application of dvgw technical rules on gas transmission … · application of dvgw technical rules...
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Contents
OGE at a Glance, OGE Pipelines in Germany
Integrated Management System
Pipeline Design & Safety Philosophy
Pipeline Integrity Management System
Corrosion Control
Hydrostatic and Tightness Testing
Inline Inspection Techniques
Defect and Failure Investigation
Troubleshooting & Repair-Techniques
Conclusions
Pipeline Operation and Maintenance | 10.4.2014
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Contents
OGE at a Glance, OGE Pipelines in Germany
Integrated Management System
Pipeline Design & Safety Philosophy
Pipeline Integrity Management System
Corrosion Control
Hydrostatic and Tightness Testing
Inline Inspection Techniques
Defect and Failure Investigation
Troubleshooting & Repair-Techniques
Conclusions
Pipeline Operation and Maintenance | 10.4.2014
3
Open Grid Europe at a Glance
Germanys leading Transmission System Operator
Founded in 2004 as E.ON Gastransport,
Change of name at 1.9.2010 to Open Grid Europe
Marketing and operation of the largest gas transmission grid in
Germany (approx. 12.000 km)
Customers: More than 450 national and international TSOs and
DSOs, municipal utilities, industry customers and gas retailers
Approx. 1.650 Employees
27 Compressor stations | 97 Compressor units
17 Entries | approx. 1.100 Exits
Annual exit quantity : Approx. 759 Mrd. kWh
4
Headquarter Kallenbergstr.
Subsidiary Altenessen
Pipeline Operation and Maintenance | 10.4.2014
The Grid of Open Grid Europe
Approx. 12.000 km pipeline length
Border entries
Market unit transition points
Network connection points
Network coupling points
Two gas qualities
H-Gas (high calorific)
L-Gas (low calorific)
5 Pipeline Operation and Maintenance | 10.4.2014
Year of construction 1912 - 2013
Diameter 4“ - 48“
Wall thickness 4 - 19.4 mm
Internal Pressure 2 - 100 bar
Material Grade Grade B - Grade X80
(St 35 - GRS 550 TM)
Total Pipeline Length approx. 12,000 km
Mill coatings Bitumen, PE (1-, 2- and 3-layer), PUR, EP
Field coatings Petrolatum, Bitumen, PE - butyl-rubber tapes, PUR
Characteristics of OGE Pipeline Grid
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Pipeline Operation and Maintenance | 10.4.2014
Contents
OGE at a Glance, OGE Pipelines in Germany
Integrated Management System
Pipeline Design & Safety Philosophy
Pipeline Integrity Management System
Corrosion Control
Hydrostatic and Tightness Testing
Inline Inspection Techniques
Defect and Failure Investigation
Troubleshooting & Repair-Techniques
Conclusions
Pipeline Operation and Maintenance | 10.4.2014
7
Pipeline Operation and Maintenance | 10.4.2014
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Integrated Management System
Management
System
Standard ISO 9001 ISO 14001
OHSAS
18001
DVGW
G 1000
Integrated
Management
System
(HSEQ)
EN 16348
Year of
implementation 1996 - 2000 1997 2002 - 2003 2003 2003 2008
Scope Quality Environment Health &
Safety
Technical
Safety
Management
(TSM)
Quality
Environment
H&S
TSM
SMS / PIMS
Management System implemented by Open Grid Europe (PIMS, IMMeR PRMS)
Integrated Management System implemented by Open Grid Europe
and certified by independent external body
DVGW Code of Practice G 1000
Assessment of:
Technical organisation
Technical processes
Qualification and training
Compliance with gas-specific regulations and standards
Methods:
Only “do-principle”
No formal audit, answering of questionaries
Carried out by DVGW experts
Re-certification after 5 years
Not included/required:
Regular internal audits (Plan Do Check Act)
Management review
Intermediate audits by DVGW experts
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Integrated Management System: Activities
Maintenance and continuous improvement of the
certified „technical safety management system“
according to DVGW Code of Practice G 1000
Maintenance and continuous improvement of the
certified integrated occupational safety,
environmental and quality management system
Coordinate and accompany the auditors in
connection with external audits
Planning, organisation and performance of
internal audits
Management and updating of management
system documents
Compilation of an annual quality report as one
part of the annual HSEQ report for the top
management
presumption of conformity with the
requirements of § 4 (3) GasHDrLtgV
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Contents
OGE at a Glance, OGE Pipelines in Germany
Integrated Management System
Pipeline Design & Safety Philosophy
Pipeline Integrity Management System
Corrosion Control
Hydrostatic and Tightness Testing
Inline Inspection Techniques
Defect and Failure Investigation
Troubleshooting & Repair-Techniques
Conclusions
Pipeline Operation and Maintenance | 10.4.2014
11
Construction in 1992 In Service since 1994
Ideal Route of High Pressure Pipelines
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Pipeline Operation and Maintenance | 10.4.2014
Quality-Control at Construction
Steel melting Testing Final Inspection Test Certificate
Girth Welds Pipe laying Stress Test
Final Dokumentation
Pipeline Construction 14
Pipeline Operation and Maintenance | 10.4.2014
DVGW G 463, 462
Survey by foot, car, helicopter
Inline Inspection Maintenance
Activities, Leaks
Corrosion Protection
Pipeline Operation
Quality-Control at Operations
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Pipeline Operation and Maintenance | 10.4.2014
DVGW G 466-1
Design of New Pipeline acc. to German Standards EN 1594, DVGW G463, EN 10208-2
Wall thickness determined by Barlow-Formula from:
MOP, Diameter, Material Grade, Design Factor
Requirements:
• Specified Minimum Wall thickness Tmin
• Specified Minimum Yield Strength Rt0.5
• High Quality Requirement on Production
• Well-known Geometrical Dimensions and Tolerances
Design of Pipelines in Germany Calculation of Wall thickness
Design
05,0t
minfR20
DxDPT
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Pipeline Operation and Maintenance | 10.4.2014
DVGW G 463
Usage factor – Coefficient of Safety (DVGW G 463)
grade Safety factor S
acc. to EN 1594 Usage factor f0
acc. to EN 1594
L245NB/MB 1.50 0.666
L290NB/MB
L360NB/MB 1.55 0.645
L415NB/MB
1.60 0.625 L450MB
L485MB
L555MB
Testing of Toughness @ 0°C
Design
TGL
W, 17
DVGW G 463
Operator Remarks
E.ON Ruhrgas depending grade
Fluxys depending grade
Swissgas no area classes
Gaz de France area classes
National Grid area classes
Snamretegas area classes
Gasunie area classes
SPP area classes1.39 - 2.28
1.38 - 2.50
1.39 - 3.33
1.39 - 2.00
1.39 - 2.50
Factor of
Safety
1.50 - 1.60
1.50 - 1.60
1.67
Safety factor acc. to EN:
1.39 = 1/0.72 , similar to
ANSI/ASME Code
Additional National Rules
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Pipeline Operation and Maintenance | 10.4.2014
DVGW G 463
OGE
Additional Loads at Construction
Tie in Field Bending
Slope Elastic bending
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Pipeline Operation and Maintenance | 10.4.2014
DVGW G 463
Contents
OGE at a Glance, OGE Pipelines in Germany
Integrated Management System
Pipeline Design & Safety Philosophy
Pipeline Integrity Management System
Corrosion Control
Hydrostatic and Tightness Testing
Inline Inspection Techniques
Defect and Failure Investigation
Troubleshooting & Repair-Techniques
Conclusions
Pipeline Operation and Maintenance | 10.4.2014
20
PIMS at Open Grid Europe – Governing Rules
Laws an Ordinances Energy law, GasHDrLtgV
Standards (DIN, EN) and Technical Rules (DVGW)
EN 1594, EN 16348, G463, G466-1
Internal standards and rules Structure of organisation, processes and
procedures, responsibilities, qualification of personell, … (e.g. RN 210-001)
Pipeline Operation and Maintenance | 10.4.2014
21 GasHDrLtgV , DVGW G …
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Integration of PIMS into other Management Systems
SMS 2) SMS 2) SMS 2)
1) Company Management System
2) Safety Management System
(for Gas transmission Infrastructure)
3) Integrity Management System
4) Pipeline Integrity Management
System
5) Environment Management System
6) Quality Management System
7) Occupational Health and Safety
Management System
Source: EN 16348
Modular structure allows later integration of other
integrity management system standards.
Overlaps with other management systems
already existing (e.g. DVGW G1000 / TSM)
TSM
EN 16348
Pipeline Operation and Maintenance | 10.4.2014
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PIMS at Open Grid Europe – Objective and Characteristics
Data- and Informational Integrity Organisational Integrity
Systematic, quality-controlled as-built
documentation
Access to all relevant data
High and increasing level of pipeline information
(e.g. integrity assessment reports) and pipeline
data
Integrity assessment based on standardized
methods and procedures
Standardized evaluation criteria and mitigation
measures
Quality-assured procedures based on specific
workflows
Optimisation of costs
Asset preservation/
Lifetime extension
Legal safety
Other objectives
Costs
Time
Objectives are reached by …
Technical safety
Asset availability
Asset performance
Main objective
Technical Pipeline
Integrity
EN 16348
Pipeline Operation and Maintenance | 10.4.2014
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Basics of Pipeline Integrity at Open Grid Europe
Desing & Construction Operation & Maintenance Verification of PL Integrity
Desing and construction are
carried out according to the
standards, technical rules
(DVGW) and company standards
valid at time of construction
Quality control during construction
(incl. Inline inspection)
Verification of CP effectiveness
according to DVGW GW10
Operation and Maintenance
according to DVGW-G 466-1.
CP monitoring according to
DVGW GW10 and G 466-1.
Docomentation in WinKKS.
Casings: AfK 1
AC corrosion: AfK11
High voltage protection: AfK 3
Significant changes are confirmed
by DVGW certified expert.
Repeated integrity assessment
considering DVGW G 466-1
(„Condition analysis“)
Control of necessary maintenance
measures
Pipeline Integrity Management
System (PIMS)
Check of completeness of
technical approval and
commissioning documentation