Ch 02 Piping and Pipeline Maintenance.pdf

Ch 2 Piping & Pipeline Pipeline Maintenance

2.1. Pipeline Components

Flange

launcher

Block Valve

pipe

Bend/ Elbow

Tee

Pig receiver

Pig receiver Kuliah MS4102 Perawatan Mesin

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Kuliah MS4102 Perawatan Mesin

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NPS & Schedule

Standard Welded & Seamless Wrought Steel Pi Pipe ta n ess tee

ASME B36.10M

pe

A

.

Specification for Line Pipe

API SPEC 5L

Seamless carbon steel pipe for high temperature service

ASTM A 106

Spiral welded steel or iron pipe

ASTM A 211

Seamless au austeniti itic steel pi pipe fo for hi high-temperature service

ASTM A 376


3


4



NPS & Schedule

Standard Welded & Seamless Wrought Steel Pi Pipe ta n ess tee

ASME B36.10M

pe

A

.

Specification for Line Pipe

API SPEC 5L

Seamless carbon steel pipe for high temperature service

ASTM A 106

Spiral welded steel or iron pipe

ASTM A 211

Seamless au austeniti itic steel pi pipe fo for hi high-temperature service

ASTM A 376


3


4




5


6


Elbow Digunak Digunakan an sebagai sebagai sambung sambungan an pada pada belok belokan an pipa pipa denga dengan n radiu radius s . . Long radius radius elbow adalah 1,5D.

Pi e B en d Digunak Digunakan an sebagai sebagai sambung sambungan an pada pada belok belokan an pipa pipa denga dengan n radiu radius s besar besar (Radius (Radius > 3D).

Ch 2 Piping & Pipeline Maintenance

FITTINGS: Mitt er Bend, Tee Joint


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8


FITTINGS: Coupling, Cap, Plug


FITTINGS: Bushing, Cross, Reducer


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10


FLANGE


FLANGE


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12


FLANGE


VALVE: Rotary Motion

PLUG VALVE

BUTTERFLY VALVE


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VALVE: Sliding Motion

NEEDLE VALVE

GLOBE VALVE


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VALVE: Flexible Valve

DIAPHAGRM VALVE

PINCH VALVE


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2.2. Maintenance Elements Gas and liquid pipelines have similar maintenance objectives and programs: “ y u y , to maximize throughput and prolong the life of a pipeline system while ensuring public safety and respecting the environment.” Two types of maintenance activities: 1. Routine maintenance: planned activities and don’t involve an nc en . 2. Emergency activities usually result from incident: rupture, leak  pipeline segment or piping replacement. There are also situations that overlap those of routine maintenance that can be lead to emergency maintenance. Kuliah MS4102 Perawatan Mesin

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Maintenance activities include the followings: • • • • • • • •

Right-of-way (ROW) and facilities environment protection. ROW and site maintenance Pi eline de th of cover maintenance Aerial inspection/patrol and leack detection ROW erosion control and stabilization Cathodic protection monitoring and maintenance Pipeline integrity assessment (corrosion and structural) Pipeline repair and modifications

• Facilities identification, signs and markers • Aesthetics and landscaping • Equipment (i.e. valves, metering) operational test and routine maintenance. Kuliah MS4102 Perawatan Mesin

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Maintenance activities that are not routine in nature, but are performed as a consequence of undertaking the routine maintenance, include: • Trenchin and excavation • Locating pipelines • Pipeline realignment/relocation • Foreign crossing • Hot tapping and stub installation • Pigging • Welding, including  Welders qualification  Maintenance and repair welding  Cutting Kuliah MS4102 Perawatan Mesin

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Maintenance activities that are not routine in nature, but are performed as a consequence of undertaking the routine maintenance, include: • Safet mana ement includin :  Indent Safe working practices  Safety gearing  Safe work permit  Confined space entry  Fire protection   Personal protective gearing  Incidence recording and reporting • Record keeping • Training Kuliah MS4102 Perawatan Mesin

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2.3. Pipeline Maintenance Code Requirment Standards 

Pipeline regulations (EUB, 2003) or acts and codes will requ re e opera ors o ma n a n e r p pe ne accor ng o prescribed standards. For example: routine maintenance includes inspection of all pipeline ROWs at least once annually.  These inspections are recommended in order to reduce potential third-party interference on such pipeline. oo p ann ng s essens a o a p pe ne ma n enance and repair work  work is done safely, on schedule and with minimum environment impact.  Scheduling and preparation are important for timely maintenance and safe work operation. Kuliah MS4102 Perawatan Mesin

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

Scheduling and preparation cover the following: • Maintenance schedule preparation • Availability of tool and equipment in good and safe working condition • Avalability of necessary resources for the job • Previous on-the-job training of personnel to ensure work safety and efficiency • Availability of safety and fire-fighting equipment, all in good working condition. • Necessary environmental protection measures • Permit to work.


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Frequency Table 2-1 provides a summary of routine maintenance activities that are required to be performed on a pipeline as per code requirements. Maintenance Activity

ROW inspection

ou ne

a n enance

Maintenance Schedule/Frequency

Annual

Monthly (gas) Pipeline patrol/leak detection/corrosion (gas)

Biweekly (liquids) : LPG/NH3 lines<1 week in common areas

c e ue o

a or

p e ne

emen s

Requirement/Remarks

CSA Z662 : (2003) Sour gas (> 10 Moles H2S/k-mole NG) required monthly/bimonthly HVP/sour condensate: bimonthly/weekly depending on class location Industry norm, B31 requires periodic/as required---leak and corrosion survey report kept while line in service ASME B31.4 (1998) Kuliah MS4102 Perawatan Mesin

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TABLE 2-1 Routine Maintenance Schedule of Major Pipeline Elements (cont’d) Maintenance Activity


Requirement/Remarks

Class 1,2 : Annual Pipeline patrol (gas lines)

Class 3: 6 months

ASME B31.8 (1999)

Class 4:3 months Annual, not to exceed 15 months

CP monitoring CP : Pipe to soil potential and rectifier readings

Monthly, Soil survey once

ASME B31.1 (1999)

Industry norm

Internal corrosion monitoring

< 6 months

ASME B31.4 (1998): if line internally coated, pigged, dehydrated/corrosion inhibition, corrosion coupon used

Exposed pipe: External monitoring;

< 3 years

ASME B31.4 (1998) Kuliah MS4102 Perawatan Mesin

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TABLE 2-1 Routine Maintenance Schedule of Major Pipeline Elements (cont’d) Maintenance Activity

Encroachment assessment


Requirement/Remarks

er o c or annua

Class location Annual assessment (Gas line)

ASME B 31.8 (1999)

Valve inspection/operation

Annual

ASME B31.4 and B31.8, partial operation required

Valve testin

Annual

Remote control shutdown devices

Annual

B 31 : For functionally test

Relief valves (liquid)

< 5 Years

ASME B31.4 (1999): LPG/CO2/NH3 Line/Storage Kuliah MS4102 Perawatan Mesin

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2.4. ROW and Site Maintenance Definition: A strip of land usually about o m w e see gure , containing the pipeline and usual appurtenances (Pipeline 101, 2002). The ROW: • Enables personnel to gain access for inspection, maintenance, testing or emergencies. • Maintain an unobstructed view for frequent aerial surveillence • Identifies an area that restricts certain activities to protect the landowner and pipeline itself. Kuliah MS4102 Perawatan Mesin

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Reason for ROW Maintenance • Maintaining the integrity of the ROW is a critical component of the ongoing O&M. • On going inspection and servicing the ROW are essential , environment and public safety. • Help ensure the continued safe, efficient operation of the pipeline and security of the supply for pipeline customers.

ROW Maintenance Re uirements Three main areas of concern in ROW maintenance. • Vegetation management • Erosion and soil stability (settlement/heave, etc.) • Landowner concerns Kuliah MS4102 Perawatan Mesin

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Environmental Protection The objectives are: • Ensure compliance with landowners and all regulatory requirements • Ensure compliance with the owners’ approved environmental plans, procedures, drawings and standards. • Ensure the lands to their original condition soon after completion of construction • Identification of environmental issues affecting pipeline • Measure actual major environmenta; effects such as slope movement, settlement/heaving to confirm any impact on design and operation.


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Environmental Protection (cont’d ) Post-construction monitoring will generally focus on the following: • Reclamation • Re-ve etation • Erosion control drainage systems • ROW and slope stability • Stream (small river) crossings • Wildlife impact assessment • Heritage resources • Impact on evnvironmentally sensitive areas such as water supply reservoirs.


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Signs and Markers 

Pipeline and facilities are marked (see figure) in accordance with the requirements of the original design as accurate as possible –and as close to their location– to reduce the activity.  They also assist in the performance of survey and patrolling requirement.  To maintain a pipeline ROW, pipeline companies usually mark the ROW and the site boundaries with either or all or the followin : • • • • •

Markers post/pole/fences Pipeline warning signs Aerial markers Owner facilities’ directional sign Owner facilities sign Kuliah MS4102 Perawatan Mesin

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Surveillance Program A continuing surveillance program is usually conducted to monitor for unusual operating and maintenance conditions. The surveillance programs cover the following: . Unsafe conditions along the pipeline ROW may consist of: • • • • • • • • • • •

Exposed or damaged pipe Leaks Pipeline breaks Construction activity Soil erosion and vegetative cover Encroachment Atmospheric corrosion Poor condition of pipeline signs and markers Missing pipeline signs and markers Dead, damaged or altered vegetations Kuliah MS4102 Perawatan Mesin

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Surveill ance Program (cont’d ) b. c. d. . f. g.

Gas/liquid leakage detection surveys Valve inspections Pressure regulating, relieving and limiting inspections Corrosion control Pipe inspections


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Site Maintenance Requirement 

Facilities sites, such as metering or valve, are generally graded and in most instances graveled. Chain link security fencing is install around most facilities.


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

Maint enance of sit e may incl ude removal of grss and shrubs, trees, etc. and snow removal is undertaken from some access roads and facilities where frequent access is required during the winter month.  Ac ces s r oads: Inspection roads need to be maintained to ensure redy and available access for maintennce.  Depth of cov er is expected to be maintained over the lifetime of the pipeline (regularity complaince: EUB, 2003 & ASME code).  Pipeline excavation: A pipeline may be excavated to check for corrosion, to cross one pipeline with another, to make ddition to a pipeline system or to make repairs. Consult the safe and efficient procedure of excavation.


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Pipeline Patro l (cont’d )  A detailed

list of what is noted while air-patrolling the pipeline ROW is provided in Table 2-2.  Patrol by helicopter or fixed-wing aircraft is normlly conducted .  In emergency situations, winter and spring runoff condition, a helicopter provides a rapid response for a detailed check.  During the air patrol, obseevation generally includes review on the condition of: • • • • • • 

Hills/mountain River crossing Shifts in soil stabilization Signs of erosion Valve sites, meter stations Pump/compressor site.

Other methods for pipeline ROW monitoring are walking, driving all terrain vehicles and satellite imagery. Kuliah MS4102 Perawatan Mesin

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TABLE 2-2 Details of Air Patrol Observation Geotechnical Problems

Signs of foreign activity

• Soil erosion

• Third-party damage

• Sand blowouts

• Drainage

• Cave-ins/subsidence

• Digging

• Hill Slides or hill sloughing

• Irrigation

• Sink holes/settlements

• Seismic activity

• River diversion/scouring

• Dug-outs

• Canal seepage/drainage

• Farmers’ deep tillage

• Fallen tress, which might indicate a new slide or the beginning of a new slide

• Survey flags/stakes • New power lines and cables

• Floating swamp weights

• New subdivisions/buildings

• Exposed pipe/loss of cover • Seismic activity/soil slides

• Local forest and timber activities (e.g., skidders crossing the line, sspecially in muskeg or wet areas) • Presence of heavy equipment

Evidence of leaks • Soil discoloration

Any maintenance to be done on the R.O.W

• Water bubbling • Dead vegetation • Isolated Patch of Wet Ground


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2.5. Pipeline Pigging 

Main purpose: • Cleaning & inspecting  Ot her ur o se: •

Hydrastatic testing

•

Air/nitrogen removal

•

Petroleum product batch separation

•

Pipeline commissioning

•

Pre-inpsection and certification of newly built pipelines

•

Integrity assessment

•

Decommissioning of an environmentally unsafe pipeline to inert condition. Kuliah MS4102 Perawatan Mesin

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Type of Pigs:




Utility pigs: Used to clean the pipe, seperate contents and dewater the line. This includes: • Cleaning pigs: Purpose is to remove solids and debris that ccumulated on the pipe walls over time. • , dewatering and removal of condensat. Typical pigs of this type are referred to as sphere, solid cas and mandrel pigs.

Cleaning pig in a pipeline Kuliah MS4102 Perawatan Mesin

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Mandrel Pig

Scraper Pig

Brush Pig Kuliah MS4102 Perawatan Mesin

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Spherical Pigs

Components of an HAPP hydraulically activated power pig Kuliah MS4102 Perawatan Mesin

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

In-line inspection (ILI) tools i ncludes: • ILI or smart pigs: Main purpose is to determine metal-loss and corrosion; they provide pipe geometry, temperature, photographic inspection, crack and leak detection, and . When in operation, ILI pig can:  

Be located in pipeline via GPS or simple transmitters Perform function using ultrasound and specialized computer software.

Typical ILI or smart pigs Kuliah MS4102 Perawatan Mesin

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• Geometry pigs/tools include: • • • • • • •

Caliper pig x, y, z geometry (inertial guidance) tool Metal loss ILI tools Conventional magnetic flux g -reso u on magne c ux ea age Transverse field inspection (TFI) Ultrasonic

Caliper Pig

MFL Kuliah MS4102 Perawatan Mesin

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

Gel pi gs: Made of static gelled liquids. Some gels are made from various chemicals. Their typical uses are product separation, removal of stuck pigs, line filing and hydro testing. 

Dehydrating gel  Hydrocanbon gel  Debris pick-up gel  Batching or separator gel.


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2.6. Pipeline Repair Integrity Assessment: 

The failures are causes by various mechanismes such as • • • • • • •

Corrosion external & internal Stress corrosion cracking (SCC) Third-party damage/contacts Soil movement/instability Material defect Construction practice Operating problems.

•

Business consequences: loss of revenue, products, organization reputation and prestige Safety consequences: fatalities, injuries, pollution, explotion, fire, property damage, environmental impact, etc.



•


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

Public concern for safety and environmental impact are the basis for the industry to initiate and implement an integrity managemenet programs.



Pipeline integrity inspection is the basis for collecting integrity u u ,w z determining the appropriate repair techniques  RBI.



Pipeline integrity inspection has developed from a mere gauging of the internal size of a pipeline (hence, pipeline inspection gauge, PIG) to usage of modern development of high-resolution tools. This includes: • • • •

Inertial (x, y, z geometry) Ultrasonic Crack detection tools Etc. Kuliah MS4102 Perawatan Mesin

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Inspection Technologies: 

There are several techniques available to assess the integrity of pipelines as follows: • Visual inspection •

• • • •

External NDT  Radiography  Magnetic particle testing  Dye penetrant  Ultrasonic inspection Cathodic protection monitoring Coating disbondment and damage survey Hydrostatic testing Use of geometry ILI tools  Caliper pig  x, y, z geometry (inertial guidance) tool Kuliah MS4102 Perawatan Mesin

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Inspection Technologies (cont’d ): • Use of metal loss ILI tools  Conventional magnetic flux  High-resolution magnetic flux leakage (MFL)   Ultrasonic • Use of stress corrosion cracking (SCC) tool ILI and SCC tools are mostly used as inspection for various tasks, including the following, (Uzelac, 2000):  Metal loss  Wall thickness measurement  Cracking  Geometry measurement  Bend measurement  Curvature monitoring  Pipe movements and profiling Kuliah MS4102 Perawatan Mesin

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Defect Assessment: It is the operator’s and the industry’s standard that dictates which defects need to be repaired and to what extent. Such defects are summarized below (Hewing, 1999) • General: Pitting, Erosion • Gouge (possibly caused by mechanically induced damage) • Mechanical damage (dent with a gouge) • Dents: Smooth (localized distortio), Kinked (rapid change of contour) • • Laps/livers/lamination (manufacturing defects) • Spalling (severe abrasion)/arc strikes. • SCC (stress corrosion cracking) • Perforations (causing rupture/leaks) Kuliah MS4102 Perawatan Mesin

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Repair and Rehabil itati on Repair techniques include the following: • Temporary/leaks clamps • Grinding/dressing • e epos on • Patch repair • Snug-fit sleeves/PetroSleeve® • • • • • •

Stand off sleeves Hot-tapping Stopple and bypass Epoxy sleeve repairs Clock spring repairs Other composite repairs

The application of the above repair technques are summarized in Table 2-3. Kuliah MS4102 Perawatan Mesin

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TABLE 2-3 Summary of Repair Applications

Type

Superficial

Moderate

Severe

Extreme

Grinding/dressing

X

X

Weld deposition

X

X

Full ercirclement

X

X

Hot ta

X

X

Cutout

X


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Patch repair Temporary Clamp

Hot tap

Bend epoxy repais sleeves Kuliah MS4102 Perawatan Mesin

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Repair and Rehabil itati on Repair techniques include the following: • Temporary/leaks clamps • Grinding/dressing • e epos on • Patch repair • Snug-fit sleeves/PetroSleeve® • • • • • •

Stand off sleeves Hot-tapping Stopple and bypass Epoxy sleeve repairs Clock spring repairs Other composite repairs

The application of the above repair technques are summarized in Table 2-3. Kuliah MS4102 Perawatan Mesin

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Integrit y Management Progr ams 

Managing pipeline system integrity in a proactice manner is essential for all owners and operators of hazardous liquid or natural gas pipelines. , Transportation (DOT) has taken initiative to ensure that U.S. Liquid pipeline companies have integrity management programs in place that define processes that a company utilizes for the purpose of improving pipeline safety and striving for incident-free operation.  , Liquid Pipelines, First Edition, November 2001, was developed to assiste operators to comply with newly established federal rules in US regarding pipeline integrity management in highconsequence areas (HCAs) (Jaske, 2002). Kuliah MS4102 Perawatan Mesin

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The guiding principles used to establidh API 1160 can be applicable to all pipeline systems and are as follows: • Integrity is built in from the beginning • Use traned people and defined processes to operate . • IM programs must be flexible • Integrate information • Risk assessment is key and continuous • Understand and utilize new technology • Third-party evaulation of IM systems.


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An IM program, as defined by U.S. DOT, is a documented set of policies, processes and procedures that includes, at a minimum, addressing the following elements: • A process for determining which pipeline segments could • A Baseline Assessmnt Plan • A process for continual integrity assessment and evaluation • An analytical process that integrates all availablr information about pipeline integrity assessment method and data analysis • A process to identify and evaluate preventive and mitigative • Method to measure the integrity management program’s effectiveness • A process for review of integrity assessment result and dat analysis by qualified individual. Kuliah MS4102 Perawatan Mesin

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Ch 02 Piping and Pipeline Maintenance.pdf

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