Pipeline Safety Update

Transcription

1 Pipeline Safety Update NAPCA Workshop August 16, 2012 Houston, Texas Safety Administration (PHMSA) Steve Nanney - 1 -

2 PHMSA Safety Update - Topics PHMSA Overview Perspective on Past Performance Agency Priorities for 2012 Where are we now? Verification of Records - 2 -

3 Who is PHMSA - DOT/PHMSA? Pipeline and Hazardous Materials Safety Administration (PHMSA) FAA FRA FHWA FMCSA MARAD NHTSA PHMSA RITA STB - 3 -

4 PHMSA Chief Counsel Office of of Pipeline Safety Public Affairs Contracts/Procurement Office of Hazardous Materials Safety Human Resources Civil Rights Training Center - 4 -

5 PHMSA - OPS Regions - 5 -

6 PHMSA Mission To ensure the operation of the Nation s pipeline transportation system is: Safe Reliable Environmentally sound - 6 -

7 U.S. Pipeline Transportation System - 7 -

8 Pipeline System Components Pipeline Mileage Total (%) Operators Total (%) Hazardous Liquid 182, Gas Transmission 304, Gas Gathering 20, Gas Distribution (main) (service) 2,113, ,232, , , Total 2,620, ,

9 Perspective on Past Performance - 9 -

10 Significant Accident Breakdown Total by Type (Fatalities) Total for All Types 1 Hazardous Liquid Gas Transmission Gas Distribution (19) 120 (1) 75 (10) 54 (8) (16) 99 (1) 62 (0) 57 (15) 3 Year Average ( ) 5 Year Average ( ) 10 Year Average ( ) 269 (14) 116 (2) 74 (3) 68 (8) 266 (15) 112 (2) 75 (3) 68 (10) 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/

11 120 Pipeline Incidents w/death or Injury ( ) y = e x (3.4% decline/yr.) Data source: DOT-PHMSA Incident data (as of Jan. 18, 2012)

12 180 Pipeline Major Injuries ( ) y = e x (4.8% decline/yr.) ,971 in Data source: DOT-PHMSA Incident data (as of Jan. 18, 2012)

13 60 Pipeline Fatalities ( ) y = e x (1.9% decline/yr.) Data source: DOT-PHMSA Incident data (as of Jan. 18, 2012)

14 (Millions) $1,600 Dollar Damage from Pipeline Incidents ( ), in 2010 Dollars $1,400 $1,200 $1,000 $800 $600 y = 5E+07e x (8.4% increase/yr.) $400 $200 $ Data source: DOT-PHMSA Incident data (as of Jan. 18, 2012)

15 All Incidents - Gas Transmission and Liquid Pipelines to 2012/ All Other Causes Corrosion Excavation Damage Incorrect Operations Material/Weld/Equip. Failure Natural Force Damage Other Outside Forces

16 Agency Priorities for

17 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

18 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

19 Where are we now?

20 Aging Infrastructure (% by Decade) Decade Hazardous Liquid Gas Transmission Distribution Main Service UNK/Pre 20s 2% s 2% 2% s 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%

21 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)

22 Managing Challenges with Pipeline Seam Welds DSAW Pipe Lap Welded Pipe Spiral Weld SAW Pipe LF and HF - ERW Pipe

23 Pipe ERW Seam Pipe Seam - Failures Submerged Arc Welded (SAW) Electric Resistance Welded Pipe (ERW)

24 What are the Issues? Seam weld integrity issues are: Not 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

25 Pipe Seams Failures ( /8) Seam Type Gas Hazardous Liquid TOTAL % of Total DSAW Flash Welded HF ERW LF ERW Lap Weld SAW Other Total

26 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

27 2011 New Pipeline Quality Low Strength Fittings Coating is cracking due to expansion of fitting during testing

28 2011 New Pipeline Quality 24-inch Fitting Hydrotest 2160 psi Failed at 1740 psig

29 2011 New Pipeline Quality Right of-way Backfill practices Clean-up practices Maintenance

30 2011 New Pipeline Quality

31 2011 New Pipeline Quality 2011 HF-ERW Pipe Seam Where is the pipe mill and construction QA/QC?

32 2011 New Pipeline Quality Mill applied repair removed by scratching No surface prep at coating plant 2-part repair over spiral seam with portion of repair lifting off coating

33 Current Challenges 2010/11/12 High Profile Accidents with Serious Consequences on Aging and New Infrastructure Incidents on Several New Pipelines in 1 st Year of Service Industry needs improved material, construction, and operational QA/QC Differing Levels of Acceptable Risk with Different Audiences

34 Verification of Records PIPE DOCUMENTATION Based on Code, Special Permit, and Operating Conditions

35 Material Records Why are pipeline material records needed? To establish design and maximum operating pressures (MOP or MAOP) For integrity management (IM) programs Anomaly evaluations for safe operating pressure

36 Records Management Materials must be manufactured in accordance: DOT referenced standards Able to maintain structural integrity of the pipeline: Operating pressure, temperature, and environmental conditions including outside force loads Fracture arrest for 80% SMYS pipelines Pipe Design Withstand external pressures and anticipated loads Designed for service and class location

37 Records Management What are the first items looked at if a pipeline has an incident? Records! Material Records pipe, fittings & fabrications, etc. QA and QC 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

38 Records Management What type pipe records are needed? For Design Formula and Maximum Operating Pressure Outside diameter Pipe wall thickness Yield Strength Weld Joint/Seam Type API 5L pipe mill test report for new pipe also has. Chemical properties Tensile properties yield and ultimate Hydrostatic test pressure

39 What pipe records are needed? Needs to be based upon Code, Special Permit and Service/Operating Conditions: 72% MAOP/MOP or % MAOP/MOP and or Special Permit CE, Charpy, DWTT, Seam Hardness, Steel/Pipe UT, Marco Etch Tests, mill hydrotest pressure, seam weld tensile strength, etc. Fracture Arrest Charpy, DWTT, etc. Strain Based Design possible all of above

40 API 5L 44 th Edition Requirements Section 13 Retention of Records heat and product analyses; tensile tests; guided-bend tests; CVN tests; DWT tests; records of any other test as specified in the annexes or the purchase order all welding procedure specifications (WPS) and welding-procedure qualification test records (WPQT/PQR) (see Annex A). hydrostatic-tester recorder charts or electronic; radiographic images for pipe inspection; non-destructive inspection by other methods where applicable; qualifications of nondestructive inspection personnel; radiographic images for jointer welds; repair welding procedure tests;

41 Metallurgical & Pipe Test Report Needs to be based upon: API 5L Operator Code Permit, if any Operating Conditions

42 Retention of Pipe Records Pipeline Operator for new pipelines: needs pipe records for Design, MAOP/MOP Determination, Operations and Integrity Management for the; Life of the Pipeline Based upon Code, Special Permit, and/or Operating Conditions/Parameters

43 Why are material records needed? NTSB recommendation (San Bruno) delete the grandfather clause and require all pre-70 gas transmission pipelines be subjected to a hydrostatic pressure test incorporating a spike test. Act requires PHMSA to: direct gas transmission operators to provide verification that their records accurately reflect MAOP of Class 3/4 location and Class 1/2 HCAs

44 NTSB San Bruno Investigation Where were the pipe material records? NTSB Board Meeting August 30,

45 Record Management Issues That PHMSA Has Seen! Unknown or unverifiable pipe specifications/mill test reports Known (but really unknown) information Project files not properly indexed or recallable poor housekeeping. Incomplete or missing hydrostatic test records Lost records acquisitions, mishaps

46 Keep in Mind We all want safe operations Operators must know their systems, including risks and potential weaknesses. In San Bruno, we didn t know?? Suspect pipe, not meeting any standard

47 PHMSA Advisory Bulletin Advisory Bulletin (ADB) - ADB Titled: Establishing MAOP or MOP using record evidence, and integrity management risk identification, assessment, prevention, and mitigation. Docket No. PHMSA Reminded operators that records used to support MAOP and MOP determinations must be reliable, traceable, verifiable and complete

48 Adversary Bulletin (ADB) Directed to ALL pipeline operators gas transmission, gas distribution and liquid Does NOT create any new records requirements Reminds operators of expectation that operational decisions are based on documented information

49 What does the ADB Require? The ADB information clarifies that adequate records should be: Traceable Verifiable Complete

50 Traceable records are: Traceable 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. Records transcribed from original documents must have careful attention: Information from a transcribed record should be verified with complementary or supporting documents

51 Verifiable records Verifiable information confirmed by other complementary, but separate, documentation. Two or more complementary records - positively linked can be used together as a verifiable record. A single record which has all needed information does not need a separate, complementary, document

52 Complete Complete records must include: a signature, date or other appropriate marking. Incomplete or partial records: not an adequate basis for establishing MAOP or MOP. If records are unknown, a more conservative approach is indicated

53 PHMSA Links PHMSA Pipeline Technical Resources Advisory Bulletins Alternative MAOP (80% SMYS) Pipeline Construction Issues Low Strength Pipe

54 ERW Pipe Needed for PHMSA R&D Program at Battelle Pipe with seam defects will be used in many tasks of the project including: Hydrotest Protocols to for ERW/FW Seams improve hydrotesting protocols and validate their practical utility. Defect Characterization: Types, Sizes, and Shapes bridge gaps in defect characterization in regard to types, sizes, and shapes improvements in the tools - ILI and hydrotesting Enhanced Detection and Sizing via Inspection work with vendors to improve the sensors, interpretive algorithms, and tool platforms in regard to ILI and ITDM to better ensure integrity Develop and Refine Essential Predictive Models and Quantify Growth Mechanism validate existing models and where gaps preclude validation refine or develop models needed to assess / quantify defect severity

55 For R&D ERW Pipe Donations The source of the pipe will be blind to DOT PHMSA Please contact Battelle directly: Bruce Nestleroth Battelle will pay freight charges

56 Thank You Steve Nanney