Pipeline Integrity Management Programs Ernest Klechka

CASA Pipeline

CASA Pipeline Product Pipeline: Diesel, Gasoline Product received from Corpus Christi Refinery transported to Victoria and San Antonio Terminals Length: 234.66 Miles CASA Pipeline system: 8-inch piping was constructed by Sinclair Pipeline in 1947 and commissioned in 1948. 6-inch pipeline to San Antonio was constructed in 1948. Line Number Miles From To Nominal Pipe Size Long Seam Comments 132A 80.27 Nueces Station Victoria Station 8 Lap 132B 70.41 Luling Station 132C 49.24 San Antonio Terminal 6 Seamless ERW (1965) 132D 34.74 Austin Idle 132E <1 San Antonio Seamless

BENEFITS OF INTEGRITY MANAGEMENT Public safety Reduced liabilities Environmental protection Enhances system reliability Extend the life of pipeline assets Goodwill Required by 49 CFR Part 192 and Part 195

PIPELINE INTEGRITY PROGRAM CONSISTS OF 5 PLANS Integrity Management Plan Performance Plan Communications Plan Management of Change Plan Quality Control plan

THREATS TO PIPELINE INTEGRITY There are numerous potential threats to pipeline integrity First challenge includes recognizing these threats and establishing an assessment program ASME B31.8S (gas pipelines) 21 Threats, 9 categories 3 time related defects External Corrosion Internal Corrosion Stress Corrosion Cracking Manufacturing and related defects Construction and related defects Equipment and related defects Third party inflicted damage Incorrect operations and procedures Weather related, earth related and other outside forces API 1160 (liquid pipelines) lists similar threats under categories of metal loss and construction/third party damage

Integrity Assessments ILI PIGGING TOOLS WALL LOSS TOOLS MFL ULTRASONIC CRACK TOOLS GEOMETRY AND MAPPING TOOLS HYDROSTATIC TESTING PRESSURE TESTING USUALLY WITH WATER TO 125% OF MOP DIRECT ASSESSMENT EXTERNAL DIRECT ASSESSMENT INTERNAL DIRECT ASSESSMENT STRESS CORROSION DIRECT ASSESSMENT OTHER TECHNOLOGY (Equivalent understanding)

ILI PIGGING TOOLS NACE SP0102 ADVANTAGES Ability to obtain accurate data for identifying and sizing defects Applicable to long sections of pipeline Ability to retrieve and compare data for corrosion trending Transferable to geographic information systems (GIS) Non-destructive nature of the tools

HYDROSTATIC PRESSURE TESTING DISTRUCTIVE PROCESS ONLY CRITICAL FLAW LEADING TO FAILURE AT THE TIME OF TEST ARE FOUND Pipeline must be taken out of service Large Volume of water must be used and disposed of in accordance with environmental regulations Introducing water into the pipeline is a corrosion risk factor Hydrostatic testing may be destructive; use in highly populated areas is not desirable

DIRECT ASSESSMENT 4 STEP PROCESS Pre-assessment Indirect inspection Direct examination Post assessment ECDA (External Corrosion Direct Assessment) NACE SP0502 ICDA (Internal Corrosion Direct Assessment) Dry gas DG-ICDA NACE SP0206 Wet gas WG-ICDA NACESP0119 Liquids LP-ICDA NACE SP0208 SCCDA (Stress corrosion cracking direct assessment) SP0204

ECONOMIC OF AN INCIDENT WHAT ARE THE REAL COSTS OF AN INCIDENT? Lost revenue from interruption operations Lost product Cost of repair and property damage Public liability including increased insurance costs Public image including investor relations Civil and criminal penalties

Bellingham, Washington June 10, 1999 Creek filled with 200,000 gallons of gasoline from a 16”D pipe that ruptured. Ignited and caused three deaths Caused $45 million in property damage That federal investigation ultimately resulted in prison or probation terms for three company officials and a settlement requiring $112 million in penalties and safety improvements. Cost of incident exceeded $1 Billion

San Bruno, California 2010 The indictment charges the utility with 12 felony violations of federal pipeline safety laws, which could carry a total possible fine of $6 million, or more if the court decides it somehow benefited financially from the disaster. Federal prosecutors allege that PG&E knowingly relied on erroneous and incomplete information when assessing the safety of the pipeline that eventually ruptured, sparked a fireball and leveled 38 homes in San Bruno. The neighborhood where eight were killed and dozens injured is still recovering.

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