phmsa update significant accidents revie · lf-erw – widely manufactured from 1920 to 1970’s...
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
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PHMSA Update Significant Accidents Review
2015 RRC/PHMSA Training and Qualification Conference
Thursday, September 17, 2015
11:15 – 11:45 AM
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
What We Regulate Pipeline Miles by System Types – end of CY 2012, as-of 3/7/2014
System Type Miles %Total # Operators
Hazardous Liquid 185,629 7% 410
Gas Transmission 303,308 11% 953
Gas Gathering 16,728 1% 342
Gas Distribution (Mains & Services ) 2,138,676 81% 1,356
Total 2,644,341 Some Operators
have multiple System Types
Liquefied Natural Gas 130 Plants 203 Tanks 82
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Categories of Incident Reports
3
All Reported – everything operators report
Serious – fatality or injury requiring in-patient hospitalization, but Fire First excluded. Fire First are gas distribution incidents with a cause of “Other Outside Force Damage” and sub-cause of “Nearby Industrial, Man-made, or Other Fire/Explosion”
Significant include any of the following, but Fire First excluded: 1. Fatality or injury requiring in-patient hospitalization 2. $50,000 or more in total costs, measured in 1984 dollars 3. Highly volatile liquid (HVL) releases of 5 barrels or more 4. Non-HVL liquid releases of 50 barrels or more 5. Liquid releases resulting in an unintentional fire or explosion
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Serious Incidents All System Types Downward Trend
Continues in 2013
4
Gas Transmission Dips Down to One Again in
2013
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Significant Incidents
All System Types Slight Rise 2013
5
Gas Transmission Slight Rise in
2013
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
2014 Pipeline Safety Challenges • Spate of High Consequence, High Profile Accidents
– Multi-stakeholder interest/concern
– Reauthorization in about 18 months
• Aging Infrastructure Being Overly Amortized - Band-Aids
• Impact of Shale Oil/Gas: New, Reversed, Converted Pipelines
• Separate Rate Recovery Authorities Worried About Rates
• Challenges to Recruit, Train and Retain Qualified Workforce
• Growing Expectations for Change in a Change Averse World
• The World is Watching – Bloggers and the Internet
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Top Priorities for FY 2014 Anticipate & Avert High Consequence Events by: i. Issue High Priority Rulemakings ii. Improve State Program Oversight iii.Implementing Congressional Act Mandates and Recommendations iv. Identify and Promote a Suite of Meaningful Performance Metrics v. Promotion of Pipeline R&D and Technological Advancement Build & Broadcast Understanding of Safety Risks by: i. Engage, Educate, and Empower the Public and ER Community (Damage
Prevention, PIPA, 811, ER Training) ii. IMP-2.0 – Sharpening Understanding and Communication
Catalog & Curtail Highest Risks by: i. Improve Consistency, Unification and Data Driven Inspections for Federal
and State Actions ii. Develop and Deploy a Pipeline Safety Workforce Management Strategy
(succession planning, training, resource allocation)
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
High Profile Accidents
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
High Profile Accidents • Marshall, Michigan (Federally Regulated)
– Major Crude Oil Spill Dramatically Impacted Several Communities in Michigan
• San Bruno, California (State Regulated)
– Major tragedy – Unimaginable Proportions
• Allentown, Pennsylvania (State Regulated)
– Cast Iron, low pressure
• Excavation Damage Fatalities (State Regulated)
– Texas, North Dakota, Georgia – to name a few
• Yellowstone River; Billings, Montana (Federally Regulated)
– Significant Oil Spill near Billings, MT
• Bison Pipeline; Rural Wyoming (Federally Regulated)
– Newly constructed natural gas pipeline
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
High Profile Accidents • Chevron; Salt Lake City, Utah (Federally Regulated) - 2012
– Crude oil and refined products
– Multiple accidents: 6/10, 12/10, 3/13
• Sissonville, West Virginia (Interstate Agent) – 2012
– Impact to major interstate highway; questions on HCA determination
– Led to Congressional oversight hearing
– NTSB investigation
• Mayflower, Arkansas (Federally Regulated) - 2013
– Canadian heavy crude
– Keystone implications?
– Investigation pending
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Sissonville Pipeline Incident • Dec 11, 2012: Rupture of a 20” X-60 gas
transmission pipeline (1967 vintage)
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Sissonville Pipeline Incident
• No injuries or fatalities (thankfully)
• Three neighboring homes destroyed, others damaged
• Interstate 77 damaged and temporarily closed
• Three pipelines in vicinity – SM-80 20” diameter PIR = 495 feet
– SM-86 26” diameter PIR = 626 feet
– SM-86 Loop 30” diameter PIR = 713 feet
• PHMSA issued Corrective Action Order
• WV PSC and PHMSA Investigation ongoing
• NTSB launched to investigate cause http://www.ntsb.gov/investigations/2012/sissonville_wva/sissonville_wva.html
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Mayflower, Arkansas Pipeline Accident
• March 29, 2012: A 20” crude oil pipeline ruptured in Mayflower, Arkansas;
• An estimated 5,000 bbl of crude was spilled;
• Pipeline carrying Canadian crude oil (Wabasca) from Patoka, Illinois to Nederland, Texas;
• Pipeline installed in 1947/1948.
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Enforcement Actions • Enforcement actions for accidents and incidents
now regularly incorporates IM principles
• Operators are responsible for performing and prioritizing integrity assessments based on all risk factors that reflect the risk conditions on the pipeline segment
• CPF No. 4-2013-5027 issued to ExxonMobil Pipeline Company, LP on 11/6/2013 resulted from investigation of the Pegasus Pipeline rupture
• The Remedial Work Plans required by the CAO for the Pegasus Pipeline have been submitted and are under review by PHMSA
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Issues Identified in CPF 4-2013-5027 • Majority of issues (8/9) involved IM regulations
– Did not include consideration of certain manufacturing information in their determination of risk factors (reasonably available information)
– Failed to declare discovery of immediate repair conditions from information received in preliminary reports from the in-line inspection (ILI) vendor (information)
– Risk assessments not updated as changes occur, which includes potential threat changes (MOC)
– failure to determine an "Identified Threat" related to Manufacturing existed on the segment, and failed to elevate the threat for risk reduction activities (MOC)
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Observations and Concerns
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Pipeline Infrastructure (% by Decade in USA)
Decade Hazardous Liquid
Gas Transmission
Gas Distribution Main Service
Unknown & <1920 2% ---
1920s 2% 2% --- ---
1930s 3% 4% 6% 3%
1940s 8% 7% 2% 2%
1950s 20% 22% 10% 8%
1960s 21% 23% 17% 13%
1970s 16% 11% 12% 14%
1980s 9% 10% 14% 17%
1990s 11% 11% 21% 22%
2000s 8% 10% 18% 21% 17
54
%
44
%
58
%
42
%
47
%
53
%
40
%
60
%
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Pipeline Infrastructure (% by Decade in USA)
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0%
5%
10%
15%
20%
25%
< 1940 1940s 1950s 1960s 1970s 1980s 1990s 2000s
Hazardous Liquid Pipeline Vintage 55% installed prior to 1970
(182,615 miles/ 74,472 HF-ERW/50,740 LF-ERW)
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Pipeline Infrastructure (% by Decade in USA)
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0%
5%
10%
15%
20%
25%
< 1940 1940s 1950s 1960s 1970s 1980s 1990s 2000s
Gas Transmission Pipeline Vintage 59% installed prior to 1970
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Pipeline Infrastructure (% by Decade in USA)
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0%
5%
10%
15%
20%
25%
< 1940 1940s 1950s 1960s 1970s 1980s 1990s 2000s
Gas Distribution Pipeline Vintage 31% installed prior to 1970
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
All Incidents – USA
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05
101520253035404550
Gas Transmission and Liquid Pipelines 2002 to 2012
All Other Causes
Corrosion
Excavation Damage
Incorrect Operations
Material/Weld/Equip.FailureNatural ForceDamageOther OutsideForces
%
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Pipe Seam Failures in USA (2002-2012)
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Seam Type Gas Hazardous Liquid TOTAL % of
Total
DSAW 9 5 14 18
Flash Welded 1 5 6 8
HF ERW 3 15 18 23
LF ERW 5 23 28 35
Lap Weld 1 2 3 4
SAW 2 3 5 6
Other 4 2 6 7
Total 25 55 80 100
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Pipeline Seam Welds
DSAW Pipe Lap Welded Pipe
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Spiral Weld – SAW Pipe LF and HF - ERW Pipe
SMLS Pipe
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
What are some of the integrity issues? Materials – pipe and coatings Pipe material –
LF-ERW – widely manufactured from 1920 to 1970’s PHMSA Advisory Bulletins in 1988 and 1989
EFW – produced between 1930 through 1969 Seams – cold welds, lack of fusion, stitched welds, hook
cracks Leads to – selective seam corrosion and corrosion
fatigue
SAW/SSAW – produced in 1930’s through today as DSAW Older pipe has lack of fusion and cracking defects
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
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Current Rulemakings in Process
Safety of On-Shore Hazardous Liquid Pipelines (NPRM stage)
NPRM moved past PHMSA ANPRM published 10/18/2010 Major topics under consideration:
• Assessments beyond High Consequence Areas (HCAs) • Leak detection beyond HCAs • Repair criteria in HCA and non-HCA areas • Stress Corrosion Cracking (SCC) • Piggability of lines • Reporting requirements for Gathering lines • Gravity Line exception
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Current Rulemakings in Process Integrity Verification Process
Issues and alternatives under development
Subject of numerous public workshops / meetings
Deals with recommendations from NTSB / Hill mandates
Discussed this in previous session
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
2013/14 Quality Observations
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Construction
• A typical role of government is to solve problems, often through regulation
• Many of the construction issues we see are not solvable through added regulation
• The operator is solely responsible for building and operating a safe and reliable pipeline system
• It is vital that we develop the infrastructure to move new found resources to market in a safe and environmentally friendly manner
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
2013 – Overview of Quality Issues
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
30
Overview of Quality Issues
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
HF–ERW Seams
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
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What caused this coating damage?
• Worn out pads on bending machine
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
33
Pipe on skids can move and fall. You want to park or stand where!
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Welding
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Arc Burns • Melting Water – running onto weld
• Weld Splatter
• Expensive Garbage Can
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Coating
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• No cleaning prior to coating • Improper application • All Operator accepted coatings
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
36
No Coating Coverage
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Lower-in and Backfill
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• Rock in ditch?
• Pad dirt under pipe?
• What is being
done to protect pipe from coating and denting damage?
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Pipe laid directly on solid rock
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Rocks against pipe (No screening for over 1 mile)
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Backfilling
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• How is soil being installed in ditch?
• Are backhoes
continuously lifting soil padding over pipe without inspection?
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Construction Damage
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• Section of Pipe was Replaced • Found by DCVG • Survey-Line was in Service)
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Bored Crossing – Failed Hydro Test
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
AC Interference Currents
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• Quick and deep • Do not put off
AC surveys
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Materials Verification
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• Good Documentation Practices
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Serious about risk and consequences? It takes all of us..
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Construction Issues - Summary
Topic Occurrences Coating* 117 Welding* 87
Excavation 20 Nondestructive testing 20
Pipe material* 12 Bending 9
Lowering in* 7 Hydrotesting 4
Design 3 Other 8
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Part 195 Citation Number of Citations
Total Civil Penalties Assessed
195.571 Adequacy of Cathodic Protection 26 $163,400
195.573(e) External Corrosion Corrective Action 21 $412,500
195.573(c) External Corrosion Rectifiers 18 $30,300
195.583(a) Atmospheric Corrosion Inspections 18 $65,700
195.569 Exposed Portions of Buried Pipe 16 $44,700
195.577(a) Interference Currents 14 $0
195.579(a) Internal Corrosion Mitigation 13 $145,000
195.573(d) Breakout Tanks 12 $51,200
195.581(a) Atmospheric Corrosion Control 10 $307,900
195.579(c) Internal Corrosion Inspection 9 $26,200
Most Cited Corrosion Regulations Hazardous Liquid Pipelines
(2009-2013)
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Pipeline R& D Activities • 2014 Awarded Projects – Focus Areas:
• Threat Prevention • Leak Detection/Mitigation & Storage • Anomaly Detection/Characterization • Anomaly Repair & Remediation • Design/Materials/Welding-Joining/Valves
• Future R&D Focus Areas: • Legacy Materials • Damage Prevention • Leak Detection • Anomaly Detection/Characterization • Risk Models
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U.S. Department of Transportation Pipeline and Hazardous Materials Safety Administration
Thank you
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