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PIPELINE INTEGRITY & RELIABILITY

GAIL (India) Limited

CONTENTS

Adopting Best Practices to Ensure the Integrity ofPipelines

Devising an Efficient Asset Integrity ManagementProgramme in Organization

Instituting Effective Pipeline ReplacementProgramme

Case study – Integrity Assessment of JLPL

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PIPELINE INTEGRITY

Maintaining the pipeline in a safe, effective, efficientand environmentally sustainable manner throughout their design life and extending beyond

PIPELINE INTEGRITY MANAGEMENT

Detailed Process of Threat Identification, Riskanalysis, Assessment Methods, Evaluation,Remediation, Reassessment and ContinuousImprovement - To Achieve One Thing “PIPELINERELIABILITY THROUGH INTEGRITY”

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INTEGRITY ANDIMPACT

IDENTIFICATION

MITIGATION

NO

GATHERING, REVIEWING

AND INTEGRATING DATA

RISK ASSESSMENT

ALL THREATEVALUATED

YES

INTEGRITYASSESSMENT

RESPONSES TO INTEGRITYASSESSMENT &

PIPELINE INTEGRITY PLAN

THREATS TO

2) Natural calamity

2)TIME DEPENDENT

ICDA

Upcoming Projects5

1) Internal CorrosionExternal Corrosion

3) Stress CorrosionCracking

PIPELINEINTEGRITY

PLAN

2) Construction Defects3) Equipment Defects

PIPELINE INTEGRITY MANAGEMENT

2) Feed Back to Project for

ASSESSMENT & MITIGATION

1) Monitoring of Flow,Pressure & Temp.

2) APPS Software3) Pipeline Patrolling4) Generating Awareness

amongst General Public1)Indirect Assessment

Corrosion CouponCoating IntegritySCC Survey

1) Manufacturing Defects 1) Supervision & QC

PiggingCPL/DGVG/CAT

2)Direct assessmentPre-assessment

ECDA Indirect Assessment / Site SelectionDirect AssessmentPost Assessment

THREATS

1) Third Party damageTIME INDEPENDENT

3) Incorrect operation

STABLE

PipelineNetwork

PipelinePatrolling

CPMonitoring

CAT/ DCVG/ CPL

IndirectAssessmentILI

DirectAssessment

1 √ √ √ √ √

2 √ √ √ √ √3 √ √ √ √ √4 √ √ √ √ √5 √ √ √ √ √6 √ √ √ √ √7 √ √ √ √ √8 √ √ √ √ √9 √ √ √ √ √10 √ √ √ √ √11 √ A.K.JANA,√ √ √ √

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PIPELINE INTEGRITY PLANMONITORING

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STEPS TOWARDS P/L INTEGRITYMANAGEMENT

1. Project Planning

2. Design & Detailed Engg

3. QA/QC During Construction Stage

4. Commissioning

5. Efficient Operation & Maintenance

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1) Construction Practices - Adoptinglatest technology envisaging stablethreats and integrity assessment

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

ESTABLISHING PIPELINEINTEGRITY

To Establish Pipeline Integrity, GAIL hasadopted two pronged practices

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OPERATIONSSYSTEM DEVELOPMENT

MOU

BENCHMARK

SAFETY

M/C AVILABILITY

MAINTENANCE

STANDARDIZATIONPOLICIES

MODIFICATIONSSHARINGEXPERENCES

O&MACTIVITIES

PROJECT SURPLUS

O&M INVENTORY

CONSUMABLES

INVENTORY MGMT.

GAS - O & M ACTIVITIES

P/L INTEGRITY

TECHNOLOGICALOBSOLESCENCE

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PRESSURE / TEMPERATURE /FLOW PROFILE

ONLINE MONITORING OF PSPREADING

HEALTHINESS OF FIRE FIGHTINGEQUIPEMENT ENROUTE PIPELINE

AVAILABILITY OF POWERSOURCES CCVT / TEG

24X7 MONITORING THROUGH 10REGINONAL GAS MANAGEMETCENTRE AND 3 MASTERCONTROL CENTRES FOR

ESTABLISHING PIPELINEINTEGRITY

ESTABLISHING PIPELINEINTEGRITY

PIPLINE PETROLLING TOAVOID ENCROCHMENT /THIRD PARTY EXCAVATION /PHYSICAL DEVELOPMENT

Foot patrolling of high consequencesarea daily

Aerial patrolling of all pipelinesmonthly

Survey of vulnerable locations likerail / road / river crossing / aboveground installations

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GAIL

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DATA MANAGEMENT

Systematic Data Management through GISfor Risk Assessment and Future IntegrityPlan

Construction Data

Operational Data

Patrolling Data

Integrity Assessment Data

Leak and Breakdown Data

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PIPELINE REHABILITATION

GAIL CARRIES OUT 4 – PRONGED STRATEGY

DEFECT ASSESSMENT SURVEYS AND DATAANALYSIS

TEMPORARY CORRECTIVE MEASURES

REFURBISHMENT OF COATING / REPLACEMENT OFPIPELINE SECTION AS PERMANENT MEASURE

ROOT CAUSE ANALYSIS AND PREVENTIVEMEASURES

A PIPELINE POLICY FOR ALL THE ABOVE IS IN PLACE FOR WITHPROCEDURES FOR UNIFORMITY ACROSS ALL SITES

REPLACEMENT METHODOLOGY

GAIL has followed Two methodology forReplacement of defective pipe section as permanentmeasure

1) Off Line Replacement:Isolating pipeline sectionthrough sectionalizing valveand evacuating the NG /LPG.

2) On line Replacement: HotTapping and StopplingTechnique is used forpipelines replacement.

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PIPELINE REPLACEMENT PLAN

Prior to replacement of any pipeline, it isestablished that the replacement becomesessential for safety reasons or cheaper thannot replacing.

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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 MANAGEMENTPLAN IS IN PLACE TO HANDLE ANY EMERGENCYARISING OUT OF THE FOLLOWING :

S.No.

Activity ANSI B31.8(NG) / ANSIB31.4(LPG)

OISD138 OISD 226(NG) / OISD 214 (LPG) GAIL

1 PipelinePatrolling

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

LPG:Patrols shall bemade at intervals notexceeding two weeks,except that pipingsystems transportingLPG or liquid ashydrousammonia shall bepatrolled at intervals notexceeding 1 week inindustrial, commercial, orresidential areas.

NG: As perANSI B31.8 Cl.851.2(Cl.4.0).

LPG: Weekly(urban areas)Monthly (otherareas)

NG: Fortnightly (class 3 & 4 )Monthly (Class 1 & 2 )Twice a year pre & postmonsoon by companyofficial)(Cl 12.3.2)ForPNGGeneral Inspection: Daily (Byopearting personnel). Once amonth by Engineer in charge ofPNG Mktg.company .

LPG : Ground Patrolling of On-shore LPG Cross CountryPipelines shall be carried outonce in a week

Line Walk by the official of thecompany at least once in a yearis required to be conductedafter the monsoon.

NG: For Twicein a yearbefore & aftermonsoononce a month-Air patrollingLPG: Weekly

by securityguard for 3weeks .Once in amonth byhelicopterTwice in a year(by companyofficial before& aftermonsoon)

2 ROWInspection

Annually(Cl 5.0)

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

NG & LPG:Valve locationonce in everymonth invulnerablelocation 17

INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS

S.No.

Activity ANSI B31.8 OISD138 OISD 226(NG) / OISD214 (LPG)

GAIL

3 Rail/ RoadBridge &suspendedcrossing

Greater frequency thanpipelines in opencountry(Main Highways & Railroad crossings)(Cl.851.2)

Quarterly(Cl.6.1)

NG & LPG:Quarterly

4 Road &Highwaycrossing

Greater frequency thanpipelines in opencountry(Main Highways & Railroad crossings)(Cl.851.2)

Quarterly(Cl.6.2)

Quarterly (Road &Highway)Water coursecrossings Twice in ayear (Pre & aftermonsoon)(Cl. 12.3.1)

NG & LPG:Quarterly

5 CleaningPigging

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

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

NG & LPG:Preferably everytwo years

6 Intelligentpigging

Once in 10 years (Cl7.2)

GAIL-DGM

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

Once in 10 years

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INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS

S.No.

Activity ANSI B31.8 OISD138 OISD 226 GAIL

7 PSP Measurements Frequency basedon variousparameters(Cl. 862.217)

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

Fortnightly atfeeding points(Cl.12.3.5.a.i)Quarterly atother locations(Cl.12.3.5.a.ii)Annual On -off(Cl.12.3.5.a.iii)

Continous atfeeding pointsthrough SCADAQuartely atother locations(3 ON & 1 on-offannually)

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 aquarter:Alongwith PSPmonitoring

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INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS

11 ExternalOverground piping

AnuallyCl. 9.2.4

Once in aquarter

12 Soil testing Mentioned-Frequency notdefined

Once in 10years

13 Inspection of pipes,valves & fittings

AnuallyCl. 9.2.4

As per OISD130(Cl.12.3.8)

NG : HalfyearlyLPG:Quarterly

14 Internal corrossionmonitoring

Mention of InhibitorInjection system,Corrossioncoupons,Corrossion probesexists but nofrequency defined.(Cl. 863.3)

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

No specificdurationdefinedexcept for I.P.

Half yearly:CorrossioncouponQuarterly: ERprobeOnce in twoyears: U.Tovergroundpiping

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INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS

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INTEGRITY ASSESSMENT OFJLPL – LPG P/L

A CASE STUDY

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PIPELINE SPECIFICATION

Pipeline Network

Product Flowing in P/L

Pipeline Section

Pipeline Length

Pipeline Diameter

:

:

:

:

:

Jamnagar Loni Pipeline

LPG

IPx to IPy

128.5 KM

16”; 406.4 mm

Pipeline Wall Thickness : 7.1 mm; 8.7 mm

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Magnetic Pig

CLEANING PIGGING

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

BR Pig

Gauge PigHigh Density Foam Pig

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Total Muck and black powder of around 150 Kg & 40Kg respectively received

All the pigs received in good condition except GaugePig.

Aluminum Gauge plate wasfound deformed from 6 O’clock

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

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

GAUGE PIGGING

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O’clock position

GAUGE PIGGING

Cleaning pigging operation completed by launching of onerun of each pig

Only 5 Kg of muck received during last pig run

To confirm deformation of P/L, 2 nos of 3C Gauge pigswere launched sequentially

Both the Gauge pigs gauge plates found deformed in 6

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CONCLUSIONCLEANING PIGGING

Pipeline must be considerably clean to runIntelligent pig

Caliper pigging is essential to locate and sizethe deformation before intelligent pigging

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During preliminary interpretation of data, noanomaly observed w.r.t. 5% reductions andovalities

Reductions & ovalities over 2% searched

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

CALIPER PIGGINGDATA ANALYSIS

Distancemeter

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 PIGGINGDATA ANALYSIS

DATA ANALYSIS

Detail of defectDistance from1.8 m to 2.28 m

Length 1.16 m

Width .21 m

oRoll 78

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CALIPER PIGGING

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VERIFICATION OF DEFECT

Location was dig where a dent of 3.8% was observed

pipeline wasresting overa huge stone

Rock wasdrilled to

make smallholes and cutoff in pieces

by chisels andhammers

after proving the sand cover31

Pipeline Coating was removed toexamine the dent

No sharp dent observed. Pipe foundflatten near the dented portion

Pipeline thickness & PSP measuredat dent location. Thickness & CPwas found normal (7.3 mm & 1.36V)

Only slight change was observedafter release of stress

No clock Spring provided

Coating repaired and pit is filled

VERIFICATION OF DEFECT

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CONCLUSION

Dent affects the safe operation of pipeline as theyrestrict the flow and tend to induce spot-likeformations of sediments, turbulence, erosion,corrosion and hydrates

Localized stress shorten Pipeline’s service life

Timely integrity assessment insures Assetintegrity and avoid any Eventuality & ProductLoss

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

RELIABILITY PROVEN OVER DECADESwith average Un-Interrupted Gas Deliverydays being more than 99.9% through trunkpipeline network

ESTABLISHED TOTAL ASSET INTEGRITYAll the Assets are as Efficient and safe as, theywere new

GAIL STRENGTH

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TemporaryRepair Cut-Out Repair

approved composite material35

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

Sleeve repair of corrodedpipe section

Sleeve repair of corrosionpitting section using API

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HOT TAPPING & STOPLING

• CONTINUOUS SYSTEMOPERATION

• NO GAS RELEASE TO THEATMOSPHERE

• REDUCED PLANNING ANDCOORDINATION COSTS

• INCREASED WORKER SAFTEY

HOT TAPPING

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