Statistical methods for the analysis of corrosion data for integrity assessments

Abstract

In the oil and gas industry, statistical methods have been used for corrosion analysis for various asset systems such as pipelines, storage tanks, and so on. However, few industrial standards and guidelines provide comprehensive stepwise procedures for the usage of statistical approaches for corrosion analysis. For example, the UK HSE (2002) report “Guidelines for the use of statistics for analysis of sample inspection of corrosion” demonstrates how statistical methods can be used to evaluate corrosion samples, but the methods explained in the document are very basic and do not consider risk factors such as pressure, temperature, design, external factors and other factors for the analyses. Furthermore, often the industrial practice that uses linear approximation on localised corrosion such as pitting is considered inappropriate as pitting growth is not uniform. The aim of this research is to develop an approach that models the stochastic behaviour of localised corrosion and demonstrate how the influencing factors can be linked to the corrosion analyses, for predicting the remaining useful life of components in oil and gas plants. This research addresses a challenge in industry practice. Non-destructive testing (NDT) and inspection techniques have improved in recent years making more and more data available to asset operators. However, this means that these data need to be processed to extract meaningful information. Increasing computer power has enabled the use of statistics for such data processing. Statistical software such as R and OpenBUGS is available to users to explore new and pragmatic statistical methods (e.g. regression models and stochastic models) and fully use the available data in the field. In this thesis, we carry out extreme value analysis to determine maximum defect depth of an offshore conductor pipe and simulate the defect depth using geometric Brownian motion in Chapter 2. In Chapter 3, we introduce a Weibull density regression that is based on a gamma transformation proportional hazards model to analyse the corrosion data of piping deadlegs. The density regression model takes multiple influencing factors into account; this model can be used to extrapolate the corrosion density of inaccessible deadlegs with data available from other piping systems. In Chapter 4, we demonstrate how the corrosion prediction models in Chapters 2 and 3 could be used to predict the remaining useful life of these components. Chapter 1 sets the background to the techniques used, and Chapter 5 presents concluding remarks based on the application of the techniques.