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February 2010

GD compliance: baseline surveys and management framework

by Todd Porter and Mark A Smith Geospatial Corporation, Houston, TX, USA

Geospatial Corporation (GSC) provides positioning, baseline surveys, assessment and data management services to numerous infrastructure industries for construction, re-routing, repair / maintenance, and monitoring. These industries include fiber optics, buried electrical transmission, water, storm and sanitary systems, oil and gas flow lines, and gathering, distribution and transmission lines in metro, urban and rural environments. The amount of installed pipeline is huge and continues to grow. Gas distribution (GD) systems are no exception. It will be the next regulated sector of the industry, adapting and implementing experience from the Hazardous Liquids and Gas Transmission rules. The need to know the exact location of pipelines is essential for any assessment. As our underground has become extremely congested, the older pipelines are in need of both condition assessment and rehabilitation. It is essential to identify the exact location of these pipelines through baseline survey methods. The advent of pipeline asset integrity management systems, which are GIS based, holds potential for accurate, comprehensive analysis which leads to confidence in decision making. GSC provides a unique bundle of systems and services for the GD industry sector using; surface (GPS) and in-pipe mapping (ILM), Ground Penetrating Radar (GPR / CART), and Oblique and Vertical Aerial Imagery. In new pipeline construction, the application of ILM in Horizontal Directional Drilling (HDD) projects across all industries has proven effective in confirming the trajectory and producing high quality as-built drawings not possible until now.. With ILM tools from NPS 1.5 inch (3.81 cm) to 60 inch (152.4 cm) for utility industries, we are adapting these systems to the GD environment, in tethered and free swimming configurations.

HE USA Gas Distribution system is comprised of approximately 1.2 million miles of main lines ranging from 2 inch (5.08 cm) to 8 inch (20.32 cm) and larger in diameter. These lines are inter-twined with all other underground utility pipelines and conduits, and of high consequence as defined by the parent 49 CFR 192 rule. An additional 800,000 miles of service lines deliver gas from the mains to over 63 million individual customer meters. These service lines are typically short in length, small diameter, and low pressure. Over 50% of the distribution system is non-metallic pipe, and new installations are predominantly plastic pipe. Small local systems have been combined to form larger distribution companies creating a mosaic of different pipe materials, age, and designs. The

system therefore is complex, diverse, and is collocated with other utilities in high consequence areas. As shown in Figure 1, distribution systems account for almost all gas delivery to residential and commercial customers, and close to half of the industrial users. All assessment, repair, and compliance operations depend on accurate XYZ position of the pipeline, and its location / proximity with respect to population, structures, and other utilities. A complementary mix of surface GPS, ILM, and imaging technologies establishes an accurate threedimensional (3D) baseline or spatial registration of the infrastructure asset. This case discusses the gas distribution

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IPELINE INTEGRITY management for gas distribution pipelines (DIMP) will become an extension of the PHMSA-DOT regulations. Parallels and exceptions are being identified on how best to adopt and modify the standing regulations 49 CFR Part 192 from the high pressure gas transmission systems to the lower pressure, smaller diameter urban and metropolitan distribution systems. The threats are similar (with the exception of corrosion in non-steel pipelines) but the consequences high due to population density of end users. Therefore, as was required through the National Pipeline Mapping System (NPMS), the need for accurate location of the lines and a management framework will be required.

Global Pipeline Monthly system, but similarly and sometimes in parallel adjacent are oil and gas pipelines, fiber optics, electric utilities, water, storm/sanitary systems which add complexity and risk. To enable verification (or further discrimination) nondestructive excavation technologies are utilized to expose the subject underground utility, minimizing the potential danger of damaging the pipeline or surrounding utilities. This baseline approach serves government and industrial entities in the following areas: Contribute to the management of infrastructure assets and pipeline integrity Provide the critical asset location for baseline assessment and subsequent regulatory compliance work process Plan for future expansion and maintenance Improve pipeline operating efficiencies Eliminate data redundancy; and Reduce operating costs. Spatial data acquisition and discrimination (identification of all proximity structures and systems) enables GIS data technologies to create accurate as-built, 3D drawings of new pipelines installed utilizing either HDD or conventional, open cut methods. Not only are the as-built drawings accurate and quick to produce, they seamlessly integrate into AutoCAD and most other major GIS databases. of various types and sizes of underground pipelines. The materials and technologies have evolved, new methods were developed to install these pipelines, thus the trenchless industry evolved as we know it today. In gas distribution there are increased threats and consequence due to other utilities, proximity to structures, population density, construction activity, and service interruption concerns. The amount of installed pipelines is huge and continues to grow with increased developments and demand. For many years, the need to know the exact location of these pipelines was not considered to be necessary. As our underground became more congested, and as it became more evident that these older pipelines were in need of both condition assessment and rehabilitation, it became increasingly more important to know exactly where these existing and new pipelines were located. The advent of pipeline asset management programs and the development of more sophisticated GIS-based management systems reaffirmed to the pipeline operator the value that could be derived from accurate XYZ spatial centreline data for their entire pipeline system. Although some progress has been made within the pipeline industry toward obtaining this data, the in-line inspection tools (smart pigs) that exist are primarily designed as assessment tools that are expensive as component add-in technology and limited in small diameter sizes of below 10 inch (25.4 cm) or 6 inch (15.24 cm) in some cases. The majority of gas distribution mains are 2 inch (5.08 cm) to 8 inch (20.32 cm), and will require specialized technology such as the ILM probe system.

Management of pipeline assets

The pipeline industry is divided into numerous industry segments which have, over the years dictated the installation

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February 2010

Fig.1. LDC system.

The Smart Probe technology

The Smart Probe technology consists of two main components. The first is the inertial navigation sensor assembly of accelerometers, gyroscopes and odometers housed in the probe pressure modules. The second is a postmission software package which extracts, computes, and interprets the collected data and allows for the seamless transfer of the computed centreline data into various GIS databases.

As the smart probe moves through the pipeline it records all changes in inclination, heading and velocity at 800 Hz, and stores the data internally. Once launched into the operating pipeline, the probe functions autonomously as most ILI tools, with tracking and above ground marker (AGM) operations are carried out. The smart probe operates in a relative coordinate frame, measuring a continuous centreline 3D trajectory. Registering and correcting the probe is achieved by launch, trap, and

Fig.2a. NPS 1.5 inch (3.8 cm) Smart Probe.

Fig.2b. NPS 6 in (15.24 cm) Smart Probe, 2D bend radius.

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Global Pipeline Monthly

Fig.3. NPS 12 inch (30.48 cm), 1.5D bend radius.

AGM tracking stations surveyed along the pipeline route using precise GPS methods (+/-0.10m accuracy). This provides the absolute XYZ pipeline positions in any datum or coordinate system worldwide. By transferring the complete pipe centreline into CAD or a GIS database, accurate XYZ registration creates the baseline or validation of the true location of the asset. A key goal in developing the smart probe technology was to design the instrumentation in such a way that it is capable of being utilized within a series of different probe body styles that would allow for the use of the technology within the widest range of pipeline types, sizes and environments. The initial instrumentation was miniaturized for operating within a 1.5 inch (3.8 cm) diameter pipeline as shown in Figure 1. An articulating body on this probe allows for movement through a pipeline with minimum 17 inch (43.18 cm) bend radius. To map larger diameter pipelines, the probe bodies are configured to allow for movement through the pipeline while tracking the pipe centreline. Figures 2, 3, and 4 show the various configurations. Depending on the pipeline interior surface and condition, various wheel-sets with protruding carrier legs are used to assure the centreed position of the probe body within the pipe. The ability to economically design and develop multiple specifications for the smart probe bodies or carriers and utilize the same instrumentation modules is a key element to the smart probe technology. Modifying the probe bodies allows operations in high pressure, high temperature and

many caustic environments. Key design factors are the articulation of the carrier bodies to negotiate tight radius bends and diameter restrictions (or changes), as well as light weight and low friction / pressure differential. All were considerations to reduce operator impact of the survey. The basic smart probe is designed for use within nonpressurized pipeline environments, with the second generation probes designed and in commercial use for pressurized environments up to 100 psi. This will be extended to ~500 psi to satisfy the gas distribution industry. For transmission and large distribution systems, the next line of high-pressure smart probes are under development primarily for the oil and gas industry for operating in long haul, high pressure environments (up to 3500 psi). Extended battery life and memory capacity can be added as needed. This flexibility provides the opportunity to service the complete range of oil and gas pipeline systems.

Data delivery
Results from the post-processing are provided in a variety of formats; GIS ready for upload into client systems, a digital plan and profile for survey segment (as shown in Figure 5), or hosted through our WEB based GeoUnderground Data Portal. This provides a form-fit deliverable to ease into the clients work process and IMP system. The primary deliverable is a complete spatial register of the pipeline position at client specified intervals, typically 0.01m. The register also contains feature tagging of girth welds and any other internal feature detectable (e.g., block valves, (mitre) bends, misalignments, tees, etc.). This facilitates downstream integration of other assessment technologies such as MFL, UT, and Caliper surveys.

Operation: push or pull

The smart probes are either tethered or propelled through the pipeline. The most common method to utilize a probe to map utility pipelines that are accessible on both ends is to insert a pull rope through the pipeline, attach the probe to the pull rope and utilize a winch to pull the probe through the pipeline. This has been done for lengths up to 2.48 mi

Fig.4. 48 inch (121.92 cm) Smart Probe.

February 2010 (4 km). For pressurized lines that need to stay in service or for much longer pipe runs, the smart probes are attached to foam pigs and they are pushed through the pipeline with either compressed air, water or the pipeline product itself. This provides operational flexibility in routine maintenance operations. Operations will include insertion and extraction methods for either flowing the tool, or using a tethered configuration. In small diameter low pressure lines, the temporary launch / trap method is under development, and a key component of the operations process. operators and engineers to obtain accurate and economical centreline data from most types of underground and above ground pipelines and enter that data into all CAD and GIS software databases. For both existing pipelines and new construction, the smart probe technology is an efficient method to create accurate asbuilt pipeline drawings. The integration of this centreline data into powerful GIS databases is a compelling addition to all pipeline asset management programs. The smart probe technology proves effective in obtaining accurate as-built drawings from pipelines installed via horizontal directional drilling. Not only is the accurate centreline mapped, but the software is capable of calculating the actual installed bending radius at every point along the pipeline. By overlaying the smart probes centreline data over existing grade information, depth of cover above the pipeline is established. With data from the smart probe all pipeline joints whether welded joints, ring joints or gasketed slip joints are easily detectable and assigned a coordinate. By reviewing the output data, the quality of certain joints can be reviewed and poorly installed offset joints can be discovered. The autonomous nature of the smart probe technology allows easy coupling with most other pipeline assessment tools and very efficiently add important positioning capabilities to these tools. Video cameras, leak detection equipment, sonar and laser evaluation tools as well as MFL, UT, and Caliper tools can be added in tandem to the smart probe for multiple assessment tasks. As the gas distribution industry has a large component of plastic pipe, corrosion is not a threat. Line location becomes difficult with damaged or deteriorated tracer

The smart probes use gyro instrumentation which is precise however has inherent errors. In order to control these errors, GPS corrections using AGM locations are introduced at designed locations and intervals. It was important to understand this control method and to develop operating procedures to ensure optimal results. The probe accuracy is < 0.25% of the distance between two known coordinates in the XY plane (plan view) and < 0.10% of the distance between known points on the Z plane (elevation). This is translates to 1:400 in horizontal, and 1:1000 in vertical. These errorn estimates are dependent on the accuracy of the odometer (velocity), and spacing of AGM locations. Accuracies of +/- 0.10m can be realized with proper program design.

Applications for the technology

The smart probe technology allows pipeline owners,

Fig.5. Plan / profile delivery.

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Accuracy

Global Pipeline Monthly wire. Therefore, accurate position / location of the pipelines is the first and most critical step in building an effective integrity management program. In addition to the assessment technologies listed, we are in development of an integrated approach for mapping complete swaths of utility corridors. GPR / CART technologies that integrate accurate probe centrelines offer great improvement to the identification and discrimination of underground features, leading to a more focused result. and planning for the management and integrity of pipeline assets. This data is also essential to the pipeline owner in scheduling and budgeting repair and maintenance of the pipeline system. This approach offers the pipeline operator flexibility and low impact to acquire an accurate 3D centreline. It can be coupled with cleaning and maintenance operations resulting in tangible downstream savings by creating and/or validating existing location data.

Conclusion
The smart probe provides an efficient and economical methodology to obtain accurate XYZ centreline mapping, bend radius, internal angle and misalignments or deformation data for most pipelines, in most industries and has become an increasingly important technology in the rapidly growing pipeline assessment industry. The critical importance of pipeline location and trajectory is not only part of regulatory compliance, but essential in creating or validating GIS systems. The data that is collected via the smart probe is not only quantifiable (correlation to as-built) but is also a qualitative check by indicating internal pipeline misalignments or deformations. Smart probe data can be utilized to aid engineers, designers and contractors in identifying, mapping,

References
1. Federal Register 49 CFR, Part 195, Pipeline Safety: Pipeline Integrity Management in High Consequence Areas (Hazardous Liquid Operators With 500 or more miles of Pipeline); Final Rule 2. Federal Register 49 CFR Part 192 Pipeline Safety: Pipeline Integrity Management in High Consequence Areas (Gas Transmission Pipelines); Final Rule 3. ASME B31.8S-2001, Managing System Integrity of Gas Pipelines 4. API Standard 1160 Managing System Integrity for Hazardous Liquid Pipelines, November 2001 5. Muhlbauer, K.M. (2003), Pipeline Risk Management Manual - Ideas, Techniques, and Resources, Third Edition Gulf Professional Publishing.