NTSB Safety Recommendation P-09-002

NTSB safety recommendation P-09-002.

TO THE PIPELINE AND HAZARDOUS MATERIALS SAFETY ADMINISTRATION: Based on the results of the study requested in Safety Recommendation P-09-1, implement the actions needed.

Priority: CLASS II

Overall Status: Closed - Acceptable Action

Issued Date: 2009-10-27

Adopted Date: 2009-10-14

Overall Date Closed: 2018-02-21

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: 2018-02-21

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2018-02-21

Communication Type: Official Correspondence

Communication Contents: We classified Safety Recommendation P-09-1 “Closed—Acceptable Action” on April 8, 2015, as a result of the October 23, 2013, completion of your Final Summary Report and Recommendations for the Comprehensive Study to Understand Longitudinal ERW Seam Failures–Phase One. We note from your current letter that you completed six specific actions based on the study, and that you have completed a final report on the software developed as a result of the study. These actions satisfy Safety Recommendation P-09-2, which is classified CLOSED--ACCEPTABLE ACTION.

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2016-12-05

Communication Type: Official Correspondence

Communication Contents: Although we are disappointed to learn that action on this issue has been delayed a year, we are nonetheless pleased that, after a planned public meeting and forum, you expect the needed actions will be complete by December 31, 2017. Pending completion of this effort, Safety Recommendation P-09-2 is classified OPEN—ACCEPTABLE RESPONSE.

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 understand that, to further develop ways to evaluate seam issues, in 2012 you added a Phase 2 to the efforts related to P-09-1 and that you plan to complete this study in late 2015. We also understand that you will need an additional 12 to 18 months after you complete Phase 2 to implement the necessary actions. Pending the timely completion of this effort, Safety Recommendation P-09-2 is classified OPEN—ACCEPTABLE RESPONSE.

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: 2017-11-13

Communication Type: Official Correspondence

Communication Contents: -From Howard R. Elliott, Administrator: PHMSA requests closure of this recommendation. PHMSA has completed the following six steps to meet this recommendation:1) Improve Hydrotesting Protocols for ERW/FW Seams To investigate hydrotesting protocols for ERW/FW seams, Battelle analyzed various crack geometries under various conditions, including hydrostatic testing and fatigue, and developed recommendations towards an optimized procedure to expose near-critical flaws during the hydrotest, while minimizing the growth of pre-existing flaws. PHMSA has used and will use these findings for enforcement and integrity management spike pressure test requirements to evaluate pipeline seam integrity issues. 2) Enhance Defect Detection and Sizing via Inspection To enhance defect detection via inspection, Battelle collected a broad range of seam anomalies representative of the field in varying sizes and types for validation, and subjected each sample to multiple rounds of testing with each inspection technology, including destructive testing. This process allowed Battelle to draw trends and observations on each inspection technique, and allowed inspection technologies to gain knowledge and make improvements between inspection rounds. It is expected that the inspection service providers will use these results for further advancement of their technology. 3) Defect Characterization: Types, Sizes, and Shapes For this task, Battelle characterized defect size and shape by defect type, defining a consistent basis to quantify these inputs to the predictions of defect severity and the timeline for operator response and re-inspection. Additionally, this activity idealized each defect type relative to its local properties and modes of failure, to make progress towards establishing predictive models. 4) Develop and Refine Predictive Models and Quantify Growth Mechanisms To develop and refine predictive models, Battelle incorporated various analytical models driven by ILI crack size and relevant material properties, based on historical literature and findings from the previous tasks. Additionally, this task completed verification and validation studies of the software developed for Task 5. 5) Develop Management Tools: Manual, Software, Protocols, and Training Battelle integrated the work from the previous tasks to develop a software package. The software, PipeAssess PI, enables evidence-based repair and replacement decisions and includes management tools. The software was released in November 2016 for validation from industry. The software is currently available to industry using multiple licensing schemes. This software enables evidence-based repair and replacement decisions that can reduce costs through optimization of re-inspection intervals and hydrotesting. 6) Hold a Public Meeting/Forum PHMSA and Battelle coordinated to complete the final task of implementation. PHMSA held a special information session, "Comprehensive Study to Understand Longitudinal ERW Seam Failures," as a part of the Pipeline R&D Forum held November 16-17, 2016. All attendees of the R&D Forum were invited to the session in which Battelle released the Management Tools software for free trial licensing and demonstrated the capabilities of the software~ PHMSA's R&D Forum was open to the public, government, and industry pipeline stakeholders. More information on this public forum is available here: https://primis.phmsa.dot.gov/rd/mtg 111616.htm, and Battelle's presentation is available here: https://primis.phmsa.dot.gov/rd/mtgs/111616/Battelle.pdf. The Battelle special session was well attended. PHMSA has completed a final report on the software, which is available online with other documentation supporting this effort, including reports on individual tasks, here: https://primis.phmsa.dot.gov/matrix/PrjHome.rdm?prj=390.

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Date: 2016-08-17

Communication Type: Official Correspondence

Communication Contents: -From Marie Therese Dominguez, Administrator: To further develop how to evaluate seam issues and to facilitate informed decision-making, PHMSA is working to: 1) Improve Hydrotesting Protocols for ERW/FW Seams 2) Enhance Defect Detection and Sizing via Inspection 3) Defect Characterization: Types, Sizes, & Shapes 4) Develop and Refine Predictive Models and Quantify Growth Mechanisms 5) Develop Management Tools: Manual, Software, Protocols, and Training 6) Hold a Public Meeting/ Forum Reports are anticipated to be completed and made public by December 31, 2016. Further, as item 6 notes, a public meeting and forum will be held. PHMSA anticipates it will take an additional 12 months to implement any determined actions; therefore, we expect implementation to be complete by December 31, 2017.

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: PHMSA will address this recommendation once the ERW study regarding P-09-1 is complete. PHMSA anticipates it will take an additional 12 to 18 months after the ERW study is complete to implement the necessary actions.

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: To further develop how to evaluate seam issues, PHMSA added a Phase 2 to the efforts described in P-09-1. Phase 2 work began in December 2012 and is scheduled to be completed by the end of 2015. Phase 2 actions are: 1) Improve Hydrotesting Protocols for ER W /FW Seams 2) Enhance Defect Detection and Sizing via Inspection 3) Defect Characterization: Types, Sizes, & Shapes 4) Develop and Refine Predictive Models and Quantify Growth Mechanisms 5) Develop Management Tools: Manual, Software, Protocols, and Training 6) Public Meeting/ Forum PHMSA will complete this recommendation after Phase 2 is complete. PHMSA anticipates it will take an additional 12 to 18 months after completion of Phase 2 to implement the necessary actions.

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-09-2 recommends that "based on the results of the study from NTSB Open Recommendation P-09-1, PHMSA implement the actions needed." Following the comprehensive study currently underway by the Battelle Memorial Institute, PHMSA will determine how to address the requirements of this recommendation. The results from this study are expected by November 2012 and PHMSA anticipates it will take an additional 12 to 18 months to fully implement the actions needed.

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 2010. The duration of this effort is unknown at this time and additional details will be provided to the NTSB as they become available.

Addressee Acronym: PHMSA

Addressee Organization Type: G-Federal Government

Communication Type: Official Correspondence