Presentation on theme: "PHMSA Perspectives Construction Process & Standards"— Presentation transcript:
1 PHMSA Perspectives Construction Process & Standards API – AGA Joint CommitteeOil & Gas Pipeline Welding PracticesNew Orleans, LASteve NanneyJanuary 27, 2010
2 Overview Regulatory Overview of 2009/2010 PHMSA Expectations PHMSA Actions to DateAPI 5L Actions to DateConstruction Issues - SummaryAPI – Needed ActionsChallengesLooking AheadPHMSA Links
3 Regulatory Overview of 2009/2010 Editorial Rule – Published 11/30/09Distribution IMP – Published 12/4/09Control Room Management – Published 12/7/09One Rule - Summer 2010Standards Update - Summer 2010Miscellaneous Rule – Summer 2010Excavation Damage – To Be Determined (TBD)Low Stress Integrated Insp. – TBD
4 PHMSA Expectations Hold safety paramount Protect the public and environmentFollow the regulationsUpdate standards - reflective of issuesFocus on people and processesQuality 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 PipeJune 5, 2009: PHMSA Letter to Industry Trade AssociationsJune 22, 2009: API Standards ConferenceSummer 2009: Letters to Alternative MAOP SP holders on Low Strength PipeSpring/Fall 2009: Worked with Operators to identify low strength pipe & removeAugust 2009: Construction web site establishedNovember 2009: Weld in service rupture due to alignment and weldingJanuary 2010: Weld in service leak due to alignment and welding
6 API 5L - Actions to DateAPI 5L – sub-committee proposed changes for “low strength” pipe issuesQA 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 changesPurchaser 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 standardsAPI 5L – sub-committee proposed changes for “low strength” pipeNeeds API Membership approvalsPHMSA is appreciative of Efforts“Proposed” Revisions to API 5L need timely approvals
9 Construction Issues - Summary TopicOccurrencesCoating*117Welding*87Excavation20Nondestructive testingPipe material*12Bending9Lowering in*7Hydrotesting4Design3Other8
10 Construction IssuesLow Strength PipeCoating Adhesion
14 Construction IssuesAlignment – does it meet standards for API 1104?
15 Construction IssuesAlignment – does it meet standards for API 1104?
16 Construction Issues Weld Failures – Transition and Cracking Pipe Sizes 42-inch36-inch30-inch20-inch
17 API 1104 – Needed Actions Appendix A – Guidance for ECA Input Parameters for ECADefined steps in defining Defect Acceptance CriteriaPipeline stress analysis – using field construction and operational extremes for proceduresWPQ – Essential VariablesDefect Acceptance CriteriaUT – verification proceduresProcedures – for field usageTraining
18 Joint API – Needed Actions Appendix A - Weld Procedure – Essential VariablesChange 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 practicesMajor 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 5LBevel Design – API 1104 & ASME B31.8 and B31.4Alignment – API 1104Varying/uneven wall thickness (ASME B31.4 and B31.8)Bends – cut within bend – ovality/out-of-roundness criteriaRepair welding – (API 1104)PreheatWelding proceduresPost heatNDT standards
20 Transition Weld Failures Alignment – bevel and uneven wall thicknessOvality and out-of-roundnessLateral displacement during constructionSoil settlementOverburden loadsPipeline right-of-way topographyWeld 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 practiceEstablishing standards that address all issuesRecognize that large diameter, higher grade material with higher operating pressures need “updated and some new” practicesPeopleGetting people to consistently do it rightFinding and retaining appropriate skill setsAchieving sustained improvementsProcessesEstablishing proper proceduresEnsuring a seamless transition between contractors and ownersContracting methods
23 Looking Ahead PHMSA construction inspection focus will continue Expect increased use of enforcement actions on all construction issues – 72%SMYS and 80%SMYSMAOP RuleConstruction OQ – required by MAOP Rule(If planning project, contact PHMSA Region for details.)May need to explore other options:More effective regulations and standardsTimely enforcement actionsOperator qualification for construction