RA 693JK3211RA0001 Attachment 7 Research Topics.pdf

U.S. Department of Transportation (USDOT) RA #693JK3211RA0001

Pipeline and Hazardous Materials Safety Administration (PHMSA) Attachment #7

Pipeline Safety Research and Development

Proposed Research Topics

Research Announcement # 693JK3211RA0001

Technology Research Sought with Resource Sharing

Underground Gas Storage

PHMSA continues to build a research portfolio of projects supporting solutions to improve safety in the full life cycle of underground gas storage (UGS) facilities.

(Technology) Developing Advanced Tubing Inspection Tools

UGS well operations with workovers and re-entry create challenges for operators which could be addressed by non-destructive examination (NDE) technology solutions that minimize damage incurred downhole during these tasks. PHMSA is seeking research to improve the ability to assess multiple strings of casing as an alternative inspection method. The goal of this technology solution is to reduce risks when performing a workover by having more integrity information from NDE and through inspection of tubing. The project scope is tied to the current PHMSA rulemaking1 in assessing well integrity and includes reviewing the applicability of American

Petroleum Institute Recommended Practices (RP): API RP 1170, “Design and Operation of

Solution-mined Salt Caverns Used for Natural Gas Storage” and API RP 1171, “Functional

Integrity of Natural Gas Storage in Depleted Hydrocarbon Reservoirs and Aquifer Reservoirs”.

Proposals should include a diverse set of SMEs from manufacturers, facility operators, and service providers. PHMSA seeks reported results in 3 years.

1 https://www.federalregister.gov/documents/2020/02/12/2020-00565/pipeline-safety-safety-of-underground-natural-gas-storage-facilities https://www.federalregister.gov/documents/2020/02/12/2020-00565/pipeline-safety-safety-of-underground-natural-gas-storage-facilities https://www.federalregister.gov/documents/2020/02/12/2020-00565/pipeline-safety-safety-of-underground-natural-gas-storage-facilities

Technology Research Sought with Resource Sharing or Non-Technology Research Sought with Resource Sharing

Threat Prevention

(Technology/General Knowledge) Measuring Accumulated Strain and Assessing Strain Demand and Capacity on Existing Pipelines

Pipeline incidents related to ground movement are on the rise at the national level, creating the need to measure/monitor strain as a possible solution in addressing the threat. PHMSA is seeking research through a comprehensive and large-scale investigation to address two primary objectives. The first objective is to develop a model to measure accumulated strain on existing pipelines. Strain-level data on pipeline infrastructure is important to understand if pipelines are at risk due to damage incurred by plastic deformation of its material. The process generates

“accumulated strain,” which is defined as the level of strain built up over time in the pipeline from commissioning through operation of the system. With existing pipelines, the accumulated strain over time is unknown, which means there is no baseline to measure strain data. Not having this strain measured over the pipeline’s operational life creates a challenge for the pipeline industry, calling for a need for both tools and models.

The second objective is to assess the strain demand and capacity of existing pipelines. To meet this objective, PHMSA is seeking research on developing a methodology for assessing strain capacity that identifies required data inputs, provides guidance on how to collect data, identifies the process to predict strain capacity, and provides model validation. Any tool or model-based solution for calculating accumulated strain must be validated by the project. The project goal is to develop and validate a model to characterize both strain demand and capacity of a pipeline based on its operational parameters to withstand geohazard forces. The research results can influence the response measures and timing required to mitigate the impacts from a ground movement event, or consider strain capacity as the limit on strain demand in evaluating that response time.

Important strain capacity considerations that should be investigated in this project include, but are not limited to, the following:

1. Failure modes promoted by both tensile and compressive stresses/strains resulting from axial extension and bending of the pipeline, including ductile tearing, brittle fracture, buckling and wrinkling;

2. Both the pipe body and circumferential (girth) weldments (e.g., heat effected zone and weld metal), which require an understanding of the relative strength or stiffness of each material so that strain concentration effects may be evaluated; and

3. The effects of anomalies or features in the pipe body and circumferential weldments, which may locally reduce the load carrying capacity of the pipeline.

To meet the objectives of this investigation, the research scope should also include a literature search, including a review of published papers, to analyze/investigate the current strain assessment methods and implementation. Proposals should involve a broad team representing researchers, pipeline operators, metallurgists, and academia. PHMSA seeks reported results in 3 years.

Non-Technology Research Sought with Resource Sharing

Threat Prevention

(General Knowledge) Corrosion, Erosion-Corrosion, Material Compatibility, and Associated

Design of Gas Gathering Pipelines

PHMSA is seeking research on corrosion/erosion threat assessment methodologies to improve the operational safety of gas gathering pipelines. More information on these threats will inform

PHMSA’s regulatory program on gas gathering pipeline operations, as well as provide operators with improved prevention and mitigation measures.

PHMSA is seeking a research study that assesses corrosion and erosion-corrosion threats on gas gathering pipelines based on the mixed-mode flow (solid, liquid, and particulate) and the gas compositions in gas gathering pipelines. The project must include material susceptibility, pressure and flow, and geologic (regional) considerations since these factors are critical when assessing the likelihood and severity of corrosion/erosion damage on pipeline materials. The project should provide measures/applications to reduce or mitigate corrosion/erosion damages.

Relevant standards such as NACE International MR0175: Petroleum and natural gas industries-

Materials for use in H2S-containing environments in oil and gas production should be considered as these standards will impact the scope of the project. Literature relevant to corrosion/erosion on pipeline materials across various operating conditions and environments should also be considered. Any lessons learned or best practices implemented from other industries/sectors should also be investigated.

Proposals should include a broad team representing manufacturers, academia, operators, and service providers. PHMSA seeks reported results in 2 years.

(General Knowledge) Design and Placement of Compact Service Regulators

Some gas service regulators have been, and in certain situations are still, placed inside of occupied structures where very limited outside space exists or where placement outside has been deemed impractical. PHMSA seeks technology solutions for service regulator design improvements or changes to address National Transportation Safety Board (NTSB)

Recommendations2. The regulator design must have a sufficiently small footprint to be installed outside where limited outside space exists and must comply with all applicable regulations.

Proposals should include a diverse set of subject matter experts (SMEs) from the gas distribution industry and relevant standards organizations. PHMSA seeks reported results in 18 months.

Underground Gas Storage

PHMSA continues to build a research portfolio of projects supporting solutions to improve safety in the full life cycle of underground gas storage (UGS) facilities.

(General Knowledge) Investigating Cement and Other Materials as a Barrier in UGS Wells

PHMSA is seeking literature review research to investigate and provide recommendations on a comprehensive definition of micro-annulus and leak paths in UGS wells. The research must identify the appropriate height of barrier make-up required to mitigate/isolate leak paths. The research proposal should also develop technology solutions to test cement and/or other materials to validate the system integrity, including if cement and production casing can be used in combination as a single barrier system. Knowledge and technology solutions from this research will provide new integrity data on the risk assessment process and integrity management programs for UGS facilities. The project scope is tied to the current PHMSA rulemaking3, particularly monitoring the annulus, assessing the well’s integrity, and reviewing the applicability to American Petroleum Institute RP 1170 and RP1171.

Proposals should include input from a diverse set of SMEs including manufacturers, facility operators, and service providers. PHMSA seeks reported results within 2 years.

Liquefied Natural Gas (LNG)

(General Knowledge) Developing Periodic External/Internal Inspection Requirements to Assess

Low Temperature and Cryogenic Storage Tanks

2 NTSB Recommendations P-19-001 & P-19-002 https://www.ntsb.gov/investigations/AccidentReports/Reports/PAR1901.pdf#search=P%2D19%2D001 3 https://www.federalregister.gov/documents/2020/02/12/2020-00565/pipeline-safety-safety-of-underground-natural-gas-storage-facilities https://www.federalregister.gov/documents/2020/02/12/2020-00565/pipeline-safety-safety-of-underground-natural-gas-storage-facilities https://www.federalregister.gov/documents/2020/02/12/2020-00565/pipeline-safety-safety-of-underground-natural-gas-storage-facilities

Title 49 Code of Federal Regulations (CFR) Part §193, Subpart C incorporates by reference the

2001 edition of National Fire Protection Association 59A: Standard for the Production, Storage, and Handling of Liquefied Natural Gas (NFPA 59A-2001) for LNG facility design. Section 4.2 in NFPA 59A-2001 requires metal, welded containers designed for no more than 15 pounds per square inch (psi), must meet the requirements in Appendix Q of American Petroleum Institute

Standard (API) 620 Design and Construction of Large, Welded, Low-Pressure Storage Tanks.

API 620 Appendix Q addresses large, low-pressure, field-assembled storage tanks used for the storage of liquefied hydrocarbon gases at temperatures above -270°F; however, the inspection requirements in API 620 Appendix Q are limited to activities conducted during the design and construction phases. There is no consideration for periodic inspections of low temperature or cryogenic tanks during the operational phase. PHMSA is seeking a study to determine recommended operational requirements for periodic external/internal inspections of refrigerated storage tanks. The research project scope must analyze/investigate existing consensus standards, such as API 620, tank builder’s experience, and data collected from previous internal tank inspections to identify the inspection requirements that were conducted, as well as the inspection findings. The project scope should determine the recommended inspection activities, including purpose of each inspection, inspection intervals, and actions required to adequately address the inspection requirements.

Proposals should include input from facility operators, independent experts, and tank builders.

PHMSA seeks reported findings in 2 years.

(General Knowledge) Developing Performance Criteria for External Loading Factors on

External Steel Shell Tanks

In the 2019 edition of NFPA 59A (NFPA 59A-2019), a full-containment tank system, as defined in Section 3.3.5.4.2 and the Annex, consists of a secondary container that is designed to contain spilled LNG from the inner container and could be constructed of either metal or pre-stressed concrete. PHMSA’s current regulations require that, if the outer wall is used as a dike serving as a storage tank impounding system, that outer wall must be constructed of concrete (49 C.F.R. §

193.2161). PHMSA is seeking research to determine whether a metal secondary container provides an equivalent level of safety and operational integrity as an alternative secondary container constructed of concrete. The research must identify applicable external and internal impacts to the secondary container, as well as the design criteria used to evaluate the safety and integrity of secondary containers constructed from metal. External impacts may include, but are not limited to, overpressure due to a vapor cloud explosion (VCE), projectiles (VCE and windborne), and radiant heat effects (fire from studied tank and adjacent tanks). Internal impacts may include, but are not limited to, thermal shock from inner tank leaks. The research must provide a case study for a 9% nickel steel secondary container and recommend future tests to validate the evaluation. The project should incorporate existing consensus standards such as

NFPA 59A with input from tank builders, relevant inspection data, and previous impact test results.

Proposals should include input from independent SMEs and LNG plant operators. PHMSA seeks reported findings in 2 years.

(General Knowledge/Modeling) Determine the Maximum Permissible Temperature Drops for

Steel when Exposed to Cryogenic Liquid

Section 193.2155(a)(3) of Title 49 CFR requires that structural members of impoundment systems must be designed and constructed to prevent impairment to the system’s performance reliability and integrity from the effect of the temperature, any thermal gradient, and any other anticipated degradation resulting from sudden or localized contact with LNG. To address new technologies such as full-containment tanks using a metal secondary outer container and for pipe-in-pipe systems, PHMSA is seeking research investigating, testing, and determining the maximum permissible rate of temperature changes for various types of steel when exposed to cryogenic liquid. The project must include two case studies involving releases from: 1) the LNG primary container; and 2) the inner pipe of a pipe-in-pipe system. The project scope must include materials that are used in the design for the LNG container inner tank, such as 9% nickel steel, as well as other types of stainless steel used for cryogenic service. Additionally, NFPA

59A-2001, Section 2.2.2.2, incorporated by reference in § 193.2101, requires that impounding areas must have a minimum volumetric capacity equal to the greatest volume of LNG, flammable refrigerant, or flammable liquid that can be discharged into the area during a 10-minute period from any single accidental leakage source. Such a large quantity of cryogenic liquid may compromise the adjacent stainless steel supporting structures for components located within the same curbed area. Based on the results of the research, the project should also recommend proper protection for these supporting structures from exposure to cryogenic temperatures.

Proposals should be informed by input from independent SMEs. PHMSA is seeking results within 2 years.

(General Knowledge/Modeling) Evaluating/Demonstrating the Feasibility of LNG Storage Tank

Operations Without Bottom Fill Capabilities

NFPA 59A-2019, Section 8.4.3 requires that all LNG containers be designed for both top and bottom filling unless other process means are provided to mitigate stratification. PHMSA is seeking research aimed to foster development of process means that can safely replace the bottom fill capability when filling light density LNG into an LNG container containing heavier density LNG. The research must identify the process means and provide the limitation of such processes. The research project must provide a case study to demonstrate the effectiveness of the proposed process’s method to mitigate stratification for LNG containers without the bottom fill capability. The research project must also recommend the applicable type/size of LNG containers and types of LNG plants.

Proposals should include input from independent SMEs. PHMSA is seeking results within 2

Materials

(General Knowledge) Review of Alternative Materials for Non-Steel or Alternative Steel Pipeline

Systems (i.e., Composite, Steel Reinforced Plastic, or Reinforced Fiber Plastic Pipe)

The overall research objective is to develop pipeline technology solutions that are not currently available to address material testing, construction damage, assessments of defects, degradation of the pipe material, and maintenance activities to ensure the integrity of non-steel or alternative steel pipeline systems. Non-steel or alternative steel pipelines could be used for gas and hazardous liquid pipelines in transmission, distribution, or gathering type systems.

PHMSA is seeking a feasibility study to review the safety, material, and design requirements needed under 49 CFR Parts 192 and 195 for non-steel or alternative steel pipeline systems.

PHMSA is seeking a review of such systems that operate between 125 pounds per square inch gauge (psig) and 2,180 psig and over 100 degrees Fahrenheit.

The following key questions must be addressed for materials manufacturing requirements for quality assurance and testing, design including safety factor and maximum allowable operating pressure (MAOP), construction, defect assessments and repairs, in-place testing, operations, maintenance, and periodic assessments:

What should be the limits for maximum operating pressure and temperature?

What is the present limit for non-steel or alternative steel pipe diameters and should there be a maximum diameter limit?

o Should or is the diameter limit based upon type of non-steel or alternative steel pipe?

What should be the operating life span?

o What parameters should be reviewed, tested, test interval, and updated

(maintained) to achieve the operating life span?

Should these non-steel or alternative steel pipe types have a periodic test program to ensure material properties are not degrading during varying service conditions (pressure, temperature, product and outside environment)?

o What should be included in an optimal type test program (type of tests and test intervals)?

o Should it be based upon the type of non-steel or alternative steel pipe materials being used?

o The types of non-steel or alternative steel pipes being manufactured should be identified.

What material, design, construction, operating, maintenance and integrity management aspects of Part 192, Part 195, or relevant consensus standards should be used?

What new requirements should be added to Part 192 or Part 195 based on the unique properties of the pipe—such as manufacturing tests, repair criteria, operating pressure and safe pressure calculations, design safety factor, bending, depth of cover for prevention of 3rd party damage, pipe backfill requirements, leakage where there are multiple layers, effects of ultraviolet rays on the pipe for storage and transportation, pressure test factor and duration during manufacturing and after construction, loss of strength over time, loss of MAOP due to anomaly growth (corrosion, denting, cracking, etc.), pressure cycling and fatigue type effects, other chemical/petroleum effects on the pipe, need for cathodic protection, etc.?

How should damage/defects to non-steel or alternative steel pipe external and internal surfaces, reinforcement, connections, and de-laminations be assessed for remediation and safe operating pressures?

Under what conditions should non-steel or alternative steel pipe be allowed in Class 1, Class 2, 3, and 4 locations, high consequence areas, moderate consequence areas, freeway/railroad crossings, waterways, etc.?

o What type design, construction, maintenance, and integrity management activities should be performed if it is allowed?

o What type of products should be allowed in composite pipelines (sweet gas, sour gas, crude oil, highly volatile liquids)?

What are the material susceptibility, pressure and flow, and geologic (regional) considerations for non-steel or alternative steel pipelines? These factors are critical when assessing the likelihood and severity of corrosion/erosion damage on pipeline materials.

o The review should provide measures/applications to reduce or mitigate corrosion/erosion damages.

o Relevant standards such as NACE International MR0175: Petroleum and natural gas industries-Materials for use in H2S-containing environments in oil and gas production should be considered as they impact the scope of the project.

o Literature relevant to corrosion/erosion on pipeline materials across various operating conditions and environments should also be considered.

o Any lessons learned or best practices from other industries/sectors should also be investigated.

What should be assessed for corrosion and erosion-corrosion threats on non-steel or alternative steel pipelines based on the mixed-mode flow (solid, liquid, and particulate) and the product compositions in the gas pipelines?

For integrity assessment, what can be effectively used to evaluate a non-steel or alternative steel pipeline for threats (inline inspection, pressure testing, direct assessment, etc.? What should be developed to reassessments?

What are the integrity threats to a non-steel or alternative steel pipeline?

o How can these threats be mitigated or remediated during the manufacturing, construction, testing, operations, and maintenance activities?

What construction operator qualifications (OQ) and operational OQ requirements are recommended for the pipeline operator?

o What should the training program include?

If PHMSA allows usage of non-steel or alternative steel pipelines under a 49 CFR

190.341 special permit, what are the recommendations for special permit conditions to maintain a safe operating life for the pipeline?

o PHMSA has issued special permits in the past for usage of non-steel or alternative steel pipelines. These special permits should be used as background information.

The research scope to address anomaly detection should include developing or validating non-destructive examination (NDE) technology to assess all types of non-steel or alternative steel pipeline and their various defect types (size/shape, etc.).

Technology solutions developed should be for both internal and/or external inspection.

For non-steel or alternative steel pipe, one major goal is to qualify/baseline new construction by inspecting for damage to external/internal materials, reinforcement, connections, de-laminations, etc.

The NDE technology developed from this project should be applicable to all pipe diameters.

The research scope must develop a methodology to assess and characterize identified damage in non-steel or alternative steel pipelines, including material degradation during ongoing operations.

PHMSA is seeking research results that can be used to determine a minimum threshold for continuing operations for MAOP and an operating safety factor. The project scope must factor in the damage type, shape, and other defect characteristics while applying the methodology to all non-steel or alternative steel pipeline materials evaluated. The research must include a recommended testing program designed to develop a qualification program for evaluation of pipe quality, including post-construction pipe repair. Lessons learned from other industries and operational experiences should be widely sought. The objectives should incorporate the previous results from any existing research projects related to non-steel or alternative steel pipeline systems.

Proposals should include input from a diverse set of SMEs including manufacturers, academia, operators, public safety experts, and service providers. PHMSA seeks reported findings in 3