the pipeline integrity management system of vng verbundnetz...
TRANSCRIPT
© VNG 20061
The Pipeline Integrity Management System of The Pipeline Integrity Management System of VNG Verbundnetz Gas AGVNG Verbundnetz Gas AG
Referent: Dr. Volker Busack, Operation / TechnologyReferent: Dr. Volker Busack, Operation / Technology
23. World Gas Conference,23. World Gas Conference,5th. 5th. -- 9th. June 2006, Amsterdam9th. June 2006, Amsterdam
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1.1. Introduction VNGIntroduction VNG-- VNG in the European gas transmission grid VNG in the European gas transmission grid --
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•• Length of pipelines:Length of pipelines:7,279 km7,279 km
•• Underground gas storages: Underground gas storages: 6 6 (at overall (at overall 55 sites)sites)
•• Total work gas capacity:Total work gas capacity:2.3 billion m2.3 billion m ³³
•• Compressor stations:Compressor stations:2 2 (+ 4 compressor units UGS)(+ 4 compressor units UGS)
•• Total compression capacity:Total compression capacity:77.8 MW77.8 MW ((88 piston compressors piston compressors
77 turbo compressors)turbo compressors)
•• Delivery stations / links: Delivery stations / links: 88
•• Metering and pressure Metering and pressure regulating stations: regulating stations: 3636
•• Cathodic corrosion protection Cathodic corrosion protection installations: installations: 727727
Gubin
Lasow
Bobbau
Kamminke
1.1. Introduction VNGIntroduction VNG-- Technical infrastructure at VNG Technical infrastructure at VNG --
supply area: 108,000 kmsupply area: 108,000 km ²²
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Reserve in the bearing capacityReserve in the bearing capacityof a highof a high --pressure gas pipelinepressure gas pipeline
2.2. Changes in pipeline statusChanges in pipeline status-- Pipeline quality curve Pipeline quality curve --
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Specific aims of Specific aims of PIMSPIMS at VNG at VNG -- Verbundnetz Gas AG:Verbundnetz Gas AG:
•• Evaluation of results of inspection pigging by neuro nal networksEvaluation of results of inspection pigging by neuro nal networks(FEM), incl. corrosion forecast with assessment program (FEM), incl. corrosion forecast with assessment program ““ COPCOP””(Corrosion On Pipelines)(Corrosion On Pipelines)
•• Technical condition analysis of pipelines by probabi listic Technical condition analysis of pipelines by probabi listic assessment criteria / parametersassessment criteria / parameters
•• Evaluation of possible service lifeEvaluation of possible service life
•• Identification of failures / weak spots with followi ng prioritizIdentification of failures / weak spots with followi ng prioritiz ation ation of needed actions / measuresof needed actions / measures
•• Optimization and Processing of needed rehabilitation m easuresOptimization and Processing of needed rehabilitation m easures
•• Data management and providing a pipeline information systemData management and providing a pipeline information system
3.3. Aims, elements and methods of PIMSAims, elements and methods of PIMS-- Aims and requirements Aims and requirements --
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Pre
ssur
eP
ress
ure
TCA Assessment of technical conditionTCA Assessment of technical condition
SRASRA Structural Reliability AnalysisStructural Reliability Analysis
Reliability analysisReliability analysis
Limit value balancingLimit value balancing
Detection of system flawsDetection of system flaws
Rehabilitation controlRehabilitation controlProof of integrityProof of integrity
Population densityPopulation density
QRAQRAQuantitative RiskQuantitative Risk
AnalysisAnalysis
QuantitativeQuantitative
risk analysisrisk analysis
PermissionPermission
How failure occurredHow failure occurred
Tra
ffic
Tra
ffic
Soi
lS
oil
Cor
rosi
onC
orro
sion
Def
ect
Def
ect
stat
istic
sst
atis
tics
PfPf 11 PfPf 22 PfPf 33 PfPf 44 PfPf 55 PfPf ii PfPf jj
. . . . . . . . . .
CalculateCalculate
failure probabilityfailure probability
Link PfLink Pf ii
Calculate effectCalculate effect
Individual risk,Individual risk,
General riskGeneral risk
. . . . . . . . . .
3.3. Aims, elements and methods of PIMSAims, elements and methods of PIMS-- Pipeline failure probability, QRA and SRA Pipeline failure probability, QRA and SRA --
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Risk
10-3/a
10-4/a
10-5/a
10-6/a
not acceptable
alarming
acceptable to staff
acceptable to general
public
10-7/a
Remarks
too high: major improvements reqd.
very high: look for alternatives/
major improvements
high: find improvements
low: find most economical
solution
negligible: take normal
precautions
3.3. Aims, elements and methods of PIMSAims, elements and methods of PIMS-- Risk triangle Risk triangle --
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3.3. Aims, elements and methods of PIMSAims, elements and methods of PIMS-- PIMS elements at VNG PIMS elements at VNG --
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•• Methods and techniques for pipeline assessment / ins pection:Methods and techniques for pipeline assessment / ins pection:
•• Pipeline Integrity Management System (PIMS)Pipeline Integrity Management System (PIMS)
•• Technical Condition Analysis (TCA)Technical Condition Analysis (TCA)
�������� specific specific expert systemsexpert systems
•• Intelligent / Inspection piggingIntelligent / Inspection pigging
•• Program Program ““ KaRoKaRo ”” for corrosion assessment / forecastingfor corrosion assessment / forecasting
•• Program Program ““ FADFAD”” for evaluation of old welding seamsfor evaluation of old welding seams
•• Cathodic corrosion protection Cathodic corrosion protection ““ CCPCCP””
3.3. Aims, elements and methods of PIMSAims, elements and methods of PIMS-- Modern and efficient methods of PIMS Modern and efficient methods of PIMS --
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Technical Condition Analysis Technical Condition Analysis for highfor high --pressure gas pipelinespressure gas pipelines
Piggable pipelines: 4,121 kmPiggable pipelines: 4,121 km
Inspection PigsInspection Pigs
-- Assess wall thickness deterioration Assess wall thickness deterioration using Finite Element Method (FEM) using Finite Element Method (FEM)
-- For calculation use neural networks For calculation use neural networks with KaRo (pipeline corrosion) with KaRo (pipeline corrosion) programprogram
-- Estimate remaining service life by Estimate remaining service life by making corrosion forecastmaking corrosion forecast
NonNon --piggable pipelines: 3,195 kmpiggable pipelines: 3,195 km
TCATCA
-- Assess Assess linear section (linear section ( pipeline data, pipeline data, ambient conditions, etc.) and specific ambient conditions, etc.) and specific featuresfeatures (valves, fittings, special (valves, fittings, special structures, etc.) acc. to probabilistic structures, etc.) acc. to probabilistic criteria (failure probability)criteria (failure probability)
-- Prioritize weak pointsPrioritize weak points
Identify immediate steps, derive multiIdentify immediate steps, derive multi --stage plan for weak point stage plan for weak point rehabilitationrehabilitation
4.4. TCA and Inspection piggingTCA and Inspection pigging-- Technical condition analysis TCA Technical condition analysis TCA --
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5.5. Content and results of TCAContent and results of TCA-- List of raw data List of raw data –– Selection of parameters Selection of parameters --
Priority: must (1)Priority: must (1)11 Year of constructionYear of construction
22 CulvertCulvert
33 DiameterDiameter
44 Casing pipeCasing pipe
Priority: shouldPriority: should
55 Design pressureDesign pressure11 Pipeline construction details (Bends etc.)Pipeline construction details (Bends etc.)
66 Settling pressuresSettling pressures22 Cathodic Corrosion ProtectionCathodic Corrosion Protection
77 CoverageCoverage33 Pigging dataPigging data
88 Wall thicknessWall thickness44 DamagesDamages
55 RepairsRepairs
Priority: must (2)Priority: must (2) ......
11 AsAs--built quality, built quality, ZfPZfP--testtest
22 Operating pressureOperating pressure
33 Empirical values at pipeline, damage statisticsEmpirical values at pipeline, damage statistics
Priority: canPriority: can
44 Above ground pipelineAbove ground pipeline11 CoatingCoating
55 SlopeSlope22 GroundwaterGroundwater
66 MediumMedium33 Ground utilizationGround utilization
77 Proximity seam of a secure connectionProximity seam of a secure connection44 Dynamic stressesDynamic stresses
88 Insufficient distance from structureInsufficient distance from structure55 Soil aggressivenessSoil aggressiveness
99 Type of seamType of seam66 Electrical external voltageElectrical external voltage
1010 Seam fracture on this pipelineSeam fracture on this pipeline......
1111 HollowHollow
1212 Mining pressuresMining pressures
1313 TemperatureTemperature
Priority: InformationPriority: Information
1414 Type of connectionType of connection
11 ManufacturerManufacturer
1515 Traffic route (rail, road)Traffic route (rail, road)
22 DocumentationDocumentation
1616 MaterialMaterial
......
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Exemplary result Exemplary result of pipeline of pipeline
characteristicscharacteristics
5.5. Content and results of TCAContent and results of TCA-- Example for pipeline assessment (I) Example for pipeline assessment (I) --
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1,00E-20
1,00E-19
1,00E-18
1,00E-17
1,00E-16
1,00E-15
1,00E-14
1,00E-13
1,00E-12
1,00E-11
1,00E-10
1,00E-09
1,00E-08
1,00E-07
1,00E-06
1,00E-05
1,00E-04
1,00E-03
1,00E-02
55000 55500 56000 56500 57000 57500 58000 58500 59000 59500 60000
Metre of pipeline
Pro
babi
lity
of fa
ilure
1 2
66
8
13
16
3
4
5
7
11
12
9 10
14 15
Limit
Exemplary result for design pressure PN 25 barExemplary result for design pressure PN 25 bar
5.5. Content and results of TCAContent and results of TCA-- Example for pipeline assessment (II) Example for pipeline assessment (II) --
Crossing with traffic Crossing with traffic route, casing piperoute, casing pipe
Crossing with traffic Crossing with traffic route, casing piperoute, casing pipe
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KaRo assessment programKaRo assessment program
Evaluate large data quantitiesEvaluate large data quantitiesfrom inspection pigging:from inspection pigging:
•• Assess / classifyAssess / classifydefective placesdefective places
•• Derive immediate stepsDerive immediate steps(e.g. safeguarding program,(e.g. safeguarding program,pressure reduction)pressure reduction)
Assess local defects (digging):Assess local defects (digging):
•• Determine defect parametersDetermine defect parameters(wall thickness reductions) on site (length, width, depth)(wall thickness reductions) on site (length, width, depth)
•• Recalculate operating pressure, identify repair methodRecalculate operating pressure, identify repair method
KaRoKaRo -- program for corrosion assessmentprogram for corrosion assessment
6.6. Selected methods and toolsSelected methods and tools-- KaRo KaRo -- Corrosion of pipelines Corrosion of pipelines --
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Aims: Aims:
•• Determine remaining operation life for wall thickness Determine remaining operation life for wall thickness
deteriorationdeterioration
•• Optimize repair time / method (avoiding supply interrupt ion, Optimize repair time / method (avoiding supply interrupt ion,
e.g. by field coating, clock spring, collars, etc.)e.g. by field coating, clock spring, collars, etc.)
•• Plan repeat inspection pigsPlan repeat inspection pigs
Applications:Applications:
•• Wall thickness deterioration requiring no immediate rep air Wall thickness deterioration requiring no immediate rep air
and for which the effectiveness of cathodic protecti on has and for which the effectiveness of cathodic protecti on has
not been provennot been proven
Corrosion forecastCorrosion forecast
6.6. Selected methods and toolsSelected methods and tools-- Corrosion forecast Corrosion forecast --
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Surface scanSurface scan FE result FE result
6. 6. Selected methods and toolsSelected methods and tools-- FE Modelling of corrosion areas FE Modelling of corrosion areas --
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7.7. Process steps of PIMSProcess steps of PIMS
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•• Using the TCA method since 1998 within the scope of PIMSUsing the TCA method since 1998 within the scope of PIMS
•• up to now approx. 3,000 km of highup to now approx. 3,000 km of high --pressure pipelines assessed pressure pipelines assessed
in detail and rehabilitation measures classified int o priority sin detail and rehabilitation measures classified int o priority s tages tages
1 1 -- 3 (defined levels)3 (defined levels)
•• Results of rehabilitation processing in reference to realistic Results of rehabilitation processing in reference to realistic
conditions optimally suitable for verifyingconditions optimally suitable for verifying
•• Advantages:Advantages: -- Planning reliability / safetyPlanning reliability / safety
-- cost lowering / optimizationcost lowering / optimization
-- proof of reliability and technical integrityproof of reliability and technical integrity
8.8. ConclusionsConclusions