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PHMSA Perspectives

Construction Process & Standards

API – AGA Joint Committee


Oil & Gas Pipeline Welding Practices
New Orleans, LA

Steve Nanney
January 27, 2010
Overview

• Regulatory Overview of 2009/2010


• PHMSA Expectations
• PHMSA Actions to Date
• API 5L Actions to Date
• Construction Issues - Summary
• API – Needed Actions
• Challenges
• Looking Ahead
• PHMSA Links
Regulatory Overview of 2009/2010
• Editorial Rule – Published 11/30/09
• Distribution IMP – Published 12/4/09
• Control Room Management – Published 12/7/09
• One Rule - Summer 2010
• Standards Update - Summer 2010
• Miscellaneous Rule – Summer 2010
• Excavation Damage – To Be Determined (TBD)
• Low Stress Integrated Insp. – TBD
PHMSA Expectations
• Hold safety paramount
• Protect the public and environment
• Follow the regulations
• Update standards - reflective of issues
• Focus on people and processes
– Quality Management Systems
PHMSA Actions to Date
April 23, 2009: PHMSA New Construction Workshop
May 14, 2009: ADB: Potential Low and Variable Yield and Tensile
Strength & Chemical Composition Properties in High
Strength Line Pipe
June 5, 2009: PHMSA Letter to Industry Trade Associations
June 22, 2009: API Standards Conference
Summer 2009: Letters to Alternative MAOP SP holders on Low Strength
Pipe
Spring/Fall 2009: Worked with Operators to identify low strength pipe &
remove
August 2009: Construction web site established
November 2009: Weld in service rupture due to alignment and welding
January 2010: Weld in service leak due to alignment and welding
API 5L - Actions to Date
• API 5L – sub-committee proposed changes for “low
strength” pipe issues
– QA management system for the supplying steel and
rolling mill (8.3.1)
– Coil/plate rolling practice shall be controlled to ensure
mechanical properties are uniform (8.3.7)
– Qualifications in hot rolling practice deviations (8.3.8)
– Standard sampling locations along plate or coil length
according to documented procedures (10.2.3.2)
– Modifications to retest procedures (10.2.12.2)
API 5L Actions to Date - continued
• Manufacturing Procedure Specification – new (B.3)
• Inspection and Test Plan – required (B.4)
• Manufacturing Procedure Qualification Tests –
mechanical tests (B.5.3)
• Qualification consider assessment of coil/plate tensile
property variability and coil/plate to pipe strength
changes
• Purchaser shall be notified of all plate/coil/pipe that do
not meet the initial defined rolling practices control
parameters, but have been re-qualified (B5.6 and B5.7)
API Actions to Date
• API 5L – subcommittee – co-chairs and members
– Great effort to improve API 5L standards
• API 5L – sub-committee proposed changes for “low
strength” pipe
– Needs API Membership approvals
• PHMSA is appreciative of Efforts
– “Proposed” Revisions to API 5L need timely approvals
Construction Issues - Summary
Topic Occurrences
Coating* 117
Welding* 87
Excavation 20
Nondestructive testing 20
Pipe material* 12
Bending 9
Lowering in* 7
Hydrotesting 4
Design 3
Other 8
Construction Issues
• Low Strength Pipe
• Coating Adhesion
Construction Issues
• Repair Weld Cracking Issues
Construction Issues
• Pipe bevel ends and alignment – high/low
Construction Issues
• Welding, NDT, Transitions, & Alignment
• Cut Induction Bends
Construction Issues
• Alignment – does it meet standards for API 1104?
Construction Issues
• Alignment – does it meet standards for API 1104?
Construction Issues
• Weld Failures – Transition and Cracking
– Pipe Sizes
• 42-inch
• 36-inch
• 30-inch
• 20-inch
API 1104 – Needed Actions
• Appendix A – Guidance for ECA
– Input Parameters for ECA
– Defined steps in defining Defect Acceptance Criteria
– Pipeline stress analysis – using field construction and
operational extremes for procedures
– WPQ – Essential Variables
– Defect Acceptance Criteria
– UT – verification procedures
– Procedures – for field usage
– Training
Joint API – Needed Actions
• Appendix A - Weld Procedure – Essential Variables
– Change in the grade or manufacturing process of the pipe
material or a change in the chemical composition or
processing –
• Different- steel manufacturers and hot rolling practices
– Major change in joint design – (API 1104 & API 5L)
– Pipe Bevel Alignment – usage of API 5L and/or
ASME B31.8 or 31.4 criteria - (API 1104 & API 5L)
Joint API – Needed Actions
• Weld Tolerances – (API 1104 and API 5L)
– Pipe, diameter of body and pipe ends - API 5L
– Bevel Design – API 1104 & ASME B31.8 and B31.4
– Alignment – API 1104
– Varying/uneven wall thickness (ASME B31.4 and B31.8)
– Bends – cut within bend – ovality/out-of-roundness criteria
• Repair welding – (API 1104)
– Preheat
– Welding procedures
– Post heat
– NDT standards
Transition Weld Failures
• Alignment – bevel and uneven wall thickness
• Ovality and out-of-roundness
• Lateral displacement during construction
• Soil settlement
• Overburden loads
• Pipeline right-of-way topography
• Weld stress concentration factor (SCF)
• Internal pressure
Transition Weld Failures
• Alignment – does it meet standards for API 1104?
Challenges
• Industry
– Putting safety first – in practice
– Establishing standards that address all issues
– Recognize that large diameter, higher grade material with higher
operating pressures need “updated and some new” practices
• People
– Getting people to consistently do it right
– Finding and retaining appropriate skill sets
– Achieving sustained improvements
• Processes
– Establishing proper procedures
– Ensuring a seamless transition between contractors and owners
– Contracting methods
Looking Ahead
• PHMSA construction inspection focus will continue
• Expect increased use of enforcement actions on all
construction issues – 72%SMYS and 80%SMYS
• MAOP Rule
• Construction OQ – required by MAOP Rule
• (If planning project, contact PHMSA Region for details.)
• May need to explore other options:
– More effective regulations and standards
– Timely enforcement actions
– Operator qualification for construction
PHMSA – links
• Pipeline Safety Guidance – Advisory Bulletins, Low
Strength Pipe Guidelines, MAOP Rule FAQs
– http://www.phmsa.dot.gov/pipeline/guidance
• Construction Workshop
– 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
QUESTIONS
Thank you

Steve Nanney
Office: 713-272-2855
Mob: 713-628-7479
E-mail: steve.nanney@dot.gov