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 PHMSA Safety Update - Topics • PHMSA – Overview • Perspective on Past Performance • Agency Priorities for 2012 • Where are we now? • Verification of Records - 2 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Who is PHMSA - DOT/PHMSA? Pipeline and Hazardous Materials Safety Administration (PHMSA) FAA FMCSA PHMSA FRA MARAD RITA FHWA NHTSA STB - 3 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration PHMSA Chief Counsel Public Affairs Office of Office of Pipeline Safety Pipeline Safety Contracts/Procurement Human Resources Office of Hazardous Materials Safety Civil Rights Training Center - 4 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration PHMSA - OPS Regions - 5 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration PHMSA Mission • To ensure the operation of the Nation’s pipeline transportation system is: – Safe – Reliable – Environmentally sound - 6 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration U.S. Pipeline Transportation System - 7 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Pipeline System Components - 2011 Total Operators Total Pipeline Mileage (%) (%) Hazardous Liquid 182,135 7 359 12 Gas Transmission 304,580 11 899 32 Gas Gathering 20,242 1 310 11 2,113,511 81 Gas Distribution 1,284 45 1,232,173 47 (main) 881,338 34 (service) Total 2,620,468 100 2,852 100 - 8 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Perspective on Past Performance - 9 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Significant Accident Breakdown Total by Type (Fatalities) Total for Hazardous Gas Gas All Types 1 Liquid Transmission Distribution 2010 255 (19) 120 (1) 75 (10) 54 (8) 2011 2 222 (16) 99 (1) 62 (0) 57 (15) 3 Year 269 (14) 116 (2) 74 (3) 68 (8) Average (2008-2010) 5 Year 266 (15) 112 (2) 75 (3) 68 (10) Average (2006-2010) 10 Year 277 (14) 119 (2) 72 (2) 76 (10) Average (2001-2010) 1 Does not include gathering lines - totals may not add – excludes “fire first” incidents; - 10 - 2 data as of 12/13.2011
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Pipeline Incidents w/Death or Injury (1986-2011) 120 100 80 y = 89.103e -0.034x 60 (3.4% decline/yr.) 40 20 0 1986 1990 1994 1998 2002 2006 2010 Data source: DOT-PHMSA Incident data (as of Jan. 18, 2012) - 11 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Pipeline Major Injuries (1986-2011) 180 160 140 120 y = 176.92e -0.048x 100 (4.8% decline/yr.) 80 60 ↑ 1,971 40 in 1994 20 0 1986 1990 1994 1998 2002 2006 2010 Data source: DOT-PHMSA Incident data (as of Jan. 18, 2012) - 12 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Pipeline Fatalities (1986-2011) 60 50 40 y = 23.102e -0.019x 30 (1.9% decline/yr.) 20 10 0 1986 1990 1994 1998 2002 2006 2010 - 13 - Data source: DOT-PHMSA Incident data (as of Jan. 18, 2012)
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Dollar Damage from Pipeline Incidents (1986-2011), in 2010 Dollars (Millions) $1,600 $1,400 $1,200 $1,000 y = 5E+07e 0.0836x $800 (8.4% increase/yr.) $600 $400 $200 $- 1986 1990 1994 1998 2002 2006 2010 Data source: DOT-PHMSA Incident data (as of Jan. 18, 2012) - 14 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration All Incidents - Gas Transmission and Liquid Pipelines - 2002 to 2012/08 50 45 40 35 All Other Causes 30 25 Corrosion 20 15 Excavation Damage 10 5 Incorrect Operations 0 Material/Weld/Equip. Failure Natural Force Damage Other Outside Forces - 15 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Agency Priorities for 2012 - 16 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration A Busy Year for PHMSA • PHMSA “reauthorized” with new mandates • 14 new NTSB recommendations • Inspector General recommendations for HL pipelines – State programs and oil spill response planning • GAO issued some recommendations • Conducted workshops, studies, and regs. • Construction Inspections - 17 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Agency Priorities for 2012 • Major Priorities – Federal enforcement on excavation damage NPRM – Hazardous Liquid Rule – through final phase – Pipeline Enforcement Rulemaking – through final phase – Gas Rulemaking – through proposed rule phase • Likely to pick up most Congressional/NTSB items – MAOP verification in class 3 & 4 + HCA’s (and beyond?) • Records inadequacies, reporting and material testing requirements - 18 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Where are we now? - 19 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Aging Infrastructure (% by Decade) Hazar Hazardous dous Gas T Gas Tran ansmission smission Distribut Distr ibutio ion Decade Dec ade Liquid Liqu id Main Main Ser Service vice UNK/Pre 2% --- 20s 1920s 2% 2% --- --- 1930s 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% - 20 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Vintage/Legacy Pipe • Grandfathered Pipe (with no pressure test) • Pipe seam issues (LF/HF-ERW, Lap Welded, etc.) • Older manufacturing quality issues • Hard spots • Laminations • Low toughness • Legacy coatings (CP shielding) - 21 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Managing Challenges with Pipeline Seam Welds DSAW Pipe Lap Welded Pipe Spiral Weld – SAW Pipe LF and HF - ERW Pipe - 22 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Pipe Seam - Failures Submerged Arc Welded (SAW) Pipe – ERW Seam Electric Resistance Welded Pipe (ERW) - 23 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration What are the Issues? • Seam weld integrity issues are: – N ot always being identified by operator’s integrity management and risk assessment approaches • Inadequate actions taken: – Pipe seam not identified for special or urgent preventive and mitigative actions in some cases • Grandfather MAOP/MOP – No Code pressure test to +125% MAOP/MOP - 24 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Pipe Seams Failures (2002-2012/8) Hazardous % of Seam Type Gas TOTAL Liquid Total DSAW 9 5 14 18 Flash Welded 1 5 6 8 HF ERW 3 15 18 23 LF ERW 5 23 28 35 Lap Weld 1 2 3 4 SAW 2 3 5 6 Other 4 2 6 7 Total 25 55 80 100 - 25 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration Remediation Uncertainties in Vintage Pipe • ILI Tool Accuracy/Tolerance and Reliability − Tool tolerance, excavations, usage of unity plots • Hard-to-Detect Threats – SCC, girth weld defects, long seam defects, equipment failure, manufacturing defects • Hydrostatic Pressure Test – Future growth of un-remediated defects • Direct Assessment – Conclusions based on minimal excavations - 26 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration 2011 – New Pipeline Quality Low Strength Fittings • Coating is cracking due to expansion of fitting during testing - 27 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration 2011 – New Pipeline Quality • 24-inch Fitting – Hydrotest – 2160 psi – Failed at – 1740 psig - 28 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration 2011 – New Pipeline Quality Right – of-Way • Backfill practices • Clean-up practices • Maintenance - 29 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration 2011 – New Pipeline Quality - 30 -
U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration 2011 – New Pipeline Quality 2011 – HF-ERW Pipe Seam • Where is the pipe mill and construction QA/QC? - 31 -
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