Inspection Procedure

02-SAIP-01 Inspection of Positive Seal Coupling Systems Document Responsibility: Inspection Dept. 31 August, 2002

Saudi Aramco DeskTop Standards

Table of Contents 1 2 3 4 5 6 Scope............................................................. 2 Purpose.......................................................... 2 References..................................................... 2 Definitions...................................................... 2 Background of the PSPC Joining System...... 3 Inspection Procedure..................................... 3

Previous Issue: 31 December, 2000 Next Planned Update: 1 September, 2007 Revised paragraphs are indicated in the right margin Primary contact: Supvr., IEU on 874-6604

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Document Responsibility: Inspection Department 02-SAIP-01 Issue Date: 31 August, 2002 Next Planned Update: 1 September, 2007 Inspection of Positive Seal Coupling Systems 1 Scope This Saudi Aramco Inspection Procedure (SAIP) establishes the Inspection requirement for the Positive Seal Coupling (PSC) System. Every pipe joint that is connected using this system shall be inspected in accordance with this SAIP. Use of this coupling system to join pipe shall be limited to API Specification 5L line pipe. 2 Purpose The purpose of this SAIP is to provide the inspector with the procedures for inspection of the Positive Seal Pipe Coupling System. 3 References 3.1 Saudi Aramco References Saudi Aramco Engineering Standard SAES-H-002 Internal and External Coatings for Steel pipelines and Piping

Saudi Aramco Materials System Specification 09-SAMSS-091 3.1 Industry Codes and Standards American Petroleum Institute API SPEC 5L Specification for Line Pipe Shop-Applied Internal FBE Coatings

Steel Structures Painting Council SSPC SP1 SSPC SP3 SSPC SP6 4 Definitions PSPC-Joint: A PSPC joint consists of a coupling sleeve that has a pipe end hydraulically rammed in each end. This provides a structural joint with a gas tight fit Coupling Threads: The internal, sharp threads like (or serrations) are machined in the bore of each end of the coupling. These threads provide the gripping action that help to secure the pipe in the coupling. Solvent Cleaning Power Tool Cleaning Commercial Blast Cleaning

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Document Responsibility: Inspection Department 02-SAIP-01 Issue Date: 31 August, 2002 Next Planned Update: 1 September, 2007 Inspection of Positive Seal Coupling Systems 5 Background of the PSPC Joining System PSPC joints consist of a coupling sleeve that has a pipe end rammed in each end, giving a gas tight interference fit. The first pipe end can be pressed into the coupling either in the yard or in the field. The second pipe end is pressed into the second coupling end in the field to effect pipeline construction. The Ramming operation is done with a hydraulically powered joining unit. Two part epoxy coating compound is applied to the pipe end exterior and coupling ends interior before joining them. This epoxy provides lubrication during ramming, the filling of joint interface voids, and the sealing of exposed joint interfaces against corrosion. PSPC joints are particularly intended for the joining of internally coated pipe without welding. The Positive Seal Coupling System joins sections of pipe while maintaining continuity of the internal coating across the joint interfaces. 6 Inspection Procedure 6.1 Inspection of the Coupling 6.1.1 The coupling shall be free from blisters, pits, and other defects which would impair the efficiency of the coupling. It shall be free from dirt, grease, scale and other foreign materials. The coupling shall be made of materials equal to or greater in mechanical properties to that of the pipe. The coupling shall be die stamped or paint stenciled on the outside of the coupling with the following information: The Positive Seal Coupling Manufacturer's - Design Specification (Part) Number and - coupling's Serial Number. 6.1.3 6.1.4 6.1.5 The nominal outside diameter and length dimensions of the coupling for the relevant pipe and pipeline shall be as specified by the Manufacturer. Internal serrated threads shall be free from any damage which will break the continuity of the threads. If the coupling is used to join internally coated pipe, the recessed area of the coupling may optionally be coated in accordance with 09-SAMSS91, except that the thickness is reduced to 300-425 microns (12-17 mils). Whenever a Seal Ring Gasket (SRG) is used in the coupling recessed area between the pipe ends, it is neither necessary nor required to coat the internal recess area of the coupling as the SRG effects a seal between the pipe ends.

6.1.2

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Document Responsibility: Inspection Department 02-SAIP-01 Issue Date: 31 August, 2002 Next Planned Update: 1 September, 2007 Inspection of Positive Seal Coupling Systems 6.1.6 If the coupling will be installed on pipe that will be buried, it shall receive an external coating in accordance with SAES-H-002. This coating may be applied after pipe joining. Any coupling not meeting the above requirements shall be separated from those that are acceptable, and repaired or discarded.

6.1.7 6.2

Inspection of the Pipe Ends 6.2.1 6.2.2 The pipe ends shall be furnished with beveled plain ends per API SPEC 5L. The surface of the pipe ends shall be free from dirt, rust, scale, oil and grease in accordance with SSPC SP1 and preferably in accordance with SSPC SP6. If SSPC SP6, Commercial Blast Cleaning, is not practical, then SSPC SP3 Power tool is acceptable. The inside and outside edges of the ends of the pipe shall be free from burrs, seams, and sand. The pipe shall be sufficiently free from indentations, projections and other such defects for a distance greater than one-half the coupling length from the end of the pipe, to permit proper make-up of the coupling. The outside diameter of the pipe ends which are to be inserted into the coupling shall conform to the pipe end tolerances of API SPEC 5L. The Inspector shall confirm that the PSPC installer has checked the size of the pipe ends with the Go/No/Go ring gages or any other Reliable measuring tool such as Varner Caliber and that they are acceptable. The small gage shall not be able to fit over the pipe end and the large gage shall be able to slip over the end, for at least 4 inches. The Go ring is also used to check for excessive Ovality, which will be cause for rejection of the pipe. Pipe ends that fail to meet the dimensional requirements above shall be repaired, or cut-off to a location on the pipe that is acceptable. A scribe mark shall be put on the pipe at the specified insertion distance from the end of the pipe. This mark will guide the insertion distance.

6.2.3

6.2.4 6.2.5 6.3

Inspection of Coupling Insertion on First Pipe 6.3.1 6.3.2 An SRG shall be installed into the coupling recess area before first pipe end insertion. Epoxy lubricant/sealant shall be put on the outside surface of one end of the pipe and the inside surface of one end of the coupling to prevent

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Document Responsibility: Inspection Department 02-SAIP-01 Issue Date: 31 August, 2002 Next Planned Update: 1 September, 2007 Inspection of Positive Seal Coupling Systems metal galling during installation. Saudi Aramco approved two-parts epoxy lubricant/sealant systems include: Hempadur 8554 Hempadur 85542 3M, Scotch Kote 312 6.3.3 At the completion of each insertion, the inspector shall confirm that sufficient hydraulic pressure was developed upon full insertion of the pipe end into the coupling. If the gage pressure is below the limits specified by the Positive Seal Coupling Manufacturer, it shall be cause for rejection of the joint. There are no "standard" minimum insertion pressures for each pipe size. The Manufacturer will provide the minimum joining unit insertion pressure gauge requirement for each pipeline job. That minimum pressure will be specific to the pipe size, wall thickness, grade, relevant coupling design being used, and the specific insertion characteristics of the particular joining unit being used. After the pipe is inserted into the coupling, the Inspector shall check that the pipe has been inserted to the correct required distance, which is onehalf of the coupling length, 3/8 inch. The scribe mark shall be covered by the coupling or stick out by no more than 3/8 inch. Verification of intolerance first-end insertion distance will confirm sufficient insertion depth for the second-end, field insertion, if the remaining insertion distance is less than the minimum requirement, then the end of the pipe shall be cut off, and the coupling discarded. The Inspector shall also check that excess sealant from paragraph 6.3.2 has been removed from the exposed face of the SRG.

6.3.4

6.3.5 6.4

Shipping 6.4.1 Before loading pipe with Positive Seal Pipe Coupling on trucks for transport, the pipe will be blown out with compressed air to remove all dirt , sand , or other foreign matter. The pipe ends will then be wrapped with plastic and taped in such a way to ensure the internal areas of the pipe and coupling remain free of dirt, sand, and other foreign matter.

6.4.2

6.5

Inspection of Complete Joint Assembly 6.5.1 The inspection steps of 6.3.1 and 6.3.2 shall be repeated for the second pipe. Page 5 of 6

Document Responsibility: Inspection Department 02-SAIP-01 Issue Date: 31 August, 2002 Next Planned Update: 1 September, 2007 Inspection of Positive Seal Coupling Systems 6.5.2 After insertion, the pipe scribe marks shall be checked. The marks on each pipe shall either be covered or stick out from the end of the coupling by no more than 3/16 in. If either mark is more than 3/16 in. from the coupling, the joint shall be rejected by the Inspector and the coupling cut out.

31 August, 2002

Revision Summary Revised the "Next Planned Updated". Reaffirmed the contents of the document, and reissued with minor changes.

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