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Oil & Gas Pipelines

Solutions to ensure the safe and reliable operation of pipeline infrastructure

The integrity of pipeline infrastructure is a matter of serious concern for those within the oil and gas industry.  Given the dynamic and complex regulatory environment, our clients seek to effectively address and manage their company’s integrity related challenges.  With 35 years of specialized industry experience, we understand the pipeline industry and its complexity.  We are committed to delivering high-quality and innovative solutions to help our clients maintain safe, reliable and efficient operations of their transmission, distribution and hazardous liquid pipelines.

Integrity Management

Structural Integrity is a leader in providing high-quality, highly-effective integrity and risk management services to the oil and gas industry. Our team has a profound understanding of the integrity issues our clients face and can provide expert engineering and consulting services to help implement these programs. The comprehensive range of services we offer includes in-line inspection (ILI) consulting, fracture mechanics, advanced materials engineering, NACE-accredited corrosion analyses and mitigation program development as well as HCA and class location analyses. In addition, our auditing and compliance verification process as well as program implementation guidance can assist clients in preparation for state and federal inspections. Structural Integrity is committed to helping clients implement a robust and compliant program that ensures the safe and reliable operation of both Hazardous Liquid and Natural Gas pipeline systems.

Integrity Management

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Integrity Management

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Transmission Integrity Management Program Support

After a recent merger of two major gas pipeline operators, Structural Integrity was retained to help merge all Transmission Integrity Management Program (TIMP) Plan documents, recommending best practices, and implementing Management of Change processes to combine the TIMP Programs.

Data Integration & Risk Analysis

For a major southeast utility, Structural Integrity implemented a PODS-based comprehensive data integration and risk assessment. All data was migrated from the client's legacy spreadsheet-based model and the updated system enabled the use of more data sets, with greater reliability and quality control of the data. The client also realized synergies between various data management activities such as MAOP verification, risk assessment, and performance metrics.

Plan Development & Implementation

For a northeast pipeline operator, Structural Integrity completed development of their Integrity Management Program plan and then subsequently assisted in developing In-Line Inspection (ILI), Direct Assessment, and Guided Wave Test plans. We were then responsible for implementing and overseeing all phases of these programs across their system.

MAOP Verification

For a major east coast pipeline operator, Structural Integrity developed protocol and supporting software tools to complete MAOP verification on over 2,700 miles of transmission pipelines. The project team sorted and reviewed tens of thousands of records identifying Traceable, Verifiable and Complete Records that would provide support in establishing the MAOP for each segment. Key metadata and record identifiers were stored in a database and program tools were used to calculate MAOP based on code requirements.

Integrity Management

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Regulatory Compliance Consulting

Due to the increasing complexity of regulations and the demand for operational transparency, pipeline operators aspire to ensure compliance with relevant laws and regulations. Working within the requirements of Federal, state and local agencies can be difficult for pipeline operators to accomplish without an independent third-party subject matter expert to evaluate their management and operational practices. Structural Integrity can help ensure compliance with current regulations, benchmark against industry best practices, and make recommendations for continuous improvement to your company's related programs and procedures.

Regulatory Compliance Consulting

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Regulatory Compliance Consulting

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Security Procedures Review

For an East Coast pipeline operator, Structural Integrity completed a detailed review of the operators' security procedures and related security documents to evaluate their alignment and consistency with the Pipeline Security Guidelines for transmission pipelines, natural gas distribution pipelines and LNG facilities created by the Transportation Security Administration (TSA).

Gas TIMP & DIMP Program Review

Structural Integrity provided consulting for a major Midwestern gas distribution pipeline operator completing a comprehensive review of their TIMP and DIMP Programs. We completed this review using our intimate knowledge of 49 CFR, Part 192, PHMSA Frequently Asked Questions (FAQs) and PHMSA Inspection Protocol as guidance. As part of this effort, we completed a detailed review of the clients' DIMP and TIMP Plans, corresponding Risk Models and relevant sections of the Company's O&M Procedures.

MAOP Verification

For a major east coast pipeline operator, Structural Integrity developed protocol and supporting software tools to complete MAOP verification on over 2,700 miles of transmission pipelines. The project team sorted and reviewed tens of thousands of records identifying Traceable, Verifiable and Complete Records that would provide support in establishing the MAOP for each segment. Key metadata and record identifiers were stored in a database and program tools were used to calculate MAOP based on code requirements.

Material Verification Development & Validation

For the pipeline's leading industry research institute, Structural Integrity completed a major research project to develop field protocol to apply a newly developed Material Verification (MV) technique and then validated this methodology along with other proprietary MV techniques commonly used to predict material properties based on in-situ measurement techniques.

Regulatory Compliance Consulting

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Pipelines are more than

Point A to Point B

Pipeline & Facility Assessments

Aging pipelines and facilities pose challenges for operators tasked with providing safe and reliable oil and gas transmission. Structural Integrity has in-depth experience supporting pipeline operators in completing various assessments on pipelines and facility piping, employing a wide range of tools and techniques. Our consulting expertise enables us to support the full assessment cycle from evaluation and implementation of the right assessment methodology, to evaluating defects and making recommendations on repairs and re-assessment intervals. With accurate, objective data, operators can better understand their assets and make informed decisions regarding pipeline safety and capital investments.

Pipeline & Facility Assessments

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Pipeline & Facility Assessments

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In-Line Inspection (ILI) Procedure & Consulting

For a major Southeast utility, Structural Integrity developed a structured process to ensure successful implementation of their ILI projects. The comprehensive process included detailed steps for all activities pertaining to: preparing for the inspection, running the tool, verifying indications, and validating the ILI results. The procedure was integrated with the client's other integrity management procedures, we then provided consulting support to assist in each step of the process on a number of ILI projects.

Research on NDE Performance for Crack Characterization

For the pipeline's leading industry research institute, Structural Integrity led a research project to evaluate NDE performance in characterizing Stress Corrosion Cracking (SCC) and Electric Resistance Welded (ERW) Seam defects. Multiple NDE technologies including Phased Array UT, Eddy Current Array, IWEX among others, were utilized on pipes containing these defects. Samples were then verified using metallurgical evaluation techniques at our Material Science Center. Truth data from metallurgical testing was then compared against the predicted NDE results.

SCCDA On a Major Interstate Pipeline

For one of the leading interstate gas pipeline operators, Structural Integrity completed three major SCCDA projects consisting of nine different pipeline segments spanning over 600 miles of pipelines.

Station & Facility Assessments

Structural Integrity has completed regulatory approved assessments on hundreds of facilities over the last decade including Gas Compressor Stations, Gas Meter and Gate/Valve Facilities, Crude Oil Pump Storage Stations, Gas Generating Facilities, and refined product terminals. Recently for one of the largest interstate gas transmission pipeline operators, SI completed ECDA and ICDA re-assessment on all their fabricated gate facility piping (metering, compressor, cross-over, etc.)

Pipeline & Facility Assessments

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Training & Certification

To help clients navigate changing regulations and manage workforce turnover, Structural Integrity provides frequent training, expertly tailored to meet the needs of all levels of pipeline and facilities operators. We offer a wide gamut of courses, ranging from materials and welding inspections, to comprehensive nondestructive examination, and much more, in an effort to constantly ensure operators have a complete understanding of pipeline regulations and related safety and integrity management topics.

Training & Certification

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Control Room Management Training

Before Implementing changes to pipeline control room operations, training should be provided to ensure controllers and supporting staff can effectively and accurately implement the change. Training may consist of informal ("on the job") training, formal classroom instruction, field visits, training simulation or any other method that the pipeline operator finds appropriate. We have strong experience formally documenting and providing a comprehensive CRM training program for a pipeline operator. In addition, we can review the OQ requirements for control center staff and those who interface with controllers in pipeline operational decisions and ensure adequate team training.

Pipeline Safety Compliance Training

This course provides a Comprehensive Review of Gas Pipeline Regulations (49 CFR, Parts 191 and 192) governing the design, construction, operation and maintenance of gas transmission and distribution pipelines. The material is presented along with practical exercises to reinforce attendees' understanding of fundamental regulatory principles. An update of current gas pipeline rulemakings and review of anticipated rulemaking changes and proposals is also included.

Fracture Mechanics & ECA Training

Structural Integrity offers training by industry leading experts that provide an overview of the basics of fracture mechanics for pipelines. This course is geared for integrity managers and pipeline engineers who need to understand the technical and regulatory challenges associated with managing stress corrosion cracking (SCC), seam weld defects and other crack-like threats to pipelines. This course will build on this basic understanding and cover tools and processes for implementing Engineering Critical Assessments (ECAs).

NDE Training & Certification

Structural Integrity can assist clients in building a best-in-class NDE program for the pipeline industry. In addition to a written practice and corresponding support procedures, we can provide the advanced NDE training and certification support to ensure technicians are certified for basic pipeline integrity inspections. Structural Integrity can also provide support and oversight of field testing to ensure clients meet the necessary requirements for certification. We also offer field data collection tools and systems to help facilitate data gathering and expedite reporting.

Corrosion Control Training

This course covers the basics of corrosion control practices and key content covered in client's and NACE procedures as well as best practices used in the prevention of corrosion in pipeline assets. The basics of Cathodic Protection (CP), coating types, and system maintenance and troubleshooting are covered. If desired, associated issues with stray current sources and mitigation techniques are also discussed.

Corrosion Engineering & Consulting

Pipeline corrosion and the associated consequences from resulting failures constitutes staggering costs in the form of injuries, environmental damage, and loss of production. Studies completed by the National Association of Corrosion Engineers (NACE), estimate the cost of corrosion on US pipeline systems to exceed $7 billion annually.

Throughout our years, Structural Integrity has developed NACE certified Corrosion Control and Cathodic Protection processes and procedures that assist pipeline operators in solving existing corrosion problems, while ensuring robust corrosion control programs.

Corrosion Engineering & Consulting

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Corrosion Engineering & Consulting

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Internal Corrosion (IC) Monitoring Solution

Structural Integrity implemented an IC monitoring system on a natural gas pipeline system. After completing ICDA, SI developed a detailed monitoring program and installed gas chromatographs to monitor gas quality and Electric Resistance (ER) probes to monitor for corrosion. From this monitoring, we proved a very low likelihood of internal corrosion. The client used this data as input into their risk model and as input to determine future assessment methodologies and reassessment intervals for this segment.

AC Mitigation

For a major products pipeline in southern Texas major damage attributed to AC corrosion was identified. The 140 mile pipeline was collocated with AC power lines for over 35 miles. With our strategic partner MESA, Structural Integrity collected critical field data, interviewed power companies to gather powerline information, and modeled the AC influence. We then designed a mitigation system that MESA installed. Since installation, no new instances of AC induced corrosion have been identified.

Direct Assessment

Following development of an Internal Corrosion Direct Assessment (ICDA), a specific cased crossing External Corrosion Direct Assessment (CECDA), and a Guided Wave Test (GWT) procedure for a select Midwestern utility, Structural Integrity implemented all related engineering and field activities to support the assessment. We applied GWT inspections at over 50 cased crossings as well as at ICDA detailed examination locations in accordance with PHMSA recommendations.

130,000 Miles

of successfull pipeline projects

Corrosion Engineering & Consulting

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NDE Consulting & Services

Structural Integrity is home to one of the most highly skilled, certified, and diverse teams of NDE consultants in any industry, maintaining multiple full-time senior Level II and Level III team leads. Our experts possess a huge depth of knowledge in a wide range of disciplines, methodologies, and techniques, and have pioneered revolutionary new nondestructive examination technologies.

In addition to providing NDE consulting services and advanced field services for the oil and gas pipeline industry, Structural Integrity can also develop detailed procedures, conduct training and certification, and can provide application tools and R&D for our clients.

NDE Consulting & Services

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NDE Consulting & Services

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SCC Crack Characterization Using Phased Array UT

Following a pipeline failure due to Stress Corrosion Cracking (SCC) in the Northeast, Structural Integrity helped evaluate risk factors and completed NDE evaluations at selected dig locations. In addition to inspecting for the presence of SCC and collecting key data on contributing factors (pH levels, microbe testing, soil analysis, etc.), sizing of a number of identified crack features using Phased Array UT was completed. In numerous instances, cracks were sized so a suitable repair decision could be made.

True Innovator

of NDE techniques & technologies

GWT & Bell Hole Inspection in Support of Direct Assessment

Following development of an Internal Corrosion Direct Assessment (ICDA), a specific cased crossing External Corrosion Direct Assessment (CECDA), and Guided Wave Test (GWT) procedure for a select Midwestern utility, Structural Integrity implemented all related engineering and field activities to support the assessment. We applied GWT inspections at over 50 cased crossings as well as at ICDA detailed examination locations in accordance with PHMSA recommendations.

Research on NDE Performance for Crack Characterization

For the pipeline's leading industry research institute, Structural Integrity led a research project to evaluate NDE performance in characterizing Stress Corrosion Cracking (SCC) and Electric Resistance Welded (ERW) Seam defects. Multiple NDE technologies including Phased Array UT, Eddy Current Array, IWEX among others, were utilized on pipes containing these defects. Samples were then verified using metallurgical evaluation techniques at Structural Integrity's Material Science Center. Truth data from metallurgical testing was then compared against the predicted NDE results.

NDE Consulting & Services

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