Billing Code: 4910-60-P
DEPARTMENT OF TRANSPORTATION
Pipeline and Hazardous Materials Safety Administration
Potential Failures Due to Brittle-Like Cracking of Older Plastic Pipe in Natural Gas
Distribution Systems.

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

ACTION: Notice; issuance of advisory bulletin on brittle-like failures of plastic pipe to owners and operators of natural gas distribution systems.

SUMMARY: PHMSA is issuing this advisory bulletin to owners and operators of natural gas distribution systems to inform them of the potential vulnerability of older plastic gas distribution pipe to brittle-like cracking. The National Transportation Safety Board (NTSB) recently issued a Special Investigation Report (NTSB/SIR-98/01), Brittle-like Cracking in Plastic Pipe for Gas Service, that described how plastic pipe installed in natural gas distribution systems from the 1960s through the early 1980s may be vulnerable to brittle-like cracking resulting in gas leakage and potential hazards to the public and property. PHMSA has also issued an additional advisory bulletin (ADB-99-01) reminding natural gas distribution system operators of the potential poor resistance to brittle-like cracking of certain polyethylene pipe manufactured by Century Utility Products, Inc.

ADDRESS: This document can be viewed on the Office of Pipeline Safety (OPS) home page at: http://ops.dot.gov.

FOR FURTHER INFORMATION CONTACT: Gopala K. Vinjamuri, (202) 366- 4503, or by email at gopala.vinjamuri@rspa.dot.gov.

SUPPLEMENTARY INFORMATION

I. Background

The National Transportation Safety Board (NTSB) recently issued a Special Investigation Report (NTSB/SIR-98/01), Brittle-like Cracking in Plastic Pipe for Gas Service, that described how plastic pipe installed in natural gas distribution systems from the 1960s through the early 1980s may be vulnerable to brittle-like cracking resulting in gas leakage and potential hazards to the public and property. An NTSB survey of the accident history of plastic pipe suggested that the material may be susceptible to premature brittle-like cracking under conditions of local stress intensification because of improper joining or installation procedures. Hundreds of thousands of miles of plastic pipe have been installed, with a significant amount installed prior to the mid-1980s. NTSB believes any vulnerability of this material to premature failure could represent a potentially serious hazard to public safety.

The NTSB report addressed the following safety issues: The vulnerability of plastic pipe to premature failures due to brittle-like cracking; The adequacy of available guidance relating to the installation and protection of plastic pipe connections to steel mains; and Performance monitoring of plastic pipeline systems as a way of detecting unacceptable performance in piping systems.

Copies of this report may be obtained by calling NTSB's Public Inquiry Office at 202-314-6551.

The phenomenon of brittle-like cracking in plastic pipe as described in the NTSB report and generally understood within the plastic pipeline industry relates to a part-through crack initiation in the pipe wall followed by stable crack growth at stress levels much lower than the stress required for yielding, resulting in a very tight slit-like opening and gas leak. Although significant cracking may occur at points of stress concentration and near improperly designed or installed fittings, small brittle-like cracks may be difficult to detect until a significant amount of gas leaks out of the pipe, and potentially migrates into a enclosed space such as a basement. Premature brittle-like cracking requires relatively high localized stress intensification that may be a result from geometrical discontinuities, excessive bending, improper fitting assemblies, and/or dents and gouges. Because this failure mode exhibits no evidence of gross yielding at the failure location, the term brittle-like cracking is used. This phenomenon is different from brittle fracture, in which the failure results in fragmentation of the pipe.

The report suggests that the combination of more durable plastic pipe materials and more realistic strength testing has improved the reliability of estimates of the long-term hydrostatic strength of modern plastic pipe and fittings. The report also documents that older polyethylene pipe, manufactured from the 1960s through the early 1980s, may fail at lower stresses and after less time than was originally projected. NTSB alleges that past standards used to rate the long-term strength of plastic pipe may have overrated the strength and resistance to brittle-like cracking of much of the plastic pipe manufactured and used for gas service from the 1960s through the early 1980s.

In 1998, NTSB made several recommendations to trade organizations and to the Pipeline and Hazardous Materials Safety Administration (PHMSA) on the need for a better understanding of the susceptibility of plastic pipe to brittle-like cracking. NTSB recommended that PHMSA "[d]etermine the extent of the susceptibility to premature brittle-like cracking of older plastic piping (beyond that marketed by Century Utilities Products Inc.) that remains in use for gas service nationwide."

II. Advisory Bulletin (ADB-99-02)

To: Owners and Operators of and Natural Gas Distribution Pipeline Systems

Subject: Potential susceptibility of plastic pipe installed between the 1960 and the early 1980s to premature failure due to brittle-like cracking.

Purpose: To inform natural gas distribution pipeline operators of the need to determine the extent of susceptibility to brittle-like cracking of plastic pipe installed between the years 1960 and early 1980s.

Advisory: A review of Office of Pipeline Safety (OPS) reportable natural gas pipeline incidents and the findings of NTSB Special Investigation Report (NTSB/SIR-98/01) indicates that certain plastic pipe used in natural gas distribution service may be susceptible to brittle-like cracking. The standards used to rate the long-term strength of plastic pipe may have overrated the strength and resistance to brittle-like cracking of much of the plastic pipe manufactured and used for gas service from the 1960s through the early 1980s.

It is recommended that all owners and operators of natural gas distribution systems identify all pre-1982 plastic pipe installations, analyze leak histories, and evaluate any conditions that may impose high stresses on the pipe. Appropriate remedial action, including replacement, should be taken to mitigate any risks to public safety.

(49 U.S.C. Chapter 601; 49 CFR 1.53)

Issued in Washington, D.C. on _____________________.

Richard B. Felder

Associate Administrator for Pipeline Safety