Developing Comprehensive Predictive and Prescriptive Management System for Flexible Pipeline Survivability

Abstract In 2020, PETRONAS had lost a flexible pipeline due to an increase level of contaminants in the process stream, which carries into the flexible pipeline system. The incident had caused a major cost impact in which the pipeline needs to be replaced and the production had to be differed for at least 1-year. Detail investigation was conducted, and the finding indicates that amongst the root cause was the unavailability of proper predictive and prescriptive approach in managing flexible pipeline integrity system. Thus, this had triggered PETRONAS to embark an initiative to develop a Flexible Pipeline Management System, which then will be included and further developed alongside with PETRONAS digitalization journey. PETRONAS Flexible Pipeline Management System will be developed by upgrading the existing PETRONAS Digital Management System for carbon steel pipeline. As an overview, scopes for the Flexible Pipeline Management System are comprises of guidelines development, risk parameters establishment, fitness for service (FFS) assessment method advancement, and flexible pipeline remaining life extension study (FLES). Its development started with leveraging on PETRONAS experience in carried out integrity assessment for the existing flexible pipeline with expired design life using analytical method. The assessment was conducted in collaboration with flexible pipeline integrity experts which had been included as part of PETRONAS capability up skilling program. Progressively, the flexible pipeline integrity management guideline, risk assessment protocol, and predictive assessment method for FFS and PLES were developed and corelated within. The above elements had been grouped and formed as Flexible Pipeline's integrity assessment manual. It has then been piloted to one of PETRONAS existing flexible pipeline and turned out very successful. The pilot had resulted in eliminating the need of pipeline replacement and generated cost avoidance of more than USD10 Mil - by assessing the remaining life of the pipeline, managing the risk failures through inspection and monitoring plan, as well as minor repair(s) whenever specified.