Pipeline Safety for Colombia: FlexSILon PMC® FLOWorX RDS

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Pipeline Safety in 20 minutes

HIMA commitment to critical applications and their customers

Pipeline protection - Safety Concept FlexSILon® PMC

– FLOWorX Leak detection and pipeline management tool

– FLOWorX RDS – Liquid pipeline rupture detector

Presented by:

Robert Hulák

r.hulak@hima.com

For:

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HIMA commitment to critical applications

and their customers

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More than 25,000 systems installed, 103 years of history

Countries with group

companies and offices

Countries with experienced

representatives (agents)

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Customers

AFC

Agip

Air Liquide

Aventis

BASF

Bayer

Borealis

BP

Celanese

Chevron

Clariant

DOW

DSM

ENI

E.ON

Ecopetrol

ExxonMobil

Hoffmann-La Roche

HOLBORN

Huntsman

INEOS

KOC

LANXESS

LyondellBasell

MAN Turbo

Mauell

MERCK

MiRO

Momentive

Perfomance

Materials

OMV

PDO

Pemex

PETRONAS

QP

RWE

SABIC

Sanofi-Aventis

SASOL

Shell

Statoil

Thai Petrochemical

TOTAL

TIGF

UNICAL

Vinnolit

Yara

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HIMA in Pipelines

• Shell Connect project (Germany)

• Cepro (Czech rep.) – countrywide network over 1000 km.

Over 150 block valves (pipeline segments)

• Slovnaft (Slovakia) - Refinery-port pipeline

• Slovnaft (Slovakia) - 380 km multiproduct pipeline

• Marsori (Mexico)

• Botas (Turkey)

• LukOil / Delta (Iraq)

• Performance during transient conditions tested by TUV

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Shell AG, Germany

• Interconnection of SHELL Godorf and SHELL Wesseling refineries

• 4x DN300 in the concrete protector

• Two tunnels 15m under Rhein river (lengths 1300m and 1200m)

• Total length ~3800m

• Transported products:

• Gasoil

• Hydrowax (~90̊C)

• Butan

• Mogas

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HIMA Pipeline Safety and Control

FlexSILon® PMC concept

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Pipeline safety concept to maximize operators long

term profit

• Pipeline operators interests:

• Maximize utilization of the pipeline

• Uninterrupted operation

• No incidents

• Minimize consequence if something bad happens

• Recognize fast, no mistakes

• Minimize the spill

• What is the cost of incident which leads to negative

publicity or even deaths of people ?

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FlexSILon® PMC

Pipeline Management & Control

Control

ESD

LDS (FLOWorX)

SCADA

Telecom

Operation

and

management(FLOWorX)

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FLOWorX Leak Detection System

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What is FLOWorX ?

• Leak Detection and Location System

• Pipeline Operation and Management Tool

• Parcel Tracking

• Pig Tracking

• Parcel Scheduler

• Archiving and Analysis

• Compliant to API 1130

• Developed and supported by HIMA

Leak detection during transient

conditions

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Comprehensive leak detection

Leak type

Burst Growing Seepage

Op

era

tion

Mo

de

Shut o

ff

EPW

PDM PDM PDM

Ste

ady

pum

pin

g

EPW

VBL VBL X

Tra

nsie

nt

VBLA

EPW VBLA X

Volume

Balance

VBLA

VBLR

PDMA

PDMR

Pressurewave

EPW

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FLOWorX Pipeline Leak Detection System principle

P T Q P T

LEAK ALARM

• Leak Detection & Location

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FLOWorX – extensively tested product

• Over 200 real field tests

• Leak size from 300 liters down to 15 liters

• Leak duration between 20s to 10min

• All condition tests – static, steady state, transient

• Successfully tested by TUV in Germany

Precise leak location, integrated

with GIS

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HIMA in pipeline leak detection

• High quality leak detection and leak location

• Eliminates problems with existing leak

detection system

• Many false alarms

• Failed to recognize the leak, low sensitivity

• Failed to locate the leak

• High maintenance cost

• Analysis of existing system and

improvement suggestion

• System proof and “Try before you buy”

model

• Off-line test

• On-line test

MAOP and slack line detection

Temperature profile calculation

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FLOWorX RDS - Fastest and autonomous

pipeline protection

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Pipelines – most economical (and safest?) means of

transport

• Potential threats

• Material defect

• Land slides

• Third party actions

• Uninteded

• Intended

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Pipeline rupture and prerequisites for the detection

• Pipeline rupture is sudden and dramatic release of the product from

the pipeline due to significant loss of pipeline integrity (For example

release of 30% of actual flow rate)

• Event causing the rupture may affect auxiliary installations like:

telecom system, control system, leak detection system

• Pipeline rupture is dramatic event where the speed of the reaction is

vital

• Its purpose is not to detect small pipeline leaks

• When can it be done ?

• Pipeline is fully packed (no slack line)

• Each pipeline is unique ! – So must be a solution !

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How to detect rupture

• Rupture is sudden event

• Hydraulic events propagates at the

speed of sound (1.2 km / sec) – the

whole process is fast

• RD detects the sudden flow increase

and pressure decrease due to the

rupture.

• Automatic valve closure will isolate

damaged segment

• The size of the rupture that can be

detect is affected by:

• Typical operating procedures, RD

location,…

P

Q

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Before the rupture

0

50

100

150

200

250

300

0

1

2

3

4

5

6

0 10,000 20,000 30,000 40,000 50,000 60,000

p (sim)

Q (sim)

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HIMA Rupture Detector

• Implemented based on extensive know-

how on pressure wave leak detection

method

• Operates on stand alone mode (no

communication ! ), pair mode or

centralized modes

• Unique algorithm based on local

measurement of pressure and flow

• Powerful HIMA SIL3 HW platform HIMax

enables safety application

• Fast IO scan

• Processing power

• Protected against modifications (cyber

security)

PTPTFT

flow direction

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Successful filed test of rupture detector

• Test on Cepro pipeline network

• Pipeline segment 76km, 8 inch

• Only local measurement, no communication to the

central station

• Four “ruptures” tested

• Total volume of leaked product before block valve

command initiated was 600 litres (average 150

liters)

• Data was measured by HIMAX device, also

algorithm of RPD was running in the same device.

Process data whole day

pump stations

Process data RPD location

Video

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Functional safety in pipeline segmentation

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Safety related implications of RDS

• Segmentation – project for functional risk reduction

• Responsibility always stays with OPERATOR

• FS project is successful, if OPERATOR risk is reduced to

tolerable level

• What is a TOLERABLE RISK? (how many undetected or

incorrectly handled ruptures per year are acceptable? )

• Example of safety function: Automatically close the

valve if the downstream pipeline is seriously damaged

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Probability that rupture detector system doesn’t provide

pipeline protection

PFD of the safety loop is the sum of the PFD of all elements:

1. Instrumentation

2. Logic solver

3. Valve and actuator

4. Ability of the algorithm/system to detect the dangerous

situation

• Stand alone

• In pair mode

• What is the probability of comms. failure

PTPTFT

flow direction

Flow

transmitter

Logic

solver

Valve and

actuator

Pressure

transmitter

Pressure

transmitter

Algorithm

1..1 1..2 1..1 1..1 1..1

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Why HIMA in pipelines

• Extremely reliable business partner

• World leading company in functional safety

• Comprehensive portfolio of pipeline safety offering

• Dedicated team of engineers and local partner

• Proven solution for segmentation project for autonomous

operation with guaranteed performance

• Solution will help User to react faster and locate incident

• Satisfied customers on our reference list

Pipeline Control and

Management

from HIMA

Center of Excellence