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Pipeline Construction Pipeline Construction Challenges Challenges - - PowerPoint PPT Presentation

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Pipeline Construction Pipeline Construction Challenges Challenges NAPCA Workshop August 19, 2010 Houston, Texas Kenneth Y. Lee Office of Pipeline

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Pipeline Construction Pipeline Construction Challenges Challenges

NAPCA Workshop

August 19, 2010 Houston, Texas

Kenneth Y. Lee Office of Pipeline Safety

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SLIDE 2

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

PHMSA Mission PHMSA Mission

  • To ensure the operation of the Nation’s pipeline

transportation system is: – Safe – Reliable – Environmentally sound

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SLIDE 3

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Incidents (2002 Incidents (2002-2009) 2009)

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SLIDE 5

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Incidents (2002 Incidents (2002-2009) 2009)

5 10 15 20 25 30 Excavation Corrosion Misc & Other Equipment Construction W & OF Materials Operations

%

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Incidents Incidents

  • 2007
  • Natural Gas
  • Excavation
  • 1 fatality
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SLIDE 7

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Incidents Incidents

  • 2007
  • Natural Gas
  • 30-inch
  • Corrosion
  • 1 fatality
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SLIDE 8

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Incidents Incidents

  • 2007
  • Natural Gas
  • 30-inch
  • Selective

Seam Corrosion

  • High

Resistivity Soils

  • No injuries
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SLIDE 9

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Incidents Incidents

  • 2007
  • 12 inch HVL
  • LF-ERW Seam
  • 2 fatalities
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SLIDE 10

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Incidents Incidents

  • 2008
  • Natural Gas
  • 30-inch
  • Excavation
  • 5 injuries
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SLIDE 11

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

New Construction Issues Observed by New Construction Issues Observed by PHMSA Inspectors PHMSA Inspectors

20 40 60 80 100 120

Coating Welding Excavation NDT Pipe Steel Bending Lowering Occurences

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Observed Coating Observed Coating Issues Issues

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SLIDE 13

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Backfill before Coating has Cured Backfill before Coating has Cured

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SLIDE 14

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Patch Stick: Inadequate Adhesion Patch Stick: Inadequate Adhesion

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Coating Over Tape Coating Over Tape

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Coating Disbondment Coating Disbondment

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Backfill Damage Backfill Damage

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SLIDE 18

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Coating Over Dirt/Debris Coating Over Dirt/Debris

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SLIDE 19

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Welding Band Damage Welding Band Damage

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Pipe Quality Issues Pipe Quality Issues

  • Low strength X70 & X80
  • Inconsistent chemical and mechanical properties
  • Poor mill rolling practices
  • Advisory Bulletin (PHMSA 2009-1048)
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Girth Weld Failures Girth Weld Failures

Radiographic Weld Inspection Hydrostatic Testing

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Hydrogen Cracking Hydrogen Cracking

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Hydrogen Hydrogen Cracking Cracking

HYDROGEN MICRO- STRUCTURE TENSILE STRESS

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Hydrogen Cracking Risk by Electrode Hydrogen Cracking Risk by Electrode Type Type

E9010 E8010 E7010 E6010 FCAW (flux-cored) E9018 E8018 E7018 GMAW (MIG)

Increasing Risk

Low Hydrogen Cellulosic

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Susceptible Microstructure (Hardness) Susceptible Microstructure (Hardness)

  • Historically, values > 350 HV should be

evaluated for the risk of hydrogen assisted cracking

  • Cracking observed at 200 to 260 HV
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Hydrogen Cracking Hydrogen Cracking

  • Thru-thickness

Repair

  • Partial-thickness

Repair

  • Transitions
  • Tie-ins

6:00 6010 9010 9018-M Full thickness repair of mechanized weld

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SLIDE 27

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Partial Thickness Repair: Partial Thickness Repair: Only 1 Cellulosic Weld Pass Only 1 Cellulosic Weld Pass

9010 9018-M Mechanized GMAW Low Hydrogen Weld Metal 9018-M 6:00 Repair

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SLIDE 28

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Partial Thickness Repair: Partial Thickness Repair: Cellulosic & Low Hydrogen Cellulosic & Low Hydrogen

Repair 6010 9010 9018-M Mechanized GMAW 12:00

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SLIDE 29

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Self Self-shielded Flux shielded Flux-Cored Transition Cored Transition

81T8 (FCAW-S) Fill & Cap 9018-M Hot 6010 Root 6010 Backweld

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Weld Preheat Weld Preheat

  • Heat entire circumference,

especially 12:00 & 6:00 locations

  • Measure temperature

immediately before start of every weld pass using:

– Temperature Indicating Crayons – Contact Pyrometer – Infrared Thermometer (reading depends on surface condition and distance)

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SLIDE 31

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Girth Weld Issues Girth Weld Issues

  • Transitions
  • Misalignment
  • Cut Induction Bends
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Improper Weld Transitions Improper Weld Transitions

ASME B31.8 Fig. I-5

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Misalignment Misalignment

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Misalignment Misalignment

Alignment – Does this meet API 1104?

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Bends & Fittings Bends & Fittings

  • If cutting bends, use

segmentable bends with tighter body tolerance

  • Ends should meet:

– API 5L dimensional limits – API 1104 fit-up requirements

Tangent End Tangent End

End Tolerance

Hot induction bend cross-section Bend fittings Hot induction bends

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SLIDE 36

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Weld Misalignment at Cut Bend Weld Misalignment at Cut Bend

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Best Practice: Best Practice: Shop fabricated bend assembly Shop fabricated bend assembly

Field weld

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Lowering In Stress Lowering In Stress

  • Maximum weld stress occurs during lowering in
  • Most weld failures at top & bottom of pipe
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Industry Actions Industry Actions

  • Workshops
  • Pipe Quality Work Groups (8 work groups)
  • Construction Work Groups (5 work groups)
  • Standards updates

PHMSA is appreciative of industry efforts

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

API 5L API 5L

  • Proposed changes to reduce potential for non-conforming pipe
  • Quality management system (QMS) for steel mill & rolling mill
  • Tensile test & bracket retest locations in coil/plate
  • Traceability of pipe to coil/plate
  • Enhanced Manufacturing Procedure Specification (MPS)

– Applies to steel mill, rolling mill, & pipe mill

  • Enhanced Manufacturing Procedure Qualification Test (MPQT)

– Test of initial production to qualify MPS. Includes assessment of coil/plate tensile property variability and coil/plate to pipe strength changes

  • New - Inspection and Test Plan (ITP)
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

API 1104 Appendix A API 1104 Appendix A

  • Guidance for ECA & lowering-in stresses
  • Retests for Charpys & crossweld tensiles
  • Consideration for weld misalignment
  • Weld Procedure Essential Variable. A change in the:

– Steel mill (slab, ingot, etc.) – Rolling mill (plate, coil) – Pipe mill (manufacturing facility) – Pipe manufacturing process (UOE, spiral, ERW, etc.) – Chemical composition limits (Pcm, CE, C)

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SLIDE 42

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

API 1104 Repair Task Group API 1104 Repair Task Group

  • Backweld, multiple, & double repairs
  • Repair length (minimum & maximum)
  • Hardness testing
  • NDT delay
  • Preheat & Postheat
  • Procedure qualification
  • Welder qualification
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SLIDE 43

U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

API 5L/1104 Joint Task Group API 5L/1104 Joint Task Group

  • Misalignment & dimensional tolerances
  • Tensile test orientation
  • Residual magnetism
  • Identification of steel/rolling mill
  • Multiple grades & strength limits
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Recent PHMSA Actions Recent PHMSA Actions

April 2009: PHMSA New Construction Workshop May 2009: ADB: Potential Low & Variable Yield & Tensile Strength & Chemical Composition Properties in High Strength Line Pipe June 2009: PHMSA Letter to Industry Trade Associations Summer 2009: Letters to Alt MAOP SP holders on Low Strength Pipe Spring/Fall 2009: Worked with operators to identify and remove low strength pipe August 2009: Construction web site established March 2010: ADB: Girth Weld Quality Issues Due to Improper Transitioning, Misalignment, and Welding Practices of Large Diameter Line Pipe April 2010: Distribution Construction Workshop

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Looking Ahead Looking Ahead

  • Continued focus on construction

inspections

  • Expect increased enforcement actions on

construction issues – for 72%SMYS and 80%SMYS pipelines

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Pipeline Construction Webpage Pipeline Construction Webpage

http://primis.phmsa.dot.gov/construction/index.htm http://primis.phmsa.dot.gov/construction/index.htm

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

PHMSA PHMSA – Links Links

  • Pipeline Safety Guidance – Advisory Bulletins,

Low Strength Pipe Guidelines, MAOP Rule FAQs

– http://www.phmsa.dot.gov/pipeline/guidance

  • Construction Issues

– http://primis.phmsa.dot.gov/construction/index.htm

  • MAOP Rule – FAQs

– http://primis.phmsa.dot.gov/maop/index.htm

  • Special Permits – FAQs

– http://primis.phmsa.dot.gov/classloc/faqs.htm

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

Thank you

Kenneth Y. Lee Office: (202) 366-2694 E-mail: kenneth.lee@dot.gov

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

QUESTIONS QUESTIONS

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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration

PHMSA PHMSA Office of Pipeline Safety Office of Pipeline Safety