Transportation of hazardous material through transmission pipelines is strictly regulated. However, pipelines within the boundaries of a chemical plant are not regulated by the Department of Transportation. As part of a continuous improvement approach, one of the world’s top chemical producers decided to proactively evaluate areas of potential risk within their plants.
This producer places the utmost importance on preventing any Loss of Primary Containment (LOPC) incidents, as the environmental, financial, and reputational consequences of these incidents can be severe. To minimize the risk of LOPC incidents, they began a proactive initiative to inspect the condition of their buried in-plant pipelines, develop a risk prioritization methodology for anomalies identified during inspections, and take corrective action where necessary to ensure safe pipeline operation within their chemical plants.
Challenge
The producer’s in-plant pipelines were unpiggable, so collecting the condition data necessary for effective risk prioritization would need to be accomplished with above-ground surveys. The in-plant pipeline system had areas of high congestion with valves and abandoned pipelines in close proximity to other in-plant infrastructure. This made inspection more challenging and underscored the need for accurate surveys.
The producer engaged multiple vendors to complete above-ground surveys but found the data provided did not meet their requirements. Engaging separate vendors for each survey also caused concern over correlating the survey results to accurately prioritize risk areas.
Solution
The producer engaged PureHM, a Xylem brand to complete above-ground surveys on their buried in-plant pipelines. The producer decided to partner with PureHM after learning the capabilities of Spectrum XLI, an advanced above-ground survey platform. A unique feature of Spectrum XLI is its ability to complete up to 10 different surveys in a single pass of the pipeline. This capability eliminated concerns over accurately correlating data from numerous vendors to complete a precise risk prioritization.
PureHM used Spectrum XLI to perform above-ground inspection at five facilities in the US Gulf Coast region. The team surveyed approximately 85 lines, totaling more than 70,000 feet of pipe that ranged in diameter from 1 to 36 inches. For this project, the following surveys were completed:
- GPS Centerline Mapping
- Depth of Cover
- Alternating Current & Direct Current Pipe-to-Soil
- Cathodic Protection (CP CIPS)
- Alternating Current Voltage Gradient (ACVG)
- Direct Current Voltage Gradient (DCVG)
- Alternating Current-Current Attenuation (ACCA)
- Soil Corrosivity
PureHM analyzed and correlated the Spectrum XLI survey results with existing data from other vendors. PureHM worked collaboratively with the producer to interpret the data, prioritize anomalies identified within the pipeline systems, and inform threat mitigation efforts.
Outcome
Above-ground surveys of the producer’s in-plant pipelines provided a comprehensive overview of anomalies in their system. Prioritizing these anomalies enabled the producer to focus on remediating corrosion risks that would pose the greatest threat if left unaddressed. Effective risk prioritization helps pipeline operators develop an efficient remediation strategy that prevents costly and unnecessary excavations. By assessing their buried piping and evaluating the identified anomalies, the producer effectively lowered their risk and ensured that their piping is fit for continued operation.