Safely Transporting Hazardous Liquids and Gases in a Changing U.S. Energy Landscape (2018) / Chapter Skim
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4 Safety Performance of Long-Distance Crude Oil, Natural Gas, and Ethanol Transportation
4 Safety Performance of Long-Distance Crude Oil, Natural Gas, and Ethanol Transportation
Pages 68-110
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From page 68... ...
Forty-seven people were killed, and 30 buildings were destroyed by explosions and fires fed by more than 1.5 million gallons (~36,000 barrels) of Bakken crude oil carried in the unit train's 63 derailed tank cars.1 Pipeline and barge incidents have also had severe consequences.
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From page 69... ...
The long-haul bulk modes of freight transportation -- rail, pipeline, and water -- move large amounts of hazardous materials on a daily basis, mostly without incident. All have done so for decades, long before the post-2005 growth in domestic crude oil, ethanol, and natural gas production.
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From page 70... ...
However, in the case of rail and water transportation, PHMSA shares hazardous materials safety oversight responsibility with the Federal Railroad Administration (FRA)
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From page 71... ...
As discussed in the previous chapter, the crude oil pipeline network grew by 54 percent from 2005 to 2015. Accordingly, when controlling for the increase in total system miles, the incident rate normalized by pipeline miles (i.e., releases per pipeline mile)
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From page 72... ...
FIGURE 4-2 Significant crude oil pipeline releases reported to PHMSA in the United States, 2005–2015. SOURCE: PHMSA, "Pipeline Incident Flagged Files," accessed November 23, 2016, http://www.phmsa.dot.gov/pipeline/library/data-stats/flagged-data-files.
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From page 73... ...
4-3 0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 0 5 10 15 20 25 30 35 40 45 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Barrels released per trillion barrel-miles Significant incidents Barrels released Significant incidents per trillion barrel-miles FIGURE 4-4 Crude oil pipeline incidents by reported cause in the United States, 2010–2015. NOTE: For causes that rely on specialized terminology, the following definitions apply: "equipment" indicates a failure of control systems or relief equipment; "incorrect operation" means operator error; "natural force" refers to damage stemming from naturally occurring phenomena, for instance, earthquakes and floods; and "outside force" indicates damage from human actions other than excavation, such as accidental vehicle collision and earth-moving activity.
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From page 74... ...
gpo.gov/fdsys/pkg/FR-2010-03-24/html/2010-6528.htm. 8 Pipeline and Hazardous Materials Safety Administration, "Pipeline Safety: Potential Low and Variable Yield and Tensile Strength and Chemical Composition Properties in High Strength Line Pipe (ABD-09-01)
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From page 75... ...
Mileage data were not available for 2016. SOURCES: PHMSA, "Pipeline Incident Flagged Files." PHMSA, "Pipeline Miles and Facilities 2010+." - 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 90,000 0 10 20 30 40 50 60 70 80 90 2010 2011 2012 2013 2014 2015 2016*
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From page 76... ...
10 Pipeline and Hazardous Materials Safety Administration, "The State of the National Pipeline Infrastructure," 7, accessed September 19, 2017, https://opsweb.phmsa.dot.gov/ pipelineforum docs/Secretarys%20Infrastructure%20Report_Revised%20per%20PHC_103111.pdf. According to PHMSA data from 2010, more than half of the mileage on the hazardous liquids pipeline network was built before 1970; https://opsweb.phmsa.dot.gov/pipelineforum/docs/ Secretarys%20Infrastructure%20Report_Revised%20per%20PHC_103111.pdf.
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From page 77... ...
From 2010 to 2015, there was a 11 Pipeline and Hazardous Materials Safety Administration, "Guidance for Pipeline Flow Reversals, Product Changes, and Conversion to Service," September 2014, http://www. occeweb.com/PLS/2014Gas/Guide-Flo%20Rev-Prod%20Ch-Conver.pdf.
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From page 78... ...
SOURCE: PHMSA, "Pipeline Incident Flagged Files." 4-7 0 20,000 40,000 60,000 80,000 100,000 120,000 0 10 20 30 40 50 60 70 80 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Barrels released per trillion barrel-miles Significant incidents Total volume released Incidents per trillion barrel-miles 4-6 0 10,000 20,000 30,000 40,000 50,000 60,000 70,000 80,000 0 5 10 15 20 25 30 35 40 45 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Incidents Significant incidents Total volume released Volume released, bbl
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From page 79... ...
Reported 12 Pipeline and Hazardous Materials Safety Administration, "Pipeline Incident Flagged Files." Data are from PHMSA's HVL incident files but exclude ammonia, refined products, and carbon dioxide pipelines. 4-8 0 200 400 600 800 1,000 1,200 1,400 1,600 1,800 2,000 0 10 20 30 40 50 60 70 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Significant incidents Significant incidents Total volume released Volume released, billions of cubic feet FIGURE 4-8 Significant natural gas pipeline releases reported to PHMSA in the United States, 2005–2015.
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From page 80... ...
In the case of the 2010 San Bruno natural gas transmission pipeline explosion, in which 8 people died and 108 homes were destroyed or damaged, NTSB concluded that the pipeline operator had not properly followed its integrity management program, as required by regulation.13 The agency raised similar concerns after investigating the 2012 natural gas pipeline incident in Sissonville, West Virginia. The 2010 Marshall, Michigan, crude oil release was found to have been caused by corrosion fatigue cracking and made worse by the pipeline operator continuing to pump product through the ruptured line after misinterpreting pressure loss data.14 13 National Transportation Safety Board, "Pacific Gas and Electric Company Natural Gas Transmission Pipeline Rupture and Fire," August 30, 2011, http://ntsb.gov/investigations/ AccidentReports/Pages/PAR1101.aspx.
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From page 82... ...
The agency held a forum in 2011 on improving pipeline risk assessments and a workshop on risk-modeling methodologies in 2015.18 It published three reports in 2016 and 2017 on pipeline risk model guidelines based on the probabilistic quantitative risk analysis approach, a risk management literature review and industry survey of risk management decision making, and a review of approaches to implementing risk-modeling and integrity-management programs.19 RAIL SAFETY TRENDS Federal regulations governing hazardous materials transportation require that certain types of hazardous materials incidents be reported by the carrier to PHMSA.20 A report must be filed if there is an unintentional release during any transportation phase, including loading and unloading, and/or a 15 Pipeline and Hazardous Materials Safety Administration, "Pipeline Safety: Pipeline Integrity Management in High-Consequence Areas (Hazardous Liquid Operators with Less Than 500 Miles of Pipelines)
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From page 83... ...
The 21 crude oil incidents accounted for more than 98 percent of the total 1.7 million gallons (40,400 barrels) of crude oil released unintentionally from tank cars during the period.
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From page 84... ...
phmsa.dot.gov/hazmat/library/data-stats/incidents. FIGURE 4-11 Reports of unintentional hazardous materials releases or damaged tank cars involving crude oil shipments by rail in the United States, 2005–2015.
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From page 85... ...
SOURCE: PHMSA, "Incident Statistics." 0 1 2 3 4 5 6 7 8 9 10 11 12 0 2 4 6 8 10 12 14 16 18 20 22 24 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Barrels Released Incidents Barrels (thousands) Incidents 0 2 4 6 8 10 12 0 2 4 6 8 10 12 14 16 18 20 22 24 26 28 2005 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Barrels (thousands)
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From page 86... ...
2015 4 17 102,934 2,451 2014 2 2 4,025 96 2013 2 4 4,581 109 2012 8 25 340,589 8,109 2011 8 40 1,084,338 25,818 2010 5 13 81,806 1,948 2009 11 28 332,560 7,918 2008 1 1 12,447 296 2007 6 9 108,506 2,583 2006 7 27 525,223 12,505 2005 4 5 22,580 538 Total 58 171 2,619,588 62,371 SOURCE: PHMSA, "Incident Statistics." TABLE 4-4 Tank Car Derailments and Collisions Involving the Unintentional Release of Crude Oil in the United States, 2005–2015 Year Incidents Cars Incurring Damage or Release Release (gallons) Release (barrels)
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From page 87... ...
21 National Transportation Safety Board, "Derailment of CN Freight Train U70691-18 with Subsequent Hazardous Materials Release and Fire, Cherry Valley, Illinois June 19, 2009," Accident Report NTSB/RAR-12/01 (Washington, D.C., February 14, 2012) , https://www.ntsb.
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From page 88... ...
8/08 8 5 34 Crude Oil 80,746 1,923 0 0 Yes Yes No Parkers Prairie, MN‡ 03/13 14 3 40 Crude Oil 30,000 714 0 0 No No Yes Aliceville, AL† 11/13 26 25 39 Crude Oil 455,520 10,846 0 0 Yes No Yes Casselton, ND¤ 12/13 20 18 42 Crude Oil 474,936 11,308 0 0 Yes Yes No New Augusta, MS† 01/14 15 7 47 Crude Oil 90,000 2,143 0 0 No Yes No Vandergrift, PA* 2/14 19 4 31 Crude Oil 10,000 238 0 0 No Yes Yes Lynchburg, VA† 4/14 17 1 24 Crude Oil 29,416 700 0 0 Yes Yes Yes Mount Carbon, WV‡ 2/15 27 20 33 Crude Oil 378,034 9,001 0 1 Yes Yes Yes Galena, ILw 3/15 21 10 23 Crude Oil 110,543 2,632 0 0 Yes Yes No Heimdall, NDu 5/15 6 5 24 Crude Oil 98,090 2,335 0 0 Yes Yes No Culbertson, ND† 7/15 22 5 44 Crude Oil 27,201 648 0 0 No Yes No NOTE: ‡ = internal rail defect; † = other rail defect; *
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From page 89... ...
8/08 8 5 34 Crude Oil 80,746 1,923 0 0 Yes Yes No Parkers Prairie, MN‡ 03/13 14 3 40 Crude Oil 30,000 714 0 0 No No Yes Aliceville, AL† 11/13 26 25 39 Crude Oil 455,520 10,846 0 0 Yes No Yes Casselton, ND¤ 12/13 20 18 42 Crude Oil 474,936 11,308 0 0 Yes Yes No New Augusta, MS† 01/14 15 7 47 Crude Oil 90,000 2,143 0 0 No Yes No Vandergrift, PA* 2/14 19 4 31 Crude Oil 10,000 238 0 0 No Yes Yes Lynchburg, VA† 4/14 17 1 24 Crude Oil 29,416 700 0 0 Yes Yes Yes Mount Carbon, WV‡ 2/15 27 20 33 Crude Oil 378,034 9,001 0 1 Yes Yes Yes Galena, ILw 3/15 21 10 23 Crude Oil 110,543 2,632 0 0 Yes Yes No Heimdall, NDu 5/15 6 5 24 Crude Oil 98,090 2,335 0 0 Yes Yes No Culbertson, ND† 7/15 22 5 44 Crude Oil 27,201 648 0 0 No Yes No NOTE: ‡ = internal rail defect; † = other rail defect; *
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From page 90... ...
Of the 10 ethanol cars that derailed in Tiskilwa, Illinois, in 2011, 9 were severely damaged, with most sustaining head and shell punctures and 3 experiencing breached tanks as a result of exposure to the high temperatures of a pool fire. Following this incident, NTSB concluded that "DOT-111 tank cars are inadequately designed to prevent punctures and breaches and that catastrophic release of hazardous materials can be expected."23 In March 2012, NTSB recommended that PHMSA require all newly manufactured and existing tank cars used for ethanol and crude oil have enhanced tank head and shell puncture–resistance systems and top fittings protection.24 When NTSB issued this recommendation in 2012, the use of unit trains to move crude oil had been growing dramatically.
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From page 91... ...
SOURCE: PHMSA, "Incident Statistics." In the February 2015 derailment in Mount Carbon, West Virginia, all of the DOT-111 cars were compliant with an upgraded CPC-1232 industry standard, which was adopted in October 2011 for new tank cars transporting crude oil and ethanol. The CPC-1232 cars, as discussed in Chapter 3, were equipped with half-height head shields, thicker tank and head steel, fitting protection, and pressure relief devices.
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From page 92... ...
Indeed, all imports of crude oil to the United States, 26 National Transportation Safety Board, "Safety Recommendation R-15-14 Through -17," April 3, 2015, http://www.ntsb.gov/safety/safety-recs/recletters/R-15-014-017.pdf. 27 Pipeline and Hazardous Materials Safety Association, "Hazardous Materials: Enhanced Tank Car Standards and Operational Controls for High-Hazard Flammable Trains," 89 FR 26644, 2015, https://www.gpo.gov/fdsys/pkg/FR-2015-05-08/pdf/2015-10670.pdf.
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From page 93... ...
Figure 4-14 shows the total volume of releases reported by tank barges of any kind of petroleum, including crude oil and refined products, from 1995 to 2015. In most years, the total volume has not exceeded 5,000 barrels.
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From page 94... ...
0 5,000 10,000 15,000 20,000 25,000 30,000 35,000 40,000 45,000 50,000 Barrels released Total volume released
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From page 95... ...
Coast Guard-American Waterways Operators Annual Safety Report: Towing Industry Safety Statistics 1994–2014," August 3, 2016, 5, http://www.americanwaterways.com/sites/ default/files/USCG%20AWO%20Annual%20Safety%20Report%20August%20 2016.pdf. 4-16 0 20 40 60 80 100 120 140 160 180 200 0 2 4 6 8 10 12 14 16 18 20 2006 2007 2008 2009 2010 2011 2012 2013 2014 2015 Incidents Incidents Barrels released Barrels 0 5,000 10,000 15,000 20,000 25,000 30,000 Barrels released per billion barrels Total volume released
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From page 96... ...
Comparisons of the safety performance of modes when they are used differently and are not viable substitutes can have limited value for decision making. OTHER SAFETY-RELATED EFFECTS The safety data reviewed above are derived largely from carrier reports of hazardous materials incidents to PHMSA.
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From page 97... ...
97 T A B L E 4 -8 A C ru de O il In ci de nt s an d R el ea se s pe r T ra ffi c V ol um e fo r Pi pe lin es , 20 05 –2 01 5 Y ea r Sh ip m en ts ( ba rr el s)
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From page 98... ...
98 T A B L E 4 -8 B C ru de O il In ci de nt s an d R el ea se s pe r T ra ffi c V ol um e fo r R ai lr oa d In ci de nt s, 2 00 5– 20 15 Y ea r Sh ip m en ts ( ba rr el s)
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From page 99... ...
99 T A B L E 4 -8 C C ru de O il In ci de nt s an d R el ea se s pe r T ra ffi c V ol um e fo r W at er w ay s, 2 00 6– 20 15 Y ea r Sh ip m en ts ( ba rr el s)
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From page 100... ...
Nevertheless, the magnitudes of the estimates suggest that even with these uncertainties, the safety impacts are likely to be large and deserving of consideration by policy makers when interpreting and comparing the modal safety data in Tables 4-8A, 4-8B, and 4-8C. MAJOR RAIL SAFETY INITIATIVES IN RESPONSE TO INCIDENTS The rail, pipeline, and water modes have long been the subject of federal regulations to ensure that hazardous materials shipments are transported safely.
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From page 101... ...
, https://www.fra.dot.gov/eLib/Details/L03467. 32 Hazardous Materials: Enhanced Tank Car Standards and Operational Controls for HighHazard Flammable Trains, p.
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From page 102... ...
A summary of the DOT-117/DOT-117R standards as they compare to the DOT-111 and the CPC-1232 is provided in Table 4-9. In creating these new tank car specifications, the HHFT rule contains a design- and commodity-specific phase-out schedule for DOT-111 and 33 Pipeline and Hazardous Materials Safety Administration, "Hazardous Materials: Enhanced Tank Car Standards and Operational Controls for High-Hazard Flammable Trains Notice of Proposed Rulemaking," 79 FR 45016 (2014)
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From page 103... ...
It merits noting that Transport Canada announced an expedited phase-out of all DOT-111 (TC-111 in Canada) tank cars used in crude oil service by moving up the deadline to November 1, 2016.35 To supplement the intended safety benefits of the DOT-117 tank car specifications, the HHFT rule also includes a provision to reduce the severity of derailments through a requirement that HHFTs be equipped with one of the following advanced braking systems: distributed power or a two-way end-of-train device.
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From page 104... ...
Department of Energy to sponsor research by Sandia National Laboratories to identify gaps in crude oil characterization and sampling methods for further research.39 An initial finding of the Sandia research is that many factors are relevant to the flammability of crude oil in a tank car derailment, and thus concern about the characteristics of tight oil, particularly from the Bakken formation, may be too narrowly focused.40 Track Safety Standards FRA issued new track inspection and maintenance regulations in 2014 that apply to hazardous materials and passenger routes. A prominent feature 38 Transportation Research Board, "A Review of the Department of Transportation Plan for Analyzing and Testing Electronically Controlled Pneumatic Brakes; Letter Report (Phase 2)
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From page 105... ...
As one of the causal factors involved in the derailment of the runaway train, in August 2015, FRA issued a rule, Securement of Unattended Equipment, to regulate the securement of unattended equipment to mitigate this risk unique among other recent crude oil derailments.44 This rule requires hand brakes or other mechanical securement devices to be sufficient to hold the equipment, as well as that the controlling locomotive hauling any hazardous materials be locked when stopped and unattended outside of a yard.
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From page 106... ...
(w) • Pipeline and Hazardous Materials Safety Administration (PHMSA)
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From page 107... ...
46 In July 2016, PHMSA proposed a rule that would expand the Bakken crude oil notification requirement to cover all HHFTs. 47 National Association of SARA Title III Program Officials, "Hazardous Materials: Oil Spill Response Plans for High-Hazard Flammable Trains," September 20, 2014, 1, https:// www.
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From page 108... ...
. Although this provision would not incorporate the American Petroleum Institute's recommended practice for testing of petroleum oil for railroad tank cars, the addition of the ASTM initial boiling point test would bring regulation and industry practice closer.
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From page 109... ...
. 51 Pipeline and Hazardous Materials Safety Administration, "2016 Emergency Response Guidebook" (U.S.
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From page 110... ...
15. FIGURE 4-18 AAR's AskRail app screenshots for train consist and tank car details, hazardous materials identification, and response guidance resources (left to right)
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