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Certification of Oil & Gas Installations
Mechanical Integrity of Ageing Pipelines
Eckhard Hinrichsen, GLO Mexico
Jan. 17. - 18., 2008
Contents
1. Certification of Oil & Gas Installations
2. Pipeline Services
3. Mechanical Integrity Certification
4. Benefits of Certification
America´s Workshop - EH Certification, Pipelines | Jan. 17. - 18., 2008 | No. 2
GL Industrial Services
– Oil and Gas
• CERTIFICATION of newbuilding projects
• In particular offshore installations and pipelines
• Large-scale projects in conjunction with the
operators of oil and gas fields
• Offshore and onshore installations (e. g. platforms,
petrochemical installations, storage tanks)
• Pipelines – offshore and onshore
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GL Industrial Services
– Oil and Gas
Inspection of materials and components
• Evaluation and selection of manufacturers.
• Supervision of the fabrication process of manufacturers
and suppliers, inspection and performance assessment
before dispatch.
Advice regarding facilities in operation
• Maintenance advice
• Risk analysis, risk-based inspection (RBI)
• Reliability centred maintenance (RCM)
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Certification/Verification Services
Accreditations

Founding Member of IACS (Intern. Association of Classification
Societies)

Germany: Technical Expert Organisation for the German Authority for
Pipelines (Mining Authority)

Mexico: Accredited Verification Unit for Gas Transport Pipelines, Gas
Distribution, LNG Terminals, Pressure Vessels, Environmental (EMA)

Canada:
Canada Oil and Gas Operations Act,
Canada Offshore Certificate of Fitness Regulations,
Nova Scotia Offshore Certificate of Fitness Regulations,
Newfoundland Offshore Certificate of Fitness Regulations (soon to be rectified).

various other accreditations worldwide
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Certification - Project Phases:
Planning
Development
Studies
Basic Design
Appraisal
Detail
Design
Appraisal
Appraisal
Design Certificate
Procurement
Mat./ Equipment
Inspection
Construction
Surveillance
Operation
Supervision
Mat./Equip. Installation Periodical
Certificate Certificate Inspection
Certificate
of Fitness
Extension
of Certificates
Lifetime
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Activities

Appraisal of basic and detail design
 Structures and foundations
 Plant layout (overall and detailed)
 Process and utility systems
 Safety systems
Deliverables: Design Certificates

Independent Analysis
 Strength analysis
 Fatigue analysis
 Fracture mechanics analysis
 Temperature distribution analysis
Deliverables: Reports
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Activities (cont.)
 Source Inspection
 Material inspection
 Inspection of components and systems
Deliverables:

Inspection Reports,
Inspection Certificates,
Release Notes,
Material Certificates
Site Surveillance
 Inspection during erection/installation
 Witnessing/monitoring of commissioning
 Witnessing of tests
(load, function, performance etc.)
Deliverables:
Progress Reports,
Installation Certificates
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Activities (cont.)


In-Service Inspection

Condition surveys

Periodical inspections

Maintenance management support

Loss prevention consultancy

Damage and repair assessment
Deliverables:
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Reports and Studies
Summary: Certification of Oil & Gas Inst.
• Concept was developed in the early 70´s in the UK
• Focus on Technical Safety and Integrity
• Applies to all Phases of a Project and the Lifetime of
the Installation (“cradle to grave”)
• Performed by larger IACS Members (ABS, BV, DNV,
LR, GL)
• In the UK the concept was modified to “Verification”
following the Piper Alpha accident (post Cullen)
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Contents
1. Certification of Oil & Gas Installations
2. Pipeline Services
3. Mechanical Integrity Certification
4. Benefits of Certification
America´s Workshop - EH Certification, Pipelines | Jan. 17. - 18., 2008 | No. 12
Principal Pipeline Services
 Certification of New Pipelines
 Re- Certification of existing
Pipelines
 Certification of Mechanical
Integrity (existing Pipelines)
 Special Services during
Operational Phase
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Certification of New Pipelines
Typical Scope of Work
 Design Appraisal (FEED, Basic, Detailed)
 Inspection of Materials and Components
 Construction Surveillance
 Witnessing of all Tests
 Issue Certificate and Final Report
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Welders Qualification Tests
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Supervision during Construction
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Witnessing of Hydrostatic Pressure
Tests
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Certificate
• Certificate of Safe Operation
• Issued if critical risks are not
existing or are controlled
• Certificate is valid together with:
• Final Report and its qualifications
• Attention to Open Items as agreed
• Annual Inspections by GL
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Re- Certification of existing Pipelines
Re-Certification - Strategy to ensure the Reliability
of Transportation
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Re-Certification - Strategy to ensure the
Reliability of Transportation
Basic Steps







Hazard Identification Procedure
Assessment Concept
Inspection Programme
Assessment of Inspection Results
Rehabilitation Programme
Certificate
Re-Arrangement of Inspection
Programme
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Hazard Identification Procedure
 Structured review and audit
 Clients operational and safety personnel will be
fully involved
 Identifies section per section the specific
reasons for possible failures and the
consequences.
 First-hand information is obtained on:
- design
- construction
- operation
 Standard questionnaires and consistent
analysis will be used.
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HAZard IDentification Procedure
Hazards (typical)
Group
Initiated by Hazard
External Interference
Construction work
Traffic load
Sabotage
Agricultural work
--------------------------------------------------------------------Natural Hazards
Earth movement
Flooding
Earthquakes
--------------------------------------------------------------------Operation
External corrosion
Internal corrosion
Erosion
bacterial corrosion
Fatigue (typically liquid lines)
America´s Workshop - EH Certification, Pipelines | Jan. 17. - 18., 2008 | No. 25
Onshore Gas Pipelines Western
Europe,
Causes for Leaks (1970-2001)
5% hot tap error
6%
other
7% ground movements
15% corrosion
17% construction and
material defects
Source: EGIG-02, data period 1970-2001
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50% external
interference
Inspection Programme
 Input: Specifications out of the assessment concept
 Considering ALL possible inspection methods:
Visual, External NDT, Intelligent Pigs (ILI), Re-Hydrotest, …
 Inspection shall be RELEVANT to the known and
pre-assessed condition
 Inspection programme shall consider the results
of earlier inspections
 Benefit: Gives a detailed input for inspection tender(s).
 Benefit: Can be used as a basic maintenance programme
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Assessment of Inspection Results
 Witnessing of essential points of inspections
 Review of inspection reports
 Verification of inspection results
 Estimation of damage growth (e.g. corrosion rate)
 Repair of critical defects; maintenance of safety relevant
systems – Under GL Surveillance
 Rearrangement of inspection programme specific to the
pipeline
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Certificate
• Certificate of Safe Operation
or Mechanical Integrity
• Issued if critical risks are not
existing or are controlled
• Certificate is valid together with:
• Performance of inspection programme
• Assessment of inspection results
• Completion of Rehabilitation
programme
• Re-arrangement of inspection
programme
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Added Value from Re-Certification
 Independent consultancy on each aspect of pipeline
integrity
 Technical input with international background and
experience
 Independent consultancy on inspection programme
(e.g. in-line inspection and alternatives)
 Recommendations for maintenance (inspection and
rehabilitation) after issue of certificate
 Ensure the safe operation of the Pipeline and reliable
supply of gas to the consumer
(RELIABLE PERFORMANCE)
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Special Services during Operation
Phase
 Feasibility study on up rating
UP rating from 70 to 84 bar
100 km, 30”, North Germany
 Risk management
Risk analysis of a 2800 km
long pipeline network
 Damage analysis
 Engineering critical assessment (ECA)
Assessment of weld defects using advanced fracture
mechanical methods
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Special Services during Operation
Phase
 Corrosion assessment
•
•
•
•
Analysis of data from various corrosion inspections
Determination of high priority rehabilitation tasks
Analysis of corrosion processes
Calculation of remaining lifetime
 Technical Audits
Camisea Pipelines, 2006-07, on behalf of Peruvian Government
 Risk Analysis (quantitative or qualitative)
 RBI / AIM Implementation for your Pipeline
GALIOM - GLO´s AIM Solution
America´s Workshop - EH Certification, Pipelines | Jan. 17. - 18., 2008 | No. 35
Contents
1. Certification of Oil & Gas Installations
2. Pipeline Services
3. Mechanical Integrity Certification
4. Benefits of Certification
America´s Workshop - EH Certification, Pipelines | Jan. 17. - 18., 2008 | No. 36
Certification of Mechanical Integrity
General Concept
• Provide to the Owners/Operators of the pipeline
an independent review, verification and supervision
of all aspects of a
pipeline inspection and rehabilitation project.
• Focus on Mechanical Integrity and Technical Safety
• GLO will act as an Independent Third Party to ensure
that the required and uniform Level of Safety among
all contractors will be achieved
America´s Workshop - EH Certification, Pipelines | Jan. 17. - 18., 2008 | No. 37
ALARP
OPERADOR
FIRMAS DE INGENIERÍA
PROVEEDORES
CONTRATISTAS DE SUBCONTRATISTAS
CONSTRUCCIÓN
con
Proyecto con Criterio Uniforme
NIVEL
DE
SEGURIDAD
FASES DE UN PROYECTO I P C :
INGENIERÍA
PROCURA
CONSTRUCCIÓN
CRITERIO DE SEGURIDAD
OPERADOR
ALARP
FIRMAS DE INGENIERÍA
Proyecto
sin Certificación
Proyecto
sin Criterio
Uniforme
CONTRATISTAS
DE
CONSTRUCCIÓN
NIVEL
DE
SEGURIDAD
PROVEEDORES
SUBCONTRATISTAS
FASES DE UN PROYECTO I P C :
INGENIERÍA
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PROCURA
CONSTRUCCIÓN
sin
Certification of Mechanical Integrity
Basic Steps (1)
• Documental Review
Design docs., Operational History, Maintenance Records,
previous Inspection Results, …
• Witnessing of ILI runs
• Review of Inspection Results
• Review of Mechanical Integrity Analysis of Contractor,
independent Analysis
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Certification of Mechanical Integrity
Basic Steps (2)
• Verification of Results in
Field (manual UT)
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Certification of Mechanical Integrity
Basic Steps (3)
• Supervision of Repairs
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Certification of Mechanical Integrity
Basic Steps (4)
• Inspection of condition of
above-ground Installations
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Certification of Mechanical Integrity
Basic Steps (5)
Witnessing of all tests:
• Pressure tests
• Characterization of Materials
• Coating tests
• …
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Certification of Mechanical Integrity
Basic Steps (6)
Final Report
Certificate
of Mechanical Integrity
Valid for 3 to 5 years
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Applicable Codes & Standards
• ASME B31.4, B31.8
• ASME B31.3
• ASME B31G, B31G mod.
• RStreng, Kastner (exceptions)
• API (as applicable)
• DNV, GLO Offshore Pipeline Rules (if applicable)
America´s Workshop - EH Certification, Pipelines | Jan. 17. - 18., 2008 | No. 45
Certification of Mechanical Integrity
References & Examples
of current projects with PEMEX in Mexico
America´s Workshop - EH Certification, Pipelines | Jan. 17. - 18., 2008 | No. 46
Current Projects with PEMEX Refinación
Inspección y Rehabilitación
Poliducto de 12” Madero-Linares y 10” Linares-Cadereyta (Rosen)
Poliducto de 12” Guaymas-Obregón (Tuboscope)
Poliducto de 12” Cangrejera-Minatitlán (Tuboscope)
Oleoducto de 24” Madero-Cadereyta (Rosen)
Poliducto de 14” Satélite-Gómez Palacios (Rosen)
Oleoducto de 30” Nuevo Teapa-Salina Cruz (Tuboscope)
Poliducto de 8” Cangrejera-Minatitlán (Tuboscope)
Poliducto de 8” Guaymas-Hermosillo (Tuboscope)
Inspección
Oleoducto de 30” Nuevo Teapa-Venta de Carpio, Tramo Maltrata-Sn Martín
Texmelucan, (Tuboscope)
Rehabilitación
Ducto de 30” Nuevo Teapa-Poza Rica (UAM-GL)
Fuga en Sección Rehabilitada
Poliducto de 14” Satélite-Gómez Palacios (Rosen)
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Inspección y Rehabilitación
Poliducto de 12” Guaymas-Obregón
(Tuboscope).
GL Orden: 00341
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Contents
1. Certification of Oil & Gas Installations
2. Pipeline Services
3. Mechanical Integrity Certification
4. Benefits of Certification
America´s Workshop - EH Certification, Pipelines | Jan. 17. - 18., 2008 | No. 49
Benefits of Certification
• Independent and Impartial Review and Supervision of
all phases and aspects of a rehabilitation project
• Ensures a unified level of safety across all contractors
• Experienced and qualified personnel, backed up by
our Head Office (800+ engineers)
• Worldwide experience from similar projects will be
applied
• Documented and auditable safety
• Shared Responsibility
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Thank you for your attention!
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