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

2010-2019 DOT 195 Accidents Review Derek Sollberger, PE

Tulsa, OK May, 7 2020

IC-Solutions-LLC www.ic-solutions-llc.com 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)

Form RSPA F 7000-1 49 CFR §195.50

• Pg. 1of 17
• Pg. 1of 4

TANK DATA

• 10,000

20,000 30,000 40,000 50,000 60,000 bbl

TANK SUBTYPE SPILLS

SINGLE BOTTOM ROOF DRAIN MIXER OTHER ROOF/ROOF SEAL DOUBLE BOTTOM

COMMODITY

CRUDE OIL NON-HVL, LIQ @ AMB HVL, GAS @ AMB BIOFUEL / ALTERNATIVE FUEL

CAUSE

EQUIPMENT FAILURE NATURAL FORCE DAMAGE OTHER INCIDENT CAUSE INCORRECT OPERATION CORROSION FAILURE OTHER OUTSIDE FORCE DAMAGE MATERIAL FAILURE OF PIPE OR WELD

• 10,000 20,000 30,000

OTHER EQUIP MALFUNCTION OF CONTROL/RELIEF EQUIP EQUIP BODY (<PUMP, TANK PLATE, MATERIAL) NON-THREADED CONNECT

EQUIPMENT FAILURE

10,000 20,000 30,000 1,000 2,000 3,000 1920 1940 1951 1956 1964 1971 1976 1981 1989 1994 2001 2006 2011 2016

• 1,000

2,000

TANK, VESSEL, OR SUMP/SEPARATOR ALLOWED OR CAUSED TO OVERFILL EQUIPMENT NOT INSTALLED PROPERLY OTHER INCORRECT OPERATION VALVE LEFT OR PLACED IN WRONG POSITION, NOT OVERFLOW OR OVERPRESSURE

INCORRECT OPERATION

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)

• 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

VALVE DATA

100 200 300 400 1945 1954 1957 1965 1968 1973 1980 1983 1986 1990 1995 2000 2003 2007 2010 2013 2016

MANUFACTURE YEAR

200 400 600 800 1000 1200 1400 1600 1800

Mainline Valve Type Failure

GATE BALL CHECK OTHER PLUG

MAINLINE LEAK TYPE

OTHER SEAL OR PACKING CONNECTION FAILURE PINHOLE CRACK

COMMODITY

CRUDE OIL HVL, GAS @ AMB NON-HVL, LIQ @ AMB CO2

• 2,000 4,000 6,000 8,000

EQUIPMENT FAILURE INCORRECT OPERATION OTHER OUTSIDE FORCE CORROSION FAILURE NATURAL FORCE EXCAVATION DAMAGE OTHER INCIDENT CAUSE

AUXILIARY OR OTHER VALVE

EQUIPMENT FAILURE

EQUIP BODY (<PUMP, TANK PLATE, MATERIAL) THREADED CONNECTION/COUPLING MALFUNCTION OF CONTROL/RELIEF EQUIP NON-THREADED CONNECTION OTHER EQUIPMENT PUMP OR PUMP-RELATED EQUIP DEFECTIVE OR LOOSE TUBING OR FITTING

VALVE DATA

• Evaluating vandalism risk and appropriate security

measures.

• Maintenance procedure development, review, and training.
• Commissioning procedures and planning
• Design and construct with operability in mind.
• Ensure OEM records are inclusive of maintenance

recommendations and easily accessible by Operations.

• Vendor Qualifications

Valve Damage Expenditures TOTAL per VALVE category

• $79,267,306

AVG per incident

• $113,401

28,369 bbl on 699 events

PIPE DATA

0% 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 100,000 4 6 6.625 8.625 10.5 12 14 20 26 32 40

COMODITY

HVL, GAS @ AMB CRUDE OIL NON-HVL, LIQ @ AMB 10000 20000 30000 40000 1910 1929 1937 1944 1950 1956 1962 1968 1974 1980 1987 1993 1999 2006 2011 2018

MANUFACTURE YEAR

• 50,000

100,000 150,000 200,000 250,000

Pipe Body, Corrosion, Material Failure, Incident Area

UNDERGROUND TRANSITION AREA ABOVEGROUND

• 50,000

100,000 CPM LEAK DETECTION OR SCADA INFO NOTIFICATION FROM PUBLIC CONTROLLER LOCAL OPERATING STAFF AND CONTRACT AIR PATROL GROUND PATROL BY OPS OR CONTRACT OTHER

ACCIDENT IDENTIFIER

0% 5% 10% 15% 20% GALVANIC OTHER MICROBIOLOGICAL STRAY CURRENT ATMOSPHERE SELECTIVE SEAM

TYPE OF CORROSION

46% of External Corrosion records noted Prior Coating Damage

PIPE DATA

51% 29% 8% 7% 5% 18 51 4 4 3 6 3

PIPE SEAM TYPE FAILURES

LONGITUDINAL ERW - HF LONGITUDINAL ERW - LF LAP WELDED FLASH WELDED SEAMLESS LONGITUDINAL ERW - UNK 0% 10% 20% 30% 40% TOTAL ILI MFL GEOMETRY COMBO CALIPER ULTRASONIC TRANSVERSE OTHER CRACK

PRIOR TOOL RUNS

0% 50% 100%

CORROSION INHIBITORS CORROSION COUPONS

INTERNAL CORROSION EFFORTS

0% 10% 20% 30% 40% INTEGRITY HYDRO CLOSE INTERVAL DIRECT INSPECT

INTEGRITY PROGRAMS

67% 33%

2018 DOT 195 Part E -ERW Pipe Seam

HIGH FREQUENCY LOW FREQUENCY AND DC 0% 20% 40% 60% 80% 100%

• 10,000

20,000 30,000 40,000 50,000 <4 8 12 16 20 24 28 32 36 40 44 48

2018 DOT 195 Part H Mileage

On Shore Off Shore %

• 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

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

EXCAVATION

• 20,000

40,000 60,000 80,000 100,000 120,000 140,000 160,000 180,000

Excavator Equipment

TRENCHER BACKHOE/TRACKHOE UNKNOWN/OTHER GRADER/SCRAPER FARM EQUIPMENT DRILLING DIRECTIONAL DRILL AUGER BORING

13 57 23 14 12

0% 20% 40% 60% 80% 100% TRENCHER BACKHOE/TRACKHOE UNKNOWN/OTHER GRADER/SCRAPER FARM EQUIPMENT DRILLING DIRECTIONAL DRILL AUGER BORING PROBING DEVICE

One Call Notice One Call Completed

EXCAVATION PRACTICES NOT SUFFICIENT LOCATING PRACTICES NOT SUFFICIENT OTHER ONE-CALL NOTIFICATION PRACTICES NOT SUFFICIENT

Comodity

HVL, GAS @ AMB CRUDE OIL NON-HVL, LIQ @ AMB

Median Grade 42,000 Median Diameter 10 Average Install Year 1968

Data includes dozer line strike to a propane pipeline, resulting in

• ne general public

fatality and one general public injury.

• 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.

Excavator Damage Expenditures TOTAL per EXCAVATOR category

• $ 173,762,000

AVG per incident

• $ 1,223,676

2010-2019 Accident Summary

Data Summary

• 3,910 Accidents
• 822,129 bbl, 38% recovered
• 10 Fatalities, 5 public
• 26 Injuries, 5 public
• 124 Ignitions & 15 Explosions
• 58 Impacted Wildlife
• 781 Drug/Alcohol tests

– 2 Failed (Contractors)

• Risk Evaluations
• Procedure development,

auditing, and training

• Mechanical Integrity
• Reliability Evaluations
• Vendor Qualifications
• Record Keeping

Opportunities for Improvement

IC-Solutions-LLC Services

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