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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
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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
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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
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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»
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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.
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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
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Geography information system
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Transit pipeline trace Pump station Air crossing
MAP of Ukraine
Image of ammonia pipeline “Togliatti – Odessa” in the ES “InfoPipeMaster”
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Calculation model for pumping station PS-13 of transit ammonia pipeline
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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)
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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:
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Transversal earth movement 7 m
Longitudinal coordinate, m
Pipe position
Earthmovement, m
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Transversal earth
movement, 7 m
Fitted pipeline geometry
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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
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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
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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
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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
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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
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Building of the see bottom pipeline with a ship
X
Y
R=228 m
14о
LodgmentFree hang
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Risk matrix for transit gas pipeline “Ivankov – Chernobyl” ø 325 mm
Category of failure probability
Category of consequences