Pipeline Integrity

A.K.JANA, GAIL-DGM1

PIPELINE INTEGRITY & RELIABILITY

A.K. [email protected]

GAIL (India) Limited

GAIL (India) Limited

A.K.JANA, GAIL-DGM2

CONTENTS

Adopting Best Practices to Ensure the Integrity of Pipelines

Devising an Efficient Asset Integrity Management Programme in Organization

Instituting Effective Pipeline Replacement Programme

Case study – Integrity Assessment of JLPL

A.K.JANA, GAIL-DGM3

PIPELINE INTEGRITY

Maintaining the pipeline in a safe, effective, efficient and environmentally sustainable manner through out their design life and extending beyond

PIPELINE INTEGRITY MANAGEMENT

Detailed Process of Threat Identification, Risk analysis, Assessment Methods, Evaluation, Remediation, Reassessment and Continuous Improvement - To Achieve One Thing “PIPELINE RELIABILITY THROUGH INTEGRITY”

A.K.JANA, GAIL-DGM4

GATHERING, REVIEWING AND INTEGRATING DATA

THREATS TO INTEGRITY AND

IMPACT IDENTIFICATION

RISK ASSESSMENT

ALL THREAT EVALUATED

INTEGRITY ASSESSMENT

RESPONSES TO INTEGRITY ASSESSMENT &

MITIGATION

NO

YES

PIPELINE INTEGRITY PLAN

A.K.JANA, GAIL-DGM5

1) Internal Corrosion2) External Corrosion3) Stress Corrosion

Cracking

PIPELINEINTEGRITY

PLAN

THREATS ASSESSMENT & MITIGATION

1) Manufacturing Defects2) Construction Defects3) Equipment Defects

1) Third Party damage2) Natural calamity3) Incorrect operation

PIPELINE INTEGRITY MANAGEMENT

1) Supervision & QC2) Feed Back to Project for

Upcoming Projects

1) Monitoring of Flow, Pressure & Temp.

2) APPS Software3) Pipeline Patrolling4) Generating Awareness

amongst General Public1)Indirect Assessment

PiggingCPL/DGVG/CAT

2)Direct assessment

ECDAICDA

Corrosion CouponCoating IntegritySCC Survey

Pre-assessmentIndirect Assessment / Site SelectionDirect Assessment Post Assessment

TIME INDEPENDENT

TIME DEPENDENT

STABLE

A.K.JANA, GAIL-DGM6

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Direct Assessment

Indirect AssessmentILI

CAT / DCVG / CPL

CP Monitoring

Pipeline Patrolling

Pipeline Network

PIPELINE INTEGRITY PLAN MONITORING

A.K.JANA, GAIL-DGM7

STEPS TOWARDS P/L INTEGRITY MANAGEMENT

1. Project Planning2. Design & Detailed Engg3. QA/QC During Construction Stage4. Commissioning 5. Efficient Operation & Maintenance

A.K.JANA, GAIL-DGM8

To Establish Pipeline Integrity, GAIL has adopted two pronged practices

1) Construction Practices - Adopting latest technology envisaging stable threats and integrity assessment

2) Operation and Maintenance Practices –Assessment and mitigation of Time Dependent and Independent Threat

ESTABLISHING PIPELINE INTEGRITY

A.K.JANA, GAIL-DGM9

O&M ACTIVITIES

OPERATIONS

MAINTENANCE

SYSTEM DEVELOPMENT

INVENTORY MGMT.

MOU

BENCHMARK

SAFETY

P/L INTEGRITY

M/C AVILABILITY

STANDARDIZATIONPOLICIES

MODIFICATIONSSHARING EXPERENCES

PROJECT SURPLUS

O&M INVENTORY

CONSUMABLES

GAS - O & M ACTIVITIES

TECHNOLOGICAL OBSOLESCENCE

A.K.JANA, GAIL-DGM10

PRESSURE / TEMPERATURE / FLOW PROFILEONLINE MONITORING OF PSP READINGHEALTHINESS OF FIRE FIGHTING EQUIPEMENT ENROUTE PIPELINEAVAILABILITY OF POWER SOURCES CCVT / TEG

24X7 MONITORING THROUGH 10 REGINONAL GAS MANAGEMET CENTRE AND 3 MASTER CONTROL CENTRES FOR




PIPLINE PETROLLING TO AVOID ENCROCHMENT / THIRD PARTY EXCAVATION / PHYSICAL DEVELOPMENT

Foot patrolling of high consequences area daily

Aerial patrolling of all pipelines monthly

Survey of vulnerable locations like rail / road / river crossing / above ground installations

GAIL


DATA MANAGEMENT

Systematic Data Management through GIS for Risk Assessment and Future Integrity Plan

Construction DataOperational DataPatrolling DataIntegrity Assessment DataLeak and Breakdown Data


PIPELINE REHABILITATION

GAIL CARRIES OUT 4 – PRONGED STRATEGYDEFECT ASSESSMENT SURVEYS AND DATA ANALYSISTEMPORARY CORRECTIVE MEASURESREFURBISHMENT OF COATING / REPLACEMENT OF PIPELINE SECTION AS PERMANENT MEASUREROOT CAUSE ANALYSIS AND PREVENTIVE MEASURESA PIPELINE POLICY FOR ALL THE ABOVE IS IN PLACE FOR WITH PROCEDURES FOR UNIFORMITY ACROSS ALL SITES


REPLACEMENT METHODOLOGY

GAIL has followed Two methodology for Replacement of defective pipe section as permanent measure

1) Off Line Replacement:Isolating pipeline section through sectionalizing valve and evacuating the NG / LPG.

2) On line Replacement: Hot Tapping and StopplingTechnique is used for pipelines replacement.


PIPELINE REPLACEMENT PLAN

Prior to replacement of any pipeline, it is established that the replacement becomes essential for safety reasons or cheaper than not replacing.


Pipeline Burst / Leak / Fire

Natural calamities viz. Flood, Earthquake etc.

Emergency caused by third party activity

Sabotage

Strike by employees

CRISIS MANAGEMENT PLAN

ON-SITE AS WELL AS OFF-SITE CRISIS MANAGEMENT PLAN IS IN PLACE TO HANDLE ANY EMERGENCY ARISING OUT OF THE FOLLOWING :


NG & LPG: Valve location once in every month in vulnerable location

Quarterly (Road & Highway)Water course crossings Twice in a year (Pre & after monsoon)(Cl. 12.3.1)

Annually(Cl 5.0)

ROW Inspection

2

NG: For Twice in a year before & after monsoononce a month-Air patrolling LPG: Weekly

by security guard for 3 weeks . Once in a month by helicopterTwice in a year (by company official before & after monsoon)

NG: Fortnightly (class 3 & 4 )Monthly (Class 1 & 2 )Twice a year pre & post monsoon by company official)(Cl 12.3.2)ForPNGGeneral Inspection: Daily (By opearting personnel). Once a month by Engineer in charge of PNG Mktg.company .

LPG : Ground Patrolling of On-shore LPG Cross Country Pipelines shall be carried out once in a week Line Walk by the official of the company at least once in a year is required to be conducted after the monsoon.

NG: As per ANSI B31.8 Cl. 851.2(Cl.4.0).

LPG: Weekly (urban areas)Monthly (other areas)

NG:Annual (Class location 1&2)Half yearly (Class location 3)Quarterly (Class 4 location) (Cl.851.2)

LPG:Patrols shall be made at intervals not exceeding two weeks, except that piping systems transporting LPG or liquid ashydrousammonia shall be patrolled at intervals not exceeding 1 week in industrial, commercial, or residential areas.

Pipeline Patrolling

1

GAILOISD 226(NG) / OISD 214 (LPG)OISD138ANSI B31.8(NG) / ANSI B31.4(LPG)

ActivityS.No.

INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS


NG & LPG: Quarterly

Quarterly(Cl.6.1)

Greater frequency than pipelines in open country(Main Highways & Rail road crossings) (Cl.851.2)

Rail/ Road Bridge & suspended crossing

3

Once in 10 yearsNG:Once in 10 years (Cl12.3.4)LPG:Once in 10 years (Cl15.4(ii))

Once in 10 years (Cl7.2)

Intelligent pigging

6

NG & LPG: Preferably every two years

NG:Annual (for wet gas)Once in three years (for dry gas)(Cl.12.3.3)LPG:Once in year (Cl.15.4(i))

Annually (Wet Gas)Once in two years (Dry gas)LPG pipeline (as per OISD 214)(Cl.7.1)

Cleaning Pigging

5

NG & LPG: Quarterly

Quarterly (Road & Highway)Water course crossings Twice in a year (Pre & after monsoon)(Cl. 12.3.1)

Quarterly(Cl.6.2)

Greater frequency than pipelines in open country(Main Highways & Rail road crossings) (Cl.851.2)

Road & Highway crossing

4

GAILOISD 226(NG) / OISD 214 (LPG)

OISD138ANSI B31.8ActivityS.No.



Continous at feeding points through SCADAQuartely at other locations (3 ON & 1 on-off annually)

Fortnightly at feeding points (Cl.12.3.5.a.i) Quarterly at other locations (Cl.12.3.5.a.ii)Annual On -off (Cl.12.3.5.a.iii)

Fortnightly at feeding points (Cl.19.1.i) Quarterly at other locations (Cl.19.1.ii)

Frequency based on various parameters (Cl. 862.217)

PSP Measurements7

Once in 5 yearsOnce in 5 years (Cl12.3.6)

Once in 5 years(Cl 9.2.1)

PEARSON/ CAT & DCVG

8

Once in 5 yearsOnce in 5 years (Cl12.3.6)

Once in 5 years(Cl 9.2.2)

CPL survey9

Once in a quarter: Alongwith PSP monitoring

Once in 5 years (Cl12.3.6)

Annually (Cl. 9.2.3)

Insulating joint/ Coupling inspection

10

GAILOISD 226OISD138ANSI B31.8ActivityS.No.



Half yearly: CorrossioncouponQuarterly: ER probe Once in two years: U.T overgroundpiping

No specific duration defined except for I.P.

Annual (CorrossionCoupon)(Cl.10.i)Quarterly (ERP)(Cl.10.ii)Once in two years (UT)(Cl.10.iii)

Mention of Inhibitor Injection system, Corrossioncoupons, Corrossion probes exists but no frequency defined. (Cl. 863.3)

Internal corrossionmonitoring

14

NG : Half yearlyLPG: Quarterly

As per OISD 130(Cl.12.3.8)

AnuallyCl. 9.2.4

Inspection of pipes, valves & fittings

13

Once in 10 years

Mentioned-Frequency not defined

Soil testing12

Once in a quarter

AnuallyCl. 9.2.4

External Overground piping

11



INTEGRITY ASSESSMENT OF JLPL – LPG P/L

A CASE STUDY


PIPELINE SPECIFICATION

Pipeline Network : Jamnagar Loni Pipeline

Product Flowing in P/L : LPG

Pipeline Section : IPx to IPy

Pipeline Length : 128.5 KM

Pipeline Diameter : 16”; 406.4 mm

Pipeline Wall Thickness : 7.1 mm; 8.7 mm


Cleaning pigging was performed in Jamnagar Loni Pipeline to make pipeline internal clean and ready for intelligent pigging.

High Density Foam Pig

BR Pig

Gauge Pig

Magnetic Pig

CLEANING PIGGING


Total Muck and black powder of around 150 Kg & 40 Kg respectively receivedAll the pigs received in good condition except Gauge Pig.

Aluminum Gauge plate was found deformed from 6 O’clock

and 3 O’ clock PositionGauge plate inward bend may be due to :

A. Improper Launching of pig B. Debris inside P/LC. Deformation in the P/L.

GAUGE PIGGING


Cleaning pigging operation completed by launching of one run of each pigOnly 5 Kg of muck received during last pig runTo confirm deformation of P/L, 2 nos of 3C Gauge pigs were launched sequentially Both the Gauge pigs gauge plates found deformed in 6 O’clock position

GAUGE PIGGING


CONCLUSIONCLEANING PIGGING

Pipeline must be considerably clean to run Intelligent pig

Caliper pigging is essential to locate and size the deformation before intelligent pigging


During preliminary interpretation of data, no anomaly observed w.r.t. 5% reductions and ovalities

Reductions & ovalities over 2% searched

Five indications noticed, Four were classified as DENT and one as OVALITY

CALIPER PIGGINGDATA ANALYSIS


%mm

8.8

15.49.1

11.2

9.7

Reduction

2483

23232475

2417

2303

Arms

dent27032.2126348.4

Dent26953.8125885.2dent27032.2123908.3

dent26952.8111507.3

Ovality25472.410717

Base

RemarkDigitDistance meter



Detail of defectDistance from 1.8 m to 2.28 m

Length 1.16 m

Width .21 m

Roll 78o



VERIFICATION OF DEFECT

Location was dig where a dent of 3.8% was observed

pipeline was resting over a huge stone

Rock was drilled to

make small holes and cut off in pieces

by chisels and hammers


Pipeline Coating was removed to examine the dent No sharp dent observed. Pipe found flatten near the dented portionPipeline thickness & PSP measured at dent location. Thickness & CP was found normal (7.3 mm & 1.36V)Only slight change was observed after release of stressNo clock Spring provided Coating repaired and pit is filled after proving the sand cover

VERIFICATION OF DEFECT


CONCLUSION

Dent affects the safe operation of pipeline as they restrict the flow and tend to induce spot-like formations of sediments, turbulence, erosion, corrosion and hydrates

Localized stress shorten Pipeline’s service life

Timely integrity assessment insures Asset integrity and avoid any Eventuality & Product Loss


GAIL has Strong back up of Rich Experience in entire Value Chain of Natural Gas business

RELIABILITY PROVEN OVER DECADES with average Un-Interrupted Gas Delivery days being more than 99.9% through trunk pipeline network

ESTABLISHED TOTAL ASSET INTEGRITY All the Assets are as Efficient and safe as, they were new

GAIL STRENGTH


Temporary Repair Cut-Out Repair


Repair of corroded section as per ANSI/ASME, B-31G

Sleeve repair of corroded pipe section

Sleeve repair of corrosion pitting section using API approved composite material


HOT TAPPING & STOPLINGHOT TAPPING & STOPLING

• CONTINUOUS SYSTEM OPERATION

• NO GAS RELEASE TO THE ATMOSPHERE

• REDUCED PLANNING AND COORDINATION COSTS

• INCREASED WORKER SAFTEY

HOT TAPPING


THANK YOU

Pipeline Integrity

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