[Federal Register Volume 74, Number 188 (Wednesday, September 30, 2009)]
[Notices]
[Pages 50272-50273]
From the Federal Register Online via the Government Publishing Office [www.gpo.gov]
[FR Doc No: E9-23527]


-----------------------------------------------------------------------

DEPARTMENT OF TRANSPORTATION

Pipeline and Hazardous Materials Safety Administration

[Docket No. PHMSA-2009-0158]


Pipeline Safety: Weldable Compression Coupling Installation

AGENCY: Pipeline and Hazardous Materials Safety Administration (PHMSA); 
DOT.

ACTION: Notice; Issuance of Advisory Bulletin.

-----------------------------------------------------------------------

SUMMARY: The Pipeline and Hazardous Materials Safety Administration 
(PHMSA) reminds pipeline owners and operators of the importance of 
installing weldable compression couplings in accordance with 
manufacturer procedures and following appropriate safety and start-up 
procedures. The failure to install weldable compression couplings 
correctly, or the failure to implement and follow appropriate safety 
and start-up procedures, could result in a catastrophic pipeline 
failure. PHMSA strongly urges operators to review, and incorporate 
where appropriate into operators' written procedures, the 
manufacturer's installation procedures and take any other necessary 
safety measures for safe and reliable operation of pipeline systems.

FOR FURTHER INFORMATION CONTACT: Ivan Huntoon by phone at (816) 329-
3829 or by e-mail at [email protected].

SUPPLEMENTARY INFORMATION:

I. Background

    In 2007, a crude oil release occurred during maintenance activities 
on a major oil pipeline. The escaping crude oil ignited and resulting 
in two fatalities. When this incident occurred the operator was 
performing a pipe replacement using pre-tested pipe and weldable 
compression couplings. The failure occurred during start-up operations 
when the forces associated with pipeline operations exceeded the 
restraining capability of the unfinished replacement assembly. As 
pressure increased, movement of the piping occurred resulting in the 
eventual separation of the pipe from the weldable compression coupling. 
There was sufficient mechanical breakdown and the escaping crude oil 
created a flammable vapor-air mixture which ignited a few seconds after 
the release began. The pipeline was being re-started to allow for 
welding of the compression couplings to the pipe when the release 
occurred. The failure occurred while pressure and flow were increasing.
    The weldable compression couplings use radial bolts (clamp screws) 
to attach the compression coupling to the surface of the pipeline. Once 
attached, longitudinal bolts apply pressure to a steel ring and 
neoprene seal which expands, providing a compressive seal between the 
weldable compression coupling and exterior surface of the pipe. The 
compression couplings are designed to be fillet welded to the pipe 
surface after bolting and sealing, making them a permanent welded 
repair.
    In the above referenced incident, the weldable compression 
couplings had been modified prior to the installation by cutting off 
approximately half of the clamping bolts which reduced the restraining 
capability of the replacement assembly. The manufacturer's installation 
procedures did not authorize this modification. In addition, operators' 
procedures specific to the installation of compression couplings must 
provide sufficient guidance for their employees to determine whether a 
pipeline is fully anchored prior to welding. In the above referenced 
incident, the manufacturer's literature described a pipeline in the 
anchored condition as being ``restricted from movement in all 
directions'' and the operating pressure chosen by the operator to be 
sustained for welding was based on the manufacturer's recommendation 
for a fully anchored installation. However, the physical

[[Page 50273]]

characteristics of the installation indicated that it was not fully 
anchored and that it needed to be limited to a much lower maximum safe 
working pressure. Operator personnel must be specifically trained and 
qualified for the installation of weldable compression couplings 
including ensuring that the extent to which the pipeline is not fully 
anchored is taken into account when determining the maximum safe 
working pressure.
    To ensure safety, pipeline operators using weldable compression 
couplings must ensure personnel are trained and qualified to perform 
the installation. Also, operators must ensure their procedures 
accurately incorporate manufacturers' procedures and limitations on the 
use of weldable compression couplings and ensure that the procedures 
are available, understood and followed by personnel. PHMSA believes 
that the risk of compromising safety posed by unauthorized 
modifications to weldable compression couplings is unacceptable. PHMSA 
strongly recommends that any field changes in the installation process 
(i.e., modifications allowed by a component manufacturer) that could 
affect component performance and safety be subject to a documented 
authorization process, communicated to appropriate personnel, and be 
reflected by allowable working pressures. Allowable working pressures 
vary greatly between anchored and un-anchored installations. In order 
to use the pressure rating for an anchored installation, the operator 
must verify the pipeline is anchored in all directions in accordance 
with company and manufacturer procedures prior to pipeline start-up. To 
ensure safety for personnel, property and the environment, pipeline 
start-up procedures must be available and followed. Finally, any 
failure to identify and restrict access to hazard zones during 
pressurization of exposed pipeline sections could compromise safety.

II. Advisory Bulletin ADB-09-02

    To: Owners and Operators of Hazardous Liquid and Natural Gas 
Pipelines.
    Subject: Weldable Compression Couplings.
    Advisory: The Pipeline and Hazardous Materials Safety 
Administration (PHMSA) advises operators of hazardous liquid and 
natural gas pipelines installing or planning to install weldable 
compression couplings and similar repair devices to follow manufacturer 
procedures to ensure correct installation. In addition, PHMSA also 
advises these operators to follow the appropriate safety and start-up 
procedures to ensure the safety of personnel and property and protect 
the environment. The failure to install a weldable compression coupling 
correctly, or the failure to implement and follow appropriate safety 
and start-up procedures, could result in a catastrophic pipeline 
failure. PHMSA strongly urges operators to review, and incorporate 
where appropriate into operators' written procedures, the 
manufacturer's installation procedures and any other necessary safety 
measures for safe and reliable operation of pipeline systems.

    Issued in Washington, DC September 23, 2009.
Jeffrey D. Wiese,
Associate Administrator for Pipeline Safety.
[FR Doc. E9-23527 Filed 9-29-09; 8:45 am]
BILLING CODE 4910-60-P