multilevel approach for opp, monitoring, and control at
TRANSCRIPT
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Multilevel Approach for OPP, Monitoring, and Control at District Stations
John R Anderson and Christina Rushworth
Version 12.0
Emerson Confidential and Proprietary/For internal use only
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Agenda
John R Anderson
Christina RushworthLayers of OPP
Dynamic Risk Findings/Actions
What to Protect?
District Stations Today
District Stations of the Future Upgrade
Path
Wrap Up
Emerson Confidential and Proprietary/For internal use only
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Layers of OPP in Gas Distribution
Emerson Confidential and Proprietary/For internal use only
MAOP Exceeded
Relief and/or Slam-shut
Monitor Lockup
Relief Valve/Monitor Setpoint
Deadband
Regulator Lockup
Regulator Setpoint
Below Regulator Setpoint
Line Break - Low Pressure
Level 1 OPP
Level 2 or 3 OPP
UPSO Slam-shut
Compliance Issue
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Layers of OPP in Gas Distribution – Another Layer?
MAOP Exceeded
Relief and/or Slam-shut
Monitor Lockup
Relief Valve/Monitor Setpoint
Deadband
Regulator Lockup
Regulator Setpoint
Below Regulator Setpoint
Line Break - Low Pressure
Level 1 OPP
Level 2 or 3 OPP
UPSO Slam-shut
Catastrophic Event
Compliance Issue
Public Issue
The gap between compliance and a catastrophic event..
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OPP at District Stations
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Dynamic Risk Report Jan 29th, 2020
• Initiated by the Massachusetts Department of Public Utilities (DPU) as a Statewide assessment of gas pipeline safety in Massachusetts
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Dynamic Risk Findings (not exhaustive)
• 23% of all pipe mains in MA are considered leak prone which is 7% of all the leak prone pipe in the USA
• Overconfidence on the jobsite
• Meaningful job briefs non existent
• Pipeline SMS API 1173 implementation
• Silos of management hinder communications
• Tracking of overpressure events
– Low pressure systems
– Higher pressure systems
• Asset tracking
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Columbia Gas of Massachusetts System Improvements
• Implements SMS
• Low pressure station documentation
• Regulator station design and over-pressure protection
• Remote monitoring
• Infrastructure modernization – pipeline upgrades
• Professional engineers
• Tie in and tapping procedures
• Capital projects review
• Management of change
• Damage prevention
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Typical Low Pressure (LP) Systems
• MAOPs : Typically at 14” w.c or lower
– How was this pressure derived? : Tribal knowledge?
• No service regulator, only meter
– Many meter sets are indoors and will be moved outdoors
• OPP is usually installed at the district station
– Does not protect if an IP system is tied into LP system, or if district station regulator fails
Low Pressure Service
- No House Service Regulator (HSR),
Commercial Service Regulator (CSR)
- Meter, House Pipe & Appliances
see street pressure directly
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The Question : Which part of the system should we protect?
• District Regulator(DR) Station OPP
– What technology should we consider?
– How many layers?
– Do we need monitoring of our DR?
– Is a remote shut off valve required?
• End User OPP
– What technology should we consider?
– Have we considered a regulated bypass?
– How many layers of OPP?
• Low pressure will be regulated to add two layer OPP at all district stations
• All other stations will be under risk assessment because if a LP station could have a failure what about all the other district and city gate stations?
– Scenario: P1 = 800-1,000 psig and P2 = 60 psig delivery
• What happens if 1,000 psig ends up in a 60 psig distribution system?
– Is it catastrophic?
– What are the implications?
– What is the best way to protect this system?
LDC Direction : Prediction
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Basic District Station Scenario Today
Emerson Confidential
Filter
High Pressure Low Pressure
Manual Valv eManual Valv e
P P
Pressure GaugePressure Gauge
Working RegulatorMonitor Regulator
Token Relief Valv e
Manual Valv e
Manual unregulated bypass
Scenario: Regulator maintenance and
technician is on manual bypass. What
happens if the operator on the valve
breaks or the valve seizes?
• Worker/monitor as single layer OPP
• Token relief valve ?
• Single manual valve with unregulated bypass
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Basic District Station Scenario Today
Emerson Confidential
Filter
High Pressure Low Pressure
Manual Valv eManual Valv e
P P
Pressure GaugePressure Gauge
Working RegulatorMonitor Regulator
Manual Valv e Manual Valv eP P
Pressure GaugePressure Gauge
Working RegulatorMonitor Regulator
• Worker/monitor as single layer OPP
• Full capacity redundant standby run
• Token relief valve
Token Relief Valv e
1-OPP
Manual Valv e
Manual unregulated bypass
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Basic District Station What’s Coming Next?
Emerson Confidential
Filter
High Pressure Low Pressure
Manual Valv eManual Valv e
P P
Pressure GaugePressure Gauge
Working RegulatorMonitor Regulator
Manual Valv e Manual Valv eP P
Pressure GaugePressure Gauge
Working RegulatorMonitor Regulator
Token Relief Valv e
1-OPP
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District Stations of the Future
Emerson Confidential
Filter
High Pressure Low Pressure
Manual Valv eManual Valv e
P P
Pressure GaugePressure Gauge
Working Regulator
Manual Valv e Manual Valv eP P
Pressure GaugePressure Gauge
Working Regulator
Monitor Regulator
Slam-shut
• Double layer OPP achieved 2 ways• Slam-shut monitoring regulators
• Relief valves
Full Capacity
Relief Valv e
2-OPP
Monitor Regulator
Slam-shut
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District Stations of the FutureCombination of Devices plus Monitoring/Control
Emerson Confidential
Filter
High Pressure Low Pressure
Manual Valv eP P
Pressure GaugePressure Gauge
Working Regulator
Manual Valv eP P
Pressure GaugePressure Gauge
Working Regulator
Monitor Regulator
Slam-shut
Full Capacity
Relief Valv e
Monitor Regulator
Slam-shut
➢ Inlet pressures – 1 AI
➢ Outlet pressures – 1 AI
➢ Filter DP – 1 AI
➢ Relief Valve Est – 1 AI
➢ Intrusion – 1 DI
➢ Water level – 1 DI
➢ Gas detection – 1 AI
➢ Control lines – 1 AI
➢ Slam-shut trip indication - 2 DI
➢ Remote setpoint control – 1 AI, AO
Analog Input
Analog Input
Discrete Input
Discrete Input
➢ Station flow est – 1 AI
➢ ROV – 2 AO/DO, 2 DI
Remote OperatedValve
P
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Slam-shut Valves Purpose & Installation
• The slam-shut valves will cut off the gas flow when the inlet and/oroutlet pressure in the system exceeds or drops below established setpoints
The slam-shut is usually installed
upstream of the regulators to
minimize pressure drop across
station or it can be integral to the
regulator.
2-OPP
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Using Slam-Shuts
The new paradigm…
• Slam-shuts in a COVID world
– Relights would be required and that would mean entry into homes and businesses
– The correct PPE would be required
– Cost considerations of relight vs relief or other redundant forms of OPP
Emerson Confidential and Proprietary/For internal use only
https://empoweringmichigan.com/new-ppe-safety-precautions-prioritize-health-and-safety-during-the-pandemic/
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2-OPP
Upgrading Existing Stations to 2 Level OPP
Drop in monitor with slam-shut to upgrade to 2 level OPP
Emerson Confidential and Proprietary/For internal use only
Monitor
Worker
• 299HV but use flanged body (not pictured)
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Upgrading Existing Stations to 2 Level OPP
Drop in monitor with slam-shut to upgrade to 2 level OPP
Emerson Confidential and Proprietary/For internal use only
Monitor
Worker
• Flanged wide open upstream monitors can easily be retrofitted with minimal piping changes
• Following ANSI face to face dimensions for flanges accommodates this change
• Integral device avoids capacity reduction
2-OPP
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2020
OPP Gate Station/District Station
Two levels will add another piece of equipment for OPP
• Two level OPP wide open monitor with integrated slam-shut
– Worker/Monitor is a flexible element
– Slam-shut is a metal plug
– Token relief
• Set at monitor pressure
Emerson Confidential and Proprietary/For internal use only
1
2
2-OPP
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Considerations for OPP in Vaults at District Stations
• State requirements for separation of devices
• Explosions and fire prevention
– Boot style or metal plug regulators
• Water in vaults
– Float switches
• Control line placement to prevent excavation damage
• Intrusion alarms
• Gas detection
• Slam-shut monitoring
• Remote setpoint control
• Remote shutdown of regulators
• Remote operated valves
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OPP at District Stations Using Section VIII Reliefs
Low Pressure Reliefs
• Two level OPP monitoring regulator station with low differential pressure full capacity relief valve
– It is a modulating design that opens as much as necessary to keep the downstream pressure at a safe value
– Remote trip indication should be considered to know when the relief valve has opened
Emerson Confidential and Proprietary/For internal use only
Main valve open
discrete indicator
2-OPP
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Slam-shut Trip Indication
OSE discrete switch
VSX8 reed switch
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Real Time Pressure Relief Valve (PRV) Monitoring
• Immediate detection of relief events is extremely important when exhausting gas to atmosphere in populated areas
• Real-time PRV monitoring
– Timestamp and duration
– Calculated flow rates possible during relief events for EPA reporting
– Set pressure verification
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Remote Setpoint Controller
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Rotork with Linear Actuation for Remote Setpoint
New model Rotork with
linear actuation which will
eliminate adjusting screw
wear…
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District Station Flow Estimation - Wireless
Rosemount 2051 WirelessHART Upstream
Pressure
Rosemount 2051 WirelessHART
Downstream Pressure
Fisher 4320 Wireless HART
Position Transmitter mounted on
Fisher 2” EZR 60% Cap Trim
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District Station Flow Computer/Controller
Wireless transmitter and receiver
RTU - FB107
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Remote Shut-off Valves
What is the best way to shut in the system?
• 3 way solenoid valve in pilot operated regulator’s pilot supply line (loading) and in bleed line if an unloading regulator
• Traditional control valve with pneumatic or electric actuator
– Can be shut off remotely or automatically by local RTU
Emerson Confidential and Proprietary/For internal use only
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The Final Questions : Which part of the system should we protect?
• District Regulator(DR) Station OPP
– What technology should we consider?
– How many layers?
– Do we need monitoring of our DR?
– Is a remote shut off valve required?
• End User OPP
– What technology should we consider?
– Have we considered a regulated bypass?
– How many layers of OPP?
– Is it catastrophic?
– What are the implications?
– What is the best way to protect this system?
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Where Will The Future Regulations Take Us….
Emerson Confidential and Proprietary/For internal use only