Pipeline Operations and Maintenance

Oil and Gas Technology October 25, 2025
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Introduction

This practical course provides a detailed guide to the day-to-day operations and maintenance of crude oil, refined product, and natural gas transmission pipelines. It covers the essential aspects of system control, flow management, and the execution of preventive maintenance activities on pipeline assets, pump/compressor stations, and block valve sites. Participants will focus on maintaining system integrity, optimizing throughput, and ensuring compliance with stringent safety and environmental regulations. The training is essential for personnel responsible for the reliable, safe, and efficient transportation of hydrocarbons across long-distance networks.

Objectives

Upon completion of this course, participants will be able to:

  • Describe the primary components of a pipeline system, including line pipe, pumps, and valves.
  • Manage and optimize pipeline hydraulics, flow rate, and pressure control for different fluids.
  • Detail the procedures for pigging (cleaning and inspection) operations and launch/receive processes.
  • Understand the function and control of pump stations (oil) and compressor stations (gas).
  • Apply basic troubleshooting techniques for flow restrictions, leaks, and pressure excursions.
  • Outline the key elements of an effective pipeline Integrity Management System (IMS).
  • Ensure operational compliance with safety regulations (e.g., control room management, SCADA alarm handling).
  • Develop and follow routine maintenance schedules for mechanical and control equipment.

Target Audience

  • Pipeline Operations and Field Supervisors.
  • Pipeline Control Room Operators and SCADA Specialists.
  • Maintenance Engineers and Technicians (Mechanical/I&E).
  • Pipeline Integrity Management Personnel.
  • Field Service and Inspection Contractors.
  • Technical Staff responsible for asset reliability.

Methodology

  • Scenarios: Managing a high-priority SCADA alarm and initiating emergency shutdown procedures.
  • Case Studies: Analyzing historical pipeline failures related to operational error or maintenance lapse.
  • Group Activities: Developing a pre-pigging checklist and risk assessment.
  • Individual Exercises: Calculating the pressure drop across a pipeline section.
  • Discussions on control room management standards and human factors.

Personal Impact

  • Gain comprehensive, practical knowledge essential for safe pipeline operations.
  • Enhance technical ability to manage hydraulic systems and control stations effectively.
  • Improve troubleshooting skills, leading to faster resolution of operational upsets.
  • Increase personal value as a competent and compliance-focused operator/maintainer.
  • Master the safe and effective use of SCADA and leak detection systems.
  • Position for career advancement into supervisory or integrity roles.

Organizational Impact

  • Maximized pipeline throughput and minimized unscheduled downtime.
  • Reduced risk of major environmental incidents and regulatory non-compliance.
  • Lower operating costs through optimized energy consumption (pumps/compressors).
  • Extended lifespan of pipeline assets through proactive maintenance and integrity programs.
  • Enhanced safety culture and consistent application of best operating practices.
  • Improved integrity management decision-making based on reliable operational data.

Course Outline

Unit 1: Pipeline System Fundamentals and Hydraulics

Section 1.1: Operational Basics
  • Review of pipeline network components: Pipe, valves, stations, and terminals.
  • Basic fluid mechanics and hydraulic principles for single-phase and multi-phase flow.
  • Managing hydraulic transients (surges) and their mitigation strategies.
  • Understanding pigging: Purpose (cleaning, inspection) and launch/receive procedures.

Unit 2: Pump and Compressor Station Operations

Section 2.1: Station Management
  • Operation and control of centrifugal and reciprocating pumps in liquid service.
  • Operation and control of gas compressor stations, including anti-surge control.
  • Optimizing station sequencing and unit utilization for maximum system efficiency.
  • Routine monitoring of vibration, temperature, and performance metrics.

Unit 3: Control Systems and Operational Safety

Section 3.1: SCADA and Control
  • The role of Supervisory Control and Data Acquisition (SCADA) systems in pipeline control.
  • Control room management (CRM) procedures and alarm rationalization.
  • Leak detection systems (LDS) and emergency shutdown (ESD) protocols.
  • Procedures for line segment isolation, lockout/tagout, and safe work permits.

Unit 4: Pipeline Maintenance and Integrity

Section 4.1: Maintenance Activities
  • Developing preventive and predictive maintenance schedules for valves and stations.
  • Maintenance procedures for pipe coating, cathodic protection, and ground monitoring.
  • Overview of In-Line Inspection (ILI) tools and interpreting ILI data.
  • Procedures for anomaly detection, repair planning, and excavation safety.

Unit 5: Troubleshooting and Regulatory Compliance

Section 5.1: Upset Management
  • Troubleshooting low flow, high pressure, and custody transfer measurement errors.
  • Responding to pigging problems, stuck pigs, and pig tracking procedures.
  • Detailed review of critical pipeline safety regulations (e.g., PHMSA, API).
  • Best practices for emergency response planning and public awareness programs.

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