The use of risk based integrity management systems for pipelines is increasing in popularity, and now changes in legislation in the USA require operators to use risk assessment in high consequence areas. The methodologies used range from point scoring qualitative schemes to detailed quantified systems requiring structural reliability analysis, release modelling and post incident behavioural modelling. In the UK a risk based approach to pipeline integrity management has been included in legislation since 1996, and is widely used. Experience with implementing systems and applying them to onshore and offshore pipeline systems has led to the following conclusions: • Point scoring systems cannot replace expert knowledge. • Point scoring systems always need to be modified to suit a particular system and need updating as parameters change. • Detailed automated systems generate a huge number of sections and range of risks. this can be confusing and cannot easily be accounted for in inspection planning. • A clear link between risks and inspection or monitoring is needed. • Simplicity and flexibility are critical. This paper describes a radical new approach to using risk assessment for pipeline integrity management. This new approach focuses on identifying whether hazards are time dependant (e.g. corrosion) or random (e.g. third party damage), and then either estimating a time to failure or a probability of occurrence. These estimates can be based on experience, history, or specific detailed studies. The effect of inspection and monitoring is also considered. This methodology allows the user to manage the risks associated with their pipeline in a way that is flexible, rational, consistent, and can be readily understood by others. It also allows the reasons for decisions regarding inspections to be recorded, and new users to quickly learn the key safety issues for the pipeline.

The United Kingdom Onshore Pipeline Operators Association (UKOPA) was formed by UK pipeline operators to provide a common forum for representing operators interests in the safe management of pipelines. This includes providing historical failure statistics for use in pipeline quantitative risk assessment and UKOPA maintain a database to record this data. The UKOPA database holds data on product loss failures of UK major accident hazard pipelines from 1962 onwards and currently has a total length of 22,370 km of pipelines reporting. Overall exposure from 1952 to 2010 is of over 785,000 km years of operating experience with a total of 184 product loss incidents during this period. The low number of failures means that the historical failure rate for pipelines of some specific diameters, wall thicknesses and material grades is zero or statistically insignificant. It is unreasonable to assume that the failure rate for these pipelines is actually zero. However, unlike the European Gas Incident data Group (EGIG) database, which also includes the UK gas transmission pipeline data, the UKOPA database contains extensive data on measured part wall damage that did not cause product loss. The data on damage to pipelines caused by external interference can be assessed to derive statistical distribution parameters describing the expected gouge length, gouge depth and dent depth resulting from an incident. Overall 3rd party interference incident rates for different class locations can also be determined. These distributions and incident rates can be used in structural reliability based techniques to predict the failure frequency due to 3rd party damage for a given set of pipeline parameters. The UKOPA recommended methodology for the assessment of pipeline failure frequency due to 3rd party damage is implemented in the FFREQ software. The distributions of 3rd party damage currently used in FFREQ date from the mid-1990s. This paper describes the work involved in updating the analysis of the damage database and presents the updated distribution parameters. A comparison of predictions using the old and new distributions is also presented.

The United Kingdom Onshore Pipeline Operators Association (UKOPA) was formed by UK pipeline operators to provide a common forum for representing operators interests in the safe management of pipelines. This includes providing historical failure statistics for use in pipeline quantitative risk assessment and UKOPA maintain a database to record this data. The UKOPA database holds data on product loss failures of UK major accident hazard pipelines from 1962 onwards and currently has a total length of 21,845 km of pipelines reporting. Overall exposure from 1952 to 2016 is 927,351 km years of operating experience with a total of 197 product loss incidents since 1962. The low number of failures means that the historical failure rate for pipelines of some specific diameters, wall thicknesses and material grades is zero or statistically insignificant. It is unreasonable to assume that the failure rate for these pipelines is actually zero. In addition to product loss incidents, the UKOPA database contains extensive data on measured part wall damage that did not cause product loss, unlike the European Gas Incident data Group (EGIG) database, which also includes the UK gas transmission pipeline product loss data. The data on damage to pipelines caused by external interference can be assessed to derive statistical distribution parameters describing the expected gouge and dent dimensions resulting from an incident. Overall external interference incident rates for different class locations can also be determined. These distributions and incident rates can be used in structural reliability based techniques to predict the failure frequency due to external interference for a given set of pipeline parameters. The current distributions of external interference damage were derived from data up to 2009 and presented as Weibull distributions for gouge depth, gouge length and dent depth. Analysis undertaken for the COOLTRANS CO2 pipeline project, undertaken by National Grid in the UK, has identified several improvements to the recommended UKOPA approach to external interference failure frequency prediction. This paper summarises those improvements and presents updated damage distribution parameters from data up to 2016.

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Operators wish to understand the condition of their pipelines to manage ongoing integrity. Information on the condition of the pipeline along its entire length can be obtained using in-line inspection (ILI). However, some pipelines cannot be internally inspected due, for example, to tee connections, tight bends, low flow or to a lack of launcher and receiver facilities. The condition of these ‘unpiggable’ lines can sometimes be largely unknown. To aid the understating of the pipeline condition without ILI data, operators will often rely on alternative sources of information, such as localised external inspections, model predictions and company and individual experience. However, there may be significant uncertainty associated with these alternative data sources when using them to assess the condition of the entire pipeline. This uncertainty may be understood by applying a probabilistic approach to the assessment of pipeline integrity using structural reliability analysis (SRA) methods. An SRA approach applies probabilistic input parameters to a failure prediction model for a defined limit state function. Previous IPC papers[1,2,3] have presented guidance on probabilistic assessments to model pipeline failure. Recommended probability distributions are presented which account for uncertainties associated with line pipe properties, defect sizing and the error associated with the predicted failure model. However, there is little published guidance readily available on recommended defect characteristic distributions specific to internal corrosion features. Parameter distributions are recommended for defect sizing based on empirical data, which are mainly used for external corrosion features. In this paper, a case study is used to present a practical application of an SRA methodology for assessment of pipeline integrity with respect to internal corrosion. Discussion is presented on alternative sources of information for the assessment when ILI data is unavailable, including targeted external inspections of unpiggable lines and data sets from comparable piggable lines. Probability distributions are derived from the available inspection data for the internal corrosion feature size and corrosion rate input parameters to the SRA. Probabilistic analysis is used to account for the expected population of unknown features in the uninspected parts of the pipelines. The expected feature size, corrosion rate and feature density calculated are used in the SRA to estimate the total probability of failure due to internal corrosion over time for the entire length of the pipeline. Recommendations are provided on the application of an SRA methodology to assess pipeline failure due to internal corrosion.