THE INTEGRITY ENGINEER’S TOOLBOX: MANAGING AGEING ASSETS AGIT Gas Speak Colloqium, Sept 2015 Markus Seitz, Integrity Engineer, APA Group, Perth

WHAT DOES AN INTEGRITY ENGINEER DO? I study corrosion…. Although utilities typically rely on established technologies for infrastructure, we innovate in integrity! I study fight corrosion….

Integrity engineer’s focus? MLVs & buried structures Safety Critical Eq Vessels, heaters & piping Pipeline fixed schedule PRV refurb PSV rotation ESD testing Coating inspections CP Surveys Wall thickness inspections

fixed schedule Integrity engineer’s focus MLVs & buried structures Safety Critical Eq Vessels, heaters & piping Pipeline PRV refurb PSV rotation ESD testing Coating inspections CP Surveys In-line Inspection Direct inspection Wall thickness inspections variable schedule

Review InspectRepairForecastAdjust THE INTEGRITY ENGINEER’S TOOLBOX In-line Inspection Direct Assessment Structural Repairs Composite Repairs Steel Repairs Coating Repairs Apply growth model Forecast repairs Forecast capacity changes Compare forecast to actuals Adjust capacity Adjust frequency Adjust model parameters

INTEGRITY ISSUES Dis-bonded field joint coatings Moisture ingress Metal loss CP shielding Corrosion

Review InspectRepairForecastAdjust In-line Inspection Accuracy: Depth 18% of wall thickness (by machine analysis) 8-10% of wall thickness (by human analyst) E.g.: for a 5mm wall thickness pipeline, feature depth can be determined to within 1mm (algorithm) or to within 0.5mm (human analyst) THE INTEGRITY ENGINEER’S TOOLBOX

ILI TOOLS IN THE FIELD

Review InspectRepairForecastAdjust Direct Assessment 3D Laser Scanner Resolution: <1mm Depth to 40µm Allows in-field sentencing THE INTEGRITY ENGINEER’S TOOLBOX

Review InspectRepairForecastAdjust THE INTEGRITY ENGINEER’S TOOLBOX Structural Repairs Composite Repairs Steel Repairs Coating Repairs

Review InspectRepairForecastAdjust THE INTEGRITY ENGINEER’S TOOLBOX Compare ‘as reported’ to actuals

Review InspectRepairForecastAdjust THE INTEGRITY ENGINEER’S TOOLBOX Apply growth model Forecast repairs Forecast capacity changes

FORECAST: APPLY CORROSION GROWTH Manage the asset’s future: Plan for repairs Plan for capacity changes

FORECASTING: BABY BOOMS AND AGEING POPULATIONS

FORECAST: THE AGEING POPULATION Within seven years the number of repairs increases more than 10-fold! With each year, our model becomes less accurate (more overly conservative?)

Review InspectRepairForecastAdjust THE INTEGRITY ENGINEER’S TOOLBOX Compare forecast to actuals Adjust model parameters

REVIEW SAFETY FACTORS Relatively low safety factors compared to other engineering disciplines 1.39 for new pipelines 1.25 to pass hydro test Inherent Conservatism In parameters In methods Consequence of under- conservatism Loss of containment Consequence of over- conservatism Business (decisions) affected by non-existent risk (e.g. supply restrictions, mitigation expenses)

Review InspectionsRepairsForecastAdjust THE INTEGRITY ENGINEER’S TOOLBOX $$$$ (specialist service) $$$ (field campaigns) $$ (in-house labour) Capacity ($?) Frequency ($?) Model Parameters ($?) $$$ (in-house labour)

Impressions RefreshmentsPresentation Own Experience Questions? THANK YOU FOR LISTENING