PHMSA Perspectives Construction Process & Standards API – AGA Joint Committee Oil & Gas Pipeline Welding Practices New Orleans, LA Steve Nanney January.

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

Thank you

Steve Nanney

Office: 713-272-2855

Mob: 713-628-7479

E-mail: [email protected]