GAIL (India) Limited
PIPELINE INTEGRITY & RELIABILITY
A.K. Jana
[email protected] GAIL (India) Limited A.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 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-DGM 3
PIPELINE INTEGRITY PLAN THREATS 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 MANAGEMENT THREATS
1) Third Party damage INDEPENDENT 2)TIME Natural calamity 3) Incorrect operation
1) Internal Corrosion 2) TIME External Corrosion DEPENDENT 3) Stress Corrosion Cracking
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 ICDA
Pre-assessment Indirect Assessment / Site Selection Direct Assessment Post Assessment
PIPELINE INTEGRITY PLAN
Corrosion Coupon Coating Integrity SCC Survey 1) Manufacturing Defects 1) Supervision & QC 2) Feed Back to Project for STABLE Defects 2) Construction A.K.JANA, GAIL-DGM Upcoming Projects 3) Equipment Defects 5
PIPELINE INTEGRITY PLAN MONITORING Pipeline Network
Pipeline Patrolling
CP Monitoring
CAT / DCVG / CPL
Indirect Assessment ILI
Direct Assessment
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STEPS TOWARDS P/L INTEGRITY MANAGEMENT 1. 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 INTEGRITY 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 A.K.JANA, GAIL-DGM 8
GAS - O & M ACTIVITIES SYSTEM DEVELOPMENT POLICIES
OPERATIONS BENCHMARK
STANDARDIZATION
SHARING EXPERENCES
MODIFICATIONS
MOU
SAFETY
O&M ACTIVITIES P/L INTEGRITY
O&M INVENTORY PROJECT SURPLUS
TECHNOLOGICAL OBSOLESCENCE CONSUMABLES
INVENTORY MGMT.
M/C AVILABILITY
MAINTENANCE A.K.JANA, GAIL-DGM 9
ESTABLISHING PIPELINE INTEGRITY 24X7 MONITORING THROUGH 10 REGINONAL GAS MANAGEMET CENTRE AND 3 MASTER CONTROL CENTRES FOR PRESSURE / TEMPERATURE / FLOW PROFILE ONLINE MONITORING OF PSP READING HEALTHINESS OF FIRE FIGHTING EQUIPEMENT ENROUTE PIPELINE AVAILABILITY OF POWER SOURCES CCVT / TEG A.K.JANA, GAIL-DGM 10
ESTABLISHING PIPELINE INTEGRITY PIPLINE PETROLLING TO AVOID ENCROCHMENT / THIRD PARTY EXCAVATION / PHYSICAL DEVELOPMENT
GAIL
Foot patrolling of high consequences area daily Aerial patrolling monthly
of
all
pipelines
Survey of vulnerable locations like rail / road / river crossing / above ground installations A.K.JANA, GAIL-DGM 11
DATA MANAGEMENT Systematic Data Management through GIS for Risk Assessment and Future Integrity Plan Construction Data Operational Data Patrolling Data Integrity Assessment Data Leak and Breakdown Data A.K.JANA, GAIL-DGM 12
PIPELINE REHABILITATION GAIL 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 MEASURES A PIPELINE POLICY FOR ALL THE ABOVE IS IN PLACE FOR WITH PROCEDURES FOR UNIFORMITY ACROSS ALL SITES A.K.JANA, GAIL-DGM 13
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 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 PLAN ON-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)
OISD138
OISD 226(NG) / OISD 214 (LPG)
GAIL
Pipeline Patrolling
NG:Annual (Class location 1&2) Half yearly (Class location 3) Quarterly (Class 4 location) (Cl.851.2)
NG: As per ANSI B31.8 Cl. 851.2 (Cl.4.0).
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 .
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)
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. 2
ROW Inspection
LPG: Weekly (urban areas) Monthly (other areas)
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. Annually (Cl 5.0)
Quarterly (Road & Highway) Water course crossings Twice in a year (Pre & after monsoon) (Cl. 12.3.1) A.K.JANA, GAIL-DGM
NG & LPG: Valve location once in every month in vulnerable 17 location
INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS
S.No .
OISD 226(NG) / OISD 214 (LPG)
Activity
ANSI B31.8
OISD138
3
Rail/ Road Bridge & suspended crossing
Greater frequency than pipelines in open country (Main Highways & Rail road crossings) (Cl.851.2)
Quarterly (Cl.6.1)
4
Road & Highway crossing
Greater frequency than pipelines in open country (Main Highways & Rail road crossings) (Cl.851.2)
Quarterly (Cl.6.2)
Quarterly (Road & Highway) Water course crossings Twice in a year (Pre & after monsoon) (Cl. 12.3.1)
NG & LPG: Quarterly
5
Cleaning Pigging
Annually (Wet Gas) Once in two years (Dry gas) LPG pipeline (as per OISD 214) (Cl.7.1)
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 & LPG: Preferably every two years
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Intelligent pigging
Once in 10 years (Cl 7.2)
NG:Once in 10 years (Cl12.3.4) LPG:Once in 10 years (Cl15.4(ii))
Once in 10 years
A.K.JANA, GAIL-DGM
GAIL NG & Quarterly
LPG:
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INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS
S.N o. 7
Activity
ANSI B31.8
PSP Measurements
OISD138
OISD 226
GAIL
Fortnightly at feeding points (Cl.19.1.i) Quarterly at other locations (Cl.19.1.ii)
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)
Continous at feeding points through SCADA Quartely at other locations (3 ON & 1 on-off annually)
Frequency based on various parameters (Cl. 862.217) 8
PEARSON/ CAT & DCVG
Once in 5 years (Cl 9.2.1)
Once in 5 years (Cl12.3.6)
Once in 5 years
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)
Once in a quarter: Alongwith PSP monitoring
A.K.JANA, GAIL-DGM
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INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS
11
External Overground piping
Anually Cl. 9.2.4
Once in a quarter
12
Soil testing
MentionedFrequency not defined
Once in 10 years
13
Inspection of pipes, valves & fittings
Anually Cl. 9.2.4
As per OISD 130 (Cl.12.3.8)
NG : Half yearly LPG: Quarterly
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Internal corrossion monitoring
Annual (Corrossion Coupon) (Cl.10.i) Quarterly (ERP) (Cl.10.ii) Once in two years (UT) (Cl.10.iii)
No specific duration defined except for I.P.
Half yearly: Corrossion coupon Quarterly: ER probe Once in two years: U.T overground piping
Mention of Inhibitor Injection system, Corrossion coupons, Corrossion probes exists but no frequency defined. (Cl. 863.3)
A.K.JANA, GAIL-DGM 20
A CASE STUDY
INTEGRITY ASSESSMENT OF JLPL – LPG P/L
A.K.JANA, GAIL-DGM 21
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
A.K.JANA, GAIL-DGM 22
CLEANING PIGGING Cleaning pigging was performed in Jamnagar Loni Pipeline to make pipeline internal clean and ready for intelligent pigging.
BR Pig Gauge Pig High Density Foam Pig
A.K.JANA, GAIL-DGM
Magnetic Pig 23
GAUGE PIGGING Total Muck and black powder of around 150 Kg & 40 Kg respectively received All the pigs received in good condition except Gauge Pig. Aluminum Gauge plate was found deformed from 6 O’clock and 3 O’ clock Position
Gauge plate inward bend may be due to : A. Improper Launching of pig B. Debris inside P/L C. Deformation in the P/L. A.K.JANA, GAIL-DGM 24
GAUGE PIGGING
Cleaning pigging operation completed by launching of one run of each pig Only 5 Kg of muck received during last pig run To 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 A.K.JANA, GAIL-DGM 25
CONCLUSION CLEANING PIGGING
Pipeline must be considerably clean to run Intelligent pig Caliper pigging is essential to locate and size the deformation before intelligent pigging
A.K.JANA, GAIL-DGM 26
CALIPER PIGGING DATA ANALYSIS
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
A.K.JANA, GAIL-DGM 27
CALIPER PIGGING DATA ANALYSIS
Distance meter
Reduction
Digit
Remark
mm
%
Base
Arms
10717
9.7
2.4
2547
2303
Ovality
111507.3
11.2
2.8
2695
2417
dent
123908.3
9.1
2.2
2703
2475
dent
125885.2
15.4
3.8
2695
2323
Dent
126348.4
8.8
2.2
2703
2483
dent
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CALIPER PIGGING DATA ANALYSIS
Detail of defect Distance from 1.8 m to 2.28 m Length 1.16 m Width .21 m Roll 78o A.K.JANA, GAIL-DGM 29
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
A.K.JANA, GAIL-DGM
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VERIFICATION OF DEFECT Pipeline Coating was removed to examine the dent No sharp dent observed. Pipe found flatten near the dented portion Pipeline thickness & PSP measured at dent location. Thickness & CP was found normal (7.3 mm & 1.36V) Only slight change was observed after release of stress No clock Spring provided Coating repaired and pit is filled after proving the sand cover A.K.JANA, GAIL-DGM 31
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
A.K.JANA, GAIL-DGM 32
GAIL STRENGTH 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 A.K.JANA, GAIL-DGM 33
Temporary Repair
Cut-Out Repair
A.K.JANA, GAIL-DGM 34
Repair of corroded section as per ANSI/ASME, B-31G
Sleeve repair of corrosion Sleeve repair of corroded pitting section using API pipe section A.K.JANA, GAIL-DGM approved composite material 35
HOT TAPPING & STOPLING • CONTINUOUS SYSTEM OPERATION • NO GAS RELEASE TO THE ATMOSPHERE • REDUCED PLANNING AND COORDINATION COSTS • INCREASED WORKER SAFTEY
A.K.JANA, GAIL-DGM
HOT TAPPING
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THANK YOU A.K.JANA, GAIL-DGM
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