PLSS Training Guide
Table of Contents
Introduction
Key Concepts & Terminology
Creating & Defining FLOCs
Creating & Defining Equipment
Creating & Defining Systems
Creating & Defining Schedules
Creating Condition Histories (ECHs)
Fitness-for-Service (FFS) Assessment
Corrosion Assessments
Corrosion Rate Calculations
Remaining Life & Next Inspection Date (NID)
Remedial Action Module
Reporting
Dashboards
Non-Piggable Pipelines
Custom Queries & Filters
Governance & Approvals
Appendix A: Step-by-Step Procedures
Appendix B: Example Calculations
1. Introduction
The Integrity Management System – Pipeline Subsea System (IMS-PLSS) module is designed to implement the Degradation Management work process for pipelines and subsea assets. Its purpose is to ensure safe, reliable, and compliant operations by managing degradation mechanisms such as internal and external corrosion, which are among the most critical threats to pipeline integrity.
PLSS integrates:
Inspection Planning: Define when and how to inspect pipelines.
Assessment: Evaluate pipeline integrity using ILI (In-Line Inspection) data and corrosion models.
Corrective Actions: Plan and track repairs.
Audit Trail: Maintain detailed records of inspections and assessments for compliance.
2. Key Concepts & Terminology
FLOC (Functional Location): Logical grouping for equipment and tasks.
Equipment Types: Pipeline, Flowline, Pipeline Jumper (focus on carbon steel).
Condition History (ECH): Stores inspection and assessment data. Only final-approved ECHs are used in RBI and Remaining Life calculations.
Schedules: Define timing for inspections and assessments; recurring schedules auto-generate next due dates.
MAOP (Maximum Operating Pressure): Mandatory for calculations.
ILI Data: Imported for FFS analysis and defect matching.
3. Creating & Defining FLOCs
A Functional Location (FLOC) is a logical grouping used to organize equipment and tasks in PLSS. It represents a physical or functional part of the plant, such as a pipeline system. FLOCs act as the parent structure for equipment and help maintain hierarchy and traceability.
Key Characteristics of FLOCs
Operating Parameters: Each FLOC typically has defined operating conditions like flow rates, temperatures, pressures, and fluid composition.
Permanent ID: FLOC IDs do not change during their lifecycle. They remain fixed until the FLOC or its associated Unit is retired.
Hierarchy: Usually, each FLOC has one child element—a piece of equipment (e.g., a pipeline) with its own Equipment ID.
Where FLOCs Fit in PLSS
Site, Plant, and Unit Details: These are configured under Settings → Company → Toplevel. This defines the organizational structure.
FLOC Registration: FLOCs are created and managed in the FLOC Main Screen, which displays an overview grid listing all FLOCs.
FLOC Details Page: This is where you define the FLOC’s properties and add equipment under it. From here, you can also navigate to related modules like Fitness-for-Service (FFS) or corrosion assessments.
To create a FLOC:
Login as INSp45.
Clear all filters and select Unit 45.
Navigate to FLOC from the top navigation bar and click the ‘+’ next to the FLOC list.
Fill in details:
Parent ID: Unit 45
FLOC ID: INSP45-PL-6
Description: My sixth pipeline
Location Type: Pipeline System - FLOC
Click Save. Your FLOC is now created.
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4. Creating & Defining Equipment
PLSS Hierarchy Overview
In PLSS, the Hierarchy visually shows how different elements are organized:
Site → Plant → Unit → FLOC → Equipment
This structure helps maintain clarity and traceability across assets.
Role of FLOC
A Functional Location (FLOC) represents a logical grouping, such as a pipeline system.
Each FLOC typically has specific operating parameters like flow rates, temperatures, pressures, and fluid composition.
FLOC IDs are permanent and do not change unless the FLOC or Unit is retired.
Generally, each FLOC has one child, which is an Equipment item (e.g., a pipeline) with its own Equipment ID.
Each FLOC type can only have one Equipment group assigned.
Example: A Pig Trap FLOC can only have Pig Trap equipment assigned.
Equipment Registration
Equipment is the physical asset linked to a FLOC.
It is registered and managed in the Equipment Main Screen.
From this screen, you can:
View all equipment linked to FLOCs.
Add new equipment.
Update details like design data, operating parameters, and integrity status.
To Create an Equipment
Navigate to the FLOC ID you just created.
Under Hierarchy, click the ‘+’ button.
Enter details:
Equipment ID: INSP-PL-6
Short Description: My 6th pipeline
Add Asset Owner, Operator Company, Pipe Type
Ensure Equipment Group, Active Status, and Equipment Status are correct.
Click Next and fill PL Design Data: Installation Date, In-Service Date.
Click Save.
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5. Creating & Defining Systems
To Create a System
Create a FLOC for the system:
Parent ID: Unit 45
FLOC ID: INSP45-System-6
Description: My sixth system
Location Type: PLSS - SYSTEM - FLOC
Click Save.
Create PLSS system under Hierarchy:
Equipment ID: INSP-System-6
Short Description: My 6th System
From top bar, go to System → select System 6.
Under Equipment, click ‘+’ and select pipeline 6 and associated pipelines.
Click OK.
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6. Creating & Defining Schedules
Schedules in PLSS
Schedules are planned activities created at the Equipment level in PLSS. They define when, what, and how an activity should be performed. This ensures that inspections, assessments, and maintenance tasks are organized and tracked systematically.
What Does a Schedule Contains?
Each schedule includes:
Date: When the activity must be executed.
Scope: The type of work (e.g., Overland Survey, Pigging, Sampling).
Plan Codes: Specific plans under the chosen scope (e.g., “CP Test Post Survey” for Overland Survey).
Narrative: Detailed description of the work.
Attachments: Optional supporting documents.
Types of Schedules
PLSS supports four schedule types:
Inspection
Examples: ILI run, CP data collection.Assessment
Examples: RBA Assessment, Internal Corrosion Assessment.Corrective Action
A one-time activity to fix an issue.Preventive Maintenance
Examples: Cleaning pigging, hydrotest.
How to Define “What to Do”
Select the Scope (e.g., Pigging, Overland Survey).
Choose the corresponding Plan for that scope by clicking “What is planned?”
Example: For Scope “Overland Survey,” select Plan “CP Test Post Survey.”
After Executuion
Once the scheduled activity is completed:
Results are stored in IMS-PLSS.
The schedule should be credited in the ECH (Condition History) for traceability.
Integration with SAP
If the SAP interface is enabled, schedule information can be sent to SAP for work order management.
Schedules define timing for inspections, assessments, and maintenance. Recurring schedules automatically generate new due dates. Use the Schedule Tracker Dashboard to monitor overdue tasks and upcoming activities.
Steps to Create a Schedule
Go to Equipment and select the equipment created earlier.
Scroll down to Schedules.
Click “+”.
Fill in:
Equipment ID (predefined)
Schedule Type (choose from four options)
Description
Inspection/Assessment Type
Next Inspection Date & Interval
Inspection Driver
Responsible Inspection: PLSS
Schedule Category
Click Save.
✅ Schedule is created.
Next Steps:
Go to Scope and Planned Codes.
Select Assessment → Planned Tab → Internal Corrosion Assessment.
Approve the schedule to finalize.
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7. Creating & Defining Condition Histories (ECHs)
The Equipment Condition History (ECH) is a permanent record in PLSS that captures all significant events and inspection results for a piece of equipment (identified by its Equipment ID). It serves as the official log of the equipment’s integrity status throughout its lifecycle.
Purpose of ECH
Primary Function: Record inspection narratives (what was done, findings, observations).
Other Functions:
Credit completed Schedules (Inspection, Assessment, Maintenance).
Document major events (e.g., rerating, process changes, damage incidents).
Attach supporting documents and tasks.
Types of ECH
Event or Opportunity Driven
Not linked to a schedule.
Used for recording events like rerates or process changes.
If no inspection data is included, it becomes a Narrative Only ECH.
Schedule Driven
Linked to one or more schedules.
Describes work and findings associated with those schedules.
Key Features
Permanent Record: Once written and approved, the ECH remains in the system and can be retrieved from active or archived locations.
Flexibility: The ECH window allows recording of all significant events for any equipment.
Approval Process:
Draft ECHs with green or orange indicators can be bulk approved.
Red indicator ECHs require investigation before approval.
PLSS-Specific Feature: Unlike standard IMS ECHs, PLSS ECHs allow Anomalies to be created directly from the ECH.
Workflow
Complete inspection or activity.
Create ECH linked to the equipment.
Add narrative, credit schedules, attach documents.
Review and Final Approve the ECH.
Condition History (ECH) stores inspection and assessment data. Draft ECHs do not influence RBI calculations. Final approval is mandatory for data to be included in Remaining Life and NID calculations.
Steps to Create ECH
In Schedule List, click the graph icon (top-right corner).
A screen opens: Condition History.
Add description and click Save.
If work is finished today:
Enter findings and next steps in Inspection Data and Code.
Create a CAIR if needed.
Final approve the ECH.
Once created, ECH moves to the Created Schedule.
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8. Fitness-for-Service (FFS) Assessment
The Fitness-for-Service (FFS) assessment determines whether a pipeline or subsea asset can continue operating safely under its current conditions. It evaluates defects, degradation, and loading conditions against design and safety standards.
Two Approaches in PLSS
ILI/IP Data-Based Assessment
Standard method using In-Line Inspection (ILI) or Inspection Point (IP) data.
Conducted in the FFS module for piggable pipelines.
Non-Piggable Assessment
Used when inspection data is not available from ILI/IP (e.g., non-piggable pipelines).
Relies on alternative integrity information and structured analysis (see NPP process).
Key Requirements
The technical authority for pipelines and subsea assets must ensure:
FFS is conducted for all defect types and loading conditions beyond workmanship standards.
Results are recorded in IMS PLSS or documented in the element section if calculations are external.
For age-related degradation (volumetric corrosion under internal pressure), Level 1 assessment methods (burst calculations) may apply.
Workflow
PLSS provides a generalized workflow and a specific process for FFS:
Import inspection data (ILI/IP or alternative).
Calculate Corrosion Tolerance (CT) and Remaining Life.
Perform risk-based assessment (RBA).
Document findings in ECH and approve.
Import ILI data for defect analysis.
Calculate Corrosion Tolerance (CT).
Review scatter charts and top-10 worst CT values.
Resolve wall thickness mismatches by importing sectioning.
Final-approve ECH after verification.
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9. Corrosion Assessments
Internal Corrosion
Add assessment with Past and Future corrosion rates.
Define sections and confidence ratings.
Use data from ILI runs, hydrocarbon analysis, corrosion monitoring, inhibitor performance.
External Corrosion
Similar process; consider CP monitoring, DCVG surveys, soil data.
Confidence rating influences RBI interval factor.
10. Corrosion Rate Calculations
Short Rate: Based on two ILI runs (e.g., 2 mm → 3 mm over 6 years = 0.17 mm/year).
Long Rate: Metal loss ÷ time since installation (e.g., 3 mm over 24 years = 0.125 mm/year).
Matching algorithm compares defects using girth weld positions and defect properties.
11. Remaining Life & Next Inspection Date
Formula:
Remaining Life = (Remaining Corrosion Tolerance) ÷ (Future Corrosion Rate)Remaining corrosion tolerance = CT – wall loss since last ILI.
NID calculated using interval factor and RBI matrix.
Example:
CT = 0.9 mm; WL = 0.5 mm; Future CR = 0.1 mm/year → RL = 4 years → NID = Assessment Date + 4 years.
12. Remedial Action Module
Visualizes defects (internal = circles, external = squares).
Plan repairs by defect or section.
After repair date entry:
Defects removed from ILI dataset.
CT and Remaining Life recalculated.
13. Reporting
Generate system reports combining multiple pipelines. Includes:
Equipment list
Remaining Life
Integrity status
Corrosion narratives
Reports are customizable; BSP example consolidates hundreds of pipelines.
14. Dashboards
Dashboards summarize key integrity data:
Barrier status (red = failed, blue = no data)
Equipment status
Integrity trends
Schedule tracker
Map view shows pipelines with integrity status colour coding.
15. Non-Piggable Pipelines
Use external corrosion life tables and barrier monitoring. Define degradation zones based on CP/DCVG/test-post data. Continuous process: update assessments as new data becomes available.
Non-Piggable Pipeline (NPP) analysis in PLSS is a structured process used when pipelines cannot be inspected with pigs. It ensures integrity by assessing confidence in available data, calculating degradation risk, and determining inspection coverage. The process involves creating an NPP case, performing corrosion assessments, calculating β (risk ratio), and scheduling inspections based on pipeline integrity status.
STEP FOR NON-PIGGABLE PIPELINES
Pre-requisites:
Fill in all design data.
On Equipment Details → Design section:
Set Piggability to Non-piggable (in current configuration).
Tick NPP mode checkbox.
Perform Internal and External Corrosion Assessments (specify Past & Future corrosion rates) and Final Approve ECH.
Perform Risk-Based Assessment (RBA).
Step 1: Create NPP Case & Determine Confidence
Navigate to FFS module → NPP tab.
Click + to create a new NPP case date → enter date → Save.
Fill out the NPP Questionnaire → Save.
Confidence Rating determines inspection scope:
Low/Very Low → Inspect ≥10% of pipeline length.
Medium/High/Very High → Define degradation zones and calculate β for each.
Step 2: Calculate β and Degradation Stage
CT = Wall Thickness – Minimum Acceptable Thickness (MAT).
Click (Re)Generate in Internal/External NPP section to calculate:
β(pre) (before inspection)
Stage:
Stage A: β < 0.2 (early life, no defects)
Stage B: 0.2 ≤ β ≤ 0.5 (mid-life, defects present but acceptable)
Stage C: β > 0.5 (late life, defects critical)
Inspection regime depends on stage:
Compliance → Estimation → Find defects.
Step 3: Enter Inspection Data
Perform sample inspection as per suggested coverage.
Enter detected defects in Assessment tab.
Final Approve ECH after adding defects.
Step 4: Recalculate β
Enter actual inspection coverage in Internal/External NPP sections.
Click Edit → Override coverage → Save → (Re)Generate.
Updates β(post) and Stage.
If coverage insufficient, system shows “Insufficient coverage”.
Step 5: Determine Integrity Status & Next Inspection
Step 5:
Based on β(post) and Stage:
If coverage sufficient → Perform FFS analysis using inspection results.
If not → Expand inspection scope and repeat steps 3–5.
Schedule next inspection based on updated integrity status.
16. Custom Queries & Filters
Filter equipment by group and status. Save and share queries for team-wide use. Build nested reports for equipment, corrosion, and test posts.
17. Governance & Approvals
Annual integrity assessments expected. Past/Future corrosion rates must be justified by data. Draft ECHs excluded from RBI summaries; only final-approved ECHs feed Remaining Life and NID.
18. Appendix A: Step-by-Step Procedures
Detailed workflows for FFS, Internal/External Corrosion, RBI, and Remedial Actions.
19. Appendix B: Example Calculations
Scenario | Inputs | Outputs |
|---|---|---|
Short Rate | Depth: 2→3 mm; Δt = 6 years | CR = 0.17 mm/year |
Long Rate | Loss: 3 mm; Δt = 24 years | CR = 0.125 mm/year |
Remaining Life | CT = 0.9 mm; WL = 0.5 mm; CR = 0.1 | RL = 4 years |
NID | Assessment Date = 2015; RL = 4 yrs | NID = 2019 |