How well do you now your pipeline?

1. How well do you now your pipeline? PPSA Seminar – Aberdeen 18th November 2009 Paul Birkinshaw

2. The industry challenge Choosing the right pigging options for in-service pipelines with little or no pigging history ‘Pigging The Unpigged’ (not the unpigabble!)

3. The challenge for Penspen • Penspen Integrity • Have been providing of pigging related consultancy services for more than10 years • Penspen O&M Services (GreyStar UK) • Significant growth area within Penspen in the UK • Providing O&M services for onshore pipelines • Pipeline operators (our clients) with little or no knowledge or experience in pigging • Particularly UK power station gas supply pipelines We are increasingly being asked to deliver ‘Turnkey Pigging Solutions’

4. Wearing the operators shoes! • We need to get to know their pipeline intimately • Gathering all the available pipeline data • Collating and carefully assessing the available data • Understand the main drivers (why are we pigging it?) • Defining the key objectives (what do have to achieve?) • Identify the key challenges and uncertainties • Identifying the major constraints A lot to think about!

5. What data do we need? • As-built data:  • Route maps/drawings • Site / AGI plans • P&IDs • Isometric Drawings (usually of AGI plant) • Pipebook / weld records or charts • Construction POs and related procurement documentation

6. What data do we need? • Operational data • Current operating conditions • Historical operating conditions • Suspected or known issues (e.g. evidence of dusts / sludge in filters) • Other useful data sources:  • Commissioning records (including pigging reports) • Construction reports • Third party incidents • Repair and maintenance records

7. Why do we need it?

8. Good ILI data is essential Repair Rejection Acceptance

9. Getting hold of the data • Review the data from proposal stage • Often limited to diameter, length, service, location • Send an initial data request (the pipeline questionnaire) • The first sign of trouble!

10. Getting hold of the data • Follow-up with meeting and site survey • To establish what's really on site (the AGI equipment) • To find out more about the buried pipeline • Your first introduction to the clients Data Room!!

11. The data room!! Getting your head around your client’s document management system can sometimes be difficult!

12. Preparing for an ILI operation • Preparations • Confirming pigging feasibility – can you get a pig through the line ? • check bores, bends, tees, line pipe data etc. • Verifying the operating conditions are adequate for pigging • flow rate, pressure, temperature etc. • Identifying the pipeline the necessary pipeline preparations or adaptations • access arrangements, fitting temporary traps , bridle pipework etc.

13. Preparing for an ILI operation • Setting out the scope of work • Defining the overall objectives • Identifying the requirements for the preparatory pigging (pig selection and sequencing of pig runs) • Choosing the right ILI services (geometry, metal loss inspection etc.) • Identifying any ancillary services required (pig tracking / location etc.) • Identifying all general site services required (manning, lifting, handling, tools, waste management etc.)

14. Preparing for an ILI operation • Procuring the equipment and services • Preparing specifications and procurement of all prep pigs and associated services • Preparing ILI technical and contract requirements specifications • Preparing and administering an ITT for ILI services • Performing tender evaluation (technical and commercial) • Selecting and procuring ILI services (in conjunction with client)

15. Preparing for an ILI operation • Executing the services at site • Preparing method statements and operating procedures • Risk assessment • Checking the serviceability of the existing pipeline equipment • Carrying out the site preparations • Provision of operators (to operate valves and run pigs) • Provision of all ancillary and general services • Carrying out preparatory pigging • Management of and supporting the ILI pigging • Provision of pig cleaning equipment and waste handling

16. Preparing for an ILI operation • Delivering the final results • Providing a preliminary assessment based on the ILI preliminary report) • Reviewing the pipeline inspection report • Delivering a integrity integrity assessment Having access to reliable pipeline data for all stages of the project is essential!

17. Penspen approach We start with a ‘Piggability Study’ • We basically take our time to gather, properly collate and to assess all the available pipeline data before embarking on a pigging campaign • This has been found to be essential, particularly for turnkey jobs… ….even if the job looks to be straight forward!

18. The piggability study – the questions • Can the pipeline be pigged? • What do we know about the pipeline? • As built data • Operational data • Construction / commissioning records • Operational history • What preparations (or adaptations) are required? • Serviceability of existing facilities • Adaptations (fitting temporary traps etc.) • Adjustments in operating conditions • What are the operational constraints?

19. The piggability study – the questions • What are the notable pipeline features? • Connections • Major crossings (e.g. road, rail, water) • What kind of ILI is required? • To facilitate a full integrity assessment • Which pig(s) to start with? • Proving and gauging • How much cleaning? • How much contingency?

20. The piggability assessment provides.. • A piggability assessment report • For the client and ourselves • An assessment summary • An overview of the issues • A pipeline data file (collating all the relevant data) • For the client and to disseminate within the project team

21. The data drives everything!

22. Piggability study – key outputs • Confirm pigging feasibility (hopefully!) • Identify any necessary pipeline adaptations and modifications • Identify any areas of uncertainty for further investigation • Scope out the appropriate preparatory pigging operations and related tasks • Collate key technical data for pig selection and specification • Identify the key requirements for ILI pigging (the ILI service requirements specification)

23. Piggability study – outputs • Identify any appropriate ancillary services (e.g. pig tracking) • Develop a project plan for the operations • Provide key input data for the development of method statements and reliable operational procedures (none routine procedure) • Provide a sound basis for risk assessment and the development of mitigation measures • Provide valuable input data for ILI data analysis process the final integrity assessment

24. Power station gas supply pipelines • Owned by power station operator • Utility companies or private operators • High pressure lines • Connected to NTS • With or without PRS • Continuous operation • Must keep the generators going • Often no alternative source of gas supply • Sole grid connection

25. Power station gas supply pipelines • No operational pigging • No permanent pigging facilities • Usually facility to install temporary traps • Limited operator knowledge • Not core business / O&M contracted out • Lack of confidence in (or availability of) pipeline as-built records

26. 24” example (turnkey project) No records of any commissioning pigging Doubts about final routing (fabricated bends?) Daily revenue from pipeline £1.2M! High Gas Flows (3.5 m/s) HDD Crossing 800m / 19.1mm pipe / 16m deep Concerns about debris (dust / liquids build up)

27. Horizontal Directional Drilling (HDD)

28. 24” Receive pipework

29. 24” example No records of any commissioning pigging Doubts about final routing Fabricated bens?) Cautious progressive approach to pigging / early geometry pig run (+ bend detection) Key input to requirements specification (ILI tool capabilities High Gas Flows (3.5 m/s) HDD Crossing 800m / 19.1mm pipe / 16m deep Concerns about debris (dust / liquids build up) Concerns reduced through further investigations

30. After the ILI pig run… Forged Bends Pipe Joints

31. Using the ILI mapping data

32. Piggability study – benefits • Confirming the adequacy of all launch and receive facilities • Pig trap requirements • Access issues • Confirming the arrangement s of the existing AGI pipework • Quantify the full range of pipe thickness and bores • Optimum sizing of pigs and sealing elements • ILI service specifications

33. Piggability study – benefits • Identifying the location and configuration of all major infrastructure crossings locations • For risk management and emergency response planning • Identification of significant geometrical features including known minimum bend radius • For correct pig selection, • Pig configurations • Sequencing of pig runs (pipeline proving)

34. Piggability study – benefits • Identification of potential debris sources and contaminants • For correct pig selection, • Evaluating risk to downstream plant and for • Preparedness at the receive end (pig cleaning and debris handling) • Sound procurement • Getting the right equipment and service levels (quality control) • Managing financial risk

35. Piggability study – benefits • Reliable planning and execution • Managing risk and QHSE • Delivering effectively and to time and budget • Reliable data analysis and reporting • Eliminating uncertainties in the data • Getting more out of the data • Assuring pipeline integrity

36. Summing up Access to good pipeline records is key to successful pigging • Increased effectiveness • Choosing the right pigs • Selecting the right ILI services • Get the most out of the results • Increased efficiency • Get it right first time • Avoiding mistakes • Take out unnecessary conservatism • Reduced risk

37. Smart pigging requires a smart approach!