PRCI 51083861-Pipeline-Repair-Manual Dec 94, 99 TOC

Catalog No. L51716e

PIPELINE REPAIR MANUAL Contract PR-218-9307

Prepared for the Pipeline Corrosion Supervisory Committee Pipeline Research Committee of Pipeline Research Council International, Inc.

Prepared by the following Research Agencies: Kiefner and Associates, Inc. Edison Welding Institute Battelle Memorial Institute

Authors: John F. Kiefner W. A. Bruce D. R. Stephens

Publication Date: December 31, 1994 Rev 1.0 Dec. 99’

“This report is furnished to Pipeline Research Council International, Inc. (PRCI) under the terms of PRCI PR-218-9307, between PRCI and Kiefner and Associates, Inc. Edison Welding Institute and Battelle Memorial Institute. The contents of this report are published as received from Kiefner and Associates, Inc. Edison Welding Institute and Battelle Memorial Institute. The opinions, findings, and conclusions expressed in the report are those of the authors and not necessarily those of PRCI, its member companies, or their representatives. Publication and dissemination of this report by PRCI should not be considered an endorsement by PRCI or Kiefner and Associates, Inc. Edison Welding Institute and Battelle Memorial Institute, or the accuracy or validity of any opinions, findings, or conclusions expressed herein. In publishing this report, PRCI makes no warranty or representation, expressed or implied, with respect to the accuracy, completeness, usefulness, or fitness for purpose of the information contained herein, or that the use of any information, method, process, or apparatus disclosed in this report may not infringe on privately owned rights. PRCI assumes no liability with respect to the use of , or for damages resulting from the use of, any information, method, process, or apparatus disclosed in this report. The text of this publication, or any part thereof, may not be reproduced or transmitted in any form by any means, electronic or mechanical, including photocopying, recording, storage in an information retrieval system, or otherwise, without the prior, written approval of PRCI.”

Pipeline Research Council International Catalog No. L51716e Price: $1095 Copyright, 1994 All Rights Reserved by Pipeline Research Council International, Inc. PRCI Reports are Published by Technical Toolboxes, Inc. 3801 Kirby Drive, Suite 340 Houston, Texas 77098 Tel: 713-630-0505 Fax: 713-630-0560 Email: [email protected]

PIPELINE RESEARCH COUNCIL INTERNATIONAL, INC. G. L. Walker, Pacific Gas Transmission Company (chairman) P. S. Anderson, Foothills Pipe Lines Ltd. R. L. Brown, MidCon Corp. E. Herløe, Statoil R C. Hesje, Transportadora de Gas del Norte M. C. Hockling, Transcontinental Gas Pipe Line Corp. D. L. Johnson, Coates, Enron Corp W. A. Johnson II, El Paso Natural Gas Company D. F. Keprta, ARCO Exploration and Production Technology R. E. Keyser, Panhandle Eastern Pipe Line Company J. K. McDonald, East Australian Pipeline Ltd. B. W. Little, Union Gas Limited J. P. Lucido, ANR Pipeline Company H. A. Madariaga Southern California Gas Company D. J. McNiel, Tenneco Gas M. Merrill, BP Pipelines (Alaska), Inc. K. J. Naarding, N. V. Nederlandse Gasunie D. E. Reid, TransCanada PipeLines, Ltd. C. W. Petersen Exxon Production Research company B. J. Sokoloski, CNG Transmission Corp. P. M. Sørensen Dansk Olie og Naturgas A/S B. C. Sosinski, Consumers Power Company E. E. Thomas, Southern Natural Gas Company R J. Turner, NOVA Gas Transmission Ltd. D. C. Walker, Oklahoma Natural Gas Company E. G. Ward, Shell Development Company T. D. Willke, Gas Research Institute K. F. Wrenn, Jr., Columbia Gas Transmission Corp. T. F. Murphy, American Gas Association A. G. Cotterman, American Gas Association

LINE PIPE RESEARCH SUPERVISORY COMMITTEE Chairman E. L. Smith, Natural Gas Pipeline Company of America Members W. E. Amend, Southern California Gas Company R. R. Bryant, Union Gas Limited L. A. Christensen, Colorado Interstate Gas Company M. J. Crump, Enron Corp B. S. Delanty, TransCanada Pipelines, Ltd. W. J. DeVries, Cousumers Power Co. B. R Dupuis, Foothills Pipe Lines Ltd. V. L. HiIl, Gas Research Institute W. E. Holmes, East Australian Pipeline Ltd. C. Juhl, Dansk Olie og Naturgas A/S T. D. Kedzie, Tenneco Gas A. C. Madsen, BP Exploration (Alaska) Inc. A. J. Maghes, Panhandle Eastern Corpora R G. Marshall, Transportadora de Gas del Norte A. Nøklebye, Statoil T. R. Odom, Texas Gas Transmission Corporation J. Rabinowitz Algonquin Gas Transmission Co. W. E. Ritchie, El Paso Natural Gas Company A. B. Rothwell, NOVA Gas Transmission Ltd. W. Sloterdijk, N. V. Nederlandse Gasunie G. L. Smith, ANR Pipeline Company) G. Venkataraman, Shell Development Company J. B. Vrable, CNG Transmission Corporation R T. Weiss, Exxon Production Research Company D. Young, Southern Natural Gas Company T. F. Murphy, Pipeline Research Committee Staff

TABLE OF CONTENTS Page INTRODUCTION

. . . . . . . . . . . . . . . . . . . . . . . . . 1

RESPONSE TO THE DISCOVERY OF AN ANOMALY OR DEFECT IN A PIPELINE . . . . . . . . . . . . . . . . . . . . . . . . . 3 Pressure Reduction Upon Discovery of Defects or Anomalies . . . . . . . . . . . . . . . . . . . 4 Isolated Defects . . . . . . . . . . . . . . . . . . 4 Responses to Leak Surveys . . . . . . . . . . . . . . 5 Responses to In-Line Inspection Results . . . . . . . 5 Other Pressure Reduction Considerations Excavation Safety

. . . . . . . . . 6

. . . . . . . . . . . . . . . . . . . . 7

Critical Information for Repair Decisions Pipe Material . . . . . . . . . . . Pipeline Operating Characteristics Pipeline Configuration . . . . . . Pipeline Location . . . . . . . . . Nature and Extent of the Defect . .

. . . . . . . . 7 . . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

7 8 8 8 8

PIPELINE REPAIR METHODS . . . . . . . . . . . . . . . . . . .

10

Removal and Replacement of a Defective Segment . . . . .

10

Grinding . . . . . . . . . . . . . . . . . . . . . . . .

11

Deposited Weld Metal . . . . . . . . . . . . . . . . . .

14

Full-Encirclement Sleeves

. . . . . . . . . . . . . . .

19

Type A Sleeves (Reinforcing) . . . . . . . . . . . Assuring Effective Reinforcement . . . . . . . . .

20 22

Pressure Reduction . . . . . . . . . . . . . . Getting the Sleeve to Fit Snugly by Mechanical Loading . . . . . . . . . . . . . . . . . . . Hardenable Fillers . . . . . . . . . . . . . . Fit-Up on SAW and Flash-Welded Line Pipe . . . Epoxy-Filled Shells . . . . . . . . . . . . .

23

i

24 26 26 27

Type B Sleeves

. . . . . . . . . . . . . . . . . .

Design . . . . . . . . . . . . . . . . The Importance of Quality Fabrication Sleeve Length . . . . . . . . . . . . Leaking Defects . . . . . . . . . . . Nonleaking Defects . . . . . . . . . . Inspection Requirements . . . . . . .

. . . . . .

. . . . . .

. . . . . .

27

. . . . . .

27 29 29 30 31 31

Special Sleeve Configurations . . . . . . . . . . .

32

Sleeves to Repair Girth Weld Defects . . . . . Sleeves to Repair Couplings . . . . . . . . . Sleeve-On-Sleeve Repair . . . . . . . . . . . Sleeve Configurations for Curved (Field-Bent) Pipe . . . . . . . . . . . . . . . . . . . . .

32 32 34 34

Defect Repair Using Clock Spring* and Other Composite Reinforcement Sleeves . . . . . . . . . . . . . . . . .

36

Clock Spring Background . . . . . . . . . . . . . .

37

Development History . . . Properties . . . . . . . . Design and Installation . Requirements for Temporary Permanent Repair . . . . .

. . . . . . and . .

. . . . . . . . . . . . . . . . . . . . . . . .

37 38 39

. . . . . . . .

40

Design of Repair Using Composite Reinforcements . .

40

General Composite Repair Design . . . . . . . Clock Spring Repair Design . . . . . . . . . .

41 41

Long-Term Performance of Permanent Composite Repairs 43 Quality Control Specifications . . . . . . . . . . 46 Mechanical Clamps

. . . . . . . . . . . . . . . . . . .

47

Bolt-On Clamps . . . . . . . . . . . . . . . . . . Leak Clamps . . . . . . . . . . . . . . . . . . . .

47 47

Hot Tapping

. . . . . . . . . . . . . . . . . . . . . .

48

Patches and Half Soles . . . . . . . . . . . . . . . . .

49

APPROPRIATE REPAIRS FOR VARIOUS TYPES OF DEFECTS Overview of Repair Applications ii

. . . . . .

50

. . . . . . . . . . . .

51

Detailed Section Criteria

. . . . . . . . . . . . . . .

Repairing External Corrosion . . Internal Corrosion . . . . . . . Plain Dents or Dents with Gouges Longitudinal Cracks and Arc Burns Girth-Weld Defects . . . . . . . Miscellaneous Defects . . . . . .

. . . . . .

59 71 72 72 73 73

. . . . . . . . . . . . . . . . . .

74

GUIDELINES FOR A REPAIR PROCEDURE . . . . . . . . . . . . . .

76

XYZ PIPELINE COMPANY PIPELINE REPAIR STANDARD NO. XXX . . . .

77

REPAIR METHODS IN EUROPE

1.0 Scope

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

. . . . . .

58

. . . . . . . . . . . . . . . . . . . . . . .

77

2.0 Policy . . . . . . . . . . . . . . . . . . . . . . .

77

3.0 Definitions

. . . . . . . . . . . . . . . . . . . .

79

4.0 Repair Methods . . . . . . . . . . . . . . . . . . .

81

4.1 Permanent Damage . 4.2 Permanent 4.3 Permanent 4.4 Temporary

Repairs . . . . Repairs repairs Repairs

. -

Onshore . . . . . Onshore Offshore Onshore .

Nonleaking Defects . . . . . . . . . Leaks . . . . . . . . . . . . . . . . . . . . . . . .

5.0 Applications . . . . . . . . . . . . . . . . . . . . 5.1 Removal of the Defective, Damaged, or Pipes . . . . . . . . . . . . . . . . 5.2 Repair by Grinding . . . . . . . . . 5.3 Repair by Deposited Weld Metal . . . 5.4 Repair by Type A Sleeve . . . . . . . 5.4.1 5.4.2 5.4.3 5.4.4 5.4.5 5.4.6

Material . . . . . . . . . . Sleeve Length . . . . . . . Accommodating Pipe Seam-Weld Repair Pressure Level . . . Installation Procedure . . . Fabrication of Side Seams .

5.5 Repair by Type B Sleeves

Leaking . . . . . . . . . . . . . . . .

. . . .

or 81 82 82 82 82 82 84 85 87

. . . . . . 87 . . . . . . 88 Reinforcement88 . . . . . . 88 . . . . . . 89 . . . . . . 90

. . . . . . . . . . .

90

5.5.1 Design and Material . . . . . . . . . . 5.5.2 Sleeve Length . . . . . . . . . . . . . 5.5.3 Accommodating Pipe Seam-Weld

90 92

iii

Reinforcements . . . . . . . . . . . . . 92 5.5.4 Repair Pressure Level . . . . . . . . . 92 5.5.5 Installation Procedure . . . . . . . . . 93 5.5.6 Fabrication of Side Seams and Fillet Welding of the Ends . . . . . . . . . . . . . . 95 5.5.7 Special Configurations . . . . . . . . . 96 5.5.8 Temporary Repair of Defects in Bondlines of ERW or Flash-Welded Seams . . . . . . . 96 5.6 Repair by Clock Spring 5.6.1 5.6.2 5.6.3 5.6.4 5.6.5 5.6.6 5.6.7 5.6.8

. . . . . . . . . . . .

Design . . . . . . . . . . . Material . . . . . . . . . . Reinforcement Length . . . . Accommodating Pipe Seam-Weld Reinforcement . . . . . . . Repair Pressure Level . . . Installation Procedure . . . Return to Operating Pressure Records . . . . . . . . . .

97

. . . . . . . . . . . . . . . . . .

97 98 98

. . . . .

98 99 99 99 99

. . . . .

. . . . .

. . . . .

. . . . .

. . . . .

5.7 Repair by Hot Tapping . . . . . . . . . . . . . 100 5.8 Repair by Mechanical Clamp

. . . . . . . . . . 100

6.0 Inspection and Documentation . . . . . . . . . . . . 100 6.1 Prior to Repair . . . . . . . . . . . . . . . . 100 6.2 After Repair

. . . . . . . . . . . . . . . . . 101

7.0 Recoating and Backfilling

. . . . . . . . . . . . . 102

7.1 Surface Preparation . . . . . . . . . . . . . . 102 7.2 Material Application 7.3 Curing

. . . . . . . . . . . . . 102

. . . . . . . . . . . . . . . . . . . . 103

7.4 Approved Coating Materials

. . . . . . . . . . 103

7.5 Special Procedure for Type A Sleeve . . . . . . 103 7.6 Approved Coating Material for Type A Sleeve . . 104 REFERENCES

. . . . . . . . . . . . . . . . . . . . . . . . . 108

iv

APPENDIX A WELDING ON A LIVE PIPELINE

. . . . . . . . . . . . . . . . . A-1 APPENDIX B

REPAIR PRACTICES OF PIPELINE OPERATORS

. . . . . . . . . . . B-1

TABLES Table 1.

Summary of Repair Applications

. . . . . . . . . .

52

Table 2.

Example of XYZ Pipeline Company's Standard Form 6.1 . . . . . . . . . . . . . . . . . . . . . 105 FIGURES

Figure

1.

Sketch of Typical Weld Deposition Sequence for a Deposited Weld Metal Repair . . . . . . . . . . .

15

Figure

2.

Type A Sleeve . . . . . . . . . . . . . . . . . .

21

Figure

3.

Theoretical Relationships Between Carrier Pipe Stress, Repair Pressure, and Wall Thickness . . .

24

Mechanical Methods for Assuring Tight-Fitting Type A Sleeves . . . . . . . . . . . . . . . . .

25

Figure

4.

Figure

5.

Type B Sleeve . . . . . . . . . . . . . . . . . .

28

Figure

6.

Typical Sleeve Configuration for Repairs of Girth Welds . . . . . . . . . . . . . . . . . . . . . .

33

Figure

7.

Typical Sleeve Configuration for Repairs of Couplings . . . . . . . . . . . . . . . . . . . . . . . . 33

Figure

8.

Sleeve-On-Sleeve Repair . . . . . . . . . . . . .

35

Figure

9.

Armadillo Sleeve

. . . . . . . . . . . . . . . .

36

Illustration of Clock SpringTM Composite Reinforcement of Metal-Loss Defect . . . . . . .

38

Figure 10. Figure 11.

Illustration of Application of Stress-Rupture Data to Define Design Stress . . . . . . . . . . . . . . 44 v

Figure 12.

Typical Mechanical Bolt-On Clamp

. . . . . . . .

47

Figure 13.

Typical Leak Clamp

. . . . . . . . . . . . . . .

48

Figure 14.

Repairs for External Corrosion

. . . . . . . . .

60

Figure 15.

Repairs for Internal Corrosion

. . . . . . . . .

61

Figure 16.

Repairs for Plain Dents or Dents with Gouges

Figure 17.

Repairs for Longitudinal Cracks, Arc Burns

Figure 18.

Repairs for Girth-Weld Defects

. .

62

. . .

63

. . . . . . . . .

64

Figure 19.

Repairs for Wrinkle Bends/Buckles . . . . . . . .

65

Figure 20.

Repairs for Hard Spots

. . . . . . . . . . . . .

66

Figure 21.

Repairs for Blisters, HIC . . . . . . . . . . . .

67

Figure 22.

Repairs for Couplings . . . . . . . . . . . . . .

68

Figure 23.

Repairs for Defective Prior Repairs . . . . . . .

69

vi