2010-2019 DOT 195 Accidents Review Derek Sollberger, PE - PowerPoint PPT Presentation

2010-2019 DOT 195 Accidents Review Derek Sollberger, PE IC-Solutions-LLC Tulsa, OK www.ic-solutions-llc.com May, 7 2020 Oklahoma City, OK dsollberger@ic-solutions-llc.com

Accident Report – Hazardous Liquid Pipeline Systems form updates: • Common Geo Ref. • Single unit of measure • 259 to 588 fields • Biodiesel • Subtypes • Coating selections • Valve type selections • SCADA / CPM adders • Drug and Alcohol tested • Unique Int/Ext Corrosion • ILI: Combo & Transverse • Excavator Equip Type • Previous Damage (Excav) Pg. 1of 4 Pg. 1of 17 Form RSPA F 7000-1 49 CFR §195.50

TANK DATA EQUIPMENT FAILURE COMMODITY NON-THREADED CONNECT TANK SUBTYPE SPILLS EQUIP BODY (<PUMP, 60,000 TANK PLATE, MATERIAL) MALFUNCTION OF CONTROL/RELIEF EQUIP 50,000 OTHER EQUIP 40,000 CRUDE OIL - 10,000 20,000 30,000 NON-HVL, LIQ @ AMB 30,000 HVL, GAS @ AMB INCORRECT OPERATION 20,000 BIOFUEL / ALTERNATIVE FUEL 10,000 VALVE LEFT OR PLACED IN WRONG POSITION, NOT OVERFLOW OR OVERPRESSURE - bbl CAUSE SINGLE BOTTOM ROOF DRAIN OTHER INCORRECT OPERATION MIXER OTHER ROOF/ROOF SEAL DOUBLE BOTTOM EQUIPMENT NOT INSTALLED 3,000 30,000 PROPERLY EQUIPMENT FAILURE 2,000 20,000 NATURAL FORCE DAMAGE TANK, VESSEL, OR OTHER INCIDENT CAUSE 1,000 10,000 SUMP/SEPARATOR ALLOWED OR INCORRECT OPERATION CAUSED TO OVERFILL 0 0 CORROSION FAILURE 1920 1940 1951 1956 1964 1971 1976 1981 1989 1994 2001 2006 2011 2016 OTHER OUTSIDE FORCE DAMAGE - 1,000 2,000 MATERIAL FAILURE OF PIPE OR WELD

• Inclement Weather planning / procedure development review • Maintenance interval review, seal type and material compatibility reviews, • Reliability programs, rotating equipment inspections. • Mechanical Integrity program reviews • Operator Training / Vendor Qualifications • Control and Safety Systems Simulations Tank Damage Expenditures TOTAL per TANK category • $73,246,437 AVG per incident • $265,385 $7-15/1,000 bll storage (0.5B-1B Part M)

VALVE DATA COMMODITY AUXILIARY OR OTHER VALVE OTHER INCIDENT CAUSE EXCAVATION DAMAGE Mainline Valve Type Failure 1800 NATURAL FORCE CORROSION FAILURE 1600 OTHER OUTSIDE FORCE 1400 INCORRECT OPERATION EQUIPMENT FAILURE 1200 - 2,000 4,000 6,000 8,000 CRUDE OIL 1000 HVL, GAS @ AMB 800 NON-HVL, LIQ @ AMB EQUIPMENT FAILURE 600 CO2 400 200 MAINLINE LEAK TYPE 0 GATE BALL CHECK OTHER PLUG MANUFACTURE YEAR EQUIP BODY (<PUMP, TANK PLATE, MATERIAL) 400 THREADED CONNECTION/COUPLING 300 MALFUNCTION OF CONTROL/RELIEF EQUIP 200 NON-THREADED CONNECTION OTHER 100 OTHER EQUIPMENT SEAL OR PACKING 0 PUMP OR PUMP-RELATED EQUIP CONNECTION FAILURE 1945 1954 1957 1965 1968 1973 1980 1983 1986 1990 1995 2000 2003 2007 2010 2013 2016 PINHOLE DEFECTIVE OR LOOSE TUBING OR FITTING CRACK

VALVE DATA • Evaluating vandalism risk and appropriate security measures. Valve Damage Expenditures • Maintenance procedure development, review, and training. TOTAL per VALVE category • Commissioning procedures and planning • $79,267,306 • Design and construct with operability in mind. • AVG per incident Ensure OEM records are inclusive of maintenance recommendations and easily accessible by Operations. • $113,401 • Vendor Qualifications 28,369 bbl on 699 events

PIPE DATA COMODITY 100,000 100% 90,000 90% 80,000 80% Pipe Body, Corrosion, Material 70,000 70% 60,000 60% Failure, Incident Area 50,000 50% 250,000 40,000 40% 30,000 30% 200,000 20,000 20% HVL, GAS @ AMB CRUDE OIL 10,000 10% 150,000 0 0% NON-HVL, LIQ @ AMB 4 6 6.625 8.625 10.5 12 14 20 26 32 40 100,000 ACCIDENT IDENTIFIER 50,000 TYPE OF CORROSION - OTHER UNDERGROUND TRANSITION AREA ABOVEGROUND GROUND PATROL BY SELECTIVE SEAM OPS OR CONTRACT 46% of External MANUFACTURE YEAR ATMOSPHERE Corrosion AIR PATROL records noted LOCAL OPERATING 40000 STRAY CURRENT Prior Coating STAFF AND CONTRACT Damage 30000 MICROBIOLOGICAL CONTROLLER 20000 NOTIFICATION FROM OTHER PUBLIC 10000 CPM LEAK DETECTION GALVANIC 0 OR SCADA INFO 1910 1929 1937 1944 1950 1956 1962 1968 1974 1980 1987 1993 1999 2006 2011 2018 0% 5% 10% 15% 20% - 50,000 100,000

PIPE DATA 2018 DOT 195 Part H Mileage INTEGRITY PROGRAMS 50,000 100% DIRECT INSPECT 40,000 80% CLOSE INTERVAL INTEGRITY HYDRO 30,000 60% 0% 10% 20% 30% 40% 20,000 40% PIPE SEAM TYPE FAILURES INTERNAL CORROSION EFFORTS 10,000 20% 3 CORROSION COUPONS 6 - 0% 18 7% 5% 3 CORROSION INHIBITORS <4 8 12 16 20 24 28 32 36 40 44 48 4 8% 0% 50% 100% On Shore Off Shore % 4 PRIOR TOOL RUNS 2018 DOT 195 Part E -ERW Pipe Seam CRACK 29% 51% OTHER 51 TRANSVERSE 33% ULTRASONIC LONGITUDINAL ERW - HF LONGITUDINAL ERW - LF CALIPER LAP WELDED COMBO 67% FLASH WELDED GEOMETRY SEAMLESS LONGITUDINAL ERW - UNK MFL TOTAL ILI HIGH FREQUENCY LOW FREQUENCY AND DC 0% 10% 20% 30% 40%

Pipe Damage Expenditures TOTAL per PIPE category • $1,676,554,446 AVG per incident • $2,250,409 279,679 bbl on 745 events Corrosion, Material Failure, & Other Incident • Integrity Management is complex • Development of excavation requirements, adherence, and representative presence during line crossing urgent • Surface owner and public relations importance to leak detection • Application and selection of integrity concepts • Aging infrastructure • Vendor Qualifications

Comodity One Call Notice EXCAVATION PROBING DEVICE BORING AUGER Excavator Equipment 180,000 DIRECTIONAL DRILL DRILLING 160,000 FARM EQUIPMENT 12 GRADER/SCRAPER 140,000 UNKNOWN/OTHER 14 BACKHOE/TRACKHOE 120,000 TRENCHER 23 HVL, GAS @ AMB 100,000 0% 20% 40% 60% 80% 100% CRUDE OIL 57 80,000 NON-HVL, LIQ @ AMB One Call Completed 60,000 40,000 Data includes dozer line 20,000 strike to a propane 13 pipeline, resulting in - TRENCHER BACKHOE/TRACKHOE UNKNOWN/OTHER one general public GRADER/SCRAPER FARM EQUIPMENT DRILLING EXCAVATION PRACTICES NOT SUFFICIENT DIRECTIONAL DRILL AUGER BORING fatality and one general LOCATING PRACTICES NOT SUFFICIENT public injury. OTHER Median Grade 42,000 Median Diameter 10 ONE-CALL NOTIFICATION PRACTICES NOT Average Install Year 1968 SUFFICIENT

Excavator Damage Expenditures TOTAL per EXCAVATOR category • $ 173,762,000 AVG per incident • $ 1,223,676 • Equipment operator training and pipeline operator requirements. • Farm and Road grading equipment One Call compliance • Line Locator training, equipment operator fundamentals • Construction Inspection • Project planning, utility and sub-surface infrastructure identification exercises.

2010-2019 Accident Summary Opportunities for Improvement Data Summary • • Risk Evaluations 3,910 Accidents • • 822,129 bbl, 38% recovered Procedure development, • 10 Fatalities, 5 public auditing, and training • 26 Injuries, 5 public • Mechanical Integrity • 124 Ignitions & 15 Explosions • Reliability Evaluations • 58 Impacted Wildlife • Vendor Qualifications • 781 Drug/Alcohol tests • Record Keeping – 2 Failed (Contractors)

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