Comprehensive Study to Understand Longitudinal ERW Seam Failures

Main Objective

1. Integrate industry and PHMSA data to quantify vintage seam failure statistics with focus on LFERW seams
2. Understand longitudinal ERW seam failures and on that basis, quantify the effectiveness of inspection and hydrotesting to manage integrity and ensure safety to avoid/eliminate catastrophic failures
3. Combine outcomes of the first two objectives to help favorably close National Transportation Safety Board Recommendation P-09-1

Public Abstract

The project will assist PHMSA in favorably closing NTSB Recommendation P-09-1 arising from the Carmichael MS pipeline rupture involving an ERW seam, which directed that PHMSA conduct a comprehensive study of ERW pipe properties and the means to assure that they do not fail in service. The scope is anticipated to validate that periodic use of the current ERW seam integrity assessment methods (hydrostatic testing and in-line inspection using a crack-detection tool) are the best means to prevent ERW seam ruptures.

The work will address the characteristics of ERW seams that make them susceptible to failure, and it will identify the factors the pipeline operators must consider in order to assure that their ERW pipelines are safe.

Final Report

PHASE II: Final Report for the Comprehensive Study to Understand Longitudinal ERW Seam Failures

Phase2FinalReport_170816_Final.pdf (1,229,867 bytes) [View] [Download/Save...]

PHASE I: Final Summary Report and Recommendations for the Comprehensive Study to Understand Longitudinal ERW Seam Failures

Phase_I_Final_Report.pdf (754,369 bytes) [View] [Download/Save...]

Other Files

Development of Selective Seam Weld Corrosion Test Method IPC2014-33562

(IPC_2014-33562)_Selective_Seam_Weld_Corrosion_Presentation.pdf (634,055 bytes) [View] [Download/Save...]

Final Report out briefing presentation

2017_09_DOT.pdf (1,809,679 bytes) [View] [Download/Save...]

Regulatory Next Steps in Addressing Pipeline Seam Weld Challenges

IPC_2014_-_Regulatory_Next_Steps_-_Steve_Nanney_-_09-29-14_-_Final.pdf (966,355 bytes) [View] [Download/Save...]

PRCI Presentation on ERW study

PRCI_-_2014_Research_Conference_-_GA_Tech_-_02-05-14_-_Final.pdf (1,764,861 bytes) [View] [Download/Save...]

A review of the DOT PHMSA ERW Pipe Study Reports from Kiefner January 2014

PRCI_Research_ExChange_review_of_Phase_1_of_DOT_PHMSA_ERW_seam_weld_project.pdf (823,120 bytes) [View] [Download/Save...]

Interim Report for Phase II – Task 2 of the Comprehensive Study to Understand Longitudinal ERW Seam Failures "Pipe Inventory, Inspection by In-The-Ditch Methods and In-Line Inspection, and Hydrostatic Tests"

Ph2Task2_FINAL.pdf (25,158,637 bytes) [View] [Download/Save...]

Interim Report for Phase II – Task 1 of the Comprehensive Study to Understand Longitudinal ERW Seam Failures

Phase2Task1_Final.pdf (813,550 bytes) [View] [Download/Save...]

Interim Report for Phase II – Task 3 of the Comprehensive Study to Understand Longitudinal ERW Seam Failures

Phase2Task3_Final.pdf (9,326,251 bytes) [View] [Download/Save...]

Interim Report for Phase II – Task 4 of the Comprehensive Study to Understand Longitudinal ERW Seam Failures "Models and Mechanisms with Validation Results"

Phase2Task4_Final.pdf (1,404,560 bytes) [View] [Download/Save...]

Interim Report for Phase II – Task 5 of the Comprehensive Study to Understand Longitudinal ERW Seam Failures "Summary Report for an Integrity Management Software Tool"

Phase2Task5_Final.pdf (3,511,744 bytes) [View] [Download/Save...]

Small-Scale Testing to Characterize ERW Seam Properties in Response to NTSB Recommendation P-09-01, Arising from the Carmichael, MS Rupture Paper No. IPC 2014-33073

Quickel_IPC_2014_PowerPoint_Presentation_(33073)_September_19.pdf (639,720 bytes) [View] [Download/Save...]

Effectiveness of Hydrostatic Testing for Assessing the Integrity of ERW and Flash-weld Pipe Seams

Task1_2-Effectiveness_of_Hydrostatic_Testing-KOLOVICH.pdf (256,287 bytes) [View] [Download/Save...]

Track Record of In-Line Inspection as a Means of ERW Seam Integrity Assessment

Task1_3-Track_Record_Of_In-Line-Inspection-KIEFNER.pdf (1,316,507 bytes) [View] [Download/Save...]

Battelle's Experience with ERW and Flash Weld Seam Failures: Causes and Implications

Task1_4-Battelle_Experience_w_ERW_and_FW_Seam_Failures-LEIS.pdf (4,273,451 bytes) [View] [Download/Save...]

Task 2.3 Characterization of the Toughness of Pipe Containing ERW Seam Defects

Task2_3-Characterization_of_the_Toughness_of_Pipe_Containing_ERW_Seam_Defects-Quickel.pdf (3,242,263 bytes) [View] [Download/Save...]

Models for Predicting Failure Stress Levels for Defects Affecting ERW and Flash-Welded Seams / Addendum on PAFFC

Task2_4-Models_for_Predicting_Failure_Stress_Levels-KIEFNER.pdf (2,258,637 bytes) [View] [Download/Save...]

Task2 6-Characterizing Aspects of Failure in ERW Line Pipe-Leis

Task2_6-Characterizing_Aspects_of_Failure_in_ERW_Line_Pipe-Leis_.pdf (13,084,165 bytes) [View] [Download/Save...]

Characterizing Failure in ERW Line Pipe

Task2_6-Characterizing_Failure_in_ERW_Line_Pipe-LEIS.pdf (13,077,962 bytes) [View] [Download/Save...]

Selective Seam Weld Corrosion Literature Review

Task3_1-Selective_seam_weld_corrosion_literature_review_BROSSIA.pdf (624,604 bytes) [View] [Download/Save...]

Task3.2-Selective Seam Weld Corrosion Test Method Development

Task3_2-Selective_Seam_Weld_Corrosion_Test_Method_Development-Brossia.pdf (776,950 bytes) [View] [Download/Save...]

Task3.3 - Selective Seam Weld Corrosion Cathodic Protection Effectiveness Evaluation

Task3_3-Selective_Seam_Weld_Corrosion_Cathodic_Protection_Effectiveness_Evaluation-Beavers.pdf (1,678,322 bytes) [View] [Download/Save...]

Task3.4 - Input to Report: Implications for Recommendation P-09-1

Task3_4-Input_to_Report_Implications_for_Recommendations_P-09-1-Brosia.pdf (679,362 bytes) [View] [Download/Save...]

Characterization of the Toughness of Pipe Containing ERW Seam Defects

Task_2_3_Characterization_of_the_Toughness_of_Pipe_Containing_Seam_Defects-Quickel.pdf (3,242,263 bytes) [View] [Download/Save...]

Predicting Times to Failure for ERW Seam Defects that Grow by Pressure-Cycle-Induced Fatigue

Task_2_5_-_Fatigue__Models__Report_-_KIEFNER.pdf (471,680 bytes) [View] [Download/Save...]

Task 3.2 – Selective Seam Weld Corrosion Test Method Development

Task_3_2_–_Selective_Seam_Weld_Corrosion_Test_Method_Development_Brossia.pdf (755,774 bytes) [View] [Download/Save...]

Task 4.1 Compare - Contrast Analysis of Inspection Data and Failure Predictions versus Burst-Test Outcomes for ERW-Seam Defects

Task_4_1-Compare_Contrast_Analysis-LEIS.pdf (1,973,114 bytes) [View] [Download/Save...]

Task 4.2 Time-Trending and Like-Similar Analysis for ERW-Seam Failures

Task_4_2-Time_Trending_and_Like-Similar_Analysis-LEIS.pdf (1,287,431 bytes) [View] [Download/Save...]

Task4.5-Phase I

Task_4_5-Phase_I_Final_Report-LEIS_01-20-2014(1).pdf (754,369 bytes) [View] [Download/Save...]

Overview of a Comprehensive Study to Understand Longitudinal ERW Seam Failures

YoungBA_at_al_IPC2014_33226_Presentation_Final.pdf (686,393 bytes) [View] [Download/Save...]

Report Analyzing 280 ERW (high-frequency-welded, low-frequency-welded, and DC-welded) and Flash Weld Seam Failures in Natural Gas and Hazardous Liquid Pipelines

task1_4-erw_and_flash_weld_seam_failures-kiefner-sept2012.pdf (11,966,561 bytes) [View] [Download/Save...]