Structure of Presentation

Pipelines division: an overview

Pipeline health monitoring
Pipeline protections measures.
Pipeline coating.
Cathodic protection
Pipeline surveys
Pipeline repair
Station/Mainline facilities
Maintenance philosophy.
Case studies

Pipelines Division of IndianOil : Assets

Pipeline network having total length of 10330 km,
comprising pipelines of sizes ranging from 8 to
48 dia and 72 MMTPA (1.44 Million bpd) capacity
72 installations across India
3 Single Point Mooring systems
63 bulk crude storage tanks (approx. total capacity
25 Million bbl)
Dedicated Telecom (with over 6,500 km OFC),
SCADA system

Growth of Pipeline Length

Length ( KM)

12000
10330
10000
7730

8000

6364
5423

6000
3980

KM 4000

2014
2000

435

0
1964

1975

1985
YEAR

1996

2000

2004

2009

Age Profile of IndianOils Existing Pipelines

1800 km
(> 40 Years)
3800 km
(<10 Years)

2200 km
(25-40 Years)

2500 km
(10-25 Years)

IOCL PIPELINES

IOCL pipelines, those commissioned in 60s have

already served for more than 40 years and still being
operated at Max. allowable operated pressure &
achieving the yearly throughput target.

Implementation of effective corrosion prevention

programme has helped in
achieving the safe,
economical & reliable operations of pipelines.

Why do pipelines fail?

Causes of pipelines failures
Third party damage
Corrosion (Internal/External)
Construction/Material defect
Natural Calamities/Ground movement
Other causes (operational error)

Failures in IOCLs Operating Pipelines

50
%

P/L FAILURES

40
30
20
10
0
Mech/Material Corrosion
failures
failures

Third
party/Pilferages
failures

Others

Integrity Management of Pipelines

Spillage of oil
&
Fire hazard

Environmental
damage
near leak spot

Pipeline
Failure:
Consequences

Legal Issues,
Financial Loss

Interruption
in petroleum
supply

Identification of possible causes of Pipeline corrosion.

Major Causes of Pipeline External Corrosion :z

Poor/defective Coatings.

Inadequate Cathodic Protection (CP).

Coating defects combination with inadequate CP.

Interference due to external agencies.

Stress & Bacterial corrosion.

Major Causes of Internal Corrosion :z

Corrosive nature of fluid transported through

pipeline.

Erosion Corrosion.

Localized Chemical attack/bacterial corrosion.

Integrity Management Practices in Indian Oil

Prevention Against Corrosion : Approach

Identification of possible causes of corrosion

Evaluating approaches / methods

corrosion

Selecting Corrosion
methods comprising
solutions

Dealing with challenges in achieving effective

corrosion mitigation measures

Instituting an effective corrosion

programme and experience sharing

to deal with

Monitoring & Mitigation

CP and diverse coating

mitigation

Integrity Management Practices in Indian Oil

Thrust
Areas

Monitoring
Monitoring
Pipeline
Integrity

Cathodic
Protection

Monitoring
Coating

Selecting Corrosion Mitigation methods.

Mitigation Of External Corrosion in Pipelines:
i) Protective Coating
Effective coating/painting on metal structures is the
best and most economical way of corrosion control.
For cross-country pipeline, the primary protection is
coating .
Coating isolates the metal surface from contact with
the surrounding & avoid corrosion.

Pipeline Coatings
Plant Coating
Coal Tar Enamel Coating
3 Layer Polyethylene Coating
Fusion Bonded Epoxy
Dual Fusion Bonded Epoxy
Field Coating/Refurbishment Coating
Coal Tar Enamel Coating
Hot Applied Coal Tar Enamel Tape
Cold Applied Tape
Polyurethanes coating
Epoxy Coatings

Selecting Corrosion Mitigation methods.

Mitigation Of External Corrosion in Pipelines:
ii)

Cathodic Protection (CP)

CP is a viable tool for Corrosion prevention.

Corrosion is an electrochemical phenomenon,
therefore effectively mitigated by altering the
electrochemical condition.
CP achieved by reversing natural corrosion current
with the supply of current from external source.
The external current supply in CP system is
generated either by sacrificial anode or impressed
current system.

Cathodic Protection Station

3
4
8
7
7
0
1
0
8
0
0
0
0
0
0
6
0
0
6
6

1 1.33
1 1.63
1 1.81
1 6.63
1 9.63
2 6.25
2 9.49
3 2.50
3 3.11
3 6.10
3 7.90
4 3.80
4 5.80
4 7.76
5 0.39
5 2.64
5 4.39
5 7.44
5 9.01
6 5.15

4 .9 2 6

2 .0 1 5

0 .2 5 0

PS P V O L T (-)

PSP profile

2.05
1.95
1.85
1.75
1.65
1.55
1.45
1.35
1.25
1.15
1.05
0.95
0.85
0.75
0.65
0.55
Qtr:2nd (April.-June 2006)
OFF PONTIAL
DATUM
PPMAX

CHAINAGE (KM)

Selecting Corrosion Mitigation methods.

Coating And Cathodic Protection
Ideally, perfect coated pipe should not take
any current.
However, even newly coated pipe requires current
for making it above protection.
The modern pipeline corrosion control work
Comprises the use of good coatings in combination
with suitable CP system as the main lines of defense.
Supplementary defense, such as use of insulated
coupling, interference mitigation device, local
environmental control etc. reinforce the main defense.

Selecting Corrosion Mitigation methods.

Mitigation Of Internal Corrosion in Pipelines:
Main Contributing factors
Corrosive nature of the transported product.
Moisture/Traces of water, CO2, oxygen, H2s, bacteria etc.

Erosion - Corrosion.

Mitigation Measures
By regular and periodic pigging of pipeline for internal
cleaning.
Introduction of corrosion inhibitor in pipeline
Ensuring transported product free from moisture &
corrosive compound.

Pipeline Coatings Types employed in IOCL

I.

Over the ditch coating :- Old pipelines such as GSPL,

BKPL, HMRB, KAPL, SMPL, MJPL are having over the ditch
CTE coating.

II.

Plant Coating :- Since the mid 90s, plant / yard coating is

being adopted for new Pipelines.
) In KBPL, for the first time, 3LPE coating was applied
) Sonipat Meerut branch line was coated with FBE
) Koyali Ratlam line was coated with DFBE

III.

Experience of yard / plant coating

)
)
)
)

Controlled condition for application

Good surface cleaning due to shot blasting
Better inspection and testing
Less current requirement for CP

Performance of Coatings employed in IOCLs

Pipelines
I. Over the ditch coating : Coating condition of certain old
pipelines having over the ditch CTE coating are not
satisfactory at many locations/stretches (current density >500
/m2).
Few

leaks due
experienced.

to

soil/external

corrosion

were

also

To achieve complete line protection of these pipelines & avoid

soil corrosion/leak, large scale refurbishment of existing

coating is being carried out.

II. Plant Coating : Since construction of KBPL (1995), plant

coating is being adopted for all new Pipelines.

Performance of all the plant coated pipeline is quite

satisfactory. All these pipelines are cathodically protected
and current density of pipelines are quite satisfactory (<100
/m2).

Current Densities of different coatings in IOCL

Pipelines
DIA

LENGTH

(inch)

(km)

TYPE OF
COATING

YEARS IN
SERVICE
(year)

AVG. CURRENT
DENSITY
(A/m2)

LINE 1

12

800

Over the Ditch

CTE

42

400-500

LINE 2

24

800

Over the Ditch

CTE

30

400-800

LINE 3

18

950

CTE
(Plant Coated)

10

8-10

LINE 4

22

950

3LPE

13

13-15

LINE 5

10

110

3LPE

13

5-7

LINE 6

10

70

FBE

40-50

LINE 7

10

170

FBE+CTE

10-15

Dealing with challenges in rehabilitation

of old operating pipelines.
Challenges

Mostly CTE (over the ditch) coated

High current density i.e poor coating.
Conventional CP system.
Inconsistent SEB Power availability/Theft of Solar
panels.
Highly corrosive soil.
Low frequency ERW mainline pipes.

Requirement of Coating Surveys

Coating deteriorates with passage of time & the load
on CP system increases day by day.
It slowly reaches a limiting condition where any
amount of additional CP protection does not improve
the situation.

Therefore, identification of coating defects with

highest accuracy becomes very important, so that
coating repairs & subsequent Line Protection is
achieved in shortest possible time.

Selecting suitable Surveys

CURRENT ATTENUATION TECHNIQUE (CAT)
9

Over all assessment/classification of

coating quality for

different stretches.
9

Most Suitable coating surveys for priority fixing for coating

refurbishment.
DC VOLTAGE GRADIENT SURVEY(DCVG)

DCVG for pin pointing the coating defects.

APPROACH

Combination of CAT & DCVG for coating assessment &

finalizing locations for refurbishment.

Selecting suitable Surveys

CIPS Survey
9

Reflects the actual status of line protection for entire section.

Indicates interference problems, if any.

Detects deficiencies in CP system that go undetected during

routine monitoring.

Coating Surveys
CURRENT ATTENUATION TECHNIQUE
(CAT) SURVEY

DC VOLTAGE GRADIENT SURVEY(DCVG)

CAT SURVEY
BASED ON DB LOSS OBSERVED FOR PIPELINE, COATING DEFECTS
CAN BE CLASSIFIED AS UNDER :
SL.
NO.

DB/KM LOSS

CLASSIFICATION

1.0

< 10 DB/KM

GOOD COATING

2.0

10 25 DB/KM

FAIR COATING

3.0

25 70 DB/KM

BAD COATING

4.0

ABOVE 70 DB/KM

MASSIVE DEFECT

Experience of IOCL

CAT is excellent in prioritizing the coating rehabilitation of old

pipelines (poor coating).

DCVG is very effective for detection of all the coating defects of

newly coated pipelines or well coated pipelines.

Combination of CAT, DCVG & CIPS is very effective &

beneficial i.e. identifying coating defect, line protection,
interference study etc.

Experience of IOCL

Pipeline metal loss features identified by IPS were plotted

with the results of CAT/DCVG/CIPS & based on result,
priority made for coating refurbishment & job executed.

Other parameters such as current density, soil resistivity,

age & type coating, leak/corrosion history etc were also
plotted along with CAT/DCVG/IPS data.

Results found to be very encouraging, Defective coatings

were identified with high degree of accuracy & repaired.

Pipeline Rehab. Coatings - IOCL Experience

COALTAR ENAMEL COATING (CTE)

Earlier, Coal tar enamel coating was used for in-situ

refurbishment of pipeline coating.

However, major limitations are:

Difficult to maintain the application temperature.

Uneven flow of molten CTE resulting in uneven

/inadequate coating thickness particularly at 4-8
O clock position,
position

Toxic fumes affect the quality of supervision.

Health hazard to applicators

Pipeline Rehab. Coatings - IOCL Experience

COALTAR BASED TAPE (CTT):

Coal Tar Enamel in pliable form & consist of coal tar

embedded in a fabric reinforcement of fiberglass with a
uniform thickness.

Application of CTT is done manually over the primed surface

by slight heating of the inner side of the tape.

CTT eliminates few application problems encountered in CTE

coating such as Toxic fumes, Health hazard to applicators
etc,

Results obtained from the dig sites were not encouraging

showing defects such as lumping & thinning, holidays,
wrinkling etc.

Pipeline Rehab. Coatings - COALTAR BASED TAPE

Pipeline Rehab. Coatings - IOCL Experience

COLD APPLIED TAPE (CAT)
9 CAT is a factory produced Tape having a backing of
Polyethylene and a Butyl Rubber adhesive layer.
9 No requirement of heating during the application.
9 Application using a wrapping machine makes it possible to
achieve correct movement as well as uniform tension.
9 Good mechanical properties & uniform coating thickness.
9 Productivity is high
9 Least Dependence on human skills
9 Environment friendly.

Pipeline Rehab. Coatings - IOCL Experience

COLD APPLIED TAPE (CAT) COATING SYSTEM
ADOPTED IN IOCL
9
9
9
9
9
9

Conforming DIN-EN-12068:1999
Primer Liquid Adhesive.
Inner Layer (3ply type)
Outer Layer (2ply type)
Overlap 50%
Total Coating Thickness 2.5 to 3.0mm

Pipeline Rehab. Coatings Polymer based

COLD APPLIED TAPE

Pipeline Rehab. Coatings Polymer based

COLD APPLIED TAPE

Pipeline Rehab. Coatings - IOCL Experience

Polyurethane (PU) coating
9

Polyurethane coating systems are generally two component airless hot spray applied
coatings.

Nominal thickness of PU maintained between 1000-1250microns.

Good mechanical properties & adhesion to the substrate.

Productivity is high.

Observations during field application:

)

Specialized procedure for application and requires trained applicators.

Close monitoring required to ensure requisite uniform thickness.

Proper PPE required during application / inspection due to toxic fumes.

Transportation of sophisticated equipment to site.

Surface preparation requirement is high. Coating is less surface

imperfection tolerant.

Insect and dust control till curing is achieved.

Pipeline Rehab. Coatings PU Coating

Pipeline Rehab. Coatings - IOCL Experience

Epoxy Coating
Epoxy coating is pretty much similar to Polyurethane and also involves
spray application.
Two pack (Base & Hardener) 100% solid solvent free epoxy was used
for trial application.

Observations during trial field application:

)
)
)
)
)

Slow Curing / Dry time, thus resulting in poor productivity rates.

Insect and dust control till curing is achieved.
Achieving targeted thickness may need multiple coats.
Close monitoring required to ensure requisite uniform thickness.
Proper PPE required during application / inspection due to toxic fumes.

Transportation of sophisticated equipment to site.

Surface preparation requirement is high. Coating is less surface

imperfection tolerant.

EPOXY COATING

Introduction of Intelligent Pig Survey (IPS)

IPS is a well proven and latest technique for health
monitoring of a pipeline and it can scan the complete
pipeline.
Generally following two types of IPS tool are used :-

1) Ultrasonic Type
2) Magnetic Flux Leakage (MFL)
a) Longitudinal
b) Transverse

Intelligent Pig Survey (IPS)

Ultrasonic type:
This type of survey requires the introduction
of a liquid into the pipeline to couple the
sensor signal to the pipe wall.
Magnetic Flux leakage (MFL) type:
MFL method involves introduction of a
magnetic field on the pipe wall and sensing
the leakage of field. Presently MFL technique
is the most commonly used technique for
Inline Inspection surveys.

REQUIREMENT OF INTELLIGENT PIG SURVEY

External and internal corrosion
subsequent growth monitoring.

detection

and

Inspection of pipeline locations which are not

approachable like river crossing, submerged
crossings, bridge crossings etc.
To identify corroded section, require replacement or
repair.
Setting operational parameters
health condition.

based on pipeline

Assessment of corrosion rate in

comparing data of previous survey.

pipeline

Planning for operation and maintenance activities.

by

BASIC PRINCIPLE OF MFL TECHNIQUE

MFL tool is housed with Permanent magnets with
sensors & secondary sensors.
Magnetically Saturate Pipewall ,One Small part at a
time.
Magnetic flux tends to travel through steel and
magnetic saturation occurs.
Once the steel becomes saturated some of the flux
starts to significantly leak out of the material.
Localized decrease in pipe wall thickness (i.e.
corrosion) causes a localized increase in magnetic
saturation that in turn causes localized increases in
flux leakage.

BASIC PRINCIPLE OF MFL TECHNIQUE

Sensors housed in tool measures the flux leakages
caused by metal loss or by other anomalies.
Primary sensors measure the flux leakage in the
internal or external pipe surface.
Secondary sensors will measure the flux leakage
caused by metal loss in the internal surface.
Flux leakages are measured and interpolated in
order to measure and characterize the defect.
Sensors detect the flux leakage and various
techniques are used to analyses the signals.
The defects are characterized on the basis of type,
size, shape, orientation and location

SEQUENCE OF INTELLIGENT PIG SURVEY

CLEANING PIGS: PIG is launched to clean the

pipeline from muck/debris, which may be
present in the pipeline.
GAUGING PIG: Gauging PIG equipped with Al
plates is launched to check the internal
geometry of the pipeline. Results are analyzed
based on physical condition of Al. plates. If
deformations is large (more than 10%),
rectification/re-run may be planned.

14GAUGE PIG BEFORE AND

AFTER RUN

before run

after run

SEQUENCE OF INTELLIGENT PIG SURVEY

MARKER MAGNETS: Before the caliper PIG run,
marker magnets are installed all along the pipelines at
every 1-2 kms of interval.
CALIPER PIG: to determine bends and their bending
direction Electronic Geometric Pig is launched. The
EGP results will clearly show if any restrictions are in
the pipeline that might prevent safe passage of the ILI
tool.
The geometry run will also give detailed information
on geometrical features, such as bends, ovalities.
Dents etc. Rectification of deformation if any which
may restrict passage of intelligent pig

SEQUENCE OF INTELLIGENT PIG SURVEY

PULL THROUGH TEST : Before the launch of ILI tool in
the pipeline the tool undergoes pull through test,
wherein the tool is passed through a section of pipeline
with known defects at contractor works.
WET LOOP TEST: Generally, during initial development
stage, ILI tool is also tested in wet loop.
The purpose of this test is to ascertain the accuracy of
the tool in terms of detection of defects.
IP SURVEY: Once the IP tool successfully passes pull
through test, the tool is introduced in the pipeline and
data is collected.

GENERAL VIEW AND FUNCTIONING

MFL INTELLIGENT PIG SENSOR.

ONLINE DATA PROCESSING

MINIMUM REQUIREMENT OF INTELLIGENT PIG

Detect following with size and chainage of pipeline.
Internal corrosion.
External corrosion.
All fitting in pipeline like valves, sleeves, leak clamps etc.
And girth weld
Length of each pipes with thickness details.
Longitudinal and circumferential grooving.
Type of defect
Associated
repair and
pipeline.

with software to prioritize

to assess the overall health

the defects
condition of

for
the

CLASSIFICATION OF DEFECTS

RELEVANCE OF IPS WITH OPERATION

IPS REPORT IS BASE FOR THE ASSESSMENT OF LINE

CONDITION AND MAOP FOR THE LINE IS SET
ACCORDINGLY.
BEFORE START OF SURVEY DETAILS OF LINE WITH EXISTING
MAOP ARE GIVEN TO THE SURVEYOR.
LINE DETAILS ARE REQUIRED TO FIX TOOL PARAMETERS
AND EVALUATION OF IPS RESULTS.
EXISTING MAOP IS REQUIRED TO EVALUATE SEVERITY OF
FEATURES AND CALCULATION OF ERF VALUE.

DETERMINATION OF ESTIMATED REPAIR

FACTOR (ERF)
ERF is calculated to classify the defects on the basis of
severity. ERF is the ratio of true MAOP of the pipeline to
the calculated MAOP in corroded area of the defect.
ERF = MAOP/MAOP in corroded area (p)

LIMITATION OF IPS
No direct assessment of pipe Strength (only
metal loss detected).
Difficult to idenfify the Weld defect/material
defect.
(Hydrotest would be required for finalization of
safe operating pressure of pipeline).
MFL is indirect measurement of wall loss, any
error in data interpretation would lead to error
in final data.
More depended on data interpreter

IPS RESULT Vs COATING SURVEY

TYPICAL PLOT RESULTS OF IPS (FEATURE DENSITY)

TYPICAL PLOT - RESULTS OF CAT SURVEY

90
80

dBLoss/ KM

70
60
50
40
30
20
10
0
0

8
10
12
Pipeline Chainage

14

16

18

20

MAINLINE MAINTENANCE

Pump Station layout

IC

12MOV

12

SLB
From Panipat IC

To Jalandhar

SRB
14

14
MOV

12MOV
8

14
MOV

2
12

IFD

12

12 MOV 12

TM

12

8
6

12

TM
12 MOV

14 MOV

E
H

10

10

MP-3

TM

10

6
14

14
10

10
S/F

MP-2

14

HSD

6
14

8 8
E

12 12 MOV

14

10

12 MOV

TM

Strainer

12

12

12

SK
ATF
MS

MP-1

INSPECTION OF R.O.W.
To observe surface condition
Wash outs
Leaks
Encroachments
To inspect the Markers & accessories
Markers
TLPs
Block Valves
CP / RCP stations
To inspect Crossings & vulnerable locations and
special attention to suspended crossings, exposed
area etc.

MAINLINE FACILITIES
Boundary Pillar (BP)
Turning Post (TP)
Kilo Meter Post (KMP)
Vent Pipe (VP)
Test Lead Post (TLP)
Caution Board
Block Valve (BV)
CP Station
Repeater Station
Repeater cum CP Station (RCP)

MAINLINE LAYOUT
Position of M/L markers
IOCL

IOCL

KBPL

KBPL

TLP

VP

BP

VP
KMP

TP
154

Casing

Pipe

IOCL
KBPL

RO
A

Caution
Board
IOCL
KBPL

MAINLINE PATROLLING
Daily Patrolling by Line Patrol Man (LPM)
Surprise check by officers
Mainline Patrolling by officers
Daily Patrolling Report
Monthly Patrolling Report
Surprise Check Report
Report on M/L Inspection by officers

ROW MAINTENANCE
Providing missing M/L markers
Painting of existing M/L markers
Updation of Caution Boards
Removal of bushes, trees etc from ROW
Attending washouts
Removal of encroachments
Attending shorted cased crossing
Refurbishing of Coat & Wrap

MAINLINE EMERGENCIES
Leak
Burst
Pilferage
Welding of Leak Clamp
Welding of Sleeve (Full/Half)

CORROSION INHIBITOR
AN INHIBITOR IS A SUBSTANCE, WHEN ADDED IN
SMALL CONCENTRATION TO AN ENVIRONMENT
DECREASES THE CORROSION RATE.
MOST INHIBITORS HAVE BEEN DEVELOPED BY
EMPIRICAL EXPERIMENTATION.
MANY INHIBITORS ARE PROPERIETARY IN NATURE
AND THEIR COMPOSITION IS NOT DISCLOSED.

CORROSION INHIBITOR
IN CROSS-COUNTRY PRODUCT PIPELINE, WE ARE
USING CORROSION INHIBITOR TO MITIGATE THE
INTERNAL CORROSION OF PIPELINE.
PRESENTLY UNICOR-J @ 6PPM IS BEING USED.
CORROSION INHIBITOR FORMS A LAYER INSIDE THE
PIPE AND MAKE IT PASSIVE.
IN CRUDE PIPELINE, NO C.I. IS INJECTED IN IOCL
PIPELINE
BH CRUDE FORMS A LAYER OF WAX.

CORROSION PROBES & COUPONS

INTERNAL CORROSION RATE OF PIPELINE IS BEING
MONITORED BY :1) CORROSION COUPON :- INSTALLED AT NRVs/AT
SUITABLE LOCATIONS.
2) CORROSION PROBES:- INSTALLED IN MAINLINE &
WORKING ON RESISTANCE MEASUREMENT.

INTERNAL CORROSION RATE

As per NACE RP-0775-91 corrosion rate is categorized as

Category
Low

Average corrosion
rate ( MPY)
< 1.0

Moderate

1.0 4.9

High

5 10.0

Severe

> 10.0

ER PROBE:
No.

Description

Material

Protective Cover

Extension Adopter

Carbon
Steel
316SS

O Ring for Cover

Viton

Hollow Plug Assy

316 SS

Primary Packing

Teflon

screw Lock

316SS

Flush ER Probe

316 SS

INTERNAL CLEANING OF PIPE

Pigging operation

Types of Pig: Cleaning Pig, Batching Pig,

Caliper Pig,Foam Pig, Instrument Pig

Purpose of pigging:
1.
2.
3.

4.

To clean the new pipe debris.

To know the inside pipe dia profile.
For inspection and measurement of any
corrosion or metal loss.
For generating initial pipe line data.

PIGGING AND ITS IMPORTANCE

Mandrel pigs, which

have a central body
tube, or mandrel, and
various components
which can be
assembled onto the
mandrel to configure
a pig for a specific
duty;

PIGGING AND ITS IMPORTANCE

Scrapper pigs, which

have a central body
tube, or mandrel, and
various components like
PU cups and spring steel
brushes which can be
assembled onto the
mandrel to configure a
pig for a specific duty.

PIGGING AND ITS IMPORTANCE

BI-DI or Batching
pigs, which have a
central body tube and
disc components can
be assembled onto
the body to configure
a pig for a specific
duty;

Experience of IOCL
Case Study

Product Pipeline in operation since 1966

(API 5L X-46 ERW)

Few corrosion failures occurred.

Pipeline was de-rated to 80% of the MAOP

In line inspection of the pipeline was

carried out.

Experience of IOCL
Case Study (cont..)

Critical defects in the pipeline were

rectified.

To check the seam integrity, hydro-test

was conducted.

Result of hyrotest was quite encouraging.

7 significant defects were eliminated.

Experience of IOCL
Case Study 2 (cont..)

CAT, DCVG & CPL Survey conducted to check the

performance of existing CP & coating.

Pipeline metal loss features identified by IPS were

plotted

with the results of CAT/DCVG/CPL &

based on result, priority made for coating

refurbishment & job executed.

Experience of IOCL
Case Study (cont..)

Results found to be very encouraging, Defective

coatings were identified high degree of accuracy &
repaired

CP system was upgraded

by providing solar

battery bank/battery bank & renovation of ground

beds

Appreciable

improvement

in

line

protection

achieved. Current density reduced up to 50%.

No corrosion failure in last 5 years.

Pipeline was re-rated to new MAOP

HYDROSTATIC TESTING
OF
P-M & M-A SECTIONS OF BKPL
DETAILS OF LINE FAILURES OCCURRED FURING
HYDROTESTING
STAGES OF
PRESSURE
TESTING

NO. OF
FAILURE

FAILURE
NOS.

SEAM
FAILURE
LENGTH/
WIDTH

FAILURE
PRESSURE
(EX-ALD) IN
KG/CM2

IST STAGE

IST

1.4 MTR/
8MM

49.5

2ND STAGE

2ND

2.1 MTR./
11 MM

63.0

35D

0.11 MTR/
4MM

61.5

4TH

0.1 MTR/
1 MM

75.0

5TH

1.0 MTR/
10 MM

75.0

6TH

2.1 MTR/
22 MM

82.0

7TH

0.04 MTR

85.0

3RD STAGE

BK/HYDRO