Class Location & Gathering Type Verification Utilizing the IntegrityMap HCA Gas Tool

Client: Global Chemical Manufacturer Operating DOT-Regulated Fuel Gas and Ethylene Transmission Pipelines

Challenge

A global chemical manufacturer needed to keep its pipeline integrity records current and audit-ready for 7 miles of DOT-regulated gas transmission pipelines at a Gulf Coast facility. The existing transmission Class Location and high consequence area (HCA) analysis, completed in 2020, appropriately reflected the conditions documented at the time and included multiple Identified Sites near the system. Because occupancy and site use can change, the operator needed to confirm that the Identified Site inventory and resulting transmission-line classifications still reflected current conditions and could be supported during a Pipeline and Hazardous Materials Safety Administration (PHMSA) audit. Accurate classifications were also important for defining integrity-management scope, prioritizing inspections and maintaining reliable regulatory records.

Solution

Altamira completed a new geographic information system (GIS) based Class Location, HCA and moderate consequence area (MCA) analysis for the facility’s transmission system, which consisted of a 6-mile, 8-inch fuel gas pipeline and a 1-mile, 10-inch ethylene gas pipeline. Altamira performed the work using its proprietary IntegrityMap HCA tool, which combines Class Location, gathering and HCA analysis in a single platform. For transmission systems such as this one, IntegrityMap HCA produces Class Location, HCA and MCA results. For gathering systems, the same platform also evaluates gathering classifications using consistent pipeline attributes and spatial inputs.

For this project, the team updated the measured centerlines, structures, pipe diameter, maximum allowable operating pressure (MAOP), building occupancy and Identified Site attributes. IntegrityMap HCA then modeled potential impact radius (PIR) buffers, applied the sliding-mile analysis and evaluated the transmission requirements under 49 CFR Part 192. The ethylene analysis used the product-specific PIR factor for flammable gases other than natural gas.

Rather than relying solely on historic site classifications, Altamira independently revalidated the existing Identified Site inventory. During that review, a GIS analyst contacted two of the previously identified sites to confirm occupancy conditions, and a field technician visited one location for additional verification. The remaining Identified Sites continued to be included, while the review established that these two properties no longer met the Identified Site criteria. Altamira reran the analysis using current conditions, documented the Class, HCA and MCA event stationing, and delivered both the final reports and supporting GIS data so the operator retained a traceable technical record of the findings.

Results

The updated transmission-line analysis gave the client a current, defensible understanding of which pipeline segments warrant higher-consequence treatment. On the fuel gas line, the Class 3-designated length decreased from 3,200 feet to 800 feet, a 75% reduction, while the HCA-designated length decreased from 1,100 feet to 800 feet, approximately 25%. The analysis also identified 640 feet of MCA. The ethylene transmission line remained entirely Class 1, Non-HCA and Non-MCA. By replacing historic occupancy classifications with direct verification and repeatable GIS analysis, Altamira helped the operator focus transmission integrity-management activities on the segments that meet current criteria, support PHMSA compliance and audit preparation, prioritize inspections and risk-management work and maintain reliable records for future updates.

For more information, please contact Dustin Sanchez, GIS Manager.
Dustin can be reached at dustin.sanchez@altamira-us.com

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