API 2012 Cybernetics Symposium

Phoenix, Arizona

Rupture Detection The 3 R’s

Larry Davied

Magellan Midstream Partners, L.P.

larry.davied@magellanlp.com

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Leak Detection – Liquid Pipelines

Keep People Safe And

Protect the Environment

• #1 Goal: Don’t Have Leaks • #2 Goal: Quickly Recognize and React to Actual and Suspected Release Events • #3 Goal: Minimize False Alarms

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Liquid Pipeline Systems SCADA Leak Detection

• Significant historic and ongoing efforts and focus from Regulators, Public, Operators, and Industry Consultants/Contractors

• Highly dedicated industry work groups focused on improvements, including development of Standards and Recommended Practices

• Significant historic and ongoing Research and Development and applied SCADA software, hardware, and pipeline instrumentation systems

• SCADA upgrades and enhancements frequently deployed • Post Incident scrutiny from Public, Regulators, Legislators,

and Operators

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Pipeline Monitoring DOT PHMSA Regulations

• CPM Leak Detection (195.134) – Design

• CPM Leak Detection (195.444) – Operations and Maintenance

• Pipeline Integrity Management (195.452) – Leak Detection for High Consequence Areas

• Control Room Management (195.446)

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Pipeline Monitoring API Recommended Practices

• API 1130 – Computational P/L Monitoring for Liquids

• API 1164 – SCADA Security

• API 1165 – SCADA Displays

• API 1167 – SCADA Alarm Management

• API 1168 – P/L Control Room Management

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Leak Detection and P/L Monitoring Liquid Operator R&D Sponsored Projects

• PL-1 Small Leak Detection for Liquid Pipelines • PL-1-1 Small Leak Detection in Liquid Pipelines –

External Leak Detection Evaluation and Development

• PL-1-2 New Look at Pipeline Variable Uncertainties and Their Effects on Leak Detection

• PL-1-3 Alternatives For Small Seeper Leak Detection During In-service Hydrotesting

• PL-2-1 Review and Develop Improved Technologies to Monitor Station / Facility Integrity at Unmanned Locations

• ROW-3 Conceptual Pipeline Integrity & Security Management [RAM Program]

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SCADA Operating Console

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…… And Yet ….. We still sometimes struggle with PROMPT:

• Recognition, • Response, and • Reporting

of Pipeline Ruptures. RUPTURE and LARGE VOLUME RELEASE events present the highest

immediate risks to Public Safety and to the Environmental. While valuing the significant efforts and results in the pursuit of quicker

detection of ever smaller releases, WE MUST BE GREAT IN “3R EXECUTION” for P/L Ruptures and Large Volume Release Events.

A focus on Pipeline Rupture Events is expected to have trickle down

positive impacts on Operator Response to large, medium, and small pipeline releases.

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Leak Detection Challenges

• While challenges exist, SCADA Systems are capable of detecting actual and suspected leaks, from large to small rate releases

• Equally important, SCADA Systems can detect when a pipeline segment is “behaving abnormally”

• Difficult, does not imply “Impossible”, although there are limits imposed by science, technology, and application

• One of the biggest challenges is accurately distinguishing between actual release events and false alarms.

• False alarms can effectively desensitize the SCADA Operator, with a potential over reliance upon analysis and hydraulic rationalization

(“I’ve seen this before, and it was caused by xxxx, so it’s probably just a false alarm – let’s just watch it and see if it happens again.”)

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• SCADA Operators are generally empowered to shut down pipelines

and equipment upon indication of a release.

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AOPL/API Leadership Leak Detection Initiatives

• August 2011 Formal Commitment to PHMSA for Operators to Improve Liquid P/L Safety

• 7 Prioritized Initiatives

• Leak Detection Improvement Initiative – Focus: P/L Ruptures and Large Volume Releases

– Elements: Prompt Recognition, Response, and Reporting (3 R’s)

–Goal: Be GREAT at 3R Execution • Recommended Leak Detection Evaluation on all

Liquid Transmission Pipelines (PHMSA ANPRM)

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3R Execution Challenges

• Strategic Shift (Large vs. Small Releases)

• Culture (React vs. Analyze)

• Applications (Distinguish Rupture from “all other events” and line imbalance signals)

• Training, Drills, and Simulations Focus

NOTE: 3R Execution is not dependent upon new technology or new SCADA Systems

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3R-1 Rupture Recognition • Premise: Every SCADA System can accurately detect a

pipeline rupture. • Sample Rupture Indicators (generally need 2 for

Rupture Detection Logic): – Large Sudden Drop in line pressure while pumps are still

running – Large Increase in Upstream Flow Rate with no line

configuration changes – Abnormally fast or slow tank volume change with no

configuration or pump status changes – Sudden unexplained Pump Speed or Control Valve Position

Increase – Sudden unexplained change in Motor Amps or Engine

Speed

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3R-1 Rupture Recognition Eliminate False Alarms

• Instantaneous Rupture Recognition is not Critical – Majority of Release Volume results from Pipeline

Draining and Field Level Response Time – not typically from pumping volume • Typical Field response to isolate release and to close manual

valves is 30 minutes to 3 hours • Pipeline draining through the Rupture can take several hours

due to line geography and Product Pressures • Containment Construction and Equipment Response can

typically require 4 to 12 hours.

• We have time to take a few minutes to minimize False Alarms caused by signal interruption, erroneous instant data readings, etc.

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3R-1 Rupture Recognition Scream

• Challenge: To Teach our SCADA Systems to SCREAM Pipeline Rupture

– Not your “standard” Code Red Level 1 Priority Alarm

– Goal is to maximize SCADA Operator Recognition of Pipeline Ruptures

– Get Creative!

• Fill the Screen – Turn on the Bells and Buzzers – Flash the Lights

• We get little value from being able to flawlessly analyze all the data and identify the rupture during a post event Incident Investigation

• What if you were the SCADA Operator?

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3R-1 Rupture Recognition “It’s Easy to See – Especially during the Post Incident Investigation.”

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3R-2 Rupture Response

Treat Suspected and Confirmed Ruptures the Same

• Shut Down Affected Line Segments

• Isolate Rupture Area – Close MOV’s

• Initiate Field Response

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3R-3 Rupture Reporting

Reporting Priorities

• Call Local 911 (May involve more than one Local Area)

• Notify Company Leadership – Use internal Emergency Incident Notification System

• Notify National Response Center (NRC) – Telephonic or Electronic

Tools:

• Interactive Internet Maps with pre-populated Emergency Contacts

• “Ready to Complete” NRC Electronic Reports

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3R Path Forward • AOPL/API Liquid Pipeline Leadership Commitment

• Alignment with API Cybernetics Workgroup

• Information sharing on how to “teach” SCADA Systems

to: SCREAM RUPTURE!

• Gather Input from Public, Emergency Responders, and Regulators on Pipeline Rupture Report – Consider variances for Confirmed Releases, Suspected

Releases, and False Alarms – Involvement of local 911 Groups and NRC

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3R Execution Initiative

We’re All in this Together

Performance Gaps associated with P/L Rupture and Large Volume Release Events are an

Industry Focus Liquid Pipeline Operators share a common goal

to SAFELY and RESPONSIBLY operate and maintain our assets

We Need and Welcome Your Input, Feedback, Ideas, and Participation!

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