You are on page 1of 45

1

MAINLINE MAINTENANCE
ROUTINE MAINTENANCE
REGULAR PATROLLING BY LPM s AND OFFICERS
REMOVAL OF ENCROACHMENTS
PREVENTIVE MAINTENANCE
BREAK DOWN MAINTENANCE

INDIAN OIL CORPORATION LIMITED


MATHURA JALANDHAR PIPELINE

QAF:MML/01

DAILY LINE PATROLLING REPORT


STATION ____________________________ LPM_______________________ DATE ___________________
From ______________________ KM/ To: _______________ KM in __________________Section
PARTICULARS

LOCATION
K.M.

VILLAGE/THANA/DISTT.

DETAILS

LEAKAGE
ENCROACHMENT
ENCROACHMENT CLEARED
WASHOUT / EXPOSURE
ROW-BOUNDARY PILLARS ,K.M. POST
T.P. POST VENT PIPE ETC.
VALVES ENCLOSURE, MARKER BOARD
CONDITION OF SUBMERGED
ROAD/RIVER/ BRIDGE ATTACHMENT
CROSSING ETC.
TEST LEAD BOX DAMAGES
C.P. STATIONS METER READING POWER
AVAILABLE

REMARKS : ____________________________________________________________
DISTRIBUTION :

SIGNATURE OF LINE PATROLLING

SECTION HEAD, MJPL, BIJWASAN/MATHURA/MEERUT/AMBALA/JALANDHAR

DATE :

INSPECTION & MONITORING

PRESENT DESIGN LIFE OF IOCL PIPELINE IS 30 Yrs.

IOCL DESIRES TO EXTEND THE SAME

IOCLs INSPECTION PHILOSOPHY IS BASED ON THIS DESIRE

IOCLs INSPECTION AND MONITORING PRACTICES ARE


FOCUSED TOWARDS THIS GOAL.

PIPELINES ARE ROUTINELY INSPECTED AND MONITORED


USING VARIOUS DIRECT AND INDIRECT METHODS. THESE
METHODS AIM TO ENSURE THE FOLLOWING:
1 PIPELINES DO NOT BECOME DEFECTIVE (PROACTIVE
METHODS)
2 DAMAGES ARE DETECTED BEFORE THEY CAUSE
SERIOUS PROBLEMS.
(REACTIVE METHODS)

PREVENTIVE MAINTENANCE
CIVIL MAINTENANCE OF ROW WASHOUTS,
MARKERS, BOUNDARY PILLARS
BRIDGE/RIVER CROSSING, HANGERS, CASING ETC.
BLOCK VALVE MAINTENANCE
PROVISIONING OF COAT & WRAP
HYDRO TESTING OF MAINLINE
CATHODIC PROTECTION INCLUDING REGULAR
CHECKING OF CP UNITS AND MONITORING OF
PARAMETERS, REVISIONING OF ANODE BEDS,
REPAIR OF TLPs & CARRYING OUT PSP SURVEYS.
AVAILABILITY OF POWER SUPPLY
UPKEEP OF MAINLINE EMERGENCY EQUIPMENTS
5

INSPECTION & MONITORING


PIPELINES HAVE HIGH FAILURE IN EARLY LIFE (e.g.
PRE-COMMISSIONING HYDRO TEST)
THEY ALSO HAVE HIGH FAILURE IN LATER LIFE
(i.e. CORROSION)
AN INSPECTION FOLLOWED BY REHABILITATION
WILL HELP EXTEND THE FLAT PORTION (LOW
PROBABILITY ) OF THE CURVE.
THUS INSPECTION HELPS EXTEND THE LIFE OF A
PIPELINE BEYOND ITS NORMAL DESIGN LIFE.

INSPECTION & MONITORING


FREQUENCY OF INSPECTION & MONITORING
LINE PATROLLING

CONTINUOUS

INTELLIGENT PIGGING

AS PER IOCL SCHEDULE

PRODUCT QUALITY

CONTINUOUS

CORROSION COUPON

QUARTERLY

PIGGING

QTR/SIX MONTHLY

CP& COATING
PSP

QUARTERLY

CP STATION

BI-MONTHLY

COATING SURVEY

AS & WHEN REQUIRED

HYDRO-TEST

AS & WHEN REQUIRED

INSPECTION & MONITORING


BEHAVIORAL PATTERN OF IOCL PIPELINE
4. FAILURE
RATES
COME
DOWN
REPAIR/REPLACEMENT (INVESTMENT)

AFTER

5. EXISTING INSPECTION/MONITORING PRACTICES


AS WELL AS EXISTING LEVEL OF MAINTENANCE
CAN PROVIDE A SAFE OPERATING LIFE OF 20+
YEARS.
6. EXTENSION OF SAFE LIFE OF THE PIPELINES
INVESTMENT IS REQUIRED BETWEEN 20 TO 25
YEARS.

PIPELINE MAINTENANCE - MAINLINE


Aligning Clamps. Producing a satisfactory
pipe-joint weld requires exact alignment
of the pipe joint. Two types of pipe-joint
aligners are available:
External, pipe-joint aligning clamps.The
clamp aligns the pipe joint externally,
eliminates almost all out-of-roundness of
the pipe ends, and holds the pipe joints
in a longitudinal position

PIPELINE MAINTENANCE - MAINLINE

10

PIPELINE MAINTENANCE - MAINLINE

Internal-type pipe-joint aligners


produce the required alignment
and eliminate the requirement for
preliminary tack welds necessary
with the external-type lineup
clamps.

11

PIPELINE MAINTENANCE - MAINLINE

12

PIPELINE MAINTENANCE - MAINLINE

13

PIPELINE MAINTENANCE - MAINLINE


Areas More Than One Half of the Pipe.
You can repair pipe that is rusted in
large areas on the top and on the
bottom by surrounding the damaged
line with a casing. To make this repair-Cut a casing, from new pipe, slightly
larger in diameter than the damaged pipe.
Cut the casing in half along the entire
length.

14

PIPELINE MAINTENANCE - MAINLINE


Wrap the two halves around the
damaged pipe.
Hold the pieces in place with clamps
and weld them together.
Run welding bead around the casing at
each end.
Maintain flow in the pipeline to carry
away the heat.

15

PIPELINE MAINTENANCE - MAINLINE


Clamp Repairs. You can temporarily repair
small pit leaks with steel leak clamps.
Using these clamps is a stopgap
measure. The repaired pipe should be
replaced as soon as possible.
To mount a steel leak clamp-Cover the leak with a cone-shaped or a flat
gasket. Make sure the gasket is made of fuelresistant material.

16

PIPELINE MAINTENANCE - MAINLINE


Cut a steel patch to cover the gasket.
Curve the patch to match the curve of
the pipeline.
Hold the gasket and the steel patch in
place and cover them with steel leak
clamps.
Put the bolts in the clamp, attach the
nuts, and tighten the nuts.

17

PIPELINE MAINTENANCE - MAINLINE

18

PIPELINE MAINTENANCE:
MAINLINE R&M

19

PIPELINE MAINTENANCE - MAINLINE


All-around pipe repair clamp to repair
pitted areas and breaks that run
completely around the pipeline. To mount
the clamp-Cover the rusted area or break with a fuelresistant gasket. You may have to use gasket
material to cut a gasket large enough to fit.
Wrap the clamp around the pipe, covering the
gasket.
Put the bolts in the clamp, place the nuts on
bobs, and tighten the nuts.

20

PIPELINE MAINTENANCE:
MAINLINE R&M

21

PIPELINE MAINTENANCE - MAINLINE


Permanent Repairs. Permanent welding
repairs are made by removing damaged
pipe and welding new pipe in place.
The temporary measures described above
should be replaced with permanently
welded pipe as soon as possible.
Permanent welding repairs are made with
and without the use of a bypass. The
method used depends on whether or not
the repair is an emergency.

22

PIPELINE MAINTENANCE - MAINLINE


Emergency Repairs. If a large leak
occurs that cannot be repaired with
clamps, pumping operations are
stopped and the commanding officer
and the safety officer are notified.
The leaking section is then replaced
as quickly as possible without taking
the time to construct a bypass.
23

PIPELINE MAINTENANCE - MAINLINE


Such an emergency pipe change can
be dangerous because of escaping fuel
and fuel vapors. You must follow all
safety rules. Once you locate the leak-Move fire-fighting equipment into the area.
Wear proper clothing and shoes for
protection from spills and welding
operations.

24

PIPELINE MAINTENANCE:
MAINLINE R&M

25

POTENTIAL MEASUREMENT
Potential criteria are one of the most
reliable and fast methods of measurement of
potential between catholically protected
pipelines from its environment. Flow of
current causes a change in potential, which is
a combination of voltage drop across the
resistance between pipeline and environment
and the polarization potential developed at
the pipe surface.
26

POTENTIAL MEASUREMENT
The
resistance
between
pipeline
and
environment includes the resistance of the pipe
coating, if any. The net result is that the pipeline will
become more negative wrt its environment. Most
easy method is to measure the potential drop in the
soil between this point and the pipe which has to be
of -0.85 V with the help of copper copper sulphate
half-cell filled with saturated solution of copper
sulphate.
This is an indication of satisfactory
protection. Experience has proved the adequacy of
this criterion for practical purpose.
27

EQUIVALENT CIRCUIT
Power Source
Point on earth Combination of anode to earth resistance &
pipe to earth resistance
Power Source

POINT B
+

PIPE

Point on earth Combination of anode to earth


resistance & pipe to earth resistance

28

FORTNIGHT READING OF CP
INSTALLATION
NAME OF CP UNIT
D
A
T
E

AC
Volt
age

AC
Cur
rent

DC
Volt
age

DC
Cur
rent

Circui
t
Resist
ance

Tapping
Coa
rse

Fi
n
e

Hou
r
met
er
rea
din
g
9

29

Measurement of On Potential Pipe to Soil

100 10

COATED PIPELINE

CU-CUSO4
ELECTRODE

MEASURING PROBE
100

10

30

Measurement of Off/ On Potential Metallic Electrode to Soil

100 10

COATED PIPELINE

CU-CUSO4
ELECTRODE

MEASURING PROBE
100

10

31

Measurement of On Potential Pipeline to Soil and


Current entering the Auxiliary Electrode

mA

100 10

COATED PIPELINE

CU-CUSO4
ELECTRODE

MEASURING PROBE
100

10

32

PSP profile (Apr-Jun03)


PSP GRAPH (DELHI-AMBALA) 6,
ON
APRJ UN'02

PSP VALUE IN (-) V

1.70
ON
APRJ UN'03

0.85
ON
J ANMAR'0
3

0.00
OFF
APRJ UN'03

MAINLINE CHAINAGE(IN KMS.)

33

PSP profile (Apr-Jun03)- Analysis


This section of the pipeline is under Ambala jurisdiction
At Ch. 136.92 Kms, the PSP in OFF condition was(-)

0.826V, however the ON potential was 0.896 V, which


was above the minimum protection level of 0.85 V.
Increased the feeding current at Samalkha and
Nilokheri CP units at Ch. 121.850 & 148.350 Kms
respectively to bring the OFF potential above 0.85 V at
this point and still keep the OFF potential below 1.2 V at
any point in between. This was possible as in ON & OFF
PSP survey readings, values were quite near and the
high contact resistance was not suspected.

34

PSP profile (Apr-Jun03)- Analysis


Second case :
OFF potential at Ch. 162.937 Kms near Pipli CP

was (-) 0.789V whereas the ON potential was (-)


1.297V. Difference too high.
This was suspected due to poor contact
resistance between the TLP wire and the
pipeline.
Examined the jointing on to the pipeline. It was
really loose. Re-jointed and values got increased
to more than 1.0 V in OFF potential.
35

36

COAL TAR ENAMEL COATING


WHITE WAS OR PROTECTIVE PAINTING
FROM ULTRAVIOLET ATTACK

CO ALTAR ENAMEL

SHOT BLASTED & DECHLOGINATED PIPE

QUICK DRYING SYNTHETIC


ENAMEL PRIMER

CO ALTAR ENAMEL IMPREGNATED


FIBER GLASS FELT OUTER WRAP

FIBERGLASS INNER WRAP 1st

FIBERGLASS INNER WRAP 2ND


IN ALL MINIMUM COATING THICKNESS
SHALL BE 4.8 MM (WITHOUT OUTER WRAP

37

PIPE SURFACE CHECKING

THE MILL COATED PIPES SHALL BE SHOT BLASTED WITH


APPROXIMATELY 25% STEEL GRIT AND 75% STEEL SHOTS
MIXTURES. THE SURFACE CLEANING SHALL CONFORM TO SA
2.5 OF SWEDISH STANDARD SIS 055900. SURFACE ANCHOR
PATTERN SHALL BE 50 TO 70 MICRONS. THIS SHALL BE
CHECKED BY USING KTA TATOR PROFILE COMPARATOR.

III. COATED PIPES SHALL BE CHECKED FOR ITS THICKNESS


AND FREQUENCY SHALL BE EVERY PIPE ON 5 EQUIDISTANT
POINT ON LONGITUDINAL WELD SEAM AND OPPOSITE SIDE
WHICH CAN BE REDUCED FURTHER DEPENDING UPON
CONSISTENCE OF RESULTS. THE AVERAGE SHOULD BE
MEETING THE SPECIFIC THICKNESS BUT NONE OF THE PLACES
IT SHOULD BE < 90% AND > 133%

38

COATING THICKNESS MEASUREMENT

39

HOLIDAY OR HIGH VOLTAGE TEST

THIS TEST IS TO BE CARRIED OUT FOR ALL THE COATED


PIPES DURING TRIAL RUN AND ALSO FOR REGULAR
PRODUCTION.

THE PIPES DEVELOPES MORE THAN 2(TWO) PIN HOLES


SHALL BE REJECTED.

FOR THIS TEST COATED PIPE IS SUBJECTED TO 25KV


BETWEEN PIPE METAL AND COATING WITH THE HELP OF DC
PULSE HIGH VOLTAGE HOLIDAY DETECTOR.

THIS CONSISTS OF A FULL CIRCLE SPRING METAL RING


WHICH IS PUT AROUND THE COATING AND MOVED SLOWLY
ON THE COATING AND INCASE OF ANY HOLIDAY THE
INSTRUMENT GIVES SIGNAL. AFTER THAT AT SAME
PERIPHARY IT IS LOCATED AND MARKED.

40

HOLIDAY OR HIGH VOLTAGE


TEST

41

RESISTANCE TO PEELING

FOR ACCEPTANCE CRITERIA 5 TEST PIPES ARE TO BE TESTED FOR


PEELING. ON EACH PIPE 3 PEEL TEST SHALL BE DONE, ONE EACH AT THE
END AND ONE AT THE MIDDLE. NONE OF THESE SHOULD FAIL.

FOR REGULAR PRODUCTION FREQUENCY OF TEST SHALL BE 1(ONE) PIPE


IN EVERY 10(TEN) PIPES INITIALLY WHICH SHALL BE REDUCED TO 2(TWO)
PIPES IN EACH SHIFT DEPENDING UPON THE CONSISTENCY.

ADDITIONALLY A 100MM WIDE STRIP, 1 MTR. LONG SHALL BE PEELED OFF


AT THE WELD SEAM TO EXAMINE AIR ENTRAPMENTS AT THE WELD SEAM.
AIR ENTRAPMENTS OF MAXIMUM DIAMETER OF 10 EXCEEDING 5 IN
NUMBER ARE NOT PERMITTED. THE FREQUENCY OF THIS TEST SHALL BE
ONE PIPE IN EVERY 10(TEN) PIPES WHICH SHALL BE FURTHER RELAXED
OR WAIVED OFF DEPENDING UPON THE CONSISTENCY OF RESULTS.

IN THIS TEST A PULL FORCE ON STRIP OF COATING IS APPLIED I.E. 35N. PER
CM WIDTH OF STRIP FOR 0.40 MINUTES. FOR THIS WE CUT A STRIP ON THE
COATING OF 50MM OR 20MM WIDE AT LEAST THEN A HORIZONTAL CUT ON
THE STRIP. WITH THE HELP OF KNIFE THE HORIZONTAL CUT PORTION IS
PIERCED OFF THE PIPE AND PULLED DOWN AT AN ANGLE OF 45 DEG. FROM
HORIZONTAL AND THEN A FORCE IS APPLIED ON THE STRIP WITH THE
HELP OF CLAMPING MECHANISM I.E. A WEIGHT OF 3.5 KG PER CM OF
WIDTH FOR 0.40 MINUTES AND IT SHOULD NOT PEEL OFF.

42

PEEL TEST
IN THIS TEST, THE SPEED OF PEELING IS DETERMINED FROM THE COATED
PIPE WITH A PREDETERMINED FORCE (4 KG/CM WIDTH) AT 25 DEG CEN.
FOR THE TEST, WE SHALL CUT A LATERAL TOP OF COATING 50 MM WIDE
FROM THE SIDE TO THE BOTTOM OF THE PIPE AND PEEL THE TOP FROM THE
SIDE BY THE WEIGHT OF 4 KG/CM WIDTH. THE TIME TAKEN TO DISBOND
THE COATING IS MEASURED AND SHOULD NOT GIVE AVERAGE PEELING
SPEED MORE THAN 1 CM / MIN. PEEL TEST COATING WILL PEEL IF IT CROSS
THE FOLLOWING DISTANCE IN GIVEN TIME :DIA

DISTANCE

TIME MINIMUM

22

22 CM

22 MINUTES

10.75

11 CM

11 MINUTES

IF ONE TEST FAIL THEN TWO MORE TEST SHALL BE CONDUCTED ON SAME
PIPE. IF BOTH TESTS MEET THE REQUIREMENT THEN COATING SHALL BE
ACCEPTED AS PER CONTRACT DOCUMENT. IF EITHER TEST FAILS THEN
COATING OF THAT JOINT SHALLL BE REJECTED. TEST SHALL BE
CONDUCTED ON PROCEEDING AND SUCCEEDING PIPE IN THE ABOVE
MENTIONED PROCEDURE TILL COATING MEET THE REQUIREMENT.

43

PEEL TEST

44

REPAIRING OF COATING
DAMAGE
1.
2.
3.
4.
5.
6.

LEANING OF COATING SURFACE


REMOVAL OF COATING & CLEANING OF PIPE
HEATING OF PIPE & APPLICATION OF EPOXY
APPLICATION OF FILLER MESTIC
SIZING OF PERP PATCH
APPLICATION OF PERP PATCH

45