[Federal Register Volume 69, Number 188 (Wednesday, September 29, 2004)]
[Notices]
[Pages 58225-58226]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: 04-21829]


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DEPARTMENT OF TRANSPORTATION

Research and Special Programs Administration


Pipeline Safety: Hazards Associated With De-Watering of Pipelines

AGENCY: Research and Special Programs Administration (RSPA), DOT.

ACTION: Notice; issuance of advisory bulletin.

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SUMMARY: On June 21, 2004, the Research and Special Programs 
Administration's Office of Pipeline Safety (RSPA/OPS) issued Advisory 
Bulletin ADB-04-01 to owners and operators of gas and hazardous liquid 
pipelines to consider the hazards associated with pipeline de-watering 
operations. This advisory bulletin was originally issued jointly with 
the Department of Labor's Occupational Safety and Health Administration 
(OSHA) as Safety and Health Information Bulletin SHIB 06-21-2004. 
Operators are strongly encouraged to follow the recommended work 
practices and guidelines to reduce the potential for unexpected 
separation of temporary de-watering pipes.

FOR FURTHER INFORMATION CONTACT: Richard Huriaux, (202) 366-4565; or by 
e-mail, [email protected]. This document can be viewed at 
the OPS home page at http://ops.dot.gov. The original advisory bulletin 
issued by OSHA can be viewed at http://www.osha.gov. General 
information about the RSPA/OPS programs may be obtained by accessing 
RSPA's home page at http://rspa.dot.gov.

SUPPLEMENTARY INFORMATION:

Background

    The OSHA Allentown and Wilkes-Barre Area Offices recently 
investigated two fatalities that occurred in conjunction with de-
watering processes associated with newly constructed gas pipelines. In 
both cases, the temporary de-watering piping violently separated from 
its couplings, striking and fatally injuring employees. In one 
instance, the separated section of pipe was thrown 45 feet from where 
it had been attached to the temporary de-watering valve. OSHA 
determined that a major contributing factor to both of the accidents 
was temporary de-watering pipelines that were not adequately secured to 
prevent the piping from moving or separating. In one case, the failure 
occurred at a pipe coupler that was not being used within the safe 
tolerances established by the manufacturer.
    After a pipeline is laid, a hydrostatic test is conducted to ensure 
its integrity. Hydrostatic testing may also be conducted during the 
service life of the pipeline to evaluate its operational integrity. The 
hydrostatic test consists of pumping water into the pipeline, 
pressuring up the line to specified test pressures, and holding that 
pressure for a discrete period of time in accordance with applicable 
regulations and guidelines, including regulations

[[Page 58226]]

promulgated by RSPA/OPS. After completion of the hydrostatic test, the 
pressure is relieved and the water is removed from the pipeline during 
de-watering procedures.
    The de-watering process involves connecting a temporary de-watering 
line to the main pipeline with mechanical couplers and adequately 
securing the temporary de-watering line to prevent displacement. A de-
watering pig is then forced through the main pipeline using several 
hundred pounds pressure of compressed air. As the pig is forced through 
the pipeline with air pressure, the water remaining in the line from 
hydrostatic testing is pushed out of the main pipeline through the 
temporary de-watering line.
    During the de-watering process, significant and sudden variations 
in pressure often occur within the main pipeline and temporary de-
watering line. These variations can be caused by changes in pig 
velocity as it passes through bends in the pipeline or changes in pig 
and water velocity due to changes in pipeline elevation. Compressed air 
escaping around the pig, which can combine with air already present in 
the main pipeline at high spots in the pipe, can also create a source 
for stored energy within the main pipeline. These sudden pressure 
changes produce surges that are transferred from the main pipeline to 
the temporary de-watering line. This can result in movement of the 
temporary de-watering line, as the pressures can easily exceed the 
working pressures and bending capabilities of the temporary de-watering 
line couplers. The movement of the de-watering line can result in 
violent failure of the temporary piping system, particularly when the 
temporary piping is not properly anchored. This situation can be 
exacerbated when the temporary pipeline suddenly changes direction, 
when couplers or pipe sections have worn beyond the specified 
tolerances established by the manufacturer of the de-watering piping 
system, or when the entire de-watering manifold is inadequately 
designed for the stresses that can be imposed while de-watering.
    RSPA/OPS recognizes the existence of hazards associated with 
testing pipelines and requires operators to protect their employees and 
the public during hydrostatic testing. Section 192.515(a) states that 
`` * * * each operator shall insure that every reasonable precaution is 
taken to protect its employees and the general public during the 
testing.'' In addition, Sec.  195.402(c) requires each pipeline 
operator to prepare and follow procedures for safety during maintenance 
and normal operation.

Advisory Bulletin (ADB-04-01)

    To: Owners and operators of gas and hazardous liquid pipeline 
systems.
    Subject: Hazards associated with de-watering of pipelines.
    Purpose: To advise owners and operators of gas and hazardous liquid 
pipelines to consider hazards associated with pipeline de-watering 
operations and to follow recommended work practices and guidelines to 
reduce the potential for unexpected separation of temporary de-watering 
pipes.
    Advisory: Each operator of a gas or hazardous liquid pipeline 
should take recommended precautions against the unexpected separation 
of temporary de-watering pipes during de-watering procedures. This 
advisory bulletin was originally issued jointly with the Department of 
Labor's Occupational Safety and Health Administration (OSHA) as Safety 
and Health Information Bulletin SHIB 06-21-2004. The original advisory 
bulletin issued by OSHA can be viewed at http://www.osha.gov, or the 
RSPA/OPS Web site at http://www.ops.gov.
    The following guidelines will help reduce the risk of injury to 
employees involved in de-watering activities:
     Study the piping system. During the initial planning stage 
of a de-watering operation, an engineering analysis of the existing and 
temporary piping system should be performed to identify the pressure 
associated with fluids and other forces that could adversely affect the 
integrity of the pipeline or the stability of the drainage and its 
components. The operator should design the de-watering system and 
develop installation techniques based on the expected forces of the 
particular project. Alternatively, designs and techniques could be 
developed for a ``worst case'' scenario that could be applied to all 
de-watering projects.
     Anchor the de-watering lines. It is accepted industry 
practice to adequately anchor or secure de-watering piping to prevent 
movement and separation of the piping. Operators should establish 
effective anchoring systems based on expected forces and ensure that 
the systems are used during de-watering projects.
     Ensure condition of couplings and parts. All couplings and 
parts of the de-watering system need to be properly selected for their 
application. The associated piping which the couplings connect is a 
significant variable in the entire mechanical piping system. The 
couplings are manufactured in a controlled environment, and variations 
in the quality of the couplings should be limited. Operators should 
ensure that couplings are within manufacturer's tolerances and free of 
damage that may result in connection failure. A chain is only as strong 
as its weakest link--in de-watering piping systems, the weakest link 
frequently is the temporary de-watering pipe connections.
     Provide adequate employee training. This training should 
instruct employees on de-watering installation designs and techniques, 
including proper coupling and anchoring methods. Operators should 
ensure that employees understand the potential hazards of improperly 
installed de-watering systems, provide employees a means of determining 
whether the pipe groove meets manufacturer's tolerances, and the 
procedures they should implement to protect themselves and others 
working around them.
     Proper procedures. Operators should ensure that proper 
installation and de-watering procedures are followed on the job site.
    Operators may refer to recommended practices provided by national 
consensus standards organizations, such as American Petroleum Institute 
(API) Recommended Practice for Occupational Safety for Oil and Gas Well 
Drilling and Servicing Operations (API RP 54-1999, Section 12.4.3); 
American National Standards Institute (ANSI) Power Piping (ANSI B31.1-
1973, Section 121.2); and U.S. Army Corps of Engineers (USACE) Safety 
and Health Requirements Manual (EM 285-1-1, 1996 Section 20).

    Issued in Washington, DC, on September 23, 2004.
Stacey L. Gerard,
Associate Administrator for Pipeline Safety.
[FR Doc. 04-21829 Filed 9-28-04; 8:45 am]
BILLING CODE 4910-60-P