7/10/2014
Guidance1 for Strengthening Pipeline Safety Through Rigorous Program Evaluation and Meaningful Metrics
1 This document is to provide guidance describing methods to evaluate and measure IM program effectiveness.
Guidance 1 for Strengthening Pipeline Safety Through Rigorous - - PDF document
Guidance 1 for Strengthening Pipeline Safety Through Rigorous Program Evaluation and Meaningful Metrics 1 This document is to provide guidance describing methods to evaluate and measure IM program effectiveness. This document is not a regulation
1 This document is to provide guidance describing methods to evaluate and measure IM program effectiveness.
Threat Performance Metrics for Prescriptive Programs External corrosion Number of hydrostatic test failures caused by external corrosion Number of repair actions taken due to in‐line inspection results Number of repair actions taken due to direct integrity assessment results Number of external corrosion leaks Internal corrosion Number of hydrostatic test failures caused by internal corrosion Number of repair actions taken due to in‐line inspection results Number of repair actions taken due to direct integrity assessment results Number of internal corrosion leaks Stress corrosion cracking Number of in‐service leaks or failures due to SCC Number of repair replacements due to SCC Number of hydrostatic test failures due to SCC Manufacturing Number of hydrostatic test failures caused by manufacturing defects Number of leaks due to manufacturing defects Construction Number of leaks or failures due to construction defects Number of girth welds / couplings reinforced / removed Number of wrinkle bends removed Number of wrinkle bends inspected Number of fabrication welds repaired / removed Equipment Number of regulator valve failures Number of relief valve failures Number of gasket or O‐ring failures Number of leaks due to equipment failures Third‐party damage Number of leaks or failures caused by third‐party damage Number of leaks or failures caused by previously damaged pipe Number of leaks or failures caused by vandalism Number of repairs implemented as a result of third‐party damage prior to a leak or failure Incorrect operations Number of leaks or failures caused by incorrect operations Number of audits / reviews conducted Number of findings per audit / review, classified by severity Number of changes to procedures due to audits / reviews Weather related and outside forces Number of leaks that are weather related or due to outside force Number of repair, replacement, or relocation actions due to weather‐related or outside‐force threats
Leading ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Indicators‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Lagging Program Element Selected IM Process, Operational or Activity Metrics Operational Deterioration Indicators Failure or Direct Integrity Metrics
could impact HCAs
identification analysis
conducted to identify new HCAs
inspections identifying new HCAs – or segments that could affect HCAs
procedures and assumptions made in identifying segments that could affect HCAs
photography used for HCA segment analysis
for information on potential "identified sites" or could affect segments
assets not incorporated within the IMP within the required timeframe
identified as HCAs in updates to the segment identification analysis
inappropriate formula for product transported (Gas Trans)
identified due to changing conditions (pipeline modifications, new public construction, change in public use of existing buildings, etc.)
stream flow rate) that exceed assumptions used in HCA or could affect segment identification
from pipe that was not determined to be a “could affect” segment (Haz Liq)
beyond the PIR (Gas Trans)
impacts to HCAs than determined by the “could affect” analysis
HCAs than determined by the “could affect” analysis
estimated volume that could be released in a segment (Haz Liq)
previously unidentified threats
assessment process procedures and practices
algorithm and / or model reviews
assessment; incorporation of new information in a timely manner
documentation and records are absent.
(e.g., ILI) results / insights into risk assessment
threats (e.g., cyclic fatigue interaction with SCC)
threats
deterioration and failure metrics with risk analysis results (i.e., are the metrics indicative of the most problematic technical areas consistent with the predictions of the risk model)
threat identification process or tools as a result of IM Program evaluations
risk assessment process or tools as a result
which indicate inaccuracies in material or component records – diameter, wall thickness, grade, seam type, toughness, coating type, etc.
unidentified threat
underestimated or misunderstood threat
interacting threats.
as high risk
contributing factor
tool or integrity assessment methodology was not employed
consequences considered in the risk analysis
manufacturing defect
assessment procedures and practices ○ ECDA ○ ICDA ○ SCCDA ○ CDA
integrity assessment
assessment
process as a result of IM Program evaluations
repair
direct examination was not conducted: ○ Mischaracterized indication severity ○ No indication was identified by DA tools / methods chosen ○ Defect growth rate underesmated
schedule
cause category
assessment method
HCA
required timeframe
and repair by detectable cause
Leading ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Indicators‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Lagging Program Element Selected IM Process, Operational or Activity Metrics Operational Deterioration Indicators Failure or Direct Integrity Metrics
miles by integrity assessment type
determination process
process
assessment
system or miles of tool runs with accuracy > [insert criteria] … to track that operators are using the best available tools and most current technology
for each type of threat
per mile for each type of integrity assessment
per mile by pipe age
discovered in the nth integrity assessment versus the (n‐1)th integrity assessment.
with tool specs could be combined to calculate probability of injurious defects remaining in pipe after integrity assessment
not conducted within the required timeframe
selection and execution process as a result
metal loss and cracking, dents and cracking, disbonded coating and SCC, etc.
cause
integrity assessment was not conducted
and repair by detectable cause
without repair: ○ Defect under‐called – no plans to repair ○ Defect not identified because interacting threats were not considered ○ Tool accuracy not appropriately considered in making repair decision ○ Defect not identified by integrity assessment method ○ Failure occurred before defect repaired ○ Defect growth rate underesmated ○ ECA not performed for remaining defects ○ B31G / RSTRENG overestimated burst pressure ○ Poor, out‐of‐spec ILI tool performance (without validation digs to calibrate interpretation of ILI logs)
and frequency process
○ 1.25 x MOP / MAOP ○ 1.39 x MOP / MAOP
Corrosion Cracking, or other crack defects identified by ILI following previous pressure test
pressure test process as a result of IM Program evaluations
indicating an increasing amount of near‐ critical manufacturing flaws present in line pipe
assessment by pressure test
amount of near‐critical manufacturing or
measure identification
evaluating preventive measures
ratios in excess of predefined criteria that are implemented)
implemented
measures – e.g., pipe replacement program, recoating program, depth of cover survey, etc.
preventive measures taken: ○ Pipe replacement ○ Recoating ○ CIS ○ ACVG / DCVG ○ Added cover ○ Increased patrols ○ Product quality improvement ○ More frequent integrity assessments ○ Changes in internal corrosion monitoring program results ○ Inhibitor injection ○ Addition of separators ○ Deformation, geometry, or DA findings for dents or expansion
prevention and mitigation process as a result of IM Program evaluations
compared to non‐HCA segments
in HCA segments compared to non‐HCA segments
pre‐ and post‐IM
employed or identified preventive measure which did not prevent the release
Leak Detection system(s) did not function as designed or anticipated to prevent the volume of the release
procedures and actions did not function as designed or anticipated to prevent the release
Leading ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Indicators‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Lagging Program Element Selected IM Process, Operational or Activity Metrics Operational Deterioration Indicators Failure or Direct Integrity Metrics
measure identification
evaluating mitigative measures
(e.g., No. of safety improvements with benefit‐to‐cost ratios in excess of predefined criteria that are implemented)
needs analysis
detection capability and enhancements analysis
measures – e.g., installation of RCV / EFRDs, leak detection improvements, emergency response procedures, etc.
mitigative measures taken: ○ EFRD’s (e.g., % of system with EFRDs deployed that meet [insert criteria based on Valve Study]) ○ Leak Detection (e.g., % of system with LD capability that meets [insert criteria based on LD study])
prevention and mitigation process as a result of IM Program evaluations
compared to non‐HCA segments
in HCA segments compared to non‐HCA segments
pre‐ and post‐IM
employed or identified mitigative measure which did not result in the full, desired mitigative effect
Leak Detection system(s) did not function as designed or anticipated to mitigate the volume of the release
facility isolation did not function as designed
release
procedures and actions did not function as designed or anticipated to mitigate the release
evaluated as requiring EFRDs, but the EFRD has not yet been installed
evaluated as requiring EFRDs, but the EFRD has not yet been installed
Procedure Reviews
procedures
maintenance procedures
procedures
conditions (AOCs)
accident investigation(s)
emergency O&M procedures
without a release
implementation of planned corrective actions
along the ROW contacted by the operator
and other local governments along the pipeline route contacted by the operator
understanding pipeline safety message
in operator drills and exercises
emergency responder drills and exercises
awareness plans
public officials, or emergency responders did not behave as expected per the
landowner not calling 811 prior to excavation, an emergency responder not utilizing information provided by the
communications plan is effective in communicating key IM program insights and results
performance measures
completed routine IM program refresher
by internal communications plan
routine IM program refresher orientation / training
Leading ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Indicators‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Lagging Program Element Selected IM Process, Operational or Activity Metrics Operational Deterioration Indicators Failure or Direct Integrity Metrics
systems
monitored via SCADA or Control Room
investigations where process or procedural inadequacies or improvement areas were identified
investigations where equipment additions
improvements were noted
○ Corrosion ○ 3rd Party Excavation Damage ○ All failures ○ Tank bottom failures ○ Tank overfills
release or other upset
release or other upset
where release volume was not minimized to the extent possible with existing equipment and procedures
not minimized to the extent possible due to availability and location of personnel
needs over time
"missing data"
pipeline installations
required Knowledge elements
without documentation of relevant data
Leading ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Indicators‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Lagging Failure Mechanism Selected Process or Operational Activities for Threat Prevention or Management Deterioration Indicators Failure or Direct Integrity Metrics Mechanical Damage First‐party (operator) and second‐party (contractor) damage
near its own pipeline
procedures were not followed or where appropriate care was not exhibited
enforcement authority
damage Third‐party excavation, construction or
Excavation, construction or other work activity occurring at some time prior to failure
call systems
stakeholders along the ROW and notification of pipeline location, threats, etc.
contractors and excavators that normally engage in excavation in area of pipeline
high‐risk excavations
prevention information
replace line markers as needed
practices
Tool (DIRT) report data
Recommended Practices
measurement
causes of damages
crossings or blasting
excavation requires the use of explosives
third‐party damage to one call tickets)
responses
calling for locates
incidents / accidents
due to third party damage
excavation practices, such as failure to hand‐dig when required
monitored
system
identification of public and other stakeholders along the ROW
identification of contractors and excavators that normally engage in excavation in area
adequate knowledge of pipeline location or threats
ROW has been cleared consistent with
call
damage
enforcement authority
should have been monitored by operator but that were not
pressure test
without a release
previous damage has occurred
Leading ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Indicators‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Lagging Failure Mechanism Selected Process or Operational Activities for Threat Prevention or Management Deterioration Indicators Failure or Direct Integrity Metrics Other Third Party Damage, including vandalism, third‐party vehicle contact with facility, interferences and other intentional
Tool (DIRT) report data
facilities
necessary follow‐up completed
first responder agencies
impact barriers
vehicles
release
inference with adjacent structures, utilities, etc.
damage
related mechanical damage
Leading ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Indicators‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Lagging Failure Mechanism Selected Process or Operational Activities for Threat Prevention or Management Deterioration Indicators Failure or Direct Integrity Metrics Corrosion ‐ Impact on bare steel pipe, cast iron pipe, coated and wrapped steel pipe, other metallic materials External corrosion
testing program
remediation program
indicated corrosion
corrosion protection program
exception reports
system survey results ○ Insufficient number of anodes ○ Low CP current ○ High CP current ○ Failed recfiers ○ Damaged test leads ○ Changes in soil resisvity ○ Consecuve low CP readings in same location (failure to correct deficiencies)
survey results ○ Insufficient number of anodes ○ Ineffecve anodes ○ Changes in soil resisvity
ACVG, DCVG, CIS, or PCM
ECDA, ACVG / DCVG, ILI, Hydro, EMAT, or excavations
currents identified ○ Electrical surveys ○ Current sources
○ Water samples from disbanded coating ○ Soil sample for bacteria
external corrosion
corrosion (in addition to coating / CP metrics) ○ Inspecon reports ○ Splash zone locaons
components / fittings in the system
pressure test
Leading ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Indicators‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Lagging Failure Mechanism Selected Process or Operational Activities for Threat Prevention or Management Deterioration Indicators Failure or Direct Integrity Metrics Internal corrosion
corrosion protection program
indicated corrosion
internal corrosion
checks ○ Inhibitor quantity ○ Water content ○ H2S content ○ CO2 content ○ Microbe content ○ Sediment content ○ Low flow
pressure test
Stress Corrosion Cracking
criteria ○ Soil conditions ○ Operating pressure and temperature ○ Coating type ○ Process for coating application
indicated cracks or crack‐like anomalies
hole exam
criteria
discovered through ECDA, ACVG / DCVG, ILI, Hydro, EMAT, Excavations, other
indicating an increasing amount of near‐ critical flaws present in line pipe
amount of near‐critical flaws present in line pipe
pressure test
Selective Seam Corrosion Same as external corrosion plus
Same as external corrosion plus
near the long seam discovered through ACVG / DCVG, ILI, Hydro, Excavations, other
corrosion metal loss, cracks, or crack‐like anomalies near the long seam
amount of near‐critical flaws present in line pipe
pressure test
Leading ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Indicators‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Lagging Failure Mechanism Selected Process or Operational Activities for Threat Prevention or Management Deterioration Indicators Failure or Direct Integrity Metrics Material Failures Pipe materials, including pipe seam
address the risks associated with specific pipe materials, seam type, manufacturer, vintage, etc.
programs to address the risks associated with specific pipe materials, seam type, manufacturer, vintage, etc.
which have not been appropriately assessed
to ensure specifications meet requirements
○ Century Ulity Products ○ Low‐ductile inner wall Aldyl pipe manufactured by DuPont prior to 1973 ○ PE 3306
detecting pipe body defects (laminations, hard spots, hook cracks, blisters, etc.)
MOP(or MAOP) ratio approaches unity
indicate inaccuracies in material or component records
defects
amount of near‐critical flaws present in line pipe
/ MOP
pressure test
manufacturing flaws Construction girth welds, including repair welds
Construction Techniques
Construction Techniques which have not been appropriately assessed
misalignment
quality
inadequate weld quality
methodology (welded sleeves, composite, etc.)
MOP(or MAOP) ratio approaches unity
monitored continuously by operator inspectors
defects
welds
/ MOP
pressure test
Transportation and Construction damage
Construction Techniques
Construction Techniques which have not been appropriately assessed
bends, or construction damage
damaged coating
MOP(or MAOP) ratio approaches unity
/ MOP
pressure test
Leading ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Indicators‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Lagging Failure Mechanism Selected Process or Operational Activities for Threat Prevention or Management Deterioration Indicators Failure or Direct Integrity Metrics Equipment Failure Equipment malfunction or failure of non‐ pipe component
○ Pumps ○ Control valves ○ High pressure shutdown devices ○ Relief valves ○ Block valves
systemic problems
maintenance program
vibration
that performs to specification when inspected or tested.
activities completed on time.
expected life cycle period
indicate inaccuracies in material or component records
failures
couplings, non‐threaded connections, tubing, equipment body
life cycle
Operational Error Valve left or placed in wrong position
contamination
(percentage of events for which
as intended)
function as intended
procedures / safety practices
procedures
Incorrect start / stop of pump or compressor
contamination
procedures / safety practices
procedures
Tank overfilled
deliveries
protection
procedures / safety practices
procedures
Leading ‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Indicators‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐‐Lagging Failure Mechanism Selected Process or Operational Activities for Threat Prevention or Management Deterioration Indicators Failure or Direct Integrity Metrics Other human errors
audits
inoperable for long periods of time
temporarily reduced when it was required
correct action in response to an abnormal
procedures
procedures
appropriate Natural Forces ‐ Impact on steel pipe, plastic pipe, cast iron pipe Cold Weather
/ snow Heavy rains / flooding
conditions
Lightning
faults
systems
Earth movement
subsidence, landslides. earthquake fault zones, and washouts
seismic activity
welds due to soil movement