New Pipeline Integrity

Management Technologies

> Paul Armstrong

> Gas Technology Institute

> Northeast Gas Association

> Fall Operations Conference > October 3, 2013

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Energy & Environmental Technology Center

Pilot-Scale Gasification Campus

Offices & Labs

GTI Overview

> Not-for-profit research,

with 70 year history

> Facilities

─ 18 acre campus near

Chicago

─ 200,000 ft2, 28 specialized labs

─ Offices in AL, CA, MA, PA

TX, Wash DC

> Staff of 250

> Market opportunities

are creating substantial

growth

> 1,200 patents; 500 products

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Our Sponsors

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Discussion Topics

> Leak-Rupture Boundary Program

> Alternative Pipeline Yield Strength Determination

and Statistical Sampling

> Asset Lifecycle Tracking and Traceability

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Leak-Rupture

Boundary Program

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Program Objectives and Benefits

>Objective: ─ Perform an engineering analysis of the leak-rupture

boundary as a function of %SMYS

> Categorize leak-rupture boundary based on material properties to allowed a tiered approach

─ Develop a software tool for the LRB model for operators to use for consequence analysis

>Benefits: ─ Develop an engineering based leak rupture boundary

with confidence limits.

─ Allow operators to understand their risk for pipes operating near the boundary.

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Failure Modes

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Assessment and Mitigation

Failure Mode Source of Energy Defect Defect Nature; Time

Scale/Dependence How Addressed

A - Propagating

Ductile Rupture

Hoop Stress from

Internal Pressure

Axial

Orientation

Defect Can be Time

Dependent; Energy Source

is Always Present

Subpart O Assessments (≤

7yrs) for Defects and Code

MAOP Calculation

B - Circumferential

Failure/Rupture

(double guillotine)

Axial Line Stress:

Soil Settlement,

Flooding,

Earthquakes, etc.

Legacy Girth

Weld

Construction

Could

Contribute

Defect is Stable; Energy

Source is Time

Independent

Construction Standards

(API 1104, ASME B 31.8,

etc.); Automatic Shutoff

Valves; ROW Design and

Monitoring

C1 - Puncture Dynamic Event (e.g.,

3rd Party Damage) NA

No Defect; Energy Source

is Time Independent

P&M Measures and Risk

Management

C2 - Tear Out/Hole Dynamic Event (e.g.,

3rd Party Damage) NA

No Defect; Energy Source

is Time Independent

P&M Measures and Risk

Management

C3 - Tearing Shear

Fracture

Dynamic Event (e.g.,

3rd Party Damage) NA

No Defect; Energy Source

is Time Independent

P&M Measures and Risk

Management

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Validation Approach

>Modeling and statistical analysis to develop a methodology to allow the theoretical model to use the entire data set.

>Factored in uncertainty/variability of measurements for diameter, thickness, toughness, and yield strength to calculate the standard errors of the models.

>This allowed the calculation of a closed-form solution with a LCL that predicts if a pipeline were to fail, that 97.5% of the time it would fail by leak vs. rupture.

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Validation Results

>638 confirmed ruptures were overlaid on the full regression model failure surfaces, a total of 14 confirmed ruptures fell below the lower confidence limit surface.

>This equates to 2.19% of the population that is in line with the 2.5% confidence level of the model and validates the accuracy of the model.

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Predictive Capability of Regression Model

> Predictive Capability of the four parameter full quadratic (15 coefficient)

regression model solution in MatLab and DX8; both have 95% two tailed

confidence limits vs. Instability Stress Model for C = 6.

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Desirability Plot Example

> C = 6, Pipe Stress = 30%SMYS, Yield Strength = 40ksi, CVN = 20ft-lb.

Red is failure by leak, blue is failure by rupture.

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Two Factor Regression LCL Surfaces

with Conclusive Rupture Data Set

> 95% two tailed CI LCL surfaces (97.5% probability above LCL) rupture failure stress as a

function of yield stress [30 to 80 ksi] and CVN [15 to 60 ft-lb] for C = 1 to 7 [top to bottom

surfaces] with 638 conclusive incident and full size test rupture points overlaid.

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Example Results

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LRB Software Tool / Calculator

> Primary Five Data Inputs

─ Pipe diameter range: 6.625 to 48 inches

─ Pipe wall thickness range: 0.093 to 0.625 inches

─ Yield strength range: 24,000 to 88,000 psi

─ Toughness range: 1 to 160 ft lbs

─ Operating pressure range: 50 to 1,450 psig

> Final Input is Defect Length at Time of Failure

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LRB Software Tool / Calculator - Plot

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LRB Software Tool / Calculator - Plot

> Lower

Pressure

> Increase

Defect Length

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LRB Software Tool / Calculator - Plot

> Lower

Toughness

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LRB Software Tool / Calculator Table Output

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Results in Action

>Several operators are using the LRB tool to:

─ Know your system and how it will behave

─ Assess consequence of failure in all high

consequence areas and recalibrate risk models

based on the results

─ Review current materials specifications and design

new pipe segments to fail by leak

─ Educate employees on the impact of material

properties (yield strength and toughness) on failure

mode

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Pipeline Yield Strength Determination and Statistical

Sampling

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Yield Strength - Program Goals

> Alternative Yield Strength Test Methodology

─ Minimize pipe specimen size so standard hot tap field

coupons can be used without line shutdown and full cross

section cutout

> Alternative Sampling Methodology

─ To develop a methodology to assist operators in backfilling

missing yield strength records of undocumented pipe for the

purposes of determining MAOP and classifying segments as

distribution or transmission.

─ The methodology may provide an alternative approach to the

prescriptive techniques currently required by federal code.

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Test Specimen Design

> Mini, Full-Wall, Longitudinal Specimens

Four per coupon.

> Based on ASTM A370 and E8 already

referenced in API 5L/Code

> No flattening required

> Can use an extensometer

> Excellent repeatability

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Sample Set

>Excellent cross section of the most important

attributes that could contribute to the yield

strength

─ Steel. Six types of steel

─ Pipe Forming. Multiple mechanical and thermo-

mechanical forming processes

─ Diameter and Thickness. Typical range of

pipeline wall thickness and diameter/thickness

ranges

─ 100’s of tensile tests completed and statistically

analyzed; thousands of metallurgical tests

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Samples for Testing

> GTI leveraged its

historic pipe library that

contains vintages from

the 1950s through 2000

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Results: Correlation of Mini, Full-Wall to Full-Size Data

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Alternative Yield Strength Test Methodology

> Standard methodology. Based on ASTM A370 and E8 with

accepted bias and uncertainty calculations already

established.

> Always conservative. On average it produces a -8.5%

lower (conservative) value for YS when compared to the full-

size test method. A sample set from the pipeline population

would result in an average YS between -13.2% and -3.8% of

the full-size method with a 95% confidence.

> More robust. The new method will allow 4 vs. 1 replicate.

This allows a StdDev and confidence calculation per pipe

specimen.

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Alternative YS Test Methodology Benefits

> Performed live. Method does not require line shutdown

and depressurization to obtain specimen(s).

> Less damage to the pipe. The hot tap method would

entail a standard, small diameter coupon removal with

weld-on fitting as compared to a ring cut out and new pup

section welded in.

> More repeatable. The new method is simpler and more

repeatable due to: no specimen curvature, ability to use

extensometer, no need to flatten the sample, and use of

standard grips.

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Alternative Yield Strength Test Methodology Implementation

>Minor Change. Method only requires a minimal

change to the currently approved practice.

>SDOs. Presented to API 5L and ASTM; ASTM

standard modified and cleared last editorial

negative ballot in May 2013.

>Special permit. Approved for Washington state.

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Sampling Requirements

> Federal code requires a sampling

methodology as shown to the right.

> Requires a larger percentage of

sampling at shorter segment lengths.

Segment

Length

Segment

Joints

Required Number of Joints

to Sample

Percent of Joints to Sample

400ft 10 10 100%

1,000ft 25 10 40%

2,000ft 50 10 20%

3,000ft 75 15 20%

4,000ft 100 20 20%

6,000ft 150 20 13.3%

20,000 ft (~4mi)

500 50 10%

60,000 ft (~11mi)

1,500 150 10%

100,000 ft (~19mi)

2,500 250 10%

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> Adaptive Geographic Segmentation

─ AGS uses an advanced statistical approach that adapts the sampling based on

accruing data instead of a pre-defined, fixed number of samples.

─ AGS demonstrated a strong ability to identify geographic segmentation of yield

strength (i.e., segment-specific properties) based on physical properties of the pipe

─ Primary benefit of AGS is the ability to optimize sampling by minimizing the number

of samples to achieve a desired level of confidence.

> Bayesian Analysis

─ Bayesian analysis provides quantitative measures for the confidence limits on

proportions, including undiscovered grades.

─ Bayesian analysis is increasingly applied in the medical and environmental sciences

to improve efficiency and effectiveness of trials and experiments. Also now being

used by gov’t agencies such as National Institutes of Health and the Environmental

Protection Agency.

─

Statistical Sampling Methodology - AGS and Bayesian Analysis

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>Benefits to the Operator and Pipeline Safety

─ Provides greater levels of knowledge about the actual

distribution of yield strengths

─ More conservative than methods required in Part 192

for pipelines that contain multiple grades of pipe

─ For pipelines that contain only one grade of pipe, AGS

and Bayesian analysis may decrease the number of

samples required to achieve the desired level of

confidence

─ Increases the operator’s ability to understand the

probability of a pipe segment containing a lower grade

section of pipe, allowing further investigation and

mitigation actions to be taken when necessary

Sampling and Analysis Methods

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Asset Lifecycle Tracking and Traceability

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Business Drivers

>Distribution Integrity Management ─ Know Your System (precise location of all assets)

─ Identify Threats (performance trending, manufacturer’s recalls)

─ Mitigate Risk (remove assets from service)

>Pipeline Integrity Management ─ Traceable, Verifiable and Complete

>Regulatory Compliance

>Reduce Operational Risk

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Unique Identifier - Industry Standard

Character Number

Source Description of Information

Character Information

1 www.componentid.org

Name of component manufacturer

A Corresponds to list on www.componentid.org 2 C

3

Component Manufacturer’s lot code

Information which can help ascertain relevant traceability information upon request

5 Corresponds to the mfg

lot number input of 1234567

4 b

5 a

6 n

7 Component production

date code per 5.3

Date of manufacture of given component

0 Corresponds to production date of

1/4/2010 8 6

9 C

10 Component material type

per Table 3 Material used for component

B PE 2708

11 Component Type per Table 4

Component type 8 Electrofusion tapping tee with a stab outlet 12 F

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Component size per 5.6

Component size 2 Corresponds to size code of 2” IPS SDR11 x 1” IPS

SDR11 14 m

15 X

16 www.componentid.org Reserved for future use 0 Default value

Information Mfg. Values

Lot Number 1234567

Production Date 1/4/2010

Material Type PE2708

Component Type Electrofusion

tapping tee with a

stab outlet

Component Size 2” IPS SDR 11 x

1” IPS SDR11

>Algorithms and ASTM Standard

─ Buried distribution components

─ Developed a series of algorithms to create a unique identifier for distribution asset tracking and traceability

─ ASTM F2897-11a

─ Manufacturer implementation through barcoding

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Purchasing Specification Guidelines

>Working group composed of operators and manufacturers

>Purchasing Specification Guidelines for Barcode Marking PE Gas System Components

─ Marking techniques (ink, labels, tags, etc)

─ Marking format (1-D, 2-D)

─ Readability (barcode and alphanumeric code)

─ Durability (36 months or up until installation)

─ Placement (longitudinal and circumferential spacing)

─ Quality control

>Version 1 now available through GTI

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GTI’s Intelligent Utility Program

>Objective - develop technologies, workflows and processes to implement a lifecycle asset tracking and traceability system

>Create an architecture that provides . . .

─ Low cost data collection devices

─ Simple software

─ Access to up-to-date facilities

information through GIS

─ Real-time data submittal from the field

─ Minimal back-office processing

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Asset Lifecycle Tracking Technology

>GTI’s Technology Solution ─ Tablet device with GIS-based data

collection software

─ High accuracy GPS receiver

─ Barcode integration

─ Application to convert barcode into asset attributes to auto populate the GIS

─ Real-time data transfer with cloud computing

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Workflow

>Automates the entire data collection process for documenting new installations

>In less than one minute . . . ─ Read and decrypt barcode on assets and create gas features in the GIS

(main, service, valve, fitting, etc)

─ Populate asset attributes from information in the barcode (material type,

batch number, etc)

─ Add additional asset information automatically to asset record from

predefined job/work order

─ Define asset position geospatially using decimeter quality real time GPS

─ Post asset to version of asset system in GIS

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High Accuracy GPS

>Integrated external high accuracy GPS receivers with tablet computers

─ 4-inch quality data in real time

─ Real-time post processing via satellite or IP correction services

─ Gas assets directly inserted into the GIS (with controls)

─ Integrated receivers, so far . . .

> Navcom

> Geneq

> Trimble

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Data Collection Process

Collect GPS Data

Hand Enter Asset

Definition

Bring Hardware

Back to the Office

Download Data

Post Process

Data

Integrate Data into

GIS System of

Record

Create Gas Asset

in Field Post to GIS Version

Integrate Asset into

GIS System of

Record

>Existing

>New

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Next Steps

>Pilot Projects ─ NiSource, Integrys, National Grid, Avista

>Technology Commercialization ─ 3-GIS

>Meters and Regulators

>Transmission Systems

>Fusion Data

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…“the Energy to Lead”

Contact information: Paul Armstrong Director Gas Technology Institute 781-449-1141 Paul.Armstrong@gastechnology.org

GTI is a company that solves important

energy changes, a company that truly

has…