🌊 Integrity Management of Subsea Pipelines: 5-Day Course Outline

Duration: 5 Days | 4 Hours Daily | 20 Total Hours
Level: Intermediate to Advanced

🎯 Course Overview

Comprehensive training on subsea pipeline integrity management covering inspection, corrosion control, risk assessment, and maintenance strategies aligned with API, DNV, and NORSOK standards.

Target Audience: Pipeline integrity engineers, subsea engineers, corrosion specialists, asset managers, operations engineers

Prerequisites: Engineering degree, 2+ years oil & gas experience

📅 DAY 1: Fundamentals & Integrity Threats

Learning Objectives: Understand subsea pipeline systems, identify integrity threats, and comprehend regulatory requirements

Modules:

1.1 Subsea Pipeline Systems

• Pipeline types, materials, and coating systems

• Design considerations and installation methods

• Industry overview and major projects

1.2 Integrity Threats & Failure Mechanisms

• External threats (corrosion, third-party damage, free spans)

• Internal threats (CO₂/H₂S corrosion, MIC, erosion)

• Manufacturing defects and time-dependent degradation

• Historical failure analysis

1.3 Regulatory Standards

• API 1160, 1163 | ASME B31.4, B31.8

• DNV-ST-F101, DNV-RP-F101, DNV-RP-F106

• NORSOK Y-002, M-001, M-506

• ISO 13623, 16708 | NACE/AMPP standards

1.4 Pipeline Integrity Management System (PIMS)

• PIMS structure and components

• Data management and KPIs

• Management of change procedures

Deliverable: Integrity threat register and PIMS framework

📅 DAY 2: Corrosion Management & Cathodic Protection

Learning Objectives: Master corrosion mechanisms, design CP systems, and implement corrosion control strategies

Modules:

2.1 Corrosion Mechanisms

• Electrochemical principles in seawater

• CO₂, H₂S, MIC, pitting, crevice corrosion

• Environmental factors and corrosion rates

2.2 Internal Corrosion Control

• Risk assessment (NORSOK M-506, DNV-RP-F106)

• Chemical injection (inhibitors, biocides)

• Pigging strategies and monitoring

2.3 External Corrosion & Coatings

• Coating types (FBE, 3LPE, concrete)

• Selection criteria and inspection

• Thermal insulation systems

2.4 Cathodic Protection Design

• Sacrificial anode systems (DNV-RP-F103)

• ICCP systems and applications

• CP monitoring and surveys

• Exercise: CP design calculations

2.5 Materials Selection

• Carbon steel grades (API 5L, X42-X80)

• CRA options (13Cr, duplex, nickel alloys)

• Qualification testing

Deliverable: Corrosion management strategy with CP design

📅 DAY 3: Inspection & Condition Assessment

Learning Objectives: Select inspection methods, interpret ILI data, and conduct fitness-for-service assessments

Modules:

3.1 Risk-Based Inspection Strategy

• RBI methodology and optimization

• Inspection frequency determination

• Cost-benefit analysis

3.2 In-Line Inspection (ILI) Technologies

• MFL, UT, caliper, IMU tools

• Tool selection and capabilities

• Pipeline preparation and run requirements

3.3 ILI Data Interpretation

• Feature identification and sizing

• Metal loss, dents, crack assessment

• POI/POD and uncertainty management

• Growth rate analysis

• Lab: ILI report analysis exercise

3.4 External Inspection

• ROV inspections (visual, CP, UT, free spans)

• AUV and diver inspections

• Survey frequency and documentation

3.5 NDT Methods

• UT, RT, MT, PT techniques

• Personnel certification requirements

3.6 Fitness-For-Service Assessment

• ASME B31G and DNV-RP-F101 methods

• Remaining strength calculations

• Crack and dent assessment (API 579, BS 7910)

• Workshop: FFS calculations

Deliverable: Inspection program and FFS assessment report

📅 DAY 4: Risk Assessment & Operating Windows

Learning Objectives: Conduct risk assessments, define integrity operating windows, and manage emergency response

Modules:

4.1 Risk Assessment Methods

• HAZID, HAZOP, FMEA, bow-tie analysis

• Qualitative vs. quantitative approaches

• Risk matrices and ALARP principle

4.2 Quantitative Risk Assessment

• Probability of Failure (PoF) assessment

• Consequence of Failure (CoF) analysis

• Risk calculation and software tools

• Case Study: Pipeline risk assessment

4.3 Risk-Based Integrity Management

• RBI optimization and repair prioritization

• Direct assessment (ECDA, ICDA, SCCDA)

• Dynamic risk updating

4.4 Integrity Operating Windows (IOW)

• Operating envelope development

• Pressure, temperature, flow, chemical limits

• IOW monitoring and excursion management

• Workshop: IOW development exercise

4.5 Flow Assurance Integration

• Hydrates, wax, scale, sand management

• Impact on integrity (erosion, under-deposit corrosion)

• Shutdown/startup considerations

4.6 Leak Detection & Emergency Response

• CPM, RTTM, acoustic, fiber optic systems

• Emergency response plans

• Oil spill response procedures

• Exercise: Emergency scenario simulation

Deliverable: Risk assessment report, IOW documentation, ERP framework

📅 DAY 5: Maintenance, Repair & Capstone Project

Learning Objectives: Plan maintenance programs, select repair methods, evaluate life extension, and complete comprehensive project

Modules:

5.1 Maintenance Strategies

• Preventive, predictive, risk-based maintenance

• Pigging programs and procedures

• Maintenance optimization

5.2 Repair Technologies

• Mechanical clamps, composite wraps

• Hot tapping and hyperbaric welding

• Repair selection and qualification

• Case Study: Major repair operations

5.3 Life Extension & Decommissioning

• Remaining life calculations

• Re-qualification for changed conditions

• Decommissioning options and regulations

• Late-life integrity management

5.4 Advanced Technologies

• Digital twins and AI/ML applications

• Fiber optic sensing (DFOS)

• Autonomous inspection (AUVs, robotics)

5.5 Capstone Project Develop complete integrity management program including:

• Asset description and threat assessment

• Risk and corrosion management strategies

• Inspection and maintenance programs

• IOW and emergency response plans

• KPIs and budget estimates

Team Presentation: 20 minutes + Q&A

5.6 Course Summary

• Key takeaways and industry trends

• Professional certifications (NACE, API, ASNT)

• Continued learning resources

Deliverable: Complete integrity management plan and presentation

🛠️ Standards & Tools Covered

Standards: API 1160/1163/579 | ASME B31G/B31.4/B31.8 | DNV-ST-F101/RP-F101/RP-F103/RP-F106 | NORSOK M-001/M-506/Y-002 | ISO 13623/16708 | BS 7910

Software: PIMS platforms, ILI analysis tools, risk assessment software, FFS calculators, CP design tools

Technologies: MFL/UT/Caliper ILI tools, ROV/AUV systems, NDT equipment, leak detection systems

📚 Course Materials

• Technical manual (400+ pages)

• Standards reference guide

• 20+ case studies

• Excel calculation tools

• Templates and checklists

• ILI sample reports

• Certificate (40 PDH / 4.0 CEU)

• 60-day technical support

🎓 Learning Outcomes

✅ Develop comprehensive PIMS programs
✅ Design corrosion control and CP systems
✅ Plan risk-based inspection programs
✅ Interpret ILI data and conduct FFS assessments
✅ Perform quantitative risk assessments
✅ Define integrity operating windows
✅ Select repair and maintenance strategies
✅ Manage emergency response
✅ Evaluate life extension options