Comprehensive review on fitness-for-service assessment of corroded pipelines - focus on model validation and industry applications

Corrosion poses a significant threat to global pipeline infrastructure, compromising burst capacity with severe safety, environmental, and economic impacts. These pipelines transport gases and crude oil, primarily composed of hydrocarbons, which dominate global energy consumption, accounting for about 85% of the supply. The transportation of these hydrocarbons relies heavily on extensive pipeline networks that are vulnerable to corrosion. Various fitness-for-service (FFS) models have been developed to evaluate corroded pipelines; however, their accuracy varies significantly with defect geometry, material grade, and operating conditions. This review provides a comprehensive overview of over 40 assessment codes, models, and techniques for estimating the pressure-carrying capacity and serviceability of corroded pipelines. Comparative analyses highlight the strengths, limitations, and applicability of these models across diverse scenarios, which are supported by experimental validation and field data. Practical insights from model validation and real-world applications are emphasized, focusing on the joint API_ASME FFS standard. A detailed examination of the underlying methodologies, inherent limitations, and practical relevance to industry applications is presented. Drawing on insights from over 50 years of research, this review offers evidence-based guidance for the oil and gas, petrochemical, and nuclear industries. It identifies critical knowledge gaps and prospective research directions aimed at enhancing the reliability of corrosion assessment practices.