Lecture content

1. Second Hungarian-Ukrainian Joint Conference on Safety, Reliability and Risk of Engineering Plants and Components, Kiev, 19-21 September 2007 The experience on safety, reliability and risks assessment of some Ukrainian, Russian and Latvian transit pipe lines A. Krasowsky G.S. Pisarenko Institute for Problems of Strength, National Academy of Sciences of Ukraine

2. Lecture content • Introduction • Expert system for pipeline management • Databases • Geography information system • Large displacements of buried transit pipelines • Risks assessment • Conclusions

3. Expert System (ES)«InfoPipeMaster» • Collection andcare of all information about pipeline: • Computer portrait, schemes, drawings, photos of object, documents, etc. • Data bases for materials, flaws, pipes, loading conditions and soils. • The results of inspections. • The results of calculations. 2. Stress and strain fields calculations : Static loadings Dynamics loadings Flaws assessment 3. Comparative analysisusing the inspection results of different time periods. 4. Technical reports and summary conclusionpreparationabout the object condition and risks. Safety declaration.

4. Data bases (DB) structure DB «Objects» «Object position» «Geometry» «Loadings» «Calculation results» • object type • dimensions • schemes, photos, drawings • documents • pressure • temperature gradient • forces • weight, etc. • displacements and angles • forces and moments • stresses and strains • object label • coordinates, GPS attachment, digital map • environment DB «Defects» «Geometry» «Calculation results» «Loadings» «Defect position» • defect type • dimensions • position • schematization • Stress intensity factor • reference stress • safety factor • risks • axial force • bending moments • pressure • corrosion rates • defect label • element number • coordinates

5. Main components of ES • Information - search component (ISC); • Geography information system (GIS); • Automatic system for current documents; • Integration module for remote-control and remote-management; • Expert modules for strength, reliability, remaining life and risk assessment; • Component for actualization of data bases distributed territorially; • Protection systemand distribution of allowed information.

6. Initial data analysis Diagnostic Initial risk assessment Risk minimization plan Inspections and mitigations Integration of data Feedback program Revision of basic plane Management Risks revision Scheme for pipeline integrity and risk assessment

7. Geography information system

8. Image of ammonia pipeline “Togliatti – Odessa” in the ES “InfoPipeMaster” Transit pipeline trace Pump station Air crossing MAP of Ukraine

9. Calculation model for pumping station PS-13 of transit ammonia pipeline

10. Creation of DB “Loadings” for transit gas pipeline “Ivankov – Chernobyl” P, kg/cm2 2000 г. 2001 г. 2002 г. days Internal pressure variation in pipeline during 2000 – 2003 years

11. ProvidingDB “Materials” Window to choice the steel and their chemical composition typical for given pipeline segment Set of physical and mechanical properties of steels typical for given pipeline segment Some special physical and mechanical properties of steels Sharpy energy vs temperature, steel X46

12. Degradation of pipeline steel 17GS after 35 years of service. Transit oil pipeline ø720 mm, Latvian oil corridor. Asreceived Aged

13. Calculation module for the flaw risks assessment Flaw condition Some corrosion flaws Some shape defects Flaw repair assessment Kr 1.0 БН Н УН Д Cracks 1.1/k 1.0

14. Comparative analysis of two procedures of intelligent pigging. Transit gas pipeline “Dolina – Rossosh” ø1420 mm 2003 1996

15. Statistics of flaws recognized on the part «Dolina – Rossosh» by two diagnostic of transit gas pipeline «Braterstvo» ø 1420 мм p; F p; F а, % wall thickness l, mm 1996 year, flaw length, mm 1996 year, flaw depth, % p; F p; F а, % wall thickness l, mm 2003 year, flaw depth, % 2003 year, flaw length, mm

16. Limited internal pressure for each defect (points) revealed during diagnostics of oil pipeline “Kremenchug - Kherson», ø720mm Pressure, МPа Internal pressure Pump station Longitudinal coordinate, m

17. Decision acceptance on the repair sequence Kr 1.0 F CF1 CF2 CF3 1/k A Т0 Т1 Т2 Т3 Sr 1/k 1.0

18. Code Assessment criterion Recommendation ВБН В.2.3 ... (Ukraine) kallowed = 0.875 < 1 Flaw is moderate Limited time of service or repair BGC/PS/P11 (British) a/t = 0.8/5.8 = 0.138 > 0.12 Flaw is moderate Repair by polishing ASME B31.8 (USA) /Тmin = 0.71 > 0.2, а a/t = 0.8/5.8. = 0.138 > 0.1, Flaw is essential Replacement of pipe RIETJENS (Holland) a/t = 0.8/5.8.= 0.138 and 0.5l/t = 145/6 = 24.2, according Fig.5 flaw belongs to zone С Limited time of service CSA-Z662 (Canada) a/t = 0.8/5.8 = 0.138 > 0.1 Flaw is essential Replacement of pipe. API 579 (USA) /= 149/0.88 = 169 > >Тmin /1.5 = 140 Flaw is essential Replacement of pipe Local integrity assessment ofgas pipeline “Ivankov – Chernobil”at excavatedpart №6 (near Priborsk) for the longitudinal scar

19. Categorizationof flaws with respect to the safety factor toprescribe the repair term (Latvian oil corridor, pipeline ø720mm, 33 years, comparison of Russian and R6 Codes)

20. Large displacements of buried transit pipelines Software complex «BucklingPipeMaster» (Courtesy of I. Orynyak & S. Radchenko) Software complex is developed to solve the geometrically andphysically nonlinear problems, related to greatdisplacements of underground transit pipelines due to: • Earth movements - longitudinal - transversal • Pipe buckling

21. Earth movement, m Transversal earth movement 7 m Pipe position Longitudinal coordinate, m