III Pandey Gail 2

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O&M OF PIPE LINE

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DELHI

DADRI

1989

DIBIYAPUR

BIJAIPUR

(3)

(5)

(3)

+ (2)

KHERA (3)

ANTA1988

1997

HAZIRA

JHABUA

(10)

(7) + (3)

+ (2)

VAGODIA (3)

FROM OGC

IPCL

18.2 33.4 MMSCMD

1987


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O&M OF PIPE LINE SYSTEM

.B. MAINLINE & ASSOCIATED EQUIPMENT

C. CATHODIC PROTECTION


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A) ROU

KM Markers,

Direction marker,

Warning sign boards,

ROU boundary pillars installed along the ROU.


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B)MAILIE & ASSOCIATED

EQUIPMET

1.MAILIE- Pi es used of various rades and is coated

with three layer of PE coating

2.SECTIOALIZIG VALVE (SV) STATIOS-consist

of mainline ball valves, manually operated ball valves /

plug valves and quick opening end closures (QOEC).

3.CASED CROSSIGS- Provided for Rail and Road

crossing, consist of casing pipe along with vent & drainpipes


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B)MAILIE & ASSOCIATED

EQUIPMET

. . -consists of gas actuated ball valves, manually operated ball

valves, plug valves, pig receiver, pig launcher, pig

signalers, pig handling devices, quick opening end closure,pressure safety valve, pressure & temperature transmitters


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T

P

G

TYPICAL SV STATION

Utility Connection 2

A V

G

T

G

P

GBy pass Line

QOEC

Utility Connection 2

MAILIE

MAIFOLD FOR PG

/TG


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SECTIOALIZIG VALVE COFIGURATIO OF LPR P/L

MOBILE FLARE

TEGLine for TEG

SV Bypass & IsolationBlind

P/L from U/S SV

Gate ValveP/L to D/S

T Y P IC A L IN T E R M E D IA T E P IG G IN G S T A T IO N


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A V

F ro m - T o T e rm in a l

T o U t il it ies

A V

T Y P IC A L IN T E R M E D IA T E P IG G IN G S T A T IO N -

F L O WT E E

M O V

F L O WT E E

M O V

QOEC

RECEIVER

LAUNCHER

B l o w

B A L LV A L V E

T SV

G L O B EV A L V E

G A T EV A L V E T E G - T H E R M O

E L E C T R I CG E N E R A T O R ( U t i l i t i e s )

R - LN G F L O WD I R E C T I O N


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TYPICAL I P STATIO OF LPG P/L

UpstreamM

M

SCRAPER

RECEIVER

SCRAPER

LAUCHER

To Customer

Downstream

M

M

M

M

M

PCV

TSV

TSV

MAILIE PUMP

To

Customer P

PS HH

M

PS LL


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CASED CROSSIGS


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C. Cathodic Protection

COMPOETS & DEVICES OF CP SYSTEM

Anode Ground Bed

Test Stations

Computerised Test Station

Zinc Grounding Cell

Spark Gap Polarisation Cell

Casing Pipes

ec r c es s ance ro es corros on sens ng pro es

Permanent Reference Cell

Insulating Joints

Power Source


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CCVT CCVTBATTERY BATTERY

ELECTRICAL LAYOUT AT

ITERMEDIATE STATIOS

600 AH600 AH

48V DC BUS

DC COOLING

SYSTEM FOR AC& EXHAUST


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OPERATION &MAINTENANCE

Time independent threats

me epen en rea sStable threats (induced during construction stage)

Based on the threats identified, preventive, corrective andmitigative actions are taken from time to time to ensure

Specific Pipeline Section.


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A) ROU

Helicopter Patrolling


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B)MAINLINE & ASSOCIATED

EQUIPMENT1)MOITORIG Inspection of SV, IP & RR installations along the pipeline

Inspection of River, Rail, Road crossings and Vulnerable locations

2)THICKESS MEASUREMET OF ABOVEGROUD PIPIG

3)PREVETIVE/ CORRECTIVE MAITEACE Periodic performance test of valves and associated equipment

Inspection of fire fighting equipments and corrective actions/, , ,

encroachments, missing/ damaged markers, boundary pillars etc


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EQUIPMENT

PREVETIVE/ CORRECTIVE MAITEACE

PERFORMACE TEST OF SV/IP/TAP.OFF FACILITIES

Any gas leakage from fittings and equipments

Operational checks of actuators, valves, launcher, receiver, QOEC, pressure

gauges, PT, TT, pig handling unit, chain pulley block and other associated

equipments/ systems installed.

Servicing, sealant injection, lubrication & greasing of above equipments

Seat test of ball valves

Old Gaskets of Limit switch enclosure & Electric junction box is replacedduring every half yearly valve performance test.


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EQUIPMENT

Fire fighting equipments a) Monthly b) Quarterly c) Yearlyactivity

Pipeline exposures, washouts, excavations ,encroachments, missing/ damaged markers, boundary

pillars etc


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P/L MONITORING & MAINT. SCHEDULE

-------------------------------------------------------------------------SL. ACTIVITY FREQUENCYNO.-------------------------------------------------------------------------1. INSPECTION OF SV, IP & T.OFF MONTHLY

2. INSPECTION OF RIVER CROSSINGS QUARTERLY

3. INSPECTION OF ROAD/RAIL XINGS QUARTERLY

4. PERFORMANCE TEST OF VALVES HALF -YLY


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P/L MONITORING & MAINT. SCHEDULE---------------------------------------------------------------------SL ACTIVITY FREQUENCYNO.

---------------------------------------------------------------------5. INSP. OF FIRE EQUIPT. MONTHLY

6. PIPELINE WALK YEARLY

7. VULNERABLE LOCATION MONTHLY

8. HELICOPTER SURV MONTHLY

9. ENCROACHMENTS MONIT. HALF YLY.


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C) Cathodic Protection

O&M of CP System consists of the following :

Periodic surveys to determine the status of CP

an re a e ems Coating maintenance

Maintenance of current sources and ground

beds in impressed current CP installations

Maintenance of test stations

Maintenance of cased crossings Maintenance at foreign line crossings


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PERIODIC SURVEYS (in line with ACE RP0169)

Pipe to soil potential survey (PSP)

Power supply output- current/voltage/wattage & efficiency

At other DC power sources, the DC current and voltage as

well as pertinent supplementary information which may

apply to the particular power source

The resistance of each impressed current ground bed

installation


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con -

Potentials of the line surveyed and of the foreign line at

foreign line crossings. Where intersystem bonds exist,

measure the bond current and direction of flow

At cased crossings, the resistance between carrier pipe and

casing plus the potential to reference electrode of both

pipeline and casing

Verification of insulated joints for effectiveness and also of

lightning arresters, spark gaps, grounding cells, and

polarization cells for performing function effectively


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Maintenance crews should be trained in good coatingapplication procedures

Care of materials, and compliance with specifications sothat acceptable coating work will result.

Maintaining a performance record of pipeline coatings on

the system


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Check output voltage and current

Clean and tighten all bolted current-carrying connections.

Clean all ventilating screens in air cooled units to ensureunobstructed air flow.

Check indicating meters for accuracy.

ep ace nsu a e w res on w c nsu a on as crac e or

been damaged.

Check all protective devices (fuses, circuit breakers, or

lightning arresters) to ensure their integrity.


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Periodic checks to take corrective action against washout Routine recording of ground bed and individual anode

resistance (to be carried out preferably in dry season) Identification of any dead anode and mitigation of problem

Cleanin and ti htenin of connections of anodes

Balancing of current flow in each anode


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Identify requirement for replacement of box covers orcover retention screws, cover gaskets or terminal nuts or

screws

Take corrective action against vandalized, broken test

station

Check and mitigate problem of connection integrity withthe pipeline


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Make observation to ensure insulation between carrier pipe

and casing

If shorted condition is found, immediate repair should be

scheduled

Determine the nature of short circuit

,

procedure is to fill the entire annular space between pipeand casing with a material that will stifle any corrosion

tendency


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Resistance bonds installed between pipelines forintersystem interference correction require periodic

checking

Exchange of operational information with the foreign line

companies

Planning for cooperative interference tests, design ofcorrective bonds, or other necessary measures to mitigate

interference damage caused to either party


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C.P. MONITORING & MAINT.SCHEDULE

-------------------------------------------------------------SL. ACTIVITY FREQUENCYNo.

1. C.P. STATIONS MONTHLY

2. T/R UNITS WEEKLY

3. PSP MONIRORING QUARTERLY

4. COMPUT. TEST STNS. HALF YLY. (NOT APPLICABLE FOR GREP)


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C.P. MONITORING & MAINT.SCHEDULE

(CONTD)------------------------------------------------------------SL. ACTIVITY FREQUENCY

o.-------------------------------------------------------------------- -

5. DC COOLING SYSTEM HALF YLY.

6. BATTERY BANKS HALF YLY.

.

8. POWER SOURCE MAINT. HALF YLY.

9. EARTHING SYSTEM HALF YLY.


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SCADA

SUPERVISORY COTROLAD

DATA

ACQUISITIO


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SUPERVISORY COTROL

OF MAJOR PIPELIE EQUIPMETSTHROUGH MCC

1.SECTIONALISING VALVES OPEN/CLOSE.

2.TEG/CCVT START AND STOP STATUS.

3.OPERATION OF COMPRESSORS .

4.FLOW CONTROL THROUGH COMPRESSORS


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DATA ACQISITION AND MONITORING

OFMAJOR PARAMETERSTHROUGH MCC

. . .2. PIPE TO SOIL POTENTIAL3. ANODE OUTPUT VOLTAGE4. ANODE OUTPUT CURRENT

5. SECTIONALISING VALVES OPEN/CLOSE6. TEG/CCVT STATUS FOR

VOLTAGE, CURRENT,RUNNING,ALARMS7. BLDG. DOOR OPEN/CLOSE8. A/C RUNNING STATUS9. RADIO ROOM TEMP ALARMS10.FIRE ALARM

11.PIGGING OPERATION


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CORROSIO COTROL CRITERIA

AD AALYSIS

HEAD QUARTER FUCTIOS


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CRITERION

PSP (ON/OFF) MAINTAINED BETWEEN 0.95v to

1.2v

EXTERNALCORROSION RATES ARE


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AALYSIS

1.PIPE TO SOIL POTENTIAL MEASURED QUARTERLY.

ALL PSP GRAPHS PREPARED AND ANALYSED FOR :

-LOCATIONS FOR SUDDEN CHANGES IN PSP

-UNDER PROTECTED/OVER PROTECTED ZONES.

-INTERFERENCE ZONES

-CORDINATE WITH RESPECTIVE MAINT.BASE FORCORRECTIVE ACTION

AALYSIS


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2.C.P. PARAMETERS AT ALL FEED POINTS

MONITORED MONTHLY CURRENT

CONSUMPTION RATE CALCULATED

FOR TOTAL PIPELINE.

AALYSIS

3.PRESENT CORROSION RATES CALCULATES

BASED ON ER PROBE MONITORING.

CORROSION RATE=(R2 R1) 4 MILS/YEARn

R1 - INITIAL READING

R2 - FINAL READING

n - ELAPSED TIME IN DAYS

BETWEEN TWO READINGS.


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GRAPH - HBJ P/L SYSTEM

1.700

1.900

0.700

0.900

1.100

1.300

1.500

PSP

Volts

(-V

E

0.500

0

.0

00

9

.0

00

1

8

.1

00

2

9

.8

36

4

2

.1

00

5

5

.3

00

6

8

.3

00

8

0

.2

17

8

9

.5

00

1

0

2

.4

85

1

1

5

.5

00

1

2

9

.0

00

1

4

1

.5

00

1

5

5

.0

00

1

6

8

.0

00

1

8

1

.0

00

1

9

3

.5

00

2

0

6

.5

00

2

1

9

.5

00

2

3

2

.5

00

2

4

5

.0

00

2

5

6

.0

00

2

6

8

.0

00

CHAINAGE (IN K.M.)

PSP UPL LPL


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CURRENT CONSUMPTION OF HBJ PIPELINE

icro

Q

.

1.00

6.00

.

OCT 95 DEC 95 OCT 96 JULY 97 MAR 98 DEC 98

YEAR

CURRENT(

m

AM

PERES

/

M

ETER

)

AV. CURRENT

CONSUMPTION


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HEALTH OF PIPELINE

ACHIEVED DESIGN

AVERAGE 10 M ICROAMP/M2

125 MICRO AMP/M2

CURRENTCONSUMPTION

PSP VALUE -0.95 TO 1.5 V -0.95 TO-1.5 V

EXT 0.15 MIL/YEAR < 1 MIL/YEARCORROSION

INTERNAL 0.01 MIL/YEAR


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3Layer copolymer coating application schematic


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Practical Galvanic Series for Materials in eutral Soils and Water measured

with respect to copper sulphate reference electrode


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Material Potential Volts (CSE)

Carbon, Graphite, Coke + 0.3

.

Mill Scale on Steel - 0.2

High Silicon Cast Iron - 0.2

Copper, Brass, Bronze - 0.2

Mild Steel in Concrete - 0.2

Lead - 0.5

Cast Iron (Not Graphitized) - 0.5

Mild Steel (Rusted) -0.2 to -0.5

Mild Steel (Clean and Shiny) -0.5 to -0.8

Commercially Pure Aluminum - 0.8

Aluminum Alloy (5% Zinc) - 1.05

Zinc - 1.1

Magnesium Alloy (6% Al, 3% Zn, 0.15% Mn) - 1.6

Commercially Pure Magnesium - 1.75

Principle of Cathodic Protection


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How It Works

Creat a corrosion cell

Make the structure to be protected cathode


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Differential Corrosion Cell

COPPER-COPPER SULFATE REFERECE

ELECTRODE


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ELECTRODE

III Pandey Gail 2

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