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O&M OF PIPE LINE SYSTEM

1989
DELHI DADRI

JPUR

1997
ANTA

DIBIYAPUR (3) + (2)

1988
BIJAIPUR (5) (3) (3) KHERA

IPCL

JHABUA (7) + (3) VAGODIA (3)

1987

HAZIRA (10) + (2)

FROM O GC

18.2

33.4 MMSCMD

O&M OF PIPE LINE SYSTEM

A. RIGHT OF USE (ROU) B. MAINLINE & ASSOCIATED EQUIPMENT C. CATHODIC PROTECTION

A) ROU
PIPELINE MARKERS
KM Markers, Direction marker, Warning sign boards, ROU boundary pillars installed along the ROU.

B)MAI LI E & ASSOCIATED EQUIPME T

1.MAI LI E- Pipes used of various grades and is coated with three layer of PE coating 2.SECTIO ALIZI G VALVE (SV) STATIO S-consist of mainline ball valves, manually operated ball valves / plug valves and quick opening end closures (QOEC). 3.CASED CROSSI GS- Provided for Rail and Road crossing, consist of casing pipe along with vent & drain pipes

B)MAI LI E & ASSOCIATED EQUIPME T

4.I TERMEDIATE PIGGI G (I.P) STATIO Sconsists of gas actuated ball valves, manually operated ball valves, plug valves, pig receiver, pig launcher, pig signalers, pig handling devices, quick opening end closure, pressure safety valve, pressure & temperature transmitters

TYPICAL SV STATION
P G

Utility Connection 2
T G

AV

P G

T G

By pass Line

QOEC

MA IFOLD FOR PG /TG MAI LI E

Utility Connection 2

SECTIO ALIZI G VALVE CO FIGURATIO OF LPR P/L

Blind
MOBILE FLARE

SV Bypass & Isolation

Line for TEG

TEG

P/L from U/S

SV P/L to D/S

Gate Valve

T Y P IC A L IN T E R M E D IA T E P IG G IN G S T A T IO N F ro m T o U tilitie s T o T e r m in a l

AV

AV

IJ
MOV MO V

IJ

FLOW TEE

FLO W TEE

QOEC

B lo w BALL VALVE TS V G LO BE VALVE GATE VALVE R -L N G F L O W D IR E C T IO N T E G -T H E R M O E L E C T R IC G E N E R A T O R ( U tilitie s )

LAUNCHER

RECEIVER

TYPICAL I P STATIO OF LPG P/L

Upstream
M

SCRAPER RECEIVER

SCRAPER LAU CHER

Downstream
M

TSV

PCV To Customer

TSV To Customer
M
PS HH

M
PS LL

To Customer

P
MAI LI E PUMP

CASED CROSSI GS

C. Cathodic Protection
COMPO E TS & DEVICES OF CP SYSTEM
Anode Ground Bed Pipeline Coating Test Stations Computerised Test Station Zinc Grounding Cell Spark Gap Polarisation Cell Casing Pipes Electric Resistance Probes (corrosion sensing probes) Permanent Reference Cell Insulating Joints Power Source

ELECTRICAL LAYOUT AT I TERMEDIATE STATIO S CCVT CCVT BATTERY 600 AH BATTERY 600 AH

48V DC BUS

T/C

SCADA

DCCS

CPVCM

DC COOLING SYSTEM FOR AC & EXHAUST

OPERATION &MAINTENANCE
Time independent threats Time dependent threats Stable threats (induced during construction stage) Based on the threats identified, preventive, corrective and mitigative actions are taken from time to time to ensure and further enhance the reliability and safety of the Specific Pipeline Section.

A) ROU
Line walk/ Foot Patrolling Helicopter Patrolling

B)MAINLINE & ASSOCIATED EQUIPMENT

1)MO ITORI G
Inspection of SV, IP & RR installations along the pipeline Inspection of River, Rail, Road crossings and Vulnerable locations

2)THICK ESS MEASUREME T OF ABOVE GROU D PIPI G 3)PREVE TIVE/ CORRECTIVE MAI TE A CE
Periodic performance test of valves and associated equipment Inspection of fire fighting equipments and corrective actions/ maintenance activities for pipeline exposures, washouts, excavations , encroachments, missing/ damaged markers, boundary pillars etc

B)MAINLINE & ASSOCIATED EQUIPMENT

PREVE TIVE/ CORRECTIVE MAI TE A CE PERFORMA CE TEST OF SV/IP/TAP.OFF FACILITIES
Any gas leakage from fittings and equipments Operational checks of actuators, valves, launcher, receiver, QOEC, pressure gauges, PT, TT, pig handling unit, chain pulley block and other associated equipments/ systems installed. Servicing, sealant injection, lubrication & greasing of above equipments Seat test of ball valves Old Gaskets of Limit switch enclosure & Electric junction box is replaced during every half yearly valve performance test.

B)MAINLINE & ASSOCIATED EQUIPMENT Corrective actions/ maintenance activities for

Fire fighting equipments a) Monthly b) Quarterly c) Yearly activity Pipeline exposures, washouts, excavations , encroachments, missing/ damaged markers, boundary pillars etc

P/L MONITORING & MAINT. SCHEDULE

------------------------------------------------------------------------SL. ACTIVITY FREQUENCY NO. ------------------------------------------------------------------------1. INSPECTION OF SV, IP & T.OFF MONTHLY 2. INSPECTION OF RIVER CROSSINGS QUARTERLY 3. INSPECTION OF ROAD/RAIL XINGS QUARTERLY 4. PERFORMANCE TEST OF VALVES HALF -YLY

P/L MONITORING & MAINT. SCHEDULE

--------------------------------------------------------------------SL ACTIVITY FREQUENCY NO. --------------------------------------------------------------------5. INSP. OF FIRE EQUIPT. MONTHLY 6. PIPELINE WALK YEARLY MONTHLY MONTHLY HALF YLY.

7. VULNERABLE LOCATION 8. HELICOPTER SURV 9. ENCROACHMENTS MONIT.

C) Cathodic Protection
O&M of CP System consists of the following : Periodic surveys to determine the status of CP and related items Coating maintenance Maintenance of current sources and ground beds in impressed current CP installations Maintenance of test stations Maintenance of cased crossings Maintenance at foreign line crossings

C) Cathodic Protection
PERIODIC SURVEYS (in line with
ACE RP0169)

Pipe to soil potential survey (PSP) Power supply output- current/voltage/wattage & efficiency At other DC power sources, the DC current and voltage as well as pertinent supplementary information which may apply to the particular power source The resistance of each impressed current ground bed The current output and resistance of each galvanic anode installation

C) Cathodic Protection
PERIODIC SURVEYS cont Potentials of the line surveyed and of the foreign line at foreign line crossings. Where intersystem bonds exist, measure the bond current and direction of flow At cased crossings, the resistance between carrier pipe and casing plus the potential to reference electrode of both pipeline and casing Verification of insulated joints for effectiveness and also of lightning arresters, spark gaps, grounding cells, and polarization cells for performing function effectively

C) Cathodic Protection
COATI G MAI TE A CE
Maintenance crews should be trained in good coating application procedures Care of materials, and compliance with specifications so that acceptable coating work will result. Maintaining a performance record of pipeline coatings on the system

C) Cathodic Protection
RECTIFIER MAI TE A CE
Check output voltage and current Clean and tighten all bolted current-carrying connections. Clean all ventilating screens in air cooled units to ensure unobstructed air flow. Check indicating meters for accuracy. Replace insulated wires on which insulation has cracked or been damaged. Check all protective devices (fuses, circuit breakers, or lightning arresters) to ensure their integrity.

C) Cathodic Protection
GROU D BED MAI TE A CE
Periodic checks to take corrective action against washout Routine recording of ground bed and individual anode resistance (to be carried out preferably in dry season) Identification of any dead anode and mitigation of problem Cleaning and tightening of connections of anodes Balancing of current flow in each anode

C) Cathodic Protection
TEST POI T MAI TE A CE
Identify requirement for replacement of box covers or cover retention screws, cover gaskets or terminal nuts or screws Take corrective action against vandalized, broken test station Check and mitigate problem of connection integrity with the pipeline

C) Cathodic Protection
CASED CROSSI G MAI TE A CE
Make observation to ensure insulation between carrier pipe and casing If shorted condition is found, immediate repair should be scheduled Determine the nature of short circuit In case of shortings that can not be repaired, the favored procedure is to fill the entire annular space between pipe and casing with a material that will stifle any corrosion tendency

C) Cathodic Protection
FOREIG LI E CROSSI GS
Resistance bonds installed between pipelines for intersystem interference correction require periodic checking Exchange of operational information with the foreign line companies Planning for cooperative interference tests, design of corrective bonds, or other necessary measures to mitigate interference damage caused to either party

C.P. MONITORING & MAINT.SCHEDULE ------------------------------------------------------------SL. ACTIVITY FREQUENCY No. --------------------------------------------------------------------1. C.P. STATIONS MONTHLY 2. 3. 4. T/R UNITS PSP MONIRORING COMPUT. TEST STNS. WEEKLY QUARTERLY HALF YLY.
(NOT APPLICABLE FOR GREP)

C.P. MONITORING & MAINT.SCHEDULE (CONTD) -----------------------------------------------------------SL. ACTIVITY FREQUENCY No. --------------------------------------------------------------------5. DC COOLING SYSTEM HALF YLY. 6. 7. 8. 9. BATTERY BANKS ANODE GROUND BED POWER SOURCE MAINT. EARTHING SYSTEM HALF YLY. YEARLY HALF YLY. HALF YLY.

SCADA
SUPERVISORY CO TROL A D DATA ACQUISITIO

SUPERVISORY CO TROL OF MAJOR PIPELI E EQUIPME TS THROUGH MCC

1.SECTIONALISING VALVES OPEN/CLOSE. 2.TEG/CCVT START AND STOP STATUS. 3.OPERATION OF COMPRESSORS . 4.FLOW CONTROL THROUGH COMPRESSORS

DATA ACQISITION AND MONITORING OF MAJOR PARAMETERS THROUGH MCC

1. 2. 3. 4. 5. 6. PRESSURE & TEMPERATURE AT I.P.STNS PIPE TO SOIL POTENTIAL ANODE OUTPUT VOLTAGE ANODE OUTPUT CURRENT SECTIONALISING VALVES OPEN/CLOSE TEG/CCVT STATUS FOR VOLTAGE, CURRENT,RUNNING,ALARMS 7. BLDG. DOOR OPEN/CLOSE 8. A/C RUNNING STATUS 9. RADIO ROOM TEMP ALARMS 10.FIRE ALARM 11.PIGGING OPERATION

CORROSIO CO TROL CRITERIA A D A ALYSIS

HEAD QUARTER FU CTIO S

CRITERION
PSP (ON/OFF) MAINTAINED BETWEEN 0.95v to 1.2v EXTERNALCORROSION RATES ARE <1 Mil /year

AVERAGE CURRENT CONSUMPTION RATE 2 SHOULD NOT EXCEED 125 MICRO AMP/M INTL. CORROSION RATE IS < 0.1 MILS/YR

A ALYSIS
1.PIPE TO SOIL POTENTIAL MEASURED QUARTERLY. ALL PSP GRAPHS PREPARED AND ANALYSED FOR : -LOCATIONS FOR SUDDEN CHANGES IN PSP -UNDER PROTECTED/OVER PROTECTED ZONES. -INTERFERENCE ZONES -CORDINATE WITH RESPECTIVE MAINT.BASE FOR CORRECTIVE ACTION

A ALYSIS
2.C.P. PARAMETERS AT ALL FEED POINTS MONITORED MONTHLY CURRENT CONSUMPTION RATE CALCULATED FOR TOTAL PIPELINE. 3.PRESENT CORROSION RATES CALCULATES BASED ON ER PROBE MONITORING. CORROSION RATE=(R2 R1) 4 MILS/YEAR n R1 INITIAL READING R2 FINAL READING n ELAPSED TIME IN DAYS BETWEEN TWO READINGS.

P S P V o lts (-V E )
0.500 0.00 0 9.00 0 1 8 .10 0 2 9 .83 6 4 2 .10 0 5 5 .30 0 6 8 .30 0 8 0 .21 7 8 9 .50 0 1 0 2 .48 5 1 1 5 .50 0 1 2 9 .00 0 1 4 1 .50 0 1 5 5 .00 0 1 6 8 .00 0 1 8 1 .00 0 1 9 3 .50 0 2 0 6 .50 0 2 1 9 .50 0 2 3 2 .50 0 2 4 5 .00 0 2 5 6 .00 0 2 6 8 .00 0 0.700 0.900 1.100 1.300 1.500 1.700 1.900

CHAINAGE (IN K.M.) PSP UPL LPL

GRAPH - HBJ P/L SYSTEM

CURRENT CONSUMPTION OF HBJ PIPELINE

C U R R E N T( m ic ro A M P E R E S /S Q . M E TE R )

11.00 6.00 1.00 OCT 95 DEC 95 OCT 96 JULY 97 MAR 98 DEC 98 YEAR

CURRENT AV. CURRENT CONSUMPTION

HEALTH OF PIPELINE
ACHIEVED AVERAGE 10 M ICROAMP/M2 CURRENT CONSUMPTION PSP VALUE EXT CORROSION INTERNAL CORROSION -0.95 TO 1.5 V 0.15 MIL/YEAR DESIGN 125 MICRO AMP/M2

-0.95 TO-1.5 V < 1 MIL/YEAR

0.01 MIL/YEAR

<0.1 MIL/YEAR

HEALTH OF HBJ PIPELINE IS EXCELLENT

3Layer copolymer coating application schematic

Practical Galvanic Series for Materials in eutral Soils and Water measured with respect to copper sulphate reference electrode

Material Carbon, Graphite, Coke Platinum Mill Scale on Steel High Silicon Cast Iron Copper, Brass, Bronze Mild Steel in Concrete Lead Cast Iron (Not Graphitized) Mild Steel (Rusted) Mild Steel (Clean and Shiny) Commercially Pure Aluminum Aluminum Alloy (5% Zinc) Zinc Magnesium Alloy (6% Al, 3% Zn, 0.15% Mn) Commercially Pure Magnesium

Potential Volts (CSE) + 0.3 0 to 0.1 - 0.2 - 0.2 - 0.2 - 0.2 - 0.5 - 0.5 -0.2 to -0.5 -0.5 to -0.8 - 0.8 - 1.05 - 1.1 - 1.6 - 1.75

Principle of Cathodic Protection

How It Works
Creat a corrosion cell Make the structure to be protected cathode

Differential Corrosion Cell

COPPER-COPPER SULFATE REFERE CE ELECTRODE