Presenters
Janelle Burd, PE, LEED AP BD+C
Sr. Mechanical Engineer/Fuel System Specialist
• 27 years of experience in fuel system design
• Pipeline Integrity Management Plans (IMP- POL)
• Engineering Project Planning Studies
Hassan Sahudin, PE, LEED AP BD+C, ENV SP
Sr. Structural Engineer/Project Manager
• 25 years of experience
• Specialized focus on fueling facilities
• Pipeline Integrity Management Plans (IMP-POL)
• Engineering Project Planning Studies
1
PETRO Expo 2013
Pipeline Integrity Management Plan
(IMP-POL)
and
Project Planning Studies
(PPS)
Common Deficiencies
18 November 2013
Agenda
• Burns & McDonnell Overview
• IMP- POL’s & Planning Studies
• Assessment Objectives
• 3 Most Common Deficiencies
 Pipe Support
 Thermal Relief
 Containment
• Additional Deficiencies
• Conclusion
• Q &A
3
Burns & McDonnell
Overview:
•
•
•
•
•
•
•
•
Founded in 1898
100% Employee-Owned
Over 4,300 Employees
$2B in Revenues per year
More than 30 Offices
We deliver successful DOD projects worldwide
50+ years of experience in design, construction,
inspection and operational assistance of POL facilities
Partners include AFCEC, USACE, NAVFAC, National
Guard, Reserves, DLA HQ, DLA-Energy
Our Mission: “Make Our Clients Successful”
4
U.S. POL/Fueling Project Sites
5
International Fueling Project Sites
6
IMP-POL and PPS Sites
IMP-POL:
• 6 Regions total


57 sites completed
17 sites future
• Follow-On IMP:


1 site in US
2 sites in Japan
Project Planning Study (PPS):
• 14 sites in US
• 1 each in Italy, Greece, Gitmo
7
IMP-POL and Project Planning Studies
What is an IMP-POL and Project Planning Study?
• Funded by Defense Logistic Agency – Energy (DLA-Energy)
• Two Parts of DLA-Energy’s Centrally Managed Program (CMP)
• Condition assessment programs
Piers and Marine
Loading Arms
Project Planning
Study (PPS)
Cathodic
Protection
System Integrity
Management
8
Automated Fuel
Service Station
Automatic Tank
Gauging
Tank Integrity
Management
(API 653 & STI)
Terminal
Automation
Pipeline Integrity
Management
Plan (IMP-POL)
Pipeline Pressure
Testing (API 570)
Rail Maintenance
Pressure Vessel
Inspection
(API 510)
Hydrant System
Tuning
(upcoming)
Ultimate Goal
Ultimate Goal for DLA-Energy and Installations:
• Provide site specific record for each facility
 Condition assessment
 Testing and inspection
 Intervals
 Responsible execution agency
• Plan and fund projects, improvements and repairs
• Risk management
9
Typical Codes and Standards
• Local, State, and Federal Environment Governing Standards
• API and ASME
• NFPA 30, Flammable and Combustible Liquids Code
• UFC 3-460-01, Petroleum Fuel Facilities
• UFC 3-460-03, Maintenance of Petroleum Systems
• UFGS-01 35 29, Safety and Occupational Health Requirements
• 33 CFR 156, Oil and Hazardous Material Transfer Operations
• 40 CFR 112, Oil Pollution Prevention
• 49 CFR 195, Transportation of Hazardous Liquids by Pipeline
• DESC-P-12 - DLA-E / DESC Sustainment, Restoration and Modernization
(SRM) Funding Policy for Fixed Petroleum Facilities
10
Assessment Objectives
Provide DLA-E and Base Fuels Personnel with:
• Assessment of facilities conditions and pipeline integrity
• Overview and understanding of existing POL infrastructure
• Record of the general integrity and condition of the piping systems
• A “road map” of integrity management and maintenance
• Identification of highest-risk elements
• Recommendations for further actions
11
IMP-POL – Common Deficiencies
Common
Deficiencies
found during
site
assessments:
12
• Pipe Support Issues
• Thermal Relief Issues
• Valve and Flange Seals – Weeps and Leaks
• Soft Materials – Brass and Bronze Valves
and Piping
• Galvanic Reactions – Dissimilar Metals
• Soil-Air / Concrete-Air Interfaces
• Coating Failure
• Cathodic Protection Issues
Planning Studies – Issues
Common
Deficiencies
found during
site
assessments:
13
• Pipe Support Issues
• Thermal Relief Issues
• Secondary Containment Issues
• Insufficient Fuel Lab Ventilation
• Corrosion/Coating Failure
• Lighting Issues
• Use of Sight Flow Indicators
• Lack of EFSO Stations
• Grounding Issues
3 Most Common Deficiencies
 Pipe Support
 Thermal Relief
 Secondary Containment
14
Deficiency 1 - Pipe Support
Issues:
• Lack of Isolation Pads
• Concrete Saddles
• Support failure
• Temporary Supports
• Inadequate Support
• No Lateral Restraint
• Spring Can Supports Disengaged
15
Pipe Support
Lacks Isolation Pad
 Metal-metal contact
16
Pipe Support
Concrete Saddle
 Concrete-steel contact, moisture collection
17
Pipe Support
“Clamshell” anchors
 Moisture collection
18
Pipe Support
Metal Roller Supports
Metal-metal contact
19
Pipe Support
“Spider” Supports
Corrosion, displaced support
20
Pipe Support
Improper pipe supports
 Lacks Lateral Restraint
21
Risks: Pipe Support
Risks from Undetected/Unaddressed Issues:
• Excessive pipe movements
• Pipe or joint failure
• Equipment and Tank Damage
• Unintended release
• Environmental impact
• System shut down
• Impact to mission
22
Risk Mitigation: Pipe Support
Risk Mitigation Recommendations:
•
Metal to Metal contact – Teflon barriers, pads, pipe collars
•
Concrete saddles – Replace with approved pipe support
•
Support failure – Perform pipe stress analysis and replace
•
Wood support – Replace with approved material
•
Inadequate Support – Replace with appropriate style
Owner Impact – Preventative maintenance is less costly than equipment
repair/ replacement and potential environmental clean up
23
Deficiency 2 - Thermal Relief
Issues:
• Insufficient Thermal Relief
• Cascading Issues
• Improper Setting
• Thermal Reliefs Not Tested
• Closed Isolation Valves
 The internal pipe pressure increase resulting from fluid thermal expansion
can equal as much as 75 psi for every degree rise in the fuel temperature
if not relieved!
24
Thermal Relief Risks
Risks from Undetected and Unaddressed Issues:
•
•
•
•
25
Over pressurization of equipment and valves – Costly repairs and
replacement
Leaking Flanges and Joints – Increased maintenance costs
Danger to operators due to high system pressures
Potential for catastrophic failure of pipe or components
Thermal Relief Risk Mitigation
Risk Mitigation Recommendations:
•
•
Conduct a thermal relief study
Change operating procedures
– leave relief valve open
Owner Impact – Preventative maintenance is less costly than equipment
repair/ replacement and potential environmental clean up!
26
Deficiency 3 – Secondary Containment
Regulations: 40 CFR Part 112, NFPA 30, and UFCs
Issues:
•
Absence of Secondary Containment
•
Cracks in Containment Concrete
•
Joints Sealant Failure
•
Liner System Problems
•
Lack of Containment Curbs
27
Secondary Containment
Absence of Containment Over Water
 Risk contamination of waterways
28
Secondary Containment
Absence of Containment at Grade
 Risk ground contamination
29
Secondary Containment
Absence of Containment Below Grade
 Risk groundwater contamination
30
Secondary Containment
Cracks in Containment Concrete
 Breach in Containment
31
Secondary Containment
Joint Sealant Failure
 Breach in Containment
32
Secondary Containment
Liner System Problems
 Ineffective Containment
33
Secondary Containment
Lack of Curbing
 Ineffective Containment
34
Secondary Containment
Say What?
 Leak Detection Plant
35
Containment Risks
Risks to unaddressed problems:
• Inability to detect small leaks
• Inability to contain fuel spills
• Environmental impact
• Non-compliance
36
Containment Risk Mitigation
Risk Mitigation Recommendations:
•
Repair cracks in concrete
•
Seal joints with jet-fuel resistant sealant
•
Provide adequately sized secondary containment or remote spill
containment system
•
Install perimeter curbs on equipment pads/pipe causeway
Owner Impact – Preventative maintenance is less costly than equipment
repair/ replacement and potential environmental clean up!
37
Additional Deficiencies
Additional Deficiencies:
•
Brass/Bronze Bodied Valves
•
Sight Flow Indicators
•
Soil-Air / Concrete–Air Interfaces
•
Product Labeling
•
Lubricated Swivel Joints
•
Fuel Lab Inadequate Ventilation
•
Coating Failure
•
Dissimilar Metals
•
Inadequate Ground Clearance
38
Brass/Bronze Bodied Valves
Issue:

Soft bodied valves and piping such as brass, bronze
and copper present in fueling system.
Risk:

NFPA 30 and 30A - Metals with lower melting point
are not to be used in fueling systems.
Recommended Mitigation:

Remove and replace with UFC compliant valves and
piping.
 UFC 3-460-01 - valves are to be CS or SS bodied.
39
Sight Flow Indicators
Issue:

Sight flow indicator in certain configurations are
subject to tank head pressure or system pressure.
Risks:

Sight glass failure may cause significant leak
 UFC 3-460-01 - Sight flow indicators are not to be
provided on thermal relief piping, filtration
devices, or product recovery tanks.
Recommendation:

40
Remove sight flow indicators in these
configurations and repair the piping.
Soil - Air Interface
Issue:

Piping is not properly coated.
Risks:

Deterioration of Extruded Polyethylene (UG pipe
coating) coatings due to UV exposure
Recommendation:

Expose the soil/air interface, prep and coat 12
inches below grade level and 6 inches above.
 Heavy body, surface tolerant epoxy coating
 Compatible with polyethylene and the existing
aboveground pipe coating.
41
Lubricated Swivel Joints
Issues:
 Lack of proper maintenance/lubrication may
cause seized joints
 Typically found at Truck Loading / Truck
Offloading. (All Products)
Risks:
 Compromised fuel quality (Aviation Fuel)
 UFC 3-460-01: Aluminum or SS non-lubricated
swivel joints
Recommendation:
 Replace with non-lubricated type swivel joints
42
Fuel Lab Inadequate Ventilation
Issues:
 Inadequate ventilation rate
 Improper equipment
Risks:
 Air quality concern
 Explosion hazard
Recommendation:
 Replace with proper fume hood
43
Coating Failure
Issue:
 Coating failure causing pipe corrosion
Risks:
 Leaks in pipes
 Failure at supports.
Recommendation:
 Clean and recoat
 Piping - UFGS Spec Section 09 97 13.27.
44
Dissimilar Metals
Issues:
 Galvanic corrosion
Risks:
 Failure of bolts
 Maintenance issue
Recommendation:
 Provide isolation flange kit
45
Inadequate Ground Clearance
Issues:
 Piping located too close to grade
Risks:
 Corrosion
 Maintenance issue
Recommendation:
 Raise piping
 18” clearance min
46
Conclusion
How thorough assessments help Bases/Installations:
•
Identify items with higher risks of failure
•
Recommend Mitigation Plans
•
Reminder of items requiring maintenance and repairs
•
Awareness of funding mechanism
A well-qualified consultant is a critical partner in your success !
47
Questions / Answers
48