SRP: CRACK MANAGEMENT
This strategic research priority focuses on the prevention of failures due to crack-like defects by making improvements in the integrity management life cycle of susceptibility, Inspection, Assessment and Remediation, and Management for the threat.
outcomes and value to industry
• Close identified gaps in performance demonstration for crack ILI and NDE
• Close identified gaps in material properties performance data
• Providing the next generation of susceptibility models by cracking threat/morphology
• Broadly communicating outcomes to advance crack management within industry fabric
• Further operationalizing the TDC and VTDC for crack management
industry improvement
SUSCEPTIBILITY
Susceptibility assessments by cracking threat/ morphology lead to selection of the appropriate integrity assessment method.
INSPECTION
Known strengths and limitations of the inspection technique(s) provide confidence in assessment and remediation programs, ultimately improving threat management.
ASSESSMENT & REMEDIATION
Effective and efficient response to inspections including improved remaining strength equation variables, dig criteria, repair criteria, and reassessment intervals.
MANAGEMENT
Management of known crack-related threats to reduce failure rates and minimize likelihood of releases before reassessment.
CURRENT RESULTS BY DESIRED KEY OUTCOME
1. Close identified gaps in performance demonstration for crack ILI, and NDE
Key Successes to Support Key Outcomes
• Established a set of test samples to perform crack inspections in at the TDC
• Established a pathway for NDE technicians and ILI service providers to communicate key variables of the feature
• Established a pathway for NDE technician improvement
Projects to support Key Outcomes
• NDE-4-12 - Continuous Improvement of ILI Capabilities
• NDE-2-14 - NDE Technician Improvement Training Course for LSW Testing
• NDE-4-25 - Fast and Accurate Feedback from Site to ILI Vendor
• NDE-4-27 - Protocol for PRCI Pipe Sample Evaluation and Documentation
• NDE-4-26 - In-Line Inspection Performance on Tight Cracks
• NDE-4-28 - Protocol for Testing New Technologies at the TDC
2. Close identified gaps in material properties performance data
Key Success to Support Key Outcomes
• Developed a material property database within the Virtual Technology Development Center
Project to support Key Outcomes
• NDE-4-17A - Pipeline Material Property Database Enhancement
3. Providing the next generation of susceptibility models by cracking threat/morphology
Key Successes to Support Key Outcomes
• Developed a susceptibility model for fatigue
• Developed a susceptibility model for stress corrosion cracking
• Developed a susceptibility model for selective seam weld corrosion
Projects to support Key Outcomes
• EC-2-12 - Evaluation of Selective Seam Weld Corrosion Susceptibility
• NDE-4-22 - Guidelines for When to Perform a Crack Detection ILI Survey
• NDE-4-24 - Circumferential Crack Management Risk Evaluation Framework
• MAT-7-2 - Hard Spot Susceptibility Review
• EC-08-13 - Influence of External Hydrogen on Crack Growth
4. Broadly communicating outcomes to advance crack management within industry fabric
Key Successes to Support Key Outcomes
• Results from NDE-4-22 will be in the next edition of API RP 1176
• Results from EC-2-12 will be in the next edition of API RP 1160
Projects to support Key Outcomes
• NDE-4-20 - Considerations for Crack ILI Response in Liquids Pipelines
• NDE-4-22 - Guidelines for When to Perform a Crack Detection ILI Survey
5. Further operationalizing the TDC and VTDC for crack management
Key Successes to Support Key Outcomes
• Significant utilization of the TDC for SRP projects
• Established material property database in the VTDC
• Established crack failure database in the VTDC
Projects to support Key Outcomes
• NDE-4-12 - Continuous Improvement of ILI Capabilities
• NDE-4-17A - Pipeline Material Property Database Enhancement
• MAT-8-3C - Understanding Why Crack Fail - Results Sharing
• NDE-2-14 - NDE Technician Improvement Training Course for LSW Testing
• NDE-4-27 - Protocol for PRCI Pipe Sample Evaluation and Documentation
• NDE-4-26 - In-Line Inspection Performance on Tight Cracks
• NDE-4-28 - Protocol for Testing New Technologies at the TDC
Leadership
Sean Keane, Enbridge Pipelines Inc. and Enbridge Energy Partners LP
Taylor Shie, Shell Global
Improvement to Susceptibility Models – When we started the SRP, we had the assumption that the major area for improvement was related to inspection. With the MAT-8-3 “Why Cracks Fail” project, we realized that not knowing a crack inspection survey was required (i.e. susceptibility) was the biggest gap. The SRP has developed projects to develop improved susceptibility models for fatigue, selective seam weld corrosion, and stress corrosion cracking. These models will aid operators in having efficient and effective crack management programs.
Sharing of Results of the SRP – The overarching goal of the SRP is for crack management to be efficient and effective for all operators. Not every operator has the opportunity to be a PRCI member. In an industry where one operators failure reflects on all operators, we established protocols for sharing project results with the industry. The next editions of API RP 1160 and API RP 1176 will have significant updates as a result of SRP projects. The key areas being in the susceptibility models referenced previously.
Relationship of ILI and NDE – In-line inspection (ILI) and Non-Destructive Examination (NDE) work hand in hand to improve integrity management programs. ILI identifies the location to examine while NDE examines the defect. The key element of this relationship is the feedback look from NDE to ILI. A series of projects have been performed to make sure that ILI and NDE service providers are on the same page and speaking the same language whenever possible.
WHAT’S NEXT FOR THE CRACK MANAGEMENT SRP
In the fall of 2023 both the research steering committee and the Executive Assembly approved the continuation of the Crack Management SRP for two more years (2024 and 2025). A budget of $1.3MM and $1.1MM has been approved for 2024 and 2025 respectively. The Crack Management Strategic Research Priority has a proven track record of being good stewards of PRCI resources. This additional scope of work will make a final work package that improves all member company integrity management programs.
At the time of this writing the scope for the next phase is still being confirmed. It is anticipated that the next two years will include projects to:
• Develop a Database of Crack-Like Defects Created by Pipe Manufacturer
• Develop a methodology to match ILI tool to expected crack morphology
• Advance circumferential crack detection in gas service
• Determination of when do SSWC features behave as cracks
• Determination of when to utilize crack profiles in defect assessment
• Determination of when do lack of fusion defects start to behave as sharp cracks
• Develop a MAT-8 software for circumferential defects
• Advance the utilization of machine learning for integrity management
• Additional scope for:
EC-8-13 - Influence of External Hydrogen on Crack Growth
NDE-4-12 - Continuous Improvement of ILI Capabilities
