2025 External Corrosion Direct Assessments in High Consequence Areas

Strengthening Pipeline Safety Through Proactive Integrity Management

While it is crucial to avoid pipeline failures, the locations where a compromised pipeline would pose the greatest risk to public safety or the environment are designated as High Consequence Areas (HCAs). For these segments, an External Corrosion Direct Assessment (ECDA) is a physical inspection conducted after IDI/ILI. LaBella completed 32 digs across seven (7) HCA zones to validate the results of previous inspections in these areas.

 

A Phased Path to Pipeline Integrity

Each phase builds on the last, combining advanced inspection techniques and targeted excavation to identify, assess, and mitigate corrosion risks in high-consequence areas.

Phase I: Pre-Assessment

Phase 1 included a thorough pre-assessment that considered construction and environmental records, segment profiles, operating pressures, and inspection history to validate HCA boundaries and make informed risk and feasibility recommendations.

The collected data was combined with existing as-built drawings and GIS overlays to identify potential areas of corrosion and inform the direct inspection methods for the Integrity Management Plan.

LaBella also coordinated with local and state agencies to obtain excavation and inspection approvals, ensuring compliance with environmental and right-of-way regulations.

Phase II: Direct Assessment

Once the sites were selected and prioritized for excavation, the team safely uncovered the pipeline to expose the surface. They performed a technical inspection of the coating, the pipe, and any features, examined the environment around the pipe, and used standard industry formulas to measure the pipeline’s structural integrity.

Phase III: Project Reporting, Recording, and Turnover

After documenting all the inspection results, LaBella compiled the following detailed findings:

  • Wall thickness measurements using Ultrasonic Testing (UT)
  • Corrosion assessment and pitting measurements
  • Soil resistivity testing at defect sites in accordance with ASTM G57 standards
  • Deposit analysis to identify corrosive agents
  • Documentation of repair methods and materials
  • Quality assurance checks on all remediation activities

The project concluded with the preparation of a comprehensive ECDA report, including GIS-compatible alignment updates, anomaly logs with severity rankings, repair documentation and quality assurance verification, and recommendations for future monitoring and mitigation.

Regulatory Driver: PHMSA Gas Mega Rule, including expanded repair criteria, enhanced corrosion control, and improved data integration requirements.

Key Client Benefits:

  • Reduced corrosion-related risk through early detection
  • Improved regulatory alignment, including Mega Rule compliance
  • Smarter capital allocation through risk-based dig prioritization
  • Enhanced system reliability through high-accuracy coating and CP performance insights