Oil and Gas Pipeline Design,

Maintenance and Repair

Dr. Abdel-Alim Hashem
Professor of Petroleum Engineering
Mining, Petroleum & Metallurgical Eng. Dept.
Faculty of Engineering Cairo University
[email protected]
[email protected]

Part 12: LEAK DETECTION AND

SCADA SYSTEM

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Content
Methods of Detecting a Leak.
Leak Detection Instruments.
Description of Leak Detection Equipment
Recommended Method for Surface Gas Detection
Survey with FI Unit.
Odorants
Follow-up Inspection.
Leak Classification and Action Criteria.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Methods of Detecting a Leak
Odor.
Vegetation.
Insects (flies, roaches, spiders).
Fungus-like Growth.
Sound.
Unaccounted for Gas.
Soap Solutions.
Leak Detection Instruments.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

1.Odor
Gas odor is a common and effective indication of a leak
Gas is intentionally odorized so that the average person can
perceive it at a concentration well below the explosive range .
Odorant concentration is generally between 0.5 to 1.0 percent by
volume or as local applicable codes dictate .A report of gas
odor should be investigated immediately .

If a leak is found, the migration pattern of the gas should be

determined .
If an immediate hazard is determined to exist, the hazard
potential should be eliminated and the leak repaired immediately .

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

2.Vegetation
Vegetation in an area of gas leakage may improve or
deteriorate, depending on:-
1- The soil.
2- The type of vegetation.
3- The environment.
4- The climate.
5- The volume and duration of the leak.
Changes in vegetation may indicate slow below ground
leaks.
A vegetation survey by itself is not an acceptable method of
complying with the pipeline safety regulations.
Leak surveys should be conducted with leak detection
equipment.
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
 3.Insects (flies, roaches,
spiders).
Insects migrate to points or areas of leakage due to microbial
breakdown of some components of gas.

Some insects like the smell of the gas odorant.

Heavy insect activity, particularly near the riser, the gas meter,
or the regulator, can sometimes indicate a gas leak.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

4.Fungus-like Growth.
Such growth in valve boxes, manholes, etc., may indicate gas
leakage.
These fungi grow best where there is a lack of oxygen, such as
in a gas leak area.
The color of the growth is generally white or grayish-white
similar to a coating of frost.
All such indications should be investigated with a leak
detection instrument.
Personnel should never enter manholes or other confined
spaces without first testing oxygen levels and gas
concentrations.
Check Occupational Safety and Health Administration
(OSHA) regulations concerning confined space entry for
further details on this subject.
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
5.Sound.
Listen for leaks.

A hissing sound almost at:

1- A bad connection.
2- A fractured pipe.
3- A corrosion pit is the usual
indication of a gas leak.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

6.Unaccounted for Gas.
A possible leak is indicated when an off-peak reading of a
master meter.

Periodic off-peak checks can be averaged to provide data for

comparison in future checks.

This method may indicate a leak on the system, but will not
provide a location for the leak.

It is also most effective if consumption figures are known for a

time period before the leak(s) occurred.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

7.Soap Solutions.
A soap solution can pinpoint the location of a leak on:
1-an exposed pipe.
2- On the riser.
3- On the meter.

The solution is brushed or sprayed on and the location of

bubbling indicates leakage.

When excavating underground piping to investigate a

suspected leak location, the pipe should be brushed and
completely clean.

Many leaks are found on the bottom of the pipe.

A mirror may beOilused
PE 607: to observe
& Gas Pipeline the underside
Design, Maintenance & Repair of the pipe.
Leak Detection Instruments

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Leak Detection Instruments.
Gas leak indicators are sophisticated instruments that require
regular care, maintenance, and calibration, and should be used
by trained personnel.

Two types are commonly used by the gas industry for

surveying and pinpointing leak:
- Bead sensor type detector.
- Combustible Gas Indicator (CGI).
- Flame Ionization (FI) gas detector.
- PD (Personal Detector) Short Locator.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Leak Detection Equipment

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Description of Leak Detection
Equipment

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Bead sensor type detector
Is most often used for inspecting exposed piping and
appliances to pinpoint leaks on those facilities.

Bead sensor instruments are not generally used for

leak surveys of underground piping.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Combustible Gas Indicator (CGI).
The CGI was designed primarily for use in a confined space.
The CGI (Figure IV-3a & IV-3 b) consists of:
- Meter. - Probe. - Aspirator bulb.
The bulb is pumped by hand to bring a sample of air into the
probe and the instrument.
The CGI is not suitable for above ground surveys.
These instruments must be calibrated for the type of gas in the
system.
The CGI should be calibrated for natural gas for use on a
natural gas system.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Combustible Gas Indicator (CGI).

Analogue Driven

Figure IV-3a

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Combustible Gas Indicator (CGI)

Digital Readouts.

Figure IV-3b
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
 LIMITS OF
FLAMMABILITY
LOWER UPPER
EXPLOSIVE EXPLOSIVE
LIMIT- (LEL) LIMIT- (UEL)

1% 5% 10% 15%
NATURAL GAS-IN-AIR MIXTURE
Figure IV-4
1- This is an illustration of the lower and upper explosive
limits for natural gas
2- Typical natural gas is flammable in 4 to 14 percent
.natural gas in air mixture
3- In a confined space, a 4 to 14 percent mixture can be
.explosive PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
 Combustible gas indicator (CGI)
There is two main applications for outside surveys are:
1- Available Openings. 2- bar holing.

A bar hole is a small diameter hole made in the ground in the

vicinity of gas piping to extract a sample of the ground
atmosphere for leak analysis.

The CGI instruments are also useful in building surveys and in

areas within a building, such as heater closets, and other
confined areas.

A CGI should always be used first when entering a building to

determine if a hazardous atmosphere is present.

The cost of PE
a CGI is substantially lower than an FI unit.
607: Oil & Gas Pipeline Design, Maintenance & Repair
 The Flame Ionization (FI)
The Flame Ionization (FI) detector uses a hydrogen fuel to power a
small flame in a detector cell.

A pump or venturi system is used to pass continuous air samples

through the detector cell.

This is detected electronically and displayed on a meter readout.

FI units are equipped with meters that indicate gas concentrations

from 1 Part Per Million (PPM) to 10,000 PPM.

They are also equipped with audible alarms to alert the operator when
there is a meter deflection.

Leak survey canPEbe done more rapidly with an FI unit than with
607: Oil & Gas Pipeline Design, Maintenance & Repair
a CGI
using the bar hole method.
 Figure IV-5
This man is checking a gas
The Flame Ionization (FI) meter for leaks with a
unit. hand-carried FI unit.
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
PD (Personal Detector) Short Locator.

The Model PD Detector acclaimed to be the fastest method known

to accurately locate points of electrical contact and insulating
joints on coated pipelines.

Unaffected by parallel lines, depths or cover, the survey can often

be, in part, conducted from a moving vehicle over the pipe.

The PD Detector can be used to locate discontinuities in the

coating of buried pipelines.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Receiver

PD Locator
Oscillator
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
PD (Personal Detector) Short Locator.
The depth of the pipe or cable can be accurately determined
without the usual bending or kneeling.

First locate center of the pipe or line "A" by crossing the pipe
in a sweeping motion.

A "null" (no signal) will mark the center of the pipe.

Mark this location "A", moving 90o from the pipe with bubble
centered in 45o angle gauge and holding the probe tip close to
the ground until another "null"- "B" is detected.

This distance from "B" to "A" less of the outside diameter

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
of the pipe will be the depth of the buried pipe as in Figure (I).
 Figure (I)
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
Recommended Method for Surface
Gas Detection Survey with FI Unit
(Natural Gas System Only)

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Recommended Method for Surface Gas
Detection Survey with FI Unit (Natural Gas
System Only)
The ability of the gas to vent at the ground surface is critical for
the success of a surface survey with an FI unit.
FI is not to be used when the ground is frozen.
A sampling of the atmosphere , the services should be made at
ground level or at no more than 2 inches above the ground surface.
In areas where the gas piping is under pavement, samplings , curb
lines & available ground surface openings Such as:-
1- manholes 2- catch basins
3- sewers 4- Telephone duct openings.
5- Fire & traffic signal boxes 6- cracks in the pavement

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 This figure shows leaking gas following the sewer line
into the home, after leaking at the service tee. Natural
gas can migrate in this manner.

GAS LEAK
RB
NATURAL GAS
EE T CU
STR STREET
MANHOLE
COVER
STORM GAS
GAS PIPELINE SEWER
B
1st FLOOR DRAIN C UR
SEWER LINE ET
RE
WATER LINE ST

STOOL GAS STREET

SINK METER
GAS
BASEMENT SERVICE
SEWER LINE GAS
LINE
SEWER
LINE

Figure IV-7 Figure IV-8

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
 Odorants

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Types of Odorants
Most odorants used in the United States are:
a) Mercaptans. b) Mercaptan sulfide blends.

The only other odorant in wide use is cyclic sulfide

(thiophane), which is mainly used in gas systems containing
natural odorants.

The human sense of smell is very discerning and can detect

mercaptans at a concentration of only 1 Part Per Billion (PPB).

The sulfur content of the odorants in the gas stream can be

measured by gas analysis, if there is sufficient odorant.

The main types of detectors are:-

1- Odor concentration meters.
2- Titrators.
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
3- Gas chromatographs.
 Odorization Equipment

The figures shows equipment which

odorizes the gas.

SINGLE-UNIT WICK ODORIZER

GAS FLOW

ODORANT LEVEL

Figure
PE 607:IV-9
Oil & Gas Pipeline Design, Maintenance & Figure
Repair IV-10
 Figure IV-13
Figure IV-12
This man is conducting a
A picture of an odor sniff test using an odor
testing instrument. testing instrument.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Follow-up Inspection

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Follow-up Inspection

The adequacy of leak repairs should be checked before

backfilling.

The perimeter of the leak area should be checked with a CGI.

a follow-up inspection should be made as soon as practical

after allowing the soil atmosphere to vent and stabilize.

OPS suggests follow-up inspection within 24 to 48 hours.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 A method to remember when investigating
gas leaks and determining it as follows:
Where is the gas ?
(Use a detector to confirm gas is present)
How much is there ?
(Take readings on the CGI)
Extent of the spread?
(Determine the migration pattern)
Relation to other structures ?
(Is gas detected in or near buildings or in manholes?)
Evaluate/evacuate?
(Classify the leak and take appropriate action)

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Leak Classification and Action
Criteria

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Leak Classification and Action Criteria

There is three grades of classification and

action criteria:
1- Grade-1
2- Grade-2
3- Grade-3

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Grade-1

A leak that represents an existing or probable hazard to

persons or property, and requires immediate repair or
continuous action until the conditions are no longer
hazardous.

Requires prompt action to protect life and property.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Grade-2
A leak that is recognized as being non-hazardous at
the time of detection, but justifies scheduled repair
based on probable future hazard.

Leaks should be repaired or cleared within one

calendar year, but no later than 15 months from the
date the leak was reported.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Grade-3
A leak that is non-hazardous at the time of
detection and can be reasonably expected to
remain non-hazardous.

These leaks should be re-evaluated during the

next scheduled survey, or within 15 months of
the date reported.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Conclusion:
1- There is Methods of Detecting a Leak in Pipes.
2- Leak Detection Instruments Must be Apply
Immediately.
3- Can Detect any leak in pipes by Leak Detection
Equipment.
4- Surface Gas Detection Can Be Detected By Survey with
FI Unit.
5- Can easily Detect gas leaking by Odorants.
6- Follow-up Inspection is Very important.
7- There is Classification for Leak .
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
 WHAT IS SCADA ?

SCADA

Supervisory Control And Data Acquisition

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair




Set Point

.
What is SCADA?
SCADA is the technology that enables a user to collect data
from distant facilities , supervise the operation and send
control instructions to those facilities as closing or opening
valves ,changing set points or shutdown in case of
emergency , so there is no need to assign operators to
those facilities in normal operating conditions.
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
IMPORTANCE OF SCADA:-:-

-
.
- The ability of monitoring and control the gas network with its details which
can be extended to thousands of kilometers.
. -
- Operational data analyses and storage for long periods ( historical).

. -
- Operational data daily and periodically reporting.

. -

- Logging of selected events and operator actions and warning alarms.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
- The ease of upgrading or reconfiguring the system as adding
or omitting
gas pipelines, gas stations or even the signals transmitted
from stations
to dispatch center by persons who have this permission
through an
engineering terminal without operational interruption.

- Remote diagnostics and upgrading for RTUs.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 SCADA

Data Acquisition
Supervision Remotely using telecomm.
Monitoring of operation Networks to connect
parameters such as control sites to control
press., temp., flow,.. centers.

Control
Issuing control commands
PE 607: Oil & to
Gas fulfill operation
Pipeline Design, demands.
Maintenance & Repair
Supervisory Control And Data Acquisition System
For The Egyptian National Gas Grid

Is integrated system used to

remotely monitor and control
different gas activities in Egypt
and is known as SCADA for
abbreviation
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
 To SCADA
To SCADA
To SCADA

8
To SCADA
To SCADA

PT PT TT

To SCADA
To SCADA
To SCADA

T. Box 8

Instrumentation cables To SCADA

R & M Station
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
RTU

Control panel
Operation Philosophy

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Each local control center collects the information of control
sites in its geographical area and perform local monitoring.
This information is transmitted to the main control center for
central monitoring.
Control is done centrally from the main control center by
sending the control information to local centers.
In case of failure of a local control center the main control
center takes over its role until it comes back and then
updates it with lost data during the failure period.
The main control center is designed in redundant
configuration to ensure reliable and secure control over the
grid, only a force major could cause the main control centre
to fail.
In case of main control center failure the emergency control
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
center takes over until it comes back and then updates it with
Applying this operation philosophy guarantees
continuous and safe control over the gas grid

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

System Objective

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

The main objective of the system is to protect the
huge investments in the national gas grid via:
Providing remote monitoring and control over the whole pipelines
network.
Proposing operation scenarios for different operating circumstances
and in emergency situations.
Leak and break detection in pipelines network.
Facilitate decision support systems.
Integration with other application such as gas accounting and billing
system.
Remote administration and maintenance of different system
components.
Telecomm systems are utilized to provide voice and data
communications between
PE 607: all systems
Oil & Gas Pipeline sites& independently
Design, Maintenance Repair of third-

party service providers

 Gas Grid Information
The System Serves (about) :
Gas Grid Length: 3000 Km
Grid Capacity: 100 SMCM/Day
Bulk Consumers: 250
Gas Fields: 15

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Components of National
Gas Grid SCADA System

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 The system consists of:
Remote Terminal Units RTUs
Control Centers
Telecomm networks
Software packages

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 First
Remote Terminal Units

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

The RTU Is a
special computer
designed to
process data
between control
sites and local
control centers
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
 Second
Control Centers

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

4 Control centers cover geographically the
whole gas grid

Delta)
Alex
Suez
Cairo

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

The main control center is located in Cairo and is responsible for
monitoring and control of the national gas grid. The center is
designed in redundant configuration for reliable operation. It takes
the role of local control centers in case of failure, and is consists
of:

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Local control centers are located in Delta, Alexandria, Suez, and Cairo.
Each control center gathers the operation data for its local sites and
perform control actions, then it transmit this data to the main control
center.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Emergency control center is designed to take over the
role of the main control center in case of emergency or
failure.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Third
Telecommunication
Networks

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

An integrated high speed digital telecomm. Network
covers the whole gas grid, while providing voice and
data services between grid sites.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Primary digital microwave network working in the 7
Giga band, indicated in red color and is used for data
transmission between control centers.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Optical fiber network and is usually installed with recent pipelines.
It is indicated in yellow colors. Fiber optics network is used to
transmit data between control centers and also transmit operation
information of the pipeline.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Secondary digital microwave network consisting of 4 local
networks covering the whole gas grid and is working in the 2.4
Giga band. This network is used to connect production,
consumers, and dispatching sites to the local control center.

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

 Fourth
Application Software Packages

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair

Application Software Packages
SCADA software package.
Network management software packages.
Gas grid simulation software is doing grid
analysis and accordingly proposing
operation scenarios in different
circumstances. It detects leak and line
break, also predict their places. It performs
other functions that ensure GASCO high
security measures.
PE 607: Oil & Gas Pipeline Design, Maintenance & Repair
References:-
Leak Detection, 49 CFR, Part 192.

From Net:
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www.caltechindia.com

PE 607: Oil & Gas Pipeline Design, Maintenance & Repair