Seam weld cracking is a primary concern for pipeline integrity programs. Effective and efficient seam integrity programs rely on a variety of technology areas including inspection, material properties, data analytics, and probabilistic assessments. Over the past 10 years, the pipeline industry has experienced failures due to seam cracking; these lessons learned helped drive advancements in In-Line Inspection (ILI), Non-Destructive Examination (NDE), ILI Validation and Fitness for Service (FFS), including associated industry code updates.

Inspection performance has undergone significant improvements in probability of detection and especially sizing performance. The use of validation spools and novel synthetic flaws has enabled the industry to measure this performance and drive technology improvements, including the development of new time-based sizing techniques for ultrasonic crack inspection tools.

Recent developments for field applied phased array ultrasonic testing techniques along with industry operator qualification programs has increased the confidence of validation results. Other data analytical methods have also been developed to assess validation results using Bayesian methods and non-linear sizing approaches that were not previously considered in the pipeline industry.

The cloud and super-computer services have enabled quicker implementation of advanced probabilistic assessments by reducing analysis time and allowing users to perform sensitivity analysis on a large scale using new Fitness for Service methods, including MAT-8, crack profiles and non-detected analysis by segments. As the industry moves more towards performance-based asset management, these techniques will allow for increased safety and efficiency given equivalent resource investment.

Many of these advances have been incorporated into API 1163 and API 1176. This paper will provide a historical summary of these improvements, how they are integrated and effectively applied through probabilistic risk-based approach and the potential key research needed for the future when considering CO2 and hydrogen pipelines.