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PHMSA Perspectives Construction Process & Standards

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

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PHMSA Perspectives Construction Process & Standards

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  1. PHMSA PerspectivesConstruction Process & Standards API – AGA Joint Committee Oil & Gas Pipeline Welding Practices New Orleans, LA Steve Nanney January 27, 2010

  2. 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

  3. 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

  4. 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

  5. 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

  6. 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)

  7. 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)

  8. 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

  9. Construction Issues - Summary

  10. Construction Issues • Low Strength Pipe • Coating Adhesion

  11. Construction Issues • Repair Weld Cracking Issues

  12. Construction Issues • Pipe bevel ends and alignment – high/low

  13. Construction Issues • Welding, NDT, Transitions, & Alignment • Cut Induction Bends

  14. Construction Issues • Alignment – does it meet standards for API 1104?

  15. Construction Issues • Alignment – does it meet standards for API 1104?

  16. Construction Issues • Weld Failures – Transition and Cracking • Pipe Sizes • 42-inch • 36-inch • 30-inch • 20-inch

  17. 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

  18. 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)

  19. 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

  20. 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

  21. Transition Weld Failures • Alignment – does it meet standards for API 1104?

  22. 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

  23. 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

  24. 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

  25. QUESTIONS

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

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