months in each case, and has provided a comprehensive assessment of the pipework vibration over the full station operating range. For example, at several stations, pipework vibration problems were identified which were a result of the interaction of the gas flow from adjacent units, phenomena that would not have been picked up by carrying out measurements on each unit separately. This equipment has also been used to investigate vibration problems following specific incidents on compressor stations and on seal and lubrication oil system pipework.

Savings: Detailed understanding of the occurrence of pipework vibration problems across the operating range of the plant ensures that full consideration is given to the causes, directing any remedial action and confirming safe operating ranges.

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CASE STUDIES

t. Assessment of risk of pipework failure due to vibration during offshore plant uprating Date: Customer: Savings: 2007 UK Offshore Operator Eliminated need for major changes to main pipework, and allowed uprating to be achieved within available timescales

Issue: Upgrade of two offshore compressor trains was planned to increase gas flow rates. A preliminary study by the Client suggested that the risk of vibration related failure of the main pipework was already unacceptable and would be increased by uprating. The available outage period was insufficient for significant design changes to the pipework to be implemented.

Methodology & Results: GL undertook a study to assess the dynamic stresses experienced by the main pipework and small bore connections during operation of the compressor units in their original configuration. Assessment of the dynamic behaviour was carried out over a range of operating conditions on both compressor trains. Knowledge gained of the relationship between vibration and gas flow was subsequently used to predict the likely behaviour of the pipework at the current maximum and uprated conditions. The study concluded that there was no need for major changes to the main pipework prior to the uprating, allowing effort to be concentrated on issues related to small bore connections.

Savings: The findings of this work eliminated the need for major changes to the main pipework, achieving significant cost savings for the project and allowing the uprating to be achieved within the available timescales.

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CASE STUDIES

u. Vibration screening at an onshore gas terminal

Date: Customer: Savings:

2005 to 2008 UK Operator Demonstrated management of risk of vibration related failure of pipework to regulatory bodies

Issue: To manage the risk of vibration related pipework fatigue failures a structured vibration screening and assessment methodology was required by the Client, to identify problem areas and define subsequent actions.

Methodology & Results: A phased approach was employed by GL to identify potential problem areas on the main pipework and small bore connections. The initial site survey consisted of a walk-round visual review of the site processes and pipework, basic vibration measurements, and assessment of the likelihood of failure of any connections. This exercise identified key problem areas for immediate remedial action and further investigation, allowing effort to be focused on the highest risk areas in subsequent stages. Recommendations included identification of pipework support design and maintenance issues, changes to the design of small bore connections that were identified to be at risk of failure, and identification of areas of the plant to be assessed in greater detail to develop an understanding of any problems identified and to develop solutions. This subsequent detailed assessment work has included installation of monitoring equipment to assess the behaviour of the plant over its full operating range. This methodology is now being deployed for the Clients offshore facilities.

Savings: This project successfully demonstrated to the UK Health and Safety Executive that the issue is being adequately managed across the Clients facilities.

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Asset Management Services

Plant Integrity Management Services Pipeline Integrity Management Services Production Optimisation (Includes RAM and Gas Processing) Dynamic and Steady State Simulation Rotating Equipment Performance & Condition Monitoring including Emissions Reporting Gas Quality and Interchangeability Oil and Gas Steinhft 9 20459 Hamburg, Germany Phone +49 40 36149-7700 Fax +49 40 36149-1781 glis@gl-group.com

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Issue no.001 15.05.2008