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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

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Phmsa perspectives construction process standards

PHMSA PerspectivesConstruction Process & Standards

API – AGA Joint Committee

Oil & Gas Pipeline Welding Practices

New Orleans, LA

Steve Nanney

January 27, 2010


Overview
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
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
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
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 - 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
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 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
Construction Issues

  • Low Strength Pipe

  • Coating Adhesion


Construction issues1
Construction Issues

  • Repair Weld Cracking Issues


Construction issues2
Construction Issues

  • Pipe bevel ends and alignment – high/low


Construction issues3
Construction Issues

  • Welding, NDT, Transitions, & Alignment

  • Cut Induction Bends


Construction issues4
Construction Issues

  • Alignment – does it meet standards for API 1104?


Construction issues5
Construction Issues

  • Alignment – does it meet standards for API 1104?


Construction issues6
Construction Issues

  • Weld Failures – Transition and Cracking

    • Pipe Sizes

      • 42-inch

      • 36-inch

      • 30-inch

      • 20-inch


Api 1104 needed actions
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
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 actions1
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
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 failures1
Transition Weld Failures

  • Alignment – does it meet standards for API 1104?


Challenges
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
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
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



Thank you

Steve Nanney

Office: 713-272-2855

Mob: 713-628-7479

E-mail: [email protected]


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