1. GAIL (India) Limited
PIPELINE INTEGRITY & RELIABILITY 1

2. Adopting Best Practices to Ensure the Integrity of Pipelines
CONTENTS
Adopting Best Practices to Ensure the Integrity of
Pipelines
Devising an Efficient Asset Integrity Management
Programme in Organization
Instituting Effective
Pipeline
Replacement
Programme
Case study – Integrity Assessment of JLPL 2

3. PIPELINE INTEGRITY MANAGEMENT
Maintaining the pipeline in a safe, effective, efficient
and environmentally sustainable manner through
out their design life and extending beyond
PIPELINE INTEGRITY MANAGEMENT
Detailed Process of Threat Identification, Risk
analysis, Assessment Methods, Evaluation,
Remediation, Reassessment and Continuous
Improvement - To Achieve One Thing “PIPELINE
RELIABILITY THROUGH INTEGRITY” 3

4. PIPELINE INTEGRITY PLAN
THREATS TO
INTEGRITY AND
IMPACT
IDENTIFICATION
GATHERING, REVIEWING
AND INTEGRATING DATA
RISK ASSESSMENT
ALL THREAT
EVALUATED
YES
INTEGRITY
ASSESSMENT
RESPONSES TO INTEGRITY
ASSESSMENT & NO
MITIGATION 4

5. PIPELINE INTEGRITY MANAGEMENT
THREATS
1) Third Party damage
TIME INDEPENDENT
3) Incorrect operation
ASSESSMENT & MITIGATION
1) Monitoring of Flow,
Pressure & Temp.
2) APPS Software
3) Pipeline Patrolling
4) Generating Awareness
amongst General Public
1)Indirect Assessment
2) Natural calamity
Pigging
CPL/DGVG/CAT
2)Direct assessment
Pre-assessment
ECDA Indirect Assessment / Site Selection
Direct Assessment
Post Assessment
PIPELINE
INTEGRITY
PLAN
1) Internal Corrosion
External Corrosion
3) Stress Corrosion
Cracking
2)TIME DEPENDENT
ICDA
Corrosion Coupon
Coating Integrity
SCC Survey
1) Manufacturing Defects 1) Supervision & QC
2) Construction Defects
3) Equipment Defects
STABLE
2) Feed Back to Project for
Upcoming Projects 5

6. PIPELINE INTEGRITY PLAN MONITORING
Network
Patrolling CP
Monitoring
CAT
/ DCVG
/ CPL
Indirect
Assessment
ILI
Direct 1 √ 2 3 4 5 6 7 8 9 10 11
A.K.JANA, 6

7. STEPS TOWARDS P/L INTEGRITY MANAGEMENT
1. Project Planning
2. Design & Detailed Engg
3. QA/QC During Construction Stage
4. Commissioning
5. Efficient Operation & Maintenance 7

8. INTEGRITY To Establish Pipeline Integrity, GAIL has
ESTABLISHING PIPELINE
INTEGRITY
To Establish Pipeline Integrity, GAIL has
adopted two pronged practices 1)
Construction Practices -
Adopting
latest technology envisaging stable
threats and integrity assessment 2)
Operation and Maintenance Practices –
Assessment and mitigation of Time
Dependent and Independent Threat 8

9. GAS - O & M ACTIVITIES OPERATIONS SYSTEM DEVELOPMENT ACTIVITIES
POLICIES
STANDARDIZATION
BENCHMARK
SHARING
MODIFICATIONS
MOU
SAFETY
EXPERENCES
O&M
ACTIVITIES
P/L INTEGRITY
TECHNOLOGICAL
OBSOLESCENCE
O&M INVENTORY
PROJECT SURPLUS
M/C AVILABILITY
MAINTENANCE
CONSUMABLES
INVENTORY MGMT. 9

10. ESTABLISHING PIPELINE INTEGRITY
24X7 MONITORING THROUGH 10
REGINONAL GAS MANAGEMET
CENTRE AND MASTER
CONTROL CENTRES FOR
PRESSURE / TEMPERATURE /
FLOW PROFILE
ONLINE MONITORING OF PSP
READING
HEALTHINESS OF FIRE FIGHTING
EQUIPEMENT ENROUTE PIPELINE
AVAILABILITY OF POWER
SOURCES CCVT / TEG 10

11. ESTABLISHING PIPELINE INTEGRITY
PIPLINE PETROLLING TO
AVOID ENCROCHMENT /
THIRD PARTY EXCAVATION /
PHYSICAL DEVELOPMENT
Foot patrolling of high consequences
area daily
GAIL
Aerial patrolling of
all
pipelines
monthly
Survey of vulnerable locations like
rail / road / river crossing / above
ground installations 11

12. DATA MANAGEMENT Systematic Data Management through GIS
for Risk Assessment and Future Integrity
Plan
Construction Data
Operational Data
Patrolling Data
Integrity Assessment Data
Leak and Breakdown Data 12

13. PIPELINE REHABILITATION
GAIL CARRIES OUT 4 – PRONGED STRATEGY
DEFECT ASSESSMENT SURVEYS AND DATA
ANALYSIS
TEMPORARY CORRECTIVE MEASURES
REFURBISHMENT OF COATING / REPLACEMENT OF
PIPELINE SECTION AS PERMANENT MEASURE
ROOT CAUSE ANALYSIS AND PREVENTIVE
MEASURES
A PIPELINE POLICY FOR ALL THE ABOVE IS IN PLACE FOR WITH
PROCEDURES FOR UNIFORMITY ACROSS ALL SITES 13

14. GAIL has followed Two methodology for
REPLACEMENT METHODOLOGY
GAIL has followed Two methodology for
Replacement of defective pipe section as permanent
measure 1)
Off Line Replacement:
Isolating pipeline section
through sectionalizing valve
and evacuating the NG /
LPG.
2) On line Replacement: Hot
Tapping and Stoppling
Technique is used for
pipelines replacement. 14

15. PIPELINE REPLACEMENT PLAN
Prior to replacement of any pipeline, it is
established that the replacement becomes
essential for safety reasons or cheaper than
not replacing. 15

16. CRISIS MANAGEMENT PLAN
ON-SITE AS WELL AS OFF-SITE CRISIS MANAGEMENT
PLAN IS IN PLACE TO HANDLE ANY EMERGENCY
ARISING OUT OF THE FOLLOWING :
Pipeline Burst / Leak / Fire
Natural calamities viz. Flood, Earthquake etc.
Emergency caused by third party activity
Sabotage
Strike by employees 16

17. INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS
Activity
ANSI B31.8(NG) / ANSI
B31.4(LPG)
OISD138
OISD 226(NG) / OISD 214 (LPG)
GAIL 1
Pipeline
Patrolling
NG:Annual (Class
location &2)
Half yearly (Class
location )
Quarterly (Class
location) (Cl.851.2)
LPG:Patrols shall be
made at intervals not
exceeding two weeks,
except that piping
systems transporting
LPG or liquid ashydrous
ammonia shall be
patrolled at intervals not
exceeding week in
industrial, commercial, or
residential areas.
NG: As per
ANSI B31.8 Cl.
851.2
(Cl.4.0).
LPG: Weekly
(urban areas)
Monthly (other
areas)
NG: Fortnightly (class 3 & 4 )
Monthly (Class & )
Twice a year pre & post
monsoon by company
official)(Cl )
ForPNG
General Inspection: Daily (By
opearting personnel). Once a
month by Engineer in charge of
PNG Mktg.company .
LPG : Ground Patrolling of On-
shore LPG Cross Country
Pipelines shall be carried out
once in a week
Line Walk by the official of the
company at least once in a year
is required to be conducted
after the monsoon.
NG: For Twice
in a year
before & after
monsoon
once a month-
Air patrolling
LPG: Weekly
by security
guard for 3
weeks
Once in a
month by
helicopter
Twice in a year
(by company
official before
& after
monsoon) 2
ROW
Inspection
Annually
(Cl 5.0)
Quarterly (Road & Highway)
Water course crossings Twice in
a year (Pre & after monsoon)
(Cl )
NG & LPG:
Valve location
once in every
month in
vulnerable
location

18. INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS
S.No .
Activity
ANSI B31.8
OISD138
OISD 226(NG) / OISD
214 (LPG)
GAIL 3
Rail/ Road
Bridge &
suspended
crossing
Greater frequency than
pipelines in open
country
(Main Highways & Rail
road crossings)
(Cl.851.2)
Quarterly
(Cl.6.1)
NG & LPG: 4
Road &
Highway
Greater frequency than
pipelines in open
(Main Highways & Rail
road crossings)
(Cl.6.2)
Quarterly (Road &
Highway)
Water course
crossings Twice in a
year (Pre & after
monsoon)
(Cl )
NG & LPG: 5
Cleaning
Pigging
Annually (Wet Gas)
Once in two years
(Dry gas)
LPG pipeline (as per
OISD 214)
(Cl.7.1)
NG:Annual (for wet
gas)
Once in three years (for
dry gas)
(Cl )
LPG:Once in year
(Cl.15.4(i))
Preferably every
two years 6
Intelligent
pigging
Once in 10 years (Cl
7.2)
GAIL-DGM
NG:Once in 10 years
(Cl12.3.4)
LPG:Once in 10 years
(Cl15.4(ii))
Once in 10 years 18

19. INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS
S.N o.
Activity
ANSI B31.8
OISD138
OISD 226
GAIL 7
PSP Measurements
Frequency based
on various
parameters
(Cl )
Fortnightly at feeding
points (Cl.19.1.i)
Quarterly at other locations
(Cl.19.1.ii)
Fortnightly at
feeding points
(Cl a.i)
Quarterly at
other locations
(Cl a.ii)
Annual On -off
(Cl a.iii)
Continous at
through SCADA
Quartely at
(3 ON & 1 on-off
annually) 8
PEARSON/ CAT &
DCVG
Once in 5 years
(Cl 9.2.1)
(Cl12.3.6) 9
CPL survey
(Cl 9.2.2) 10
Insulating joint/
Coupling inspection
Annually
(Cl )
Once in a
quarter:
Alongwith PSP
monitoring 19

20. INTEGRITY PLAN IN GAIL BASED ON VARIOUS STANDARDS Once in a11
External
Overground piping
Anually Cl
Once in a
quarter 12
Soil testing
Mentioned-
Frequency not
defined
Once in 10
years 13
Inspection of pipes,
valves & fittings
As per OISD
130
(Cl )
NG : Half
yearly
LPG:
Quarterly 14
Internal corrossion
monitoring
Mention of Inhibitor
Injection system,
Corrossion
coupons,
Corrossion probes
exists but no
frequency defined.
(Cl )
Annual
(Corrossion
Coupon)
(Cl.10.i)
Quarterly (ERP)
(Cl.10.ii)
Once in two years
(UT)
(Cl.10.iii)
No specific
duration
except for I.P.
Half yearly:
coupon
Quarterly: ER
probe
Once in two
years: U.T
overground
piping 20

21. INTEGRITY ASSESSMENT OF JLPL – LPG P/L
A CASE STUDY
INTEGRITY ASSESSMENT OF
JLPL – LPG P/L 21

22. PIPELINE SPECIFICATION
Pipeline Network
Product Flowing in P/L
Pipeline Section
Pipeline Length
Pipeline Diameter :
Jamnagar Loni Pipeline
LPG
IPx to IPy
128.5 KM
16”; mm
Pipeline Wall Thickness :
7.1 mm; 8.7 mm 22

23. Cleaning pigging was performed in Jamnagar Loni Pipeline to
make pipeline internal clean and ready for intelligent pigging.
BR Pig
Gauge Pig
High Density Foam Pig
Magnetic Pig 23

24. GAUGE PIGGING Total Muck and black powder of around 150 Kg & 40
Kg respectively received
All the pigs received in good condition except Gauge
Pig.
Aluminum Gauge plate was
found deformed from 6 O’clock
and 3 O’ clock Position
Gauge plate inward bend
may be due to :
A. Improper Launching of pig
B. Debris inside P/L
C. Deformation in the P/L. 24

25. Cleaning pigging operation completed by launching of one
GAUGE PIGGING
Cleaning pigging operation completed by launching of one
run of each pig
Only 5 Kg of muck received during last pig run
To confirm deformation of P/L, 2 nos of 3C Gauge pigs
were launched sequentially
Both the Gauge pigs gauge plates found deformed in 6
O’clock position 25

26. CONCLUSION Pipeline must be considerably clean to run Intelligent pig
CLEANING PIGGING
Pipeline must be considerably clean to run
Intelligent pig
Caliper pigging is essential to locate and size
the deformation before intelligent pigging 26

27. CALIPER PIGGING DATA ANALYSIS
During preliminary interpretation of data, no
anomaly observed w.r.t. 5% reductions and
ovalities
Reductions & ovalities over 2% searched
Five indications noticed, Four were classified
as DENT and one as OVALITY 27

28. CALIPER PIGGING DATA ANALYSIS Distance meter Reduction Digit Remark mm%
Base
Arms
10717
9.7
2.4
2547
2303
Ovality
11.2
2.8
2695
2417
dent
9.1
2.2
2703
2475
15.4
3.8
2323
Dent
8.8
2483 28

29. CALIPER PIGGING DATA ANALYSIS Detail of defect Distance from
1.8 m to 2.28 m
Length 1.16 m
Width .21 m o
Roll 78 29

30. VERIFICATION OF DEFECT
Location was dig where a dent of 3.8% was observed
pipeline was
resting over
a huge stone
Rock was
drilled to
make small
holes and cut
off in pieces
by chisels and
hammers 30

31. VERIFICATION OF DEFECT
Pipeline Coating was removed to
examine the dent
No sharp dent observed. Pipe found
flatten near the dented portion
Pipeline thickness & PSP measured
at dent location. Thickness & CP
was found normal (7.3 mm & 1.36V)
Only slight change was observed
after release of stress
No clock Spring provided
Coating repaired and pit is filled
after proving the sand cover 31

32. CONCLUSION Dent affects the safe operation of pipeline as they
restrict the flow and tend to induce spot-like
formations of sediments, turbulence, erosion,
corrosion and hydrates
Localized stress shorten Pipeline’s service life
Timely integrity assessment insures Asset
integrity and avoid any Eventuality & Product
Loss 32

33. GAIL STRENGTH GAIL has Strong back up of Rich Experience in
entire Value Chain of Natural Gas business
RELIABILITY PROVEN OVER DECADES
with average Un-Interrupted Gas Delivery
days being more than % through trunk
pipeline network
ESTABLISHED TOTAL ASSET INTEGRITY
All the Assets are as Efficient and safe as, they
were new 33

34. Temporary
Repair
Cut-Out Repair 34

35. Repair of corroded section as per ANSI/ASME, B-31G
Sleeve repair of corrosion
pitting section using API
Sleeve repair of corroded
pipe section
approved composite material 35

36. • INCREASED WORKER SAFTEY
HOT TAPPING & STOPLING
• CONTINUOUS SYSTEM
OPERATION
• NO GAS RELEASE TO THE
ATMOSPHERE
• REDUCED PLANNING AND
COORDINATION COSTS
• INCREASED WORKER SAFTEY
HOT TAPPING 36

37. 37