Pipeline Integrity

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GAIL (India) Limited

PIPELINE INTEGRITY & RELIABILITY

A.K. Jana akjana@gail.co.in GAIL (India) LimitedA.K.JANA, GAIL-DGM 1

CONTENTS

Adopting Best Practices to Ensure the Integrity of Pipelines Devising an Efficient Asset Integrity Management Programme in Organization Instituting Effective Programme Pipeline Replacement

Case study Integrity Assessment of JLPL

A.K.JANA, GAIL-DGM 2

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

PIPELINE INTEGRITY MANAGEMENTDetailed Process of Threat Identification, Risk analysis, Assessment Methods, Evaluation, Remediation, Reassessment and Continuous Improvement - To Achieve One Thing PIPELINE RELIABILITY THROUGH INTEGRITYA.K.JANA, GAIL-DGM 3

PIPELINE INTEGRITY PLANTHREATS TO INTEGRITY AND IMPACT IDENTIFICATION GATHERING, REVIEWING AND INTEGRATING DATA

RISK ASSESSMENT

NO

ALL THREAT EVALUATED

YES

INTEGRITY ASSESSMENT

RESPONSES TO INTEGRITY ASSESSMENT & A.K.JANA, GAIL-DGM MITIGATION 4

PIPELINE INTEGRITY MANAGEMENTTHREATS ASSESSMENT & MITIGATION 1) Monitoring of Flow, Pressure & Temp. 2) APPS Software 3) Pipeline Patrolling 4) Generating Awareness amongst General Public 1)Indirect Assessment Pigging CPL/DGVG/CAT 2)Direct assessment ECDA ICDAPre-assessment Indirect Assessment / Site Selection Direct Assessment Post Assessment

1) Third Party damage TIME INDEPENDENT 2) Natural calamity 3) Incorrect operation

1) Internal Corrosion 2) TIME DEPENDENT External Corrosion 3) Stress Corrosion Cracking

PIPELINE INTEGRITY PLAN

Corrosion Coupon Coating Integrity SCC Survey 1) Manufacturing Defects 1) Supervision & QC 2) Feed Back to Project for STABLE 2) Construction Defects A.K.JANA, GAIL-DGM Upcoming Projects 3) Equipment Defects5

PIPELINE INTEGRITY PLAN MONITORINGPipeline Network 1 2 3 4 5 6 7 8 9 10 11 Pipeline Patrolling CP Monitoring CAT / DCVG / CPL Indirect Assessment ILI Direct Assessment

6

A.K.JANA, GAIL-DGM

STEPS TOWARDS P/L INTEGRITY MANAGEMENT1. Project Planning 2. Design & Detailed Engg 3. QA/QC During Construction Stage 4. Commissioning 5. Efficient Operation & Maintenance

A.K.JANA, GAIL-DGM 7

ESTABLISHING PIPELINE INTEGRITYTo Establish Pipeline Integrity, GAIL has adopted two pronged practices 1) Construction Practices Adopting latest technology envisaging stable threats and integrity assessment Operation and Maintenance Practices Assessment and mitigation of Time Dependent and Independent ThreatA.K.JANA, GAIL-DGM 8

2)

GAS - O & M ACTIVITIESSYSTEM DEVELOPMENTPOLICIES

OPERATIONSBENCHMARK

STANDARDIZATION

SHARING EXPERENCES

MODIFICATIONS

MOU

SAFETY

O&M ACTIVITIESO&M INVENTORY PROJECT SURPLUS TECHNOLOGICAL OBSOLESCENCE CONSUMABLES M/C AVILABILITY P/L INTEGRITY

INVENTORY MGMT.

MAINTENANCEA.K.JANA, GAIL-DGM 9

ESTABLISHING PIPELINE INTEGRITY24X7 MONITORING THROUGH 10 REGINONAL GAS MANAGEMET CENTRE AND 3 MASTER CONTROL CENTRES FORPRESSURE / TEMPERATURE / FLOW PROFILE ONLINE MONITORING OF PSP READING HEALTHINESS OF FIRE FIGHTING EQUIPEMENT ENROUTE PIPELINE AVAILABILITY OF POWER SOURCES CCVT / TEGA.K.JANA, GAIL-DGM 10

ESTABLISHING PIPELINE INTEGRITYPIPLINE PETROLLING TO AVOID ENCROCHMENT / THIRD PARTY EXCAVATION / PHYSICAL DEVELOPMENTFoot patrolling of high consequences area daily Aerial patrolling monthly of all pipelinesGAIL

Survey of vulnerable locations like rail / road / river crossing / above ground installationsA.K.JANA, GAIL-DGM 11

DATA MANAGEMENTSystematic Data Management through GIS for Risk Assessment and Future Integrity Plan Construction Data Operational Data Patrolling Data Integrity Assessment Data Leak and Breakdown DataA.K.JANA, GAIL-DGM 12

PIPELINE REHABILITATIONGAIL CARRIES OUT 4 PRONGED STRATEGY DEFECT ASSESSMENT SURVEYS AND DATA ANALYSIS TEMPORARY CORRECTIVE MEASURES REFURBISHMENT OF COATING / REPLACEMENT OF PIPELINE SECTION AS PERMANENT MEASURE ROOT CAUSE ANALYSIS AND PREVENTIVE MEASURESA PIPELINE POLICY FOR ALL THE ABOVE IS IN PLACE FOR WITH PROCEDURES FOR UNIFORMITY ACROSS ALL SITESA.K.JANA, GAIL-DGM 13

REPLACEMENT METHODOLOGYGAIL has followed Two methodology for Replacement of defective pipe section as permanent measure1) Off Line Replacement: Isolating pipeline section through sectionalizing valve and evacuating the NG / LPG.

2) On line Replacement: Hot Tapping and Stoppling Technique is used for pipelines replacement.A.K.JANA, GAIL-DGM 14

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.

A.K.JANA, GAIL-DGM 15

CRISIS MANAGEMENT PLANON-SITE AS WELL AS OFF-SITE CRISIS MANAGEMENT PLAN IS IN PLACE TO HANDLE ANY EMERGENCY ARISING OUT OF THE FOLLOWING : Pipeline Burst / Leak / Fire Natural calamities viz. Flood, Earthquake etc. Emergency caused by third party activity Sabotage Strike by employees

A.K.JANA, GAIL-DGM 16

INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS

S. N o. 1

Activity

ANSI B31.8(NG) / ANSI B31.4(LPG) 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 ashydrous ammonia shall be patrolled at intervals not exceeding 1 week in industrial, commercial, or residential areas.

OISD138

OISD 226(NG) / OISD 214 (LPG)

GAIL

Pipeline Patrolling

NG: As per ANSI B31.8 Cl. 851.2 (Cl.4.0). LPG: Weekly (urban areas) Monthly (other areas)

NG: Fortnightly (class 3 & 4 ) Monthly (Class 1 & 2 ) Twice a year pre & post monsoon by company official)(Cl 12.3.2) ForPNG General Inspection: Daily (By opearting personnel). Once a month by Engineer in charge of PNG Mktg.company . LPG : Ground Patrolling of Onshore 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: For Twice in a year before & after monsoon once a monthAir patrolling LPG: Weekly by security guard for 3 weeks . Once in a month by helicopter Twice in a year (by company official before & after monsoon) NG & LPG: Valve location once in every month in vulnerable 17 location

2

ROW Inspection

Quarterly (Road & Highway) Water course crossings Twice in a year (Pre & after monsoon) (Cl. A.K.JANA, GAIL-DGM 12.3.1)

Annually (Cl 5.0)

INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS

S.No . 3

Activity Rail/ Road Bridge & suspended crossing

ANSI B31.8 Greater frequency than pipelines in open country (Main Highways & Rail road crossings) (Cl.851.2) Greater frequency than pipelines in open country (Main Highways & Rail road crossings) (Cl.851.2)

OISD138 Quarterly (Cl.6.1)

OISD 226(NG) / OISD 214 (LPG)

GAIL NG & Quarterly LPG:

4

Road & Highway crossing

Quarterly (Cl.6.2)

Quarterly (Road & Highway) Water course crossings Twice in a year (Pre & after monsoon) (Cl. 12.3.1) NG:Annual (for wet gas) Once in three years (for dry gas) (Cl.12.3.3) LPG:Once in year (Cl.15.4(i)) NG:Once in 10 years (Cl12.3.4) LPG:Once in 10 years (Cl15.4(ii))

NG & LPG: Quarterly

5

Cleaning Pigging

Annually (Wet Gas) Once in two years (Dry gas) LPG pipeline (as per OISD 214) (Cl.7.1) Once in 10 years (Cl 7.2)

NG & LPG: Preferably every two years

6

Intelligent pigging

Once in 10 years

A.K.JANA, GAIL-DGM

18

INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS

S.N o. 7

Activity PSP Measurements

ANSI B31.8

OISD138 Fortnightly at feeding points (Cl.19.1.i) Quarterly at other locations (Cl.19.1.ii)

OISD 226 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) Once in 5 years (Cl12.3.6)

GAIL Continous at feeding points through SCADA Quartely at other locations (3 ON & 1 on-off annually) Once in 5 years

Frequency based on various parameters (Cl. 862.217) 8 PEARSON/ CAT & DCVG Once in 5 years (Cl 9.2.1)

9

CPL survey

Once in 5 years (Cl 9.2.2)

Once in 5 years (Cl12.3.6)

Once in 5 years

10

Insulating joint/ Coupling inspection

Annually (Cl. 9.2.3)

Once in 5 years (Cl12.3.6)

A.K.JANA, GAIL-DGM

Once in a quarter: Alongwith PSP monitoring

19

INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS

11 12

External Overground piping Soil testing

Anually Cl. 9.2.4 MentionedFrequency not defined Anually Cl. 9.2.4 As per OISD 130 (Cl.12.3.8) No specific duration defined except for I.P.

Once in a quarter Once in 10 years NG : Half yearly LPG: Quarterly Half yearly: Corrossion coupon Quarterly: ER probe Once in two years: U.T overground piping

13

Inspection of pipes, valves & fittings

14

Internal corrossion monitoring

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

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

A.K.JANA, GAIL-DGM 20

A CASE STUDY

INTEGRITY ASSESSMENT OF JLPL LPG P/L

A.K.JANA,