Application of DVGW Technical Rules on Gas Transmission … · Application of DVGW Technical Rules on Gas Transmission in Practice Innogate | 10.4.2014 ... DVGW G 463 . Usage factor

Application of DVGW Technical Rules on Gas Transmission in Practice

Innogate | 10.4.2014 | Essen

Contents

OGE at a Glance, OGE Pipelines in Germany

Integrated Management System

Pipeline Design & Safety Philosophy

Pipeline Integrity Management System

Corrosion Control

Hydrostatic and Tightness Testing

Inline Inspection Techniques

Defect and Failure Investigation

Troubleshooting & Repair-Techniques

Conclusions

Pipeline Operation and Maintenance | 10.4.2014

2

Contents





Corrosion Control





Conclusions


3

Open Grid Europe at a Glance

Germanys leading Transmission System Operator

Founded in 2004 as E.ON Gastransport,

Change of name at 1.9.2010 to Open Grid Europe

Marketing and operation of the largest gas transmission grid in

Germany (approx. 12.000 km)

Customers: More than 450 national and international TSOs and

DSOs, municipal utilities, industry customers and gas retailers

Approx. 1.650 Employees

27 Compressor stations | 97 Compressor units

17 Entries | approx. 1.100 Exits

Annual exit quantity : Approx. 759 Mrd. kWh

4

Headquarter Kallenbergstr.

Subsidiary Altenessen


The Grid of Open Grid Europe

Approx. 12.000 km pipeline length

Border entries

Market unit transition points

Network connection points

Network coupling points

Two gas qualities

H-Gas (high calorific)

L-Gas (low calorific)

5 Pipeline Operation and Maintenance | 10.4.2014

Year of construction 1912 - 2013

Diameter 4“ - 48“

Wall thickness 4 - 19.4 mm

Internal Pressure 2 - 100 bar

Material Grade Grade B - Grade X80

(St 35 - GRS 550 TM)

Total Pipeline Length approx. 12,000 km

Mill coatings Bitumen, PE (1-, 2- and 3-layer), PUR, EP

Field coatings Petrolatum, Bitumen, PE - butyl-rubber tapes, PUR

Characteristics of OGE Pipeline Grid

6


Contents





Corrosion Control





Conclusions


7


8


Management

System

Standard ISO 9001 ISO 14001

OHSAS

18001

DVGW

G 1000

Integrated

Management

System

(HSEQ)

EN 16348

Year of

implementation 1996 - 2000 1997 2002 - 2003 2003 2003 2008

Scope Quality Environment Health &

Safety

Technical

Safety

Management

(TSM)

Quality

Environment

H&S

TSM

SMS / PIMS

Management System implemented by Open Grid Europe (PIMS, IMMeR PRMS)

Integrated Management System implemented by Open Grid Europe

and certified by independent external body

DVGW Code of Practice G 1000

Assessment of:

Technical organisation

Technical processes

Qualification and training

Compliance with gas-specific regulations and standards

Methods:

Only “do-principle”

No formal audit, answering of questionaries

Carried out by DVGW experts

Re-certification after 5 years

Not included/required:

Regular internal audits (Plan Do Check Act)

Management review

Intermediate audits by DVGW experts


9

Integrated Management System: Activities

Maintenance and continuous improvement of the

certified „technical safety management system“

according to DVGW Code of Practice G 1000

Maintenance and continuous improvement of the

certified integrated occupational safety,

environmental and quality management system

Coordinate and accompany the auditors in

connection with external audits

Planning, organisation and performance of

internal audits

Management and updating of management

system documents

Compilation of an annual quality report as one

part of the annual HSEQ report for the top

management

presumption of conformity with the

requirements of § 4 (3) GasHDrLtgV


10

Contents





Corrosion Control





Conclusions


11

Construction in 1992 In Service since 1994

Ideal Route of High Pressure Pipelines

12


Real Route of High Pressure Pipelines

13


Quality-Control at Construction

Steel melting Testing Final Inspection Test Certificate

Girth Welds Pipe laying Stress Test

Final Dokumentation

Pipeline Construction 14


DVGW G 463, 462

Survey by foot, car, helicopter

Inline Inspection Maintenance

Activities, Leaks

Corrosion Protection

Pipeline Operation

Quality-Control at Operations

15


DVGW G 466-1

Design of New Pipeline acc. to German Standards EN 1594, DVGW G463, EN 10208-2

Wall thickness determined by Barlow-Formula from:

MOP, Diameter, Material Grade, Design Factor

Requirements:

• Specified Minimum Wall thickness Tmin

• Specified Minimum Yield Strength Rt0.5

• High Quality Requirement on Production

• Well-known Geometrical Dimensions and Tolerances

Design of Pipelines in Germany Calculation of Wall thickness

Design

05,0t

minfR20

DxDPT

16


DVGW G 463

Usage factor – Coefficient of Safety (DVGW G 463)

grade Safety factor S

acc. to EN 1594 Usage factor f0

acc. to EN 1594

L245NB/MB 1.50 0.666

L290NB/MB

L360NB/MB 1.55 0.645

L415NB/MB

1.60 0.625 L450MB

L485MB

L555MB

Testing of Toughness @ 0°C

Design

TGL

W, 17

DVGW G 463

Operator Remarks

E.ON Ruhrgas depending grade

Fluxys depending grade

Swissgas no area classes

Gaz de France area classes

National Grid area classes

Snamretegas area classes

Gasunie area classes

SPP area classes1.39 - 2.28

1.38 - 2.50

1.39 - 3.33

1.39 - 2.00

1.39 - 2.50

Factor of

Safety

1.50 - 1.60

1.50 - 1.60

1.67

Safety factor acc. to EN:

1.39 = 1/0.72 , similar to

ANSI/ASME Code

Additional National Rules

18


DVGW G 463

OGE

Additional Loads at Construction

Tie in Field Bending

Slope Elastic bending

19


DVGW G 463

Contents





Corrosion Control





Conclusions


20

PIMS at Open Grid Europe – Governing Rules

Laws an Ordinances Energy law, GasHDrLtgV

Standards (DIN, EN) and Technical Rules (DVGW)

EN 1594, EN 16348, G463, G466-1

Internal standards and rules Structure of organisation, processes and

procedures, responsibilities, qualification of personell, … (e.g. RN 210-001)


21 GasHDrLtgV , DVGW G …


22

Integration of PIMS into other Management Systems

SMS 2) SMS 2) SMS 2)

1) Company Management System

2) Safety Management System

(for Gas transmission Infrastructure)

3) Integrity Management System

4) Pipeline Integrity Management

System

5) Environment Management System

6) Quality Management System

7) Occupational Health and Safety

Management System

Source: EN 16348

Modular structure allows later integration of other

integrity management system standards.

Overlaps with other management systems

already existing (e.g. DVGW G1000 / TSM)

TSM

EN 16348


23

PIMS at Open Grid Europe – Objective and Characteristics

Data- and Informational Integrity Organisational Integrity

Systematic, quality-controlled as-built

documentation

Access to all relevant data

High and increasing level of pipeline information

(e.g. integrity assessment reports) and pipeline

data

Integrity assessment based on standardized

methods and procedures

Standardized evaluation criteria and mitigation

measures

Quality-assured procedures based on specific

workflows

Optimisation of costs

Asset preservation/

Lifetime extension

Legal safety

Other objectives

Costs

Time

Objectives are reached by …

Technical safety

Asset availability

Asset performance

Main objective

Technical Pipeline

Integrity

EN 16348


24

Basics of Pipeline Integrity at Open Grid Europe

Desing & Construction Operation & Maintenance Verification of PL Integrity

Desing and construction are

carried out according to the

standards, technical rules

(DVGW) and company standards

valid at time of construction

Quality control during construction

(incl. Inline inspection)

Verification of CP effectiveness

according to DVGW GW10

Operation and Maintenance

according to DVGW-G 466-1.

CP monitoring according to

DVGW GW10 and G 466-1.

Docomentation in WinKKS.

Casings: AfK 1

AC corrosion: AfK11

High voltage protection: AfK 3

Significant changes are confirmed

by DVGW certified expert.

Repeated integrity assessment

considering DVGW G 466-1

(„Condition analysis“)

Control of necessary maintenance

measures

Pipeline Integrity Management

System (PIMS)

Check of completeness of

technical approval and

commissioning documentation

Documents

Application of DVGW Technical Rules on Gas Transmission … · Application of DVGW Technical Rules on Gas Transmission in Practice Innogate | 10.4.2014 ... DVGW G 463 . Usage factor