Dent integrity assessments typically rely on high-resolution dent profile data to estimate strain levels and assess fatigue life. However, when such data is unavailable, operators must adopt alternative strategies to evaluate dent severity and prioritize resources effectively. This study focuses on a 48-inch liquid sour service pipeline, where multiple dents were detected during an ILI run using a caliper tool, but no detailed dent profiles were available.

To overcome this limitation, historical ILI data—including MFL, UTCD, and UTML—was integrated to assess dent interactions with metal loss and crack-like features. Given the sour service environment, a fatigue life evaluation was essential due to the increased risk of crack initiation and propagation. Additionally, UTCD data was explored as a screening tool to confirm the absence of cracks, reducing unnecessary excavations.

Without direct dent profile data, stress concentration factors (SCFs) derived from FEA were used to estimate fatigue life. A parametric FEA-based sensitivity study was conducted, considering wall thickness variations, dent curvature, and pipe OD to understand their impact on dent strain and fatigue performance. These results helped prioritize remediation efforts, ensuring that the most critical dents were identified for further action while avoiding excessive conservatism in repair decisions.

This case study highlights practical strategies for dent integrity assessments when profile data is unavailable. By leveraging historical ILI datasets, applying targeted FEA, and incorporating crack screening techniques, operators can make informed decisions, minimize unnecessary interventions, and enhance pipeline integrity management despite data limitations.