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1 - R Uprety PDF
1 - R Uprety PDF
Presenting
Author Photo
Present Affiliation
Academic Qualification
Area of Specialization
Achievements / Awards
Authors
FOR
PIPE TRIANGLE
PIPE
PLEASURE
PAIN
3
PIGGABLE PIPELINE
: 40,000 KM
2011-12
80
2012-13
70
2013-14
2014-15 (till date)
60
50
40
30
20
2014-15 (till date)
10
2013-14
0
2012-13
Ref &
GPP
PL
MO
2011-12
E& P
Total
2012-13
Number of Fatalities
40
35
2013-14
30
25
20
15
10
2014-15 (till
2013-14
2012-13
PL
2011-12
MO
E& P
PIPELINE INTEGRITY
EXAMPLE :
TWO CASES OF SEAM FAILURE IN A
CRUDE PL WITHIN 18 YEARS OF SERVICE
(SURGE ANALYSIS, HYDRAULICS, LDS,
VALVES, WT)
EXAMPLE :
FLASH FIRE DURING
GRINDING OPERN AT
NIGHT IN A TANK FARM
(MISSING BOUNDARY
PILLARS/TP/TLP,
SOP, ESD, CP
MONITORING,
COATING SUEVEY)
EXAMPLE :
FIRE & EXPLOSION IN A
NATURAL GAS PIPELINE
LEADING TO MULTIPLE
FATALTIES (PIGGING,
COATING)
OVERVIEW OF OISD-STD-233
a) INSPECTION
PROCEDURE
FOR
CROSS-COUNTRY
PIPELINES :
i. INTERNAL INSPECTION
ii. PRESSURE TESTING SUCH AS HYDROTESTING
iii. COMBINATION OF i) & ii)
b) INSPECTION PROCEDURE FOR NON-PIGGABLE PIPELINES
:
i. EXTERNAL CORROSION DIRECT ASSESSMENT
(ECDA)
ii. INTERNAL CORROSION DIRECT ASSESSMENT
(ICDA)
iii.STRESS CORROSION CRACKING DIRECT ASSESSMENT
(SCCDA)
OVERVIEW OF OISD-STD-233
c) INTERNAL CORROSION :
a) EFFECTIVENESS
OF
CORROSION
MITIGATION
MEASURES SHOULD BE CHECKED ONCE IN SIX
MONTHS BY ANALYSING CORROSION COUPON.
b) ER PROBES/ ECN PROBES/ LPR (LINEAR POLARISATION
TECHNIQUE) PROBES SHOULD BE INSTALLED.
c) IF RATE OF INTERNAL CORROSION IS > 1 mpy,
CORROSION INHIBITOR SHALL BE USED.
d) WHENEVER REPLACEMENT OF PIPELINE IS CARRIED
OUT, INTERNAL VISUAL INSPECTION SHALL BE
CARRIED OUT.
OVERVIEW OF OISD-STD-233
d)
OVERVIEW OF OISD-STD-233
e)
OVERVIEW OF OISD-STD-233
h) INSPECTION
PROCEDURE
FOR
PIPELINE
HAVING
EXTERNAL COATING BUT WITH CATHODIC PROTECTION
SYSTEM (IMPRESSED CURRENT BASED OR SACRIFICIAL
CURRENT BASED).
i) HYDROTESTING
(1) CASE-I :
THE LINE WAS COMMISSIONED IN 1999 AND IPS WAS
CARRIED OUT IN THE YEAR 2013. THE IPS REPORT WAS
NOT MADE AVAILABLE AS IT WAS INFORMED THAT THE
SAME IS UNDER REVIEW BY TPI. PIG RESIDUE ANALYSIS
SHOWED IRON CONTENT AS HIGH AS 49%. THERE WAS
NO ACTION TAKEN BY THE OPERATOR.
(2) CASE-II :
(4) CASE-IV :
Pipeline Operator
Pipe Size
Remarks
(1)
Reliance (RGTIL)
Natural Gas
Line is intact
(2)
GAIL India
Natural Gas
(3)
Natural Gas
(4)
Reliance Industries
(RIL)(NG)
Ch. 29.150 KM
Pipeline Operator
Pipe Size
Remarks
(5)
Gujarat State Petronet Ltd., (GSPL 24 OD x 0.688 (17.5 mm) WT, API About 100 m pipeline is
exposed.
NG)
5L X 60 Gr.
Ch. 17.000 KM
(6)
ONGC (Ch. 14.200 KM) CRUDE OIL 8.625 OD x 0.375 (9.53 mm) WT, Leakage in line
API 5L X 46 Gr.
(7)
(8)
ONGC (OPAL)
Naptha
(1)
(2)
THE RIVER BANK (SOUTH SIDE) WAS NOT REINFORCED, WHICH RESULTED IN HEAVY SOIL
EROSION.
(3)
(4)
IRRIGATION DEPT. DID NOT PROVIDE ANY PRIOR WARNING BEFORE RELEASE OF
ABRUPT WATER DISCHARGE IN SUCH A LARGE QUANTITY.
(5)
S.No
(6)
(7)
Date/Time of incident
No. of fatalities
22
Operating pressure
42 to 45 Kg/cm2
Design pressure
72 Kg/cm2
RIVER
BRIDGE
SV-1
SV-2
SV-5
SV-4/ I P
HIGHWAY X-ING
SV-3
(PIGGING STATION)
(CANAL)
POWER PLANT
RIVER X-ING
SV-6
SV-7
SV-8
12
35
36
RECOMMENDATIONS
PROPER CLEANING PIGGING TO BE CARRIED OUT REGULARLY FOLLOWED BY
PIG RESIDUE ANALYSIS.
INSTRUMENTED PIG SURVEY TO BE CARRIED OUT REGULARLY AND THE
ANOMALY RECTIFICATION TO BE CARRIED OUT AS PER THE
RECOMMENDATIONS .
PROPER PROCEDURE TO BE MADE FOR REPAIR OF PIPELINE.
ANY CHANGE FROM THE INITIAL CHANGE SHOULD BE ROUTED THROUGH A
MANAGEMENT OF CHANGE PROCEDURE AFTER PROPER TECHNICAL ANALYSIS.
CORROSION INHIBITOR TO BE USED IN THE LINE AS PER REQUIREMENT.
IN ADDITION TO OFC COMMUNICATION THERE SHOULD ALSO BE ANOTHER
37
STAND BY MODE OF COMMUNICATION.
(8)
(9) INCIDENT
ANALYSIS
INVESTIGATION
&
&
(11) OPERATIONS
INTEGRITY
ASSESSMENT AND IMPROVEMENT
2. TECHNICAL
INTEGRITY
DESIGN INTEGRITY
SAFETY FACTORS IN DESIGN IS ACHIEVED BY :
APPLICATION OF THE APPROPRIATE CODES AND SYSTEM HARDWARE COMPONENTS (ASME STANDARD
& OISD STANDARDS).
SELECTION OF PIPE MATERIAL AND ITS WALL THICKNESS, MATERIAL OF CONSTRUCTION FOR VALVES
AND OTHER PIPE FITTINGS.
CONSIDERING THE LOADS & STRESSES IMPOSED ON THE PIPELINE BY PHYSICAL PRESSURES AND
FORCES, SUCH AS INTERNAL PRESSURE, STATIC LOADINGS AND WEIGHT EFFECTS.
DESIGN INTEGRITY
SAFETY FACTORS IN DESIGN ACHIEVED BY:
(A) PIPE THICKNESS :
THE NOMINAL WALL THICKNESS T FOR THE STEEL PIPE, SHALL BE CALCULATED IN ACCORDANCE WITH
ASME B 31.4 - CONSIDERS LONGITUDINAL JOINT FACTOR FOR TYPE OF PIPELINE MANUFACTURING,
FACTORS FOR RAIL, ROADS, RIVER CROSSINGS, PIPES ON BRIDGES, LOCATION CLASS ETC.
CORROSION ALLOWANCE ADDED TO THE CALCULATED THICKNESS.
(B) ALL PIPING JOINTS ARE WELDED
(C)THE HAZOP AND RISK ANALYSIS
(D) LOCATING SECTIONALIZING VALVES AT IDENTIFIED LOCATIONS FOR ISOLATIONS EASILY APPROACHABLE.
SECTIONALIZING VALVES SHALL BE REMOTE OPERATED.
DESIGN INTEGRITY
SAFETY FACTORS IN DESIGN ACHIEVED BY:
(E) SURGE ANALYSIS TO PREVENT OVER-PRESSURIZATION ON CLOSURE.
(F) FEATURE OF DE-PRESSURIZATION, SHUTDOWN & ISOLATION LOGIC AT PUMP STATIONS.
OVERSIGHT OF
(H) LEAK DETECTION SYSTEM WITH PROVISION FOR IDENTIFICATION / LOCATION OF LEAK AND ISOLATION OF
AFFECTED SECTION.
(I) EXTERNAL COATING & CATHODIC PROTECTION FOR EXTERNAL CORROSION CONTROL.
(J) INHIBITOR INJECTION FOR INTERNAL CORROSION CONTROL CASE.
TECHNICAL INTEGRITY
INTERNAL HEALTH MONITORING
PIPELINE PIGGING - PIGS ARE INSERTED INTO THE PIPELINE WHILE IT IS
OPERATIONAL AND ARE CARRIED ALONG BY THE FLUID BEING PUMPED.
CLEANING PIGS
TECHNICAL INTEGRITY
INTERNAL HEALTH MONITORING
THEIR BASIC PURPOSE OF PIGGING IS THREEFOLD:
(1) CLEANING PIG - PROVIDE A WAY TO CLEAN DEBRIS AND SCALE FROM
THE INSIDE OF THE PIPE,
(2) INTELLIGENT PIG - INSPECT OR MONITOR THE CONDITION OF THE
PIPE,
(3) OR ACT AS A PLUG OR SEAL TO SEPARATE PRODUCTS IN MULTIPRODUCT COMMERCIAL PIPELINES OR TO ISOLATE A SEGMENT FOR
REPAIR WITHOUT DEPRESSURIZING THE REMAINDER OF THE
PIPELINE.
(4) PIG RESIDUE ANALYSIS TO BE CARRIED OUT REGULARLY TO MONITOR
THE TREND OF INTERNAL CORROSION RATE.
TECHNICAL INTEGRITY
INTERNAL HEALTH MONITORING :
INTELLIGENT PIG
PIGS THAT MONITOR THE CONDITION OF THE PIPE ARE IN-LINE INSPECTION TOOLS.
MONITORING PIGS, ALSO CALLED INSTRUMENT PIGS OR SMART PIGS.
TECHNICAL INTEGRITY
EXTERNAL HEALTH
PROTECTION:
MONITORING
PIPELINE
COATING
&
CATHODIC
PROTECTIVE COATING : TO PREVENT DIRECT CONTACT BETWEEN THE PIPE & THE
ENVIRONMENT & TO PREVENT ITS PARTICIPATION IN ELECTROCHEMICAL REACTIONS
PROPERTIES REQUIRED
(A) ELECTRICAL INSULATING PROPERTIES,
RESISTANCE TO MOISTURE
(B) MECHANICAL- ADHESION, ABRASION RESISTANCE,
FLEXIBILITY, IMPACT RESISTANCE
(C) STABILITY AGAINST TEMP CHANGE
3 LAYER POLYETHYLENE / POLYPROPYLENE OR FUSION BONDED EPOXY COATING IS
PROVIDED
TECHNICAL INTEGRITY
FOLLOWING COATING SURVEYS ARE DONE ON UNDERGROUND PIPELINES ONE MONTH
AFTER THE COMMISSIONING OF IMPRESSED CURRENT SYSTEM:
a. CLOSE INTERVAL COMPUTERIZED [ON & OFF] POTENTIAL LOGGING (CIPL) @
EVERY 1M OF PIPELINE ROW.
b. PEARSON SURVEY ALONG PIPELINE ROW.
c.
OPERATIONAL INTEGRITY
ALL THE PIPELINE OPERATORS MUST HAVE A CORPORATE POLICY TO IMPROVE PIPELINE AND
FACILITY INTEGRITY TO PROTECT THE SAFETY OF THE PUBLIC, THE ENVIRONMENT AND ITS
EMPLOYEES.INTEGRITY MANAGEMENT GOALS SHALL INCLUDE :
PROMOTE THE LONG TERM INTEGRITY OF THE PIPELINE SYSTEM
CONDUCT BUSINESS IN A SAFE AND ENVIRONMENTALLY RESPONSIBLE MANNER
COMPLY WITH APPLICABLE REGULATIONS AND STANDARDS
DEMONSTRATE CONTINUOUS IMPROVEMENT THROUGH THE MONITORING
PERFORMANCE MEASURES AND THROUGH ANNUAL RISK ASSESSMENTS
OF
OPERATIONAL INTEGRITY
PRESSURE SET POINTS SHOULD BE APPROPRIATELY DEFINED AND BUILT IN THE
OPERATION PHILOSOPHY.
ESD LOGIC (CAUSE AND EFFECT DIAGRAM) SHOULD BE PROPERLY DEFINED.
CLEANING PIGGING HAS TO BE CARRIED OUT AS PER OISD GUIDELINES AND PIGRESIDUE ANALYSIS SHOULD BE CARRIED OUT REGULARLY. THE RESULTS OF THE
PIG-RESIDUE ANALYSIS SHOULD BE ANALYSED WITH THE HELP OF STATISTICAL
TECHNIQUES TO WORK OUT THE TREND OF INTERNAL CORROSION RATE.
NO SAFETY SYSTEMS SHOULD BE BY-PASSED.
OPERATIONAL INTEGRITY
ROU INSPECTION
INSPECTIONS CAN INVOLVE INDIVIDUALS WALKING THE ROU AND ALSO AERIAL
SURVEILLANCE.
A) NO DWELLING OR PERMANENT STRUCTURE IN ANY FORM SHALL BE PERMITTED
WITHIN THE RIGHT OF USER
B) CONTROLLING VEGETATION GROWTH IN THE FORM OF TREES,
C) PREVENTING ENCROACHMENT FROM ABOVE AND BELOW GROUND STRUCTURES,
D) MAINTAINING VISIBILITY OF PIPELINE MARKERS
PATROLLING ( GROUND / AERIAL ) OF ROW / ROU
TO BE CARRIED OUT REGULARLY (URBAN AREAS AND NON-URBAN AREAS)
OBSERVE
SURFACE
CONDITIONS,
LEAKAGE,
CONSTRUCTION
ACTIVITY,
ENCROACHMENTS, WASHOUTS AND ANY OTHER FACTORS AFFECTING THE SAFETY AND
OPERATION OF THE PIPELINE.
OPERATIONAL INTEGRITY
MANAGEMENT OF CHANGE
MONITORING & REVIEW OF
OPERATING BARRIERS.
CLASS LOCATION
A CLASS LOCATION CAN CHANGE AS POPULATION GROWS AND MORE PEOPLE LIVE OR
WORK NEAR THE PIPELINE.
CONCLUSION
PIPES LAID UNDERGROUND CANNOT SPEAK, IT IS OUR DUTY TO CARE FOR THE PIPE
& GIVE EITHER PAIN OR PLEASURE. NEED OF THE HOUR TO IS TO HAVE A
SENSITIVITY TOWARDS PIPE.
PIPELINE INTEGRITY MUST CONSIDER ALL ASPECTS OF DESIGN, CONSTRUCTION &
OPERATION PHASES.
PIPELINE INTEGRITY REQUIRES ADOPTING A FAILURES ARE PREVENTABLE
MINDSET.
ADOPTION OF CORROSION MANAGEMENT BEST PRACTICES CAN IMPROVE
OVERALL PERFORMANCE OF PIPELINE OPERATIONS.