Reverse Cleaning Reverse Cleaning PiggingPigging

By: By: GAS O&M, NCRGAS O&M, NCRRandeep NainRandeep NainAbhinav GoelAbhinav Goel

Flow of PresentationFlow of Presentation

• A brief Introduction to pipeline piggingA brief Introduction to pipeline pigging

• Why reverse pigging of Jatauli – Dadri sectionWhy reverse pigging of Jatauli – Dadri section

• Planning for reverse piggingPlanning for reverse pigging

• Pre pigging preparationsPre pigging preparations

• Actual execution of the exercise Actual execution of the exercise

• Key TakeawaysKey Takeaways

Pipeline PiggingPipeline Pigging

• Removal of accumulated dust Removal of accumulated dust from the pipeline by using from the pipeline by using cylindrical shaped pigs.cylindrical shaped pigs.

• No interruption of flow in the No interruption of flow in the pipeline.pipeline.

• The pig is launched upstream The pig is launched upstream from the pig launcherfrom the pig launcher

• Pressure driven flow of gas Pressure driven flow of gas pushes the pig along down pushes the pig along down the pipeline.the pipeline.

• Pig is received downstream at Pig is received downstream at the pig receiver along with the pig receiver along with the collected dustthe collected dust

NCR PIPELINES DETAILSNCR PIPELINES DETAILS

G’BAD11 CUSTOMERS

SECUANDARABAD4 CUSTOMERS

SHIWALI RR STN

SONEPAT 11 CUSTOMERS

NTPC FARIDABAD

HBJ 24”

MARUTI

B’ GARH11 CUSTOMERS

S’BAD10 CUSTOMERS

GREP36”, 76 Km

18”, 47 Km. 24”, 45 Km.

14”, 14 KM

16”, 64 KM

CHAINSA

12”, 34 KM.

8”, 59KM.

4”, 18.2 KM.

8”/4”, 19 Km

6” / 4”, 19.8 KM

6” / 4”19.2 KM

DESUNTPCDADRI

JATOULI

4”, 21 KM

HNG/HSI

DHAULA KUAN

NOIDATAP OFF

KURI KHERA

PR SEC’BAD

Sv-3

8”

IGL N/GN

G0UNA36”

38.27KM

BAWANA

NANGAL

20”56KM

NDPL

8”13KM

20 NEW CUSTOMERS

JHAJHAR

36”, 71.6 KMVDPL48”, 76 Km

SULTANPUR

18” SNPL MANESAR

5 CUSTOMERS

10”, 5.4 KM

Hayatpur Tap OffOMAX

Auto

KAJARIA

Rathi Steel

Lafarge Baral

Maruti Suzuki

OMAX Auto

Suzukii Power Train

GGL-CGD

GGL-TOYO

Croslay PushpanjaliBhushan 2

Tirupati

Diamond Potteries

IOCL DADRI

PARLE

HNG

Ghazipur

Bamheta

Sv-4

Dasna

CGS MEERUT

Apprehension and area of concern for Pigging Apprehension and area of concern for Pigging of NCR Pipelinesof NCR Pipelines

• 20 MMSCMD of NCR gas supply can't be interrupted20 MMSCMD of NCR gas supply can't be interrupted

• previous pigging experiences were not very encouraging previous pigging experiences were not very encouraging

• An un quantified huge quantity of dust anticipated An un quantified huge quantity of dust anticipated

• It may effect the gas supply to power plants and other It may effect the gas supply to power plants and other customerscustomers

Why Reverse PiggingWhy Reverse Pigging

• NTPC Dadri is located at the fag end of GREP .NTPC Dadri is located at the fag end of GREP .

• All the dust collected during pigging gets accumulated at NTPC All the dust collected during pigging gets accumulated at NTPC Dadri .Dadri .

• The accumulated dust can lead to interruption of gas supply to The accumulated dust can lead to interruption of gas supply to NTPC .NTPC .

• The dust also gets transferred to pipeline section connected to The dust also gets transferred to pipeline section connected to Dadri such Dadri o Desu p/l .Dadri such Dadri o Desu p/l .

Past Pigging experiencePast Pigging experience

• Intelligent Pigging of 36” Jatauli- Intelligent Pigging of 36” Jatauli- Dadri section was executed in Dadri section was executed in 20062006

• First Foam PIG received with 15 Kg. First Foam PIG received with 15 Kg. dust on 30th March’06.dust on 30th March’06.

• Gauge PIG received with 1900 Kg. Gauge PIG received with 1900 Kg. dust on 30th March’06. dust on 30th March’06.

• Magnetic PIG received with huge 40-Magnetic PIG received with huge 40-50 tons of dust on 31st March’0650 tons of dust on 31st March’06

• Scrubber , filter vessels , PCV and Scrubber , filter vessels , PCV and station piping got damaged.station piping got damaged.

• Gas supply to NTPC Dadri was Gas supply to NTPC Dadri was interruptedinterrupted

Damaged Scrubber Drain Elbow Replacement Of Elbow

EFFECT OF PIGGING

Cleaning pigging of Dadri-Desu line in 2007Cleaning pigging of Dadri-Desu line in 2007

• Cleaning pigging of Dadri-Cleaning pigging of Dadri-Desu line was done on Desu line was done on December’07December’07

• Gas flow was hampered Gas flow was hampered during pigging during pigging

• Foam pig retrieve in piecesFoam pig retrieve in pieces

• Customers had refused to Customers had refused to give their consent for pigging.give their consent for pigging.

• There after pigging operations There after pigging operations were come to halt.were come to halt.

Planning for Reverse Pigging operationPlanning for Reverse Pigging operation

Connectivity of Bawana – SV-4 Desu-Bahadurgarh pipeline

Interconnection of GREP and VDPL at DadriInterconnection of GREP and VDPL at Dadri

-Enabled flow of gas from VDPL to GREPEnabled flow of gas from VDPL to GREP

-Both VDPL and GREP could be operated at different pressureBoth VDPL and GREP could be operated at different pressure

--10 MMSCMD uncompressed HP gas in GREP

Pre Pigging activitiesPre Pigging activities• Modification of receiver at Dadri Modification of receiver at Dadri

• Checking of Sv’s valve performance, receiver launcher Checking of Sv’s valve performance, receiver launcher barrels barrels

• Arranging Logistics during pigging at JatoliArranging Logistics during pigging at Jatoli

• Team deployed at Chhainsa, Faridabad and Gurgaon Team deployed at Chhainsa, Faridabad and Gurgaon

• Arranging the fire tender at Jatoli and other dust and Arranging the fire tender at Jatoli and other dust and liquid hydrocarbon handling and disposal liquid hydrocarbon handling and disposal arrangementsarrangements

Reverse Cleaning Pigging of 36" Dia GREP Reverse Cleaning Pigging of 36" Dia GREP PipelinePipeline

Section:- Dadri - Jatauli (73.850 KM) :Section:- Dadri - Jatauli (73.850 KM) :

- Pigs were launched from Dadri for reverse Pigs were launched from Dadri for reverse

- Received at IP Station Jatauli Received at IP Station Jatauli

- Four runs of pigs i.e. Foam Pig , Gauge Pig , Brush Pig and - Four runs of pigs i.e. Foam Pig , Gauge Pig , Brush Pig and magnetic pig magnetic pig

SV StationSV Station

Station Station Interval Interval Distance Distance

(KM)(KM)

Distance Distance BetweeBetwee

n SV n SV (KM)(KM)

Gas flow In Gas flow In MMSMMMSM

DD

Gas/Pig Gas/Pig VelocitVelocit

y y (KM/Hr)(KM/Hr)

Time Time DuraDurationtion

Expected Expected PIG PIG

Arrival Arrival Time Time HrsHrs

DADRIDADRI 499499 00 9.339.33 8.838.83 0.000.00 0.290.29

LADPURA LADPURA (SV-12)(SV-12) 479.66479.66 19.3419.34 9.339.33 8.838.83 2.192.19 0.450.45

CHAINSA(SV-CHAINSA(SV-11+CP+11+CP+RR)RR) 456.75456.75 22.9122.91 9.089.08 8.608.60 2.662.66 0.590.59

JATAULI JATAULI (IP5+CP(IP5+CP+RR)+RR) 423.35423.35 33.433.4 4.524.52 4.284.28 7.807.80 0.670.67

      75.6575.65       12.6512.65   

PIGPIG TRACKING CHARTTRACKING CHART

In-house Cleaning Pigging of 36" In-house Cleaning Pigging of 36" Dia GREP Pipeline Dia GREP Pipeline Section:- Dadri - Section:- Dadri - Jatauli 73.850 KMJatauli 73.850 KM

Pig runPig run 11 22 33 44

DateDate 17-Oct-1117-Oct-11 18-Oct-1118-Oct-11 19-Oct-1119-Oct-11 20-Oct-1120-Oct-11

Type of PIGType of PIG FOAMFOAM GAUGEGAUGE

Cleaning Cleaning (Brush + (Brush + Magnet) Magnet)

PigPig

Cleaning Cleaning (Brush + (Brush + Magnet) Magnet)

PigPig

Launching stnLaunching stn DADRIDADRI DADRIDADRI DADRIDADRI DADRIDADRI

Launch timeLaunch time 8:30 AM8:30 AM 4:10 PM4:10 PM 6:25 AM6:25 AM 5:13 AM5:13 AM

Receiving stnReceiving stn JATAULIJATAULI JATAULIJATAULI JATAULIJATAULI JATAULIJATAULI

Received timeReceived time 01:30 AM on 01:30 AM on 18.10.201118.10.2011

02:00 AM on 02:00 AM on 19.10.201119.10.2011 5:30 PM5:30 PM 9:20 PM9:20 PM

PIG travelling time in hrsPIG travelling time in hrs 17 hrs17 hrs 09 hrs 50 min09 hrs 50 min 11 hrs 05 min11 hrs 05 min 16 hrs 07 min16 hrs 07 min

Condition of pigCondition of pig Partially damagePartially damage GoodGood GoodGood GoodGood

Debris in kgDebris in kg 20.020.0 50.050.0 5.05.0 10.010.0

Liquid in lit.Liquid in lit. 2020 00 00 00

CUMMULATIVE DEBRIS IN CUMMULATIVE DEBRIS IN LtrLtr 20.020.0 20.020.0 20.020.0 20.020.0

CUMMULATIVE DEBRIS IN CUMMULATIVE DEBRIS IN kgkg 20.020.0 70.070.0 75.075.0 85.085.0

RemarksRemarks Partially foam Partially foam damagedamage

Gauge plate Gauge plate found OKfound OK      

Pig launched at Dadri Pig received at Jatoli

Challenges faced during pigging:-Challenges faced during pigging:-GREP line pig barrel door got stick at Dadri and Jatoli because of GREP line pig barrel door got stick at Dadri and Jatoli because of

misalignment between barrel door and barrelmisalignment between barrel door and barrel

DO’sDO’s• Always check all the valvesAlways check all the valves• Always close the barrel door in align condition only by simple pushAlways close the barrel door in align condition only by simple push• Regularly open and close barrel doorsRegularly open and close barrel doors• Always make the pig receiving trolley and pig handling arrangements Always make the pig receiving trolley and pig handling arrangements

(chain pulley blocks, trolley etc)(chain pulley blocks, trolley etc)• Arrangements for hydrocarbon mug and liquid handling and disposalArrangements for hydrocarbon mug and liquid handling and disposal• Always launch the pig with pig tracking system with adequate battery Always launch the pig with pig tracking system with adequate battery

lifelife

Main Challenges

AchievementsAchievements

• Successful completion of GREP cleaning pigging Successful completion of GREP cleaning pigging

• Confidence build up to do future pigging of various other NCR Confidence build up to do future pigging of various other NCR pipelines with effecting the gas supplypipelines with effecting the gas supply

Future Course of actionFuture Course of action• Scrubber shall be installed at Jatoli for future cleaning piggingScrubber shall be installed at Jatoli for future cleaning pigging

• Foam pigs OF DADRI-DESU Pipeline is planed.Foam pigs OF DADRI-DESU Pipeline is planed.

• Job awarded for the Intelligent Pigging of 16” CFPL & 14” CGPLJob awarded for the Intelligent Pigging of 16” CFPL & 14” CGPL

Benefits of the exerciseBenefits of the exercise

TangibleTangible• Prevention of revenue lossPrevention of revenue loss • Pipeline EfficiencyPipeline Efficiency

• confidence for future pigging operationsconfidence for future pigging operations

• Goodwill among customersGoodwill among customers

Intangible

THANK YOU