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PHMSA PerspectivesConstruction 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 DateApril 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 - SummaryTopic 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
