Pipeline Safety Update NAPCA Workshop August 16, 2012 Houston, - - PowerPoint PPT Presentation
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Pipeline Safety Update NAPCA Workshop August 16, 2012 Houston, Texas Pipeline and Hazardous Materials Safety Administration (PHMSA) Steve Nanney - 1
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Pipeline and Hazardous Materials Safety Administration (PHMSA)
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Office of Hazardous Materials Safety Chief Counsel Public Affairs
Contracts/Procurement
Human Resources Training Center Civil Rights
Office of Pipeline Safety
Office of Pipeline Safety
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Pipeline Mileage Total (%) Operators Total (%) Hazardous Liquid 182,135 7 359 12 Gas Transmission 304,580 11 899 32 Gas Gathering 20,242 1 310 11 Gas Distribution
(main) (service)
2,113,511 81 1,284 45
1,232,173 47 881,338 34
Total 2,620,468 100 2,852 100
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Total for All Types1 Hazardous Liquid Gas Transmission Gas Distribution 2010 255 (19) 120 (1) 75 (10) 54 (8) 20112 222 (16) 99 (1) 62 (0) 57 (15) 3 Year Average
(2008-2010)
269 (14) 116 (2) 74 (3) 68 (8) 5 Year Average
(2006-2010)
266 (15) 112 (2) 75 (3) 68 (10) 10 Year Average
(2001-2010)
277 (14) 119 (2) 72 (2) 76 (10)
1 Does not include gathering lines - totals may not add – excludes “fire first” incidents; 2 data as of 12/13.2011
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
y = 89.103e-0.034x
(3.4% decline/yr.)
20 40 60 80 100 120 1986 1990 1994 1998 2002 2006 2010
Data source: DOT-PHMSA Incident data (as of Jan. 18, 2012)
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
y = 176.92e-0.048x
(4.8% decline/yr.)
20 40 60 80 100 120 140 160 180 1986 1990 1994 1998 2002 2006 2010
↑ 1,971 in 1994
Data source: DOT-PHMSA Incident data (as of Jan. 18, 2012)
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
y = 23.102e-0.019x
(1.9% decline/yr.)
10 20 30 40 50 60 1986 1990 1994 1998 2002 2006 2010
Data source: DOT-PHMSA Incident data (as of Jan. 18, 2012)
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
y = 5E+07e0.0836x
(8.4% increase/yr.)
$- $200 $400 $600 $800 $1,000 $1,200 $1,400 $1,600 1986 1990 1994 1998 2002 2006 2010 (Millions)
Data source: DOT-PHMSA Incident data (as of Jan. 18, 2012)
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
5 10 15 20 25 30 35 40 45 50
All Other Causes Corrosion Excavation Damage Incorrect Operations Material/Weld/Equip. Failure Natural Force Damage Other Outside Forces
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– State programs and oil spill response planning
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– Federal enforcement on excavation damage NPRM – Hazardous Liquid Rule – through final phase – Pipeline Enforcement Rulemaking – through final phase – Gas Rulemaking – through proposed rule phase
– MAOP verification in class 3 & 4 + HCA’s (and beyond?)
requirements
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Dec Decade ade Hazar Hazardous dous Liqu Liquid id Gas Gas T Tran ansmission smission Distr Distribut ibutio ion Main Main Ser Service vice
UNK/Pre 20s 2%
2% 2%
3% 4% 6% 3% 1940s 8% 7% 2% 2% 1950s 20% 22% 10% 8% 1960s 21% 23% 17% 13% 1970s 16% 11% 12% 14% 1980s 9% 10% 14% 17% 1990s 11% 11% 21% 22% 2000s 8% 10% 18% 21%
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
DSAW Pipe Lap Welded Pipe
Spiral Weld – SAW Pipe LF and HF - ERW Pipe
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Pipe – ERW Seam Submerged Arc Welded (SAW)
Electric Resistance Welded Pipe (ERW)
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– Not always being identified by operator’s integrity management and risk assessment approaches
– Pipe seam not identified for special or urgent preventive and mitigative actions in some cases
– No Code pressure test to +125% MAOP/MOP
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Seam Type Gas Hazardous Liquid TOTAL % of Total
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
− Tool tolerance, excavations, usage of unity plots
– SCC, girth weld defects, long seam defects, equipment failure, manufacturing defects
– Future growth of un-remediated defects
– Conclusions based on minimal excavations
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
to expansion of fitting during testing
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– Hydrotest – 2160 psi – Failed at – 1740 psig
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
removed by scratching
plant
seam with portion of repair lifting off coating
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– Industry needs improved material, construction, and
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– DOT referenced standards – Able to maintain structural integrity of the pipeline:
including outside force loads
– Withstand external pressures and anticipated loads – Designed for service and class location
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– Material Records – pipe, fittings & fabrications, etc.
– Standards – API, ASME, ANSI, MSS, and ASTM – Tests – mechanical & chemical properties, welding, NDE, and hydrostatic test
– Design and Construction Records – Hydrostatic Test – Operations and Maintenance Records – Integrity Management Records
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– For Design Formula and Maximum Operating Pressure
– API 5L – pipe mill test report for new pipe also has….
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– 72% MAOP/MOP
– 80% MAOP/MOP
Marco Etch Tests, mill hydrotest pressure, seam weld tensile strength, etc. – Fracture Arrest – Charpy, DWTT, etc. – Strain Based Design – possible all of above
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
charts or electronic;
inspection;
applicable;
destructive inspection personnel;
welds;
tests;
specified in the annexes or the purchase order
specifications (WPS) and welding-procedure qualification test records (WPQT/PQR) (see Annex A).
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– API 5L – Operator – Code – Permit, if any – Operating Conditions
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– delete the grandfather clause and require all pre-70 gas transmission pipelines be subjected to a hydrostatic pressure test incorporating a spike test.
– direct gas transmission
verification that their records accurately reflect MAOP of Class 3/4 location and Class 1/2 HCAs
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
pipe specifications/mill test reports
unknown) information
indexed or recallable – poor housekeeping.
hydrostatic test records
mishaps
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– Titled: Establishing MAOP or MOP using record evidence, and integrity management risk identification, assessment, prevention, and mitigation. Docket No. PHMSA-2010-0381 – Reminded operators that records used to support MAOP and MOP determinations must be reliable, traceable, verifiable and complete.
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– clearly linked to original information about a pipeline segment or facility Examples might include: – Pipe mill records, purchase requisition or as-built documentation indicating minimum pipe yield strength, seam type, wall thickness and diameter.
– Information from a transcribed record should be verified with complementary or supporting documents.
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– information confirmed by other complementary, but separate, documentation.
– positively linked can be used together as a verifiable record.
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– a signature, date or other appropriate marking.
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
– improve hydrotesting protocols and validate their practical utility.
– bridge gaps in defect characterization in regard to types, sizes, and shapes – improvements in the tools - ILI and hydrotesting
– work with vendors to improve the sensors, interpretive algorithms, and tool platforms in regard to ILI and ITDM to better ensure integrity
Quantify Growth Mechanism
– validate existing models and where gaps preclude validation refine or develop models needed to assess / quantify defect severity.
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
steve.nanney@dot.gov