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O&M OF PIPE LINE
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DELHI
DADRI
1989
DIBIYAPUR
BIJAIPUR
(3)
(5)
(3)
+ (2)
KHERA (3)
ANTA1988
1997
HAZIRA
JHABUA
(10)
(7) + (3)
+ (2)
VAGODIA (3)
FROM OGC
IPCL
18.2 33.4 MMSCMD
1987
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O&M OF PIPE LINE SYSTEM
.B. MAINLINE & ASSOCIATED EQUIPMENT
C. CATHODIC PROTECTION
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A) ROU
KM Markers,
Direction marker,
Warning sign boards,
ROU boundary pillars installed along the ROU.
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B)MAILIE & ASSOCIATED
EQUIPMET
1.MAILIE- Pi es used of various rades and is coated
with three layer of PE coating
2.SECTIOALIZIG VALVE (SV) STATIOS-consist
of mainline ball valves, manually operated ball valves /
plug valves and quick opening end closures (QOEC).
3.CASED CROSSIGS- Provided for Rail and Road
crossing, consist of casing pipe along with vent & drainpipes
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B)MAILIE & ASSOCIATED
EQUIPMET
. . -consists 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
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T
P
G
TYPICAL SV STATION
Utility Connection 2
A V
G
T
G
P
GBy pass Line
QOEC
Utility Connection 2
MAILIE
MAIFOLD FOR PG
/TG
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SECTIOALIZIG VALVE COFIGURATIO OF LPR P/L
MOBILE FLARE
TEGLine for TEG
SV Bypass & IsolationBlind
P/L from U/S SV
Gate ValveP/L to D/S
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
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A V
F ro m - T o T e rm in a l
T o U t il it ies
A V
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 L O WT E E
M O V
F L O WT E E
M O V
QOEC
RECEIVER
LAUNCHER
B l o w
B A L LV A L V E
T SV
G L O B EV A L V E
G A T EV A L V E T E G - T H E R M O
E L E C T R I CG E N E R A T O R ( U t i l i t i e s )
R - LN G F L O WD I R E C T I O N
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TYPICAL I P STATIO OF LPG P/L
UpstreamM
M
SCRAPER
RECEIVER
SCRAPER
LAUCHER
To Customer
Downstream
M
M
M
M
M
PCV
TSV
TSV
MAILIE PUMP
To
Customer P
PS HH
M
PS LL
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CASED CROSSIGS
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C. Cathodic Protection
COMPOETS & DEVICES OF CP SYSTEM
Anode Ground Bed
Test Stations
Computerised Test Station
Zinc Grounding Cell
Spark Gap Polarisation Cell
Casing Pipes
ec r c es s ance ro es corros on sens ng pro es
Permanent Reference Cell
Insulating Joints
Power Source
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CCVT CCVTBATTERY BATTERY
ELECTRICAL LAYOUT AT
ITERMEDIATE STATIOS
600 AH600 AH
48V DC BUS
DC COOLING
SYSTEM FOR AC& EXHAUST
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OPERATION &MAINTENANCE
Time independent threats
me epen en rea sStable threats (induced during construction stage)
Based on the threats identified, preventive, corrective andmitigative actions are taken from time to time to ensure
Specific Pipeline Section.
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A) ROU
Helicopter Patrolling
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B)MAINLINE & ASSOCIATED
EQUIPMENT1)MOITORIG Inspection of SV, IP & RR installations along the pipeline
Inspection of River, Rail, Road crossings and Vulnerable locations
2)THICKESS MEASUREMET OF ABOVEGROUD PIPIG
3)PREVETIVE/ CORRECTIVE MAITEACE Periodic performance test of valves and associated equipment
Inspection of fire fighting equipments and corrective actions/, , ,
encroachments, missing/ damaged markers, boundary pillars etc
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B)MAINLINE & ASSOCIATED
EQUIPMENT
PREVETIVE/ CORRECTIVE MAITEACE
PERFORMACE 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 replacedduring every half yearly valve performance test.
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B)MAINLINE & ASSOCIATED
EQUIPMENT
Fire fighting equipments a) Monthly b) Quarterly c) Yearlyactivity
Pipeline exposures, washouts, excavations ,encroachments, missing/ damaged markers, boundary
pillars etc
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P/L MONITORING & MAINT. SCHEDULE
-------------------------------------------------------------------------SL. ACTIVITY FREQUENCYNO.-------------------------------------------------------------------------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
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P/L MONITORING & MAINT. SCHEDULE---------------------------------------------------------------------SL ACTIVITY FREQUENCYNO.
---------------------------------------------------------------------5. INSP. OF FIRE EQUIPT. MONTHLY
6. PIPELINE WALK YEARLY
7. VULNERABLE LOCATION MONTHLY
8. HELICOPTER SURV MONTHLY
9. ENCROACHMENTS MONIT. HALF YLY.
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C) Cathodic Protection
O&M of CP System consists of the following :
Periodic surveys to determine the status of CP
an re a e ems 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
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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
installation
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C) Cathodic Protection
con -
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
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C) Cathodic Protection
Maintenance crews should be trained in good coatingapplication procedures
Care of materials, and compliance with specifications sothat acceptable coating work will result.
Maintaining a performance record of pipeline coatings on
the system
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C) Cathodic Protection
Check output voltage and current
Clean and tighten all bolted current-carrying connections.
Clean all ventilating screens in air cooled units to ensureunobstructed air flow.
Check indicating meters for accuracy.
ep ace nsu a e w res on w c nsu a on as crac e or
been damaged.
Check all protective devices (fuses, circuit breakers, or
lightning arresters) to ensure their integrity.
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C) Cathodic Protection
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
Cleanin and ti htenin of connections of anodes
Balancing of current flow in each anode
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C) Cathodic Protection
Identify requirement for replacement of box covers orcover retention screws, cover gaskets or terminal nuts or
screws
Take corrective action against vandalized, broken test
station
Check and mitigate problem of connection integrity withthe pipeline
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C) Cathodic Protection
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
,
procedure is to fill the entire annular space between pipeand casing with a material that will stifle any corrosion
tendency
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C) Cathodic Protection
Resistance bonds installed between pipelines forintersystem interference correction require periodic
checking
Exchange of operational information with the foreign line
companies
Planning for cooperative interference tests, design ofcorrective bonds, or other necessary measures to mitigate
interference damage caused to either party
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C.P. MONITORING & MAINT.SCHEDULE
-------------------------------------------------------------SL. ACTIVITY FREQUENCYNo.
1. C.P. STATIONS MONTHLY
2. T/R UNITS WEEKLY
3. PSP MONIRORING QUARTERLY
4. COMPUT. TEST STNS. HALF YLY. (NOT APPLICABLE FOR GREP)
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C.P. MONITORING & MAINT.SCHEDULE
(CONTD)------------------------------------------------------------SL. ACTIVITY FREQUENCY
o.-------------------------------------------------------------------- -
5. DC COOLING SYSTEM HALF YLY.
6. BATTERY BANKS HALF YLY.
.
8. POWER SOURCE MAINT. HALF YLY.
9. EARTHING SYSTEM HALF YLY.
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SCADA
SUPERVISORY COTROLAD
DATA
ACQUISITIO
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SUPERVISORY COTROL
OF MAJOR PIPELIE EQUIPMETSTHROUGH MCC
1.SECTIONALISING VALVES OPEN/CLOSE.
2.TEG/CCVT START AND STOP STATUS.
3.OPERATION OF COMPRESSORS .
4.FLOW CONTROL THROUGH COMPRESSORS
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DATA ACQISITION AND MONITORING
OFMAJOR PARAMETERSTHROUGH MCC
. . .2. PIPE TO SOIL POTENTIAL3. ANODE OUTPUT VOLTAGE4. ANODE OUTPUT CURRENT
5. SECTIONALISING VALVES OPEN/CLOSE6. TEG/CCVT STATUS FOR
VOLTAGE, CURRENT,RUNNING,ALARMS7. BLDG. DOOR OPEN/CLOSE8. A/C RUNNING STATUS9. RADIO ROOM TEMP ALARMS10.FIRE ALARM
11.PIGGING OPERATION
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CORROSIO COTROL CRITERIA
AD AALYSIS
HEAD QUARTER FUCTIOS
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CRITERION
PSP (ON/OFF) MAINTAINED BETWEEN 0.95v to
1.2v
EXTERNALCORROSION RATES ARE
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AALYSIS
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 FORCORRECTIVE ACTION
AALYSIS
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2.C.P. PARAMETERS AT ALL FEED POINTS
MONITORED MONTHLY CURRENT
CONSUMPTION RATE CALCULATED
FOR TOTAL PIPELINE.
AALYSIS
3.PRESENT CORROSION RATES CALCULATES
BASED ON ER PROBE MONITORING.
CORROSION RATE=(R2 R1) 4 MILS/YEARn
R1 - INITIAL READING
R2 - FINAL READING
n - ELAPSED TIME IN DAYS
BETWEEN TWO READINGS.
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GRAPH - HBJ P/L SYSTEM
1.700
1.900
0.700
0.900
1.100
1.300
1.500
PSP
Volts
(-V
E
0.500
0
.0
00
9
.0
00
1
8
.1
00
2
9
.8
36
4
2
.1
00
5
5
.3
00
6
8
.3
00
8
0
.2
17
8
9
.5
00
1
0
2
.4
85
1
1
5
.5
00
1
2
9
.0
00
1
4
1
.5
00
1
5
5
.0
00
1
6
8
.0
00
1
8
1
.0
00
1
9
3
.5
00
2
0
6
.5
00
2
1
9
.5
00
2
3
2
.5
00
2
4
5
.0
00
2
5
6
.0
00
2
6
8
.0
00
CHAINAGE (IN K.M.)
PSP UPL LPL
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CURRENT CONSUMPTION OF HBJ PIPELINE
icro
Q
.
1.00
6.00
.
OCT 95 DEC 95 OCT 96 JULY 97 MAR 98 DEC 98
YEAR
CURRENT(
m
AM
PERES
/
M
ETER
)
AV. CURRENT
CONSUMPTION
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HEALTH OF PIPELINE
ACHIEVED DESIGN
AVERAGE 10 M ICROAMP/M2
125 MICRO AMP/M2
CURRENTCONSUMPTION
PSP VALUE -0.95 TO 1.5 V -0.95 TO-1.5 V
EXT 0.15 MIL/YEAR < 1 MIL/YEARCORROSION
INTERNAL 0.01 MIL/YEAR
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3Layer copolymer coating application schematic
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Practical Galvanic Series for Materials in eutral Soils and Water measured
with respect to copper sulphate reference electrode
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Material Potential Volts (CSE)
Carbon, Graphite, Coke + 0.3
.
Mill Scale on Steel - 0.2
High Silicon Cast Iron - 0.2
Copper, Brass, Bronze - 0.2
Mild Steel in Concrete - 0.2
Lead - 0.5
Cast Iron (Not Graphitized) - 0.5
Mild Steel (Rusted) -0.2 to -0.5
Mild Steel (Clean and Shiny) -0.5 to -0.8
Commercially Pure Aluminum - 0.8
Aluminum Alloy (5% Zinc) - 1.05
Zinc - 1.1
Magnesium Alloy (6% Al, 3% Zn, 0.15% Mn) - 1.6
Commercially Pure Magnesium - 1.75
Principle of Cathodic Protection
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How It Works
Creat a corrosion cell
Make the structure to be protected cathode
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Differential Corrosion Cell
COPPER-COPPER SULFATE REFERECE
ELECTRODE
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ELECTRODE