MPWT19-15299

LAY-UP CONSTRUCTABILITY CHALLENGES IN CROSS COUNTRY GAS PIPELINES

Mostafa A. Alabudib
Inspection Department
Saudi Aramco
Dhahran, Eastern Province, 31311
Saudi Arabia

ABSTRACT

Lay-up is a process that provides internal protection on equipment (pipeline, piping, heat
exchanger...etc.) and controls internal corrosion by ensuring water and oxygen-free environments.
Corrosion may occur and be accelerated by water contact after hydrostatic testing and even a small
amount of stagnant water and oxygen ingress will cause bacteria to grow in water which may result in
loss of thickness due to high concentration of sulfate-reducing bacteria (SRB) and accelerate internal
corrosion in equipment due to Microbiological Induced Corrosion (MIC). Lay-up helps to greatly reduce
these risks of internal corrosion and provide assurance of design life. The objective of this study is to
identify constructability challenges faced during construction and carry out a lay-up in a cross country
pipeline in gaseous services. Six challenges are discussed and explored in the study including: the long
duration from water fill to final lay-up, pipeline segments are used as water reservoirs,
intermediate/segment lay-up, failure to maintain lay-up, indefinite lay-up periods, and rainwater. A case
scenario is used to demonstrate the extent of these challenges and issues. It is hoped that this study will
help avoid and minimize these constructability challenges in future cross country gas pipelines projects.

Keywords: corrosion, lay-up, hydro-test, preservation, cross country, pipelines, construction, projects

INTRODUCTION

Controlling corrosion during the construction of cross country pipelines is a challenge, especially after
introducing water in the system for hydrostatic testing. The presence of water or moisture with oxygen
ingress causes bacteria to grow which may result in loss of thickness due to high concentration of sulfate-
reducing bacteria (SRB) and accelerate internal corrosion in the system due to Microbiological Induced
Corrosion (MIC). In order to avoid that, the pipeline must be laid-up immediately after the hydrostatic test.
Lay-up is a process that provides internal protection on equipment (pipeline, piping, heat
exchanger...etc.) and controls internal corrosion by ensuring a water and oxygen-free environment. There
are many methods of lay-up (dry lay-up, wet lay-up, inert gas lay-up…etc.), and the goal is the same for
all methods: to ensure a corrosion-free environment and maintain it until commissioning. After examining
many cross country gas pipeline projects, six constructability challenges were identified. These
challenges affect instating and maintaining the lay-up. In this paper, each of the six challenges will be
examined to reach a recommendation to minimize and avoid these constructability challenges from
happening in future projects to ensure better corrosion control.

EXPERIMENTAL PROCEDURE

A case study was designed to examine the current process of lay-up and preservation in cross country
gas pipelines after hydro-testing to determine the constructability challenges faced in the construction
phase.

Case Study

The scenario for the case study is as follows: a 120 KM long cross country gas pipeline with 56-inch
diameter, crossing through remote area, and constructed in five segments:
1- Segment A: 30 KM
2- Segment B: 25 KM
3- Segment C: 30 KM
4- Segment D: 15 KM
5- Segment E: 20 KM

Method of Water Filling:

Water filling in pipelines for hydro-testing is usually done using one of the following sources and
pumped into the pipeline by hydro-testing pumps:
- Temporary tanks (filled by water tankers)
- Existing water wells
- Existing water lines

Chemical Addition:
Chemicals, usually oxygen scavengers and/or biocides, are added/mixed in water during
water filling from day one. Addition of chemicals allows water contact time to exceed 30
days for the entire cycle from the start of water filling to de-watering, however when de-
watering is done, immediate lay-up is to be applied.

Sequence of Water Transfer:

The sequence used to transfer water from one segment to another is as follows:
- Water transfer from tested segment to a temporary tank
- Tank to filter to remove solid particles
- A sampling of water for lab analysis
- Transferring water after acceptable lab results

Prior to transferring the water from one segment to another, water chemical analysis is to be
carried out to assure the quality of water is not compromised. Expected time of this activity is one
day when SRB kits are available for field check. Other conventional methods (lab test) for SRB
take two to three weeks when SRB kits are not available on site.

The process:
Each segment is tested separately, then the water is transferred to the succeeding segment to be
tested, and so on. To calculate the duration for each step/activity for each segment, the following
numbers were used from real-time data of a 56-inch pipeline on average:
- Average filling rate = 1.6 KM/Day
- Average de-watering/water transfer rate = 1.4 KM/Day
Figures 1 through 9 show the basic set-up for testing each segment and transferring water from
one segment to another:

Figure 1: segment A basic testing set-up

Figure 2: segment B basic testing set-up

Figure 3: set-up to transfer water from segment A to segment B

 Figure 4: segment C basic testing set-up

Figure 5: set-up to transfer water from segment A and B to segment C

Figure 6: segment D basic testing set-up

 Figure 7: set-up to transfer water from segment C to segment D

Figure 8: segment E basic testing set-up

Figure 9: set-up to transfer water from segment C and D to segment E

 Tables 1 through 5 detail each activity and its duration on average for testing each segment:

Segment A:
Activity Duration (Average)

Filling water in seg. A of 30 KM 20 Days

Pressurizing time 2 Days
Depressurizing time 2 Days
De-watering/water transfer time 18 Days
Table 1: Segment A test duration

Segment B:
Activity Duration (Average)

Transferring water from seg. A to seg. B of 25 KM 18 Days

Pressurizing time 2 Days
Depressurizing time 2 Days
De-watering/water transfer time 22 Days
Table 2: Segment B test duration

Segment C:
Activity Duration (Average)

Transferring water from seg. A and B to seg. C of 30 KM 22 Days

Pressurizing time 2 Days
Depressurizing time 2 Days
De-watering/water transfer time 11 Days
Table 3: Segment C test duration

Segment D:
Activity Duration (Average)

Transferring water from seg. C to seg. D of 15 KM 11 Days

Pressurizing time 1 Days
Depressurizing time 1 Days
De-watering/water transfer time 15 Days
Table 4: Segment D test duration
 Segment E:
Activity Duration (Average)

Transferring water from seg. C and D to seg. E of 20 KM 15 Days

Pressurizing time 1 Days
Depressurizing time 1 Days
De-watering time 15 Days
Table 5: Segment E test duration

Constructability Challenges

After examining the case study scenario, the following constructability challenges were determined:

Challenge 1: Long Duration from Water Filling to Final Lay-up

Because cross country pipelines are long and large in volume, it takes a long time to fill the
pipeline with water for hydrostatic testing, finish the test, drain all the water, and then dry the
whole system and put in the under lay-up. Another reason for this is having multiple segments
being tested because of site conditions. Also having many construction activities right after the
hydro-test (tie-in welding, valve installation, chemical cleaning…etc.) cause a considerable delay
in instating or re-instating the lay-up. All this results in longer water contact time, which puts the
system at a higher risk of corrosion.

Challenge 2: Pipeline Segments Being Used as Water Reservoir

When the pipeline is in a remote area of the desert, water sourcing for hydrostatic testing is
difficult, and transferring or draining the water is challenging as well. As a result, when the pipeline
is divided into multiple segments with different sizes during the hydro-test, the segment is
sometimes used as a water reservoir to store the water to hydro-test the succeeding segments.
This causes a longer water contact duration, and with the presence of oxygen, corrosion of the
system might be accelerated as a result.

Challenge 3: Intermediate (Segment) Lay-up

Intermediate or segment lay-up is done when the pipeline is divided into multiple segments during
the hydro-test and when there are other construction activities to be done after hydro-testing, such
as tie-in welding, valve installation, chemical cleaning…etc. The challenge with intermediate lay-
up is when the contractor does not follow the approved procedure or only follows part of the
approved procedure. This might affect the integrity of the lay-up during this period before instating
the final lay-up.

Challenge 4: Failure to Maintain Lay-up

Lay-up, in many cases, cannot be maintained due to other construction activities (tie-in welding,
valve installation, chemical cleaning…etc.) that require the lay-up to be broken. Leaving the
system open for long periods of time means it is exposed to the elements which increases the
risk of corrosion.
 Challenge 5: Indefinite Lay-up Period

Lay-up is a temporary means to preserve pipelines from material degradation. When the hydro-
test is performed early in the project, it puts the pipeline at risk of being in lay-up for longer or
indefinite durations. Without proper planning, this might affect the integrity of the lay-up and
preservation before the final commissioning of the pipeline.

Challenge 6: Rain Water

Rainwater accumulation is a challenge during the breaking of lay-up when the pipeline is open for
construction activities or is exposed in open trenches, especially in wadi areas in extreme weather
conditions due to lack of awareness with geographical locations or weather conditions. This risks
getting untreated rainwater inside the pipeline resulting in a higher risk of corrosion.

RESULTS

As a result of examining the above challenges faced during the construction of cross country gas
pipelines and in order to avoid or minimize these challenges, the following recommendations should be
followed:

- Remaining hydro-test water shall be disposed or transferred immediately (pipe should

not be used as a water reservoir).
- Lay-up shall be applied for the tested segment immediately after drying.
- Lay-up shall be reinstated after completion of each activity immediately whenever
there is a breaking of lay-up.
- Appropriate planning is required:
o Specify time frame/table in the hydro-test/lay-up procedures.
o Include planning of hydro-testing and lay-up in the design stage (length of
hydro-test segments, water filling/disposal method, and lay-up method to be
identified by the designer).
o Utilize high-efficiency pumps for water filling to reduce water filling time.
o Corrosion engineer should be involved in the review process of hydro-test/lay-
up procedures.
- Lay-up procedure shall include mothballing plan to be implemented in case lay-up
duration exceeds a certain time frame.
- Rain effects need to be considered during planning by ensuring:
o Awareness of geographical locations to identify wadi areas.
o Awareness of weather history for extreme weather conditions.
o Bury pipeline immediately after lowering.
o Provide airtight seal end caps to prevent water entry.
- Dry air lay-up in pipelines is not recommended due to difficulty in maintaining dew
point temperature.

CONCLUSIONS

Lay-up is an important procedure to ensure the protection of the system against corrosion, but there are
challenges faced during the construction of cross country gas pipelines to implement and maintain the
lay-up. With proper planning and communication between all parties, all these challenges can be avoided
or minimized, ensuring successful implementation of lay-up, and therefore have a corrosion-free
environment throughout the construction phase.
 ACKNOWLEDGEMENTS

Bassam I Ugaily
Majed F Rajeh
Mohammed Y Nuwaiser
Mohammed A Ashour
Farhan Ali
Mohammed H Idayathullah
Simonraj Boopalan