Professional Documents
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Management
Module 5 Pipeline Repairs
Pipeline Operations
Pipeline Maintenance
Where are we? Pipeline Integrity management
Inspection and Assessment Methods
Pipeline repairs
4
5
Repair
6
*UK’s HSE Safety Alert on ‘Leak Sealing Repair Clamps’. 28 February, 2007
Pipeline Repairs
• The concept of repairing a pipe presumes that an
injurious defect is present.
• The purpose of a repair is to restore the full
serviceability of the pipe permanently, although
temporary repairs may sometimes be necessary.
• Safety before, during, and after the repair operation
is the first priority.
▪ A leak is discovered
▪ Excavator reports or is observed
hitting the pipe
▪ An anomaly identified by in-line
inspection is confirmed in the field
▪ Excavation for another purpose reveals
a repairable condition
©
20
*R Coote, J Kyle Keith, ‘Pressure Reductions and Pipeline Excavation’, International Pipeline Conference, Calgary, Canada, 2004. IPC04-0395
PRESSURE REDUCTIONS: Why reduce
pressure for non-leaking defects?
Failures after 24 hours at constant pressure are unlikely See B Leis, A Cosham, ‘The assessment 21
of time-delayed failure
under constant pressure’, 17th EPRG/PRCI Joint Technical Meeting, Milan 2009.
PRESSURE REDUCTIONS: Examples of Pressure
Reductions
We have two types of guidance for pressure reductions that relate
to the ‘severity’ of damage:
Microbe-induced
corrosion
Cold Bond
(LF only)
Hot Cracks
Offset
Beads
Shipment
Fatigue
Alan Murray 2017 36
Typical
mechanical
damage
Alan Murray 2017 37
Typical mechanical damage
Note creases in pipe wall (left);
cracking, and crushed
microstructure (below).
Pressure-cycle induced
Coating disbondment and fatigue in rerounded dent
corrosion in rock dent (following removal of rock)
Ripples
in field
bend
Onshore
line
Offshore line
Alan Murray 2017 45
Buckles due to soil movement
Slag Inclusions
Incomplete
Penetration (IP)
Hydrogen-Induced Cracking
(HIC), High-Low, and
Excess Penetration
53
*We will not consider ‘pumpkin’ sleeves – these were used to reinforce old compression couplings. Because they were very
big, they have been used to repair buckles, leaking clamps, etc.. They are considered ‘temporary’.
Type A and Type B Sleeves
• Defect filled with hardenable
material
• Steel half shells closely fitted
around the defect area
• Joined by longitudinal welds
• Ends not welded (Type A) or
welded (Type B)
• Type B sleeves designed to be
pressure containing
54
WELDED SLEEVE REPAIR
❖ The welded sleeve involves welding* together two ‘half shells’
around the damaged pipeline, to form a ‘sleeve’.
❖ See API RP 1107 and API STD 1104 for guidance on their
application.
Sleeve Half shell
Half shell
Half shell
Pipeline
(damage under sleeve)
55
Non-pressure containing sleeves:
• side seams groove or fillet welds
• end gaps sealed to keep out water
60
WELDED SLEEVE: Principles of
operation (1)
STRESS SHARING: If the welded sleeve fits around the pipeline perfectly, there
is ‘stress sharing’ – the stress in the carrier pipe is reduced.
If this sleeve is of a similar thickness to the carrier pipe, and applied at a
pressure of Pr, and the pipeline pressure is then increased to Po, the
sleeve shares the increases in stress from Po to Pr.
Thicker sleeves take higher stresses. Any carelessness in fitting will result
in poor stress sharing. 2. DEFECT IS
1. LOAD IS RESTRAINED
TRANSFERRED
REPAIR
DEFECT SHELL
PIPELINE
61
WELDED SLEEVE: Principles of
operation (2)
RESTRAINT OF BULGING :The sleeves stop a defect from ‘bulging’ in
the ductile line pipe.
Defects in pressurised pipe bulge outwards prior to failure.
If this bulging is prevented or restricted, the failure is prevented.
2. DEFECT IS
1. LOAD IS RESTRAINED
TRANSFERRED
REPAIR
DEFECT SHELL
PIPELINE
62
Methods for
achieving tight fit-
up between
sleeve and pipe
Fill
***’Repair of Pressure Equipment and Piping’, ASME PCC-2-2006. January, 2007, and ASME B31.8 Section 851.42.
66
Comments About Sleeves
Restoration of
pressure capacity
Improvement of
fatigue life
Alan Murray 2017 81
Grinding out mechanical damage in
dents
Grind out gouge to smooth contour, to max depth of
40% of wall over limited to length as follows:
1/ 2
g / t 2
L (1.25Dt) 1
1.1g / t 1
Ref: CSA Z662 and “Repair of Pipeline Dents Containing Minor Scratches”
J.F. Kiefner and C.R. Alexander, PRCI L51788, 3/18/99
Damage repaired
by grinding
Inspection by PT and UT
verified removal of any
cracks and adequate
remaining wall.
Alan Murray 2017 83
Nonmetallic composite wrap repair
85
Composite wrap repairs
Clockspring®
1. Apply Filler 2. Apply composite wrap
Adhesive repair
5. Coat and
Backfill
3. Wrap
4. Tighten
Alan Murray 2017 86
COMPOSITE REINFORCEMENT
SLEEVES
• Fibreglass re-inforced composite
material wrapped around the pipe
can restore pipeline strength in the
hoop direction.
• Composites can have 10x the
strength of a steel, and 25% of the ‘ClockspringTM’
weight and can have wide-ranging
applications**.
• They follow the contour of the
pipe/damage.
• They are light and easy to handle.
• No pipeline ‘hot work’ is required. Usually defect is first filled with
high compressive strength filler
material
87
COMPOSITE REINFORCEMENT
SLEEVES
• All composite repair systems on
pipelines employ*:
• some type of fibre system that
provides strength and stiffness
(typically glass or carbon fibres);
• a resin matrix used to transfer load
between fibres; and in the case of
‘layered’ systems;
• an adhesive that is used to bond
layers.
*C Alexander, ‘Repairing Damaged Pipelines’, Pipeline and Gas Technology, March 2008 88
COMPOSITE SLEEVES: Caution
89
COMPOSITE SLEEVES: Caution
91
TD Williamson
Black-Diamond® CF
composite wrap
repair
Temporary SANDWICH®
2. Valves are installed on the
fittings, and taps are made
through the valves.
Remove
Replace
109
Cut out
• If line can be shut down, depressurized, and evacuated, a relatively simple
repair
• If the line cannot be shut down, depressurized, and evacuated, a much
more complicated repair:
– Requires stopple fittings (a way to stop the flow in the pipe) on both
sides of the section to be replaced
– After stopples are activated, section with defect
is depressed, removed, and replaced
• Bypass piping can be connected to stopple
and used to maintain flow.
• Stoppling and by-passing is really expensive
110
We can bypass damaged pipe, and maintain flow by constructing a ‘hot tap,
stopple, and bypass’.
HOT TAP: cutting into a live pipeline using a special tee, welded or clamped to the pipe
STOPPLE*: insertion of a temporary plug into the line, through a hot-tap tee, to isolate
BYPASS: attachment of bypass pipe to a pair of hot-tap tees to provide a flow
bypass aroundthe isolated section.
TDW now have a One piece bypass fitting
Freeze plugging
▪ Freeze plugging is used to isolate
a pipe segment containing a
liquid without draining down
entire line
▪ LN2 is circulated within a jacket
around the pipe
▪ Temperatures are monitored to
assure freezing of liquid
▪ Plug is locked in place by thermal
contraction of the pipe
▪ Pipe to be frozen should be
subjected to NDE
▪ If plugged section is on test, plug
should be clear of personnel
In-Service Welding
Production welding procedures are
inappropriate for welding on a line in service
if the line contains a flowing gas or a flowing
or quiescent liquid. Such conditions cause
high weld cooling rates, which, when
combined with susceptible base metal
chemistry and the presence of hydrogen in
the welding environment, may lead to
underbead or hydrogen-induced cracking
(HIC) in the heat-affected zone.
116
*This is not ‘puddle welding’, although similar. Puddle welding was often done under poor quality control, and has caused operational failures
WELD METAL DEPOSITION*
Photograph from: R Gordon et al, ‘Internal Repair of Pipelines Review & Evaluation of 117
Internal Pipeline
Repair Trials Report’, Edison Welding Institute, EWI Project No. 46211GTH. Sept 2004
WELD METAL DEPOSITION:
Advantages
• Gas Research Institute (USA) say weld deposition is feasible to 900 psi
for minimum 0.125” wall thickness pipe. API 1160 limits this to >0.181”
(4.5mm).
• Can be useful where sleeves are not possible - at fittings and bends - or
where access is difficult.
• Fatigue and fracture tests at Edison Welding Institute (USA) have shown
good properties.
• Recognised in ASME B31.8.
118
WELD METAL DEPOSITION:
Concerns
• Defect assessment can usually show it is not needed.
• Possible blow-out or penetration of pipe:
– penetration depends on wall thickness, weld heat input and
removal of heat by flow of fluid inside pipe.
• The pipe’s static and fatigue strength must be restored, and
significant defects must not be introduced (including hydrogen
cracking in the heat affected zone).
• The repair can be difficult to QA, and can show as small pits in an
MFL pig run, due to material change, and may lead to excavation.
119
In-Service Welding
Recommended maintenance procedure
qualification test arrangement
Pipe coupon
inclined at 45
degrees with
fresh water flow.
Simulated repair
sleeve clamped
in place prior to
welding.
Defect types can include external and internal defects with greater than 80%
metal loss or less than 80% metal loss.
Compare the operators selected repair methods with industry codes and
standards for acceptable repairs for particular types of defects, including
§195 Subparts C and D,
ASME B31.4 Code, Section 451.6.2
API Standard 1160, and
API Standard 1107