NTSB Safety Recommendation P-09-001

NTSB safety recommendation P-09-001.

TO THE PIPELINE AND HAZARDOUS MATERIALS SAFETY ADMINISTRATION: Conduct a comprehensive study to identify actions that can be implemented by pipeline operators to eliminate catastrophic longitudinal seam failures in electric resistance welded pipe (ERW); at a minimum, the study should include assessments of the effectiveness and effects of in-line inspection tools, hydrostatic pressure tests, and spike pressure tests; pipe material strength characteristics and failure mechanisms; the effects of aging on ERW pipelines; operational factors; and data collection and predictive analysis.

Priority: CLASS II

Overall Status: Closed - Acceptable Action

Issued Date: 2009-10-27

Adopted Date: 2009-10-14

Overall Date Closed: 2015-04-08

Synopsis: On November 1, 2007, at 10:35:02 a.m. central daylight time, a 12-inch-diameter pipeline segment operated by Dixie Pipeline Company (Dixie) was transporting liquid propane at about 1,405 pounds per square inch, gauge (psig), when it ruptured in a rural area near Carmichael, Mississippi. The resulting gas cloud expanded over nearby homes and ignited, creating a large fireball that was heard and seen from miles away. About 10,253 barrels (430,626 gallons) of propane were released. As a result of the ensuing fire, two people were killed and seven people sustained minor injuries. Four houses were destroyed, and several others were damaged. About 71.4 acres of grassland and woodland were burned. Dixie reported that property damage resulting from the accident, including the loss of product, was $3,377,247.

Probable Cause: The National Transportation Safety Board determines that the probable cause of the November 1, 2007, rupture of the liquid propane pipeline operated by Dixie Pipeline Company near Carmichael, Mississippi, was the failure of a weld that caused the pipe to fracture along the longitudinal seam weld, a portion of the upstream girth weld, and portions of the adjacent pipe joints.

Ntsbnumber: DCA08MP001

Report Number: PAR-09-01

Addressee Name: PHMSA

Addressee Status: Closed - Acceptable Action

Addressee Date Closed: 2015-04-08

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2016-12-05

Communication Type: Official Correspondence

Communication Contents: On April 8, 2015, based on information provided in your January 22, 2015, letter, Safety Recommendation P-09-1 was classified “Closed—Acceptable Action.” In so doing, we wrote: We note that, on October 23, 2013, you completed your study, Final Summary Report and Recommendations for the Comprehensive Study to Understand Longitudinal ERW Seam Failures–Phase One, and you have posted the report on the project website and presented it at various industry events. These actions satisfy Safety Recommendation P-09-1, which is classified CLOSED—ACCEPTABLE ACTION.

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2014-01-03

Communication Type: Official Correspondence

Communication Contents: We understand that the study of longitudinal ERW seam failures that Battelle Memorial Institute has undertaken for PHMSA is scheduled to be completed by the third quarter of 2014 and that PHMSA will address Safety Recommendation P-09-2 following the study’s completion. Pending the timely completion of the needed actions, Safety Recommendations P-09-1 and -2 remain classified OPEN—ACCEPTABLE RESPONSE.

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2015-04-08

Communication Type: Official Correspondence

Communication Contents: We note that, on October 23, 2013, you completed your study, Final Summary Report and Recommendations for the Comprehensive Study to Understand Longitudinal ERW Seam Failures–Phase One, and you have posted the report on the project website https://primis.plm1sa.dot.gov/matrix/PrjHome.rdm?prj=390 and presented it at various industry events. These actions satisfy Safety Recommendation P-09-1, which is classified CLOSED—ACCEPTABLE ACTION.

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2011-10-19

Communication Type: Official Correspondence

Communication Contents: The NTSB understands that Battelle Memorial Institute is conducting a study to identify actions that will enable pipeline operators to eliminate catastrophic longitudinal seam failures in ERW pipe. The study, expected to be completed in November 2012, will then be used to address Safety Recommendation P-09-2. Pending completion of the study, Safety Recommendation P-09-1 is classified OPEN--ACCEPTABLE RESPONSE. Pending implementation of necessary remedies that the study identifies, Safety Recommendation P-09-2 is classified “Open—Acceptable Response.”

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2010-05-18

Communication Type: Official Correspondence

Communication Contents: The NTSB is pleased that on November 3, 2009, PHMSA published a solicitation for a comprehensive research project on Low Frequency ERW Pipeline Failures in FedBizOps, which includes, but is not limited to, the assessment of current methods to test and detect flaws and a study of failure mechanisms in ERW pipelines. Pending completion of the study, Safety Recommendation P-09-1 is classified Open Acceptable Response. Pending implementation of the actions needed from this study, Safety Recommendation P-09-2 is classified OPEN -- ACCEPTABLE RESPONSE.

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2010-12-29

Communication Type: Official Correspondence

Communication Contents: The NTSB is aware that on November 3, 2009, PHMSA solicited a comprehensive research project proposal regarding low-frequency ERW pipeline failures on the government website FedBizOps. The project was to include, but not be limited to, an assessment of current methods to test and detect flaws and a study of failure mechanisms in ERW pipelines. We are disappointed to learn that PHMSA received only four white papers and one proposal and that the proposal was not recommended for award by the review panel. However, the NTSB is encouraged that PHMSA plans to solicit proposals once again in early FY 2011. Pending the outcome of this effort and subsequent implementation of the study’s recommendations, Safety Recommendation P-09-1 and -2 are classified OPEN -- ACCEPTABLE RESPONSE.

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2013-08-29

Communication Type: Official Correspondence

Communication Contents: -From Cynthia L. Quarterman, Administrator: In 2011, PHMSA launched a two-phase, comprehensive study to understand longitudinal ERW seam failures. The objectives of the study, which is being performed by the Battelle Memorial Institute, are to integrate data from industry and PHMSA to quantify vintage seam failure statistics with a focus on low-frequency ERW seams; to understand longitudinal ERW seam failures, and on that basis, quantify the effectiveness of inspection and hydrotesting to manage integrity and ensure safety in order to avoid and eliminate catastrophic failures. Phase 1 of the study is scheduled to be completed on August 31, 2013. Phase 2 work began in December 2012 and is scheduled to be completed by the third quarter of 2014. The results-to-date are available at: https://primis.phmsa.dot.gov/matrix/PrjHome.rdm?prj=390.

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2015-01-22

Communication Type: Official Correspondence

Communication Contents: -From Timothy P. Butters, Acting Administrator: PHMSA proposes to close this recommendation based on completion of the comprehensive study. In 2011, PHMSA launched a comprehensive study to understand longitudinal ERW seam failures. The objectives of the study were to: 1) integrate data from industry and PHMSA to quantify vintage seam-failure statistics with a focus on low-frequency ERW seams, 2) understand longitudinal ERW seam failure mechanisms, and 3) quantify the effectiveness of inspection and hydrotesting to manage integrity and ensure safety in order to avoid and eliminate catastrophic failures. This study analyzed ER W seams as follows: incident history and operational factors; effectiveness of pressure testing including spike tests to expose near-critical defects; models to predict failure and re-inspection intervals based upon material strength and toughness; and detection and sizing via ILI and in-ditch tools. The final report was published on October 23, 2013. The results-to-date and final report are available at: https://primis.plm1sa.dot.gov/matrix/PrjHome.rdm?prj=390. PHMSA communicated the study's findings to industry and the general public through the project web site and presentations, and has used this information to help inform the draft NPRM titled "Pipeline Safety: Safety of Gas Transmission Pipelines" (see Safety Recommendation P-11-14 below).

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2011-08-04

Communication Type: Official Correspondence

Communication Contents: CC# 201100307: - From Cynthia L. Quarterman, Administrator: The safety recommendation P-09-1 recommends PHMSA "conduct a comprehensive study to identify actions that can be implemented by pipeline operators to eliminate catastrophic longitudinal seam failures in electric resistance welded (ERW) pipe; at a minimum, the study should include assessments of the effectiveness and effects of in-line inspection tools, hydrostatic pressure tests, and spike pressure tests; pipe material strength characteristics and failure mechanisms; the effects of aging on ERW pipelines; operational factors; and data collection and predictive analysis." On May 26, 2011, PHMSA selected Battelle Memorial Institute to conduct a comprehensive study identifying actions that can be implemented by pipeline operators to eliminate catastrophic longitudinal seam failures in ERW pipe. Results from this study are expected in November 2012 and will influence how PHMSA addresses NTSB Recommendation P-09-02. For more information, see the "Comprehensive Study to Understand Longitudinal ERW Seam Failures" public project page at http://primis.phmsa.doLgov/matrixlPrjHome.rdm?prj=390. In addition a public meeting held on July 20, 2011 expanded the study's focus and stakeholder awareness beyond low frequency ERW to all potential threats in seam welds. For more information on the July meeting "Managing Challenges with Pipeline Seam Welds" see http://primis.phmsa.doLgov/meetings/MtgHome.mtg?mtg=71.

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2010-09-01

Communication Type: Official Correspondence

Communication Contents: 201000347: - From Cynthia L. Quaterman, Administrator: In November 2009 PHMSA solicited for a comprehensive study on low frequency Electric Resistance Welded pipe recommended by the NTSB and from technical consensus reached during the 2009 Pipeline R&D Forum. PHMSA received four white papers on that topic, requested proposals from two offerors but only received a proposal from one offeror. Unfortunately that sole offeror was not recommended for award by the diverse Merit Review Panel formed for the solicitation based on the criteria used to evaluate the submissions. PHMSA will try again to solicit for a comprehensive study on low frequency Electric Resistance Welded pipe starting in early FY 2011. NTSB also recommended PHMSA initiate a program to evaluate pipeline operators’ public education programs, including pipeline operators’ self-evaluations of the effectiveness of their public education programs, and to provide the NTSB with a timeline for implementation and completion of this evaluation (NTSB safety Recommendation P-09-3). PHMSA co-sponsored a public awareness workshop with the National Association of Pipeline Safety Representatives (NAPSR) on June 30, 2010, in Houston, Texas. The workshop provided an opportunity for PHMSA and the NAPSR representatives to hear about the implementation progress and ascertain what is working and not working regarding the use of the RP 1162 for developing, implementing and evaluating public awareness programs as well as jointly identify critical elements of a successful operator public awareness program. Trade associations and pipeline operators shared lessons learned from implementing their public awareness programs based on the RP 1162 and its incorporation by reference into the Federal pipeline safety regulations. The interests of the public were largely represented at the workshop by representatives from the Pipeline Safety Trust. PHMSA and State Partners discussed the timelines for conducting effectiveness evaluations and the plans to use the results from this event in addition to inspection activities to further develop our program for evaluating pipeline operator public awareness programs. In addition, PHMSA along with our State pipeline partners have formed an ad hoc public awareness team to develop policy and guidance material for upcoming public awareness effectiveness inspections of pipeline operator public awareness programs. The inspections will focus on how operators evaluated their program for effectiveness, what were the results, were results documented, and what improvements were identified and/or implemented. Inspector training and data collection will also be addressed in these plans. Pilot inspections will be conducted to gain more insight and validate the inspection tools and are expected to take place in the first and second quarter of FY 2011. PHMSA takes the NTSB safety recommendations seriously and works hard to fulfill the requirements of each recommendation. If you have questions, please feel free to contact me at 202-366-4433.

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2010-01-29

Communication Type: Official Correspondence

Communication Contents: Letter Mail Controlled 2/3/2010 6:14:55 PM MC# 2100043: - From Cynthia L. Quaterman, Administrator: We have been and continue to investigate the technical issues regarding ERW line pipe with a focus on low frequency Electric Resistance Welded (ERW) and Electric Flash Welded (EFW) pipe. An internal and external document search was completed to identify all known prior studies involving ERW and EFW failures. This effort helped to strengthen our understanding of the issues with natural gas pipelines and to identify possible gaps in knowledge on how this issue is affecting hazardous liquid systems. In June of 2009, PHMSA hosted a Pipeline Research and Development Forum. The forum provided an opportunity for Federal, State and industry stakeholders to meet and reach a consensus on future pipeline research needs that enhance safety. A comprehensive ERW study was debated in one of the sessions along with the associated technical challenges. The session produced a gap analysis and comprehensive research recommendation on “Low Frequency ERW Pipeline Failures” with input from several stakeholders including the NTSB. PHMSA recently published a solicitation for a comprehensive research project on “Low Frequency ERW Pipeline Failures” (Solicitation Number: DTPH56-10-BAA-000001) in FedBizOps on November 3, 2009. The research solicitation includes but is not limited to the assessment of current methods to test and detect flaws and a study of failure mechanisms in ERW pipelines, and will address NTSB Safety Recommendation P-09-1. An award from this solicitation is anticipated during Spring 201 0. The duration of this effort is unknown at this time and additional details will be provided to the NTSB as they become available.