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Methane Pipeline Pigging Risk Management 421 Case Study
Methane Pipeline Pigging Risk Management 421 Case Study
Team Leader:
Andrew Simms 1485 7397
Team Members:
Jonathan Clare 1552 3071
Ross Gustafsson 1551 3179
Alex Neamtu 1554 7437
Nicholas Rodan 1484 1073
Nabil Tiba 1550 9547
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Table of Contents
Introduction................................................................................................................................................................2
Background.................................................................................................................................................................2
Objective and Scope of Work.....................................................................................................................................2
Methodology...............................................................................................................................................................3
Process Description....................................................................................................................................................3
Process Diagram – Overall Sketch.............................................................................................................................5
Process Diagram – Node 1.........................................................................................................................................6
Process Diagram – Node 2.........................................................................................................................................7
Process Diagram – Node 3.........................................................................................................................................8
Process Diagram – Node 4.........................................................................................................................................9
Process Diagram – Node 5.......................................................................................................................................10
Risk Assessment – HAZID......................................................................................................................................11
Risk Assessment – HAZOP Overall........................................................................................................................15
Risk Assessment – HAZOP Node 1.........................................................................................................................17
Risk Assessment – HAZOP Node 2.........................................................................................................................20
Risk Assessment – HAZOP Node 3.........................................................................................................................22
Risk Assessment – HAZOP Node 4.........................................................................................................................24
Risk Assessment – HAZOP Node 5.........................................................................................................................26
Recommendations....................................................................................................................................................28
Conclusions..............................................................................................................................................................31
References................................................................................................................................................................32
Appendix A: Risk Likelihood/Consequence Tables................................................................................................33
Appendix B: HAZOP Guidewords...........................................................................................................................36
Appendix C: Ranking Matrix...................................................................................................................................37
Appendix D: P+ID Symbols.....................................................................................................................................38
Appendix E: Meeting Minutes.................................................................................................................................39
Meeting 1 Minutes....................................................................................................................................................39
Meeting 2 Minutes....................................................................................................................................................40
Meeting 3 Minutes....................................................................................................................................................41
Meeting 4 Minutes....................................................................................................................................................42
Meeting 5 Minutes....................................................................................................................................................43
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Introduction
In the oil and gas industry, there are many maintenance issues which arise from the processing and
handling of process fluids and products. One of these issues is the maintenance and cleaning of the inside
of pipelines between key extraction, processing and distribution centres. These jobs are completed
through the use of the pigging process. This risk management report details the hazards and risks
associated with the assembly, operation and maintenance of pigging equipment.
Background
Pigging is used in the oil and gas industry as an integral part of the maintenance regime for many
companies throughout the world. Pigs are used for many reasons which may include:
The aim of this study is to firstly identify all of the hazards that would be present or could potentially
exist during the assembly, operation and maintenance of the pigging equipment for a methane gas
pipeline. Following this, this study aims to suggest ways to minimize or eliminate the impact of these
hazards, to promote a safe working environment and limit negative social and environmental
consequences.
To accomplish this, the study will do the following items:
1. Analyse and interpret a sample process and instrumentation diagram (P+ID)
2. Analyse and interpret several user manuals outlining the assembly, operation and maintenance of
pigging equipment
3. Separate the sample P+ID into individual nodes for a safety analysis including nodal HAZID and
HAZOP risk assessments on the existing safeguards and equipment.
4. Provide recommendations that could potentially improve process safety, targeting inadequate
safeguards or procedures.
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Methodology
This risk management report uses current industry tables and figures (detailed in the appendix) for a
complete and through risk management study of pig launchers and receivers to be completed. From this
risk assessment HAZID and HAZOP tables could be created, which could then be used in a real world
situation.
Process Description
The pigging process has a diverse number of applications and hence there are several types of pig
launcher/receiver configurations, resulting in there being different operating procedures. For the purpose
of this report, a general process description will be provided.
The following general pig launching and receiving procedure is adapted from one written by Girard
Industries and can be found on the Tremco pipeline website.
Pig Launching
1. Make sure the trap isolation valve and the valve on the kicker line are closed.
2. Open the vent on the launching barrel and allow the launching barrel to vent to atmospheric
pressure.
3. When the launching barrel is completely drained (Barrel at atmospheric pressure), with the vent
and drain valves still opened, open the trap closure door.
4. Install the pig into the launching barrel.
5. Clean the trap closure seal and other sealing surfaces, applying a lubricant if necessary. Close and
secure the trap closure door.
6. Close the drain valve. Slowly fill the trap by gradually opening the valve on the kicker line and
venting through the the vent valve.
7. When filling is complete, close the vent valve to allow pressure to equalise across the trap
isolation valve.
8. Open the isolation valve – the pig is now ready for launching.
9. Partially close the main line valve. This will increase flow through the kicker line and hence
increase flow behind the pig. Continue to close the main line valve until the pig leaves the trap
into the main line as indicated by the pig signaller.
10. After the pig leaves the trap into the main line, fully open the main line valve. Close the trap
isolation valve and the valve on the kicker line.
Pig Receiving
1. Ensure that the receiver is pressurised.
2. Fully open the valve on the bypass line.
3. Fully open the trap isolation valve and partially close the main line valve.
4. Monitor the pig signal indicating pig arrival.
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11.
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n3 xt
I-1 I-4
P-9
n5 downstream
P-27 HV-2 P-28 SDV-1 P-29
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P-20 To flare
RAV-2
P-18 P-19
V-46
P-17
P-22
vent
n2 Check valve 2
pg xt pt
Sb-2
V-5 n1 V-6 P-30 P-31 P-32 V-8
P-12 P-16 P-14
P-15 P-21
n5:launcher barrel n4
V-11
P-23 P-24
V-9 V-10
Sb-3 Sb-4
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Table 1: HAZID
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6 Ingress of air Explosion Risk Pipe at greater Composition sensor to Same As (1)
pressure than monitor the level of
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Recommendations
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1 1
S-3 P-8 To flare
PSV-1
PAH PDIC
1
P-6 P-7
P-3 pdt P-4 1 V-4
AIT
P-5
S-4
P-1 P-37
P-10 V-11
P-2
V-1 P-20 To flare
PSV-2
pt
4
P-35
P-23 P-24
V-9 V-10
Sb-3 Sb-4
P-26
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Conclusions
This report focusses on a typical pig launcher/receiver system in a gas pipeline, looking at it from all
angles to complete a safety analysis. Firstly, we analysed and interpreted the P+ID instrumentation
diagram to get a better understanding of the intricate details of the pig launching/receiving system. From
here, we read numerous operator manuals to learn how it was assembled, operated and maintained
picking out hazards along the way. Combining both of these, we identified the specific hazards hidden
within the system. We found this was much easier when we split the P+ID into separate nodes allowing
us to be more specific on each segment of pipeline tailoring specific recommendations to each valve/
pipeline/ sensor. This taught us how to pay attention to detail and think outside of the box for any possible
situation that may occur within the system. HAZID and HAZOP risk assessments were used as tools in
this process aiding us in our analysis. Lastly, Recommendations were made based on the hazards
identified in the HAZID and HAZOP analysis teaching us how to solve problems with realistic
constraints.
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References
Arjomandnia, Pooya. 2014. “Lecture 3: Risk – Classification, Factors and Estimation”. PDF Lecture
notes. https://lms.curtin.edu.au/bbcswebdav/pid-2923378-dt-content-rid-
12480625_1/courses/302269-CU-061-01-Sxx-x1/ChE%20421_Lect3%20PA.pdf
Arjomandnia, Pooya. 2014. “Lecture 4: Risk – The Safety Concept”. PDF Lecture notes.
https://lms.curtin.edu.au/bbcswebdav/pid-2923383-dt-content-rid-12539903_1/courses/302269-
CU-061-01-Sxx-x1/ChE%20421_Lect4%20PA.pdf
Jamison Products. Accessed 28th April 2014. “Pig Launchers/Receivers”.
http://www.jamisonproducts.com/pipeline-products/pig-launchers-receivers.html
Maynard, Nicoleta. 2012. “Lecture 5: Hazard Identification”. PDF Lecture notes.
https://lms.curtin.edu.au/bbcswebdav/pid-2924535-dt-content-rid-12845333_1/courses/302269-
CU-061-01-Sxx-x1/ChE%20421_Lect5.pdf
Girard Industries. 2014. “Launching and Retreiving Procedures”.
http://www.tremcopipeline.com.au/pdf/girard/launching_retrieving_procedures1.pdf
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Flanges
Check valve
Spectacle blind
Shut down valve
sdv
vent
vent
pg Pressure gauge
pt Pressure transmitter
Hand operated control valve
HV
ni Outlet to node i
Gate valve
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Meeting 1 Minutes
1. Andrew Simms Student ID: 14857397 4. Alex Neamtu Student ID: 15547437
2. Jonathan Clare Student ID: 15523071 5. Nabil Tiba Student ID: 15509547
3. Ross Gustafsson Student ID: 15513179 6. Nicholas Rodan Student ID: 14841073
1. Attendees:
1. Andrew Simms Student ID: 14857397 4. Alex Neamtu Student ID: 15547437
2. Jonathan Clare Student ID: 15523071 5. Nabil Tiba Student ID: 15509547
3. Ross Gustafsson Student ID: 15513179 6. Nicholas Rodan Student ID: 14841073
3. Items discussed:
Items / Actions By Due date
1 Introduction to each other Everyone
2 Finding an operational manual Everyone 11/04/2014
3 Completion of a personal HAZID – Allow for differing Everyone 14/04/2014
views to be expressed
4 Report overview Everyone 14/04/2014
5 PID Drawings Everyone
4. Follow ups: (Next meeting actions and if anything remains from item 3)
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Meeting 2 Minutes
1. Andrew Simms Student ID: 14857397 4. Alex Neamtu Student ID: 15547437
2. Jonathan Clare Student ID: 15523071 5. Nabil Tiba Student ID: 15509547
3. Ross Gustafsson Student ID: 15513179 6. Nicholas Rodan Student ID: 14841073
1. Attendees:
1. Andrew Simms Student ID: 14857397 4. Alex Neamtu Student ID: 15547437
2. Jonathan Clare Student ID: 15523071 5. Nabil Tiba Student ID: 15509547
3. Ross Gustafsson Student ID: 15513179 6. Nicholas Rodan Student ID: 14841073
3. Items discussed:
Items / Actions By Due date
1 HAZID Everyone 14/04/2014
2 Report overview Andrew 14/04/2014
3 PID Drawings Nick 14/04/2014
4 Selecting nodes for HAZOP Everyone 18/04/2014
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4. Follow ups: (Next meeting actions and if anything remains from item 3)
Items / Actions By Due date
1 HAZID Compilation – send out once complete Andrew 18/04/2014
2 Node PID Drawings – send out once complete Nick 18/04/2014
3 Look into HAZOP, start having ideas for Friday Everyone 18/04/2014
Meeting 3 Minutes
1. Andrew Simms Student ID: 14857397 4. Alex Neamtu Student ID: 15547437
2. Jonathan Clare Student ID: 15523071 5. Nabil Tiba Student ID: 15509547
3. Ross Gustafsson Student ID: 15513179 6. Nicholas Rodan Student ID: 14841073
1. Attendees:
1. Andrew Simms Student ID: 14857397 4. Alex Neamtu Student ID: 15547437
2. Jonathan Clare Student ID: 15523071 5. Nabil Tiba Student ID: 15509547
3. Ross Gustafsson Student ID: 15513179 6. Nicholas Rodan Student ID: 14841073
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4. Follow ups: (Next meeting actions and if anything remains from item 3)
Items / Actions By Due date
1 HAZOP – Complete at next meeting Everyone 25/04/2014
2 Recommendations – based on HAZID Ross 25/04/2014
3 Type and edit first part of HAZOP Andrew 25/04/2014
Meeting 4 Minutes
1. Andrew Simms Student ID: 14857397 4. Alex Neamtu Student ID: 15547437
2. Jonathan Clare Student ID: 15523071 5. Nabil Tiba Student ID: 15509547
3. Ross Gustafsson Student ID: 15513179 6. Nicholas Rodan Student ID: 14841073
1. Attendees:
1. Andrew Simms Student ID: 14857397 4. Alex Neamtu Student ID: 15547437
2. Jonathan Clare Student ID: 15523071 5. Nabil Tiba Student ID: 15509547
3. Ross Gustafsson Student ID: 15513179 6. Nicholas Rodan Student ID: 14841073
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3. Items discussed:
Items / Actions By Due date
1 HAZOP – Complete Everyone 25/04/2014
2 Review recommendations Everyone 25/04/2014
3 Conclusion Ross ASAP
4 Pig operating procedure Alex, Nabil ASAP
5 Completing Draft Report Andrew 02/05/2014
6 PID with recommendations Nicholas 02/05/2014
4. Follow ups: (Next meeting actions and if anything remains from item 3)
Items / Actions By Due date
1 Editing report Jonathan 05/05/2014
2 Any other reviews Everyone 02/05/2014
3 Ask lecturer/tutor for suggestions, include draft report Jonathan 02/05/2014
4 Ask about marking guides for report and presentation Jonathan 02/05/2014
Meeting 5 Minutes
1. Andrew Simms Student ID: 14857397 4. Alex Neamtu Student ID: 15547437
2. Jonathan Clare Student ID: 15523071 5. Nabil Tiba Student ID: 15509547
3. Ross Gustafsson Student ID: 15513179 6. Nicholas Rodan Student ID: 14841073
1. Attendees:
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3. Items discussed:
Items / Actions By Due date
1 Editing report Jonathan 05/05/2014
2 Review of draft report before email for suggestions Everyone 02/05/2014
3 Ask lecturer/tutor for suggestions, include draft report Jonathan 02/05/2014
4 Ask about marking guides for report and presentation Jonathan 02/05/2014
5 Any other things to email to lecturers Everyone 02/05/2014
4. Follow ups: (Next meeting actions and if anything remains from item 3)
Items / Actions By Due date
1 Report submission Andrew 05/05/2014
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