INGAA Foundation Workshop - Industry Initiatives Regarding Welding of Field Segmented Induction Bends and Elbows for Pipeline Construction

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1 INGAA Foundation Workshop - Industry Initiatives Regarding Welding of Field Segmented Induction Bends and Elbows for Pipeline Construction October 20, 2011 Steve Rapp, P.E. Spectra Energy Transmission

2 Background A number of pipeline girth weld failures have occurred in the US recently Some in newly-constructed pipeline during pre-service hydrostatic proof testing Advisory Bulletin was issued by Pipeline and Hazardous Materials Safety Administration (PHMSA) that highlights these and other issues ADB Girth Weld Quality Issues Due to Improper Transitioning, Misalignment, and Welding Practices of Large Diameter Line Pipe Contributing factors include: High-low misalignment Unequal-wall-thickness transitions High longitudinal stress/strain associated with lifting and lowering-in practices Inadequate tie-in and repair welding procedures Improper inspection and delay times Insufficient adherence to qualified welding procedures 2

3 Industry-Sponsored Activities Guidelines for Interpretation and Application of API 1104 Funded by Pipeline Research Council International (PRCI) Hydrogen Diffusion Demonstration video Funded by Det Norske Veritas (U.S.A.), Inc. (DNV) and Spectra Energy Pre-Advisory Bulletin Guidelines to Address Construction Quality Issues Funded by PRCI and PHMSA In-kind contribution from PRCI to PHMSA Welding of Field Segmented Induction Bends and Elbows for Pipeline Construction Joint industry project (JIP) at DNV In response to Advisory Bulletin 3

4 PRCi Project API1-2, Catalog L52306 Guidelines for Interpretation and Application of API 1104 The application of requirements in many industry codes and standards requires interpretation by the user (and by the regulator who is called upon to enforce their use) Often differences occur in the application of API 1104 due to unclear specification language Some industry codes and standards contain guidance in the form of commentary sections or companion documents AWS D1.1 Structural Welding Code Steel CSA Z662 Oil and Gas Pipeline Systems This is not the case for API 1104 Requests for interpretation are common because of unclear requirements or an absence of information pertaining to rationale 4

5 Objective/Status Objective was to develop a companion document for API 1104 to allow users to better understand: The intent regarding interpretation of some requirements The rationale behind the requirements The applicability of API 1104 to both conventional and modern high-strength pipelines Status Project was completed in April 2010 Report is available from PRCI Report describes development of guidance document Guidance document is contained in appendix to report PRCI.org > Published Reports > search Catalog No.: L52306 Free for PRCI members, $400 for non-members 5

6 PRCi Project MATH 5-1 Guidelines to Address Construction Quality Issues Objective is to develop guidelines pertaining to issues identified by PHMSA related to pipeline construction quality and how these issues should be addressed in the field Joint project between DNV and CRES Initial tasks being funded by PRCI Remainder of tasks being funded by PHMSA PRCI work being provided as in-kind contribution to PHMSA Approximately 60% complete Targeted completion date is December 31,

7 PRCi Project MATH 5-1 Construction Quality Project Activities Task 1 Review of Recent Incidents and Relevant Literature Task 2 Examination of Key Contributing Factors Task 2a High-Low Misalignment* Task 2b Unequal-Wall-Thickness Transitions* Task 2c Lifting and Lowering-In Practices Task 2d Tie-in and Repair Welding* Task 2e Inspection and Delay Times* Task 2f Adherence to Qualified Welding Procedures Task 3 Integration of Results Task 4 Development of Guidelines Document Task 5 Reporting and Program Management CRES primary responsibility DNV primary responsibility * Also covered in Segmented Induction Bends and Elbows JIP 7

8 Review of Recent Incidents and Relevant Literature Common factors for recent girth weld failures during hydrostatic testing were identified Many attributed to hydrogen-induced cracking Production welds in pipelines constructed using conventional stove-pipe techniques (cellulosic-coated electrodes) Welds at wall thickness transitions in particular Repair and tie-in welds (cellulosic-coated electrodes) in pipelines otherwise constructed using mechanized gas-metal arc welding No failures of mechanized gas-metal arc welds Transition welds at segmented induction bends and elbows Many involve pipelines targeted for operation at 80% SMYS Large diameter line pipe made from high-strength steel and/or heavy wall thickness material Increased stiffness tends to concentrate bending stresses during movement at girth welds 8

9 Development of Guidelines Results are being used to develop guidelines that address the construction quality issues that have been identified Two versions are being developed Technical version for engineers, etc. Non-technical version for welders, helpers, etc. The primary focus is the development of easy to read, cohesive documents that will be useful to both owner companies and contractors Proper alignment helps reduce stress 9

10 Joint Industry Project Welding of Field Segmented Induction Bends and Elbows for Pipeline Construction 10

11 Joint Industry Project: Welding of Field Segmented Induction Bends and Elbows for Pipeline Construction Cold field bends are not practical for all pipeline construction applications Segmenting long radius elbows and induction bends is often a necessary part of normal construction practice Current guidance that existed regarding the use of segmented fittings for pipeline construction was less than adequate Joint Industry Project (JIP) was organized by Spectra Energy and conducted by DNV to develop guidelines Guidance regarding the specification and purchase of segmentable fittings Guidance for field construction practices Guidance for segmented fittings in existing pipelines 11

12 JIP Project Participants Spectra Energy - Chair Alliance Pipeline CenterPoint Energy El Paso Corporation Kinder Morgan NiSource/Columbia Gas Panhandle Energy TransCanada PipeLines Williams PHMSA/INGAA to be kept abreast of progress 12

13 Project Activities Phase 1 Guidance for specification and purchase Task 1 Review current industry codes and company specifications Task 2 Review current manufacturing practices Task 3 Establish dimensional control capabilities Task 4 Develop proposed specification requirements for purchasing Phase 2 Guidance for field construction practices Task 5 Develop optimal methods for mapping, cutting, beveling, and transitioning Task 6 Develop limits for high-low misalignment and alternative joint designs Task 7 Develop methods for measuring high-low and addressing misalignment Task 8 Develop backwelding guidance Task 9 Address radiographic issues for welds with internal misalignment Task 11 Development of guidance for revision of construction specifications Phase 3 Guidance for existing pipelines Task 10 Assess use of caliper tool data 13

14 Technology Transfer The PRCi and JIP projects provide detailed guidance on how to responsibly apply best practice field construction methods with an emphasis on methods to field segment and install fittings and induction bends. It is now the shared responsibility of pipeline operators and contractors to implement these construction methods. 14

15 Thank You for Your Attention Questions??? 15