Second Hungarian-Ukrainian Joint Conference on Second Hungarian-Ukrainian Joint Conference on Safety, Reliability and Risk of Engineering Plants Safety, Reliability and Risk of Engineering Plants

and Components, Kiev, 19-21 September 2007and Components, Kiev, 19-21 September 2007

The experience on safety, reliability The experience on safety, reliability and risks assessment of some and risks assessment of some Ukrainian, Russian and Latvian Ukrainian, Russian and Latvian

transit pipe linestransit pipe lines

A. KrasowskyA. Krasowsky

G.S. Pisarenko Institute for Problems of Strength, G.S. Pisarenko Institute for Problems of Strength, National Academy of Sciences of UkraineNational Academy of Sciences of Ukraine

Lecture content

1.1. IntroductionIntroduction

2.2. Expert system for pipeline managementExpert system for pipeline management

3.3. DatabasesDatabases

4.4. Geography information systemGeography information system

5.5. Large displacements of buried transit pipelinesLarge displacements of buried transit pipelines

6.6. Risks assessmentRisks assessment

7.7. ConclusionsConclusions

Expert System (ES) «InfoPipeMaster» Expert System (ES) «InfoPipeMaster»

1. Collection and care of all information about pipeline:

2. Stress and strain fields calculations :Static loadingsStatic loadings

Computer portrait, schemes, drawings, photos of object, documents, etc.

Data bases for materials, flaws, pipes, loading conditions and soils.

The results of inspections.

The results of calculations.

3. Comparative analysis using the inspection results of different time periods.

4. Technical reports and summary conclusion preparation about the object condition and risks. Safety declaration.

Dynamics loadingsDynamics loadings

Flaws assessment Flaws assessment

Data bases (DB) structure Data bases (DB) structure

«Object position»

«Geometry» «Calculation results»«Loadings»• object type

• dimensions

• schemes, photos, drawings

• documents

• object label

• coordinates, GPS attachment, digital map

• environment

• pressure

• temperature gradient

• forces

• weight, etc.

• displacements and angles

• forces and moments

• stresses and strains

«Defect position»

«Geometry» «Calculation results»«Loadings»• defect type

• dimensions

• position

• schematization

• defect label

• element number

• coordinates

• axial force

• bending moments

• pressure

• corrosion rates

• Stress intensity factor

• reference stress

• safety factor

• risks

DB «Objects»

DB «Defects»

Main components of ES

Information - search componentInformation - search component ( (ISCISC);); Geography information system Geography information system ((GISGIS);); Automatic system for current documents;Automatic system for current documents; Integration module for remote-control and remote-Integration module for remote-control and remote-

management;management; Expert modules for strength, reliability, remaining life Expert modules for strength, reliability, remaining life

and risk assessmentand risk assessment;; Component for actualization of data bases distributed Component for actualization of data bases distributed

territoriallyterritorially;; Protection systemProtection system and distribution of allowed and distribution of allowed

information.information.

Diagnostic Initial data analysis

Initial risk assessment

Risk minimization plan

Inspections and mitigations

Feedback programFeedback program

Revision of basic plane

Risks revision

Integration of data

Management

Scheme for pipeline integrity and risk assessmentScheme for pipeline integrity and risk assessment

Geography information system

Transit pipeline trace Pump station Air crossing

MAP of Ukraine

Image of ammonia pipeline “Togliatti – Odessa” in the ES “InfoPipeMaster”

Calculation model for pumping station PS-13 of transit ammonia pipeline

Creation of DB “Loadings” for transit gas pipeline “Ivankov – Chernobyl”

0,0

10,0

20,0

30,0

40,0

50,0

60,0

0 365 730 1095

2000 г. 2001 г. 2002 г.

P, kg/cm2

days

Internal pressure variation in pipeline during 2000 – 2003 years

Providing DB “Materials”

Window to choice the steel and their chemical composition typical for given pipeline segment

Set of physical and mechanical properties of steels typical for given pipeline segment

Some special physical and mechanical properties of steels

103 104

44,0

44,5

45,0

45,5

46,0

46,5

47,0

47,5

48,0

48,5

49,0

49,5

50,0

Х46

X42 состареный

X42

р

об, к

Г/м

м2

N, цикли

B воздух C аммиак F воздух E аммиак H воздух I аммиак

Рис. Температурная зависимость ударнойвязкости образцов, вырезанных из труб сталей Х46.

-5

5

15

25

35

-60 -50 -40 -30 -20 -10 0 10 20 30Т, 0С

KCU кгс*м/см2 архив.

состар.

Sharpy energy vs temperature, steel X46

0 50 100 150 200 250 300

0

250

500

750

1000

1250

1500

1750

2000

2250

Stre

ss,

(M

Pa)

0.2

S K

RMC = 1100 MPa

Temperature, T ( K )

0

20

40

60

80

Red

uctio

n,

(%

)

150 200 250 3000

40

80

120

160

Temperature, T ( K )

Cha

rpy

ene

rgy,

C

VN

(

J / c

m2 )

TcAgTc

Ar

Degradation of pipeline steel 17GS after 35 years of service. Transit oil pipeline ø720 mm, Latvian oil corridor.

As received

Aged

Calculation module for the flaw risks assessmentCalculation module for the flaw risks assessment

Some shape defects

Some corrosion flaws

Cracks

Flaw condition

Flaw repair assessmentFlaw repair assessment1.0

1.1/k 1.0

ДУН

Н

БН

B

BT

2.2

Kr

Comparative analysis of two procedures of intelligent pigging. Transit gas pipeline “Dolina –

Rossosh” ø1420 mm

Comparative analysis of two procedures of intelligent pigging. Transit gas pipeline “Dolina –

Rossosh” ø1420 mm

2003

1996

Statistics of flaws recognized on the part «Dolina – Rossosh» by two diagnostic of transit gas pipeline «Braterstvo» ø 1420 мм

1996 year, flaw length, mm1996 year, flaw length, mm 1996 year, flaw depth, %1996 year, flaw depth, %

20032003 year, flaw length, mm year, flaw length, mm 20032003 year, flaw depth, % year, flaw depth, %

а, % wall thickness

а, % wall thickness

l, mm

l, mm

p; F p; F

p; F p; F

Longitudinal coordinate, m

Pre

ssur

e, М

Pа

Limited internal pressure for each defect (points) revealed during diagnostics of oil pipeline “Kremenchug - Kherson», ø720mm

Limited internal pressure for each defect (points) revealed during diagnostics of oil pipeline “Kremenchug - Kherson», ø720mm

Pump station

Internal pressure

Decision acceptance on the repair sequence Decision acceptance on the repair sequence

Kr

1.0

1/k 1.0

CF1

B

BT

2.2

A

F

Sr

1/k

B

BT

2.2

Т3

Т2

Т1Т0

CF2

CF3

Local integrity assessment of gas pipeline “Ivankov – Chernobil” at excavated part №6 (near Priborsk) for the longitudinal scar

Code 

Assessment criterion Recommendation

ВБН В.2.3 ...(Ukraine)

kallowed = 0.875 < 1 Flaw is moderateLimited time of service or repair  

BGC/PS/P11(British)

a/t = 0.8/5.8 = 0.138 > 0.12 Flaw is moderateRepair by polishing 

ASME B31.8(USA)

/Тmin = 0.71 > 0.2,

а a/t = 0.8/5.8. = 0.138 > 0.1,

Flaw is essentialReplacement of pipe 

RIETJENS(Holland)

a/t = 0.8/5.8.= 0.138 and 0.5l/t = 145/6 = 24.2, according Fig.5 flaw belongs to zone С

Limited time of service

CSA-Z662(Canada)

a/t = 0.8/5.8 = 0.138 > 0.1 Flaw is essentialReplacement of pipe. 

API 579(USA) 

/ = 149/0.88 = 169 >

>Тmin /1.5 = 140

 

Flaw is essentialReplacement of pipe 

Categorization of flaws with respect to the safety factor to prescribe the repair term (Latvian oil corridor, pipeline ø720mm, 33 years, comparison of Russian and R6 Codes)

Large displacements of buried transit pipelines

Large displacements of buried transit pipelines

• Earth movements- longitudinal- transversal

• Pipe buckling

• Earth movements- longitudinal- transversal

• Pipe buckling

Software complex «BucklingPipeMaster»

(Courtesy of I. Orynyak & S. Radchenko)

Software complex «BucklingPipeMaster»

(Courtesy of I. Orynyak & S. Radchenko)

Software complex is developed to solve the geometrically and physically nonlinear problems, related to great displacements of underground transit pipelines due to:

Software complex is developed to solve the geometrically and physically nonlinear problems, related to great displacements of underground transit pipelines due to:

Transversal earth movement 7 m

Longitudinal coordinate, m

Pipe position

Earthmovement, m

Transversal earth

movement, 7 m

Fitted pipeline geometry

Longitudinal displacements of ammonia transit pipeline «Togliatty - Odessa» near observatory «Stepove 2»

Longitudinal displacements of ammonia transit pipeline «Togliatty - Odessa» near observatory «Stepove 2»

Measured earth marker displacement

Ammonia pipeline longitudinal displacement

Longitudinal co-ordinate, m

Ear

th m

ovem

ent,

m

1700 м

Дюкер

ОНК Тросс

Лебедка

Кожух

Installation of new pipe ø720 mm into old one ø1020 mm at crossing of river Dnepr

r. Dnepr

filering

New pipe

Old pipe

elevator

Rings position optimization, crossing of river Dnepr by pipe ø720 мм through the pipe ø1020 мм, oil pipeline “Kremenchug – Kherson”

Rings position optimization, crossing of river Dnepr by pipe ø720 мм through the pipe ø1020 мм, oil pipeline “Kremenchug – Kherson”

Longitudinal co-ordinate, m

Depth, m

Old pipe New pipe

Plastic rings

Buckling of buried pipeline at excavation (software complex «PipeMovement»)Buckling of buried pipeline at excavation (software complex «PipeMovement»)

20 m

T =30oC

1 м

№ Внутреннеедавление,Р, МПа

Перепадтемпературы, 0C

Максимальноеперемещение, м

1 0 0 0.0040

2 5.5 0 0.0042

3 5.5 10 0.0044

4 5.5 30 0.0054

5 5.5 39 0.0089

6 5.5 40 1.2719

0

0.2

0.4

0.6

0.8

1

1.2

1.4

0 10 20 30 40 50 60 70м

Transversal displacements at buckling, m

Transversal displacements at buckling, m

-120000

-70000

-20000

30000

80000

130000

0 10 20 30 40 50 60 70

м

Bending moment at buckling, Нm

Bending moment at buckling, Нm

Pressure Delta T Displacement, m

Buckling of pipeline in water Buckling of pipeline in water

3.4m Fт=3680 Н/m

FA= 415 Н/m

Site of failed weight

№ Внутреннее давление,Р, МПа

Перепад температуры,0C

Максимальноеперемещение, м

1 0 0 0.0040

2 5.5 0 0.0042

3 5.5 10 0.0044

4 5.5 30 0.0054

5 5.5 39 0.0089

6 5.5 40 1.2719

Pressure, MPa Delta T, 0C Displacement, m

Building of the see bottom pipeline with a ship

X

Y

R=228 m

14о

LodgmentFree hang

Risk matrix for transit gas pipeline “Ivankov – Chernobyl” ø 325 mm

Category of failure probability

Category of consequences