Covington, Tameka (PHMSA)

From: Nanney, Steve <PHMSA>

Sent: Tuesday, January 06, 2009 10:49 AM
To: Mayberry, Alan <PHMSA>
Cc: Gute, William <PHMSA>
Subject: Kinder Morgan - Louisiana Pipeline - yield strength issues - Wellspun/Mittal

Attachments: Scan001.PDF; Scan001.pdf

Scan001.PDF (3 Scan001 pdf (5 MB)

MB)

Alan, attached is the Kinder Morgan presentation to SW Region on the pipe failure issue due to yield strength
being about X56 on X70 pipe. The pipe was in an 80%MAOP pipeline, but this pipe was not special permit
pipe. The pipe failed on hydrotest. The have several low yield strength pipe joints in this pipeline.

Steve

1
 KMLP Issue Assessment/Testing
• High resolution caliper tool data — diameter measurements
. Diameter variability - Minimum diameter variability within single pipe
 KMLP Issue Assessment/Testing
43e1M19..MMCVA.

High resolution caliper tool data — diameter measurements

• Diameter variability — Manuf. variability at 0.10 threshold in single pipe
 KMLP Issue Assessment/Testing
+00.21eanISINI.Magyyrzeovav

• High resolution caliper tool data — diameter measurements

Diameter variability - Signature criteria and threshold within single pipe 1 41

41.0 SOLIILL2.
eve diameter Joint 560
max diameter
40.9
min diameter
flpe nom ID
40.8 Pipe tolerance +

40.7 •

40.6

-; 40.5

40.4

40.3

40.2

40.1

40.0
1770 1760 1790 1800 1810 1820
Approx log distance (it)
 KMLP Issue Assessment/Testing
High resolution caliper tool data — diameter measurements
• Diameter variability — Data rate change and threshold within single pipe
 KMLP Issue Assessment/Testing

n Testing
• Selected pipe joints that had indications of 'potential' expansion
• Applied established caliper tool data criteria and remove pipe joints
suspected of having experienced expansion
• Removed approximately 7,100 ft of pipe out of 36,000 ft of pipe surveyed
for diameter variability (approx. 19.7%)
From the 7,100 ft of pipe, 30 pipe joints that had 'identified
expansion' were selected for additional testing
• Performed tensile testing on the 30 pipe samples
• Performed chemical analysis on samples with low tensile results
• Performed Charpy V-notch (Cvn) impact testing on three pipe samples
with lower yield values.
 KMLP Issue Assessment/Testing

• Testing (con/0
• Selected 30 random pipe from pipe that had not been tested or
that was tested at pressures that produce hoop stress less than
75% SMYS
▪ Performed tensile testing on the 30 pipe samples
▪ Performed chemical analysis on samples with low tensile results
 KMLP Project Summary Test Results
• Results from tensile tests
• 43% of the pipe samples from the set containing pipe
identified with potential expansion had low yield or tensile
. 69% of samples identified with potential expansion greater that 0.20
inches had yield values below 70 ksi
. 14% of samples identified with potential expansion of 0.20 inches or
less had yield values below 70 ksi (suggests diameter variance of 0.20
inches is the threshold)
. 0% of samples having indications of expansion 0.10 inches or less had
yield values below 70 ksi (suggests diameter variance of 0.10 inches
was conservative)
• 13% of the pipe samples from the set containing pipe that
had not been tested or tested to less than 75% SMYS had
low yield or tensile
 KMLP Project Summary Test Results

Tensile testing results

• Pipe set containing potentially expanded pipe — see separate attachment
• Pipe set containing Non-tested samples — see separate attachment
• Charpy V-notch (Cvn) impact testing and shear results
• The Cvn impact tests were conducted using 1/2 samples; the full size equivalent
absorbed energy range is 160 ft-If to 198 ft-lb
The full size Cvn results from the pipe MTR's ranged from 150 ft-lb to 220 ft-lb

Heat No. , Pipe No. Absorbed Energy, ft-lb Lateral Expansion, mils Shear Appearance, %

Y632978 30613 93-92-80 69-76-76 100-100-100

Y632978 -- 90-83-99 75-76-76 100-100-100

Y632199 30370 81-80-82 68-70-71 100-100-100

 Transverse Tensile Test Results
NPS 42 x 0.864" WT API 5L Grade X70 Welspun LMLP Linepipe
Random Pipe Samples

An-Tech Heat # Pipe # Yield Tensile % YT Ratio

Job # Strength Strength Elongation
(ksi) (ksi) in 2"
08-3111 Y924709 36903 70.3 81.6 46.80 0.86
08-3112 Y632978 36715 65.8 80.0 50.75 0.82
08-3113 Y632975 29998 69.2 86.4 45.50 0.80
08-3114 Y612880 37060 73.0 87.1 48.30 0.84
08-3115 Y622906 36949 76.4 91.0 44.60 0.84
08-3116 Y612877 30071 74.4 86.2 42.60 0.86
08-3117 Y622901 30066 76.4 88.6 44.50 0.86
08-3118 Y622896 31024 81.6 97.0 43.75 0.84
08-3119 Y622910 30359 74.2 90.3 47.50 0.82
08-3120 Y612860 30030 74.1 85.7 46.05 0.86
08-3121 Y612862 30821 72.9 84.2 46.05 0.87
08-3122 Y632974 30507 77.5 90.0 45.15 0.86
08-3123 Y632976 30646 74.7 90.8 45.55 0.82
08-3124 Y917277 30236 68.1 80.4 51.95 0.85
08-3125 Y622909 30559 86.1 99.7 43.15 0.86
08-3126 Y642892 30093 77.3 88.9 44.30 0.87
08-3127 Y632988 30680 78.9 91.8 46.95 0.86
08-3128 Y642902 30524 76.0 91.0 47.50 0.84
08-3129 Y612878 30684 80.8 93.3 44.60 0.87
08-3130 Y632999 31038 77.6 93.2 45.65 0.83
08-3131 Y612868 30786 83.8 98.3 41.75 0.85
08-3132 Y632987 37713 75.8 91.5 43.75 0.83
08-3133 Y643162 36489 86.0 100.4 41.60 0.86
08-3134 Y632997 30744 84.7 97.7 44.30 0.87
08-3135 Y642887 37786 82.0 98.2 43.15 0.84
08-3136 Y623197 30419 79.4 93.3 45.30 0.85
08-3137 Y632986 37817 74.3 88.1 42.35 0.84
08-3138 Y632991 30919 86.0 98.7 43.85 0.87
08-3139 Y613177 37670 74.5 93.1 45.65 0.80
08-3140 Y623209 30045 81.0 96.3 43.55 0.84

Count 30 .. 30 30 30
Average 77.1 91.1 45.22 0.85
Std.Dev. 5.3 5.7 2.38 0.02
Minimum 65.8 80.0 41.60 0.80
Maximum 86.1 100.4 51.95 0.87
KMLP Project Summary Conclusions/Actions

Conclusions / Discussion
▪ Tensile test results suggest approximately 13% of the 42" OD x 0.864 API
5LX70 pipe supplied to KMLP did not meet the API 5LX70 yield strength
specifications
▪ Tensile test results from the set of pipe identified as having indications of
expansion suggest the 0.10 inch criteria used to remove pipe was
conservative.
• The data supports a threshold for diameter variability of up to 0.20 inches
• Pipe having diameter variability less than 0.20 inches resulted in 14% low
yield, which falls within the13% random sample results.
• 19% of pipe surveyed with the caliper tool was removed using 0.10 inch
threshold, this supports that the 0.10 inch threshold was conservative when
compared to the 13% random sample results and the 14% results on pipe
having expansion indications of 0.20 inches or less.
 KMLP Project Summary Conclusions/Actions

n Conclusions / Discussion (con't)

• Coating containing stress marks performs as well as coating that does not
contain stress marks
• No degradation in coating and corrosion protection
• Coating that contained longitudinally aligned imperfections were repaired
prior to installation on HDD's that were installed prior to discovery of
issue. Pipe was jeeped and coating repaired after testing and prior to
installation of the HDD
• The variability in the pipe yield properties is a result of deviation from
plate controlled rolling parameters
• Tensile testing supports the metallurgical strength modeling in establishing a
lower bound yield strength of 56 ksi with minimal controlled rolling and can
approach 80 ksi with appropriate processes and controls.
• Even at the lower bound yield strength pipe meets MAOP service design
requirements for 0.72 factor applications
KMLP Project Summary Conclusions/Actions

Actions
• Pipe joints having diameter variability measurements of 0.10 inch and
greater were removed from tested pipe strings prior to installation.
• Installed HDD's requiring 0.6 or greater design factor were removed if it
contained pipe joints having diameter variability measurements of 0.10
inch and greater.
• Pipe mill was requested to investigate the issue and review all
manufacturing and test data to re-establish a lower bound yield strength
for each heat.
▪ Pipe mill is recertifying pipe based on mill manufacturing and test records.
▪ KMLP has started receiving recertification documents for the 42" OD x
0.864" w.t. pipe.
Pipe mill recertification's received are API 5LX56, X60, and X65
 KMLP Project Summary Conclusions/Actions

n Actions (con' t)
• HDD installations requiring 0.6 or greater design factors have been tested
between 95% and 100% of SMYS based on API 5LX70 criteria, or will
use pipe that has been Mill recertified to meet the design factor
requirement.
n KMLP will provide technical support to leave the four HDD's that were
installed prior to discovery of issue in place.
n HDD's require a 0.72 design factor
n HDD's are avoidance drills and do not cross roads
 KMLP HDD DRILLS
12-Dec-08

Design Stations Approx. Align.

HDD # DESCRIPTION Factor To From Footage Page #
1 Hwy. 82 0.60 02+57 25+57 2560 2
2 South of Sabine Lake 0.72 153+08 201+08 5380 4,5
3 Sabine Lake - PL avoidance 0.72 848+10 868+10 2560 15
4 Shell Island 0.72 899+31 952+31 5300 16,17
5 Shell Island to S ICWW Site 1-2 0.72 954+31 984+31 3000 17,18
6 S ICWW to S ICWW Site 3-4 0.72 1048+54 1097+52 5160 19,20
7 S ICWW to S ICWW Site 4-5 0.72 1098+72 1129+72 3100 20
8 S ICWW to S ICWW Site 5-6 0.72 1130+72 1168+72 3900 20-21
9 S ICWW to S ICWW Site 6-7 0.72 1170+22 1194+22 2400 21-22
10 S ICWW to S ICWW Site 7-8 0.72 1264+54 1304+42 3988 22-23
11 5 ICWW to S ICWW Site 9-10 PL avoid. 0.72 1307+10 1351+55 4445 23-24
12 S ICWW to N ICWW (Intracoastal Canal) 0.72 1533+99 1590+99 5700 27-28
13 Vinton Drainage Canal 0.72 1593+39 1642+99 4960 28
14 Pipeline Corridor (Charlie Moss Rd.) 0.72 2045+60 2064+69 1909 35
15 Bayou Choupique (Ellis Moss Rd.) 0.60 2238+06 2279+56 4150 38
16 Calcasieu River 0.72 2547+21 2593+22 4601 43-44
17 LNG Terminal Canal (Bait Shop) 0.72/0.5? 2596+97 2639+73 4276 44-45
18 State Hwy. 384 (Big Lake Rd.) 0.6 2668+54 2695+99 2745 45-46
19 Joe Ledoux Rd. 0.6 2697+49 2732+34 3485 46
20 Intersate 10 0.6 4029+10 4071+04 4194 69
21 Bayou Nezpique 0.72 5199+63 5159+83 3980 87
22 Tiger Gully 0.6 5905+55 5935+55 3000 100
23 24" FGT Lateral - Bayou Des Cannes 0.72 63+20 87+20 2 FGT lateral
24 Cheniere Pipeline Avoidance 0.72 35+25 56+24 2000 1
Kinder Morgan Louisiana Pipeline
(KMLP) Pipe issues

PHMSA meeting
MOnday December 15, 2008
 KMLP Project Summary Introduction

• Project Description
• 137 mile 42 inch diameter pipeline
• 18 miles open water (approx.)
• 17 miles marsh (approx.)
• 102 miles upland (approx.)
• 23 HDD's totaling approx. 87,000 ft
Approx. 2.1 Bcf capacity at 1,440 psig MAOP
• 12 interconnects
• Special Rermit / 0.8 design waiver Class 1 locations only
• Class 1— 0.72 design factor (HDD's)
• Class 2 — 0.6 design factor (all)
• Class 3 — 0.5 design factor (all)
• Other design factors per 49 CFR part 192
KMLP Project Map
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Hon e DESCRIPTION Pastor start Rnbh Length DO
Grand Chanter
1 Hwy. 52 0.60 02457 25057 MO
2 Moth of Sabine lake 0.72 153008 201008 5310
3 Make 1.434.81.4voldanda 0.72 14410 mum •. 2540
4 Shag Island 0.72 499+31 952+31 5300
S 35.0 island to 5 ICVMMte 1-2 072 95401 904+31 3000
6 SICVAVto 3 ICWW SW 34 0.72 1048+54 1097+52 5110
7 5 ICVAV to 5 1400 05065
05 0.72 I090+I2 1129+72 3100
8 3 ICVAV to 5 ICVONSIte 34 0.72 1130+72 1164.72 9900
9 S1CWW to SIONVISIte 67 0.71 1170+22 1194+22 2480
10 S ICVAV to 310Wd Ste 7.8 011 1164054 2304042 KINDEIIMORGAII
11 5 ICMAVMSICWW 51% 9-10 PL avoid. 0.72 1507+10 1151053 4445
12 5101W to 6 WNW (bitmenastal Candi 0.72 , 1313049 1330069 9740
13 Vinton 116414134 Canal 0.72 159349 1642+99 4950
14 Pipeline Corddet Podia Moss Rd.) 0.72 2015060 206449 1909 Kinder Morgan Louisiana Pipeline
ligyou Chouplque (Ids Most Rd.) 0.60 2236+06 2279+56 41.50
15
16 Caleaslau River 0.72 2547+21 2393+22 4601
Horizontal Directional Drills
17 1.140TerrninsiCanel (Bait Shop) 780 2336037 2639+73 4276
East Cargernii
sa State lexy.314Gre Lair NJ 0.60 2668.54 2895+99 2745 Prep by: SADavis 10 December 2006
19 km tarknor Rd. 000 2637046 2732+34 3485
20 Inta1911e10 0.60 4019010 4071004 4194 Design Scale: 1 4 Mies File: KMLP_HDD DrIlls_b_y1208a.mxd
21 BAYOU 4e509*. 0.71 5199+63 515943 3910
The sup Wm been mreMlly earnollarl and printed by Kinder Morgan from available Information.
22 716er WM 0.40 3905015 5935+55 3000 Nadu Morgan dee. net guaranies Via soeureey of Ns map or information delineated 01010011.
U 24' KM Lateral- Bayou Des Canna 0.71 63+20 67+20 2400 Her 4000 gamic. Malan *swim reapomfbIlry for any reliance themen. Radplant aim., not
uph diesIbuts or 4gilk. WI map without exprass oinsont from Kinder Morgan id Rs effillales.
24 re Pipeline Avoidance 0.72 95.25 56.24 2000
 KMLP Project Summary Issue/Discovery
OfIRMISMS650.1511.11WATMATI , MMV,Vr

Identified pipe issue

▪ 42" OD x 0.864 w.t. pipe not in conformance to API 51.)(70
• Random tensile testing results indicate approx. 13% of 0.864 w.t. pipe
has yield values that are not in conformance to API 51)(70
• pipe in question exceeds yield strength required for MAOP
• Yield value variability within same heats
Plate rolling parameters
Metallurgical strength model by DGS Metallurgical Solutions, inc.
• Discovery of issue
• It is standard practice to subject assembled string of HDD pipe to a
pre-installation hydrostatic pressure test
• Pre-installation test pressures from approx. 2,160 psig (1.5 x design) to
approx. 2,678 psig (93% SMYS)
• Minor deformation in the pipe diameter of several pipe joints was
observed on pipe tested to 93% SMYS or higher.
 KMLP Project Summary —Discovery (con't)

• Discovery of issue (con't)

• Deformation confirmed with diameter tape measurements and
later using high resolution caliper tool survey
It The discovery of deformation of pipe resulting from pre-test
suggested low yield strength
• At time of discovery five (HDD's) had already been pulled in
place, five additional HDD's ready for installation
HDD #1 — Hwy 82, 2,560 ft (removed after discovery of pipe issue)
HDI? #4 — Shell Island, 5,300 ft
4 HDD #5 — Shell Island site 1— 2, 3,000 ft
HDD #7 - Shell Island site 4 — 5, 3,100 ft
4 HDD #8 — Shell Island site 5 — 6, 3,900 ft
• Upon discovery of the issue, KMLP undertook a study to
determine the extent of the pipe issue and develop resolutions.
 KMLP Issue Assessment/Testing

• Assessment
• Review pipe that had been tested to approx. 93% SMYS
▪ Reviewed tested pipe ready for HDD installation
Coating on pipe strings was visually inspected
. Indications of coating stress marks (discoloration) and longitudinally
aligned (LA) coating imperfections were identified
• Jeeping confirmed LA coating imperfections
Diameter tape measurements confirmed pipe had expanded at locations of
LA coating anomalies and minor expansions at locations with coating stress
Marks
• Preparedplan to run high resolution caliper surveys
▪ Reviewed information on installed HDD's
it Multiple coating repairs were required after pressure testing and prior to
HDD installation
Conducted high resolution caliper surveys
 KMLP Issue Assessment/Testing
Assessment (con/0
• Picture — pipe with confirmed expansion, approx. 0.27 and 0.5 inch
 KMLP Issue Assessment/Testing

• Assessment (con't)
• Picture — coating longitudinally aligned imperfections
 KMLP Issue Assessment/Testing

I. Assessment (con't)
• Picture — coating stress marks (discoloration)
 KMLP Issue Assessment/Testing

• Assessment (con't)
• Picture — coating stress marks (discoloration)
 KM LP Issue Assessment/Testing

• Assessment (con't)
• Commissioned third party coating lab to analyze stressed FBE/ARO
coating
▪ Coating test results indicate that the areas with stress marks perform
as well as areas without stress marks; "...the coating should deliver
satisfactory performance in the intended service...'
▪ Reviewed high resolution survey results by comparing variability from
nominal diameter within each pipe joint
Diameter variability ranged from approx. 0.05 inches to approx. 0.8 inches
for all pipe surveyed, and approx .05 inches to approx. 0.46 inches in the
installed HDD's.
Qeveloped criteria using caliper tool data to flag 'potential" expansion
within each joint based on:
• Criteria needed to account for pipe manufacturing/forming process
allowance of +0.250 inches, per API 5L
▪ Criteria used data trends (signature), severity of (data) rate change
• Criteria established a variance threshold — 0.10 inch min to max
diameter variance
 KMLP Issue Assessment/Testing

Magpie high resolution caliper tool

III