1. Second Hungarian-Ukrainian Joint Conference on Safety, Reliability and Risk of Engineering Plants and Components, Kiev, 19-21 September 2007 Second Hungarian-Ukrainian Joint Conference on Safety, Reliability and Risk of Engineering Plants and Components, Kiev, 19-21 September 2007 The experience on safety, reliability and risks assessment of some Ukrainian, Russian and Latvian transit pipe lines A. Krasowsky A. Krasowsky G.S. Pisarenko Institute for Problems of Strength, National Academy of Sciences of Ukraine G.S. Pisarenko Institute for Problems of Strength, National Academy of Sciences of Ukraine

2. Lecture content 1. Introduction 2. Expert system for pipeline management 3. Databases 4. Geography information system 5. Large displacements of buried transit pipelines 6. Risks assessment 7. Conclusions

3. Expert System (ES) «InfoPipeMaster» 1.Collection and care of all information about pipeline: 2. Stress and strain fields calculations : Static 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 loadings Flaws assessment

4. 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»

5. Main components of ES Information - search component (ISC); Information - search component (ISC); Geography information system (GIS); Geography information system (GIS); Automatic system for current documents; Automatic system for current documents; Integration module for remote-control and remote- management; Integration module for remote-control and remote- management; Expert modules for strength, reliability, remaining life and risk assessment; Expert modules for strength, reliability, remaining life and risk assessment; Component for actualization of data bases distributed territorially; Component for actualization of data bases distributed territorially; Protection system and distribution of allowed information. Protection system and distribution of allowed information.

6. Diagnostic Initial data analysis Initial risk assessment Risk minimization plan Inspections and mitigations Feedback program Revision of basic plane Risks revision Integration of data Managemen t Scheme for pipeline integrity and risk assessment

7. Geography information system

8. Transit pipeline tracePump stationAir crossing MAP of Ukraine Image of ammonia pipeline “Togliatti – Odessa” in the ES “InfoPipeMaster”

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

10. Creation of DB “Loadings” for transit gas pipeline “Ivankov – Chernobyl” 2000 г.2001 г.2002 г. P, kg/cm 2 days Internal pressure variation in pipeline during 2000 – 2003 years

11. 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 Sharpy energy vs temperature, steel X46

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

13. Calculation module for the flaw risks assessment Some shape defects Some corrosion flaws Cracks Flaw condition Flaw repair assessment 1.0 1.1/k 1.0 Д УН Н БН Kr

14. Comparative analysis of two procedures of intelligent pigging. Transit gas pipeline “Dolina – Rossosh” ø1420 mm 2003 1996

15. Statistics of flaws recognized on the part «Dolina – Rossosh» by two diagnostic of transit gas pipeline «Braterstvo» ø 1420 мм 1996 year, flaw length, mm 1996 year, flaw depth, % 2003 year, flaw length, mm 2003 year, flaw depth, % а, % wall thickness l, mm p; F

16. Longitudinal coordinate, m Pressure, МPа Limited internal pressure for each defect (points) revealed during diagnostics of oil pipeline “Kremenchug - Kherson», ø720mm Pump station Internal pressure

17. Decision acceptance on the repair sequence KrKr 1.0 1/k 1.0 CF1 A F SrSr 1/k Т3Т3 Т2Т2 Т1Т1 Т0Т0 CF2 CF3

18. 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) k allowed = 0.875 < 1 Flaw is moderate Limited time of service or repair BGC/PS/P11 (British) a/t = 0.8/5.8 = 0.138 > 0.12 Flaw is moderate Repair by polishing ASME B31.8 (USA)   /  Т min = 0.71 > 0.2, а a/t = 0.8/5.8. = 0.138 > 0.1, Flaw is essential Replacement 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 essential Replacement of pipe. API 579 (USA)   /  = 149/0.88 = 169 > >  Т min /1.5 = 140 Flaw is essential Replacement of pipe

19. 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)

20. 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:

21. Transversal earth movement 7 m Longitudinal coordinate, m Pipe position Earth movement, m

80. Transversal earth movement, 7 m Fitted pipeline geometry

81. Longitudinal displacements of ammonia transit pipeline «Togliatty - Odessa» near observatory «Stepove 2» Measured earth marker displacement Ammonia pipeline longitudinal displacement Longitudinal co-ordinate, m Earth movement, m

82. Installation of new pipe ø720 mm into old one ø1020 mm at crossing of river Dnepr r. Dnepr file ring New pipe Old pipe elevator

83. 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 pipeNew pipe Plastic rings

84. Buckling of buried pipeline at excavation (software complex «PipeMovement») 20 m  T =30 o C 1 м м Transversal displacements at buckling, m Transversal displacements at buckling, m м Bending moment at buckling, Нm Pressure Delta T Displacement, m

85. Buckling of pipeline in water 3.4mF т =3680 Н/m F A = 415 Н/m Site of failed weight Pressure, MPaDelta T, 0 CDisplacement, m

86. Building of the see bottom pipeline with a ship X Y R=228 m 14 о Lodgment Free hang

87. Risk matrix for transit gas pipeline “Ivankov – Chernobyl” ø 325 mm Category of failure probability Category of consequences