CH 02 Piping and Pipeline Maintenance PDF

Ch 2 Piping & Pipeline Maintenance
2.1. PipelineComponents
Flange Block
Bend/
Valve
Elbow
Pig Straight
launcher pipe Tee Pig
receiver
Pig
receiver
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NPS & Schedule
Standard
Welded & Seamless Wrought Steel Pipe ASME B36.10M
St i l Steel
Stainless St l Pipe
Pi ASME B36.19M
B36 19M
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 austenitic steel pipe for high-temperature service ASTM A 376

Elbow
Digunakan sebagai sambungan
pada belokan pipa dengan radius
kecil Short radius elbow adalah 1D.
kecil. 1D
Long radius elbow adalah 1,5D.
Pipe
p Bend
Digunakan sebagai sambungan
pada belokan pipa dengan radius
besar (Radius > 3D).

FITTINGS: Mitter Bend, Tee Joint
FITTINGS: Coupling, Cap, Plug

FITTINGS: Bushing, Cross, Reducer
FLANGE

FLANGE
FLANGE

VALVE: Rotary Motion
BALL VALVE CHECKVALVE
PLUG VALVE BUTTERFLY

VALVE
VALVE: Sliding Motion
GATE VALVE
NEEDLE VALVE
GLOBE VALVE

VALVE: Flexible Valve
DIAPHAGRM VALVE
PINCH VALVE
2.2. MaintenanceElements
Gas and liquid pipelines have similar maintenance objectives
and programs:
The primar
primary p
purposes
rposes of an
any pipeline maintenance program,
program is
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 dont involve an
i id t
incident.
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.
Maintenance activities include the followings:

Right-of-way (ROW) and facilities environment protection.
ROW and site maintenance
Pipeline
p depth
p 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
Pipeline encroachment assessment
Facilities identification, signs and markers
Aesthetics and landscaping
Equipment (i.e. valves, metering) operational test and
routine maintenance.
Maintenance activities that are not routine in nature,

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

but are performed as a consequence of undertaking
the routine maintenance, include:
Safety management, including:
Indent Safe working practices
Safety gearing
Safe work permit
Confined space entry
Fire protection
Material amd hazardous material handing and disposal
Personal protective gearing
Incidence recording and reporting
Record keeping
Training
2.3. PipelineMaintenanceCodeRequirment
Standards
Pipeline regulations (EUB, 2003) or acts and codes will
require
i ththe operators
t t maintain
to i t i theirth i pipeline
i li according
di tto
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.
Good
G d planning
l i iis essenstial
ti l tto allll pipeline
i li maintenance
i t
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.
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.
Necessaryy environmental p protection measures
Permit to work.
Frequency
Table 2-1 provides a summary of routine maintenance activities
that are required to be performed on a pipeline as per code
requirements.
TABLE 2-1
2 1 Routine
R ti M Maintenance
i t S h d l off M
Schedule Major
j PiPipeline
li ElElements
t
Maintenance Maintenance
Requirement/Remarks
Activity Schedule/Frequency
CSA Z662 : (2003) Sour gas (> 10 Moles
H2S/k-mole NG) required monthly/bimonthly
ROW inspection Annual
HVP/sour condensate: bimonthly/weekly
depending
p g on class location
Monthly (gas) Industry norm, B31 requires periodic/as
required---leak and corrosion survey report
Pipeline patrol/leak kept while line in service
detection/corrosion
(gas) Biweekly (liquids) :
LPG/NH3 lines<1 week in ASME B31.4 (1998)
common areas
TABLE 2-1 Routine Maintenance Schedule of Major Pipeline Elements (contd)
Requirement/Remarks
Class 1,2 : Annual
Pipeline patrol Class 3: 6 months ASME B31.8 (1999)
(gas lines)
Class 4:3 months
Annual, not to exceed 15

CP monitoring ASME B31.1 (1999)
months
CP : Pipe to soil
Monthly, Soil survey once Industry norm
potential and
per year
rectifier readings
ASME B31.4 (1998): if line internally coated,
Internal corrosion
< 6 months pigged, dehydrated/corrosion inhibition,
monitoring
corrosion coupon used
Exposed pipe:
< 3 years ASME B31.4 (1998)
External monitoring;
TABLE 2-1 Routine Maintenance Schedule of Major Pipeline Elements (contd)
Requirement/Remarks
Encroachment
c oac e t
P i di or annuall
Periodic
assessment
Class location
Annual ASME B 31.8 (1999)
assessment (Gas line)
Valve ASME B31.4 and B31.8, partial operation

Annual
inspection/operation required
Valve testingg Annual
Remote control
Annual B 31 : For functionally test
shutdown devices
ASME B31.4 (1999): LPG/CO2/NH3

Relief valves (liquid) < 5 Years
Line/Storage

2.4. ROWandSiteMaintenance
Definition:
A strip of land usually about
10 to
t 50 m wide
id (see
( figure),
fi )
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.
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
processes that focus on protecting the integrity of pipeline
pipeline,
environment and public safety.
Help ensure the continued safe, efficient operation of the
pipeline and security of the supply for pipeline customers.
ROW Maintenance Requirements

Three main areas of concern in ROW maintenance.
Vegetation management
Erosion and soil stability (settlement/heave, etc.)
Landowner concerns

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
operation as well as impact on adjacent land
Measure actual major environmenta; effects such as slope
movement, settlement/heaving to confirm any impact on
design and operation.
Environmental Protection (contd)

Post-construction monitoring will generally focus on the following:
Reclamation
Re-vegetation
g
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.

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
possibility of damage or interference resulting from third
third-party
party
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
following:
Markers post/pole/fences
Pipeline warning signs
Aerial markers
Owner facilities directional sign
Owner facilities sign

Surveillance Program
A continuing surveillance program is usually conducted to monitor
for unusual operating and maintenance conditions.
The surveillance programs cover the following:
a Patrols at regular interval
a.
Unsafe conditions along the pipeline ROW may consist of:
Exposed or damaged pipe
Leaks
Pipeline breaks
Construction activity
Soil erosion and vegetative cover
Shallow pipe
Encroachment
Atmospheric corrosion
Poor condition of pipeline signs and markers
Missing pipeline signs and markers
Dead, damaged or altered vegetations
Surveillance Program (contd)

b. Gas/liquid leakage detection surveys
c. Valve inspections
d. Pressure regulating, relieving and limiting inspections
e
e. Failure investigations
f. Corrosion control
g. Pipe inspections

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.
Maintenance of site may include 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.
Access roads: Inspection
p roads need to be maintained to
ensure redy and available access for maintennce.
Depth of cover 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.

Pipeline Patrol (contd)

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
on monthly basis
basis.
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.
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 Survey flags/stakes
beginning of a new slide New power lines and cables
Floating swamp weights New subdivisions/buildings
Exposed pipe/loss of cover Local forest and timber activities (e.g., skidders crossing
Seismic activity/soil slides 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

2.5. PipelinePigging
Main purpose:
Cleaning & inspecting
Other purpose:
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.

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.
Sealing pigs: Purspose is to perform hydrostatic testing
testing,
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
Mandrel Pig
Scraper Pig Brush Pig

Spherical Pigs
Components of an HAPP
hydraulically activated power pig
In-line inspection (ILI) tools includes:

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
mapping.
mapping
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

Geometry pigs/tools include:

Caliper pig
x, y, z geometry (inertial guidance) tool
Metal loss ILI tools
Conventional magnetic flux
Hi h
High-resolution
l ti magnetic ti flux
fl leakage
l k (MFL)
Transverse field inspection (TFI)
Ultrasonic
Caliper Pig MFL

Gel pigs:
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.
There four types:
Dehydrating gel
Hydrocanbon gel
Debris pick-up gel
Batching or separator gel.

2.6. PipelineRepair
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.
The consequences may be group two categories:
Business consequences: loss of revenue, products,
organization reputation and prestige
Safety consequences: fatalities, injuries, pollution, explotion,
fire, property damage, environmental impact, etc.
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
data thro
through
gh a risk assessment techniq
technique,
e while
hile prioriti
prioritizing
ing and
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:
Magnetic flux leakage (MFL)
Inertial (x, y, z geometry)
Ultrasonic
Crack detection tools
Etc.

Inspection Technologies:
There are several techniques available to assess the integrity
of pipelines as follows:
Visual inspection
Depth of cover survey
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
Inspection Technologies (contd):

Use of metal loss ILI tools
Conventional magnetic flux
High-resolution magnetic flux leakage (MFL)
Transverse field inspection (TFI)
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

Defect Assessment:
It is the operators and the industrys standard that dictates which
defects need to be repaired and to what extent. Such defects are
summarized below (Hewing, 1999)
Corrosion
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)
Cracks (planar two-dimensional defects with fracture)
Laps/livers/lamination (manufacturing defects)
Spalling (severe abrasion)/arc strikes.
SCC (stress corrosion cracking)
Perforations (causing rupture/leaks)
Repair and Rehabilitation

Repair techniques include the following:
Temporary/leaks clamps
Grinding/dressing
Weld
W ld d deposition
iti
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.
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 tap X X
Cutout X
Patch repair
Temporary Clamp
Hot tap Bend epoxy repais sleeves

Repair and Rehabilitation

Repair techniques include the following:
Temporary/leaks clamps
Grinding/dressing
Weld
W ld d deposition
iti
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.
Integrity Management Programs

Managing pipeline system integrity in a proactice manner is
essential for all owners and operators of hazardous liquid or
natural gas pipelines.
In the late 1990s and to date
date, the United State Department of
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.
API Standard 1160
1160, Managing System Integrity for Hazardous
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 high-
consequence areas (HCAs) (Jaske, 2002).

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
maintained facilities
facilities.
IM programs must be flexible
Integrate information
Risk assessment is key and continuous
Understand and utilize new technology
Third-party evaulation of IM systems.
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
affetc an HCA
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
measures to protect HCAs
Method to measure the integrity management programs
effectiveness
A process for review of integrity assessment result and dat
analysis by qualified individual.
The key to any IM Programs is to establish a Baseline Assessment

Plan with the following elements addressed:
Identify all pipeline segments that could affect HCAs
Specify the integrity assessment method(s) for these segments
(acceptable methods include internal inspection
inspection, hydrostatic
pressure testing or equivalent methodology)
Prioritize, based on risk assessment
Provide a schedule for assessment
Explain the technical basis for integrity assessment method(s)
selection and risk factors used in scheduling the assessments.
References
MoMphitpour,JasonSzaboandThomasVanHardeveld,
PipelineOperation&Maintenance:APracticalApproach,
ASME,NewYork,2005.
k

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Ch 2 Piping & Pipeline Maintenance

Ch 2 Piping & Pipeline Maintenance

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NPS & Schedule

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Ch 2 Piping & Pipeline Maintenance

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Ch 2 Piping & Pipeline Maintenance

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FITTINGS: Mitter Bend, Tee Joint

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Ch 2 Piping & Pipeline Maintenance

FITTINGS: Coupling, Cap, Plug

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FITTINGS: Bushing, Cross, Reducer

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Ch 2 Piping & Pipeline Maintenance

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Ch 2 Piping & Pipeline Maintenance

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VALVE: Rotary Motion

BALL VALVE CHECKVALVE

PLUG VALVE BUTTERFLY

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Ch 2 Piping & Pipeline Maintenance

VALVE: Sliding Motion

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VALVE: Flexible Valve

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Ch 2 Piping & Pipeline Maintenance

Two types of maintenance activities:

There are also situations that overlap those of routine

Maintenance activities include the followings:

Ch 2 Piping & Pipeline Maintenance

Maintenance activities that are not routine in nature,

Maintenance activities that are not routine in nature,

Ch 2 Piping & Pipeline Maintenance

Scheduling and preparation cover the following:

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Ch 2 Piping & Pipeline Maintenance

TABLE 2-1 Routine Maintenance Schedule of Major Pipeline Elements (contd)

Annual, not to exceed 15

Ch 2 Piping & Pipeline Maintenance

TABLE 2-1 Routine Maintenance Schedule of Major Pipeline Elements (contd)

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

Valve testingg Annual

ASME B31.4 (1999): LPG/CO2/NH3

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Ch 2 Piping & Pipeline Maintenance

Reason for ROW Maintenance

ROW Maintenance Requirements

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Ch 2 Piping & Pipeline Maintenance

Environmental Protection (contd)

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Signs and Markers

Ch 2 Piping & Pipeline Maintenance

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Ch 2 Piping & Pipeline Maintenance