northeast gas association fall operations conference ... · pdf fileapi 5l. electric...

Northeast Gas AssociationFall Operations Conference

Saratoga Springs, NYOctober 3, 2012

1

mailto:[email protected]�

2

• Supply Corporation• Distribution Corporation• Empire Corporation• Transmission Mileage – 1952 • HCA Miles – 196• Distribution Customers ~ 728,000

Buffalo

Erie

Pittsburg

3

San Bruno 9/9/2010 – Post Incident

4

DSAW SEAM

San Bruno – Fracture Location on Pipe

San Bruno – MAOP

MAOP of 400 psig failed at 396 psig Based on Grandfather Clause No Pressure Test Note: Class 3 Pressure Test to 600 psig probably

would have caused the faulty pipe to fail under test

Invalid Design Information Note: Faulty seamed pipe was documented as

seamless5

6

9/9/2010 12/31/2012

1/1/2011 1/1/2012

9/30/2011NTSB – San Bruno Final Report

1/4/2011PHMSA Advisory

8/25/2011PHMSA Advanced NPRM

9/9/2010San Bruno

1/3/2011NTSB Safety Recommendations

1/3/2012Pipeline Safety, Regulatory Certainty, and Job Creation Act of 2011

4/13/2012PHMSA Request For Comments on Changes to the Annual Report

5/7/2012PHMSA MAOP Advisory Bulletin

9/21/2012PHMSA Notice on Annual Report

10/3/2012

Today

• Traceable• Verifiable• Complete

7

Traceable - Traceable records are those which can be clearly linked to original information about a pipeline segment or facility. Traceable records might include pipe mill records, purchase requisition, or as built documentation indicating minimum pipe yield strength, seam type, wall thickness and diameter. Careful attention should be given to records transcribed from original documents as they may contain errors. Information from a transcribed document, in many cases, should be verified with complementary or supporting documents.

8

Verifiable - Verifiable records are those in which information is confirmed by other complementary, but separate, documentation. Verifiable records might include contract specifications for a pressure test of a line segment complemented by pressure charts or field logs. Another example might include a purchase order to a pipe mill with pipe specifications verified by a metallurgical test of a coupon pulled from the same pipe segment. In general, the only acceptable use of an affidavit would be as a complementary document, prepared and signed at the time of the test or inspection by an individual who would have reason to be familiar with the test or inspection.

9

AGA – In a letter to PHMSA on 6/28/2012, the AGA sought clarification as to whether a single quality document that contains the information needed to confirm a pipeline's Maximum Allowable Operating Pressure (MAOP) or Maximum Operating Pressure (MOP) would satisfy the intent of the Advisory Bulletin.

PHMSA – PHMSA responded on 7/31/2012 to the AGA letter, that operators need to identify appropriate records that establish a high level of confidence regarding the pipeline's MAOP or MOP, whether that record is a single quality record or information confirmed by other complementary, but separate, documents. Therefore, a single quality document that is traceable and complete, as evidenced by appropriate markings, would be acceptable.

Complete - Complete records are those in which the record is finalized as

evidenced by a signature, date or other appropriate marking. For example, a complete

pressure testing record should identify a specific segment of pipe, who conducted the

test, the duration of the test, the test medium, temperatures, accurate pressure readings,

and elevation information as applicable. An incomplete record might reflect that the

pressure test was initiated, failed and restarted without conclusive indication of a

successful test. A record that cannot be specifically linked to an individual pipe segment

is not a complete record for that segment. Incomplete or partial records are not an

adequate basis for establishing MAOP or MOP. If records are unknown or unknowable, a

more conservative approach is indicated.

10

Potential MAOP Document Sources

11

Age Records PHMSA Special Permits July 1, 1965 - July 1, 1970 Line High Pressure Documents Pipeline Elevation Profile

As-built Drawings EFA Pipe Sample Records Laboratory Analysis Records Pressure Volume Plots

Bellhole Inspections Engineering drawings/prints Leak & Main Inspection Reports Remaining Strength Analysis

Bid Documents Field View Maps Storage Records Purchase Orders (PO)

Bill of Lading, trucking consignment slips Field Verification Records Safety Related Condition

Reports Purchase Requisitions (PR)

Certified Mill Test Report(s) (CMTR) Gas Measurement Records Manufacturers'

SpecificationsPurchasing Department

Records

Completion Reports (CR) GIS Database Records Mill surveillance/inspection reports SCADA System Records

Compressor Station Discharge Records Government Filings Minimum wall thickness for

pipe size Welding Records

Class Location Studies Pressure Test Records MMD (Material Management Department) Catalog Welding Specifications

Engineering Review Packages

In-Line-Inspection (ILI) Results

Management of Change Records

12

Advanced Segmentation

Initial Segmentation

Verification Package

Segments Meet MAOP?

PARs (NFG/GIS questions and

comments)

GIS Data Migration


scanned to OnBase

File physical documentation

with Central File

Quality Review

End

Remediation Process

Yes No

Line PrioritizationSelect Line

Project Preparation

and Development

Start

Data Validated?

Yes

No

All Lines Done?

Yes No

13




Segments Meet MAOP?


comments)

GIS Data Migration


scanned to OnBase


with Central File

Quality Review

End

Remediation Process

Yes No


Project Preparation

and Development

Start

Data Validated?

Yes

No

All Lines Done?

Yes No

14

Project Staffing

Workspace Conversion

High Density File Space

Segmentation Spreadsheet

MAOP Algorithm

Verification Spreadsheet

MAOP Project Guidelines Training Tracking

Spreadsheet

15

NFG Project Manager

NFG Integrity Engineers (5)

Temporary Engineers (2)

NFG GIS Manager

NFG GIS Technicians (2)

Temporary GIS Technicians (5)

NFG Clerical Manager

Temporary Clerical (2)

NFG Clerical (1)

Note: Some NFG Personnel Have Additional Job Responsibilities Beyond the MAOP Project

Segmentation Spreadsheets

Developed in an Excel Spreadsheet New File Created For Each Line Drop-down Domains For Data Entry Match GIS System

Domains Custom Excel Functions are Written in Visual Basic to

Calculate MAOP Includes a Main Line Section Tab Includes a Branch Line Tab to Capture all Branch Line Data Spreadsheet is Formatted For Direct Import Into the GIS

APDM Database

18

19

General Information Pipe Segment Coating

Information Pressure Types Fitting Information

Segment Number Length Primary External Coating Grandfather Pressure Inlet Diameter

Comments Begin Station Primary External Sub-Type Operator Pressure Inlet Wall

Year Booked End Station Secondary External Coating Alternative Pressure Outlet Diameter

Completion Report # Pipe Source Secondary External Sub-Type Special Permit Pressure Outlet Wall

Companion Job # Design Factor Certificated Pressure Branch Diameter

Companion Job Date Design Factor Type Branch Wall

Facility Type Outside Diameter Specification

Install Date Pipe Material

Town Code Wall Thickness

Current DOT Class Pipe Grade

Original DOT Class Seam Type

Listed MAOP

Verification ID

Additional Remarks

RAM Segment # (pre-GIS Database)

20

Valve Information Casing Information Tap Information Flange

InformationMiscellaneous Information

Pressure Test Information (1-5)

Facility Size Casing Diameter Tap Type Flange Type Sleeve Type Test Date

Pressure Rating Casing Length Tap Size Flange Specification Coupling Type Project Number

Inlet Connection Type Crossing Type Flange Pressure

RatingControl Fitting

Mfg/Type Test Type

Outlet Connection Type Year Booked Closure Type Installation

Specification Completion Report Number

Common Safe Working Pressure MAOP Validation

Integrity Assessment (Y/N)Pressure Volume

Plot (Y/N)

Test Medium

Minimum Adjusted Pressure

Test Duration

Spike Pressure

Spike Duration

Determined By 49 CFR Part 192.619Lowest of :Design CalculationPressure Test

Pre-1970 Installation Allows:Highest Pressure From 1965-1970Known as the Grandfather Clause

21

Maximum Allowable Operating Pressure(Simplified Version)

P = (2 × S × t) ÷ D × (F × E × T)

22

Design Formula Variable Pipe Characteristic

S Yield Strength (Pipe Grade)

t Wall Thickness

D Diameter

F Design Factor

E Longitudinal Joint Factor

T Operating Temperature Factor

MAOP – Design Pressure (192.105)

Design Factor (192.111)

23

Class 4 ? Enter F = 0.40

Steel pipe, including a pipe riser, on a platform located offshore or in inland navigable waters.

No

Yes

111(d)(2)

Steel pipe in a compressor station, regulating station, or measuring station

111(d)(1)Or

Uncased steel pipe that crosses the right-of-way of a hard surfaced road, a highway, a public street,

or a railroad

111(c)Or

Steel pipe crosses the right-of-way of an unimproved public road, without a casing

111(b)(1)Or

Steel pipe crosses without a casing, or makes a parallel encroachment on, the right-of-way of either a hard surfaced road, a highway, a

public street, or a railroad

111(b)(2)Or

Steel pipe is used in a fabricated assembly, (including separators, mainline valve assemblies, cross-connections, and river crossing

headers) or is used within five pipe diameters in any direction from the last fitting of a fabricated assembly, other than a transition piece or an elbow used in place of a pipe bend which is not associated with

a fabricated assembly.

111(b)(4)

Steel pipe is supported by a vehicular, pedestrian, railroad, or pipeline bridge

111(b)(3)Or

Class 3 ?

No

Yes Enter F = 0.50

Class 2 ?

Class 1 - Do Any of These Conditions Exist?

Enter F = 0.72

Enter F = 0.60

Enter F = 0.50

Yes

Yes

NoClass 2 - Do Any of These Conditions Exist?

No

Yes

No

MAOP – Pressure Test192.619(a)(2)

P = Test Value ÷ Class Factor

24

Class Class Factor Divisor -

Post - 1970

Class FactorDivisor –Pre-1970

Segment Converted

under §192.14Class Factor

Divisor1 F = 1.10 F = 1.10 F = 1.25

2 F = 1.25 F = 1.25 F = 1.25

3 F = 1.50 F = 1.40 F = 1.50

4 F = 1.50 F = 1.40 F = 1.50

MAOP – Seam Factor (192.113)

25

Specification Pipe Class Longitudinal joint factor (E)

All Specifications Seamless 1

Electric resistance welded 1

Furnace butt welded 0.6

A333M Electric resistance welded 1

ASTM A381 Double submerged arc welded

1

ASTM A671, A672, A691 Electric fusion welded 1

API 5L Electric resistance welded 1

Electric flash welded 1

Submerged arc welded 1

Furnace butt welded 0.6

Other Pipe over 4 inches (102 millimeters)

0.8

MAOP – Temperature Factor(192.115)

26

Gas Temperature in degrees Fahrenheit (Celsius) Temperature De-rating Factor

250ºF (121ºC) or less 1300ºF (149ºC) 0.967350ºF (177ºC) 0.933400ºF (204ºC) 0.9450ºF (232ºC) 0.867

MAOP – Algorithm

27

Custom Excel

Functions

• Written in Visual Basic• Logic

Duplicated in GIS

Design Pressure

• Design Formula (192.105)• Unknown

Seam Type or Grade Logic

Pressure Test (192.619(a)(2))

• Subpart J Test• Subpart K

Test• Pressure

Rated Components• Class Factor• Pre/Post 1970

Logic

Class Function

• Class Factor• Class Change

MAOP Determining

Function

• Special Permit• Alternative

MAOP• Operator

Determined• Grandfather

Pressure• Pressure Test• Design

Pressure

MAOP – Class Change(192.611)

28

Original Class

Pressure Test

Multiplier Pre-1970

Pressure Test

Multiplier Post-1970

Percent SMYS

AllowedPost -1970

New Class

NewPressure

Test Multiplier

New Percent SMYS

Allowed

1 .909 .909 72 1 .909 72

2 .800 .800 60 2 .800 72

3 .714 .667 50 3 .667 60

4 .714 .667 40 4 .555 50

Note: The New Class Pressure Test Multiplier is Applied to the Original Pressure Test

MAOP Determination

(Prior to anticipatedregulatory changes)

29

Alternative MAOP?

MAOP = Alternative MAOP (P5)

No

Yes

192.619(d), 192.620

192.619(a)(1)

OperatorDetermined

MAOP?

MAOP = Operator MAOP (P4)

Yes

No

ValidGrandfather Pressure?

MAOP = Grandfathered

MAOP (P3)

Yes

No

Consider Remediation or Validation Pressure

Test

MAOP = lowest of Test Pressure or Design

Calculation Pressure (P1) or P(2)

192.619(a)(4)

192.619(a)(3),(c)

Yes

Note: Operator MAOP must be less

than the Design Pressure or

Pressure Test MAOP Values

SpecialPermit?

MAOP = As Designated by the Special Permit

No

Yes

Subpart Jor Subpart K

Test?

Valid Design Calculation?

No

Yes Yes

No

192.619(a)(1),(2)

Pre-1970Pipe?

No

192.619(a)(2)

30

• Verification Number• Line Name• Verification Date• Verified By• Reviewed By• Wall Thickness• Grade• Seam Type• Diameter

• Original Class• Current Class• Install Year• Design Factor• Temperature De-rating Factor• Conversion To Service• Pressure Test• Grandfathered Pressure• Operator Determined Pressure

• Over Pressure Protection Installed• Special Permit• Alternative MAOP• System Elements• Certificated Pressure• Verification Signature• Verification Date• Review Signature• Review Date:

List of Document Sources For MAOP Elements Up to Three Document Sources Per Element Linked to GIS By Verification NumberMultiple Spreadsheet Files per Line

31

Decision Making Logic

Project Objective

Project Definition

Project Responsibilities

List of Acceptable Document Sources (Best to Worst)

Design Variables Research Guidance

Pressure Test Research Guidance

Class Locations Research Guidance

In-Line Inspection Review and Comparison Guidance

32

Regulatory Requirements

GIS Training

MAOP Calculation

Verification Process

Record Systems

Record Review

33

Project Statistics KeptTotal CR Mileage Reviewed (all):

Total Mileage w/Advanced

Segmentation & Data Entry Complete:

Total Mileage with Completed

Verification Forms:

Total Verified Mileage Meeting

MAOP:

Grandfathered Mileage:

Total Mileage Scheduled for Remediation:

Total Mileage Under Review for

Remediation:

Footage Replaced/Assessed to

Meet MAOP:

34




Segments Meet MAOP?


comments)

GIS Data Migration


scanned to OnBase


with Central File

Quality Review

End

Remediation Process

Yes No


Project Preparation

and Development

Start

Data Validated?

Yes

No

All Lines Done?

Yes No

35

Remaining SegmentsNo Pressure Test & Unknown Key Data No Pressure Test Unknown Key Data Pressure Tested and

Key Data Known

Non-HCA segments operating > 30% SMYSNo Pressure Test & Unknown Key Data No Pressure Test Unknown Key Data Pressure Tested and

Key Data Known

Class 3 or 4 segments that are in non-HCA areasNo Pressure Test & Unknown Key Data No Pressure Test Unknown Key Data Pressure Tested and

Key Data Known

HCA segments operating <= 30% SMYSNo Pressure Test & Unknown Key Data No Pressure Test Unknown Key Data Pressure Tested and

Key Data Known

HCA segments operating > 30% SMYSNo Pressure Test & Unknown Key Data No Pressure Test Unknown Key Data Pressure Tested and

Key Data Known

36

Transmission Lines

(Includes Branch Lines)

Regulated Gathering Segments

Distribution Mains

37




Segments Meet MAOP?


comments)

GIS Data Migration


scanned to OnBase


with Central File

Quality Review

End

Remediation Process

Yes No


Project Preparation

and Development

Start

Data Validated?

Yes

No

All Lines Done?

Yes No

38

Start a New Line Based on Priority

Determine Beginning Stationing

Create New Segmentation Sheet

Print Age Records

Review Historical Pipeline Data (GIS)

Initial Data Entry

• Segment Length• Stationing• Year Booked• Completion Report• Facility Type• Install Date• Town Code• Current DOT Class• Outside Diameter• Location of road crossings

39




Segments Meet MAOP?


comments)

GIS Data Migration


scanned to OnBase


with Central File

Quality Review

End

Remediation Process

Yes No


Project Preparation

and Development

Start

Data Validated?

Yes

No

All Lines Done?

Yes No

40

Review Completion Reports

Review Other Documents

Review GIS Alignment Sheets

Integrity Engineer Review

Field Data Requests

Identify Remediation Issues

Final Review / Quality Assurance

• Design Factor• Class• Pipe Material• Wall Thickness• Grade• Seam Type• Coating Specifications• Grandfather Pressure• Operator Pressure• Alternative MAOP Pressure• Special Permit Pressure• Fitting Specifications• Valve Specifications• Casing Specifications• Tap Specifications• Flange Specifications,• Pipe Repair Specifications• Coupling Type • Pressure Test Information

41




Segments Meet MAOP?


comments)

GIS Data Migration


scanned to OnBase


with Central File

Quality Review

End

Remediation Process

Yes No


Project Preparation

and Development

Start

Data Validated?

Yes

No

All Lines Done?

Yes No

42

Copy All Relevant Documents

Highlight Relevant Information

Document Sources in Spreadsheet

Scan and File Verification Package

Verification ID Links to GIS Segment

• Collect Documents• Calculations• Add Notes/Comments• Spreadsheet Listing Sources• Verification ID

43




Segments Meet MAOP?


comments)

GIS Data Migration


scanned to OnBase


with Central File

Quality Review

End

Remediation Process

Yes No


Project Preparation

and Development

Start

Data Validated?

Yes

No

All Lines Done?

Yes No

44

Pressure Test

Replace Pipe/Facility

Relocate Pipe/Facility

Lower MAOP

Field Verify Data

45




Segments Meet MAOP?


comments)

GIS Data Migration


scanned to OnBase


with Central File

Quality Review

End

Remediation Process

Yes No


Project Preparation

and Development

Start

Data Validated?

Yes

No

All Lines Done?

Yes No

46

Review / Adjust

Centerline

Map Pipe Features

Map Pressure Ranges

Calculate / Compare

MAOP

Scan / Index Documents

File Paper Documents

Next Line

Data is Validated Through an

Iterative Process Between National Fuel GIS and GIS

Contractor Technicians

47

• Review Issues Document• Review Specific Questions• Review Process Questions

Weekly Conference Call

• Project Managers and Executives• Project Status and Concerns• Executive Status Reports

Bi-Weekly Executive

Committee Review

• Remediation Planning• Budget Planning• Executive Approvals

Periodic Remediation

Meetings

48

Questions?