Draft Work In Progress

White Paper
Definition and Application of
Fitness For Service to Gas Pipelines

INGAA Integrity Management

Continuous Improvement
Work Group 4
May 31, 2012

Interstate Natural Gas

Association of America

Fitness for Service White Paper - Draft

Definition and Application of Fitness For Service to Gas Pipelines

What Is Fitness for Service (FFS)?

FFS is the ability of a system or component, in this case a pipeline system or portion
thereof, to provide continued service, within established regulations and margins for
safety, until the end of some desired period of operation or scheduled inspection and
reassessment. FFS is a well-accepted approach to evaluate flaws that may be
injurious to integrity in equipment, including pipelines, to determine acceptability for
continued operation. The FFS approach is used extensively throughout the world in
transportation, energy, construction and many other industries since the 1980s.
FFS evaluations for pipelines rely on a detailed threat assessment, risk analysis, the
selection of appropriate inspection techniques, and flaw acceptance criteria. Results
from FFS evaluations provide guidance on equipment inspection intervals and shape
decisions to operate, repair, monitor, or replace equipment.
FFS was the key criteria behind the development of the first ASME B31.8 consensus
standards. Through prescriptive recommendations, those initial standards laid out how
a pipeline should be designed, constructed, operated and maintained so the pipeline
could be judged fit for service. Eventually, PHMSA and its predecessors imported many
of these practices into 49 CFR Part 192 as the Minimum Pipeline Safety Standards in
effect today. Subsequent ASME editions modified and improved the initial standards
and methods. The most recent version, ASME B31.8S, is the latest step in improving
FFS.
Implementing the FFS process will require time to evaluate pipelines in a prioritized
manner, manage customer service impacts and implement necessary actions. The
paper addresses how to start applying the process and extend it over time.

What Data and Information Do FFS Evaluations Rely On?

FFS evaluations employ a review of historical performance, among other things, to
identify threats that have and could pose a risk to the safe operation of the facility.
Technical analyses, including stress analysis and fracture mechanics, are then
employed to evaluate each of the threats and the associated physical flaws (for
example, metal loss, cracks, dents, deformations and conditions such as
outside/dynamic loads).

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Have FFS Evaluations Been Applied in Other Industries?

The methods currently used in FFS evaluations have been applied in the petroleum
refining, petrochemical, pulp and paper and the nuclear, coal and gas-fired electric
power industries since the 1980s. One of the first acknowledged threat specific
applications was actually in the pipeline industry with the development of B31G, a
method for calculating the remaining strength of pipelines in areas with metal loss, first
published in 1984.
In the absence of federal regulations covering analysis of complex systems, subject
matter experts across of number of these industries decided to create a compendium of
the methods to address a breadth of defect types in the late 1990s. The document was
first published in 2000, as American Petroleum Institute (API) Recommended Practice
(RP) 579. It was updated in 2007 through a joint effort between API and ASME and
published as API RP 579-1/ASME FFS 1.
API RP 579-1/ASME FFS 1 provides for three levels of analysis based on the amount of
available data, depth of knowledge, and the degree of conservatism desired:

Level 1 is used for rapid evaluation, requires the least number of measurements,
the few key parameters, and is quite conservative, i.e., it provides for a relatively
large safety factor.

Level 2 requires a deeper analysis and therefore more measurements to

establish the actual remaining cross sectional area. It is generally less
conservative than Level 1 because of the additional knowledge and information
required to conduct a deeper engineering analysis.

Level 3 relies on stress analysis to provide an even more in-depth examination of

metal loss. Level 3 requires an intensive quantification of measurement, loading
stresses, and material properties, to meet the detailed needs of a finite element
analysis.

The widespread acceptance and use of API RP 579-1/ASME FFS 1 demonstrates the
well-established precedence of successfully applying the principles of FFS for verifying
the mechanical integrity of pipelines.

Is Evaluating FFS Different for the Pipeline Industry?

Yes and no. The process is the same, but the setting is not. In every other industry
where FFS evaluations are applied, the equipment being evaluated is generally within a
fence line and often above ground. This means that the environment around the
equipment including piping can readily be monitored and quite often controlled.
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FFS evaluations for pipelines are different in that they rely on a detailed threat
assessment, risk analysis, selection of appropriate inspection techniques, and
acceptance criteria for non-injurious defects.
Where other facilities subject to FFS assessment generally are accessible and
geographically contained, pipelines typically are buried, traversing linearly through the
countryside, passing through a variety of soil types and geological conditions while
encountering flooding, storm damage and other environmental challenges. Burying
minimizes some environmental threats, but burying also subjects pipelines a variety of
ground movements such as subsidence, vibration effects and even damage through
direct contact and disturbance from excavation work.1 Evaluating a pipelines FFS thus
requires an operator not only to understand threats to integrity, but also to assess a
pipeline environment spanning tens, hundreds and often thousands of miles.
Risk assessment is essential in prioritizing and managing preventive and mitigation
measures. A complete understanding of the threats to integrity is essential including the
potential contribution of the surrounding environment. Risk assessment is most
effective when available data, including data specific to individual operating
environments, is examined as an integrated whole. FFS evaluations use data from
assessments, as well as from routine maintenance activities, often to identify areas
warranting further investigation through excavation and inspection. FFS methods are
used in these excavations to evaluate fitness based on a pipeline segments actual, asfound condition.
Assessment tools and engineering methods are imperfect, so an operator will integrate
the data collected during an excavation with other information (such as coating condition
and as-found pipe to soil potentials) to form the analytical foundation for making
decisions on preventive and mitigation measures. Finally, as part of a continuing desire
to improve processes and achieve the target of zero incidents, the as-found conditions
and results of evaluations are fed back into the threat assessment and risk analysis
processes. Lessons learned from the findings and analyses are shared throughout the
organization and, where applicable, throughout the industry.

While the NTSB concluded that pipe bursting activities nearby the transmission line did not contribute to
the San Bruno failure, the fact that it was the subject of significant fact gathering and analysis in their
investigation provides a key lesson learned: Pipeline operators must be aware of excavation and
construction work around their facilities. Of equal importance, entities planning to work around
underground facilities, including pipelines, must contact One Call, which was done for work in San Bruno.

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Examples of FFS Evaluations for Metal Loss/Corrosion, Dents and

Deformations
The corrosion evaluation method, ASME B31G, is a Level 1 type method. It is used for
rapid evaluation of a concern; it requires data for just a few key parameters; and it is
quite conservative in that it provides for a relatively large safety factor. RSTRENG
applied in two-parameter mode (using length and depth) is also a Level 1 method.
RSTRENG applied using a metal loss profile (sometimes referred to as a river bottom
analysis) is a Level 2 method. API RP 579-1/ASME FFS 1, described above, provides
Level 3 methods as well.
Pipeline operators also apply a variety of techniques to assess a pipeline segments
physical condition. In-line inspection (ILI) with high-resolution magnetic flux leakage
sensors are used to identify and characterize metal loss. High-resolution geometry
sensors are used to identify and characterize deformations in pipelines.
The FFS evaluation results in an estimate of a segments remaining strength, which can
be characterized by a predicted failure pressure ratio. Operators use the predicted
failure pressure ratio, a measure of the margin above the MAOP, and the calculated
pipeline strains to determine whether to excavate and the timing of excavations. Where
an excavation is made to evaluate the metal loss, an indentation or both, FFS methods
are then applied using actual measurements to determine a safe operating pressure.
These comparative measurements are then used to improve ILI technology. Where
excavation is not warranted, the operator uses the predicted failure pressure ratio to
define an interval where the segment will be monitored pending the next assessment.
It is important to understand that operators do not rely simply on one measure or one
tool. The corrosion control methods in ASME B31.8, which are in large part incorporated
into 49 CFR 192 Subpart I, provide for layers of protection from failure. The concept of
layers of protection analyses or LOPA was first described in the chemical industry in
the mid-1990s. It was recognized as a way of demonstrating while failures are so
infrequent, while assessing the rare failures both to diagnose what occurred and to
identify measures to prevent recurrence. LOPA was first captured in a book entitled,
Inherently Safer Chemical Processes, published by the Center for Process Safety (part
of the American Institute of Chemical Engineers). LOPA approach designs in
redundancy, so failure is prevented even if one layer of defense is weakened or lost.

FFS Applied to Environmental-Related Cracking

There are FFS methods available for evaluating environmental-related cracking,
including stress corrosion cracking (SCC). SCC direct assessment (DA) prioritizes
locations along the pipeline for investigative excavations. Nondestructive evaluations
and measurements on the exposed pipe provide the inputs for FFS evaluations that
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estimate a segments remaining strength and predicted failure pressure ratio. As was
the case with metal loss and indentations, the operator uses the results of the FFS
evaluation to determine whether to excavate and, where there is a sufficient margin of
safety, to define a future interval to the next assessment.

FFS Applied to Pre-Regulation Pipe

There are approximately 179,000 miles of on-shore natural gas transmission pipe
installed prior to pipelines safety regulations (1970) out of a total 300,000 miles. INGAA
operates approximately two-thirds of the total mileage.
A process was developed to address the FFS of pre-regulation pipe (pipe installed
before March 12, 1970) given 1) concerns raised by the Pipeline and Hazardous
Materials Safety Administration (PHMSA) in their January 4, 2011 Advisory Bulletin, 2)
recommendations issued by the National Transportation Safety Board (NTSB) following
their investigation of the Pacific Gas and Electric Incident in San Bruno, California, and
3) requirements in Section 23 of the recently enacted pipeline safety legislation, Pipeline
Safety, Regulatory Certainty and Job Creation Act of 2011.
The FFS process is best managed by way of following a flow or process diagram
through a series of screening steps and decision gates (Figure 1, at the end of this
section, below). The text that follows provides a description of how one (referred to as
an operator) systematically works through the decision process. The process, as
depicted in Figure 1 is designed to make use of existing pressure test and other records
and where records do not exist, through demonstrating a historical pressure test (see
inset below for background on pressure testing). Where records or pressure testing are
inadequate, the process moves the operator in a direction such that each decision
becomes more and more conservative.

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Jan'12,'2012'

Improvement*Process*for*Traceable,**
Veriable*and*Complete*Records*

Start'

Locate'Records'

Compile'Data'

Dene'Means'To'
Resolve'Gaps'

Are'Gaps'
Resolved?''

Lack of Pressure Test

Meeting 1.25xMAOP Apply Process For Managing
Pre-Regulation Pipe '

Yes'

Valid'Data'

Verify'Data'

Document'Gaps'

Yes'

Are'There'
Gaps'In'
Data?''
No'

Link'To'Data'Base'
and'Retain'

Apply'MOC'In'
Changing'Records''

Figure 1 Improvement Process for Traceable, Verifiable and Complete

Records
Overview of the Process
The FFS process is best managed by way of following a flow or process diagram
through a series of screening steps and decision gates (Figure 2, at the end of this
section, below). The text that follows provides a description of how one (referred to as
an operator) systematically works through the decision process. The process is
designed to make use of existing pressure test and other records and where records do
not exist, through demonstrating a historical pressure test (see inset below for
background on pressure testing). Where records or pressure testing are inadequate,
the process moves the operator in a direction such that each decision becomes more
and more conservative.
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At a high level there are eight cases addressed by the process. They are:
1. Pipe segments in HCAs, Class 3 or 4 that have a strength test to at least
1.25xMAOP can continue to operate under 49 CFR 192, subject to the Continual
Evaluation requirements of 49 CFR 192.937.
2. Pipe segments in HCAs, Class 3 or 4 that have a strength test to at least
1.1xMAOP that are piggable can:
a. Conduct a pressure test to 1.25xMAOP,
b. Run ILI that identifies and characterizes long seam and pipe body
anomalies,
c. Reduce pressure to 80% of the established MAOP or
d. Replace the pipe not meeting these conditions.
3. Pipe segments in HCAs, Class 3 or 4 that have a strength test to at least
1.1xMAOP that are not piggable or those that do not have a strength test of
at least 1.1xMAOP can:
a. Conduct a pressure test to 1.25xMAOP,
b. Reduce pressure to 80% of the established MAOP or
c. Replace the pipe not meeting these conditions.
4. Pipe segments in Class 1 or 2 that have a strength test to at least 1.1xMAOP
that do not contain pipe with known long seam issues can continue to
operate under 49 CFR 192.
5. Pipe segments in Class 1 or 2 that contain pipe with known a history of long
seam issues that are also piggable can:
a. Run ILI that identifies and characterizes long seam and pipe body
anomalies,
b. Conduct a pressure test to 1.25xMAOP,
c. Reduce pressure to 80% of the established MAOP or
d. Replace the pipe not meeting these conditions.
6. Pipe segments in Class 1 or 2 that contain pipe with known a history of long
seam issues that are non-piggable segments can:
a. Conduct a pressure test to 1.25xMAOP,
b. Reduce pressure to 80% of the established MAOP or
c. Replace the pipe.
7. Pipe segments in Class 1 or 2 that contain pipe with no known history of
long seam issues can continue to operate under 49 CFR 192, subject to the
Continual Evaluation requirements of 49 CFR 192.937.
8. Pipe segments that are not HCAs, Class 3 or 4, operating below 30% SMYS
can continue to operate under 49 CFR 192, subject to the Continual Evaluation
requirements of 49 CFR 192.937.
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The technical basis for these outcomes is described below. An operator can always
choose to conduct a 49 CFR 192, Subpart J pressure test and demonstrate fitness to
operate at its MAOP.

Starting The Process

The process begins with a question about what year the pipeline segment was
installed (Figure 2 (end of paper), Diamond 1). Pipe installed on or after March 12,
1970, became subject to new regulatory requirements for design and construction,
which required FFS testing by way of a pressure for establishing MAOP. Pipe installed
prior to that date was not subject to the regulatory requirements.
If the answer is Yes, i.e., the segment, was installed prior to March 12, 1970,
then the operator moves to a question, Was Segment Pressure Tested? (Diamond 2). If
the answer is No, then proceed to B on the second page of the flow chart. If the
answer is Yes, which means a pressure test was conducted, the process proceeds
through a series of questions to determine what kind of testing was conducted and what
level of assurance is provided by that testing.

Historical Pressure Testing

The series of questions in Diamonds 3, 4 and 5 are set up to determine what type
of pressure testing was done. Questions that address the level or intensity of the
pressure test are addressed subsequently in Diamonds 6 and 7.

Was A Field Installation Pressure Test Conducted?

The process first raises the question, was a field installation pressure test, i.e.,
was there a pressure test at the time of installation of the pipe (Diamond 3)? If the
answer is Yes, the operator goes to Diamond 6. If the answer in Diamond 3 is No,
the operator moves to Diamond 4, which asks if a post-installation test was conducted.

Was A Post Installation Pressure Test Conducted?

The process then raises the question, was there a post installation pressure
test?, i.e., was there a pressure test conducted at some point after installation of the
pipe? (Diamond 4). If the answer is Yes, the operator goes to Diamond 6. If the
answer in Diamond 4 is No, the operator moves to Diamond 5, which asks if a test was
conducted in the mill, i.e., the manufacturing complex often referred to as a pipe mill or
more simply a mill.

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Background on Pressure Testing

ASME B31.8 included use of an installation field pressure test beginning in the 1955.
The 1967 edition of B31.8, Section 841.14 requires a test to at least 85 percent of mill
test pressure if the mill test pressure was less than 85% SMYS. There were operators
using pressure testing on pipe at the time of pipeline installation as early as 1942
following ASA B31.1-223.
The initial research that established the use of a 1.25 safety factor between the test
pressure and the maximum operating allowable pressure was conducted by Duffy and
others at Battelle.1 The authors stated In view of the evidence discussed in this report,
it is recommended that the allowable operating pressure be set at 80 percent of the
minimum hydrostatic proof test pressure level when a high test pressure is used
specifically when the minimum test pressure is equal to 90 percent of the minimum
specified yield strength or higher.
PHMSAs predecessor agency, the Research and Special Programs Administration
(RSPA), issued an advisory on low-frequency electric resistance welded (LF-ERW) pipe
following a number of incidents, primarily on hazardous liquid pipelines. RSPA issued
an Alert Notice on January 28, 1988.2 The alert notice stated, All operators who have
pre-1970 ERW pipe in their systems should carefully review their leak, failure, and test
history as well as their corrosion control records to ensure that adequate cathodic
protection has been and is now being provided. In areas where cathodic protection has
been deficient for a period or periods of time, the operators should conduct an
examination of the condition of the pipeline, including close interval pipe-to-soil
corrosion surveys, selective visual examination of the pipe coating, and/or other
appropriate means of physically determining the effects of the environment on the pipe
seam. If an unsatisfactory condition is found, or if a pre-1970 ERW pipeline has not
been hydrostatically tested to 125% of the maximum allowable pressure, operators
should consider hydrostatic testing to assure the integrity of the pipeline. RSPA issued
a second Alert Notice in March 1989 expressing continued concern over failures on LFERW seams.3 This notice recommended hydrostatically testing all hazardous liquid
pipelines containing LF-ERW that had not been hydrostatically tested to 1.25xMOP, or
alternatively, reduce the operating pressure 20 percent. Some natural gas transmission
operators are known to have pressure tested pipeline segments containing pre-1970
ERW line pipe as a result of these notices.
Strength Test Portion of a Pressure Test
The strength test, sometimes referred to, as a proof test, is the initial portion of a
pressure test that is conducted to a desired level to establish or provide proof of the
strength of the pipe. Pressures tests conducted on pipe as installed or at some time
after construction also typically have an additional portion of the test, referred to as a
leak test. This portion of the test, as the name denotes, is used to detect and to
confirm that leaks may have occurred, as will be indicated by a drop in pressure. The
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drop in pressure may be gradual if the leak is small. By contrast, if a test failure in the
pipe results in a rupture, the pressure will fall rapidly. Water leaking from a failure will be
found near the pipe perforation.
The duration of the Proof portion of the pressure test is typically the time required for
the pressure to stabilize in the test section. The duration is a function of test section
length, elevation change and temperature. Typically the segment is stabilized within 30
minutes to an hour.
In a report prepared for GRI in 2001, Eiber and Leis stated Strength re-tests of
pipelines should be conducted using high pressures (90 to 110% SMYS) and held for
30 minutes at maximum pressure. The pressure should then be decreased to 90% of
the test pressure and held for as long as necessary for a leak check. This will eliminate
defect growth during the leak check and minimize growth during the pressure test.4
In a paper at IPC in 2004, Brian Leis stated that, It is emphasized that a one-hour long
hold at maximum pressure remains a viable upper bound for typical ductile line pipe. As
this hold time also leads to ductile tearing along the tips of the larger defects remaining
in the pipeline, care must be to select the hydrotest parameters consistent with the
purpose of the test and the properties of the line pipe body and seam. 5
The 2010 edition of B31.8 requires a pressure test to 1.25 times MAOP in Class 1 and 2
locations. This change was a result of research and industry practice as outline in
several studies as discussed above. This level of testing also matches the B31.4
requirements for hazardous liquid pipelines; however, class location is not used in that
code, all pipe is tested to a minimum of 1.25 times MAOP.
In a manufacturing mill, a pipe joint, typically 40 feet in length, is tested for
approximately ten seconds. This is the time needed to stabilize the pressure within the
pipe joint. Pipe with a sufficiently large flaw in the pipe body or long seam that does not
have sufficient strength will fail at the test pressure. The higher the test pressure, the
smaller the flaw size required to fail the test. A field pressure test on multiple miles of
installed pipe takes a longer period to stabilize. As stated above, the time required to
stabilize a long field test segment is a function of the segment length but is typically 3060 minutes. The same principle applies to the single pipe joint in the mill; as soon as the
pressure is stabilized at the desired level, the strength is established or the pipe fails.
Therefore, the short duration mill test is as effective as a strength and leak test for the
purpose of establishing fitness for service for the long seam and pipe body as a field
pressure test.

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Was A Mill Pressure Test Conducted?

The process raises the question, was there a pressure test conducted at the pipe
manufacturing mill?, i.e., was there a pressure test in the mill for each joint of pipe?
(Diamond 5). If the answer is Yes, the operator goes to Diamond 7. If the answer in
Diamond 5 is No, the operator moves to B, a risk based alternative, on the second
page of the flow chart.
The mill test is considered in this process because every joint of pipe made to
API 5L Specification for Line Pipe had to be hydrostatically tested since the first edition
of API 5L, Specification for Line Pipe was published in 1928.6

Pressure Testing Level

Where a pressure test was conducted at original installation or at some later
time, the next step in the process is to determine whether the test meets a level of
1.25xMAOP. This level was selected to screen out pipe from further analysis and
evaluation based on NTSB Recommendation P-11-15. From an engineering
standpoint, this establishes an adequate safety margin above the maximum operating
pressure. Note that lower test pressures may also be acceptable under certain
conditions, but the 1.25xMAOP test level has been shown and accepted by virtually all
studies and safety and regulatory authorities as adequate under all conditions.
The question of test level is applied to pipe that was either tested at installation or
subsequently in Diamond 6, which asks if the pipe was tested to a level of 1.25xMAOP
or greater? If the answer is Yes, the pipe meets the intent of the NTSB
recommendation and is routed to A.
A stipulates that the pipe is operated and maintained under 49 CFR 192. If the
answer in Diamond 6 is No, the operator moves to Diamond 8, which asks if the
segment contains pipe that has a weld seam types known to be have experienced
integrity issues. The seam types include low-frequency electric resistance welded (LFERW), direct-current electric resistance welded (DC-ERW), electric fusion or flash
welded, furnace butt-welded, and lap welded.
In Diamond 7, the question is posed, was the mill test at least equivalent to
1.25xMAOP? The question uses 1.25xMAOP equivalence to keep the testing level at
the same level as a field test. For Class 1 pipe to be operated at 72% SMYS, a mill test
to 90% is equivalent to 1.25xMAOP. For Class 2 pipe to be operated at 60% SMYS, a
mill test to 75% is equivalent (API 5L required an 80% SMYS test starting in 1931 so
tests on Class 2 pipe manufactured under 5L editions in effect since that time meet the
1.25xMAOP equivalence). For Class 3 pipe to be operated at 50 %SMYS, a mill test of
at least 62.5%SMYS provides equivalence.
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Diamond 8 asks if the segment contains pipe that has a weld seam types known
to be have experienced integrity issues. The seam types include low-frequency electric
resistance welded (LF-ERW), direct-current electric resistance welded (DC-ERW),
electric fusion or flash welded, furnace butt-welded, and lap welded. If the answer is
Yes, the pipe contains one of the identified long seam weld types and has not had a
test to 1.25xMAOP, and is routed to a risk based alternative, indicated in Figure 2 by B.
If the answer in Diamond 8 is No, the pipe does not have the identified long
seam types and was not tested to 1.25xMAOP. The operator is routed to Diamond 9.
Diamond 9 asks if a pressure test to 1.1xMAOP was conducted at installation or
sometime during the life of the segment. If the answer is No, the operator is routed to
the risk-based alternative, B. If the answer to the question in Diamond 9 is Yes, i.e.,
the pipe segment has undergone a 1.1xMAOP pressure test, Class 1 in that segment is
routed to A. While this test level does not meet the literal expectation of NTSB
Recommendation 11-15, line pipe in Class 1 not containing the identified long seam
types, tested to at least 1.1xMAOP, has operated safely since these tests were first
used.

Risk-Based Evaluation Of Certain Pre-Regulation Pipe (B) And Use of

ILI In Lieu of Pressure Testing
Pipeline segments that follow the path to B in the application of this FFS process
are treated through a more detailed evaluation, shown on page 2 of Figure 2 of the
process. This portion of the process draws upon the approach developed for previously
untested hazardous liquid pipelines in the 1990s. The specific regulatory requirements
are found at 49 CFR 195.303. The basis of the risk-based approach is the close
proximity to population. In addition, the approach allowed for the use of ILI assessments
in lieu of a pressure test. Similarly, the same approach is being proposed for natural gas
transmission pipeline systems. As an added benefit of employing ILI, anomalies can be
found that are smaller than the largest defect that would just fail a pressure test. HCAs
and class locations serve as the means of helping calculate risk by prioritizing
probability of consequences while ILI is used to prioritize the probability of failure.

HCAs
The highest priority segments are HCAs and these are identified in Diamond 10,
which asks if the segment is an HCA? If the answer is No, then the operator moves to
Diamond 13, which asks if the segment is Class 3 or 4? If the answer in Diamond 10 is
Yes, the operator moves to Diamond 11, which asks if a strength test was conducted
to 1.25xMAOP? If the answer is Yes, that is, the segment was tested to at least 1.25x
MAOP, then the operator goes to L, which indicates that the pipe continues to be
operated under 49 CFR 192, and in addition, 49 CFR 192.937 is applied. The intent is
to apply continual evaluation, including past and present integrity assessment results,
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data integration and risk assessment information, and decisions about remediation and
additional preventive and mitigative actions. It is also intended that the operator use the
results from this evaluation to identify the threats specific to each covered segment and
the risk represented by these threats.
If the answer in Diamond 11 is No, a strength test of 1.25x MAOP was not
achieved and the operator moves to Diamond 12. Diamond 12 poses the question of
was a strength test of 1.1xMAOP conducted? The No answer out of Diamond 12
requires that the operator conduct a pressure test to 1.25xMAOP, reduce pressure to
80% of the established MAOP or replace the pipe not meeting these conditions.
If the answer in Diamond 12 is Yes, i.e., a 1.1xMAOP strength test was
conducted, then the operator goes to Diamond 17. The safety margin of 1.1 is used
today for pipelines in areas where there is not an abundance of population nearby.
While the strength test in this instance does not meet the 1.25xMAOP recommended by
NTSB, the approach is to ensure that the segment has a safety margin above the
MAOP, and in addition, ILI will be applied to identify and characterize flaws such as
long-seam weld anomalies that would pose a threat to integrity.
Identification of long seam weld anomalies requires use of transverse-oriented
magnetic flux leakage (MFL) technology on an ILI tool. Electromagnetic-acoustic
transducer (EMAT) technology has been shown to provide additional data to
supplement MFL technology for seam weld assessments. Alternatively, ultrasonic
technology (UT) can be used; however, there has been limited application of EMAT and
UT technologies for seam weld assessment on natural gas transmission pipelines. The
transverse-oriented technology is available only in selected diameters. UT requires use
of a liquid couplant, making their applicability limited. INGAA members are working with
the American Gas Association, ILI providers and research organizations such as the
Pipeline Research Council International and the Gas Technology Institute to improve the
identification and characterization of long seam anomalies that would pose a threat to
integrity by taking advantage of multiple technologies. It is anticipated that the
technologies and their analysis processes will continue to improve during the timeframe
in which HCAs are being addressed and operators begin to address Class 3 and 4 pipe.
Diamond 17 poses the question of whether or not the segment is piggable. If the
segment is piggable then the operator goes to M. The operator can run ILI that identifies
and characterizes long seam and pipe body anomalies, reduce pressure to 80% of the
established MAOP, or replace the pipe not meeting these conditions. Conceivably, an
operator could elect to conduct a pressure test to 1.25xMAOP instead of using ILI.
If the answer in Diamond 17 is No, i.e., the segment is not piggable, the
operator goes to H and can conduct a pressure test to 1.25xMAOP, reduce pressure to
80% of the established MAOP, or replace the pipe not meeting these conditions.
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Class 3 or 4
Class 3 or 4 segments are identified in Diamond 13, which asks if the segment is
in Class 3 or 4? If the answer is No, then the operator moves to Diamond 14, which
asks if the segment is operated at greater than 30% SMYS? If the answer is Yes in
Diamond 13, the operator moves to Diamond 11, which asks if a strength test was
conducted to 1.25xMAOP? The operator will proceed from Diamond 11 as above for
HCAs.

Pipe Segments Operated At Less Than 30% SMYS

Diamond 14 poses the question of whether or not the segment is operated at a
level greater than 30% SMYS. The level of 30% SMYS was selected as it is generally
accepted to be the low stress boundary between leaks and ruptures for likely pipeline
defects7. The basis of this approach is that preventing ruptures represents a much
higher consequence priority than leaks on transmission pipelines. Leaks are important
and will be discussed below. In applying the 30% SMYS threshold, operators need to
recognize that the threshold presumes an understanding of the minimum level of
toughness and the knowledge of pipe diameter, wall thickness and other metallurgical
properties such as the grade of pipe. Operators are encouraged to refer to the reference
above to evaluate whether adjustments should be made to the 30% threshold level for
the pipe segment being evaluated.
If the answer in Diamond 14 is No, the segment can continue to operate under
49 CFR 192, subject to the Continual Evaluation requirements of 49 CFR 192.937. If
the answer in Diamond 14 is Yes, the operator proceeds to Diamond 15.
Diamond 15 poses the question of whether or not the segment contains pipe that
has a joint factor of less than 1.0 (such as lap-welded pipe, hammer-welded pipe, and
butt- welded pipe) or if the pipeline is composed of LF-ERW, DC-ERW, electric fusion or
flash-welded, and if the answer is Yes, a manufacturing threat is considered to exist.
If the answer in Diamond 15 is No, i.e., the segment does not contain the pipe
identified above as specified in B31.8S, Appendix A-4, and the segment can continue to
operate under 49 CFR 192, subject to the Continual Evaluation requirements of 49 CFR
192.937.
If the answer in Diamond 15 is Yes, the operator proceeds to Diamond 16,
which poses the question of whether there is a history of long-seam related failures for
that mill production run of pipe used in the segment. If there has not been a prior failure
history for this pipe on the segment, the operator can go to M and run ILI that identifies
and characterizes long seam and pipe body anomalies, reduce pressure to 80% of the
established MAOP, or replace the pipe not meeting these conditions.
May 31, 2012

15

Fitness for Service White Paper - Draft

If the answer in Diamond 16 is Yes, i.e., there has been a history of long-seam
failures on the segment, the operator proceeds to Diamond 17 (discussed above) and
follows the same path.
If the answer in Diamond 17 is Yes, the operator goes to M and can run ILI that
identifies and characterizes long seam and pipe body anomalies, reduce pressure to
80% of the established MAOP, or replace the pipe not meeting these conditions. If the
answer in Diamond 17 is No, then the operator goes to H and conducts a pressure
test, reduces the operating pressure, or replaces the pipe.

Timeframe For Implementation

INGAA members are committed to completing the FFS process for HCAs by
2020 and segments in Class 3 and 4 on a risk-prioritized basis using the experience
gained in HCAs as a next step. The FSS also process establishes a framework for
segments beyond HCA's, Class 3 and 4, and the timeline for implementation in those
areas would occur after the higher priority segments in a risk-prioritized manner,
incorporating lessons learned during the earlier implementation of the process.

Conclusions
The paper addresses background on FFS, how to start applying the FFS process
for pre-regulation pipe and extend it over time. The FFS process prioritizes the right
place to start as pipelines within HCAs that have incomplete strength test records. The
testing, repair, remediation or replacement of these pipelines within HCAs will be
accomplished over a defined time frame, and during that period findings will be
continually evaluated to derive lessons learned for future work. Implementing the FFS
process will require time to evaluate pipelines in a prioritized manner, manage customer
service impacts and implement necessary actions.

References
1.

Duffy, A.R., McClure, G.M., Maxey, W.A. and Atterbury, T.J.,, Feasibility of Basing
Natural Gas Pipeline Operating Pressure on Hydrostatic Test Pressure, Battelle
Memorial Institute, PRC/AGA NG-18 Report L30050, 1968.
2. Anonymous, Research and Special Projects Administration, U.S. Department of
Transportation, Alert Notice, ALN-88-01, January 28, 1988
3. Anonymous, Research and Special Projects Administration, U.S. Department of
Transportation, Alert Notice, ALN-89-01, March 1, 1989
4. Eiber, Robert and Brian Leis, Review of Pressure Retesting for Gas Transmission
Pipelines, Battelle Memorial Institute, GRI-01/0083, Feb 2001.
5. Leis, Brian, Hydrotest Protocol for Applications Involving Lower Toughness
Steels, IPC04-0665, ASME IPC Calgary, Sept 2004.
6. Kiefner, John & Edward Clark, History of Line Pipe Manufacturing, ASME CRTD Vol.43, 1996.
May 31, 2012
16

Fitness for Service White Paper - Draft

7.

Ersoy, D., and E. Lever, Leak Rupture Boundary Determination Project, GTI
Report 02819, Gas Technology Institute, prepared for the Operations Technology
Development Company, May 4, 2011.

May 31, 2012

17

Fitness for Service White Paper - Draft

Process'For'Managing'Pre.Regula2on'Pipe'
Fitness For Service Process for
Start&
Managing Pre-Regulation Pipe
Pipe&Installed&
Prior&to&March&
12,&1970*?&&
1

Yes

Was&
Segment&
Pressure&
Tested?&

No

Conrm&Pressure&Test&
Performed&in&
Accordance&With&
192.619?&

A&3&Operate&and&Maintain&

Under&49&CFR&192&Subparts&
A,&I,&K,&L,&M,&N&and&O&

*Effective date for initial regulations applicable to design and construction as published.
B'
Field&
Installa,on&
Pressure&
Test?&

Yes

Post3
Installa,on&
Pressure&

No

Yes

B'
Pressure&Test&>&
1.25xMAOP?&&

Yes

No

A'

A'
Yes

A'
Mill&Pressure&
Test&>&
Equivalent&of&
1.25xMAOP**
?&&
7

**Includes analysis of ILI to

identify gross seam or pipe
body anomalies

Discussion&DraZ&&Work&In&Progress&

Figure 2 Fitness for Service Process for Managing Pre-Regulation Pipe

May 31, 2012

No

No

Yes

Yes

Segments&
Contains&LF3
ERW,&EFW&or&
JF<1.0?&&&

18

No

Yes

No

Mill&
Pressure&
Test?&&

No

Test?&&

No

Pressure&Test&>&
1.1xMAOP?&&

Jan 12, 2012

B'

Yes

Fitness for Service White Paper - Draft

Fitness For Service Process for

Process%For%Managing%PreRRegula/on%Pipe%

Jan 12, 2012

Managing Pre-Regulation Pipe

B%

Risk Based Alternative Draws From Approach Used for

Hazardous Liquid Pipelines at 49 CFR 195.303

Yes
HCA?%%

Strength%
Test>1.25x
MAOP?%%

10

11

No

Strength%
Test>1.1x%
MAOP?%%
12

Yes

No
Yes
Class%3%or%4?%%
13

No

H%%High%Priority:%
Pressure%Test%or%Reduce%
No
Pressure%or%Replace%
Within%7%Years%for%HCAs%
(from%12)%

A%

Yes

L%
Class 3 and 4 will
be addressed after
HCAs utilizing what is
learned with HCAs.
The expectation is
that ILI will be
sufficiently
advanced to use.

Is%Segment%
Piggable?%%

No

17

Yes
Yes

MAOP%>%30%%
SMYS?%%
14

Yes

Segments%
Contains%LFC
ERW,%EFW%or%
JF<1.0?%%

Yes

History%of%
Seam%
Related%
Failures?%
16

No

15

No

Manage stable threats

and fatigue as in IMP

No

L%%Low%Priority:%
Operate%and%Maintain%
Under%49%CFR%192,%and%
Apply%192.937%

LF-ERW is low frequency electric resistance welded; EFW is electric fusion or flash welded; and JF is joint factor as defined at 49 CFR 192.113

Discussion%DraS%%Work%In%Progress%

Risk%Based%Alterna/ve%

Figure 2 Fitness for Service Process for Managing Pre-Regulation Pipe (Continued)

May 31, 2012

19