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MAOP

MAOP
Maximum Allowable Operating Pressure means the maximum pressure at which a pipeline or segment of a pipeline may be operated under this part. (192.3 Definitions)

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MAOP
MAOP is Calculated by using:
192.619 - Maximum allowable operating pressure - Steel or plastic pipelines 192.621 - Maximum allowable operating pressure: High-Pressure distribution systems. 192.623 - Maximum and minimum allowable operating pressure: Low-pressure distribution systems. 192.620 - Alternative maximum allowable operating pressure for certain steel pipelines

Factors Affecting MAOP

Class location (Steel pipelines) Design of pipe and components System pressure test Operating history Overpressure protection

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192.619 (a)
No person may operate a segment of steel or plastic pipeline at a pressure that exceeds a maximum allowable operating pressure determined under paragraph (c) or (d) of this section, or the lowest of the following:

192.619 (a)
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element Test Pressure (de-rated by class location factor) MOP during the 5 years preceding applicable date Maximum safe pressure determined by the operator

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192.619 (a)
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element Test Pressure (de-rated by class location factor) MOP during the 5 years preceding applicable date Maximum safe pressure determined by the operator

Design Pressure

The pressure for which a pipeline or segment of a pipeline is designed using appropriate engineering parameters, formulas, and component pressure ratings

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Design
Pipe Design Formulas
Steel - 192.105 Plastic - 192.121 Limitations for Plastic - 192.123

Components
Manufacturers rating

MAOP based on Design

Based on the weakest link
Pipe Component Fabricated fitting

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192.619
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element Test Pressure (de-rated by class location factor) MOP during the 5 years preceding applicable date Maximum safe pressure determined by the operator

Test Pressure
Tested according to the requirements of Subpart J Steel
Test pressure de-rated by class location factor

Plastic
Test Pressure divided by 1.5 for all locations

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192.619
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element Test Pressure (de-rated by class location factor) MOP during the 5 years preceding applicable date Maximum safe pressure determined by the operator

5 Year MOP
The highest operating pressure in the 5 years preceding
Onshore pipelines 7/1/1970 Gathering pipelines 3/15/2006 or date line becomes subject to this part, whichever is later

Unless
Tested in accordance with 192.619(a)(2) after July 1, 1965 or Uprated in accordance with Part 192 Subpart K

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5 Year MOP Except for newly regulated gathering lines, using the 5-year pressure to establish MAOP is not an option.

192.619
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element Test Pressure (de-rated by class location factor) MOP during the 5 years preceding applicable date Maximum safe pressure determined by the operator

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Maximum Safe Pressure

The pressure determined by the operator to be the maximum safe pressure after considering the history of the segment, particularly known corrosion and the actual operating pressure.

Used for derating pressure only!

192.619 (a)
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element Test Pressure (de-rated by class location factor) MOP during the 5 years preceding applicable date Maximum safe pressure determined by the operator

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192.619 (b)
If MAOP established by a maximum safe pressure (193.619 (a)(4)), must have overpressure protective devices installed on the segment in a manner that will prevent the maximum allowable operating pressure from being exceeded, in accordance with 192.195.

192.619 (c)
The requirements on pressure restrictions in this section do not apply in the following instance.

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192.619 (c) (Grandfather Clause)

An operator may operate a segment of pipeline found to be in satisfactory condition, considering its operating and maintenance history, at the highest actual operating pressure to which the segment was subjected during the 5 years preceding the applicable date in the second column of the table in paragraph (a)(3) of this section.

192.619 (c) (Grandfather Clause)

The highest operating pressure in the 5 years preceding
Onshore pipelines 7/1/1970 Gathering pipelines 3/15/2006 The five years prior to the date the line becomes regulated

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Steel MAOP Calculation

Steel transmission line constructed in 1995 6, Grade B pipe, 0.280 wall thickness Installed in a Class 2 location Valves, fittings ANSI 300 (740 psig) Tested to 650 psig for 8 hours

What is the MAOP?

192.619 (a)
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element Test Pressure (de-rated by class location factor) MOP during the 5 years preceding applicable date Maximum safe pressure determined by the operator

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MAOP Steel Pipe 192.619(a)(1)

192.105 Design of Steel Pipe

P = (2St/D) x F x E x T
S=Grade of pipe t = thickness D=diameter F=Design Factor 192.111 E=Longitudinal Joint Factor 192.113 T=Temperature Derating Factor 192.115

MAOP Steel Pipe 192.619(a)

192.105 Design of Steel Pipe

P = (2St/D)xFxExT
S=Grade of pipe Grade B or 35,000 t = thickness 0.280 D=diameter 6.625 F=Design Factor 192.111 0.6 E=Longitudinal Joint Factor 192.113 1.0 T=Temperature Derating Factor 192.115 1.0

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MAOP Steel Pipe 192.619(a)

192.105 Design of Steel Pipe
P = (2St/D)xFxExT P = ((2x35,000x0.280)/6.625)x0.6x1x1 P=1775 psig Fittings ANSI 300 = 740 psig

MAOP by Design 740 psig

192.619 (a)
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element = 740 psig Test Pressure (de-rated by class location factor) MOP during the 5 years preceding applicable date Maximum safe pressure determined by the operator

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MAOP Steel Pipe 192.619 (a)(2)

Test Pressure (de-rated by class location factor) MAOP = Test Pressure/Class Location Factor Test Pressure = 650 psig Class Location Factor for class 2 = 1.25 MAOP = 650/1.25

MAOP by test pressure = 520 psig

192.619 (a)
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element = 740 psig Test Pressure = 520 psig MOP during the 5 years preceding applicable date Maximum safe pressure determined by the operator

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MAOP Steel Pipe 192.619 (a)(3)

The highest operating pressure in the 5 years preceding applicable date
Onshore pipelines 7/1/1970 Gathering pipelines 3/15/2006 or date line becomes subject to this part, whichever is later

Not applicable, built in 1995

192.619 (a)
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element = 740 psig Test Pressure = 520 psig MOP during the 5 years preceding applicable date = NA Maximum safe pressure determined by the operator

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MAOP Steel Pipe 192.619 (a)(4)

Maximum safe pressure determined by the operator

Not applicable, built in 1995

192.619 (a)
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element = 740 psig Test Pressure = 520 psig MOP during the 5 years preceding applicable date = NA Maximum safe pressure determined by the operator = NA MAOP of steel pipeline = 520 psig as determined by 192.619 (a)(2)

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Plastic MAOP Calculation

Plastic line constructed in 2005 2, PE 3408, SDR =11 Installed in a Class 2 location Tested to 150 psig

What is the MAOP?

192.619 (a)
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element Test Pressure (de-rated by class location factor) MOP during the 5 years preceding applicable date Maximum safe pressure determined by the operator

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MAOP Plastic Pipe 192.619(a)(1)

192.121 Design of Plastic Pipe P = (2S/SDR 1) x DF
S = HDB (Hydrostatic Design Basis) in accordance with listed specification at given temperature SDR = Standard dimension ratio DF=Design Factor 0.32 or 0.40 for PA-11

Hydrostatic Design Basis signBasis Thermoplastic Pipe ThermoplasticPipe

Piping Material

73 F 100 F

120 F

140 F

2406 3408

1250 1600

1250 1250

1000 1000

800 800

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MAOP Plastic Pipe 192.619(a)(1)

192.121 Design of Plastic Pipe P = (2S/SDR 1) x DF
S = HDB (Hydrostatic Design Basis) in accordance with listed specification at given temperature = 1600 SDR = Standard dimension ratio = 11 DF=Design Factor 0.32

MAOP Plastic Pipe 192.619(a)(1)

192.121 Design of Plastic Pipe P = (2S/SDR 1) x DF
P = (2)(1600)/(11-1) X 0.32 P = 3200/10 x 0.32 P = 320 x 0.32 = 102 MAOP by Design = 102psig

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192.619 (a)
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element = 102 psig Test Pressure (de-rated by class location factor) MOP during the 5 years preceding applicable date Maximum safe pressure determined by the operator

MAOP Plastic Pipe 192.619 (a)(2)

Test Pressure (de-rated by class location factor) MAOP = Test Pressure/1.5 MAOP = 150/1.5

MAOP by test pressure = 100 psig

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192.619 (a)
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element = 102 psig Test Pressure = 100 psig MOP during the 5 years preceding applicable date Maximum safe pressure determined by the operator

MAOP Plastic Pipe 192.619 (a)(3)

The highest operating pressure in the 5 years preceding applicable date
Onshore pipelines 7/1/1970 Gathering pipelines 3/15/2006 or date line becomes subject to this part, whichever is later

Not applicable, built in 2005

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192.619 (a)
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element = 102 psig Test Pressure = 100 psig MOP during the 5 years preceding applicable date = NA Maximum safe pressure determined by the operator

MAOP Plastic Pipe 192.619 (a)(4)

Maximum safe pressure determined by the operator

Not applicable, built in 2005

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192.619 (a)
MAOP cannot exceed the LOWEST of:
Design pressure of weakest element = 102 psig Test Pressure = 100 psig MOP during the 5 years preceding applicable date = NA Maximum safe pressure determined by the operator = NA MAOP of plastic pipeline = 100 psig as determined by 192.619 (a)(2)

For Distribution

Not done calculating MAOP yet!

From 192.619, must move to: High pressure distribution - 192.621 Low pressure distribution - 192.623

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High Pressure Distribution System

A distribution system in which the gas pressure in the main is higher than the pressure provided to the customer. (Service Regulators)

192.621 MAOP High Pressure Distribution Systems

Lowest of the following: Design (redundant from 192.619) 60# - unless service lines equipped with pressure limiting devices meeting 192.197(c)

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192.621 MAOP High Pressure Distribution Systems

25# - Cast Iron Pipe if there are

Unreinforced Bell and Spigot Joints

" The Pressure Limits to which a Joint

could be Subjected without the Possibility of its Parting."

Maximum Safe Pressure determined by

the Operator ~Must provide Overpressure Protection per 192.195 (Redundant from 192.619)

Low Pressure Distribution

A distribution system in which the gas pressure in the main is substantially the same as the pressure provided to the customer. (No Service Regulators)

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192.623 Low Pressure Distribution Systems

Maximum and Minimum Allowable Operating Pressure
Cannot operate at a pressure high enough to make unsafe the operation of properly adjusted low -pressure gas burning equipment.

192.623 Low Pressure Distribution Systems

Maximum and Minimum Allowable Operating Pressure Cannot operate at a pressure lower than the minimum pressure at which the safe and continuing operation of any properly adjusted low-pressure gas burning equipment can be assured.

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Established MAOP

Do not have to operate at MAOP

Established MAOP
Once established, MAOP not lost unless: Down rate pipe according to maximum safe pressure 192.619(a)(4) Install pipe or component that does not comply with design formula or pressure requirements Install untested or low tested pipe Class location change

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Temporary Pressure Reductions

May have temporary pressure reductions due to:
Operations and maintenance issues Safety related conditions IM requirements Pressure reductions due to PHMSA orders

What should an operator do if the pipeline has been operating for a significant time at a pressure lower than established MAOP?

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Verify MAOP
Recommend follow requirements similar to 192.555 or 192.557
Review the design, operating, and maintenance history of the segment of pipeline to determine whether the proposed increase is safe and consistent with the requirements of this part; and Make any repairs, replacements, or alterations in the segment of pipeline that are necessary for safe operation at the increased pressure. Written plan for procedure

Verify MAOP
Check for
Any component changes since installation Class changes Regulation and overpressure protection Leak history and repairs

Pipeline really suitable to be operated at higher pressure?

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Re-establish MAOP
Modified 192.555(e) or 192.557(c) Where a segment of pipeline has a pressure increase to established MAOP, the increase in pressure should be made in increments that are equal to:
(1) 10 percent of the operating pressure before the increase; or (2) 25 percent of the total pressure increase, whichever produces the fewer number of increments.

Re-establish MAOP
Modified requirements of 192.553
At the end, the pressure should be held constant while the entire segment of the pipeline that is affected is checked for leaks. Each leak detected must be repaired before a further pressure increase is made, except that a leak determined not to be potentially hazardous need not be repaired, if it is monitored during the pressure increase and it does not become potentially hazardous.

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Summary
Consider fitness for service prior to reestablishing MAOP
Design, repairs, operating and maintenance history Written procedure Incremental pressure increases Leak surveys

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