Management System. Updated Document Review

Transcription

1 Pipeline Integrity Management System Updated Document Review 2Q 2011 POMA Subcommittee Meeting

2 Introduction PIMS = A comprehensive, systematic and integrated management program Objectives: Provide information to effectively allocate resources for appropriate prevention, detection and mitigation activities Provide safe and reliable delivery of hydrocarbons Provide the means to improve the safety and incident-free operation Principles: Prescriptive Based Program Incorporate the worst case growth indications to establish intervals between successive integrity assessments Performance Based Program Utilize more data and extensive risk analyses, to achieve a greater degree of flexibility, specifically in the areas of inspection intervals, tools used and mitigation techniques employed

3 Integrity Management Plan Process Flow

4 Pipeline Integrity Management System INTEGRITY MANAGEMENT PROGRAM VICO Pipeline Integrity Management System COMMUNICATIONS PLAN MANAGEMENT OF CHANGE PLAN PERFORMANCE PLAN Pipeline Operation & 2 Annual Performance Report 3 Maintenanance Agreement 4 5 VICO Authorization For Alteration (AFA) (POMA) MEETING - POMA Operations & Maintenance Subcommittee - POMA Finance & Audit Subcommittee - POMA Management - Bi-parties - Gas Coordination THREAT IDENTIFICATION - Critical Task Analysis (CTA) PIPELINE DATA - POMA PIMS (GIS) - VICO PCT Archives QUALITY CONTROL PLAN BPMIGAS Oil & Gas Transportation Operation & Maintenance Guideline for Oil & Gas Upstream Activities RISK ASSESSMENT - Task Risk Assessment (TRA) - Department Risk Register (DRR) - HLRR (High Level Risk Register) - MAR (Major Accident Review) - QRA (Quantitative Risk Assessment) 1 INTEGRITY MANAGEMENT PLAN 10 Year Pipeline Integrity Plan INTEGRITY ASSESSMENT - Intelligent Pigging - Pressure Test - Direct Assessment - Fitness for Purpose Assessment MAINTENANCE & INSPECTION - External Condition Monitoring - Internal Condition Monitoring - Civil & Peripheral Works - Pipeline Repair Programs PROCEDURES - International Codes - Government Regulation - VICO Engineering Standard (VES) - Pipeline SOP - Manpower Allocation - Pipeline SWP EMERGENCY PREPAREDNESS - East Kalimantan Pipeline Network Emergency Coordination Plan (EKPNECP) - Emergency Pipeline RepairSystem (EPRS) -Major Pipeline Contingency Plan (MPCP) REPORTS - Intelligent Pigging - FFP Assessment - Direct Assessment - Early Landslide Detection - Pipeline Coating Surveys

5 End of Presentation End of Presentation Thank You!

6 Identify Potential Pipeline Impact by Threat External corrosion Internal corrosion Stress corrosion cracking Manufacturing related defects Welding/fabrication related Equipment Third party/mechanical damage Incorrect operational procedure Weather related and outside force

7 Gathering Reviewing & Integrating Data List of data: Attribute Construction Operational Inspection Stored in PCT Archives system POMA PIMS - provide timely and efficient access to all pipeline information, to maintain i pipeline integrity it data, and to develop a solid foundation for a Geographic Information System (GIS)

8 Data Management Manual Storage Server Store POMA PIMS A computer software to store, inspect, combine, analysis and display geographical data Facilitates the management of data with a geographic component, and eases data acquisition and utilization Developed by local IT company Web based system migration (being developed)

9 Risk Assessment TRA (Task Risk Assessment) CTA (Critical Task Analysis) DRR (Departmental Risk Assessment) HLRR (High Level Risk Register) MAR (Major Accident Risk) QRA (Quantitative Risk Assessment)

10 Integrity Assessment Intelligent surveys (in-line inspection) Pressure testing Direct assessment Fitness for purpose (FFP) assessment

11 Intelligent Surveys (In-line inspection) To check the general condition of the pipeline with respect to metal loss To inspect, electronically, every piggable pipeline on a regular basis Type: Magnetic Flux Leakage, High Resolution Tool Responses: Immediate Indication shows that defect at failure point Scheduled Indication shows defects is significant but not at failure point Monitored Indication shows defect will not fail before next inspection Promptly review the result for immediate response indications Review within six months and a response plan developed

12 Pressure Testing An industry-accepted method for validating the integrity of pipelines Function: Strength test Leak test Address time-dependent threats (external corrosion, internal corrosion, stress corrosion cracking, and other environmentally assisted corrosion mechanisms) Response: Any defect that fails a pressure test shall be promptly remediated by repair or removal

13 Direct Assessment Utilize a structured process to integrate knowledge of the physical characteristics and operating history of a pipeline system or segment Assessment purpose: External corrosion (ECDA) Internal corrosion (ICDA) Stress corrosion cracking (SCCDA) Th i t lb t b t i ti h llb The interval between subsequent examinations shall be consistent with guideline in ASME B31.8S

14 Fitness for purpose (FFP) assessment Objectives: Assess the results of the inspection Identify and prioritize any features, both corrosion and any other features, which may be an immediate threat to the integrity of the pipeline for remedial action Justify the need for a further detailed FFP by third party The initial defect assessment criteria will use ANSI/ASME B31.G Some integrity assessment approaches (RSTRENG, DNV) can be utilized to reduce the number of repairs

15 Update, Integrate & Review Data The improved status and updated information is retained and added to the data base Additional operating, maintenance and any other information is collected to improve the historical data base

16 Reassess Risk Performed periodically within regular intervals and when substantial changes occur to the pipeline Consideration: Recent operating data Changes to pipeline design and operation Analysis of the impact of any external changes Incorporation of data from risk assessment Th lt f i t it t f t d i t f t The results of integrity assessments are factored into future risk assessments

17 Integrity Management Plan 10 Year Pipeline Integrity Plan document: Integrity Assessment Method Response to Integrity Assessments and Mitigation (Repair and Prevention) Repair Methods Prevention Strategy/Methods

18 Prevention Activities Prevention Activities Controlling Corrosion Preventing Third Party Damage Detecting Unintended Releases Civil and Peripheral Works Pipeline Accessories Maintenance a. Pig Traps b. Isolating Joints c. Chemical Injection Facilities d. Instrumentation e. Relief Valves f. ESD Valves g. Block Valve Stations a. Regular Patrol b. One Call System c. Pipeline Marker & Barrier d. External Protection a. Visual/Mechanical Inspection b. Leakage Control Measures c. Ground Movement a. Civil and earthworks b. Soil stability c. Erosion d. External Protection d. Pipeline road maintenance e. Population density impact f. Support structures g. Buildings CP Monitor & Maintenance a. Transformer/Rectifier b. Test Point c. On/Off Potential Survey Internal Condition a. Routine Pigging b. Internal Condition Monitoring External Condition Monitoring a. Coating b. Above Ground Facility

19 1.Pipeline Accessories Pig Traps End Closure Seals Controlling Corrosion (1/2) Visually inspect, clean, grease & change if required Every pigging operation Bleed Locks Visually inspect, ensure seal, clean & grease Every pigging operation Launcher Barrel Visually inspect internal & external condition Every pigging operation Receiver Barrel Visually inspect internal & external condition Every pigging operation Associated Valves Inspect for leaks or passing, grease, flush & repack if required Isolating Joints Electrical isolation check As required Chemical Injection Facilities & sample point inspected Annually Instrumentation Control & protective equipment check to pipeline Annually operation parameters Relief Valves Tested for setting pressure, re-certificate 2 years Valves operated twice per year (minimum) ESD Valves Function/stroke test Annually (opportunity basis) Block Valve Stations Valves Greasing, flushing, re-packing & stroking Annually (opportunity basis) Site Condition Warning signs, fence & availability of access Twice annually (keys, gate etc.)

20 Controlling Corrosion (2/2) 1.2. Cathodic Protection Transformer/Rectifier Outputs to checked As required Test Points Outputs to checked Four monthly On/Off Survey Potentials recorded As required 1.3. Internal Condition Monitoring Routine Pigging i Internal Condition Monitoring Prevent corrosion product, debris, build up/liquid hold up Based on assessment Product Analysis Product to be collected & analyzed 3 months Corrosion Coupons/Probes Retrieve and inspect One result per 3 months Pigging Debris 1.4. External Condition Monitoring Coating Above Ground Facility Sample to be collected and analyzed Check pipeline coating using CIPS, backed by DCVG & coating survey Visually inspect where external corrosion is suspected When sudden increase in debris observed 3 years (See attachment 2) Continuous

21 Preventing Third Party Damage a Regular Patrol Monitor third party activities, especially excavations, unauthorized vehicle crossing, pipeline security, encroachment, and special projects Daily Monitor condition of pipeline ROW, especially areas of landslip, soil subsidence and road crossing 1-3 month b One Call System Call number is stated in warning sign, and socializes through various public educations. As required c Pipeline Marker & Barrier Check overall condition, and increase marker frequency in heavily populated area Continuous d External Protection Protect pipeline from external activities such as increasing wall thickness, line relocation, increase cover depth, and ROW rehabilitation As required

22 Detecting Unintended Releases a Visual/Mechanical Inspection Above/below ground interface Associate Buried Pipe Selected Buried Pipe Visual inspection, UT (internal corrosion) If corrosive conditions detected in above ground pipe or bad coating Excavate at selected locations to examine coating Annually (Optimized 2 year depend results) Condition dependant Every 10 years or based on coating survey result b Leakage Control Measures Manual leak survey 6 month c Ground Movement Install & monitor pipe clamp monitoring, monument, inclinometer and piezometer 1-3 month

23 Civil & Peripheral Works a Pipeline ROW Civil and earthworks, soil stability, erosion, pipeline road maintenance, population density impact, support structures and buildings. As required

24 Performance Plan All performance information is annually evaluated Monitor the success of integrity assessment techniques, pipeline repair activities and mitigation risk control activities The overall measurements: Number of kilometers of pipeline inspected vs. program requirements Number of immediate repairs completed Number of scheduled repairs completed Number of leaks, failures, and incidents (classified by caused)

25 External Communication Communications Plan Landowners and tenants along the Rights of Way Local and regional emergency responders Public officials other than emergency responders Internal Communication Committee meetings (POMA Operations & Maintenance and Finance & Audit Subcommittee) in quarterly basis Bi-annually POMA Management Meeting Monthly Bi-parties Meeting Monthly Gas Coordination Meeting

26 Management of Change Plan AFA - Authorization for Alteration, to ensure that, prior to implementation, changes to the pipeline system design, operation, or maintenance are evaluated AFA process: Proposal Review of proposal Approval Implementation ti Information of this alteration shall be distributed to everyone involved in the operation

27 Quality Control Plan The documented proof of the integrity management plan are fulfilled Guidelines: BPMIGAS Working Guideline for Operations and Maintenance of Oil and Gas Pipeline Transportation for Upstream Oil & Gas Activities No. 012/PTK/II/2007 An independent third-party review of the entire program may be requested to perform integrity it management program audit & review