ภาคผนวก ข.3 Maintenance Strategy-Bulklines

Transcription

1 บร ษ ท ปตท.สผ. สยาม จ าก ด รายงานผลการปฏ บ ต ตามมาตรการป องก นและแก ไขผลกระทบส งแวดล อม และมาตรการต ดตามตรวจสอบผลกระทบส งแวดล อม โครงการผล ตป โตรเล ยมแหล งปร อกระเท ยม ระยะท 2 และพ นท ใกล เค ยง แปลงเอส 1 จ งหว ดก าแพงเพชร พ จ ตร และพ ษณ โลก ของบร ษ ท ปตท.สผ.สยาม จ าก ด ฉบ บเด อนมกราคม - ม ถ นายน พ.ศ.2562 ภาคผนวก ข.3 Maintenance Strategy-Bulklines

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3 S1.SMNT.MS.M.06 Greater S1 Assets: Bulklines Document Owner: Document Custodian: DSF/M DSF/M Revision REVISION HISTORY Description 1 New issue Issued after company ownership change Issued Date 25/03/08 Next Review 2 Change document No. A72 to SMNT 28/08/09 3 (1) Reformatted from SMNT-MS-M-06: BULKLINES 18/10/10 18/10/13 (2) Aligned with new PTTEP SSHE MS, ISO14001:2004 and OHSAS18001:2007 requirement. (3) Updated Organizational Indicators from JGO to DSO. 4 Update inspection strategy 18/10/ /10/2016 Rev.04, 18 October 2013 UNCONTROLLED when printed and without valid stamp. Latest version is available on Intranet: MS-M-06%20Bulklines.pdf i

4 S1.SMNT.MS.M.06 Greater S1 Assets: Bulklines COVERAGE This generic maintenance strategy is written to cover inspection methodology of all the bulklines within PTTEP Siam Limited. The term bulkline is defined as pipeline transferred multiphase crude, gas and produced water from well sites to Central Production Station or from well sites to another well sites. The bulklines consist of crude production pipelines (crude, gas and water), water injection pipelines (produced water), main gas lift pipelines (high-pressure gas) and gas production pipelines (wet gas). Equipment covered with this strategy is defined with Equipment Number PL in PTTEP Computerized Maintenance Management System (SAP). OBJECTIVES The objectives of the maintenance strategy are: To demonstrate and maintain the technical integrity of (safety critical) assets. To fulfil maintenance activities in the most business-efficient manner by effective and efficient deployment and use of resources. To improve asset reliability, availability and performance and optimise maintenance efforts such that company targets in terms of product quantity, quality and unit maintenance cost can be met. To have in place and operate an auditable system of asset performance and maintenance controls. To comply with all applicable legislation and company HSE policies. To provide inspection methodology and guideline to inspect and maintain the technical integrity of NTM-A gas pipelines. To provide pipeline defect assessment guideline to verify their fitness for services and continuous operation. REFERENCES S1.SMNT.PH.00, PTTEP S1 Maintenance Philosophy COR GS 001 External anticorrosion coating for pipelines COR GS 002 Field joint coating for pipelines COR GS 022: Design and installation of external cathodic protection of buried pipeline. NACE SP , Control of External Corrosion on Underground or Submerged Metallic Piping Systems. ANSI/NACE SP /ISO (MOD), Petroleum and natural gas industries - Cathodic protection of pipeline transportation systems SP , Field Application of Bonded Tape Coatings for External Repair, Rehabilitation, and Weld Joints on Buried Metal Pipelines Rev.04, 18 October 2013 UNCONTROLLED when printed and without valid stamp. Latest version is available on Intranet: 1 MS-M-06%20Bulklines.pdf

5 S1.SMNT.MS.M.06 Greater S1 Assets: Bulklines TM , Measurement Techniques Related to Criteria for Cathodic Protection on Underground or Submerged Metallic Piping Systems ASME B31G Manual to Determining the Remaining Strength of Corroded Pipelines ASME B31.4 Pipeline Transportation System for Liquid Hydrocarbon and Other Liquids ASME B31.8 Gas Transmission and Distribution Piping System. API 579-1/ASME FSS-1 Fitness for Services API 579-2/ASME FSS-2 Fitness for Services Example Manual API 571 Damage mechanism affecting fixed equipment in refinery industry Pipeline defect assessment manual (PDAM). API 570 Piping inspection code, In-service inspection, rating, repair and alteration of piping system. API 651 Cathodic protection of aboveground storage tank STRATEGY In the end of year 2013, there are total 229 bulklines with approximately 506 km in total lengths. The pipelines are not internally coated and passed through block culverts and road crossings. The pipeline section under block culverts and road crossing are externally coated to prevent external corrosion. Some sections of pipelines are laid underground with external coating protection. These pipelines are subject to both internal and external corrosion threats. The water cut in produced oil (currently at 50% average) tends to increase by an introduction of water flooding system also results in an increasing of corrosion rate. The main inspection methodology will be based on MFL external scanning and ultrasonic thickness measurement (UTM) since external surface of those pipelines can be accessible. Some additional inspection methods are implemented to improve inspection effectiveness and coverage in order to ensure integrity and health of all bulklines. CORROSION THREATS: Internal corrosion CO2 corrosion Carbon dioxide (CO2) corrosion results when CO2 dissolves in water to form carbonic acid (H2CO3). The acid may lower the ph and sufficient quantities may promote general corrosion and/or pitting corrosion of carbon steel. Rev.04, 18 October 2013 UNCONTROLLED when printed and without valid stamp. Latest version is available on Intranet: 2 MS-M-06%20Bulklines.pdf

6 S1.SMNT.MS.M.06 Greater S1 Assets: Bulklines Microbiologically Induced Corrosion (MIC) A form of corrosion caused by living organisms such as bacteria, algae or fungi. It is often associated with the presence of tubercles or slimy organic substances. Erosion/Erosion-Corrosion Erosion is the accelerated mechanical removal of surface material as a result of relative movement between, or impact from solids, liquids, vapor or any combination thereof. Erosion-corrosion is a description for the damage that occurs when corrosion contributes to erosion by removing protective films or scales, or by exposing the metal surface to further corrosion under the combined action of erosion and corrosion. Sulfide stress corrosion cracking (SSC) Sulfide Stress Cracking (SSC) is defined as cracking of metal under the combined action of tensile stress and corrosion in the presence of water and H2S. SSC is a form of hydrogen stress cracking resulting from absorption of atomic hydrogen that is produced by the sulfide corrosion process on the metal surface. External corrosion Soil corrosion The deterioration of metals exposed to soils is referred to as soil corrosion. The severity of soil corrosion is determined by many factors including operating temperature, moisture and oxygen availability, soil resistivity (soil condition and characteristics), soil type (water drainage), and homogeneity (variation in soil type), cathodic protection, stray current drainage, coating type, age, and condition. Atmospheric corrosion A form of corrosion that occurs from moisture associated with atmospheric conditions. Marine environments and moist polluted industrial environments with airborne contaminants are most severe. Dry rural environments cause very little corrosion. Other treats External interference by third party activities (i.e. puncture, gouge and dent) Sabotage and pilferage Natural hazard (land slide, flood, earth quake) Mechanical failure Construction and material defects Rev.04, 18 October 2013 UNCONTROLLED when printed and without valid stamp. Latest version is available on Intranet: 3 MS-M-06%20Bulklines.pdf

7 S1.SMNT.MS.M.06 Greater S1 Assets: Bulklines INSPECTION FREQUENCIES The inspection intervals of bulklines shall be established and maintained based on Risk Base Inspection (RBI) assessment including inspection history, corrosion rate and remaining life. Unless RBI assessment is carried out, the maximum inspection intervals (fixed intervals approach) and techniques of buried shall be conformed to the following recommended guidelines. Aboveground bulkline 3 months: General visual inspection and route survey. 1 or 1.25 or 1.5 or 2 years (based on corrosion rate and remaining life assessment results): MFL external scan and UTM inspection at 20% of aboveground sections. (100% inspection coverage of aboveground sections in 5 years), or 1 or 1.5 or 2 or 3 or 4 years (based on corrosion rate and remaining life assessment results): MFL external scan and UTM inspection at 100% of aboveground sections. 2 years: Close visual inspection (walk along pipeline visual inspection). 4 years: Under block culvert external coating inspection on selected location. Under block culvert MFL external scan and UTM inspection on selected location. Rev.04, 18 October 2013 UNCONTROLLED when printed and without valid stamp. Latest version is available on Intranet: 4 MS-M-06%20Bulklines.pdf

8 S1.SMNT.MS.M.06 Greater S1 Assets: Bulklines Underground bulkline 3 month: Instant-off pipe to soil potential survey. (For cathodic protection bulkline only). Above-grade visual surveillance. 3 years: Random excavation and coating removal. Ultrasonic thickness measurement (UTM) inspection. 5 years: Close Interval potential survey (CIPS) or DC voltage gradient survey (DCVG). ACCEPTANCE CRITERIA Instant-off pipe to soil potential survey After polarization, the instant-off pipe to soil potential of carbon steel buried pipelines shall be More negative than -850 mv/cu/cuso4 in aerated soil More negative than -950 mv/cu/cuso4 for in environment with possible development of sulphate reducing bacteria (de-aerated soil with confirmation of active bacteria presence). Note: The instant-off pipe to soil potential of pipeline shall not be more negative than mv to prevent coating disbonding. Defect assessment Assessment of corrosion defects shall be conformed to ASME B31G Manual to Determining the Remaining Strength of Corroded Pipelines or recognized international practices i.e. DNV-RP-F101 or RSTRENG. In Level 1 Evaluation, equation of original B31G, modified B31G and DNV-RP-F101 can be used to determine safe operating pressure of corroded pipelines. Rev.04, 18 October 2013 UNCONTROLLED when printed and without valid stamp. Latest version is available on Intranet: 5 MS-M-06%20Bulklines.pdf

9 S1.SMNT.MS.M.06 Greater S1 Assets: Bulklines Nevertheless, the recommended retirement thickness of pipelines due to corrosion defects (structural retirement thickness conservative approach) shall be conformed to the followings Pipeline nominal diameter (inch) Structural retirement thickness (mm) Assessment of gouge, dent, girth weld defects and crack shall be conformed to Pipeline defect assessment manual (PDAM). DOCUMETATIONS The following documents shall be maintained for Pipeline safety information (PSI) of Bulklines. All design documents. All as-built drawings. HAZOP study. RBI study. Pipeline inspection reports including cleaning pig reports. Cathodic protection survey reports, Close Interval potential survey (CIPS) or DC voltage gradient survey (DCVG) reports. Rev.04, 18 October 2013 UNCONTROLLED when printed and without valid stamp. Latest version is available on Intranet: 6 MS-M-06%20Bulklines.pdf

10 บร ษ ท ปตท.สผ. สยาม จ าก ด รายงานผลการปฏ บ ต ตามมาตรการป องก นและแก ไขผลกระทบส งแวดล อม และมาตรการต ดตามตรวจสอบผลกระทบส งแวดล อม โครงการผล ตป โตรเล ยมแหล งปร อกระเท ยม ระยะท 2 และพ นท ใกล เค ยง แปลงเอส 1 จ งหว ดก าแพงเพชร พ จ ตร และพ ษณ โลก ของบร ษ ท ปตท.สผ.สยาม จ าก ด ฉบ บเด อนมกราคม - ม ถ นายน พ.ศ.2562 ภาคผนวก ข.4 Flowlines and Well Gas Lift Lines

11 PTT Exploration and Production Public Company Limited PTTEP Procedure FLOWLINE AND WELL GAS LIFT LINE Document No: SMNT-MS-M-05 Revision No: 05

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14 FLOWLINE AND WELL GAS LIFT LINE SMNT-MS-M-05 TABLE OF CONTENTS 1.0 PURPOSE SCOPE REFERENCES DEFINITIONS ROLES AND RESPONSIBILITIES STRATEGY APPENDIX... 4 July 2016 Rev.5 UNCONTROLLED when printed, visit PTTEP Intranet for latest version TOC

15 FLOWLINE AND WELL GAS LIFT LINE SMNT-MS-M PURPOSE The objectives of the maintenance strategy are: To demonstrate and maintain the technical integrity of (safety critical) assets To fulfil maintenance activities in the most business-efficient manner by effective and efficient deployment and use of resources To improve asset reliability, availability and performance and optimise maintenance efforts such that company targets in terms of product quantity, quality and unit maintenance cost can be met To have in place and operate an auditable system of asset performance and maintenance controls To comply with all applicable legislation and company SSHE policies 2.0 SCOPE This generic maintenance strategy is written to cover well flowlines and well gas lift lines in perimeter of PTTEP Siam, S1 Asset. The term flowline is used to define line from wellhead to the first common manifold including the part of the manifold, which is directly connected to the well (i.e. the section after the choke valve). 3.0 REFERENCES 3.1 PTTEP CONTROLLING DOCUMENTS Document Number S1.SMNT.PH.00 EP Document Title PTTEP S1 Maintenance Philosophy Carbon Steel Pipeline Corrosion Engineering Manual 3.2 OTHER REFERENCE DOCUMENTS Document Number Document Title API 570 NACE Standard RP NACE Standard RP ASME B31.3 ASME B31.8 Piping Inspection Code High Voltage Electrical Inspection of Pipeline Coating Control of External Corrosion on Underground or Submerged Metallic Piping Systems Process Piping Gas Transmission and Distribution Piping System 4.0 DEFINITIONS Terminology Flowline Description B31.3 Process piping between wellhead to manifold July 2016 Rev.5 UNCONTROLLED when printed, visit PTTEP Intranet for latest version Page 1 of 7

16 FLOWLINE AND WELL GAS LIFT LINE SMNT-MS-M COMMON ACRONYMS Set out below are common specific terms presented in alphabetical order: SAP PI CI PTTEP Computerized Maintenance Management System Planned Inspection (Work Order Type) Corrective Inspection (Work Order Type) 5.0 ROLES AND RESPONSIBILITIES 5.1 OWNERSHIP OF THE DOCUMENT: PS1/M The owner of the document is Superintendent, Maintenance with responsibilities for: Issuing the FLOWLINE AND WELL GAS LIFT LINE INSPECTION Procedure and its revisions Ensuring effective implementation of the procedure 5.2 CUSTODIAN OF THE DOCUMENT: TA1 The custodian of the document is TA1, In-service Inspection and Corrosion with responsibilities for: Identifying deficiencies or potential improvements Initiating periodic revision Maintaining revision history and document status register 6.0 STRATEGY The need for the regular inspection of flowlines on PTTEP facilities to assure integrity in service is identified in PTTEP Maintenance Philosophy and also in Statutory Regulations. 6.1 FLOWLINE In PTTEP the wells are drilled from common well site locations and grouped in manifolds after a short distance from wellhead. A. INTERNAL CORROSION Currently the field operates with low carbon dioxide contents (approx. 1.5% mole) and minor amount of hydrogen sulphide. The water cut averages at 50% across the field with some wells producing up to 90% water. With the introduction of the water flooding of the reservoir the water cut will increase more rapidly than before. B. SAND EROSION Some wells are producing high volume of sand and sand erosion takes place at flow direction change location such as elbow, and tee junction. C. EXTERNAL CORROSION A large portion of the flowline is underground. That section is protected against external corrosion by protective wrapping. No cathodic protection is applied. In some well locations that section of the flowline is routed through open concrete trench and some have no protective coating, as such they are more vulnerable to external corrosion. July 2016 Rev.5 UNCONTROLLED when printed, visit PTTEP Intranet for latest version Page 2 of 7

17 FLOWLINE AND WELL GAS LIFT LINE SMNT-MS-M WELL GAS LIFT LINES A. EXTERNAL CORROSION Same as well flowlines B. INTERNAL CORROSION The lift gas is generally dry. However with the introduction of wet gas wells directly to the gas lift system there is an increasing risk of internal corrosion. 6.3 INSPECTION FREQUENCIES Since well fluid condition of each well is changed with hardly to notice and re-evaluate inspection frequencies on time. Therefore, thickness monitoring frequency of each flowline is 3 monthly as campaign basis on February, May, August and November. SAP shall regularly generated PI Work Order of each well site accordingly. Thickness monitoring location for each flowline and manifold shall be followed Appendix II using Ultrasonic Thickness Measurement to find minimum thickness of each location. In case possibility of high wall thickness loss due to well fluid condition changing such as high sand alert from lab sampling, CI Work Order shall be manually created in SAP for the concerned well to monitor thickness ASAP. July 2016 Rev.5 UNCONTROLLED when printed, visit PTTEP Intranet for latest version Page 3 of 7

18 FLOWLINE AND WELL GAS LIFT LINE SMNT-MS-M APPENDIX 7.1 APPENDIX I: CALCULATION OF MINIMUM ALLOWABLE PIPING WALL THICKNESS A. The Final retirement thickness for piping is based on the higher of two thicknesses: Pressure design thickness under internal pressure - Wall thickness required for pressure competency can be calculated with the following formula (as per ANSI B31.3) t = P * D / [2(SE+PY)] Where D= Nominal outside diameter of pipe, mm P= Operating pressure, barg S= Stress value at design temperature, MPa E= Quality factor Y= Coefficient t= Pressure Design thickness, mm Wall thickness required to cover other loading on the pipe, besides internal pressure, e.g. support loading, third party damage, vibration etc., which are very difficult to quantify, often called the "Structural retirement thickness" NPS (in) Recommended retirement Thickness (mm) B. Line standards A standard well flowline consist of the following sections: 3 - SCH 160 line pipe and elbows, material API 5L Grade B (Yield Strength 241 MPa), from X-mas tree until the choke valve 3 - SCH 80 line pipe and elbows, material API 5L Grade B, from choke valve to the manifold 1 - SCH 80 line pipe and elbows, material API 5L Grade B, drain line after choke valve Gas lift lines are 2 SCH 80 line pipe, material API 5L Grade B NPS (in) SCH OD (mm) WT (mm) July 2016 Rev.5 UNCONTROLLED when printed, visit PTTEP Intranet for latest version Page 4 of 7

19 FLOWLINE AND WELL GAS LIFT LINE SMNT-MS-M APPENDIX I: THICKNESS MONITORING LOCATION GUIDELINE Manifold Thickness Monitoring Location July 2016 Rev.5 UNCONTROLLED when printed, visit PTTEP Intranet for latest version Page 5 of 7

20 FLOWLINE AND WELL GAS LIFT LINE SMNT-MS-M-05 Crude Flowline Monitoring Location July 2016 Rev.5 UNCONTROLLED when printed, visit PTTEP Intranet for latest version Page 6 of 7

21 FLOWLINE AND WELL GAS LIFT LINE SMNT-MS-M-05 Water Flowline Monitoring Location July 2016 Rev.5 UNCONTROLLED when printed, visit PTTEP Intranet for latest version Page 7 of 7

22 บร ษ ท ปตท.สผ. สยาม จ าก ด รายงานผลการปฏ บ ต ตามมาตรการป องก นและแก ไขผลกระทบส งแวดล อม และมาตรการต ดตามตรวจสอบผลกระทบส งแวดล อม โครงการผล ตป โตรเล ยมแหล งปร อกระเท ยม ระยะท 2 และพ นท ใกล เค ยง แปลงเอส 1 จ งหว ดก าแพงเพชร พ จ ตร และพ ษณ โลก ของบร ษ ท ปตท.สผ.สยาม จ าก ด ฉบ บเด อนมกราคม - ม ถ นายน พ.ศ.2562 ภาคผนวก ข.5 Oil Spill Response Plan

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