In this post we will be looking at pipeline construction/ maintenance services, importance, challenges of pipeline maintenance and Tracking pipeline condition. Also some of the challenges that can arise during the pipeline construction process and what a project manager can do to overcome them. In Nigeria, before you start any pipeline construction and maintenance activities, you must obtain permit/ approval(s) from regulatory authory that is in charge.
INTRODUCTION
A pipeline is simply a system of pipes used to transport fluids or gases from one place to another. They can be used for all sorts of things, including carrying oil and gas, water, sewage, and even food products. Building a major oil and gas pipeline is among the most complex projects that any organization can undertake.
Read: Pipeline Construction/ Installation Services
It is filled with many different potential external bottlenecks that can cause delays, excessive costs, and various other problems. In order to keep a major pipeline construction project on schedule and under budget, you will have to plan ahead, adopt the right technology, and take advantage of assistance from the right kinds of partners, when necessary.
Read this post to learn more about some of the challenges that can arise during the pipeline construction process and what a project manager can do to overcome them. Pipelines are integral to industrial processes. They are the most cost-efficient method of transporting different types of fluids within a plant, as well as across different geographies.
PIPELINE MAINTENANCE PROCEDURES
According to the Pipeline Association for Public Awareness, government statistics show that “a common cause of pipeline incidents is improper or unauthorized digging near a pipeline.” Other major causes include “mechanical failure, human error, and corrosion. How can you ensure that you’re doing your part to prevent these kinds of incidents? With pipeline maintenance, of course. The following are pipeline maintenance procedures:
- Right-Of-Way Clearing: An important aspect of pipeline maintenance is right-of-way clearing. This is because a pipe needs a clear path of travel in order to operate the most efficiently and uninhibited. During right-of-way clearing, trees and roots are removed so that the land near pipes is free of the threats of these conditions. It’s also important that the right-of-way remains clear so that in the event of an emergency with your pipeline, it’s easily accessible for repair.
Read: Flowline, Pipeline & Riser Systems for Operations
- Hydrostatic Testing: To ensure the strength of the pipes in a pipeline, hydrostatic testing is recommended before and during their use. Hydrostatic testing is a procedure where the pipes you will use in your project are connected to one another. They are then filled with water at a higher rate of pressure than they will normally be. These high pressures help you see how well your pipeline will perform under heavy use. Besides doing this before pipes are put in the ground, hydrostatic testing is also used to measure the strength of pipelines over time.
- Identifying Corrosion: A way to help extend the life of your pipeline is by monitoring your pipes for any evidence of corrosion. Protecting your pipeline against corrosion begins long before your pipes are put in the ground. Depending on the material your pipes are made out of, you should ensure you’re using an anti-corrosive coating. But even then, you still can’t protect 100 percent against corrosion. This is because natural conditions and accidents create a threat to your pipes. For example, a leak, emergency or natural disaster can cause serious damage. This means you should monitor how these substances impact your pipes. One way to address corrosion concerns is to use “pigs”. These are devices used to identify corrosion. They also repair certain issues without losing production time.
- Maintain Complete Records: When it comes to maintaining your pipelines, you should keep accurate records. By doing this, you’ll give others a complete record of the life cycle of your pipeline. Besides keeping a database of site plans and pipeline product guides, you should also take lots of pictures. This helps when it comes to showing the condition of pipes at installation. It will also serve as an important baseline to determine how quickly your pipes are corroding.
Read: LPG Tank Construction & Installation
- Perform Regular Inspections: Regularly inspecting your pipeline is a great way to stay on top of maintenance issues that may arise. This means being proactive and using an experienced crew who knows what to look for and what to do based on their observations. If you’re not performing regular inspections, you put yourself at a greater risk for an emergency situation. This can be dangerous for your employees and costly to your business – especially if the situation causes your operation to be offline for an extended time.
- Retiring the Pipeline: Eventually, all pipelines need to be retired. This usually occurs when the pipeline has reached the end of its useful life or when it is no longer needed. Pipeline maintenance companies can help with this process, including decommissioning the pipeline and removing it from service.
- Corrosion Prevention: One of the biggest threats to pipelines is corrosion. This can be caused by a number of factors, including water, chemicals, and even the pipeline itself. That’s why it’s so important to take steps to prevent corrosion, such as using coatings and cathodic protection.
Proper ways to handle pipeline maintenance
Best practices for pipeline maintenance are the tried and tested techniques formalized over years of pipeline operations. Some are unique for pipelines, while others are the result of standard asset maintenance practices and the ability to see the big picture.
Read: NCEC Certificate Registration
- Planning during the pipeline design phase: Pipelines should always be designed and built with future maintenance requirements in sight to ensure ease of maintenance and reduced long-term maintenance costs. Otherwise, performing regular maintenance can become a daunting and expensive task.
- Inspection and testing: The most basic agenda for pipeline maintenance is regular inspection and testing. A comprehensive system like a CMMS will help you schedule maintenance resources (labor, tools, parts) needed to execute regular inspections. Drones and robots can be employed for inspecting hard-to-reach and remote areas. Inspections are done manually if the pipelines are easily accessible. However, the inspection of underground pipelines will need to be preceded by a preventive maintenance dig. In addition to visual inspections, non-destructive tests like ultrasonic testing, eddy current testing, and leak testing can be used to check pipe integrity.
- Hydrostatic testing: Pipelines in operation should be able to withstand the pressure exerted by the fluid passing through them. In fact, for safety reasons, healthy pipelines should be able to withstand more than just their normal operating pressure. This is done by hydrostatic testing, which plays a crucial role in ensuring pipeline integrity. Hydrostatic testing uses water to exert above-standard pressure on the pipeline. The pipeline segment to be tested is temporarily removed from service by closing the valves at both ends. Here is a great explainer video for those that want to learn more about the process.
Read: How to Start Oil & Gas Business in Nigeria
IMPORTANCE OF PIPELINE MAINTENANCE
No matter what pipeline construction companies you might use, the fact is that pipeline maintenance is of critical importance. A failure to maintain your pipelines can lead to all sorts of disastrous consequences, including service disruptions, environmental damage, and even explosions. That’s why it’s so important to have a good pipeline construction company in place for maintenance. Pipeline maintenance is the process of inspecting, repairing, and cleaning pipelines to ensure they are in good working order. This is typically performed on a regular basis, depending on the pipeline’s location and the materials it is made from.
Prevent Service Disruption: One of the biggest dangers of not maintaining your pipeline is that it could lead to a service disruption. This could mean anything from a temporary interruption in service to a complete shutdown of the pipeline. Either way, it would be a major inconvenience for everyone involved.
Prevent Explosions: Another serious consequence of not maintaining your pipeline is that it could lead to an explosion. This is a very real danger, especially if the pipeline is carrying flammable materials.
Prevent Environmental Damage: Not only can pipelines cause service disruptions and explosions, but they can also cause environmental damage. This is why it’s so important to take steps to prevent corrosion and leaks.
Regular Maintenance Prevents Long-Term Issues: The biggest benefit of all these service points is they prevent long-term issues. Pipeline maintenance is an ongoing process, but it’s one that is well worth the investment. By taking care of your pipeline now, you can avoid major problems down the road. The same is true for pipe inspection and repair. If you don’t inspect and repair your pipeline on a regular basis, small problems can turn into big ones. But if you do inspect and repair your pipeline, you can avoid those bigger problems altogether.
Read: Central Gas Supply System Installation
PIPELINE MAINTENANCE CHALLENGES
- Pipeline maintenance comes with a few unique challenges you have to actively work through:
- Pipeline length: Pipelines can run for thousands of miles and across international borders. It is difficult to monitor and maintain such large infrastructure.
- Corrosion: Corrosion is probably a pipeline’s #1 health issue. As pipes can run above and below the ground, they are exposed to various elements. Fighting corrosion will be your top priority in pipeline maintenance.
- Fluids transported: Pipelines often house flammable or toxic fluids. Even when the pipeline is shut down for maintenance, there will be remnant fuel that can complicate the repair and maintenance processes. You have to exercise extreme care not to destabilize pipeline content during maintenance.
- Jurisdiction: When pipelines pass through different jurisdictions, you end up in a situation where you have to adhere to different regulatory standards for the same pipeline. Additionally, pipelines that go through unstable geopolitical areas can further complicate the entire process.
Read: Gas Pipeline System Guideline
Tracking pipeline condition
The health of pipelines has to be constantly monitored. This detailed log serves as raw data for maintenance analytics. It also helps in maintaining an audit trail. Some of the key parameters to be recorded and tracked are:
- Fluid flow
- Pressure on pipeline walls
- Valve pressure
- Record of inspections
- Testing records
- Maintenance records
- Changes in depth cover
- Environmental conditions at different pipeline locations
Depending on the fluid that flows through the pipeline, there might be other parameters that need to be monitored. The amount of data to be collected is enormous, making it difficult to track using traditional methods. When possible, you should employ condition-monitoring sensors, non-destructive tests, and digital tools such as CMMS to stay on top of all of these variables. Having access to such data and technology will enable you to run condition-based maintenance and predictive maintenance, which will help you optimize your maintenance resources and cut long-term maintenance costs.