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Pipeline Integrity Basic For All Engineers PDF
Pipeline Integrity Basic For All Engineers PDF
PresentedbyDr.JohnF.Kiefner
June22,2011
Topics
ClassLocations1,2,3,and4
HighConsequenceAreas(HCAs)
PotentialImpactRadius(PIR)
ThreatstoPipelineIntegrity
MeansofMitigatingThreats
ReferenceDocuments
CodeofFederalRegulations,Title49,Part
192,(49CFR192) TransportationofNatural
andOtherGasByPipeline:MinimumFederal
SafetyRegulations
ASMEB31.8 2007GasTransmissionand
DistributionPipingSystems
ASMEB31.8S 2004ManagingSystem
IntegrityofGasPipelines
3
CLASSLOCATIONS
Classlocationsareusedtoestablishdesign
factors(safetymargins).Theyarebasedon
populationdensity.Classlocationsare
definedin49CFR192,192.5
CLASSLOCATIONUNIT
Pipeline
220yds
220yds
OneMile
CLASS1
Anoffshorearea.
Classlocationunithas10orfewerbuildings
intendedforhumanoccupancy.
Eachseparatedwellingunitinamultipledwelling
unitbuildingiscountedasaseparatebuilding
intendedforhumanoccupancy.Thus,afour
familyapartmentwouldbeconsideredasfour
buildingsintendedforhumanoccupancy.
6
Class2
Classlocationunithasmorethan10butfewer
than46buildingsintendedforhuman
occupancy.
CLASS3
Classlocationunithas46ormorebuildings
intendedforhumanoccupancy;or
Pipelinelieswithin100yardsofeithera
buildingorplaceofpublicassemblythatis
occupiedby20ormorepersonsonatleast5
daysaweekfor10weeksinany12month
period
Class4
Aclasslocationunitwherebuildingswithfour
ormorestoriesabovegroundareprevalent.
DESIGNFACTORS
Thedesignfactorsdeterminethemaximum
allowableoperatingstressinthepipeline.
Class1 72%ofSMYS
Class2 60%ofSMYS
Class3 50%ofSMYS
Class4 40%ofSMYS
whereSMYSstandsforspecifiedminimumyield
strengthofthepipe.
10
RELATIONSHIPBETWEENPRESSUREAND
STRESS
Themaximumallowableoperatingpressure
(MAOP)inapipelineisrelatedtothe
maximumallowableoperatingstressbythe
Barlow formula.ForaClass1location:
MAOP=0.72*SMYS*2t/(D)
where:
Distheoutsidediameterofthepipeand
tisthewallthicknessofthepipe
11
MAXIMUMALLOWABLEOPERATINGPRESSURE
(MAOP)
Forapipelinecomprisedof30inchoutside
diameter,0.375inchwallthickness,GradeX52
(52,000poundspersquareinchminimumyield
strength)steelpipe,theMAOPforeachclass
locationisasfollows:
Class1
Class2
Class3
Class4
936poundspersquareinch
780poundspersquareinch
650poundspersquareinch
520poundspersquareinch
12
MINIMUMREQUIREDWALLTHICKNESS
Fora30inchoutsidediameterpipelinecomprised
ofX52steelpipethatisoperatedatanMAOPof
936poundspersquareinch,thewallthicknessof
thepipeforeachclasslocationwouldhavetobe:
Class1
Class2
Class3
Class4
0.375inch
0.450inch
0.540inch
0.675inch
13
EFFECTOFPOPULATIONINCREASES
Inmostcasespopulationgrowththatwouldchange
aclasslocationunitbytwoclasslocationswould
requireinstallingnewpipewithgreaterwall
thicknessorreducingtheMAOPcommensurate
withthecurrentclasslocation.
Thus,ifthenumberofbuildingsinaClass1location
unitincreasesfrom10orlessto46ormore
(Class3location),theexistingpipewouldhaveto
bereplacedwithpipeof44%greaterwall
thicknessorthepressurewouldhavetobe
loweredbyjustover30%.
14
HIGHCONSEQUENCEAREA
Theconceptofahighconsequenceareawas
developedjointlybypipelineindustryexperts
andfederalregulatorstodeterminetheparts
ofapipelinesystemwhereperiodicintegrity
assessmentsareneededtoprotectthepublic
andtheenvironment.
15
HIGHCONSEQUENCEAREADEFINITION
AClass3orClass4location.
AnareainaClass1orClass2locationwhere
thepotentialimpactradiusisgreaterthan660
feet(220yards)andthepotentialimpact
circlecontains20ormorebuildingsintended
forhumanoccupancyoranidentifiedsite.
16
IDENTIFIEDSITES
Outsideareasoccupiedby20ormorepeople
onatleast50daysinany12monthperiod.
Buildingsoccupiedby20ormorepeopleon
atleast5daysaweekfor10weeksinany12
monthperiod.
Afacilitysuchasahospitalwereevacuation
wouldbedifficult.
17
POTENTIALIMPACTRADIUS(PIR)
18
POTENTIALIMPACTRADIUS(PIR)
PIRisthedistancebeyondwhichaperson
standingoutsideinthevicinityofapipeline
ruptureandfirewouldhavea99%chanceof
surviving.
ThePIRincreasesasthediameterofthe
pipelineincreasesandasthepressureinthe
pipelineincreases.
19
EXAMPLESOFPIRs
Diameter,
inches
16
30
36
Pressure,
psig
1440
1000
1000
PIR,
Feet
419
654
786
PIR,
Yards
140
218
262
PIR=0.69*(diameter)*(pressure)0.5
20
Whatisapipelineintegritythreat?
Aconditionorsetofcircumstances
that,ifnotmitigated,couldcausea
pipelinetofail.
21
THEFIRSTLINEOFDEFENCEAGAINST
INTEGRITYTHREATS
DesignbyASMEStandards
Selectgoodlinepipematerials
Providecompetentsupervisionandinspection
Coatandcathodicallyprotectthepipeline
Conductanappropriatepreservicehydrostatic
test
Maintainandinspectthepipelineinservice
Protectthepipelinefromoutsideforces
Operatethepipelinesafely
22
TIMEDEPENDENTTHREATS
Threat
External
Corrosion
Internal
Corrosion
StressCorrosion
Cracking
PercentageofSignificant
PipelineIncidentsbetween
1991and2010
9.9%
12.9%
1.0%
23
TIMESTABLETHREATS
Threat
Manufacturing
Defects
Construction
andFabrication
Defects
PercentageofSignificant
PipelineIncidentsbetween
1991and2010
3.4%
3.3%
24
RANDOMTHREATS
Threat
Mechanical
Damage
Equipment
Failure
Incorrect
Operations
PercentageofSignificant
PipelineIncidentsbetween
1991and2010
23.4%
13.3%
1.8%
25
RANDOMTHREATS(continued)
Threat
Forcesof
Nature
Miscellaneous
&Unknown
PercentageofSignificant
PipelineIncidentsbetween
1991and2010
11.8%
18.9%
26
MITIGATIONOFTIMEDEPENDENTTHREATS
Indentifyapplicablethreats
Prioritizesegmentsbyperceivedseverity
Conducttheappropriateassessmentsto
determinetheconditionsofthesegments
Repairinjuriousdefects
Calculatetimestofailureforanomaliesthatwere
notsevereenoughtorequirerepair
Reassesswellbeforethetimestofailureare
reached,repairinjuriousdefects,andrecalculate
thetimestofailure
27
ASSESSMENTMETHODS
ILI
HT
ECDA
ICDA
SCCDA
NDE
inlineinspectionwithsmart pig
hydrostatictest
externalcorrosiondirectassessment
internalcorrosiondirectassessment
stresscorrosioncrackingdirect
assessment
nondestructiveexaminationofan
exposedorabovegroundcomponent
28
LIMITATIONSONASSESSMENTMETHODS
Pipelinemustbepiggable touseILI
ILItechnologynotyetreliableforalltypesof
anomalies
Somesegmentscannotbetakenoutof
serviceforHT
ECDA,ICDA,andSCCDAeachonlyapplyto
onesinglethreatalthoughECDAcanbe
effectiveforfindingpriorexcavationdamage
29
ASSESSMENTMETHODSFORTIMEDEPENDENT
THREATS
Threat
External
Corrosion
Internal
Corrosion
Environmental
Cracking
AssessmentMethods
ILI,ECDA,HT
ILI,ICDA,HT
ILI,SCCDA,HT
30
ASSESSMENTMETHODSFORTIMESTABLE
THREATS
Threat
Manufacturing
Defects
Construction
andFabrication
Defects
AssessmentMethods
HT,ILI
HT,NDE
31
MITIGATIONOFTIMESTABLETHREATS
Goodpreservicehydrostatictest
Nondestructiveinspectionofweldsduring
constructionandfabrication
32
MITIGATIONOFRANDOMTHREATS
Threat
Mechanical
Damage
Equipment
Failure
Incorrect
Operations
MitigationMethods
Onecallsystem,markers,
publicawareness,patrolling
Periodicinspectionand
maintenance
Operatortrainingand
qualification
33
MITIGATIONOFRANDOMTHREATS(continued)
Threat
Forcesof
Nature
Miscellaneous
&Unknown
MitigationMethods
Patrollingandmonitoring
Mitigationcannotbedefined
unlessthethreatisknown
34
QUESTIONS?
35