1. Pipeline Integrity Management Programs
Ernest Klechka

2. CASA Pipeline

3. CASA Pipeline Product Pipeline: Diesel, Gasoline
Product received from Corpus Christi Refinery transported to Victoria and San Antonio Terminals
Length: 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

4. 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

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

6. 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

7. 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)

8. 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

9. 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

10. 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

11. 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

12. 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

13. 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.

14. QUESTION?