AIM sept issue

Issue 1, September 2015
www.mcitechnology.org
High Quality 3 Layer Pe
Coatings For The Sauni
Project In India
12
15
Pipeline Life-Cycle
Extension Strategies –
Operation & Maintenance
20
Measuring & Controlling
Soil-side Corrosion on Above
ground Storage Tank Bottoms
Using ER Probes and Amine
Carboxylate VpCI Technology
Model
Management
Asset
Integrity
Pg. 5
Pipeline IndustryNext Issue
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Published by:
MCI Technology
Contributors:
J N Agrawal
Ex. Chief Manager (O&M)
GAIL
Chanchal Dasgupta
Application Marketing Manager
Borouge (India) Pvt. Ltd.
Amish Gandhi
Country Head (India)
Metal Samples
Khalil Abed
Business Development Manager
CORTEC Middle East
Designing:
J. Roy
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Copyright 2015 by MCI Technology.
Editorial 04
Asset Integrity
Management Model (AIMM)
05
High Quality 3 Layer PE Coatings
For The SAUNI Project In India
12
Pipeline Life-Cycle Extension
Strategies – Operation &
Maintenance
15
List of Training Programs 20
Measuring & Controlling Soil-side 22
Corrosion on Above ground Storage
Tank Bottoms Using ER Probes and
Amine Carboxylate VpCI Technology
List of Conferences And
Exhibitions on Asset Integrity
26
Industry News 28
Asset Integrity Management
Model (AIMM) | 05
High Quality 3 Layer PE Coatings For
The SAUNI Project In India | 12
Issue 1, September 2015
Content
www.mcitechnology.org 3

www.mcitechnology.org www.mcitechnology.org 54
W
elcome to the first issue of
e-newsletter on Asset Integrity
Management (AIM). This initiative
has been taken to provide a
platform to all the technologists, educationists,
scientists, academicians and professionals of all
the industries to share their knowledge and discuss
issues pertaining to Asset Integrity.
From a life cycle perspective, which includes
the design, storage, installation, operation and
maintenance, an asset should always perform to
its required design function both effectively and
efficiently.Theassetsmaybesusceptibletophysical
damage and/or external/internal corrosion which
may lead to pre-mature failure, safety, integrity and
environmental issues, affecting brand image, huge
replacement/repair cost and production loss.
It is a hard fact that we are not fool proof in
maintaining asset integrity despite of availability
of latest technology and materials for corrosion
control and mitigation measures. The recent failure
of a gas pipeline in KG basin and explosion is a
latest example of slackness in asset integrity. The
time has come now to understand the implication
of slackness in maintaining asset integrity. Some of
the measures required to maintain asset integrity
are right selection of material and processes
during design stage, right construction practices,
proper operation, maintenance and monitoring
methodology and adequate mitigation measures.
A separate AIM group is required for coordinating
all these activities following asset integrity
management procedure to ensure reliability and
safety of our assets in a cost-effective manner.
Our engineers are required to undergo various
training programmes and courses on corrosion
prevention and control together with Case studies,
field surveys, live demo of inspection and testing,
analysis of data and its interpretation and finally
taking appropriate mitigation measures to
understand theoretical and practical aspects of
corrosion prevention and control. The expenses
incurred on corrosion prevention are quite less
in comparison to loss due to corrosion. Cost of
corrosion also includes waste of materials and
energy.
Through this e-newsletter we want to spread the
knowledge of asset integrity management among
industry professionals. The e-newsletter will
contain articles, reports, case studies, discussions,
problems and solutions, information about new
technology, materials and processes and other
products & services related to asset integrity.
We invite all professionals to contribute in
successful mission of spreading knowledge of
asset integrity through exchange of information.
Your feedback is important to us so write to us
about its contents and your suggestions to improve
it.
Well wishes to all and HAPPY READING
Mr. J. N. Agrawal
Ex. Chief Manager (O&M), GAIL
On behalf of AIM Team
Welcome
Message
A
sset integrity is of paramount importance
for optimization of asset utility and cost
reduction apart from safety and environmental
issues. Asset integrity is required in all industries
ranging from oil and gas, power, fertilizer,
petrochemicals, construction, chemicals,
construction, steel and host of other industries
utilizing assets susceptible to corrosion.
Unfortunately a robust system of asset integrity
management system (AIMS) does not exist in
most of the organizations with the result that
huge repair and replacement cost is incurred due
to breakdown of asset. There is no system to
compute cost of asset breakdown due to lapse
in quality control at each stage of asset life cycle,
hence the subject needs attention. I will be dealing
with asset integrity management model with
particular reference to corrosion threats. The idea
contained in this article is basic and based on my
personal experience and expertise. Professionals
may devise their own model depending upon their
organizational structure and asset integrity issues.
WHAT IS
ASSET
INTEGRITY?
We should first
understand the
meaning of asset
integrity. Asset
integrity may be defined as “The ability of an asset
to perform its required function effectively and
efficiently within its life cycle protecting health,
safety and environment”. Asset integrity can be
maintained by strict Quality Management System
(QMS) incorporating QA/QC at each stage of the
asset life cycle such as designing, manufacturing,
project execution, operation and maintenance
and retiring. It is also to be understood that by
asset integrity we mean that the asset performs
and produces desired result as per expectation as
well as with optimum result and minimum cost.
The knowledge and skill is required at every stage
of asset life cycle to maintain asset integrity. A
close interaction is required between different
Asset Integrity Management Model
(AIMM)
Mr. J. N. Agrawal
Ex. Chief Manager (O&M)
GAIL

functions of an organization such as design,
project, construction, operation and maintenance,
internal audit, quality control, risk management,
safety, health and environment to achieve asset
integrity. Asset integrity management system
(AIMS) adopts systematic approach to identify
threats, assess health condition and take suitable
mitigation measures to address threats and
maintain safety and integrity of assets. Asset
Integrity management improves plant reliability
and safety while reducing unplanned maintenance
and repair costs.
SALIENT FEATURES OF
ASSET INTEGRITY:
Asset integrity management model may be
conceptualized on the basis of certain salient
features of asset integrity. They are as follows:
(i) A centralized asset integrity management
group (CAIMG) and regional asset integrity
management group (RAIMS) should be
established.
(ii) Asset integrity management policy with its
objectives, target and plan (OTP), processes
and procedures, roles and responsibilities
etc. should be established.
(iii) Computation of cost of corrosion and ROI
on corrosion control should be done.
(iv) Asset integrity management system should
be a part of each element of asset life
cycle such as design, manufacturing and
construction, operation and maintenance
and retirement. In addition, system should
be aligned with other disciplines related to
asset integrity such as SHE, quality, risk
management etc.
(v) SOP’s should be available for each activity
at each stage of asset life cycle to maintain
asset integrity and the job should be
done under supervision of competent
professional.
(vi) AIMG should have monitoring and reporting
mechanism of each activity at each stage of
asset life cycle to ensure that job is done as
per approved SOP’s and as per standards and
statutory regulations.
(vii) Periodic reviews by Board should be done
on integrity issues at each stage of asset life
cycle and nature of non-conformities and its
remedial actions be monitored with timeline
and responsibilities.
(viii) AIMG should monitor vendors and supplier’s
performance and credibility in asset
integrity control practices and guide them
for complying with asset integrity control
processes.
(ix) Internal and external audit for compliance
of asset integrity, quality and safety, risk
analysis and mitigation measure should be
done engaging professional in related field
and time bound remedial measures should be
taken.
(x) Human resources are important so far as
asset integrity is concerned, hence well
qualified and experienced preferably NACE
certified professionals should be deputed at
various stages of asset life cycle.
(xi) Motivation and reward are other ingredients
for successful asset integrity management
system. Annual performance report should
have KPA/KPI in asset integrity task to
measure individual’s performance in that field.
(xii) Knowledge sharing, training and
communication play an important part in
asset integrity management. Group meet, on-
site and off- site training, internal discussion
and case studies help in maintaining asset
integrity.
(xiii) Documentation plays an important part in
asset integrity management system. All
the asset initial design, manufacturing and
construction, operation and maintenance and
retrieval data including drawings, documents
and records should be available in digital form
in centralized document cell.
ASSET INTEGRITY TOOLS:
The important aspect of asset integrity
management system is application of asset integrity
tools to identify threats, assess health condition
with respect to application and take mitigation
measures. The tools will be specific to function of
departments looking after asset integrity. Specific
tools related to different asset life cycle will be
discussed.
m Design and engineering: Design and
engineering software based module based
on ASME, API, DNV considering all aspects
of material selection for specific use, design
life, cost optimization, safety, statutory
requirement etc.
m Manufacturing/Construction:
(i) QMS software tools
(ii) Risk Management software tools
(iii) SHE software tools
m Operation and maintenance:
(i) Electronic data management system for
records in soft form
(ii) O&M software modules for meeting
schedules
EXAMPLES OF PIPELINE
INTEGRITY MANAGEMENT
SYSTEM (PIMS):
m Objective:
u Aims at prevention of metal loss due to
external and internal corrosion and disastrous
Integrity Management System
Fig 1: Asset integrity management model 1

failures endangering public safety,
environment and financial & reputation loss.
u Evaluate the risk associated with
natural gas and LPG pipelines and
effectively allocate resources for prevention
and detection of corrosion and mitigation
activities
u Improve the safety and integrity of
pipelines to protect the personnel, property,
public and environment
u To streamline effective operations to
minimize the probability of pipeline failure.
m Strategies:
u Risk based integrity assessment
u Quality assessment plan
u Cost and performance evaluation
u Integrity audit
u Software application and automation
u Condition monitoring
m Processes: Applicable to all asset cycle
that is design, construction, O&M and
abandonment
u Risk assessment and IM planning:
Threat to asset integrity and risk, risk score
and existing practices, integrity plan for
inspection, monitoring and testing, integrity
assessment and mitigation, intervention
and repair.
u Inspection, monitoring and testing:
u Integrity assessment
u Mitigation, intervention and repair
m Codes and regulatory requirement:
u PNGRB-IMS Regulation 2012
u OISD 226
u ASME B31.8S/API 1160
u NACE SP 0502-2010 ECDA
u NACE SP 0206-2006 ICDA
m Solution:
u Integrated enterprise wide GIS enabled
software solution
u Compilation of all data in PIMS aligned
with SAP/DCS/ECDS
Fig 2: Asset integrity management model 2
Fig 3 Total concept of Asset integrity management model
Conclusion:
This article has exhibited different
aspects of asset integrity management
model and why it has got tremendous
importance for obtaining quality,
safety and long life of asset thus
saving enormous cost in repairing and
rehabilitation. A systematic AIMM is
the need for quantitative and qualitative
evaluation of asset integrity for taking
decision on inspection, testing and
monitoring, integrity assessment and
finally repair and rehabilitation.
ASSET INTEGRITY
MANAGEMENT MODEL:
m Basis of asset integrity management model
The basis of integrity management model is
explained in the example of pipeline integrity
management system. Similarly for other
assets integrity management model may be
designed. The sequence of events in asset
integrity model may be expressed as follows:
Model 1: Shows the integrity management
process and role of other services
Model 2: Sequence of events in risk estimation
and integrity management planning
Model 3: Total concept of Asset integrity
management model

F o r D e t a i l s l o g o n t o :
w w w . p i p e l i n e i n t e g r i t y m a n a g e m e n t . i n
2nd International
Conference & Exhibition
on
“Pipeline Integrity Management
(ICEPIM 2016)”
5 - 6 February 2016
The Grand Hotel, New Delhi
Participation in ICEPIM 2015
Organized by Supported by
World ils
Conference
Paper Presentations / Poster Papers
Theme Topics of ICEPIM 2016
Session 1: Planning, Design and Construction of pipeline
Session 2: Pipeline Materials, various issues in Pipeline Fabrication & Repair
Session 3: Corrosion & its Control Techniques- Cathodic Protection, Inhibitors & Coatings
Session 4: Latest Inspection Techniques in Pipelines Risk Management
Session 5: Operation, Maintenance Repair & Rehabilitation of Aging Pipelines
Session 6: Pipeline Integrity, Safety and Reliability Management
Session 7: Challenges and Development in Pipeline & City Gas Distribution (CGD Industry)
Panel Discussion
Awards and Recognition
- Best Oral Paper
- Best Poster Paper
- Award for Best Exhibition Booth
- Award for Innovative technology
- The Pipeline Integrity Expert Award
Pre-conference Training Programs
Topic 1 Pipeline Integrity Management (1 day)
Topic 2 Cathodic Protection design, applications and Survey (1 day)
Topic 3 Coating Integrity Evaluation & Surveying (1 day)
Topic 4 Inspection & Repair techniques in Pipeline (1 day)
Important
deadlines
Abstract Submission: 30.09.15
Acceptance of Paper: 31.10.15
Submission of Full Paper: 30.11.15
Registration of Delegates: 15.01.16
Registration for Pre-conference
Training Programs:
15.01.16
Exhibition
Complimentary delegates
Company profile/ Advertisement in Souvenir
Display of company logo in the Venue
Display of company logo in Website
Advertisement in Newsletter “Asset Integrity
Management”

High Quality 3 Layer PE Coatings For
The SAUNI Project In India
smaller diameter pipes of 750 mm.
Traditionally in India an internal cement coating
(popularly known as guniting) has been used to
protect the steel water pipes from corrosion but
there have been problems with this solution. For
example recently it was reported in the Times
of India that 384 villages in Gujarat State went
without water for a couple of days owing to
pipeline failures due to corrosion. The problem is
that over time the cement coating cracks, allowing
water to permeate through the coating which
leads to corrosion of the steel pipe and eventually
failure. Unfortunately the quality of the cement
coating itself may vary a lot because it is largely
a manual mixing and application process that is
difficult to control.
THE CHALLENGE
Higher performance coating required for
these important water pipelines.
It was essential that the large diameter steel water
pipes for the SAUNI project were well protected
from corrosion throughout their lifetime and with
a much higher service life. This includes any
potential impact during handling, transportation,
outdoor storage, installation and corrosion
protection for a long operational life.
THE SOLUTION
The engineers choose high performance
3LPE coating for pipelines.
After substantial technical and commercial
deliberation, the SAUNI project engineers decided
to adopt the superior protection provided by 3LPE
coatings for these strategically important water
pipelines following the international trends. The
oil and gas industry already relies heavily on 3LPE
coatings to protect the majority of their pipelines.
A high level of factor of safety and quality control
is maintained as failures of these pipelines can be
very costly indeed. In the Middle East many mega
water projects areutilising these same materials
such as the Ras Al Khair project for Saline Water
Conversion Company (SWCC) in Saudi Arabia. In
this project twin large diameter pipelines are used
to transport one million cubic metres of water per
day from the desalination plant at Ras Al Khair to
Saudi Arabia’s capital city of Riyadh.
Even in India Gujarat Water Infrastructure limited
carried out a large water pipeline project In 2012,
where 437 kms of pipelines with diameter ranging
from 1800 to 2400 mm were coated. However,
3LPE coating of 3 meter diameter steel pipe line
was carried out first time in the world by Indian
coaters for SAUNI project
THE BACKGROUND
Long term solutions required for water
scarcity in India
The State of Gujarat in western India has suffered
three drought years in the past decade and in
the worst affected areas, such as the Saurashtra
and Kutch regions, the usual mode of providing
drinking water was in road tankers. Irrigation,
which uses >80% of available surface and
groundwater used to suffer due to lack of water
availability. Though Gujarat is a front runner in
water saving methods like drip irrigation and
mulching for irrigation, they needed to develop a
longer term solution.
Hence Gujarat Govt designed the ambitious
SAUNI water conservation scheme. This involves
charging 115 reservoirs in the Saurashtra district
with water from the Narmada River and linking
them with 464km of large steel pipes up to 3meter
in diameter and 1,100km of pipes in total including
Mr. Chanchal Dasgupta
Application Marketing Manager

THE BENEFITS
The coating of the SAUNI pipes
is taking place in a number of
stages since early 2014 and
most of the work was carried
out by coating companies
who have plants in Gujarat
State. This includes Jindal Saw
Limited, Welspun Corp, Man
Industries, Ratnamani and
Hazira Pipe Mill (Essar). These
coating companies are regular
users of Borcoat 3LPE coating
materialswhich are approved
by all international standards.
Pipeline construction also
taking place in several stages
and many leading contractors
are involved including Larsen
and Toubro (L&T), SPML
Infra, Hindustan Construction
Company (HCC), Megha
Engineering and Infrastructure
Ltd (MEIL), NCC and Pratibha
Industries.
SAUNI project specification has
been drawn exactly in the same
way as Oil and Gas pipeline
specification to provide same
kind of reliability to the pipelines.
Borouge produces the
BorcoatPE top coat in its plant
in Abu Dhabi using patented
bimodal technology which
enables the balance between
the processing and mechanical
and ESCR properties of the
material which is supplied as
fully formulated compounds.
The high mechanical properties,
resistance to UV and
Environmental Stress Cracking
ensure that the coating will
provide a high level of protection
to these important water
transportation pipelines for
many years to come.
ABSTRACT
Safe and secure energy transport is of paramount
importance for all economies in the world. Safety,
reliability, integrity and economics of oil & gas
pipelines are key parameters for the acceptance of
all stakeholders involved.
India currently has a network of over 40,000 Kms
of cross country oil & gas pipeline with additional
15000 Kms upcoming. With this quantum of
hydrocarbon pipeline network, it is must to
ensure the pipeline safety and to minimize the
environmental risks. As pipelines become older, it
becomes important for an operator to implement
efficient operation & maintenance practices for
enhanced life cycle of pipelines.
Pipeline operators/owners can help in a big way
even the aging pipelines (50 years+) by operating
in a safe manner by adhering to the national/
international codes & standards.
The PIMS (Pipeline Integrity Management
System) is the need of the hour, where all relevant
information, integrity
evaluation methods,
repair tools and
standards for the
pipeline are laid down
in the most user
friendly way. PIMS is
fed by data received through In-Line Inspection,
cathodic protection system, and the historical data
inputs including the pipeline base data. Together
with other integrating tools (SCADA, SAP etc.)
and innovative maintenance methods a long and
economically reasonable pipeline life-cycle can be
achieved.
This paper shall discuss how advance operation &
maintenance technologies lead to the pipeline life-
cycle extension, besides other important factors
such as construction and material selection.
Key Words
GIS : Geographic Information Systems
Pipeline Life-Cycle Extension Strategies
– Operation & Maintenance
Mr. Amit Kumar Sharma
DGM – Business Development
Sanmarg Projects Pvt. Ltd.

PNGRB : Petroleum and Natural Gas Regulatory
Board
OISD : Oil Industry Safety Directorate
SCADA : Supervisory Control and Data
Acquisition
SAP : System, Applications and Products in
Data Processing
ILI : In – Line Inspection
NDE : Non – Destructive Testing
PSL : Pipe Specification Level
MPS : Manufacturing Procedure Specification
ERW : Electrical Resistance Welding
HFW : High Frequency Welding
CAT : Current Attenuation Test
DCVG : Direct Current Voltage Gradient
CIPS : Close Interval Potential Survey
SCC : Stress Corrosion Cracking
ISO : International Organization for
Standardization
API : American Petroleum Institute
ERRS : Emergency Response & Repair System
DIMP : Distribution Integrity Management
Program
INTRODUCTION
India has been among the world’s fastest growing
economies. With expanding economy comes an
increasing demand for energy and, if current trends
continue, India will be the world’s third largest
energy consumer by 2020. Due to the expected
strong growth in demand, India’s dependency
on oil & gas imports is likely to increase further.
Rapid economic growth is leading to the higher
dependency on pipeline infrastructure which is the
safest mode of Oil & Gas transport.
Leaks are common in the old pipelines all across
the world. For instance, 39% of the UK gas network
was considered at-risk, and the last statistics
for leaks was 23,000 per year Similar situations
are with all the pipelines and this is because of
many reasons but primarily because of ageing of
the pipeline. Recently, in New York east Harlem
neighborhood, an explosion destroyed a five story
building and killed eight people. The pipeline was
127 year old. Investigations determined that the
cause of the explosion was natural gas leaking
through fractured pipes due to stress cracking.
In the Indian context, recently a major accident
happened in a natural gas pipeline in South India
which caused death of 16 people. The cause
behind accident was major leak due to corrosion.
It was raining on the day, whole the night the gas
was leaking, which possibly formed vapor cloud. A
tea stall owner turned on the stove in the morning,
possibly provided the source of ignition. In another
episode, a crack in mainline valve, led to gas
leakage thus causing an explosion, however no
casualties were reported. In Delhi recently, a gas
pipeline burst due to accidental digging of pipeline
by PWD workers.
Pipelines worldwide are leaking, cracking and
creating the potential for catastrophic accidents.
The causes could be corrosion, defective material
or construction practices, not following safety
protocols etc.
Out of the present Indian pipeline infrastructure,
about 33% are more than 25 years old and about
5000 Kms pipelines are non piggable.
The task of replacing outdated gas pipelines
typically falls on the pipeline operators which
is a costlier affair. Various studies shows that
implementation of an effective program go a long
way in maintaining the structural integrity of the
ageing pipelines with extended service life.
Pipeline operators are expected to pay for much-
needed upgrades and maintenance work that
will prevent future disasters and loss of life, for
which recovering of the cost of those upgrades
are in terms of reduction in long term risks e.g.
reputational effects, damage to share price and
production loss because of shut down time.
Fortunately, regulatory bodies and pipeline
operators worldwide are working together to
face this situation head-on. In India, pipeline
operators and government bodies such as PNGRB
& OISD are working in incorporating the best
practices followed worldwide. More focus is given
to the preventive inspection methodologies by
increasing the frequencies of periodic inspection
such as Inline Inspection & Cathodic Protection
surveys. Implementation of the pipeline integrity
management system is another important area
where PNGRB has come up with a mandatory
notification of pipeline integrity management
plan implementation in phased manner for all the
pipeline operators.
CAUSES AFFECTING THE
PIPELINE INTEGRITY:
The causes of failure can be from any of the three
stages of pipeline such as Design & Engineering,
Construction and Operation phase.
Without taking care of ground realities, going
for readymade solutions can cause the wrong
material selection, coating selection and selection
of welding technology/procedures etc.
Lack of quality control during construction
period (such as sand padding in trench, cut back
length, radiography, surface cleaning etc.) leads
to damage to the pipeline coating/joint coating
which further leads to susceptibility of the pipeline
towards severe corrosion in a small period of time.
In upstream, one has producers producing the Oil
& Gas to fulfill the growing demand whereas in
the downstream, you have hundreds of kilometer
of pipeline infrastructure to deliver the same to
market.
At the point of custody transfer from upstream
producer to the downstream operator, are the
multitudes of analyzers that ensure contaminants
such as sulphur / water are at low enough levels
to protect the pipelines and keep the public safe.
This critical measurement prevents corrosion,
which in the worst case can lead to pipeline
rupture.
Also the communication plays a crucial role in
smooth operation of the pipelines. Improper
maintenance of instruments, calibration issues,
third party damage can lead to the communication
problems which can cause a major incident.
In the pipelines, all elements of your measurement
system must be optimized. If you are not using the
total measurement system, then you risk making
a less accurate measurement, which leaves you
susceptible to economic losses.
MAJOR CHALLENGES IN
PIPELINE OPERATION &
MAINTENANCE:
The first and foremost challenge is to create the
serious concern about the risk associated and its
mitigation measure for pipeline assets amongst
all the key stake holders, be it the operator,
Per-capita Energy Consumption (PEC) increased from 3,497.59 KWh in 2005-06 to 6748.61 KWh in 2012-13, a CAGR of
8.56%(Table 6.2). The annual increase in PEC for 2012-13 over 2011-12 was 8.76%.
Source: Energy Statistics 2014, Ministry of Statistios and Programme Implementation

government, regulatory bodies, customers and the
society.
Secondly, to create an integrated approach
towards smooth operation & maintenance along
with the emergency response & repair system
which will lead towards long term profitability and
enhanced life of the asset.
IMPLEMENTATION OF NEW
TECHNOLOGIES:
Implementation of next generation technologies
will be integral to enabling the safe and reliable
delivery of energy – now and for generations to
come.
A successful strategy will demand that utilities
pilot new technologies and design process that
make sense for their customers and regulators,
win the rate case, define comprehensive
implementation and change management plans,
and integrate all the pieces to realize efficient,
reliable and safer pipeline operations.
Overcoming the hurdles to implementing the next-
generation leak-detection technologies won’t
be easy. However new ways of leak detection
are based on fiber optic cable and work on the
temperature sensing and acoustic sensing.
Robotic ILI tools with high-accuracy NDE sensors
have proven through numerous inspections
to be highly effective tools that supplement
pipeline operators’ traditional flow driven smart
pigging activities. Robotic ILI tools are used in
the portion of their pipeline systems that include
sections with low flow, geometric challenges, or
other parameters that make flow driven pigging
impossible or uneconomical. Robotic ILI is also
valuable for use in performing detailed “remote
examination” of pipe sections that cannot be
excavated.
The Introduction of the HFW welding process as a
mandatory requirement for PSL2 pipes in table 2
& 3 of API 5L/ISO 3183 is indeed an improvement
over the inherent problems of hardness, lack
of fusion and susceptibility of stress corrosion
cracking (SCC) in line pipes associated with
ERW process pipes. The engineers responsible
for selecting material should consider these
improvements during the manufacturing
procedure specification (MPS) approval of the pipe
procurement process.
AN INTEGRATED APPROACH
TOWARDS MAINTENANCE
AND EMERGENCY
PREPAREDNESS:
We can never say, ‘It will never happen again,’ but
we becoming more prepared and can reduce high-
profile incidents like in New York and India.
In the wake of four major pipeline accidents in
June, emergency preparedness is taking center
stage. With a leaking oil pipeline igniting a huge
blaze in China, Pipelines exploding in Malaysia,
Ukraine and India operators are taking a hard look
at how vulnerable their assets are to third party
threats.
These incidents are dramatic reminder of the
random threats that can affect pipelines and the
urgency of having an emergency response &
repair system (ERRS) in place.
They must also achieve the highest possible level
of post-repair integrity, at the lowest possible cost.
There are advancements in ERRS practice to save
clients’ time and significantly reduce the financial
impact by using a structured process approach
to integrated maintenance and emergency repair
planning during an unplanned repair where the
timeline for accident to re-commissioning can be
dramatically compressed, minimizing downtime.
Based on a thorough understanding of the risks
and repair scenarios for an asset, combinations of
repair methods are selected. Procedures along the
critical path-from isolation of the damaged section
to re-commissioning are adjust and through
smarter outsourcing strategies for equipment and
services contracts are awarded. Finally, roles of
personnel and departments are aligned around
the maintenance & repair plan, so each party
work together during routine maintenance and
emergency.
Selecting the right team to perform integrated
outsourced services can lead to lower costs,
accelerated ramp-up schedules and experts to
manage program scale. Pipeline operators in India
have already adopted this concept as a result of
which 1014 Kms crude oil pipeline from Mundra
to Bhatinda is maintained on this concept for last
four years. Two more major pipeline operators
have conceived the idea and are coming with
similar approach for a part of their existing pipeline
networks as a pilot project.
Outsourcing a composite work program can free
up internal resources, eliminate the need to hire
and train personnel, and keep payroll and benefits
expenses in check.
However at the same time the operator should
keep in mind the key consideration when selecting
the outsourced partner:
- Range of services
- Level of participation
- Breadth of experience
- Years of experience
- Access to new technology
- Geographic reach
A distribution integrity management program
(DIMP) is the need of the hour and should be
implemented in India, just like in the United States
which is a state federal partnership that requires
pipeline operators to formally prioritize pipeline
replacement projects, ensuring that the oldest and
most damaged pipelines are replaced first.
ROLE OF THE PIPELINE
OPERATOR:
Change in mind set from Detection to Prevention.
Improvement in training to all stakeholders.
Testing, supporting and implementing new
technologies.
Improvement in communication practice with all
stakeholders and with other pipeline operators,
authorities and government departments.
CONCLUSION
To sum up, Integrity assurance of ageing pipelines
is the need of the hour for pipeline companies
considering the high replacement cost of pipeline
infrastructure.
Acknowledgement
I would like to thank to my senior colleagues Mr.
R. C. Jindal and Mr. P. Chicker who have provided
me an opportunity and guided me to present this
paper on pipeline operation & maintenance. I also
like to thank to my colleague Ms. Jigyasa Kaul for
keep on motivating me for writing this paper.
References
1. Pipeline & Gas Journal, Vol. No. 241, January 2014
2. Pipeline & Gas Journal, Vol. No. 240, October
2013
3. Pipeline & Gas Journal, Vol. No. 241, December
2014
4. Oil & Gas Journal website, www.ogj.com
5. US Energy Information Administration, www.eia.
gov
6. Petroleum & Natural Gas Regulatory Board
7. Oil Industry Safety Directorate
8. Energy Statistics 2014, Ministry of Statistios and
Programme Implementation.
9. Petroleum Planning and Analysis Cell
10. ASME B31.8S
11. DNV USA, www.dnvusa.com

www.mcitechnology.org20
Submit an Article
“Asset Integrity Management”newsletter,is an important initiative for sharing
information and knowledge to increase integrity, reliability and safety of assets.
The newsletter will deliberate on the state-of-the art material &corrosion
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application of advanced materials and various Inspection/NDE techniques to
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We welcome all the authors and professionals for contributing your technical
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contractors, supplier as well as end users, this is the right place to present
your company/ product. The advertisement rate is very much competitive and
special discount provided for multiple advertisement.
No. Training Course Title Duration
Asset Integrity Courses
1 Refresher Course on Corrosion Basics, Control, Monitoring and Management 3 days
2 Cathodic Protection: Principles & Practices 2 days
3 Industrial Cooling Water Treatment Management to Control Scaling, Fouling and MIC 2 days
4 Different Forms of Corrosion: Mechanisms, Recognition & Prevention 2 days
5 Corrosion Control by Selection of Materials 2 days
6 Pipeline Integrity Management 3 days
7 Industrial Coating Systems- Selection & Applications 2 days
8 Ageing Plants Assets Corrosion Management 2 days
9 Corrosion Inspection and Monitoring of Plant Equipment 2 days
10 Concrete & Steel Structure Corrosion Control Management 2 days
11 Coastal Plants Corrosion Control Management 2 days
API Preparatory Courses
1 API 510 Pressure Vessel Preparatory Course 5 days
2 API 570 Piping Inspector Preparatory Course 5 days
3 API 653 Above Ground Storage Tank Inspector Preparatory Course 5 days
4 API 577 Advance knowledge of welding inspection and metallurgy course 3 days
5 API 580 Advance knowledge of risk based inspection course 3 days
6 API 571 Advance knowledge of corrosion and material course 3days
7 API – 936 Refractory Design, Installation, Inspection & Repair 3 days
8 API – 1169 Pipe Line Inspector 5 days
Certified NDT LEVEL I or II - Course Exam & Certification
1 Liquid Penetrant Testing Direct Level I or II, Course Exam & Certification 2 days
2 Magnetic Particle Testing Direct Level I or II Course & Examination 5 days
3 Ultrasonic Testing Direct Level I or II, Course Exam & Certification 5 days
4 Radio Graphic FilmInterpretation level II 5 days
5 Radiographic Testing Direct Level I or II Course Exam & Certification 5 days
6 Visual Testing Direct Level I or II, Course Exam & Certification 3 days
Certified Advance NDT Level I or II Course Exam & Certification
1 Eddy Current Testing Level I or II, Course Exam & Certification 5 days
2 Helium Leak Testing Level I or II, Course Exam & Certification 5 days
3 Infrared Thermography – Direct Level –II 5 days
4 Vibration Analysis Level I or II Course 5 days
Pressure Vessel& Piping Coursesw
1 National Seminar On Pressure Vessel & Piping Technology 3 days
Based on the Client’s requirement, the above training programs can be modified to suits Client’s Job profile.
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THE PROBLEM
Aboveground Storage Tanks (ASTs) are used to
contain a variety of fluids that may pose minor
or very serious threats to the environment and
public safety, in case of leakage. Leaks due to
external corrosion of single and double-bottom
aboveground storage tank bottoms are a
serious industrial challenge from both an
operational and regulatory perspective.
Different protective methods have been
utilized to provide corrosion protection
to the underside of a tank floor, such
as cathodic protection. However, air
gaps between the bottom plates and
construction pad may render a CP system
ineffective in those areas and result in
accelerated reduction in metal thickness,
pit holes, and eventual leaks1
. This happens
due to the fact that air gaps break the
essential electro-chemical circuits formed by
direct contact between the soil (electrolyte) and
the metal tank bottoms. This problem may be
further worsened by the use of bituminous beds
or oily sand below the tank bottoms.
The ingress of water, moisture present in the
Measuring & Controlling Soil-side
Corrosion on Above ground Storage
Tank Bottoms Using ER Probes and
Amine Carboxylate VpCI Technology
atmosphere, as well as airborne chlorides through
the unsealed gap between the tank annular plate
and the foundation is another important factor
for accelerating the soil-side corrosion on the
perimeter of the tank.
Due to such corrosion issues and possible
leaks, operators have to put the tank out of
service for inspection, patchwork repairs, and
sometimes replace bottom plates, within the first
few years of the tank’s life or at the scheduled
inspection intervals. Therefore, adequate and
effective corrosion protection and monitoring
methods should be implemented to ensure the
bottom plates’ integrity for continuous, safe and
economical operation of the storage tank.
APPLICATION OF VpCI
A growing industrial practice to mitigate soil-
side corrosion of tank bottoms is to introduce
amine carboxylate based Vapor phase Corrosion
Inhibitor (VpCI) materials under the tank bottom
and monitor the impact on corrosion rates using
Electrical Resistance (ER) corrosion probes.
When VpCI is delivered and released under the
tank, protective vapors disseminate, adsorb onto
the metal surface and form a monomolecular
protective layer throughout the soil-side surface of
the tank bottom plates. This solution is applicable
for cathodically protected and unprotected tanks
during scheduled maintenance outage, while in
service or during construction.
CORROSION MONITORING OF
SOIL-SIDE BOTTOM PLATES
OF ASTs USING ER METHOD
Implementing one or more reliable online
corrosion monitoring systems under the tank is
as important as selecting an effective corrosion
control method for soil-side corrosion.
Unlike other indirect corrosion monitoring
systems, ER probes are designed to evaluate and
continuously monitor the corrosiveness of the
Figure 1
Typical ER probe installation through the tank wall in a double-bottom tank2
Mr. Amish Gandhi
Corrosion Monitoring Consultant
Metal Samples
Mr. Khalil Abed
Business Development Manager
Cortec Middle East

surrounding environment under the tank floor. ER
probes are positioned close to the tank floor and
exposed to the same environmental conditions as
the tank floor, ,hence, establishing a correlation
between the corrosion rate of the ER probe and
the tank floor corrosion rate (Figures 1, 2 and 3).
In most cases, ER probes are used as the
primary corrosion rate monitoring technique to
demonstrate the effectiveness ofthe inhibitor by
observing the change in metal loss trend before
and after application.
Generally, multiple ER probes are installed and
uniformly distributed to cover the tank bottom
plate area. They are usually installed away from
the inhibitor injection point to confirm inhibitor
diffusion and evaluate the overall effectiveness of
VpCI material.
Metal loss measurements using ER probes
are usually acquired over a two to three month
period prior to the introduction of the vapor phase
corrosion inhibitors and for several months to
many years after the inhibitor injection. There
are different methods of interpreting ER data and
generally a linear trend or moving point average
method is used to check the performance of the
inhibitor. Figure 4 shows the typical trendof metal
loss of an ER probe for the inhibitor pre-injection
and post-injection period obtained from a field
installed probe. Such trend of metal loss also
determines the timing of reinjection of inhibitors if
the reduction of its efficiency is observed.
Cylindrical element ER probe with its slim profile
is convenient for locations with restricted access
such as AST soil-side bottom plate structures and
other infrastructure applications. Such probes
provide good sealing of the reference element
and the check element provides confidence
in the continued performance of the corrosion
sensor. Cylindrical probe may be connected
to a cathodically protected structure using the
attached grounding lead. This allows the probe
to measure the effectiveness of the Cathodic
Protection System under operating conditions.
If left unconnected from the structure, the probe
monitors the direct corrosivity of the soil or
environment.
SYSTEM MAINTENANCE
A significant advantage associated with this
type of corrosion mitigation system is reduced
maintenance costs. There are no ongoing
maintenance requirements, other than collecting
the corrosion monitoring system data on a
predetermined schedule. There are no power
costs, no wiring to repair and no equipment to
maintain. If the corrosion rates increase sometime
in the future to higher than desired levels, the
inhibitor can be replenished.
CONCLUSIONS
When steel is exposed to properly designed and
applied vapor phase corrosion inhibitor system,
soil-side corrosion on tank bottoms is reliably
mitigated. This has been proven in a wide variety
of applications for many years throughout the
world. Application of vapor phase corrosion
inhibitor, combined with real-time corrosion rate
monitoring, provides AST owner/operators with an
effective and economical solution to the challenge
of soil-side corrosion mitigation of ASTs.
Figure 2
Typical ER probe installation thorough concrete ring wall
in a single bottom tank setting on sweet sand pad
Figure 4: Typical metal loss trend observed from ER data for pre-injection and post-injection period
Figure 3: Typical ER probe installation with grout removed above probe location2
References
1. Xianming (Andy) Yu, Saudi Arabian Oil Company
“Evaluation of the Tank Bottom Corrosion and CP
Effectiveness at a Saudi Aramco Crude Oil Tank
Farm”, Paper 10043, 13th Middle East Corrosion
Conference and Exhibition
2. Tim Whited, Cortec Corporation; Xianming (Andy)
Yu and Robin Tems, Saudi Aramco “Mitigating Soil-
Side Corrosion on Crude Oil Tank Bottoms Using
Volatile Corrosion Inhibitors”, Paper 2242, NACE 2013

SEPTEMBER
IADC Asset Integrity &
Reliability Conference
& Exhibition
16-17 September 2015
Norris Conference Center – CityCentre,
Houston, Texas, USA
http://www.iadc.org/event/2015-iadc-
asset-integrity-reliability-conference-
exhibition
10th Annual Asset Integrity
Management Aberdeen 2015
29-30 September, 2015
Ardoe House, Aberdeen, Scotland, United
Kingdom
http://www.aimaberdeen.com
OCTOBER
3rd Annual Subsea Integrity
Conference 2015
5-6 October 2015
Doubletree Greenway Plaza Hotel,
Houston TX
http://www.upstreamintel.com/subsea-
integrity
FPSO Asset Integrity
Management and Life
Extension Forum
15th - 16th October 2015
Crowne Plaza Hotel – Heathrow, London,
United Kingdom
http://www.bis-grp.com/portfolio/
conferences/oil-and-gas/fpso-asset-
integrity-management-and-life-extension-
forum
Asset Integrity and Process
Safety World
27-28 October 2015
Hilton Hotel, Doha, Qatar
http://energy.fleminggulf.com/asset-
integrity-process-safety-world
NOVEMBER
4th Structural Integrity
Management Conference,
North Sea 2015
10-11 November 2015
Aberdeen Ardoe House Hotel, United
Kingdom
http://www.upstreamintel.com/structural-
integrity
23-24 November 2015
DusitThani Lakeview Cairo, Cairo, Egypt
http://www.assetintegrityna.com
DECEMBER
Summit Asia 2015
01-03 December, 2015
Amara Sanctuary Resort Sentosa,
Singapore
http://www.assetintegritysummit.com
FEBRUARY
2nd International Conference & Exhibition on Pipeline Integrity
Management (ICEPIM 2016)
5-6 February 2016
Hotel Grand, New Delhi, India
www.pipelineintegritymanagement.in
Asset Integrity
Conferences
& Exhibitions on
2 01 5
2 016

Petrofac awarded US$780
million project in Kuwait
(Source: Petrofac)
The international oil and gas service provider
Petrofac, has been awardedKuwait Oil Company’s
(KOC) manifold group trunk line (MGT) project
in the north of Kuwait.The EPC project, valued at
approx. US$780 million, is crucial to KOC’s plans
to increase and maintain crude production over
the next five years. Three new gathering centers
(GC), which form part of the broader project, are
under construction with Petrofac executing the
EPC contract for GC 29.To be completed towards
the end of 2017, the MGT system will provide
the feedstock to each of the Gathering Centers
via three independent networks of intermediate
manifolds and pipelines. Each of the three GCs will
be capable of producing around 100,000 bpd of
oil together with associated water and gas.
British Gas announces first oil
from Mukta-B offshore platform
(Source: BG Group)
British Gas India achieved first oil production
from itsMukta-B, a 4 legged Wellhead Unmanned
Platform in the offshore Bombay basin, on 1 July.
British Gas has a 30% interest in the Panna-Mukta
oil and gas fields alongside their partners, ONGC
and Reliance Industries.
The MB and MA pipelines have been successfully
completed as part of the project, enabling a restart
of production from the MA platform, which had
been shut-in due to pipeline integrity issues for
the last 2.5 years.
The project clocked more than 2 million ‘LTI free’
man-hours and has several firsts to its credit,
including the use of green technology involving
hybrid solar panels and wind turbines for self
sufficient power, remote monitoring facilities for
process optimization and VOIP protocol for better
communication.
Oil-Pipeline Explosion in
Nigeria Kills 12, Injures 3
(Source: Bloomerg + NewBase)
In a tragic accident, twelve people died and
three were injured in an explosion during repair
work at an Eni SpA crude oil pipeline in Nigeria.
The victims were part of a maintenance team
for a local service company, Rome-based Eni
said in a statement Friday. The Tebidaba-Clough
Creek pipeline in the Niger delta was previously
“damaged by acts of sabotage.” The company
said it is still investigating the cause of Thursday’s
blast.
Eni had 13 incidents related to pipelines and oil
wells in Nigeria in May including equipment
failure, theft and pipelines being cut using a
Industry News Compiled By:
Chanchal Dasgupta
hacksaw, according to the company’s website.
Seventeen were reported in April and 14 in March.
Hundreds have been killed in Nigerian pipeline
accidents in the past decade. An explosion at a
vandalized oil pipeline in Lagos, Nigeria’s largest
city, started a fire that killed at least 200 people
and burned many more in December 2006. In
May that year, about 200 people were killed when
another oil pipeline exploded near Lagos.
Nigeria, Africa’s biggest oil producer, loses an
estimated 300,000 barrels a day to criminal
gangs that tap crude from pipelines that crisscross
the southern, oil-rich delta for local refining or sale
to tankers waiting offshore, according to state-
owned Nigerian National Petroleum Corp.
ORPIC installs Oman’s first
hydrocracker
(Written by Oman Observer)
Oman Refineries and Petroleum Industries
Company (ORPIC), the Sultanate’s refining
and petrochemicals major, has completed the
installation of a giant hydrocracker reactor — the
first of its kind in Oman — as part of the Sohar
Refinery Improvement Project (SRIP).
This will enable ORPIC to meet increasing demand
of petroleum products in the Sultanate, as wellas
reducing refinery emissions and improving
refinery margins. The hydrocracker unit will result
inincreased distillates production complying with
Euro V specifications.
The Sohar Refinery Improvement Project (SRIP) is
scheduled for commissioning in 2016. It is being
delivered in response to the need to upgrade
ORPIC’s refining capability in order to further
maximize the value of Omani crude oil, and to
ensure that the Sultanate’s increasing demand for
fuel will be met.
When SRIP comes on stream, current production
of fuels, naphtha and propylene will be raised by
70 per cent. From a fuels perspective, this increase
will meet the needs of continually growing fuel
consumption in the country, which has increased
by 10 per cent annually over the past 5 years.
BPCL petrochemical
(Source: IHS Chemweek, Jul 2015)
BPCL petrochemical moved aheadwith its
proposed petrochemical project adjacent to
the BPCL refinery at Kochi in Kerala. BPCL is
expanding refining capacity at Kochi and, as
part of those plans, establishing a fluid catalytic
cracker that will produce 500KTA of propylene for
the proposed petrochemical complex to consume
as feedstock.
Mangalore Refinery and Petrochemicals Ltd
(MRPL)(Source: ICIS News, Jun 2015)
Mangalore Refinery and Petrochemicals Ltd
(MRPL)started commercial production at its new
440kta Polypropylene plant in June 2015. The
plant will get fresh supply of feedstock propylene
from MRPL’s upstream petrochemical fluidized
catalytic cracking unit (PFCCU).
SK Global Chemical
sellingNexlene
(Source: IHS Chemweek, Jun 2015)
SK Global Chemical is to sell Nexlene, its premium
PE business to its joint venture (JV) with SabicSK
Nexlene Co. (Singapore). The JV will be the owner
of the technology as well as the 230kta Nexlene
PE plant at Ulsan, South Korea.
Disclaimer: Please note, the above information’s and news were collected from
various sources and the author or the publisher extends no liabilities for the
accuracy or completeness of the information provided here.

F o r d e t a i l s p l e a s e c o n t a c t
i n f o @ m c i t e c h n o l o g y . o r g
Training Program on
“Pipeline Integrity & Corrosion Management-
Maintaining Safe & Reliable Pipelines”
Organizing
Supported by
Dr G. H. Thanki
Dr. G. H. Thanki a highly renowned Corrosion Expert in the Chemical & Process
Industry with more than 40years of hands-on experience in Corrosion Control
Management, Corrosion survey and corrosion audit, Corrosion Integrity
Management, Corrosion testing and Monitoring, Cathodic Protection,Plant Corrosion
Inspection and Failure Analysis.
Program Overview
- Corrosion Control for Buried Pipelines, Pipeline Integrity
Management techniques
- Corrosion Survey & Inspection
- Cathodic Protection, CP survey, DCVG, CIPL
- Protective Coatings & tapes, Coating Survey
- Pipeline corrosion monitoring, Intelligent pigging, Direct
assessment
- Internal & external corrosion, deep water conditions, offshore
environment
- Estimation of corrosion, corrosion rate models, Pitting Rates,
Bacteria, Multiphase corrosion.
- Under Insulation Corrosion of Pipelines
- Internal Corrosion Control in Multiphase Oil and Gas
Pipelines
- ‘worst case’ corrosion, corrosion with protective film, bottom
of the line corrosion, top of the line corrosion
- Inhibitors, distribution along the pipeline, hydrate preventers,
reduce water wetting, CO2 pressure.
- Pipeline material selection & CRAs, cost comparisons
- Corrosion at Pipe Supports- Causes and Solutions
- Case Studies & Trouble Shooting
4-5 December 2015
Hotel Jaypee Vasant Continental, New Delhi

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