U.S.

Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
T&Q Pipeline Safety Seminar
High Grade Pipe and Construction
Issues
US DOT, PHMSA, Southwest Region
John W. Pepper
Project Manager
New Orleans La
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New Orleans, La.
July 2009
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
High Grade Pipe
Materials & Inspection
Observations
1 P iti Ob ti 1. Positive Observations
2. Pipe Manufacturing Findings
3. Quality Materials
4. Quality Assurance / Inspection
5. Problem Identification In Service
Pipelines
6 Conclusions
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6. Conclusions
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Positive Observations
(Data Driven) (Data Driven)
Parallel construction existing pipelines and power
lines
Few incidents Few incidents
Pipeline Safety Cooperation
Operators worked with PHMSA to ensure pipeline safety
MAOP Rule/Special Permit
Finding low yield strength pipe
DCVG Surveys DCVG Surveys
Used on many recent projects
Finding coating and pipe damage
W k h
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Workshops
API & INGAA
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe ManufacturingFindings Pipe Manufacturing Findings
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturing
Quality Issues pipe (remains under investigation)
Chemical composition Chemical composition
Low and variable yield strength
Laminations and Inclusions
Pipe bevel ends high/low
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturing
Low Yield Strength Low Yield Strength
Yield Strength <62Ksi for X70 pipe
Maximum ID: 109% of normal
Not an isolated project concern
Out of Spec Chemical Composition
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturing
Low yield strength pipe; 56Ksi to 62Ksi for X70 pipe
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturing
Laminations and Inclusions
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturing
Pipe bevel ends high/low and flat spots
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturing
Pipe bevel ends high/low
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturing
Pipe End Conditions High Low
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturing Attendant Problems
X-70 and X-80 Pipe Grades
More susceptible to hydrogen cracking than lower
pipe grades
Hydrogen is present in the coating of all E XX10
electrodes
Three conditions must be present in the weld to p
initiate hydrogen cracking:
Source of hydrogen,
Micro structure susceptible to the effects of Micro-structure susceptible to the effects of
hydrogen, and
Stresses in the weld.
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Quality Materials Quality Materials
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Possible Causes
Factors found to contribute to low and variable yield
strength pipe
Wrong heat chemistry from steel supplier
Pipe test locations for yield/ultimate tensile
strengths at steel and pipe mills strengths at steel and pipe mills
Plate/coil ordered under strength based on the
type pipe rolling process
Incorrect plate/coil rolling process
Improper plate/coil cooling rates
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Plate/coil switch at pipe mill
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturing API 5L
Section 6.1 Chemical Properties
Section 9.3 Testing of Mechanical Properties - Section 9.3 Testing of Mechanical Properties
- Is one test per heat adequate for high grade
microalloyed steel?
- Should additional requirements be included in
API 5L based upon type steel grade, plate or
coil?
Section 9.10 Retests
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturing API 5L
Section 9.11.3 - Diameter Tolerances for Pipe Ends
44
th
Edition - Tolerances for pipe ends of large diameter p p g
pipe such as 36 and 42 (pipe >24 to 56) has a
tolerance of +/-63 mils on welded pipe.
43
th
Edition - Tolerances for pipe ends of large diameter p p g
pipe such as 36 and 42 (pipe >24 to 56) has a
tolerance of -1/32 to +3/32 on welded pipe.
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturing API 1104
Section 7.2 Alignment
The alignment of abutting ends shall minimize the offset g g
between surfaces.
For pipe ends of the same nominal thickness, the offset
should not exceed 1/8. /
Mechanized welding units can not space high/low
variations around the pipe.
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Quality Assurance / Inspection Quality Assurance / Inspection
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturing - I nspection
API Monogram Certification
Steel Supplier/Manufacturer Steel Supplier/Manufacturer
Pipe Mill
Purchaser
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturing I nspection
Did the rolling mill/purchaser set up procedures to Did the rolling mill/purchaser set up procedures to
properly monitor and test the incoming coil/plate for
mechanical and chemistry properties?
Was inspection used by the purchaser at the steel Was inspection used by the purchaser at the steel
mill and pipe rolling mill?
Are there problems with the API 5L standard for high
grades/microalloyed steel?
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Problem Identification
In Service Pipelines
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Problem Identification
LowYieldStrength Pipe Low Yield Strength Pipe
100% SMYS Hydrotest of in place/in service pipe 100% SMYS Hydrotest of in place/in service pipe
Running of Deformation Tools after Hydrotest
calibrated to find expanded pipe p p p
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Deformation Tool expanded pipe
Expanded J oint - Deformation
3.4%Expansion
Testedto104%
SMYS
Non-ExpandedLongSeamView
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Non Expanded Long Seam View
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Conclusions
Pipe Manufacturing
Coating Coating
Welding
Construction
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Broader Construction Findings Broader Construction Findings
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Construction Issues
Worker, Inspector and General Public Safety
Welding Welding
Best Practices
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Worker, Inspector and General Public
Safetyy
Safety is extremely important.
H l d d l i i l Heavy loads and large equipment can present special
risks
Do not place yourself in harms way p y y
Make eye contact with heavy equipment operators
Wear PPE and safety vests
Be extremely cautious about entering the area
between the pipe and ditch, standing next to the
ditch and entering the ditch to observe welding
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g g
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Safety Where are you standing?
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe on skids can move and fall. You want to
park where!
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction-Safety First
Know where you are with respect to the equipment around you.
Make sure to look around and take stock of what is going on Make sure to look around and take stock of what is going on.
Review what is going on & what could go wrong?
Is the ground around the bell hole cracked?
A h i h i b h h d ? Are they using a shoring box when they need to?
Are they trying to save time & cut corners vs. working efficiently?
Is the equipment in good shape, breaking down, damaging the
pipe? pipe?
Do the company inspectors have the correct inspection
equipment?
Are procedures available?
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Are procedures available?
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
WeldingI ssues Welding Issues
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Welding Procedure Development
API 1104 main body, Appendix A or ASME (?
Appendix B ?)
List of Rules Essential variables other variables
(non-essential variables)
Recently Identified Problems (IP) Recently Identified Problems (IP)
Did not state all required variables
Did not qualify sufficient procedures for project Did not qualify sufficient procedures for project
Failed test coupons
Special issues API 1104 Appendix A (next slide)
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p pp ( )
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
API 1104 Appendix A
To use Appendix A must have:
Stress analysis, ECA or Engineering Critical Assessment
AUT error determination
Written welding procedure with weld testing results g p g
Identified Problems
No stress analysis
N AUT d t i ti No AUT error determination
Insufficient Charpy tests or CTOD tests that bust out
Testing lab issue - CTOD test locations are different in the
20
th
edition
Failed bend, nick, or tensile test results
No radiographs of qualification welds
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g p q
Using the example calculation in Appendix A is not
acceptable
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Projects with failed welds that were
not detected by NDT
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Repair Weld Cracking Issues
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Solutions
In a high strength pipeline weld use low hydrogen
welding process (GMAW FCAW - E XX18)
Allow time at temperature to allow hydrogen to
diffuse from the weld (higher preheat temperatures,
preheat maintenance, avoid weld interruption) p , p )
Follow welding procedures
Welding inspection
Delay NDT to allow for the possibility of delayed
hydrogen cracking to be detected
Verify NDT technicians KSA and actual actions
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Verify NDT technicians KSA and actual actions
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Preheat
Heating the weld joint before welding
Temperature of the weld joint immediately before the Temperature of the weld joint immediately before the
arc is struck. (Arc start temperature)
Procedures can state Infrared thermometer, Contact
Pyrometer or Temperature Indicating Crayon Pyrometer, or Temperature Indicating Crayon
Range of preheat values found in the welding
procedure
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Use of Temperature Indicating Crayon
Temperature indicating crayons (Tempilstik) are specially
formulated to change color and melt at a specific g p
temperature.
On a cold pipe surface upon heating, the mark changes
color and melts at the specific temperature
Used on a hot surface the crayon only indicates the
temperature is greater than the specified temperature on
the crayon if the crayon melts
Applying the crayon on an area adjacent to a weld joint and
then heating with a propane torch directed on the mark
will give a false temperature indication. In this case the
flame heats the crayon mark faster than the pipe. The pipe
will not be up to the required temperature.
On a hot surface the crayon should be used after heating
d t diff t t t b
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and two different temperature crayons may be necessary
to determine the preheat is within the welding procedure.
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Temperature Indicating Crayons
The crayon
holder
ifi h specifies the
melt
temperature
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Preheat
In the event of
inadequate q
preheat;
document
occurrence and occurrence and
notify inspector
and operator
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
High Mechanized Defect Rate
PHMSA Concerns:
Having defects not an issue. g
Defect repair, NDT and tracking is an issue.
Industry experience usually shows
- 2 10% defect rate on mechanized welding
- 2 5% on manual welding
- less than 2% - examine NDT are operators procedures less than 2% examine NDT are operators procedures
adequate? are radiographic and ultrasonic procedures
good? are NDT technicians following procedures? - are
the NDT technicians proficient?
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Radiographic Requirement
Both Parts 192 and 195 require a certain percentage
(based on location or class location) of welds be
d i l d d h f nondestructively tested and that a percentage of a
welders daily work product must be nondestructively
tested.
If the radiographs image quality indicators are not
acceptable, then there may be insufficient numbers
of radiographs to meet the percentage and/or daily
requirements of the applicable code.
Use of API 1104 Appendix A requires essentially
100% NDT - AUT
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
192.235 Preparation for welding.
Before beginning any welding, the welding surfaces
must be clean and free of any material that may be
d i l h ld d h i detrimental to the weld, and the pipe or component
must be aligned to provide the most favorable
condition for depositing the root bead. This
alignment must be preserved while the root bead is alignment must be preserved while the root bead is
being deposited.
Sometimes called Hinging
1 Hydrotest failure on attributed to hinging
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Arc Burns
Arc burns are not acceptable on high pressure gas
pipelines and liquid pipelines.
The following slides show that arc burns can happen
during internal back welding.
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
API 1104 Edition, Appendix A
Many operators are
choosing Alternative
Acceptance Standard For Acceptance Standard For
Girth Welds
Fracture mechanics
analysis used to determine analysis used to determine
the acceptance standard
instead of the traditional
method of empirical
criteria for workmanship
(API 1104, Section 9)
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
API 1104 Appendix A
Essential Variables Essential Variables
Any change in the
essential variables
specified below shall specified below shall
require requalification of
the welding procedure.
b. a change in the grade
f t f th or manufacturer of the
pipe material or a basic
change in the chemical
composition or processing
b i l f by a single manufacturer.
Requalification was not
performed.
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Pipe Manufacturers
3 plate manufacturers of 0.617 WT (Mittal, Saltzgitter, VoestAlpine).
VoestAlpine was not addressed in the welding procedure qualification
Pipes were supplied to the welding crews and welded in random order
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
The Challenge
Procedures arent being followed - there is a
disconnect between the operators
i i /d i d fi ld i i engineering/design group and field practitioners.
Many operators are now choosing Appendix A
acceptance criteria to keep up with the volume of p p p
new construction and preference for automated
welding. Are all the required variables being
checked?
PHMSA is working on a standard for interpretation
and enforcement.
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Best Practices Best Practices
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction
Good Dirt Good Dirt
Level
St i ht Sh t Straight Shot
No rocks
Good Trench
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction
Good Trench Good Trench
With Proper Egress
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction
Uh Oh! Found a
rock.
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction
Documentation!
Ho la ge of a ock How large of a rock
can be left in
backfill?
Ask the inspector.
Check the Check the
procedures.
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction
Crossing other
utilities safely. y
Rock Shield where
applicable.
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction-Trenching/ Stringing
Steep terrain.
Be Ca ef l Be Careful.
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction
Mi ht d k hi ld Might need rock shield
in this area?
Note stationing and ask g
for records in office if
you are not there when
backfilling occurs.
Did you see a padding
machine on this job?
Do they use sifter Do they use sifter
buckets?
Is the mesh in the
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bucket the proper size?
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction-Coating & J eeping
There. Fixed it with There. Fixed it with
a patch stick! Just
dripped it on big
time. Has to be time. Has to be
well coated now!
Is this ok?
Why?
Why Not?
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y
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction
When do you look When do you look
for holidays?
A lot of Contractors
ll f P allow for Pre-
jeeping.
Code requires to Code requires to
inspect the coating
just before lowering
in
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in.
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction-J eeping
Is the equipment in
good condition?
Ask inspector questions.
Check procedures.
Watch how the crew
repairs holidays.
Patch stick is for Patch stick is for
holidays </= pin hole
holidays.
2 part epoxy for larger
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2 part epoxy for larger
holidays.
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction-Fitting Pipe to the ditch
Be observant while
driving around. g
What happenned to
the coating on this
pipe?
Ask inspector.
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction-Bending
Check the Check the
equipment.
Is it in good repair? Is it in good repair?
Does it need work?
Is it damaging the Is it damaging the
pipe?
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction-Damaged Pipe
Dents Dents
Wrinkles
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction
Foam installed after
lowering in = trench
b k breakers.
Installed on slopes
Protects trench from Protects trench from
washouts.
Correct spacing?
Ask the inspector.
Check procedures.
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction
Fittings-Piggable?
Short Pups
How small can a pup
be? be?
Ask the inspector.
Check the procedures.
Why the different
coating color? ARO vs.
FBE
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Shrink sleeves on welds
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction
Sand Bags for Pipe
Support pp
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction
Power Lines
Is pipe g o nded? Is pipe grounded?
Can booms reach
power lines? power lines?
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction
Length of Length of
Unsupported Spans
Are there enough Are there enough
Side Booms?
Ask inspector. p
Check Procedures.
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction-Padding/ Backfill
Use all your senses. y
Is the padding getting
all the way around the
pipe? pipe?
Is it deep enough over
the pipe before the
dozer completes the dozer completes the
job?
Ask Inspector/Check
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Procedures
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction-Padding/ Backfill
Coating Damage Coating Damage
Response = that is what
CP is for! Not!
Easier to fix prior to
burial
Post Construction DCVG Post Construction DCVG
Survey Required
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
New Construction
You are inspecting for problems that
might cause a failure in 1 year (dent might cause a failure in 1 year (dent
w/metal loss);
5 years rock impingement/shielding 5 years rock impingement/shielding
CP
20-50 years corrosion leak/rupture
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U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Inspection Tips
Notify Operator contact. Be considerate.
Construction is unique; the opportunity to inspect is limited.
Naturally an adversarial relationship.
Be professional and courteous.
Know plans and procedures Know plans and procedures.
Observe.
Ask questions then listen.
Take notes.
Take photographs.
R t d d t Report and document.
Do not direct contractor or employees actions.
Direct contractor questions to the inspection company (take note
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q p p y (
of occurrence; ask yourself why is the workman asking you
questions about construction procedures or practices).
U.S. Department of Transportation
Pipeline and Hazardous Materials
Safety Administration
Thanks! Thanks!
Questions? Questions?
John W. Pepper
713-272-2849 work
713 826 3575 cell 713-826-3575 cell
john.pepper@dot.gov
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