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A Data Driven Approach to Improving Suitability of External Corrosion Risk Algorithm for Pipelines with Unique Operating Conditions – A Case Study of Hot Bitumen Pipelines

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Suncor is an integrated oil, gas exploration, and production company that operates over 1000 km (622 miles) of pipeline in Canada and approximately 386 miles (621 km) of pipeline in US. Suncor also operates refineries in Alberta, Ontario, Quebec (Canada) and in Colorado (USA). Additionally, the company owns a network of more than 1,800 Petro-CanadaTM retail and wholesale locations across Canada.

Product Number: 51323-19170-SG
Author: Cathy Lee Tetreault, Qing Lan
Publication Date: 2023
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Bitumen is a solid or semi-solid high-viscosity liquid petroleum product at room temperature. The hot bitumen line discussed in this paper was uniquely designed to transport product at temperatures typically ranging from 140 to 149 degrees Celsius (284-300°F), preventing the application of an anti-corrosion external coating, which is ineffective at such temperatures. In this case, polyurethane foam insulation was used and an integrated moisture detection surveillance system for external moisture infiltration was installed for the long-term integrity of the bitumen line.


Inline inspections are used to identify external corrosion where insulation degradation may occur. Due to the unique properties of the pipeline in the study, the conventional method to assess the risk of external corrosion required further consideration. This paper will provide an example of how the conventional method of assessing external corrosion risk was modified to better suit a buried insulated pipeline through a series of additional environmental data inputs, validated with ILI results, to improve the predictive capability of the inferential external corrosion threat model.

Bitumen is a solid or semi-solid high-viscosity liquid petroleum product at room temperature. The hot bitumen line discussed in this paper was uniquely designed to transport product at temperatures typically ranging from 140 to 149 degrees Celsius (284-300°F), preventing the application of an anti-corrosion external coating, which is ineffective at such temperatures. In this case, polyurethane foam insulation was used and an integrated moisture detection surveillance system for external moisture infiltration was installed for the long-term integrity of the bitumen line.


Inline inspections are used to identify external corrosion where insulation degradation may occur. Due to the unique properties of the pipeline in the study, the conventional method to assess the risk of external corrosion required further consideration. This paper will provide an example of how the conventional method of assessing external corrosion risk was modified to better suit a buried insulated pipeline through a series of additional environmental data inputs, validated with ILI results, to improve the predictive capability of the inferential external corrosion threat model.

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