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The experience on safety, reliability and risks assessment of some

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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
G.S. Pisarenko Institute for Problems of Strength,
National Academy of Sciences of Ukraine
Lecture content
1.
2.
3.
4.
5.
6.
7.
Introduction
Expert system for pipeline management
Databases
Geography information system
Large displacements of buried transit pipelines
Risks assessment
Conclusions
Expert System (ES) ?InfoPipeMaster?
1. Collection and care of all information about pipeline:
?
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.
2. Stress and strain fields calculations :
Static loadings
Dynamics loadings
Flaws assessment
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.
Data bases (DB) structure
DB ?Objects?
?Object
position?
?Geometry?
?Loadings?
?Calculation results?
? object type
? pressure
? displacements and angles
? object label
? dimensions
? temperature gradient
? forces and moments
? coordinates, GPS
attachment, digital
map
? schemes,
photos, drawings
? forces
? stresses and strains
? documents
? weight, etc.
? environment
DB ?Defects?
?Defect
position?
?Geometry?
?Loadings?
?Calculation results?
? defect type
? axial force
? Stress intensity factor
? defect label
? dimensions
? bending moments
? reference stress
? element number
? position
? pressure
? safety factor
? coordinates
? schematization
? corrosion rates
? risks
Main components of ES
?
?
?
?
?
?
?
Information - search component (ISC);
Geography information system (GIS);
Automatic system for current documents;
Integration module for remote-control and remotemanagement;
Expert modules for strength, reliability, remaining life
and risk assessment;
Component for actualization of data bases distributed
territorially;
Protection system and distribution of allowed
information.
Scheme for pipeline integrity and risk assessment
Diagnostic
Initial data analysis
Initial risk assessment
Risk minimization
plan
Inspections and
mitigations
Revision of
basic plane
Feedback
program
Risks
revision
Integration of data
Managemen
t
Geography information system
Image of ammonia pipeline ?Togliatti ? Odessa? in the ES ?InfoPipeMaster?
Transit pipeline trace
Pump station
Air crossing
MAP of
Ukraine
Calculation model for pumping station PS-13 of transit ammonia pipeline
Creation of DB ?Loadings? for transit gas pipeline ?Ivankov ? Chernobyl?
P, kg/cm2
60,0
2000 г.
50,0
2001 г.
2002 г.
40,0
30,0
20,0
10,0
0,0
0
365
730
1095
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
B в о зд ух
C аммиак
F в о зд ух
E аммиак
H в о зд ух
I аммиак
5 0 ,0
4 9 ,5
X42
4 9 ,0
4 8 ,5
X 4 2 со ста р е н ы й
?
роб
, кГ/м м
2
4 8 ,0
KCU кгс*м/см2
35
архив.
состар.
25
4 7 ,5
4 7 ,0
15
Х46
4 6 ,5
5
4 6 ,0
-5
-60 -50 -40 -30 -20 -10
Т, 0С
4 5 ,5
4 5 ,0
4 4 ,5
4 4 ,0
10
3
10
4
N , ц и кл и
0
10
20
30
Рис.
Температурная зависимость ударной
вязкости образцов, вырезанных из труб сталей
Х46.
Sharpy energy vs temperature, steel X46
Degradation of pipeline steel 17GS after 35 years of service.
Transit oil pipeline ?720 mm, Latvian oil corridor.
( J / cm2 )
2250
2000
K
1500
1250
1000
750
?
0 .2
80
250
?
60
40
0
20
0
0
50
100
150
200
250
T em perature, T ( K )
As received
120
R M C = 1100 M P a
500
Charpy energy, CVN
160
1750
300
R eduction, ? (% )
S t r ess, ? (M P a )
S
80
Aged
40
0
150
TcAr
TcAg
200
250
Temperature, T ( K )
300
Calculation module for the flaw risks assessment
Flaw
condition
Some corrosion flaws
Some shape defects
Flaw repair
assessment
Kr
1.0
БН
Н
УН
Д
?T ?? B
2.2? B
Cracks
1.1/k
1.0
Comparative analysis of two procedures of
intelligent pigging. Transit gas pipeline ?Dolina ?
Rossosh? ?1420 mm
2003
1996
Statistics of flaws recognized on the part ?Dolina ? Rossosh? by
two diagnostic of transit gas pipeline ?Braterstvo? ? 1420 мм
p; F
p; F
а, % wall thickness
l, mm
1996 year, flaw length, mm
1996 year, flaw depth, %
p; F
p; F
l, mm
2003 year, flaw length, mm
а, % wall thickness
2003 year, flaw depth, %
Pressure, МPа
Limited internal pressure for each defect (points) revealed during
diagnostics of oil pipeline ?Kremenchug - Kherson?, ?720mm
Internal pressure
Pump station
Longitudinal coordinate, m
Decision acceptance on the repair sequence
Kr
1.0
?T ??B
F
2 . 2? B
CF1
1/k
CF2
CF3
A
Т3
Т2
1/k
Т1
Т0
? T ? ? B 1.0
2 . 2? B
Sr
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 moderate
Limited time of service
or repair
BGC/PS/P11
(British)
ASME B31.8
(USA)
a/t = 0.8/5.8 = 0.138 > 0.12
Flaw is moderate
Repair by polishing
??/?Тmin = 0.71 > 0.2,
Flaw is essential
Replacement of pipe
а a/t = 0.8/5.8. = 0.138 > 0.1,
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
a/t = 0.8/5.8 = 0.138 > 0.1
Flaw is essential
Replacement of pipe.
??/?
Flaw is essential
Replacement of pipe
(Canada)
API 579
= 149/0.88 = 169 >
>?Тmin /1.5
= 140
Categorization of flaws with respect to the safety factor
to prescribe the repair term (Latvian oil corridor, pipeline
?720mm, 33 years, comparison of Russian and R6 Codes)
Large displacements of buried
transit pipelines
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:
? Earth movements
- longitudinal
- transversal
? Pipe buckling
Earth
movement, m
Transversal earth
movement 7 m
Pipe position
Longitudinal coordinate, m
Transversal
earth
movement, 7 m
Fitted pipeline
geometry
Earth movement, m
Longitudinal displacements of ammonia transit pipeline
?Togliatty - Odessa? near observatory ?Stepove 2?
Measured earth marker displacement
Ammonia pipeline longitudinal displacement
Longitudinal co-ordinate, m
Installation of new pipe ?720 mm into old
one ?1020 mm at crossing of river Dnepr
r. Dnepr
elevator
Old pipe
file
ring
New pipe
Rings position optimization, crossing of river Dnepr by pipe ?720 мм
through the pipe ?1020 мм, oil pipeline ?Kremenchug ? Kherson?
Old pipe
New pipe
Plastic rings
Depth, m
Longitudinal co-ordinate, m
Buckling of buried pipeline at excavation
(software complex ?PipeMovement?)
?T =30oC
Transversal displacements
at buckling, m
1.4
1.2
1
0.8
1м
0.6
0.4
0.2
0
0
20 m
10
П ерепад
0
Delta
тем
п ератTуры , C
Displacement,
m
пер ем ещ ени е, м
1
В н ут ренн ее
Pressure
давлен ие,
Р, М П а
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
30
40
50
60
Bending moment at
buckling, Нm
130000
?
20
М аксим аль н ое
70
м
80000
30000
-20000 0
10
20
30
40
50
60
70
м
-70000
-120000
Buckling of pipeline in water
FA= 415 Н/m
3.4m
?
Fт=3680 Н/m
Site of failed weight
1
В н утр е н н е е д а в л е н и е ,
Pressure,
MPa
Р, М Па
0
П е р е п а д те м п ер а тур ы ,
Delta
0 T, 0C
C
0
М а к си м а л ьн о е
Displacement, m
п е р е м е щ ен и е , м
0 .0 0 4 0
2
5 .5
0
0 .0 0 4 2
3
5 .5
10
0 .0 0 4 4
4
5 .5
30
0 .0 0 5 4
5
5 .5
39
0 .0 0 8 9
6
5 .5
40
1 .2 7 1 9
Building of the see bottom pipeline with a ship
Y
Free hang
Lodgment
X
Risk matrix for transit gas pipeline ?Ivankov ?
Chernobyl? ? 325 mm
Category of failure probability
Category of consequences
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