Pipeline Construction Challenges - NAPCAnapca.com/webfiles/napca 2010 workshop-kenneth lee... ·...
Transcript of Pipeline Construction Challenges - NAPCAnapca.com/webfiles/napca 2010 workshop-kenneth lee... ·...
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Pipeline Construction Pipeline Construction ChallengesChallenges
NAPCA WorkshopAugust 19, 2010 Houston, Texas
Kenneth Y. Lee
Office of Pipeline Safety
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
PHMSA MissionPHMSA Mission
• To ensure the operation of the Nation’s pipeline transportation system is:
– Safe
– Reliable
– Environmentally sound
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Incidents (2002Incidents (2002--2009)2009)
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Incidents (2002Incidents (2002--2009)2009)
0
5
10
15
20
25
30
Excavation Corrosion Misc & Other Equipment Construction W & OF Materials Operations
%
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
IncidentsIncidents
• 2007
• Natural Gas
• Excavation
• 1 fatality
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
IncidentsIncidents
• 2007
• Natural Gas
• 30-inch
• Corrosion
• 1 fatality
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
IncidentsIncidents• 2007
• Natural Gas
• 30-inch
• Selective Seam Corrosion
• High Resistivity Soils
• No injuries
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
IncidentsIncidents• 2007
• 12 inch HVL
• LF-ERW Seam
• 2 fatalities
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
IncidentsIncidents
• 2008
• Natural Gas
• 30-inch
• Excavation
• 5 injuries
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
New Construction Issues Observed by New Construction Issues Observed by PHMSA InspectorsPHMSA Inspectors
0
20
40
60
80
100
120
Coating Welding Excavation NDT Pipe Steel Bending Lowering
Occ
ure
nce
s
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Observed Coating Observed Coating IssuesIssues
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Backfill before Coating has CuredBackfill before Coating has Cured
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Patch Stick: Inadequate AdhesionPatch Stick: Inadequate Adhesion
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Coating Over TapeCoating Over Tape
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Coating DisbondmentCoating Disbondment
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Backfill DamageBackfill Damage
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Coating Over Dirt/DebrisCoating Over Dirt/Debris
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Welding Band DamageWelding Band Damage
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Pipe Quality IssuesPipe Quality Issues• Low strength X70 & X80
• Inconsistent chemical and mechanical properties
• Poor mill rolling practices
• Advisory Bulletin (PHMSA 2009-1048)
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Girth Weld FailuresGirth Weld Failures
Radiographic Weld Inspection Hydrostatic Testing
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Hydrogen Cracking Hydrogen Cracking
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Hydrogen Hydrogen CrackingCracking
HYDROGEN
MICRO-STRUCTURE TENSILE
STRESS
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Hydrogen Cracking Risk by Electrode Hydrogen Cracking Risk by Electrode TypeType
E9010E8010E7010E6010FCAW (flux-cored)E9018E8018E7018GMAW (MIG)
Increasing Risk
LowHydrogen
Cellulosic
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Susceptible Microstructure (Hardness)Susceptible Microstructure (Hardness)
• Historically, values > 350 HV should be evaluated for the risk of hydrogen assisted cracking
• Cracking observed at 200 to 260 HV
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Hydrogen CrackingHydrogen Cracking
• Thru-thickness Repair
• Partial-thickness Repair
• Transitions
• Tie-ins 6:006010
9010
9018-M
Full thickness repair of mechanized weld
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Partial Thickness Repair:Partial Thickness Repair:Only 1 Cellulosic Weld PassOnly 1 Cellulosic Weld Pass
9010
9018-M
Mechanized GMAW
Low Hydrogen
WeldMetal
9018-M
6:00
Repair
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Partial Thickness Repair:Partial Thickness Repair:Cellulosic & Low HydrogenCellulosic & Low Hydrogen
Repair
6010
9010
9018-M
MechanizedGMAW
12:00
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
SelfSelf--shielded Fluxshielded Flux--Cored TransitionCored Transition
81T8 (FCAW-S) Fill & Cap
9018-M Hot 6010 Root
6010 Backweld
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Weld PreheatWeld Preheat
• Heat entire circumference, especially 12:00 & 6:00 locations
• Measure temperature immediately before start of every weld pass using:
– Temperature Indicating Crayons
– Contact Pyrometer
– Infrared Thermometer (reading depends on surface condition and distance)
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Girth Weld IssuesGirth Weld Issues• Transitions• Misalignment • Cut Induction Bends
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Improper Weld TransitionsImproper Weld Transitions
ASME B31.8 Fig. I-5
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
MisalignmentMisalignment
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
MisalignmentMisalignment
Alignment – Does this meet API 1104?
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Bends & FittingsBends & Fittings
• If cutting bends, use segmentable bends with tighter body tolerance
• Ends should meet:
– API 5L dimensional limits
– API 1104 fit-up requirements
Tangent End
Tangent End
EndTolerance
Hot induction bend cross-section
Bend fittingsHot induction bends
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Weld Misalignment at Cut BendWeld Misalignment at Cut Bend
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Best Practice:Best Practice:Shop fabricated bend assemblyShop fabricated bend assembly
Field weld
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Lowering In StressLowering In Stress• Maximum weld stress occurs during lowering in
• Most weld failures at top & bottom of pipe
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Industry ActionsIndustry Actions
• Workshops
• Pipe Quality Work Groups (8 work groups)
• Construction Work Groups (5 work groups)
• Standards updates
PHMSA is appreciative of industry efforts
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
API 5LAPI 5L• Proposed changes to reduce potential for non-conforming pipe
• Quality management system (QMS) for steel mill & rolling mill
• Tensile test & bracket retest locations in coil/plate
• Traceability of pipe to coil/plate
• Enhanced Manufacturing Procedure Specification (MPS)
– Applies to steel mill, rolling mill, & pipe mill
• Enhanced Manufacturing Procedure Qualification Test (MPQT)
– Test of initial production to qualify MPS. Includes assessment of coil/plate tensile property variability and coil/plate to pipe strength changes
• New - Inspection and Test Plan (ITP)
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
API 1104 Appendix AAPI 1104 Appendix A• Guidance for ECA & lowering-in stresses
• Retests for Charpys & crossweld tensiles
• Consideration for weld misalignment
• Weld Procedure Essential Variable. A change in the:
– Steel mill (slab, ingot, etc.)
– Rolling mill (plate, coil)
– Pipe mill (manufacturing facility)
– Pipe manufacturing process (UOE, spiral, ERW, etc.)
– Chemical composition limits (Pcm, CE, C)
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
API 1104 Repair Task GroupAPI 1104 Repair Task Group
• Backweld, multiple, & double repairs
• Repair length (minimum & maximum)
• Hardness testing
• NDT delay
• Preheat & Postheat
• Procedure qualification
• Welder qualification
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
API 5L/1104 Joint Task GroupAPI 5L/1104 Joint Task Group
• Misalignment & dimensional tolerances
• Tensile test orientation
• Residual magnetism
• Identification of steel/rolling mill
• Multiple grades & strength limits
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Recent PHMSA ActionsRecent PHMSA Actions
April 2009: PHMSA New Construction Workshop
May 2009: ADB: Potential Low & Variable Yield & Tensile Strength & Chemical Composition Properties inHigh Strength Line Pipe
June 2009: PHMSA Letter to Industry Trade Associations
Summer 2009: Letters to Alt MAOP SP holders on Low Strength Pipe
Spring/Fall 2009: Worked with operators to identify and remove low strength pipe
August 2009: Construction web site established
March 2010: ADB: Girth Weld Quality Issues Due to Improper Transitioning, Misalignment, and Welding Practices of Large Diameter Line Pipe
April 2010: Distribution Construction Workshop
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Looking AheadLooking Ahead
• Continued focus on construction inspections
• Expect increased enforcement actions on construction issues – for 72%SMYS and 80%SMYS pipelines
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Pipeline Construction WebpagePipeline Construction Webpagehttp://primis.phmsa.dot.gov/construction/index.htmhttp://primis.phmsa.dot.gov/construction/index.htm
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
PHMSA PHMSA –– Links Links
• Pipeline Safety Guidance – Advisory Bulletins, Low Strength Pipe Guidelines, MAOP Rule FAQs
– http://www.phmsa.dot.gov/pipeline/guidance
• Construction Issues
– 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
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
Thank you
Kenneth Y. LeeOffice: (202) 366-2694
E-mail: [email protected]
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
QUESTIONSQUESTIONS
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U.S. Department of TransportationPipeline and Hazardous Materials Safety Administration
PHMSAPHMSAOffice of Pipeline Safety Office of Pipeline Safety