An In-house Analysis of T4S requirement of Vent Size

equivalent to one third of Main Line Size for Cross Country Pipe Lines
Gorthi SSRV Vara Prasad, KVS Rao and B N Rao
varaprasad@gail.co.in

Abstract
GAIL (India) Limited is India’s Largest Natural Gas Company and in KG Basin, Andhra
Pradesh, GAIL operates nearly 890 KM of regional Pipe Line Network. PNGRB approved Third
Party Inspection Agency External Audits are carried out regularly at GAIL’s Installations in KG
Basin and the audit observations are given utmost importance and complied on priority. During
the recent T4S audit conducted in the Month of May 2018, the Audit team has observed that the
Vent Pipe Sizes at some of the terminals are not of one third main line size and hence the audit
team desired the same to be reviewed and acted upon.

While the compliance of audit observations related to statutory standards such as T4S is very
much important and need to be complied, considering the huge financial implications and safety
aspects involved in carrying out modifications to existing Hydrocarbon Gas Pipe Lines which
also involve considerable Shut-Down times, it is also essential that the audit observations be
evaluated on merits of their contribution for enhancing the operational performance, safety
aspects and only after ascertaining their effectiveness, the audit observations be complied with.
Through this paper, the authors present the analysis of the audit observation for vent
requirements in cross country pipelines in light of the provisions in various codes including T4s
which concludes that no significant gains could be achieved even after replacing the existing
vents with one third main line size vents. The authors intent to present this paper is to make the
GAIL team across other locations to rationally analyze the audit observations which involve
huge financial implications and shutdown times. (Based on the internal review by the KG Basin
in-house team, The Petroleum and Natural Gas Regulatory board is being informed through
GAIL HSE for closure of the audit observation related to one third vent size requirement.)

1. Introduction
GAIL (India) Limited is India’s Largest Natural Gas Company and in KG Basin, Andhra
Pradesh, GAIL operates nearly 890 KM of regional Pipe Line Network. PNGRB
approved Third Party Inspection Agency External Audits are carried out regularly at
GAIL’s Installations in KG Basin and the audit observations are given utmost importance
and complied on priority.

During the recent T4S audit conducted in the Month of May 2018, the Audit team has
observed that the Vent Pipe Sizes at some of the terminals are not of one third main line
size and hence the audit team desired the same to be reviewed. The Audit Observations
are as under.(Copy of T4S audit observations attached as annexure-1)
 Quote:
I. NFCL Terminal : Size of QOEC Line of Low Pressure 18”Line is 4”. Which
should be minimum 6”. To be reviewed.

II. IP Station Mortha , SV Station Bimadolu and Lanco Receiving Terminal :

QOEC line is 4”Size which should be minimum one third of main pipe size of
18” which should be minimum 6”size. To be reviewed.

Un-Quote
In Line with the audit observations, an In-house review is carried out by GAIL KG Basin
and the analysis is presented in this paper in the following way.

 Review of Requirements for Vent Line at SV stations and Blow Down Time
Calculations
 Review of Requirements for Vent Line at SV stations as per T4S, ASME Code
and PHMSA
 Blow Down Time Calculations for the Existing Vents viz-a-viz T4S Requirement.
 Observations / Analysis of the Blow Down Time calculations
 Conclusions
 Recommendations

2. Review of Requirements for Vent Line at SV stations as per T4S, ASME Code and
PHMSA.
Immediately after the audit observations, it was decided to look into the practicability and
feasibility of replacing the existing vent connections with one third main line size vent
connections. During the discussions it has emerged that lot of pipe line modification is
required and shutdowns of significant duration are also required to comply with the audit
observations. Then it was decided to look into the relevant provisions in National /
International codes / regulations and also Technical aspects of Vent Requirement for SV
Stations.

2.1 The Provisions in various Codes / Standards / Regulation are as under.

Quote
2.1.1 The T4S standard .
Sectionalizing Valve (s) station shall have blow down or vent line connection to evacuate
the isolated pipeline section in case of an emergency and / or repair. The size of the
connections for blowing down the mainline line shall be not be less than 1/3rd of the
mainline size.
2.1.2 ASME B31.8 Code Requirement.
Clause no. A 846.2.1.c The sizes and capacity of the connections for blowing down the line shall be
such that under emergency conditions the section of line can be blown down as rapidly as is
practicable.

2.1.3 PHMSA Clause No. 49 CFR 192.179.c

Each section of a transmission line, other than offshore segments, between main line valves must
have a blow-down valve with enough capacity to allow the transmission line to be blown
down as rapidly as practicable.

Un-Quote
2.1.4 During the review of the relevant provisions applicable for Vents / Blow Down
connections in ASME B31.8 or T4S or PHMSSA, the following were observed.

i. ASME B31.8 and PHMSA does not specify any vent size but only mention
evacuation of the Pipe line Section between Two Main Line Valves as rapidly as is
practicable.

ii. As per ASME , PHMSA and T4S, the blow down or vent requirement is for a blow
down connection for evacuating the gas of an Isolated Main Line Section, which
suggests that one Vent Line is suffice to meet the regulatory requirements.

2.1.5 As envisaged in the T4S standard, the very purpose of the vent line is to evacuate the gas
inventory in the isolated pipeline section during an exigency or repair. Since, the
purpose of a blow-down line is to safely vent the Natural Gas between two
Sectionalizing Valve Stations, it was considered prudent to calculate the blow-down
time of the Existing Vent Connections, viz-a-viz a T4S standard recommended
Vent Blow Down time for assessing any further action as regards to compliance with
the T4S audit observation.

2.2 Blow Down Time Calculations :

It is pertinent to mention here that no code or standard has defined the Equation for Blow
Down Time calculation for a natural Gas Pipe Line. In the absence of any standard /
codes, the blow down times are calculated based on A Technical paper named “
Simple Method Predicts Gas Line Blow Down times” Published in Oil and Gas
Journal way back in 1988 which has incorporated several correction factors and sonic /
sub sonic velocities encountered during the Blow Down Venting.( Copy of the paper is
attached as annexure – 2.)

2.2.1 The Audit observation was for the 139 KM, 18 Inch, Mortha - Lanco Pipe Line which
transfers natural gas from ONGC to Lanco Power Station near Vijayawada and also for
City Gas Distribution for Autos in Vijayawada. Hence Blow Down Times for Mortha –
 Lanco Pipe Line are calculated based on the above three methods and the Blow Down
Time summary is as under.

2.2.2 Blow Down Time Calculation Based on Oil and Gas Journal Technical Paper
The blow-Down Times for each of the Pipe Line Section with P/L Code 10500503 were
also calculated based on the referred Technical Paper and are attached as annexure 3.
The Summary of the same is as under.
Blow Down Time Comparison for the Existing Blow Down Connections at SV Stations
of 139 KM, Mortha - Lanco Pipe Line ( 10600503) based on Technical Paper in Oil and Gas Journal

Blow Down Time in Minutes at

Max.Pipeline Design Prssure of 72 Kg/Sq.Cm GAIL's
Name of the Pipe Line Length between
Existing Blow
Sl.No Section Between Two SV Two SV Stations GAIL's Existing Remarks
As Per PNGRB Down Time is
stations in KM Facilitites in
with 1/3rd Vent Higher by
(Based on ILI) Mortha - Lanco
Size
Line

One 3 Inch, Blow Downs at Mortha and One 4 Inch

1 18"Mortha - Tadepalli 23.532 105.33 98.64 -6.69
Blow Down at Tadepalli to be used simultaneously.

4 Inch Blow Down at Tadepalli & Bhimadole to be used

2 18"Tadepalli - Bhimadole 26.287 120.88 99.92 -20.96
simultaneously.

4 Inch Blow Down at Bhimadole & Koppaka to be used

3 18"Bhimadole - Koppaka 28.375 133.02 108.31 -24.71
simultaneously.

4 Inch Blow Down at Koppaka and Agripalli to be used

4 18"Koppaka - Agripalli 28.464 133.54 108.67 -24.87
simultaneously.

One 3 Inch, at Lanco and One 4 Inch Blow Down

5 18"Agripalli - Lanco 33.148 161.84 166.25 4.41
Agripalli to be used simultaneously.

2.2.3 Similar Calculations were also carried out for all the KG Basin Vents which are of lesser size
than 1/3rd vent size, and the Summary of blowdown times for all vent lines in KG Basin is
attached as annexure 4.)

3. Observations / Analysis of Blowdown Time Calculations

3.1.1 In addition to calculating the blow down times for the existing vent lines using the Oil and Gas
Journal Technical paper, the blow down calculations were also carried out using two more
theoretical methods as described in two books - Gas Pipeline Hydraulics and Compressed Fluid
Flow. The following are observed.

3.1.2 For all the cases even with T4S standard recommended vent line sizes, the Blow Down times are
high and due to the very nature of compressible fluids such as Natural Gas, and locational
constraints, it is very difficult to achieve faster blow down times.

3.1.3 It is understood that during the leakage or during any incident, maximum impact is felt in the first
few Seconds or even minutes and the blow down connections between the sectionalizing valves
are only used for venting the gas quickly so as to carry out any required repair / rectification.

3.1.4 It is observed that the blow Down Times are higher and are of the order of 2-3 hours even with
T4S standard Specified vent size at some locations.

3.1.5 An increased blow down time does not cause serious consequences except for delay in evacuating
the gas during any leakage or incident and considering the fact that the impacts during any
 incident / leakage, consequences or damages are felt in the first few minutes or even seconds, it is
envisaged that no significant gains could be achieved even after replacing the existing vent lines
with T4S recommended vent sizes.

3.1.6 Based on the blowdown time calculation Technical Paper published in Oil and Gas Journal , the
calculations revealed the Blow Down Time with One Vent Connection as per T4S is higher than
the combined blow down time of existing Vent lines, as GAIL has used two Blow Down
Connections for each Section between 2 Sectionalizing Valves.

4. Conclusion

4.1.1 While making the Risk Studies for spills / releases during any leak, the failure consequences are
assessed for initial few minute releases as the failure consequences are severe during this period
and become less critical after first 10-15 minutes. Even after carrying out the modifications and
replacing the existing Blow Down Lines at KG Basin, the Blow Down times shall still be on
higher side and blow down time of nearly 10-15 minutes could not be achieved.

4.1.2 Accordingly, based on all the above review , it is concluded that no further action is
required at GAIL – KG Basin as regards to vent lines and the T4S audit observation for
Review of Existing Vent Lines be treated as Complied without resorting to any
modification.

4.1.3 The analysis results were also shared with GAIL’s Central Integrity Management group through
competent authority and it was decided to intimate PNGRB that the T4S audit observation was
reviewed and no further action is required.

4.1.4 The compliance of Audit Observation related to vent size at KG basin for Mortha-Lanco line
alone would have cost an amount of Rs. more than 1 crore in venting of valuable Natural gas
alone excluding cost of modification , shutdown and revenue loss during shutdown. Hence an
earnest attempt be made to represent the reasoning and technical justification for maintaining the
status quo with concerned Statutory authorities when such audit observations are to be complied.

5. Recommendations
5.1.1 Based on the above presented analysis of T4S audit observation related to Vent Sizes, the
authors strongly recommend that any Audit Observation , as it involves price and resource
implications, be thoroughly evaluated , deliberated internally and represented to concerned
statutory authorities with substantiating Technical Calculations before resorting to
implementation, particularly if the Audit Observation relates to carrying out Modifications
to existing Hydrocarbon Pipe Lines.
6. References.
a. "Simple Method Predicts Gas Line Blowdown Times", by M.H. Weiss, K.K. Botros,
W.M. Jungowski, Oil & Gas Journal, Dec. 12, 1988
b. “GAIL’s KG Basin Pipeline Network P&ID’s

7. Annexure
Annexure 1 – Copy of Third Party T4S audit observations at KG Basin – 2018.
Annexure 2 - A Technical paper named “ Simple Method Predicts Gas Line Blow Down times”
Published in Oil and Gas Journal in 1988
Annexure 3 – Blow Down Calculations for Mortha-Lanco Line using Oil and Gas Journal
Technical Paper.
Annexure 4 – Summary of Blow Down Calculations for KG Basin Vents – Based on
Technical Paper published in Oil and Gas Journal.