1. PHMSA Perspectives Construction 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 ( )
Modifications to retest procedures ( )

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
Topic
Occurrences
Coating*
117
Welding* 87
Excavation 20
Nondestructive testing
Pipe material* 12
Bending 9
Lowering in* 7
Hydrotesting 4
Design 3
Other 8

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 People Processes
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
Construction Workshop
MAOP Rule – FAQs
Special Permits – FAQs

25. QUESTIONS

26. E-mail: steve.nanney@dot.gov
Thank you
Steve Nanney
Office:
Mob: