Pipeline Safety Research Development & Technology Program Updates

PHMSA Research Overview Past, Current, and Future Needs

CEC Staff Workshop July 16, 2015

Pipeline Safety RD&T Pipeline Safety RD&T Program Mission: To sponsor research and development projects focused on providing near-term solutions that will improve the safety, reduce environmental impact, and enhance the reliability of the Nation’s pipeline transportation system.

Key Points • We employ a collaborative approach to address mutual challenges • We help remove technical barriers on a given challenge • We measure our research results/impacts • We are transparent - http://primis.phmsa.dot.gov/rd/ Pipeline Safety Improvement Act of 2002 established our modern program

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Current RD&T Program Objectives Developing Technology

Strengthening Consensus Standards

Promoting Knowledge

Fostering the development of new technologies so that pipeline operators can improve safety performance and more effectively address regulatory requirements.

Targeting and feeding new knowledge into the process of keeping standards relevant to their purpose.

Generating and promoting general knowledge to decision makers.

FY 2002 2003 2004 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015

Authorization: $10M $10M $10M $10M $11.7M $11.7M $11.7M $11.7M $11.7M $6.92M $6.92M $6.92M $6.92M $6.92M

Appropriation: $4.8M $7.5M $7.8M $7.7M $7.7M $7.8M $6.9M $5.8M $6.9M $6.9M $6.9M $6.92M $12.3M $12.3M

Authorizations vs. Appropriations

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Collaborative and Coordinated Program Process

1. Stakeholder based, consensus driven research agendas and roadmaps

2. Interagency review of competitive pre-award process to reduce duplication, leverage resources and secure best researchers

3. Paperless & secure 21st Century solution used to monitor, report and assure contract performance

4. Post-award peer review process executed annually

5. Tech demonstrations and full use of contract authority to commercialize, disseminate and promote results

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Past Performance Metrics (since 2002)

Total Program: 229 Projects, $89.4M PHMSA + $84.8M Resource Sharing

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Courtesy: Pipetel Technologies

Courtesy: CRC Evens

Courtesy: Pure Technologies Leak Detection

Hand-Held Tools for In-Ditch Inspections

Courtesy: LASEN

Courtesy: EXCELIS

RECENT PHMSA RD&T SUCCESSES

Gas/Liq Leak Detection by Fixed

Wing/ Helicopter along pipeline

Guided Wave Ultrasonics

Performance Metrics (since 2002)

• Logic modeling used to determine best attainable/ sustainable metrics

• Info is all publically available at: https://primis.phmsa.dot.gov/rd/performance.htm

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Competitive Academic Agreement Program Objectives

1. Started Early FY 2013 – From a growing desire to evolve our research program into more basic investigations while addressing workforce planning challenges

2. Spur innovation through enabling an academic research focus on high risk and high pay-off solutions for the many pipeline safety challenges – Intended to potentially deliver desired solutions that can be a

“hand-off” to further investigations in this or PHMSA’s core research program

3. Expose “students” to subject matter common to pipeline safety challenges and illustrating how their engineering or technical discipline is highly desired and needed in the pipeline field

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Performance to Date (FY13&FY14) • Two FOAs, 45 Applications, 15 Awards

– $1.5M PHMSA + $745K Resource Sharing – 79 involved students!!!

• Nine student poster papers at Aug 2014 R&D Forum https://primis.phmsa.dot.gov/rd/mtg_080614.htm

– 1 confirmed internship reported. More anticipated

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Solicited Projects & Topics – Aug 2014 R&D Forum –

Damage Prevention Technology –

Developing System-Defense Tools for New and Existing Pipelines from Excavation Damage Threats

Technology/Product – Intrinsically Locatable Plastic Materials (New construction and replacement) Leak Detection/Fugitive Methane Technology/General Knowledge –

Refine/Enhance/Develop Methane Leak Survey Technologies and Methodologies to Quantify Detected Emissions from Relatively Small Volume Rate Leaks to Prioritize a Remedial Action Plan

General Knowledge/Consensus Standard – Verification and Validation Framework for Assessing the Viability and Performance of New Natural Gas/Liquid Leak Detection and Quantification Technologies and Methodologies 10

Solicited Projects & Topics – Aug 2014 R&D Forum – Cont.

Anomaly Detection & Characterization Technology – Develop/Enhance Inspection Technology for small diameter (2”-8”) and Difficult to Inspect pipelines. General Knowledge – Improving Non-Destructive Evaluation (NDE) Performance/Reliability Through Reducing Human Effects on NDE Measurement Systems Materials Technology – Development of Inspection Tools to Quantify Pipe Strength and Toughness Consensus Standard and General Knowledge – Development of Comprehensive Pressure Test Design Guidelines General Knowledge/Model - Evaluation of Corroded Cast Iron Pipe Consensus Standard and General Knowledge - Slow Crack Growth Evaluation of Vintage Polyethylene Pipes General Knowledge – Engineering Critical Assessment of Cured in Place Pipe Liners at Bends, Valves and Service Taps 11

Risk Models General Knowledge - Paper Study on a Critical Review of Candidate Models General Knowledge - Paper Study on Review of Approaches for Preventing Catastrophic Events General Knowledge - Paper Study on Risk Tolerance LNG General Knowledge - Statistical Review and Gap Analysis of Data Currently Underlying PHMSA’s LNG Failure Rate Table and Methodology General Knowledge – Development of LNG Substrate Heat Transfer Properties General Knowledge - Comparison of Various Exclusion Zone Calculations and Vapor Dispersion Modeling Tools https://primis.phmsa.dot.gov/matrix/RfpInfo.rdm?rfp=51 For detailed descriptions.

Awards anticipated by August 2015

Solicited Projects & Topics –cont. – Aug 2014 R&D Forum –

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– Inline Inspection Improvements – Ground Movement Issues – Load Effects on Pipeline Anomalies – Guided Wave Ultrasonics (GWUT) – Proposed Integrity Verification Process (IVP) – Strain Based Design

Examples of PHMSA Research in Support of:

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ILI Improvements

• Adapted Meandering Winding Magnetometer Arrays from DOD application to inspection and characterization of pipeline damage via traditional ILI.

• Created robotic platform and MFL sensors for use in unpiggable gas lines. Now researching crack and MD sensors for this platform. – Other Technology Notifications

have been approved Courtesy: Pipetel Technologies

Courtesy of JENTEK Sensors, Inc.

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Pipeline Integrity Management for Ground Movement Hazards

Main Objectives

• Address large scale ground movement events including long term slope movement , and ground subsidence landslides,

• Develop recommendations on engineering practices in assessment of these large scale ground movement geohazards,

• Provide guidance for appropriate pipeline design and operational measures for mitigation of large scale ground displacement effects on buried pipelines.

Visit https://primis.phmsa.dot.gov/matrix/PrjHome.rdm?prj=202 for more information

Project ended – 12/15/2008 • Final report and web-based presentation uploaded

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Research Award Recipient:

Pipeline Research Council International 3141 Fairview Park Dr. Suite 525 Falls Church, Virginia 22042 Falls Church, VA 22042

AOTR: James Merritt, james.merritt @ dot.gov, (303)638-4758

Contract #: DTPH56-06-T-000015 Researcher Contact

Info: PRCI-Ken Lorang

Financial and Status Data Project Status: Closed

Start Fiscal Year: 2006 (06/15/2006) End Fiscal Year: 2009 (12/15/2008)

PHMSA $$ Budgeted: $525,241.00

Defining Geotechnical and Operational Load Effects on Pipeline Anomalies

Main Objectives: • Using previously validated pipe soil

interaction model, develop new models defining operational and geotechnical loads on O&G pipelines for severity or repair scheduling decision making.

• Incorporate strain based design assessment to consider complex flexural loading scenarios, pipeline subsidence , & ground movements inducing lateral pipeline movements.

• Results will define local nominal strain state and assess localized anomalies / defects (e.g. corrosion, cracks, dents, weld faults, gouges, etc.).

Visit https://primis.phmsa.dot.gov/matrix/PrjHome.rdm?prj=561 for more information

Project will end – January 31,2016

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Guided Wave Ultrasonics (GWUT) Anomaly Detection/Characterization

Project ID and Title Status Ended Contractor CY DTRS56-02-T-0007, Enhancement of the Long-Range Ultrasonic method for the Detection of Degradation of Pipelines

Closed 07/2005 PetroChem Inspection Services

2002

DTRS56-04-T-0008, Stage 2 Phased Array Wheel Probe for In-Line Inspection

Closed 02/2007 Olympus NDT 2004

DTRS56-05-T-0002, Validation & enhancement of long range guided wave ultrasonic testing: A key technology for DA of buried pipelines

Closed 12/2006 Northeast Gas Association

2004

DTR57-06-C-10004, In-Line Nondestructive Inspection of Mechanical Defects in Pipelines with Shear Horizontal Wave EMAT

Closed 06/2006 Intelligent Automation, Inc.

2005

DTRT57-06-C-10005, Feasibility of an Ultrasonic Based Instrument for Assessing In-Situ Pipeline Coatings

Closed 06/2006 FBS, Inc. 2005

DTPH56-06-T-000009, Enhancing Direct Assessment with Remote Inspection through Coatings and Buried Regions

Closed 07/2007 EMAT Ultrasonics Inc. 2006

DTPH56-08-T-000002, Enhanced Defect Detection and Sizing Accuracy Using Matrix Phased Array Ultrasonics Tools

Closed 07/2011 Edison Welding Institute 2008

DTPH56-08-T-000004, Improving Magnetic Flux Leakage In-Line Inspection Corrosion Sizing Using Phased Array Guided Ultrasonics

Closed 11/2010 Battelle Memorial Institute

2008

DTPH56-13-T-000008, In-Ditch Validation Methodology for Determination of Defect Sizing

Active RTD Quality Services USA, L.P.

2013

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Research Addressing Proposed IVP • Focus is generally

on natural gas – liquid later

• Current focus on vintage pipe hydrotesting & guidelines for when to replace

• Future focus on pipe properties and the spike test

Project details and deliverables via https://primis.phmsa.dot.gov/matrix/ 18

https://primis.phmsa.dot.gov/matrix/PrjHome.rdm?prj=390

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Key Project in Support of IVP

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How is Research Helping IVP?

• Creating guidelines for implementing and executing a pre-regulation pipeline repair/replace program

• Creating guidelines for comprehensive pressure test design that focus on reliability, spike tests, destructive/damage, and integration of inspection data

• NDE In ditch or In-Line Inspection tools that determine pipe strength and toughness either in the pipe body or in the pipe seam

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• IVP Chart • Applicable Segments

– ( Steps 1, 2, 3 and 4) • MAOP Determination Methods (Steps 5 – 10)

– Pressure Test – Pressure Reduction – Engineering Critical Assessment (ECA) – Pipe Replacement – Pressure Reduction for Segments w/Small PIR – Alternative Technology

• Materials Documentation (11) – Destructive – Non-destructive

• Continue Operations (12) • IVP Chart – on PHMSA web site • http://primis.phmsa.dot.gov/meetings/Mtg

Home.mtg?mtg=91

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Stress and Strain Based Design

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Strain Based Design

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Strain Based Design - details • Strain-Based Design – for longitudinal forces

– Control of longitudinal strain from frost heave and thaw settlement

• No Code Standards for Guidance - − Material (Acceptance criteria for strain demand, capacity and

displacement) − Design – pipe and weld joint strain capacity determined from

material and welding tests − Construction - Welding (Weld flaw acceptance criteria and

weld joint misalignment) − Maintenance - Strain Monitoring, Overstrain Mitigation, etc. − Integrity Management - Anomaly evaluation analysis

• Standards require testing and validation • Research – PHMSA and Industry – ongoing

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Research Addressing Strain Based Design

Failure Modes Addressed

Project details and deliverables via https://primis.phmsa.dot.gov/matrix/ 25

Strain Based Design R&D Goals

• Develop practical and ready-to-use guidelines and tools for strain-based design and assessment (SBDA) of pipeline segments containing: – Transition welds, – Corrosion anomalies, and – Dents.

• The limit states include: – Tensile strain – transition welds, corrosion anomalies – Compressive strain – transition welds, corrosion anomalies, and

dents – Burst pressure under longitudinal strain – corrosion anomalies

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Web-Based Debriefs

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Pipeline Technical Resources – R&D

https://primis.phmsa.dot.gov/rd/index.htm

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Thank You!/Program Contacts

Jim Merritt Department of Transportation Pipeline & Hazardous Materials Safety Administration Office of Pipeline Safety P(303) 638-4758 Email james.merritt@dot.gov

Robert Smith Department of Transportation Pipeline & Hazardous Materials Safety Administration Office of Pipeline Safety P(919) 238-4759 Email robert.w.smith@dot.gov

Kenneth Lee Director – Engineering & Research Department of Transportation Pipeline & Hazardous Materials Safety Administration Office of Pipeline Safety P(202) 366-2694 Email kenneth.lee@dot.gov

PHMSA RD&T Providing/Supporting:

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Questions?

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Thank You

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Steve Nanney steve.nanney@dot.gov

US DOT / PHMSA

James Merritt james.merritt@dot.gov

US DOT / PHMSA

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