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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
slide26

Thank you

Steve Nanney

Office: 713-272-2855

Mob: 713-628-7479

E-mail: [email protected]

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