www.mcitechnology.org Issue 1, September 2015
High Quality 3 Layer Pe Coatings For The Sauni Project In India
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Pipeline Life-Cycle extension Strategies – Operation & Maintenance
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Measuring & Controlling Soil-side Corrosion on Above ground Storage Tank Bottoms Using eR Probes and Amine Carboxylate VpCI Technology
Asset
Integrity
Management
Model Pg. 5
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Pipeline Industry
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Content
I s s u e 1, S e pte m b e r 2 015
editorial
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Asset Integrity Management Model (AIMM)
05
High Quality 3 Layer Pe Coatings For The SAUNI Project In India
12
Pipeline Life-Cycle extension Strategies – Operation & Maintenance
15
Published by: MCI Technology
Contributors: J N Agrawal ex. Chief Manager (O&M) GAIL
List of Training Programs
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Chanchal Dasgupta
Measuring & Controlling Soil-side Corrosion on Above ground Storage Tank Bottoms Using eR Probes and Amine Carboxylate VpCI Technology
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26
Khalil Abed
List of Conferences And exhibitions on Asset Integrity
Business Development Manager CORTeC Middle east
Industry News
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Application Marketing Manager Borouge (India) Pvt. Ltd.
Amish Gandhi Country Head (India) Metal Samples
Designing: J. Roy
Asset Integrity Management Model (AIMM) | 05
Contact Us: MCI Technology Email:- contact@mcitechnology.org www.mcitechnology.org
Suggestions & Feedbacks: Please send your suggestions, comments and views on the Newsletter for improvement to contact@mcitechnology.org Disclaimer: The information provided in this newsletter is for educational purpose only. Articles and editorials herein represent the opinions of the authors, MCI Technology extends no warranties/ liabilities for the accuracy or completeness of the information contained herein, and assumes no responsibility regarding the consequences of its use or for any printing errors. Advertising is included as an information sharing service, and the publishers do not accept responsibility for any claims made by advertisers about their products and/or services. Publisher reserves the right to prohibit any advertisement. Reproduction of the contents, either as a whole or in part, is forbidden unless permission has been obtained from the publisher.
High Quality 3 Layer Pe Coatings For The SAUNI Project In India | 12
Copyright 2015 by MCI Technology.
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Welcome Message
W
elcome to the first issue of e-newsletter on Asset Integrity Management (AIM). This initiative has been taken to provide a platform to all the technologists, educationists, scientists, academicians and professionals of all the industries to share their knowledge and discuss issues pertaining to Asset Integrity. From a life cycle perspective, which includes the design, storage, installation, operation and maintenance, an asset should always perform to its required design function both effectively and efficiently. The assets may be susceptible to physical damage and/or external/internal corrosion which may lead to pre-mature failure, safety, integrity and environmental issues, affecting brand image, huge replacement/repair cost and production loss. It is a hard fact that we are not fool proof in maintaining asset integrity despite of availability of latest technology and materials for corrosion control and mitigation measures. The recent failure of a gas pipeline in KG basin and explosion is a latest example of slackness in asset integrity. The time has come now to understand the implication of slackness in maintaining asset integrity. Some of the measures required to maintain asset integrity are right selection of material and processes during design stage, right construction practices, proper operation, maintenance and monitoring methodology and adequate mitigation measures. A separate AIM group is required for coordinating all these activities following asset integrity
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management procedure to ensure reliability and safety of our assets in a cost-effective manner. Our engineers are required to undergo various training programmes and courses on corrosion prevention and control together with Case studies, field surveys, live demo of inspection and testing, analysis of data and its interpretation and finally taking appropriate mitigation measures to understand theoretical and practical aspects of corrosion prevention and control. The expenses incurred on corrosion prevention are quite less in comparison to loss due to corrosion. Cost of corrosion also includes waste of materials and energy. Through this e-newsletter we want to spread the knowledge of asset integrity management among industry professionals. The e-newsletter will contain articles, reports, case studies, discussions, problems and solutions, information about new technology, materials and processes and other products & services related to asset integrity. We invite all professionals to contribute in successful mission of spreading knowledge of asset integrity through exchange of information. Your feedback is important to us so write to us about its contents and your suggestions to improve it. Well wishes to all and HAPPY ReADING Mr. J. N. Agrawal ex. Chief Manager (O&M), GAIL On behalf of AIM Team
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Asset Integrity Management Model (AIMM)
A
sset integrity is of paramount importance for optimization of asset utility and cost reduction apart from safety and environmental issues. Asset integrity is required in all industries ranging from oil and gas, power, fertilizer, petrochemicals, construction, chemicals, construction, steel and host of other industries utilizing assets susceptible to corrosion. Unfortunately a robust system of asset integrity management system (AIMS) does not exist in most of the organizations with the result that huge repair and replacement cost is incurred due to breakdown of asset. There is no system to compute cost of asset breakdown due to lapse in quality control at each stage of asset life cycle, hence the subject needs attention. I will be dealing with asset integrity management model with particular reference to corrosion threats. The idea contained in this article is basic and based on my personal experience and expertise. Professionals may devise their own model depending upon their organizational structure and asset integrity issues.
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WHAT IS ASSET INTEGRITY? Mr. J. N. Agrawal We should first ex. Chief Manager (O&M) understand the GAIL meaning of asset integrity. Asset integrity may be defined as “The ability of an asset to perform its required function effectively and efficiently within its life cycle protecting health, safety and environment�. Asset integrity can be maintained by strict Quality Management System (QMS) incorporating QA/QC at each stage of the asset life cycle such as designing, manufacturing, project execution, operation and maintenance and retiring. It is also to be understood that by asset integrity we mean that the asset performs and produces desired result as per expectation as well as with optimum result and minimum cost. The knowledge and skill is required at every stage of asset life cycle to maintain asset integrity. A close interaction is required between different
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Integrity Management System
Fig 1: Asset integrity management model 1
functions of an organization such as design, project, construction, operation and maintenance, internal audit, quality control, risk management, safety, health and environment to achieve asset integrity. Asset integrity management system (AIMS) adopts systematic approach to identify threats, assess health condition and take suitable mitigation measures to address threats and maintain safety and integrity of assets. Asset Integrity management improves plant reliability and safety while reducing unplanned maintenance and repair costs.
established. (ii)
Asset integrity management policy with its objectives, target and plan (OTP), processes and procedures, roles and responsibilities etc. should be established.
(iii)
Computation of cost of corrosion and ROI on corrosion control should be done.
(iv)
Asset integrity management system should be a part of each element of asset life cycle such as design, manufacturing and construction, operation and maintenance and retirement. In addition, system should be aligned with other disciplines related to asset integrity such as SHe, quality, risk management etc.
(v)
SOP’s should be available for each activity at each stage of asset life cycle to maintain asset integrity and the job should be done under supervision of competent professional.
(vi)
AIMG should have monitoring and reporting
SALIENT FEATURES OF ASSET INTEGRITY: Asset integrity management model may be conceptualized on the basis of certain salient features of asset integrity. They are as follows: (i)
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A centralized asset integrity management group (CAIMG) and regional asset integrity management group (RAIMS) should be
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mechanism of each activity at each stage of asset life cycle to ensure that job is done as per approved SOP’s and as per standards and statutory regulations. (vii) Periodic reviews by Board should be done on integrity issues at each stage of asset life cycle and nature of non-conformities and its remedial actions be monitored with timeline and responsibilities. (viii) AIMG should monitor vendors and supplier’s performance and credibility in asset integrity control practices and guide them for complying with asset integrity control processes. (ix)
(x)
(xi)
Internal and external audit for compliance of asset integrity, quality and safety, risk analysis and mitigation measure should be done engaging professional in related field and time bound remedial measures should be taken. Human resources are important so far as asset integrity is concerned, hence well qualified and experienced preferably NACE certified professionals should be deputed at various stages of asset life cycle. Motivation and reward are other ingredients for successful asset integrity management system. Annual performance report should have KPA/KPI in asset integrity task to measure individual’s performance in that field.
(xii) Knowledge sharing, training and communication play an important part in asset integrity management. Group meet, onsite and off- site training, internal discussion and case studies help in maintaining asset integrity. (xiii) Documentation plays an important part in asset integrity management system. All the asset initial design, manufacturing and construction, operation and maintenance and retrieval data including drawings, documents and records should be available in digital form in centralized document cell.
ASSET INTEGRITY TOOLS: The important aspect of asset integrity management system is application of asset integrity tools to identify threats, assess health condition with respect to application and take mitigation measures. The tools will be specific to function of departments looking after asset integrity. Specific tools related to different asset life cycle will be discussed. m
Design and engineering: Design and engineering software based module based on ASMe, API, DNV considering all aspects of material selection for specific use, design life, cost optimization, safety, statutory requirement etc.
m
Manufacturing/Construction: (i)
QMS software tools
(ii) Risk Management software tools (iii) SHe software tools m
Operation and maintenance: (i) electronic data management system for records in soft form (ii) O&M software modules for meeting schedules
EXAMPLES OF PIPELINE INTEGRITY MANAGEMENT SYSTEM (PIMS):
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m
Objective:
u Aims at prevention of metal loss due to external and internal corrosion and disastrous
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Fig 2: Asset integrity management model 2
failures endangering public safety, environment and financial & reputation loss.
u evaluate the risk associated with natural gas and LPG pipelines and effectively allocate resources for prevention and detection of corrosion and mitigation activities
u Improve the safety and integrity of pipelines to protect the personnel, property, public and environment
u To streamline effective operations to minimize the probability of pipeline failure.
m
Strategies:
u Risk based integrity assessment
u Quality assessment plan
u Cost and performance evaluation
u Integrity audit
u Software application and automation
u Condition monitoring
m
Processes: Applicable to all asset cycle that is design, construction, O&M and
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abandonment
u Risk assessment and IM planning: Threat to asset integrity and risk, risk score and existing practices, integrity plan for inspection, monitoring and testing, integrity assessment and mitigation, intervention and repair.
u Inspection, monitoring and testing:
u Integrity assessment
u Mitigation, intervention and repair
m
Codes and regulatory requirement:
u PNGRB-IMS Regulation 2012
u OISD 226
u ASMe B31.8S/API 1160
u NACe SP 0502-2010 eCDA
u NACe SP 0206-2006 ICDA
m
Solution:
u
Integrated enterprise wide GIS enabled software solution
u
Compilation of all data in PIMS aligned with SAP/DCS/eCDS
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Fig 3 Total concept of Asset integrity management model
ASSET INTEGRITY MANAGEMENT MODEL: m
Conclusion:
Basis of asset integrity management model
This article has exhibited different
The basis of integrity management model is explained in the example of pipeline integrity management system. Similarly for other assets integrity management model may be designed. The sequence of events in asset integrity model may be expressed as follows:
aspects of asset integrity management
Model 1: Shows the integrity management process and role of other services Model 2: Sequence of events in risk estimation and integrity management planning Model 3: Total concept of Asset integrity management model
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model and why it has got tremendous importance for obtaining quality, safety and long life of asset thus saving enormous cost in repairing and rehabilitation. A systematic AIMM is the need for quantitative and qualitative evaluation of asset integrity for taking decision on inspection, testing and monitoring, integrity assessment and finally repair and rehabilitation.
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2nd International Conference & Exhibition on
“Pipeline Integrity Management (ICEPIM 2016)� 5 - 6 February 2016 The Grand Hotel, New Delhi Organized by
Supported by
World ils
Participation in ICEPIM 2015
For Details log on to: www.pipelineintegritymanagement.in
Conference Paper Presentations / Poster Papers Theme Topics of ICEPIM 2016 Session 1: Planning, Design and Construction of pipeline Session 2: Pipeline Materials, various issues in Pipeline Fabrication & Repair Session 3: Corrosion & its Control Techniques- Cathodic Protection, Inhibitors & Coatings Session 4: Latest Inspection Techniques in Pipelines Risk Management Session 5: Operation, Maintenance Repair & Rehabilitation of Aging Pipelines Session 6: Pipeline Integrity, Safety and Reliability Management Session 7: Challenges and Development in Pipeline & City Gas Distribution (CGD Industry) Panel Discussion
Exhibition
Awards and Recognition - Best Oral Paper
Complimentary delegates
- Best Poster Paper - Award for Best exhibition Booth
Company profile/ Advertisement in Souvenir
- Award for Innovative technology - The Pipeline Integrity expert Award
Display of company logo in the Venue
Pre-conference Training Programs
Display of company logo in Website
Topic 1 Pipeline Integrity Management (1 day) Topic 2 Cathodic Protection design, applications and Survey (1 day) Topic 3 Coating Integrity evaluation & Surveying (1 day) Topic 4 Inspection & Repair techniques in Pipeline (1 day)
Advertisement in Newsletter “Asset Integrity Management�
Important deadlines
Abstract Submission: 30.09.15 Acceptance of Paper: 31.10.15 Submission of Full Paper: 30.11.15 Registration of Delegates: 15.01.16 Registration for Pre-conference Training Programs: 15.01.16
High Quality 3 Layer PE Coatings For The SAUNI Project In India
Mr. Chanchal Dasgupta Application Marketing Manager Borouge (India) Pvt. Ltd.
THE BACKGROUND Long term solutions required for water scarcity in India The State of Gujarat in western India has suffered three drought years in the past decade and in the worst affected areas, such as the Saurashtra and Kutch regions, the usual mode of providing drinking water was in road tankers. Irrigation, which uses >80% of available surface and groundwater used to suffer due to lack of water
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availability. Though Gujarat is a front runner in water saving methods like drip irrigation and mulching for irrigation, they needed to develop a longer term solution. Hence Gujarat Govt designed the ambitious SAUNI water conservation scheme. This involves charging 115 reservoirs in the Saurashtra district with water from the Narmada River and linking them with 464km of large steel pipes up to 3meter in diameter and 1,100km of pipes in total including
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smaller diameter pipes of 750 mm.
THE SOLUTION
Traditionally in India an internal cement coating (popularly known as guniting) has been used to protect the steel water pipes from corrosion but there have been problems with this solution. For example recently it was reported in the Times
The engineers choose high performance 3LPE coating for pipelines.
Higher performance coating required for these important water pipelines.
After substantial technical and commercial deliberation, the SAUNI project engineers decided to adopt the superior protection provided by 3LPe coatings for these strategically important water pipelines following the international trends. The oil and gas industry already relies heavily on 3LPe coatings to protect the majority of their pipelines. A high level of factor of safety and quality control is maintained as failures of these pipelines can be very costly indeed. In the Middle east many mega water projects areutilising these same materials such as the Ras Al Khair project for Saline Water Conversion Company (SWCC) in Saudi Arabia. In this project twin large diameter pipelines are used to transport one million cubic metres of water per day from the desalination plant at Ras Al Khair to Saudi Arabia’s capital city of Riyadh.
It was essential that the large diameter steel water pipes for the SAUNI project were well protected from corrosion throughout their lifetime and with a much higher service life. This includes any potential impact during handling, transportation, outdoor storage, installation and corrosion protection for a long operational life.
even in India Gujarat Water Infrastructure limited carried out a large water pipeline project In 2012, where 437 kms of pipelines with diameter ranging from 1800 to 2400 mm were coated. However, 3LPe coating of 3 meter diameter steel pipe line was carried out first time in the world by Indian coaters for SAUNI project
of India that 384 villages in Gujarat State went without water for a couple of days owing to pipeline failures due to corrosion. The problem is that over time the cement coating cracks, allowing water to permeate through the coating which leads to corrosion of the steel pipe and eventually failure. Unfortunately the quality of the cement coating itself may vary a lot because it is largely a manual mixing and application process that is difficult to control.
THE CHALLENGE
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THE BENEFITS The coating of the SAUNI pipes is taking place in a number of stages since early 2014 and most of the work was carried out by coating companies who have plants in Gujarat State. This includes Jindal Saw Limited, Welspun Corp, Man Industries, Ratnamani and Hazira Pipe Mill (essar). These coating companies are regular users of Borcoat 3LPe coating materialswhich are approved by all international standards. Pipeline construction also taking place in several stages and many leading contractors are involved including Larsen and Toubro (L&T), SPML Infra, Hindustan Construction Company (HCC), Megha engineering and Infrastructure Ltd (MeIL), NCC and Pratibha Industries. SAUNI project specification has been drawn exactly in the same way as Oil and Gas pipeline specification to provide same kind of reliability to the pipelines. Borouge produces the BorcoatPe top coat in its plant in Abu Dhabi using patented bimodal technology which enables the balance between the processing and mechanical and eSCR properties of the material which is supplied as fully formulated compounds. The high mechanical properties, resistance to UV and environmental Stress Cracking ensure that the coating will provide a high level of protection to these important water transportation pipelines for many years to come.
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Pipeline Life-Cycle Extension Strategies – Operation & Maintenance
ABSTRACT Safe and secure energy transport is of paramount importance for all economies in the world. Safety, reliability, integrity and economics of oil & gas pipelines are key parameters for the acceptance of all stakeholders involved. India currently has a network of over 40,000 Kms of cross country oil & gas pipeline with additional 15000 Kms upcoming. With this quantum of hydrocarbon pipeline network, it is must to ensure the pipeline safety and to minimize the environmental risks. As pipelines become older, it becomes important for an operator to implement efficient operation & maintenance practices for enhanced life cycle of pipelines. Pipeline operators/owners can help in a big way even the aging pipelines (50 years+) by operating in a safe manner by adhering to the national/ international codes & standards. The PIMS (Pipeline Integrity Management System) is the need of the hour, where all relevant
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information, integrity evaluation methods, repair tools and Mr. Amit Kumar Sharma standards for the DGM – Business Development pipeline are laid down Sanmarg Projects Pvt. Ltd. in the most user friendly way. PIMS is fed by data received through In-Line Inspection, cathodic protection system, and the historical data inputs including the pipeline base data. Together with other integrating tools (SCADA, SAP etc.) and innovative maintenance methods a long and economically reasonable pipeline life-cycle can be achieved. This paper shall discuss how advance operation & maintenance technologies lead to the pipeline lifecycle extension, besides other important factors such as construction and material selection.
Key Words GIS
: Geographic Information Systems
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PNGRB : Petroleum and Natural Gas Regulatory Board OISD
: Oil Industry Safety Directorate
SCADA : Supervisory Control and Data Acquisition SAP
: System, Applications and Products in Data Processing
ILI
: In – Line Inspection
NDe
: Non – Destructive Testing
PSL
: Pipe Specification Level
MPS
: Manufacturing Procedure Specification
eRW
: electrical Resistance Welding
HFW
: High Frequency Welding
CAT
: Current Attenuation Test
DCVG : Direct Current Voltage Gradient CIPS
: Close Interval Potential Survey
SCC
: Stress Corrosion Cracking
ISO
: International Organization for Standardization
API
: American Petroleum Institute
eRRS
: emergency Response & Repair System
DIMP
: Distribution Integrity Management Program
INTRODUCTION India has been among the world’s fastest growing economies. With expanding economy comes an increasing demand for energy and, if current trends continue, India will be the world’s third largest energy consumer by 2020. Due to the expected strong growth in demand, India’s dependency on oil & gas imports is likely to increase further. Rapid economic growth is leading to the higher dependency on pipeline infrastructure which is the safest mode of Oil & Gas transport. Leaks are common in the old pipelines all across the world. For instance, 39% of the UK gas network was considered at-risk, and the last statistics for leaks was 23,000 per year Similar situations are with all the pipelines and this is because of many reasons but primarily because of ageing of the pipeline. Recently, in New York east Harlem neighborhood, an explosion destroyed a five story building and killed eight people. The pipeline was 127 year old. Investigations determined that the cause of the explosion was natural gas leaking through fractured pipes due to stress cracking. In the Indian context, recently a major accident happened in a natural gas pipeline in South India
Per-capita energy Consumption (PeC) increased from 3,497.59 KWh in 2005-06 to 6748.61 KWh in 2012-13, a CAGR of 8.56%(Table 6.2). The annual increase in PeC for 2012-13 over 2011-12 was 8.76%. Source: energy Statistics 2014, Ministry of Statistios and Programme Implementation
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which caused death of 16 people. The cause behind accident was major leak due to corrosion. It was raining on the day, whole the night the gas was leaking, which possibly formed vapor cloud. A tea stall owner turned on the stove in the morning, possibly provided the source of ignition. In another episode, a crack in mainline valve, led to gas leakage thus causing an explosion, however no casualties were reported. In Delhi recently, a gas pipeline burst due to accidental digging of pipeline by PWD workers. Pipelines worldwide are leaking, cracking and creating the potential for catastrophic accidents. The causes could be corrosion, defective material or construction practices, not following safety protocols etc. Out of the present Indian pipeline infrastructure, about 33% are more than 25 years old and about 5000 Kms pipelines are non piggable. The task of replacing outdated gas pipelines typically falls on the pipeline operators which is a costlier affair. Various studies shows that implementation of an effective program go a long way in maintaining the structural integrity of the ageing pipelines with extended service life. Pipeline operators are expected to pay for muchneeded upgrades and maintenance work that will prevent future disasters and loss of life, for which recovering of the cost of those upgrades are in terms of reduction in long term risks e.g. reputational effects, damage to share price and production loss because of shut down time. Fortunately, regulatory bodies and pipeline operators worldwide are working together to face this situation head-on. In India, pipeline operators and government bodies such as PNGRB & OISD are working in incorporating the best practices followed worldwide. More focus is given to the preventive inspection methodologies by increasing the frequencies of periodic inspection such as Inline Inspection & Cathodic Protection surveys. Implementation of the pipeline integrity management system is another important area where PNGRB has come up with a mandatory notification of pipeline integrity management plan implementation in phased manner for all the pipeline operators.
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CAUSES AFFECTING THE PIPELINE INTEGRITY: The causes of failure can be from any of the three stages of pipeline such as Design & engineering, Construction and Operation phase. Without taking care of ground realities, going for readymade solutions can cause the wrong material selection, coating selection and selection of welding technology/procedures etc. Lack of quality control during construction period (such as sand padding in trench, cut back length, radiography, surface cleaning etc.) leads to damage to the pipeline coating/joint coating which further leads to susceptibility of the pipeline towards severe corrosion in a small period of time. In upstream, one has producers producing the Oil & Gas to fulfill the growing demand whereas in the downstream, you have hundreds of kilometer of pipeline infrastructure to deliver the same to market. At the point of custody transfer from upstream producer to the downstream operator, are the multitudes of analyzers that ensure contaminants such as sulphur / water are at low enough levels to protect the pipelines and keep the public safe. This critical measurement prevents corrosion, which in the worst case can lead to pipeline rupture. Also the communication plays a crucial role in smooth operation of the pipelines. Improper maintenance of instruments, calibration issues, third party damage can lead to the communication problems which can cause a major incident. In the pipelines, all elements of your measurement system must be optimized. If you are not using the total measurement system, then you risk making a less accurate measurement, which leaves you susceptible to economic losses.
MAJOR CHALLENGES IN PIPELINE OPERATION & MAINTENANCE: The first and foremost challenge is to create the serious concern about the risk associated and its mitigation measure for pipeline assets amongst all the key stake holders, be it the operator,
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government, regulatory bodies, customers and the society. Secondly, to create an integrated approach towards smooth operation & maintenance along with the emergency response & repair system which will lead towards long term profitability and enhanced life of the asset.
IMPLEMENTATION OF NEW TECHNOLOGIES: Implementation of next generation technologies will be integral to enabling the safe and reliable delivery of energy – now and for generations to come. A successful strategy will demand that utilities pilot new technologies and design process that make sense for their customers and regulators, win the rate case, define comprehensive implementation and change management plans, and integrate all the pieces to realize efficient, reliable and safer pipeline operations. Overcoming the hurdles to implementing the nextgeneration leak-detection technologies won’t be easy. However new ways of leak detection are based on fiber optic cable and work on the temperature sensing and acoustic sensing. Robotic ILI tools with high-accuracy NDe sensors have proven through numerous inspections to be highly effective tools that supplement pipeline operators’ traditional flow driven smart pigging activities. Robotic ILI tools are used in the portion of their pipeline systems that include sections with low flow, geometric challenges, or other parameters that make flow driven pigging impossible or uneconomical. Robotic ILI is also valuable for use in performing detailed “remote examination” of pipe sections that cannot be excavated. The Introduction of the HFW welding process as a mandatory requirement for PSL2 pipes in table 2 & 3 of API 5L/ISO 3183 is indeed an improvement over the inherent problems of hardness, lack of fusion and susceptibility of stress corrosion cracking (SCC) in line pipes associated with eRW process pipes. The engineers responsible for selecting material should consider these
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improvements during the manufacturing procedure specification (MPS) approval of the pipe procurement process.
AN INTEGRATED APPROACH TOWARDS MAINTENANCE AND EMERGENCY PREPAREDNESS: We can never say, ‘It will never happen again,’ but we becoming more prepared and can reduce highprofile incidents like in New York and India. In the wake of four major pipeline accidents in June, emergency preparedness is taking center stage. With a leaking oil pipeline igniting a huge blaze in China, Pipelines exploding in Malaysia, Ukraine and India operators are taking a hard look at how vulnerable their assets are to third party threats. These incidents are dramatic reminder of the random threats that can affect pipelines and the urgency of having an emergency response & repair system (eRRS) in place. They must also achieve the highest possible level of post-repair integrity, at the lowest possible cost. There are advancements in eRRS practice to save clients’ time and significantly reduce the financial impact by using a structured process approach to integrated maintenance and emergency repair planning during an unplanned repair where the timeline for accident to re-commissioning can be dramatically compressed, minimizing downtime. Based on a thorough understanding of the risks and repair scenarios for an asset, combinations of repair methods are selected. Procedures along the critical path-from isolation of the damaged section to re-commissioning are adjust and through smarter outsourcing strategies for equipment and services contracts are awarded. Finally, roles of personnel and departments are aligned around the maintenance & repair plan, so each party work together during routine maintenance and emergency. Selecting the right team to perform integrated outsourced services can lead to lower costs, accelerated ramp-up schedules and experts to manage program scale. Pipeline operators in India
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have already adopted this concept as a result of which 1014 Kms crude oil pipeline from Mundra to Bhatinda is maintained on this concept for last four years. Two more major pipeline operators have conceived the idea and are coming with similar approach for a part of their existing pipeline networks as a pilot project. Outsourcing a composite work program can free up internal resources, eliminate the need to hire and train personnel, and keep payroll and benefits expenses in check. However at the same time the operator should keep in mind the key consideration when selecting the outsourced partner: -
Range of services
-
Level of participation
-
Breadth of experience
-
Years of experience
-
Access to new technology
-
Geographic reach
A distribution integrity management program (DIMP) is the need of the hour and should be implemented in India, just like in the United States which is a state federal partnership that requires pipeline operators to formally prioritize pipeline replacement projects, ensuring that the oldest and most damaged pipelines are replaced first.
stakeholders and with other pipeline operators, authorities and government departments.
CONCLUSION To sum up, Integrity assurance of ageing pipelines is the need of the hour for pipeline companies considering the high replacement cost of pipeline infrastructure.
Acknowledgement I would like to thank to my senior colleagues Mr. R. C. Jindal and Mr. P. Chicker who have provided me an opportunity and guided me to present this paper on pipeline operation & maintenance. I also like to thank to my colleague Ms. Jigyasa Kaul for keep on motivating me for writing this paper.
References 1. Pipeline & Gas Journal, Vol. No. 241, January 2014 2. Pipeline & Gas Journal, Vol. No. 240, October 2013 3. Pipeline & Gas Journal, Vol. No. 241, December 2014 4. Oil & Gas Journal website, www.ogj.com 5. US energy Information Administration, www.eia. gov 6. Petroleum & Natural Gas Regulatory Board
ROLE OF THE PIPELINE OPERATOR:
7. Oil Industry Safety Directorate
Change in mind set from Detection to Prevention.
8. energy Statistics 2014, Ministry of Statistios and Programme Implementation.
Improvement in training to all stakeholders.
9. Petroleum Planning and Analysis Cell
Testing, supporting and implementing new technologies.
10. ASMe B31.8S 11. DNV USA, www.dnvusa.com
Improvement in communication practice with all
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Enhance Your
Technical Skills & Expertise No.
Training Course Title
Duration
Asset Integrity Courses 1
Refresher Course on Corrosion Basics, Control, Monitoring and Management
3 days
2
Cathodic Protection: Principles & Practices
2 days
3
Industrial Cooling Water Treatment Management to Control Scaling, Fouling and MIC
2 days
4
Different Forms of Corrosion: Mechanisms, Recognition & Prevention
2 days
5
Corrosion Control by Selection of Materials
2 days
6
Pipeline Integrity Management
3 days
7
Industrial Coating Systems- Selection & Applications
2 days
8
Ageing Plants Assets Corrosion Management
2 days
9
Corrosion Inspection and Monitoring of Plant equipment
2 days
10
Concrete & Steel Structure Corrosion Control Management
2 days
11
Coastal Plants Corrosion Control Management
2 days
API Preparatory Courses 1
API 510 Pressure Vessel Preparatory Course
5 days
2
API 570 Piping Inspector Preparatory Course
5 days
3
API 653 Above Ground Storage Tank Inspector Preparatory Course
5 days
4
API 577 Advance knowledge of welding inspection and metallurgy course
3 days
5
API 580 Advance knowledge of risk based inspection course
3 days
6
API 571 Advance knowledge of corrosion and material course
3days
7
API – 936 Refractory Design, Installation, Inspection & Repair
3 days
8
API – 1169 Pipe Line Inspector
5 days
Certified NDT LEVEL I or II - Course Exam & Certification 1
Liquid Penetrant Testing Direct Level I or II, Course Exam & Certification
2 days
2
Magnetic Particle Testing Direct Level I or II Course & examination
5 days
3
Ultrasonic Testing Direct Level I or II, Course Exam & Certification
5 days
4
Radio Graphic FilmInterpretation level II
5 days
5
Radiographic Testing Direct Level I or II Course Exam & Certification
5 days
6
Visual Testing Direct Level I or II, Course Exam & Certification
3 days
Certified Advance NDT Level I or II Course Exam & Certification 1
Eddy Current Testing Level I or II, Course Exam & Certification
5 days
2
Helium Leak Testing Level I or II, Course Exam & Certification
5 days
3
Infrared Thermography – Direct Level –II
5 days
4
Vibration Analysis Level I or II Course
5 days
1
National Seminar On Pressure Vessel & Piping Technology
Pressure Vessel& Piping Coursesw 3 days
Based on the Client’s requirement, the above training programs can be modified to suits Client’s Job profile. Please contact info@mcitechnology.org for details
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Submit an Article “Asset Integrity Management”newsletter,is an important initiative for sharing information and knowledge to increase integrity, reliability and safety of assets. The newsletter will deliberate on the state-of-the art material &corrosion science and technologies outlining various ways to control corrosion, exploring application of advanced materials and various Inspection/NDe techniques to assess/ monitor the prevailing problems. We welcome all the authors and professionals for contributing your technical articles for publishing.
Gifts and Reward Systems Based on the review by the editorial board and feedbacks from the readers, few authors will be selected for special gifts or rewards to encourage.
Advertisement It is one of the largest circulated e-newsletter dedicated exclusively onthe “Asset Integrity Management”. With a significant no of free circulation (more than 15,000 worldwide) covering almost all the industry, service provider, contractors, supplier as well as end users, this is the right place to present your company/ product. The advertisement rate is very much competitive and special discount provided for multiple advertisement. Advertisement Rate Details Single Issue (INR/USD) Front Cover 25,000 (500) Back Cover 20,000 (400) Inside of Front/ Back Cover 15,000 (300) Full Page 10,000 (200) Half Page 6,000 (120)
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Measuring & Controlling Soil-side Corrosion on Above ground Storage Tank Bottoms Using ER Probes and Amine Carboxylate VpCI Technology aboveground storage tank bottoms are a serious industrial challenge from both an operational and regulatory perspective. Different protective methods have been utilized to provide corrosion protection to the underside of a tank floor, such as cathodic protection. However, air gaps between the bottom plates and construction pad may render a CP system Mr. Amish Gandhi Mr. Khalil Abed ineffective in those areas and result in Corrosion Monitoring Consultant Business Development Manager accelerated reduction in metal thickness, Metal Samples Cortec Middle east pit holes, and eventual leaks1. This happens due to the fact that air gaps break the essential electro-chemical circuits formed by Aboveground Storage Tanks (ASTs) are used to direct contact between the soil (electrolyte) and contain a variety of fluids that may pose minor the metal tank bottoms. This problem may be or very serious threats to the environment and further worsened by the use of bituminous beds public safety, in case of leakage. Leaks due to or oily sand below the tank bottoms. external corrosion of single and double-bottom The ingress of water, moisture present in the
THE PROBLEM
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atmosphere, as well as airborne chlorides through the unsealed gap between the tank annular plate and the foundation is another important factor for accelerating the soil-side corrosion on the perimeter of the tank. Due to such corrosion issues and possible leaks, operators have to put the tank out of service for inspection, patchwork repairs, and sometimes replace bottom plates, within the first few years of the tank’s life or at the scheduled inspection intervals. Therefore, adequate and effective corrosion protection and monitoring methods should be implemented to ensure the bottom plates’ integrity for continuous, safe and economical operation of the storage tank.
APPLICATION OF VpCI A growing industrial practice to mitigate soilside corrosion of tank bottoms is to introduce amine carboxylate based Vapor phase Corrosion Inhibitor (VpCI) materials under the tank bottom
and monitor the impact on corrosion rates using electrical Resistance (eR) corrosion probes. When VpCI is delivered and released under the tank, protective vapors disseminate, adsorb onto the metal surface and form a monomolecular protective layer throughout the soil-side surface of the tank bottom plates. This solution is applicable for cathodically protected and unprotected tanks during scheduled maintenance outage, while in service or during construction.
CORROSION MONITORING OF SOIL-SIDE BOTTOM PLATES OF ASTs USING ER METHOD Implementing one or more reliable online corrosion monitoring systems under the tank is as important as selecting an effective corrosion control method for soil-side corrosion. Unlike other indirect corrosion monitoring systems, eR probes are designed to evaluate and continuously monitor the corrosiveness of the
Figure 1 Typical eR probe installation through the tank wall in a double-bottom tank 2
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demonstrate the effectiveness ofthe inhibitor by observing the change in metal loss trend before and after application. Generally, multiple eR probes are installed and uniformly distributed to cover the tank bottom plate area. They are usually installed away from the inhibitor injection point to confirm inhibitor diffusion and evaluate the overall effectiveness of VpCI material.
Figure 2 Typical eR probe installation thorough concrete ring wall in a single bottom tank setting on sweet sand pad
surrounding environment under the tank floor. ER probes are positioned close to the tank floor and exposed to the same environmental conditions as the tank floor, ,hence, establishing a correlation between the corrosion rate of the eR probe and the tank floor corrosion rate (Figures 1, 2 and 3). In most cases, eR probes are used as the primary corrosion rate monitoring technique to
Metal loss measurements using eR probes are usually acquired over a two to three month period prior to the introduction of the vapor phase corrosion inhibitors and for several months to many years after the inhibitor injection. There are different methods of interpreting ER data and generally a linear trend or moving point average method is used to check the performance of the inhibitor. Figure 4 shows the typical trendof metal loss of an eR probe for the inhibitor pre-injection and post-injection period obtained from a field installed probe. Such trend of metal loss also determines the timing of reinjection of inhibitors if the reduction of its efficiency is observed. Cylindrical element ER probe with its slim profile is convenient for locations with restricted access such as AST soil-side bottom plate structures and other infrastructure applications. Such probes
Figure 3: Typical eR probe installation with grout removed above probe location2
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Figure 4: Typical metal loss trend observed from eR data for pre-injection and post-injection period
provide good sealing of the reference element and the check element provides confidence in the continued performance of the corrosion sensor. Cylindrical probe may be connected to a cathodically protected structure using the attached grounding lead. This allows the probe to measure the effectiveness of the Cathodic Protection System under operating conditions. If left unconnected from the structure, the probe monitors the direct corrosivity of the soil or environment.
SYSTEM MAINTENANCE A significant advantage associated with this type of corrosion mitigation system is reduced maintenance costs. There are no ongoing maintenance requirements, other than collecting the corrosion monitoring system data on a predetermined schedule. There are no power costs, no wiring to repair and no equipment to maintain. If the corrosion rates increase sometime in the future to higher than desired levels, the inhibitor can be replenished.
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CONCLUSIONS When steel is exposed to properly designed and applied vapor phase corrosion inhibitor system, soil-side corrosion on tank bottoms is reliably mitigated. This has been proven in a wide variety of applications for many years throughout the world. Application of vapor phase corrosion inhibitor, combined with real-time corrosion rate monitoring, provides AST owner/operators with an effective and economical solution to the challenge of soil-side corrosion mitigation of ASTs.
References 1. Xianming (Andy) Yu, Saudi Arabian Oil Company “Evaluation of the Tank Bottom Corrosion and CP Effectiveness at a Saudi Aramco Crude Oil Tank Farm”, Paper 10043, 13th Middle east Corrosion Conference and exhibition 2. Tim Whited, Cortec Corporation; Xianming (Andy) Yu and Robin Tems, Saudi Aramco “Mitigating SoilSide Corrosion on Crude Oil Tank Bottoms Using Volatile Corrosion Inhibitors”, Paper 2242, NACe 2013
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Conferences & Exhibitions on
Asset Integrity 2015 SEPTEMBER
OCTOBER
IADC Asset Integrity & Reliability Conference & Exhibition
3rd Annual Subsea Integrity Conference 2015
16-17 September 2015 Norris Conference Center – CityCentre, Houston, Texas, USA http://www.iadc.org/event/2015-iadcasset-integrity-reliability-conferenceexhibition
10th Annual Asset Integrity Management Aberdeen 2015 29-30 September, 2015 Ardoe House, Aberdeen, Scotland, United Kingdom http://www.aimaberdeen.com
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5-6 October 2015 Doubletree Greenway Plaza Hotel, Houston TX http://www.upstreamintel.com/subseaintegrity
FPSO Asset Integrity Management and Life Extension Forum 15th - 16th October 2015 Crowne Plaza Hotel – Heathrow, London, United Kingdom http://www.bis-grp.com/portfolio/ conferences/oil-and-gas/fpso-assetintegrity-management-and-life-extensionforum
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Asset Integrity Management
Asset Integrity and Process Safety World
23-24 November 2015 DusitThani Lakeview Cairo, Cairo, egypt http://www.assetintegrityna.com
27-28 October 2015 Hilton Hotel, Doha, Qatar http://energy.fleminggulf.com/assetintegrity-process-safety-world
DECEMBER
NOVEMBER Asset Integrity Management Summit Asia 2015
4th Structural Integrity Management Conference, North Sea 2015 10-11 November 2015 Aberdeen Ardoe House Hotel, United Kingdom http://www.upstreamintel.com/structuralintegrity
01-03 December, 2015 Amara Sanctuary Resort Sentosa, Singapore http://www.assetintegritysummit.com
2 016 FEBRUARY
2nd International Conference & Exhibition on Pipeline Integrity Management (ICEPIM 2016) 5-6 February 2016 Hotel Grand, New Delhi, India www.pipelineintegritymanagement.in
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Industry News Petrofac awarded US$780 million project in Kuwait (Source: Petrofac) The international oil and gas service provider Petrofac, has been awardedKuwait Oil Company’s (KOC) manifold group trunk line (MGT) project in the north of Kuwait.The ePC project, valued at approx. US$780 million, is crucial to KOC’s plans to increase and maintain crude production over the next five years. Three new gathering centers (GC), which form part of the broader project, are under construction with Petrofac executing the ePC contract for GC 29.To be completed towards the end of 2017, the MGT system will provide the feedstock to each of the Gathering Centers via three independent networks of intermediate manifolds and pipelines. each of the three GCs will be capable of producing around 100,000 bpd of oil together with associated water and gas.
British Gas announces first oil from Mukta-B offshore platform (Source: BG Group)
British Gas India achieved first oil production from itsMukta-B, a 4 legged Wellhead Unmanned Platform in the offshore Bombay basin, on 1 July. British Gas has a 30% interest in the Panna-Mukta oil and gas fields alongside their partners, ONGC and Reliance Industries.
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Compiled By: Chanchal Dasgupta Borouge (India) Pvt. Ltd.
The MB and MA pipelines have been successfully completed as part of the project, enabling a restart of production from the MA platform, which had been shut-in due to pipeline integrity issues for the last 2.5 years. The project clocked more than 2 million ‘LTI free’ man-hours and has several firsts to its credit, including the use of green technology involving hybrid solar panels and wind turbines for self sufficient power, remote monitoring facilities for process optimization and VOIP protocol for better communication.
Oil-Pipeline Explosion in Nigeria Kills 12, Injures 3 (Source: Bloomerg + NewBase) In a tragic accident, twelve people died and three were injured in an explosion during repair work at an eni SpA crude oil pipeline in Nigeria. The victims were part of a maintenance team for a local service company, Rome-based eni said in a statement Friday. The Tebidaba-Clough Creek pipeline in the Niger delta was previously “damaged by acts of sabotage.” The company said it is still investigating the cause of Thursday’s blast. eni had 13 incidents related to pipelines and oil wells in Nigeria in May including equipment failure, theft and pipelines being cut using a
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delivered in response to the need to upgrade ORPIC’s refining capability in order to further maximize the value of Omani crude oil, and to ensure that the Sultanate’s increasing demand for fuel will be met. When SRIP comes on stream, current production of fuels, naphtha and propylene will be raised by 70 per cent. From a fuels perspective, this increase will meet the needs of continually growing fuel consumption in the country, which has increased by 10 per cent annually over the past 5 years.
hacksaw, according to the company’s website. Seventeen were reported in April and 14 in March. Hundreds have been killed in Nigerian pipeline accidents in the past decade. An explosion at a vandalized oil pipeline in Lagos, Nigeria’s largest city, started a fire that killed at least 200 people and burned many more in December 2006. In May that year, about 200 people were killed when another oil pipeline exploded near Lagos. Nigeria, Africa’s biggest oil producer, loses an estimated 300,000 barrels a day to criminal gangs that tap crude from pipelines that crisscross the southern, oil-rich delta for local refining or sale to tankers waiting offshore, according to stateowned Nigerian National Petroleum Corp.
ORPIC installs Oman’s first hydrocracker (Written by Oman Observer) Oman Refineries and Petroleum Industries Company (ORPIC), the Sultanate’s refining and petrochemicals major, has completed the installation of a giant hydrocracker reactor — the first of its kind in Oman — as part of the Sohar Refinery Improvement Project (SRIP). This will enable ORPIC to meet increasing demand of petroleum products in the Sultanate, as wellas reducing refinery emissions and improving refinery margins. The hydrocracker unit will result inincreased distillates production complying with
BPCL petrochemical (Source: IHS Chemweek, Jul 2015) BPCL petrochemical moved aheadwith its proposed petrochemical project adjacent to the BPCL refinery at Kochi in Kerala. BPCL is expanding refining capacity at Kochi and, as part of those plans, establishing a fluid catalytic cracker that will produce 500KTA of propylene for the proposed petrochemical complex to consume as feedstock. Mangalore Refinery and Petrochemicals Ltd (MRPL)(Source: ICIS News, Jun 2015) Mangalore Refinery and Petrochemicals Ltd (MRPL)started commercial production at its new 440kta Polypropylene plant in June 2015. The plant will get fresh supply of feedstock propylene from MRPL’s upstream petrochemical fluidized catalytic cracking unit (PFCCU).
SK Global Chemical sellingNexlene (Source: IHS Chemweek, Jun 2015) SK Global Chemical is to sell Nexlene, its premium Pe business to its joint venture (JV) with SabicSK Nexlene Co. (Singapore). The JV will be the owner of the technology as well as the 230kta Nexlene Pe plant at Ulsan, South Korea.
Euro V specifications. The Sohar Refinery Improvement Project (SRIP) is scheduled for commissioning in 2016. It is being
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Disclaimer: Please note, the above information’s and news were collected from various sources and the author or the publisher extends no liabilities for the accuracy or completeness of the information provided here.
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Organizing
Training Program on “Pipeline Integrity & Corrosion ManagementMaintaining Safe & Reliable Pipelines” 4-5 December 2015 Hotel Jaypee Vasant Continental, New Delhi Program Overview -
Corrosion Control for Buried Pipelines, Pipeline Integrity Management techniques
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Corrosion Survey & Inspection
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Cathodic Protection, CP survey, DCVG, CIPL
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Protective Coatings & tapes, Coating Survey
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Pipeline corrosion monitoring, Intelligent pigging, Direct assessment
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Internal & external corrosion, deep water conditions, offshore environment
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estimation of corrosion, corrosion rate models, Pitting Rates, Bacteria, Multiphase corrosion.
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Under Insulation Corrosion of Pipelines
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Internal Corrosion Control in Multiphase Oil and Gas Pipelines
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‘worst case’ corrosion, corrosion with protective film, bottom of the line corrosion, top of the line corrosion
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Inhibitors, distribution along the pipeline, hydrate preventers, reduce water wetting, CO2 pressure.
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Pipeline material selection & CRAs, cost comparisons
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Corrosion at Pipe Supports- Causes and Solutions
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Case Studies & Trouble Shooting
Dr G. H. Thanki Dr. G. H. Thanki a highly renowned Corrosion expert in the Chemical & Process Industry with more than 40years of hands-on experience in Corrosion Control Management, Corrosion survey and corrosion audit, Corrosion Integrity Management, Corrosion testing and Monitoring, Cathodic Protection,Plant Corrosion Inspection and Failure Analysis.
Supported by
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