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How well do you now your pipeline?. PPSA Seminar – Aberdeen 18 th November 2009 Paul Birkinshaw. The industry challenge. Choosing the right pigging options for in-service pipelines with little or no pigging history ‘Pigging The Unpigged’ (not the unpigabble!).
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How well do you now your pipeline? PPSA Seminar – Aberdeen 18th November 2009 Paul Birkinshaw
The industry challenge Choosing the right pigging options for in-service pipelines with little or no pigging history ‘Pigging The Unpigged’ (not the unpigabble!)
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’
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!
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
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
Good ILI data is essential Repair Rejection Acceptance
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!
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!!
The data room!! Getting your head around your client’s document management system can sometimes be difficult!
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.
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.)
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)
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
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!
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!
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?
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?
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
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)
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
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
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
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)
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
After the ILI pig run… Forged Bends Pipe Joints
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
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)
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
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
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