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
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-10-03 – 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
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Industry-Sponsored Activities
• Guidelines for Interpretation and Application of API 1104
• Funded by Pipeline Research Council International (PRCI)
Pre-Advisory
• Hydrogen Diffusion Demonstration video Bulletin
• Funded by Det Norske Veritas (U.S.A.), Inc. (DNV) and
Spectra Energy
• Guidelines to Address Construction Quality Issues
• Funded by PRCI and PHMSA
• In-kind contribution from PRCI to PHMSA In response
to Advisory
• Welding of Field Segmented Induction Bends and Bulletin
Elbows for Pipeline Construction
• Joint industry project (JIP) at DNV
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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
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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
• [Link]
• [Link] > Published Reports > search Catalog No.:
L52306
• Free for PRCI members, $400 for non-members
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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, 2011
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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* CRES primary
responsibility
• Task 2c – Lifting and Lowering-In Practices
• Task 2d – Tie-in and Repair Welding*
• Task 2e – Inspection and Delay Times* DNV primary
responsibility
• Task 2f – Adherence to Qualified Welding Procedures
• Task 3 – Integration of Results
• Task 4 – Development of Guidelines Document
• Task 5 – Reporting and Program Management
* Also covered in Segmented Induction Bends and Elbows JIP
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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
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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
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Joint Industry Project
• Welding of Field Segmented Induction Bends and Elbows
for Pipeline Construction
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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
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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
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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
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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.
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Thank You for Your Attention
Questions???
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