Professional Documents
Culture Documents
III Sinha Iocl
III Sinha Iocl
Pipelines division: an overview Pipeline health monitoring Pipeline protections measures. Pipeline coating. Cathodic protection Pipeline surveys Pipeline repair Station/Mainline facilities Maintenance philosophy. Case studies
2000 0
1996
2000
2004
2009
IOCL PIPELINES
IOCL pipelines, those commissioned in 60s have already served for more than 40 years and still being operated at Max. allowable operated pressure & achieving the yearly throughput target. Implementation of effective corrosion prevention programme has helped in achieving the safe, economical & reliable operations of pipelines.
P/L FAILURES
40 30 20 10 0
Mech/Material Corrosion failures failures Third party/Pilferages failures Others
Identification of possible causes of Pipeline corrosion. Major Causes of Pipeline External Corrosion :Poor/defective Coatings. Inadequate Cathodic Protection (CP). Coating defects combination with inadequate CP. Interference due to external agencies. Stress & Bacterial corrosion. Major Causes of Internal Corrosion :Corrosive nature of fluid transported through pipeline. Erosion Corrosion. Localized Chemical attack/bacterial corrosion.
Dealing with challenges in achieving effective corrosion mitigation measures Instituting an effective corrosion programme and experience sharing mitigation
Thrust Areas
Pipeline Coatings
Plant Coating Coal Tar Enamel Coating 3 Layer Polyethylene Coating Fusion Bonded Epoxy Dual Fusion Bonded Epoxy Field Coating/Refurbishment Coating Coal Tar Enamel Coating Hot Applied Coal Tar Enamel Tape Cold Applied Tape Polyurethanes coating Epoxy Coatings
CP is a viable tool for Corrosion prevention. Corrosion is an electrochemical phenomenon, therefore effectively mitigated by altering the electrochemical condition. CP achieved by reversing natural corrosion current with the supply of current from external source. The external current supply in CP system is generated either by sacrificial anode or impressed current system.
PS P V O L T (-)
2.05 1.95 1.85 1.75 1.65 1.55 1.45 1.35 1.25 1.15 1.05 0.95 0.85 0.75 0.65 0.55
0 .2 5 0 2 .0 1 5 4 .9 2 6 1 1.33 3 4 8 7 7 0 1 0 8 0 0 0 4 5.80 4 7.76 5 0.39 5 2.64 5 4.39 5 7.44 5 9.01 6 5.15 0 0 0 6 0 0 6 6 1 1.63 1 1.81 1 6.63 1 9.63 2 6.25 2 9.49 3 2.50 3 3.11 3 6.10 3 7.90 4 3.80
PSP profile
CHAINAGE (KM)
II.
III.
To achieve complete line protection of these pipelines & avoid soil corrosion/leak, large scale refurbishment of existing coating is being carried out.
LENGTH
(km)
TYPE OF COATING Over the Ditch CTE Over the Ditch CTE CTE (Plant Coated) 3LPE 3LPE FBE FBE+CTE
YEARS IN SERVICE
(year)
12 24 18 22 10 10 10
42 30 10 13 13 9 6
Mostly CTE (over the ditch) coated High current density i.e poor coating. Conventional CP system. Inconsistent SEB Power availability/Theft of Solar panels. Highly corrosive soil. Low frequency ERW mainline pipes.
DCVG for pin pointing the coating defects. APPROACH Combination of CAT & DCVG for coating assessment & finalizing locations for refurbishment.
Coating Surveys
CURRENT ATTENUATION TECHNIQUE (CAT) SURVEY
CAT SURVEY
BASED ON DB LOSS OBSERVED FOR PIPELINE, COATING DEFECTS CAN BE CLASSIFIED AS UNDER : SL. NO. 1.0 2.0 3.0 4.0 DB/KM LOSS < 10 DB/KM 10 25 DB/KM 25 70 DB/KM ABOVE 70 DB/KM CLASSIFICATION GOOD COATING FAIR COATING BAD COATING MASSIVE DEFECT
Experience of IOCL
CAT is excellent in prioritizing the coating rehabilitation of old pipelines (poor coating). DCVG is very effective for detection of all the coating defects of newly coated pipelines or well coated pipelines. Combination of CAT, DCVG & CIPS is very effective & beneficial i.e. identifying coating defect, line protection, interference study etc.
Experience of IOCL
Pipeline metal loss features identified by IPS were plotted with the results of CAT/DCVG/CIPS & based on result, priority made for coating refurbishment & job executed.
Other parameters such as current density, soil resistivity, age & type coating, leak/corrosion history etc were also plotted along with CAT/DCVG/IPS data.
Results found to be very encouraging, Defective coatings were identified with high degree of accuracy & repaired.
Observations during field application: Specialized procedure for application and requires trained applicators. Close monitoring required to ensure requisite uniform thickness. Proper PPE required during application / inspection due to toxic fumes. Transportation of sophisticated equipment to site. Surface preparation requirement is high. Coating is less surface imperfection tolerant. Insect and dust control till curing is achieved.
EPOXY COATING
REQUIREMENT OF INTELLIGENT PIG SURVEY External and internal corrosion subsequent growth monitoring. detection and
Inspection of pipeline locations which are not approachable like river crossing, submerged crossings, bridge crossings etc. To identify corroded section, require replacement or repair. Setting operational parameters health condition. based on pipeline pipeline by
CLEANING PIGS: PIG is launched to clean the pipeline from muck/debris, which may be present in the pipeline. GAUGING PIG: Gauging PIG equipped with Al plates is launched to check the internal geometry of the pipeline. Results are analyzed based on physical condition of Al. plates. If deformations is large (more than 10%), rectification/re-run may be planned.
before run
after run
SEQUENCE OF INTELLIGENT PIG SURVEY MARKER MAGNETS: Before the caliper PIG run, marker magnets are installed all along the pipelines at every 1-2 kms of interval. CALIPER PIG: to determine bends and their bending direction Electronic Geometric Pig is launched. The EGP results will clearly show if any restrictions are in the pipeline that might prevent safe passage of the ILI tool. The geometry run will also give detailed information on geometrical features, such as bends, ovalities. Dents etc. Rectification of deformation if any which may restrict passage of intelligent pig
SEQUENCE OF INTELLIGENT PIG SURVEY PULL THROUGH TEST : Before the launch of ILI tool in the pipeline the tool undergoes pull through test, wherein the tool is passed through a section of pipeline with known defects at contractor works. WET LOOP TEST: Generally, during initial development stage, ILI tool is also tested in wet loop. The purpose of this test is to ascertain the accuracy of the tool in terms of detection of defects. IP SURVEY: Once the IP tool successfully passes pull through test, the tool is introduced in the pipeline and data is collected.
MINIMUM REQUIREMENT OF INTELLIGENT PIG Detect following with size and chainage of pipeline. Internal corrosion. External corrosion. All fitting in pipeline like valves, sleeves, leak clamps etc. And girth weld Length of each pipes with thickness details. Longitudinal and circumferential grooving. Type of defect Associated with software to prioritize the defects for repair and to assess the overall health condition of the pipeline.
CLASSIFICATION OF DEFECTS
IPS REPORT IS BASE FOR THE ASSESSMENT OF LINE CONDITION AND MAOP FOR THE LINE IS SET ACCORDINGLY. BEFORE START OF SURVEY DETAILS OF LINE WITH EXISTING MAOP ARE GIVEN TO THE SURVEYOR. LINE DETAILS ARE REQUIRED TO FIX TOOL PARAMETERS AND EVALUATION OF IPS RESULTS. EXISTING MAOP IS REQUIRED TO EVALUATE SEVERITY OF FEATURES AND CALCULATION OF ERF VALUE.
LIMITATION OF IPS
No direct assessment of pipe Strength (only metal loss detected). Difficult to idenfify the Weld defect/material defect. (Hydrotest would be required for finalization of safe operating pressure of pipeline). MFL is indirect measurement of wall loss, any error in data interpretation would lead to error in final data. More depended on data interpreter
MAINLINE MAINTENANCE
IC
12
SLB
From Panipat IC To Jalandhar
SRB
14 14 MOV
IFD
14 MOV
12MOV 3 8 2
12
12
12
12
12
TM
6 12
12 MOV
MP-3 MP-2 MP-1
8 8 8 8
E
12 MOV 12
12
TM
14 MOV 12 MOV
Strainer
10 10 10 14
E H
TM
TM
10 14 10
S/F
14 10
INSPECTION OF R.O.W.
To observe surface condition Wash outs Leaks Encroachments To inspect the Markers & accessories Markers TLPs Block Valves CP / RCP stations To inspect Crossings & vulnerable locations and special attention to suspended crossings, exposed area etc.
MAINLINE FACILITIES
Boundary Pillar (BP) Turning Post (TP) Kilo Meter Post (KMP) Vent Pipe (VP) Test Lead Post (TLP) Caution Board Block Valve (BV) CP Station Repeater Station Repeater cum CP Station (RCP)
MAINLINE LAYOUT
Position of M/L markers
IOCL KBPL IOCL KBPL
BP
VP TP
TLP
VP KMP 154
Pipe
RO A
IOCL KBPL
MAINLINE PATROLLING
Daily Patrolling by Line Patrol Man (LPM) Surprise check by officers Mainline Patrolling by officers Daily Patrolling Report Monthly Patrolling Report Surprise Check Report Report on M/L Inspection by officers
ROW MAINTENANCE
Providing missing M/L markers Painting of existing M/L markers Updation of Caution Boards Removal of bushes, trees etc from ROW Attending washouts Removal of encroachments Attending shorted cased crossing Refurbishing of Coat & Wrap
MAINLINE EMERGENCIES
Leak Burst Pilferage Welding of Leak Clamp Welding of Sleeve (Full/Half)
CORROSION INHIBITOR
AN INHIBITOR IS A SUBSTANCE, WHEN ADDED IN SMALL CONCENTRATION TO AN ENVIRONMENT DECREASES THE CORROSION RATE. MOST INHIBITORS HAVE BEEN DEVELOPED BY EMPIRICAL EXPERIMENTATION. MANY INHIBITORS ARE PROPERIETARY IN NATURE AND THEIR COMPOSITION IS NOT DISCLOSED.
CORROSION INHIBITOR
IN CROSS-COUNTRY PRODUCT PIPELINE, WE ARE USING CORROSION INHIBITOR TO MITIGATE THE INTERNAL CORROSION OF PIPELINE. PRESENTLY UNICOR-J @ 6PPM IS BEING USED. CORROSION INHIBITOR FORMS A LAYER INSIDE THE PIPE AND MAKE IT PASSIVE. IN CRUDE PIPELINE, NO C.I. IS INJECTED IN IOCL PIPELINE BH CRUDE FORMS A LAYER OF WAX.
Category Low
Moderate High Severe
ER PROBE:
No. 1 2 3 4 5 6 8 Description Protective Cover Extension Adopter O Ring for Cover Hollow Plug Assy Primary Packing screw Lock Flush ER Probe Material Carbon Steel 316SS Viton 316 SS Teflon 316SS 316 SS
4.
To clean the new pipe debris. To know the inside pipe dia profile. For inspection and measurement of any corrosion or metal loss. For generating initial pipe line data.
Mandrel pigs, which have a central body tube, or mandrel, and various components which can be assembled onto the mandrel to configure a pig for a specific duty;
Scrapper pigs, which have a central body tube, or mandrel, and various components like PU cups and spring steel brushes which can be assembled onto the mandrel to configure a pig for a specific duty.
BI-DI or Batching pigs, which have a central body tube and disc components can be assembled onto the body to configure a pig for a specific duty;
Experience of IOCL
Case Study
Few corrosion failures occurred. Pipeline was de-rated to 80% of the MAOP In line inspection of the pipeline was carried out.
Experience of IOCL
Case Study (cont..)
Experience of IOCL
Case Study 2 (cont..)
CAT, DCVG & CPL Survey conducted to check the performance of existing CP & coating.
Pipeline metal loss features identified by IPS were plotted with the results of CAT/DCVG/CPL & based on result, priority made for coating refurbishment & job executed.
Experience of IOCL
Case Study (cont..)
Results found to be very encouraging, Defective coatings were identified high degree of accuracy & repaired
by providing solar
Appreciable
improvement
in
line
protection
HYDROSTATIC TESTING OF P-M & M-A SECTIONS OF BKPL DETAILS OF LINE FAILURES OCCURRED FURING HYDROTESTING
STAGES OF PRESSURE TESTING IST STAGE 2ND STAGE NO. OF FAILURE FAILURE NOS. SEAM FAILURE LENGTH/ WIDTH 1.4 MTR/ 8MM 2.1 MTR./ 11 MM 0.11 MTR/ 4MM 0.1 MTR/ 1 MM 1.0 MTR/ 10 MM 2.1 MTR/ 22 MM 0.04 MTR FAILURE PRESSURE (EX-ALD) IN KG/CM2 49.5 63.0 61.5 75.0 75.0 82.0 85.0
BK/HYDRO
1 4
3RD STAGE
6TH 7TH