1. Prevention of Pipeline Failures by adopting Integrity Management System
N . Bose Babu
Executive Director GSPL & CEO – GITL
Gandhinagar

2. Disclaimer :
The views and opinions expressed are solely those of the presenter and do not represent the views or opinions of any company or entity that the presenter is associated.

3. What happens ……..
When a Pipeline leak and operator fails to recognise…

4. Loss of Life, Loss of Property and affect on Environment....

5. Few Pipeline Incidents

6. Pipeline Incidents Gas Pipeline Explosion in Belgium
Fatality: 24 people
Injury: 122
Reason: Gas leakage

7. Pipeline Incidents Gas Pipeline Explosion in India Fatality: 14 people
Injury: 40
Reason: Gas leakage

8. Pipeline Incidents Gas Pipeline Explosion in Japan (Kaohsiung)
Fatality: 30 (Approx)
Injury: 300
Reason: Explosion

9. Safety Vs Integrity
When injuries are preventable , why can’t pipeline failures
SAFETY
INTEGRITY
Fatality
Higher Consequence Event
Disabling Injury
Critical Equipment Outage
Abnormal Operation Events
Recordable
First Aid
Accelerated Failures
Unsafe Act
Failures on Demand
Hazard Identification, Policies, Procedure
Pre-empted / Detected Failures and Non-Critical Equipment Failure
Injuries are Preventable
Failures are Preventable

10. IMS - Background
ASME B31.8 S, was first issued in 2004, the standard was non-mandatory and designed to supplement ASME - B 31.8 which is applicable to onshore “Natural Gas Pipelines”.
PNGRB “Pipeline Integrity Management” regulation is notified in Nov , with a objective to :
Evaluate the risk associated & effective allocation of resources, prevention and mitigation measure.
Improve the safety of pipelines to protect people, property & environment
To minimize the probability of pipeline failures.

11. Pipeline Integrity Management What is Pipeline Integrity ?

12. “A comprehensive, systematic and integrated process that includes all the activities that are required to prevent a failure”

13. IMP – “Process Flow Diagram”
Gathering, reviewing, and integrating data
Identifying potential pipeline impact by threat
Risk Assessment
All threats evaluated
Integrity Assessment
Responses to integrity assessments NO
YES

14. Risk Assessment
“A systematic process in which all potential hazards from the facilities under operation are identified, and the likelihood and consequences of potential are estimated”
RISK = Probability x Consequences
Risk Assessment shall be carried out for each pipeline segment.

15. Types of Risk Assessment
RA Technical Approaches
Knowledge-based – Subject Matter Experts develop ranking based on experience.
Scenario-based – Events analysis, fault trees, or failure-mode-and-effects analysis.
Relative Risk Model – Numerical score from algorithm that uses weighting factors on multiple attributes, based on actual data.
Probabilistic Model – Detailed statistical data about actual attributes used to estimate absolute risk.

16. Integrity Assessment Methods
Reference : ASME B31.8 S, Clause - 6:
Which method of Integrity Assessment ?
In Line Inspection (ILI)
Hydro testing and
Direct Assessment (ICDA, ECDA and SCCDA)

17. What can Risk Assessment do ?
Where will the next failure happen?
Where are the hot spots?
How many failures next year?
What is the best use of my resource?
What are the priorities?
When will a failure occur?
“A risk assessment, no matter what method, cannot be precise because risk is not a precise concept.”

18. HCA Zone Radius Equation
1320
1155
1000 ft
Diameter (in)
990
42.00
825
36.00
660 ft
30.00
Influence zone radius (ft)
660
24.00
18.00
12.75
495
6.63
330
165
500
600
700
800
900
1000
1100
1200
1300
1400
1500
Maximum operating pressure (psi)

19. Integrity Management Program Elements

20. Integrity Management Program
Integrity Management Program Elements
Integrity Management Plan
Performance Plan
Communication Plan
Management of
Change
Quality Control Plan

21. Integrity Management Plan
Development of Plan
Updating the Plan
Plan Framework
Gathering, Reviewing and Integrating Data
Assess Risk
Integrity Assessment
Responses to Integrity Assessment, Mitigation (Repair and Prevention), and Intervals

22. “Complete and Accurate data is the key to a successful IMP program”
Collection of Data
Gathering, Reviewing and Integrating Data
Data Requirements
Data Sources ( from where )
Data Collection, Review and Analysis
Data Integration
“Complete and Accurate data is the key to a successful IMP program”

23. Data Integration & Dynamic Segmentation
Materials
Coating
CIS Data
Elevation Profile
Soil Types
Inclination Angle
ILI Data
The computer program is given a list of items to compare. It will go down the pipeline meter by meter and check to see if the classifications are similar and assign that length of pipe to a grouping. Each grouping could have the same pipe grade, coating, inspection value range, historical performance, or just be assigned a computed risk factor. The computer will assign a color to each range of risk and then display this color on center line of the pipe. The risk can then be seen layered on the alignment drawings.

24. Performance Plan Help an operator answer the following Questions:
Were all integrity management program objectives accomplished?
Were pipeline integrity and safety effectively improved through the integrity management plan.
Performance Measures Characteristics
Activity Measures
Operational Measures
Direct Integrity Measures

25. Communication Plan External Communication Internal Communication
Landowners and Tenants long the Rights-of-way
Public Officials other than Emergency Responders
Local and Regional Emergency Responders
General Public
Internal Communication
Operator management and other appropriate operator personnel MUST understand and support the Integrity Management Plan

26. Management of Change Plan
Reason for change
Authority for approving Changes
Analysis of Implications
Documentation
Document is a KEY to QUALITY….…
“If it is not documented, it didn’t happen.”
Communication of change to affected parties
Time limitations
Qualification of staff

27. Quality Control Plan
Documentation proof that the operator meets all the requirements of their integrity management program
Requirements of Quality Control Plan:
Documentation
Implementation
Maintenance
Responsibilities and Authorities shall be CLEAR
Requirement of Competent Personnel (“Span of Control”)

28. Time Dependent Stable Pipeline Threats Different Threats
External Corrosion
Internal Corrosion
Stress Corrosion Cracking (SCC)
Time Dependent
Manufacturing Related Defects
Defective pipe seam
Defective pipe
Welding/Fabrication Related
Defective pipe girth weld
Defective fabrication weld
Wrinkle bend or buckle
Stripped threads/broken pipe/coupling failure
Equipment
Gasket O-ring failure
Control/Relief equipment malfunction
Seal/pump packing failure
Miscellaneous
Stable
Different Threats

29. Pipeline Threats
Time Independent: a) Third party / Mechanical damage Damage by first, second, or third parties Vandalism / Sabotage b) Incorrect operations c) Weather related outside force Lightning Heavy rains or floods Earth Movements

30. Important websites.
– European Gas Industry Database - Pipeline & Hazardous Materials Administration – Pipeline Association for Public Awareness – Common Ground Alliance – Common Ground Alliance – DIRT Reports – American Petroleum Institute Standards – ASME Codes & Standards - PHMSA Gas Integrity Management

31. Pipeline Industry concerns:
Key Challenges
Pipeline Industry concerns:
Control on the land use pattern (RoU)
Ex: No control on development along pipeline corridors.
Pipeline Personnel qualifications (B31Q)
Ex : Vendors, Contractors and Service providers is essential.

32. Summary
Global experience demonstrates the integrity management program has proven in prevention of incidents.
District Disaster management or Independent agency shall set up Single call system to prevent / reduce the third party damages.
There shall be a co-operation agreement among all pipeline operators in respective states to share the resources and materials in case of any emergency.
In order to develop confidence of public, joint collaboration between statutory bodies and pipeline operators is very much important to develop better understanding and ensure safe operations.

33. Thank you…
Jaihind