Capt.S.K.Moorthy

Rehabilitation

How far is installation safe? Does need to initiate safety report(SCR)?

Does need to benchmark risk level with other or similar installation while doing business?

Is compensation moving high to settle score with neighbouring assets? or worker comp?

Is there a level of risk existing measured?

Is the risk being periodically reviewed & measures taken?

Is the residual risk appropriate to the proportion & CBA study?

All the more need is QRA enabling to sort out.

QRA for the line by E&P, classified it as HCA.Mole factor predicted 1000-3000ppm H2S by analysis. Moreover, class location 1,2 & 3 were using pipes more than 15 years old.No reliable data or drawing was available.Presumably, line was not maintained properly by the operator.Here, as a precaution to avoid fire, cold cutting machine is used with non-sparking tools.Continuous monitoring of gas was conducted.Totally depressurised line, after Purging thoroughly were cut.

Cold cut

Preparration for welding is a real safety concern.Good quality of weld & integrity assured by careful selection and use of electrode.To avoid Sulphur induced crack, hydrogen contented electrode were used.Storing & disposal were closely monitored.Bevelling of edge, cleaning the objects were given extra attention to avoid any inclusion during the process of welding.Energy required were strictly controlled to accomplish a nice weld.

Cut-out

Lifting

Mis-match,Hi-Lo of metal, Under-cut, Inclusion (slag,wagon track,hydrogen,sulphur,any such items),Poor lap ( over-lap / under lap),Poor fusion,Burnt off(poor electrode/poor selection of current)cause poor welding & makes metal integrity less than the original.Such things assure poor safety in pressurised vessel and leads to unexpected HCA(High consequence accident).Its para mount importance to ensure good weld for safety.

View Resume

Fitfor Service

Achieving weld gap required is a real task. Consumes more than an hour to align. Carefully balanced line was inserted and levelled to achieve 1/16"penny land.With much difficulty,after alignment, weld clamps fitted.Gas plugs on both the sides used.Also where the LEL was high, continuous purging carried out.

Spool replacement

Rehabilitating cross country pipeline posed diversifed problem. Mainly, dewatering bell-holes, marshy land, arid temperature, dearth for logistic support, drinking water & food, tracing pigs all day nights, nitrogen-gas fumes used for venting/purging, huge crane for lifting heavy 42, 34,30 inch valves, pipe spools etc.

5m Depth valve station.

Constriction of space, 3-5 meter depth covered pits, no clear access to heavy equipment, concentration of H2S, seated on concrete base valves, restricted hot works made maintenance of valve tedious.

Heavy Pneumatic valve Lifting

Lifting with Pullyblock

Servicing Valve

Non-routine maintenance of valve on as and when need basis, irregular excersizng of valves, cause wear & tear on unique place of the ball. Susequent to non-schedulled maintenance, valves warrant either replacing accessaries, that are obviously not available in the current market or replacing valve itself.Failing to do so, provides scope for leaks that ultimately leads to potential incident either to equipment or people.

Clients briefing

Clock spring trainer from USA,conducted workshop for Clients' key personnel; Demonstrated application methods and storage of materials;enabling them to learn key skills.

Surface preparation

Carried out, sieved by 40 size, sand blasting to get good profile for coating.Nozzle pressure and mixure of sand was adeptly applied to get NACE standard.Mind that blasting was on live line. Pressure inside and remaining wall thickness was calculated with GRI WRAP before blasting. Safety factor was calculated with MOP& MWP.If required , internal pressure was reduced.

Adhesive mixing

Intelligent pigging carried out 2 years before by actual application of coating.Now the crux is to decide remining wall thickness. Data-by-pig passed 2 years.Possible corrosion changed wall thickness.So need for direct assessment.Its a cumbersome job.Because the line is about 200-300 kms.Moreover , there was restriction on mechanical excavation.

Fillar mixing

Filler gives 100% compressive strength of a metal.For dent repairing single wrap applied to hold filler. After curing, clockspring applied.

Direct assessment

Not only did H2S present at higher level. Also the phyrophoric scales added another dimension especially while pigging. Traps had heavy amount of phyrophoric scales.At places, it was found leak at Kicker valves giving room for Gas in the launching vessel.

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