GU-379_Pipeline_Emergency_Repair_Manual.doc

GU-379 Pipeline Emergency Repair Manual

Authorised For Issue --/--/----

Signed:........................................................................................

M. Zadjali, UIP CFDH Pipelines

The following following is a brief s!!ar" s!!ar" of #he $ !os# re%en# re%en# re&isions #o #his do%!en#. do%!en#. De#ails De#ails of all re&isions re&isions prior #o #hese are are held on file b" #he issing depar#!en#. depar#!en#.

'ersion (o. +e&. -. +e&. 5./

Da#e (o& /)pril /2 Feb. /2

)#hor U01*2 + Harris 6IP*52 U01*2

S%ope* +e!ars 3+P pipeline se%#ion added. Do%!en# re4for!a##ed. 0le%#roni% %op" of 0!ergen%" Ma#erials 1is# 7)ppendi8 259 added. Designed as CD 3ideline. Minor #e8#al %hanges #o adap# #o 3U4 for!a# and referen%e pda#ed. Te%hni%al Te%hni%al %on#en# no# re&iewed.

+e&. 5.2

+e&. 5

;ne 2<<<

6IP*-

Upda#ed #o refle%# %hanges in responsibili#ies de #o asse# based organisa#ion and refor!a##ed #o new #e!pla#e.

+e&. /

Mar 2<<$

)0F*=52

Page / of >=


Authorised For Issue --/--/----

Signed:........................................................................................

M. Zadjali, UIP CFDH Pipelines

The following following is a brief s!!ar" s!!ar" of #he $ !os# re%en# re%en# re&isions #o #his do%!en#. do%!en#. De#ails De#ails of all re&isions re&isions prior #o #hese are are held on file b" #he issing depar#!en#. depar#!en#.

'ersion (o. +e&. -. +e&. 5./

Da#e (o& /)pril /2 Feb. /2

)#hor U01*2 + Harris 6IP*52 U01*2

S%ope* +e!ars 3+P pipeline se%#ion added. Do%!en# re4for!a##ed. 0le%#roni% %op" of 0!ergen%" Ma#erials 1is# 7)ppendi8 259 added. Designed as CD 3ideline. Minor #e8#al %hanges #o adap# #o 3U4 for!a# and referen%e pda#ed. Te%hni%al Te%hni%al %on#en# no# re&iewed.

+e&. 5.2

+e&. 5

;ne 2<<<

6IP*-

Upda#ed #o refle%# %hanges in responsibili#ies de #o asse# based organisa#ion and refor!a##ed #o new #e!pla#e.

+e&. /

Mar 2<<$

)0F*=52

Page / of >=


Table Of Content Authorised For Issue --------!!!!!!!!!!!!!!!!!!!!!!! --------!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!!" !!!!!!!!!!!!!!!!!!!!" #!$ Introd Introducti uction!!! on!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!!! !!!!!! !!! 2.2 6bje%#i&e.. 6bje%#i&e....... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............... ................... ...........$ ..$ 2./ S%ope.... S%ope......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............. ................$ ........$ 2.5 )ppli%able )ppli%able S#andards.. S#andards....... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .............. .................. ...................= ..........= 2.Defini#ion Defini#ionss and )bbre&ia# )bbre&ia#ions.. ions....... .......... .......... ......... ......... .......... .......... .......... .......... ........... ................ ................... ..................= .........= 2.$ Dis#rib#io Dis#rib#ion*T n*Tar arge# ge# )dien%e.. )dien%e....... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............. ................. ............> ...> 2.= Do%!en# Do%!en# S#r%#re... S#r%#re........ .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... ............ ................ ................... .............> ...> 2.> +e&iew +e&iew ? I!pro&e!e I!pro&e!en#.... n#......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .............. ............@ ...@ "!$ Emergenc Emergency y Repairs Repairs %or &ar'on &ar'on (tee (teell Pipelines! Pipelines!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!!!! !!!!!!!!!!!!!!!! !!!!!!!!!!!!! !!!! !!! /.2 S%ope.... S%ope......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............. ................< ........< /./ T"pes T"pes of defe%#s defe%#s and and i#s %ases...... %ases........... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .........< ....< /.5 Cases of 0!ergen%" 0!ergen%" Defe%#s..... Defe%#s.......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............. .........2 .2 /.T"pes T"pes of 1e&el I 0!ergen%" 0!ergen%" Defe%#s..... Defe%#s.......... .......... ......... ......... .......... .......... .......... .......... .......... .............. .................. ..........2 .2 /.$ 1e&el4I 1e&el4I 0!ergen%" 0!ergen%" Defe%#s..... Defe%#s.......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .............. .........22 22 /.= Co!pos Co!posi#e i#e +epair: +epair: )n )l#ern )l#erna#i a#i&e &e +epair Me#hod. Me#hod.... ...... ...... ...... ...... ...... ...... ...... ...... ....... ........ ........ ........ ......./< .../< /.> 1e&el 1e&el II 0!erg 0!ergen%" en%" Defe% Defe%#s4 #s4 Injri Injrios os non non leaing leaing defe%# defe%#s... s...... ...... ...... ...... ...... ...... ...... ...... ....... ......5 ..5 /.@ +epair +epair organisa# organisa#ion... ion........ .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .............. ................... ..................5 ........5 3!$ Emerge Emergency ncy Repair Repairss %or %or G Glas lasss Rein%o Rein%orc rced ed Plast Plastic ic )GRP* )GRP* Pipeli Pipeline nes!!! s!!!!!! !!!!!! !!!!!! !!!!!!! !!!!!!!! !!!!!!!! !!!!!! 5.2 3eneral.... 3eneral......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............ ................. .............52 ...52 5./ S%ope.... S%ope......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............... ..............52 ....52 5.5 Cases Cases of defe% defe%#s #s in an oper opera#i a#ing ng 3+P 3+P pipel pipeline ine s"s#e!. s"s#e!.... ...... ...... ...... ...... ...... ...... ....... ........ ........ ........ .....52 .52 5.Defe%#s Defe%#s de #o o&er pressrisa#io pressrisa#ion.... n......... .......... .......... .......... .......... .......... .......... ......... ......... ............... ................... ..............52 .....52 5.$ Defe%# %a#egorisa#io %a#egorisa#ion.... n......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .........52 ....52 5.= +epair +epair of 1e&el4I 0!ergen%" 0!ergen%" Defe%#s.... Defe%#s......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ........... ........5/ ..5/ 5.> 0!ergen%" 0!ergen%" +epair +epair Pro%edre Pro%edre Aalifi%a#io Aalifi%a#ion.... n......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .........5= ....5= 5.@ Aali#" Aali#" Progra!!e Progra!!e dring dring +epair..... +epair.......... .......... .......... .......... .......... .......... .......... .......... ......... ......... ........... ............... ............5= ...5= 5.< 0!ergen%" 0!ergen%" +epair +epair Bi#....... Bi#............ .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ...............5 ..........5= = +!$ Emerge Emergency ncy Repa Repair ir o% o% (u (u'se 'sea a &ar'on &ar'on (tee (teell Pipeli Pipeline nes!!! s!!!!!! !!!!!! !!!!!! !!!!!! !!!!!!! !!!!!!!! !!!!!!!! !!!!!!!! !!!!!!!! !!!!!!!! !!!!!!!! !!!!!! !!!! -.2 3eneral.... 3eneral......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............ ................. .............5@ ...5@ -./ S%ope.... S%ope......... .......... .......... .......... .......... .......... .......... .......... ......... ......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............... ..............5@ ....5@ -.5 Cases of Defe%#s..... Defe%#s.......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............. .............5< .....5< -.1e&el  I 0!ergen%" 0!ergen%" Defe%#s...... Defe%#s........... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .............. .............5< ....5< -.$ +esor%es.. +esor%es....... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... ............... ................... ..............-2 .....-2 ,!$ Emergenc Emergency y (toc (toc Materials Materials!!!! !!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!!! !!!!!!!!!!!!!!!! !!!!!!!!!!!!!!!!!! !!!!!!!! ! $.2 Philosoph" Philosoph"..... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ............. .........-/ .-/ $./ 1oa%#i 1oa%#ion on and Aan#i Aan#i#ies #ies of 0!erg 0!ergen%" en%" S#o% S#o% Ma#eria Ma#erials.. ls..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ....-/ -/ .!$ (a%ety!! (a%ety!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!! !!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!!!!!! !!!!!!!!! ! =.2 Safe#" Safe#" reir reire!e e!en#s n#s dring dring repai repairr of e!ergen%" e!ergen%" defe%# defe%#s.. s..... ...... ...... ...... ...... ...... ...... ...... ...... ...... ....... ......-5 ..-5 =./ )%%iden#al )%%iden#al releases..... releases.......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... .......... ......... ......... ........... ............-......-7!$

Re%eren Re%erences ces!!!!! !!!!!!!!!! !!!!!!!!! !!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!! !!!!!!!!!!!!!! !!!!!!!!!!!!! !!!! !

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)ppendi842 )ppendi84/ )ppendi845 )ppendi84)ppendi8 $ )ppendi8 = )ppendi84> )ppendi84@ )ppendi84< )ppendi842

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Me%hani%al !e#hods #o be sed in ins#alla#ion of slee&es Plid%o Spli# E Slee&e Plid%o S!i#h E Cla!p Plid%o eld E Cap Fi8ing arrange!en#s for Plid%o eld E 0nd Plid%o Flange E +epair +ing Plid%o Flange +epair E Spli# Slee&e 1is# of 0!ergen%" Ma#erial Manfa%#rer Ins#r%#ions User Co!!en# For!


1.0 Introduction #!#

/'0ecti1e

The obje%#i&e of #his !anal is #o pro&ide a s#r%#red approa%h for e!ergen%" repairs #o Carbon s#eel pipelines, 3+P off4plo# pipelines and sbsea pipelines. The !ain prpose of an e!ergen%" repair is #o res#ore #he s#r%#ral in#egri#" of #he pipeline in #he !os# effi%ien# !anner, #o a&oid fr#her da!age #o heal#h, safe#" and #he en&iron!en# and #o res!e #he opera#ion wi#ho# an" fr#her loss in prod%#ion. In #his regard e8pedien%" is a !ore i!por#an# fa%#or #han a%hie&ing #he %heapes# %api#al %os# of #he repair i#self, par#i%larl" as #he #i!e sa&ed de #o fas# repair will lead #o lower losses in prod%#ion #hroghp# of #he pipeline. )n e!ergen%" repair differs fro! a planned repair in #ha# #he #i!e a&ailable for assess!en# of #he bes# %orse of a%#ion, !a#erial sppl" and e8e%#ion #i!e are li!i#ed b" #he need for res!p#ion of prod%#ion. The !ain prpose of #he !anal is #o define #he gidelines and reire!en#s for e!ergen%" repairs in order #o red%e #he e8e%#ion #i!e in #he assess!en# of #he e!ergen%" s%enario and de%iding #he bes# %orse of a%#ion. The !anal gi&es pra%#i%al repair and !ain#enan%e sol#ions #o &arios po#en#ial e!ergen%" si#a#ions. The !anal pro&ides #he ser wi#h infor!a#ion #o sele%# and e8e%#e a si#able repair !e#hod for a gi&en pipeline da!age s%enario. I# is no# possible #o foresee e&er" %ondi#ion #ha# !a" arise in #he e&en# of a pipeline reiring repairs and, #herefore, #he e8a%# %orse of a%#ion #o be #aen !s# be de%ided pon b" #he engineer in %harge of #he repair. In #he e&en# of an e!ergen%" si#a#ion, referen%e shall be !ade #o #he PD6 0!ergen%" Pro%edres. These pro%edres pro&ide infor!a#ion essen#ial #o #he 0!ergen%" Con#roller when !aing de%isions and for!la#ing an a%#ion plan #o %on#rol and re%#if" a wide range of e!ergen%" si#a#ions. #!"

(cope

This do%!en# %o&ers #he e!ergen%" repairs of off4plo# pipelines. The re%o!!enda#ions %o&ered per#ain #o bo#h abo&egrond and ndergrond Carbon s#eel and 3+P pipelines. +epair of sbsea %arbon s#eel pipelines is briefl" %o&ered in #his do%!en#. The repair !e#hods spe%ified in #his !anal %an be sed for repair of all %lasses of pipelines as defined in se%#ion 5./.$ of SP42/22. Howe&er, #he e!ergen%" !a#erial is s#o%ed for %lass4I pipelines onl". This do%!en# %o&ers e!ergen%" s%enarios for #he off4plo# por#ion of a pipeline o#side #he plan# bondar". 6n plo# e!ergen%" repairs in%lding #hose rela#ed #o s%raper #raps, b"pass lines and o#her rela#ed on plo# fa%ili#ies are e8%lded. These la##er repairs shall for! par# of #he plan# repair*sh#down !anal. The do%!en# %o&ers e!ergen%" repairs for in#ernall" and e8#ernall" %oa#ed*lined pipelines b# repairs #o %a#hodi% pro#e%#ion s"s#e!s are e8%lded.

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6nl" leaage e!ergen%" s%enarios are %o&ered in #his !anal. For non4leaing injrios defe%#s, referen%e is !ade #o reisi#e D0P*PD6 s#andards. The s%ope of #he !anal is #aen fro! #he poin# where #he lea has been iden#ified and lo%a#ed. I# also briefl" %o&ers #he aspe%# of de#e%#ion or iden#ifi%a#ion of #he defe%#s b" referen%e #o #he rele&an# D0P * S#andards. #!3

Applica'le (tandards

The lis# of appli%able s#andards, spe%ifi%a#ions, %odes, gidelines and pro%edres are indi%a#ed in se%#ion =. of #his do%!en#. #!+ #!+!#

2e%initions and A''re1iations General 2e%initions &ontractor 4 The par#" #ha# has a %on#ra%# wi#h #he Co!pan" for pro&iding wor

7in%lding e!ergen%" repairs9, eip!en#, !a#erial, ser&i%es 7in%lding %onsl#ing ser&i%es9 and !anpower. GCon#ra%#or shall be read #o also in%lde Gsb4%on#ra%#or and par#ies pro&iding sppor# #o %on#ra%#ors and sb4%on#ra%#ors. The %o!pan" !a" nder#ae all or par# of #he d#ies of #he %on#ra%#or. &ompany - is Pe#role! De&elop!en# of 6!an 11C. The %o!pan" !a" in%lde an

agen# or %onsl#an# a#horised #o a%# on behalf of #he %o!pan". (hall 4 indi%a#es a reire!en#. (hould - indi%a#es a re%o!!enda#ion.

May - indi%a#es a possible %orse of a%#ion. #!+!"

(peci%ic 2e%initions 2e%ect : 4 a flaw whi%h !a" ha&e a dele#erios effe%# on #he s#r%#ral in#egri#" of #he pipeline. Emergency : 4 a %ri#i%al %ondi#ion #ha# !a" endanger life, en&iron!en# and*or asse#s. In0urious de%ect : 4 a defe%# whi%h reires re!o&al, repair or dera#ing of #he pipeline. Permanent repair: 4 a repair #ha# !aes a pipeline safe for %on#inos ser&i%e for #he re!aining period of i#s design life a# i#s !a8i!! allowable opera#ing pressre or a# a red%ed pressre. emporary repair: 4 a repair #ha# !aes a pipeline safe for ser&i%e for a li!i#ed period of !ini!! 5 !on#hs. 4eaing cracs: 4 S#ress ind%ed separa#ion of #he pipe !a#erial, whi%h, wi#ho# an" o#her inflen%e, is insffi%ien# in e8#en# #o %ase %o!ple#e rp#re. The %ra%s sall" o%%r de #o e8%essi&e s#raining dring #he ini#ial !e%hani%al for!a#ion of #he pipe or as a resl# of !i%ro4s#r%#ral sensi#i&i#" #o %er#ain en&iron!en#s, whi%h are of#en high in h"drogen or slphr %on#en#, in %o!bina#ion wi#h #ensile s#resses. Cra%s !a" be fond in #he gir#h welds, sea! welds or in #he pipe bod".

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Prompt action: Consis#s of dispa#%hing alified personnel wi#ho# dela" for e&ala#ing and, where ne%essar", aba#ing #he e8is#ing or probable haard. #!+!3

#!,

A''re1iations

)PI

)!eri%an Pe#role! Ins#i##e.

)(SI

)!eri%an (a#ional S#andards Ins#i##e

)SM0

)!eri%an So%ie#" of Me%hani%al 0ngineers

D0P

Design and 0ngineering Pra%#i%e 7SH011 do%!en#s9

HIC

H"drogen Ind%ed Cra%ing

MPI

Magne#i% Par#i%le Inspe%#ion

(PS

(o!inal Pipe Sie

SCC

S#ress Corrosion Cra%ing

UT

Ul#rasoni% Tes#ing

2istri'utionarget Audience

The do%!en# is in#ended for se b" PD6 and all o#her par#ies in&ol&ed in #he pipeline !ain#enan%e and e!ergen%" repairs as a basi% gideline for #he e!ergen%" repair of pipelines. T"pi%al par#ies in%lde opera#ors, design %onsl#an#s, %ons#r%#ion %on#ra%#ors, inspe%#ion, repair and !ain#enan%e %on#ra%#ors, %er#if"ing agen%ies and a#hori#ies. #!.

2ocument (tructure

The do%!en# %o!prises of #he following se%#ions: 2.

In#rod%#ion

/.

0!ergen%" repairs for Carbon s#eel pipelines

5.

0!ergen%" repairs for 3+P pipelines

-.

0!ergen%" repairs for Sbsea CS pipelines

$.

Safe#"

=.

+eferen%es

The se%#ions will be fr#her sb4di&ided #o %o&er #he rele&an# #e%hni%al * safe#" %onsidera#ions, pro%edres and planning reired #o !ee# #he obje%#i&es of #he !anal. +eferen%es a# #he ba% of #he !anal will in%lde rele&an# referen%e !a#erial. The do%!en# is in#ended for se b" PD6 and all o#her par#ies in&ol&ed in #he pipeline !ain#enan%e and e!ergen%" repairs as a basi% gideline for #he e!ergen%" repair of pipelines. T"pi%al par#ies in%lde opera#ors, design %onsl#an#s, %ons#r%#ion %on#ra%#ors, inspe%#ion, repair and !ain#enan%e %on#ra%#ors, %er#if"ing agen%ies and a#hori#ies.

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#!7

Re1ie5 6 Impro1ement

These 3idelines will be re&iewed and pda#ed on%e e&er" #hree "ears. The re&iew a#hori#" will be CFDH Pipelines. (o %hanges will be !ade wi#ho# #he appro&al of #he Cs#odian 7CFDH Pipelines9.

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2.0 Emergenc !e"airs for Carbon #teel $i"elines "!#

(cope

This par# of #he do%!en# defines e!ergen%" repair reire!en#s for %arbon s#eel pipelines. The pipelines %o&ered are for dia!e#ers ranging fro! -J #o -@J, wall #hi%ness ranging fro! -.@!! #o /.=!! and s#eel grades %onfor!ing #o )PI $1 p #o 3rade K4>. I# e8%ldes #he repair de#ails for o#her !e#alli% pipelines e.g. d%#ile iron, dple8 !a#erial e#%. The sbje%#s addressed in #his par# of #he do%!en# %on#ain infor!a#ion regarding assess!en# of an e!ergen%" defe%#, inspe%#ion, repair !e#hods and #he safe#" reire!en#s #o be followed dring repair. "!"

ypes o% de%ects and its causes

The possible repair !e#hods are, #o a large e8#en#, di%#a#ed b" #he #"pe of #he defe%#. The &arios #"pes of defe%#s in a pipeline s"s#e! %an be %lassified on #he basis of a&ailabili#" of #i!e reired for repair, #he resor%es reired #o deal wi#h #he repair and #he %onseen%es. These are %lassified in #he following #wo !ain #"pes: 4 Emergency de%ects :4 a defe%# in #he pipeline #ha# has a dele#erios effe%# on #he heal#h, safe#", en&iron!en# and*or prod%#ion. S%h defe%#s in a pipeline s"s#e! are #hose, whi%h reire i!!edia#e and pro!p# a%#ion and also need spe%ialised pro%edres, eip!en#, !anpower and spplies #o pro#e%# #he pbli% safe#" or proper#" fro! an e8is#ing or po#en#ial haard.

0!ergen%" defe%#s %an be fr#her %a#egorised 1e&el 2 and 1e&el /. Level I emergency defects: 4 )ll leaing defe%#s in Class I pipelines are %lassified as 1e&el I e!ergen%" defe%#s. These 1e&el I e!ergen%" defe%#s pose an i!!edia#e #hrea# #o #he heal#h, safe#", en&iron!en# and prod%#ion and #herefore needs #o be re%#ified on an i!!edia#e basis wi#h Gpro!p# a%#ion. The period be#ween repor#ing of a defe%# and #he repair shall be ep# as shor# as pra%#i%able. Level II emergency defects: 4 )ll non4leaing injrios defe%#s as defined in SP4 2/5$ in Class I pipelines are defined as 1e&el II e!ergen%" defe%#s. These defe%#s do no# pose an i!!edia#e #hrea# #o heal#h, safe#", en&iron!en# and prod%#ion. Howe&er, #he e8#en# of da!age #o #he pipeline s"s#e! is s%h #ha# #hese defe%#s %an a# an" #i!e be%o!e leaing defe%#s. Therefore #he #i!e a&ailable for %arr"ing o# repairs for s%h defe%#s is !ore #han #he #i!e a&ailable in 1e&el I e!ergen%" defe%#s, b# is less #han #he #i!e a&ailable for non4 e!ergen%" defe%#s. on-Emergency de%ects8 - a defe%# whi%h, in i#s presen# s#a#e, does no# ha&e an" i!!edia#e i!pa%# on #he heal#h, safe#", en&iron!en# and*or prod%#ion. Howe&er, s%h defe%#s %an if no# re%#ified, ha&e #he po#en#ial #o be%o!e e!ergen%" defe%#s and #hereof need planned repair. The #i!e a&ailable for %arr"ing o# repairs for s%h defe%#s is !ore #han #he #i!e a&ailable in %ases of e!ergen%" defe%#s. Therefore, no spe%ialised pro%edres and resor%es are reired.

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S%h defe%#s %an be repaired in a planned !anner, b# !s# also be re%#ified in a #i!el" !anner #o ensre #ha# do no# be%o!e e!ergen%" defe%#s. $ i " e l in e ) e f e c t s

E m e r g e n c  ) e fe c ts

% in o r & e a'

 o n -E m e r g e n c  ) e f e c ts

&e*el-I

&e*el-II

& e a ' i n g In ( u r io u s ) e f e c t s

 o n & e a ' in g In ( u rio u s ) e fe c t s 0As "er #$-123

% a (o r & e a '

$ i " e % il l ) e f e c t s

+ ir t h , e l d ) e f e c t s

) e n ts

C r a c ' s /A r c  u r n s

! u " tu re

# " a l l in g . + o u g e s . + r o o * e s

+ e n e r a l /& o c a l % e t a l & o s s

Fig. 2: S!!ar" of pipeline defe%#s

"!3

&auses o% Emergency 2e%ects

The o%%rren%e of e!ergen%" defe%#s in #he pipeline s"s#e! %an be a##rib#ed #o one or a %o!bina#ion of #he following %ases: 4 2. Third par#" in#erferen%e /. Manfa%#ring*%ons#r%#ion*design*!a#erial defe%#s 5. 08%essi&e opera#ional loads*errors -. 3eo4#e%hni%al for%es $. Corrosion*sensi#i&i#" #o en&iron!en# The !os# %o!!on reasons for pipeline failres are #hird par#" in#erferen%e or %orrosion. "!+

ypes o% 4e1el I Emergency 2e%ects

1e&el I e!ergen%" defe%#s %an be fr#her %a#egorised based on #he #"pe of leas in#o: 4 Minor 1ea

) lea 7also %alled a pinhole lea9, where #he larges# di!ension of #he leaing hole is L 5!!.

Major 1ea

) lea, where #he larges# di!ension of #he lea hole is  5!! b# less #han =N of #he o#er dia!e#er of #he line pipe

+p#re

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) rp#re is a defe%# where #he larges# di!ension of #he lea hole is =N of #he o#er dia!e#er of #he line pipe. In #hese %ases, #he pressre in #he pipeline s"s#e! is dras#i%all" red%ed and also, #he leaage ra#e fro! #he defe%# is high.


In addi#ion #o #he abo&e, leas o%%rring fro! flanges* flanged fi##ings, &al&es e#%., shall also be %onsidered as 1e&el I e!ergen%" defe%#s. +epair !e#hods adop#ed for 1e&el I e!ergen%" defe%#s will depend on #he na#re of #he lea and lo%a#ion a# whi%h #he lea o%%rs. 1eas o%%rring in pipeline s"s#e!s in #he &i%ini#" of road and wadi %rossings shall reire differen# repair !e#hods #han #he leas repor#ed fro! o#her areas. "!,

4e1el-I Emergency 2e%ects

The e&en#s*a%#i&i#ies rela#ed #o 1e&el I e!ergen%" defe%#s %an be %a#egorised nder following for !ain headings: 4 2. De#e%#ion of defe%#*lea /. Perfor! da!age*lea assess!en# sr&e" 5. )nal"se da!age assess!en# sr&e" and de%ide pon repair op#ions -. Mobilise e!ergen%" repair eip!en#*%on#ra%#ors and %o!!en%e repair wors as per pro%edres o#lined in #his !anal. (o#e: This !anal pla%es grea#er e!phasis poin#s 5 ? - abo&e. Poin#s 2 ? / ha&e onl" been %o&ered in brief.

"!,!#

2etectionidenti%ication o% lea

Ti!el" de#e%#ion*iden#ifi%a#ion of leas is essen#ial #o pre&en# %a#as#rophi% effe%#s of #he lea. For de#ailed gidelines on #he lea de#e%#ion, referen%e shall be !ade #o D0P 52.-.=.22 and P+42== 7Clase /.5.< and /.5.29. Iden#ifi%a#ion of sspe%#ed leas, nless i# has been sigh#ed and repor#ed b" 5 rd par#"* PD6 sr&eillan%e #ea! or in #he absen%e of a si#able lea de#e%#ion #e%hnie, will in&ol&e pa#rolling 7waling, dri&ing or fl"ing9 #he pipeline #o iden#if" e&iden%e of one or !ore of #he following: 2. 'ege#a#ion dis#rban%es 4 &isal obser&a#ion #o de#e%# abnor!al or nsal indi%a#ions in &ege#a#ion, e.g. an area of dead &ege#a#ion or a bild p of fros# on #he grond /. 'isal iden#ifi%a#ion of flid spillage 5. ) lod whis#ling sond asso%ia#ed wi#h a lea in a high pressre pipeline s"s#e! -. S!ell of #he flid being #ranspor#ed in #he leaing pipeline $. Possible shor#ness of brea#h in #he area of a lea =. Fire near a pipeline fa%ili#" 6#her essen#ial warnings signs of a lea in%lde a red%#ion in #he pressre or dis%harge flow ra#e in #he pipeline s"s#e!, whi%h %anno# be e8plained b" #he anal"sis of #he reglar opera#ing %ondi#ions. ) dras#i% red%#ion in pressre nor!all" indi%a#es #he presen%e of rp#re in #he pipeline and reires an i!!edia#e sh# down of #he s"s#e!. The e8#en# of pressre red%#ion in #he s"s#e! is no!inal in %ases of !ajor leas whereas i# !a" be nno#i%eable for %ases of !inor leas.

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6n%e a sspe%#ed lea is %onfir!ed, iden#ifi%a#ion of #he e8a%# lo%a#ion of #he lea in&ol&es !obilisa#ion of %rews wi#h lea de#e%#ion eip!en# s%h as gas de#e%#ors, l#rasoni% lea de#e%#ion #ools e#%. This phase will also in&ol&e e8posing #he pipeline a# probable lo%a#ions of a lea #o as%er#ain #he e8a%# lo%a#ion. )ll ne%essar" safe#" !easres as reired and spe%ified in #he la#er par#s of #his do%!en# shall be adop#ed dring #he opera#ion. For leaage sr&e" pro%edres, leaage pinpoin#ing, eip!en# and #es# !e#hods for gas leaage, referen%e shall be !ade #o appendi84M of )SM0  52.@4/5. "!,!"

2e%ect4ea AssessmentInspection

6n%e #he lea has been de#e%#ed and lo%a#ed i# shold be a%%essed and %a#egorised in a%%ordan%e wi#h Se%#ion /.- of #his !anal. )ssess!en# and %a#egorisa#ion is essen#ial in de%iding on #he repair pro%edre and safe#" !e#hods #o be adop#ed dring #he repair. In #he absen%e of readil" a&ailable inspe%#ion #ools or de #o #he la% of #i!e, lea assess!en#*inspe%#ion for bried pipeline is nor!all" done b" digging a# #he lo%a#ion of #he lea and rea%hing #he lea posi#ion on #he pipeline. The probable lo%a#ions of #he leas are iden#ified in #he pre&ios phase of lea de#e%#ion. Si#able safe#" !easres as de#ailed in Se%#ion $. shall be i!ple!en#ed before s#ar# of digging. 08%a&a#ion for li&e pipelines shall be done as per 0+D 5@422. 08%a&a#ion a# #he da!aged por#ion of pipeline shall be %arried o# wi#h de regard #o #ren%h s#abili#" and safe egress. In %ases where #he lea has been de#e%#ed b" inspe%#ion #ools, no digging !a" be reired a# #his s#age as #he resl#s prod%ed fro! #he inspe%#ion #es#s nor!all" de#ail #he #"pe, sie and assess!en# of #he defe%#*lea. These inspe%#ion resl#s shall be fr#her in#erpre#ed*assessed b" #rained personnel #o %lassif" #he lea in#o !ajor, !inor or rp#re, #he reason for lea and #o propose #he s#ra#eg" #o be followed in #he repair of #hese defe%#s. 6n rea%hing #he lo%a#ion of #he lea, fr#her &isal inspe%#ion shall be done #o assess and %a#egorise #he da!age. )ll loose wrapping shall be re!o&ed and #he da!aged area shall be %leaned of all #ra%es of !d and e8#raneos !a##er. "!,!3

(hut do5n and pressure reduction

Under nor!al %ir%!s#an%es, no sh#down is reired for %ases of !inor leas as #he repair %an be done on a rnning pipeline e8%ep# in %ases of pipelines #ranspor#ing e8%essi&el" sor or haardos flid and passing #hrogh areas of higher lo%a#ion %lasses 7%lass 5 and - as per SP42/229. Sh##ing down or pressre red%#ion dring !inor leas be%o!es essen#ial in #he following %ases: 4 2. +is of grow#h of #he defe%# a# lo%a#ions wi#h s#resses o#her #han #hose de #o in#ernal pressre onl" e.g. a# lo%a#ions of soil !o&e!en# or se##le!en# or inadea#e pipe sppor# %ondi#ions e#%. /. Presen%e of defe%# 7lea9 in %ri#i%al lo%a#ion 5. Use of ho# wor for #he repair 7!a" reire de%o!!issioning of #he pipeline9

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-. The lea, al#hogh !inor, will s#ill resl# in na%%ep#able safe#" si#a#ion or an en&iron!en#al i!pa%#. Howe&er i# is essen#ial #ha# #he opera#ing pressre of #he s"s#e! be red%ed for all %ases of !inor leas #o a !a8i!! of @N of #he opera#ing pressre a# #he #i!e of defe%# repor#ing #o ensre safe repair opera#ions. Spe%ifi% %are shall be e8er%ised for %ases of downhills of a liid line where #he reired pressre red%#ion of !ore #han @N de #o s#a#i% head of #he liid. The %ri#eria and e8#en# of #he pressre red%#ion shall be &erified b" #he engineer4in4%harge. Se##ings of safegarding ins#r!en#s shall be adjs#ed #o !ain#ain #he pressre red%#ion dring repair period. ote: The pressre red%#ion re%o!!ended abo&e is #he red%#ion reired a# #he #i!e of repair. The pressres a# whi%h #he pipeline s"s#e! shall be opera#ed af#er a%%o!plish!en# of repair shall be de%ided b" #he engineer4in4%harge in i#s %lose o# repor#. For down hill se%#ions where #he @N red%#ion %ri#eria %old no# be !e# de #o s#a#i% head, #he engineer in %harge shall de%ide #he opera#ing pressre dring repair period.

In %ases in&ol&ing haardos !ajor leas, i# is re%o!!ended #o sh#down #he s"s#e! #o a&oid an" disas#ros %onseen%es dring #he repair wors, #o pre&en# an" grow#h in #he defe%# and #o pre&en# an" in%rease in #hrea# #o heal#h, safe#" or #he en&iron!en#. The de%ision for sh##ing down #he pipeline shall be #aen b" #he lo%al e!ergen%" %oordina#or who !s# %arefll" assess #he ris and %onseen%es in&ol&ed and #he loss in prod%#ion on a%%on# of a sh#down. In %ases in&ol&ing rp#re, #he pipeline s"s#e! will in%r a serios pressre drop in #he area of #he rp#re resl#ing in e8%essi&e loss of prod%#. In #hese si#a#ions, sh##ing down #he s"s#e! shold be %arried o# i!!edia#el" #o a&oid fr#her da!age, %on#rol #he ris and a&oid fr#her loss of prod%#. +epairs in #hese %ases nor!all" reire se%#ional repla%e!en#. If #he pipeline has been sh# down, repressrising for #es#ing af#er #he repair shold be done wi#h e8#re!e %a#ion. +epressrising shold be a%%o!plished slowl" and s#eadil" wi#ho# srges #o a&oid &ibra#ion of #he pipeline and fi##ings. (o personnel shold be allowed near #he repair n#il #he #es# has been %o!ple#ed. 6#her safe#" !easres as de#ailed in #he la#er par#s of #his do%!en# shall be adop#ed dring s%h repairs. "!,!+

Repair options

The preferred op#ion for a per!anen# repair is #o %o!ple#el" de%o!!ission #he pipeline, #hen %# o# and repla%e #he se%#ion of pipe %on#aining #he defe%#. Howe&er, #his op#ion is rarel" sed de #o #he #i!e %ons#rain#s. The preferred repair op#ions for 1e&el I e!ergen%" defe%#s %an be %lassified in#o: 4 emporary repair options : 4 These pro&ide #e!porar" relief #o #he defe%#s in #he pipeline s"s#e! b# ha&e #o be re!o&ed and repla%ed wi#h !ore per!anen# al#erna#i&es dring a planned sh#down or as soon as pra%#i%all" possible. S%h !e#hods are e!plo"ed #o red%e #he down #i!e of #he pipeline. ) #e!porar" repair is re%o!!ended onl" when #he loss of prod%#ion %ased b" #he #i!e needed #o e8e%#e a per!anen# repair is s%h #ha# i# js#ifies #he %os# in&ol&ed in bo#h #he #e!porar" repair and #he sbseen# planned per!anen# repair.

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Permanent repair options : 4 These pro&ide per!anen# relief #o #he defe%#s, enabling #he nor!al opera#ing pressre of #he s"s#e! #o be !ain#ained for #he re!aining design life. ) #e!porar" repair shold be repla%ed wi#h a per!anen# repair !e#hod wi#hin a period of 5 !on#hs 7as per SP 2/29. )n" fr#her e8#ension be"ond 5 !on#hs shall be sbje%# #o de!ons#ra#ion of perfor!an%e wi#h %onfiden%e and wri##en appro&al fro! %o!pe#en# a#hori#" 7CFDH pipelines9.

6n%e #he defe%# has been %a#egorised and lo%a#ed #he following repair op#ions are re%o!!ended depending pon #he #"pe of defe%#. 7+efer Table 29. a'le - #8 (election o% emergency repair options - &( pipelines ype o% de%ect

emporary repair option

Permanent repair option

Minor lea

Plid%o S!i#hECla!p, Plid%o S!i#hECla!pE Plid%o Spli# E Slee&e or si!ilar Plid%o eldECap Co!posi#e +epairOOOO Plid%o Spli# E Slee&e 7dl" welded9 or si!ilar Se%#ional repla%e!en#O Co!posi#e +epairOOOO Major lea Plid%o Spli# E Slee&e or si!ilar Plid%o Spli# E Slee&e 7dl" Co!posi#e +epairOOOO welded9 or si!ilar Se%#ional repla%e!en# Co!posi#e +epairOOOO 1eaing %ra%s Plid%o Spli#ESlee&eOO or si!ilar Se%#ional repla%e!en# +p#re (I1 Se%#ional repla%e!en# 1eaage #hrogh flange Plid%o Flange E +epair4+ing Se%#ional repla%e!en# Plid%o Flange4+epair E Spli#4 Slee&eOOO or si!ilar 1eaage #hrogh &al&e (il 'al&e repla%e!en#*repair as per !anfa%#rers re%o!!enda#ion 1eas in road %rossings See Se%#ion /.$.=

1eas in wadi %rossings ote: Plid%o brand repair !a#erials are indi%a#ed in #he #able for referen%e prpose onl". )ll Plid%o ei&alen# PD6 appro&ed brand repair !a#erials %an also be sed for e!ergen%" repair.

O

Se%#ional repla%e!en# %an also be a%hie&ed sing Plid%o weldEend %oplings. +efer #o de#ails gi&en below in Se%#ion /[email protected]. OO The leng#h of spli# slee&e shall be si#able for #he leng#h of %ra%. The welded spli# slee&e %anno# be %onsidered as a per!anen# repair de #o possible propaga#ion of %ra% dring #he ser&i%e. OOO (o# appli%able for &al&e flanges OOOO Co!posi#e repair %an be sed wi#h in #he li!i#s of alifi%a#ion in a%%ordan%e #o )SM0 Code. Please +efer Se%#ion /.=.

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"!,!,

Repair o% internal PE lined pipelines

The P0 lined pipelines !a" de&elop leas ei#her de #o 5 rd par#" in#erferen%e #o s%h an e8#en# #ha# #he liner is also da!aged or in4ser&i%e failre of liner and sbseen# %orrosion of #he pipeline. The leas in #hese lines shall be #e!poraril" repaired sing Plid%o spli# slee&es or !e%hani%al %la!p in an e!ergen%" si#a#ion. The #e!poraril" repaired se%#ions of #hese in#ernal P0 lined pipelines shall be repla%ed b" a per!anen# al#erna#i&e !e#hod wi#hin 5 !on#hs period as per se%#ion /.-.$.5 of SP42/2. The flange4#o4flange se%#ional repla%e!en# in%lding repla%e!en# of da!aged liner is #he onl" re%o!!ended per!anen# !e#hod of repair for P0 lined pipelines. "!,!.

Repair options %or leas at areas o% road and 5adi crossings

The repair op#ions spe%ified in Se%#ion /.$.- are appli%able for pipeline leas a# road %rossings sbje%# #o #he %ondi#ion #ha# open %# repair is feasible for s%h roads, e.g. #raffi% di&ersion dring #he repair wors shold no# lead #o an" !ajor disrp#ion. Te!porar" repair op#ions for leas in #hese areas are no# re%o!!ended de #o #he following asso%ia#ed disad&an#ages:4 2. The #e!porar" repair op#ions do no# enable #he %o!ple#e s#r%#ral in#egri#" of #he pipeline #o be res#ored. This is !ore %ri#i%al in areas of road %rossings. /. Te!porar" repairs are shor# #er! and will l#i!a#el" ha&e #o be repla%ed wi#h !ore per!anen# repairs whi%h will reire fr#her %losre of #he road for open %##ing. For roads where open %# is no# possible, e.g. on a !ajor road, #he repair wors shall be done sing boring*drilling #o a&oid disrp#ing #he #raffi% !o&e!en#. In s%h %ases a %asing pipe, along wi#h #he se%#ional spool pie%e, shall be laid sing #hrs#*ager boring. The se%#ional pipe shall be joined #o #he !ain line sing Pild%o eld E 0nd Coplings or welding as shown in Figre4/ .

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Figure "8 (ectional replacement o% de%ecti1e pipeline at road crossings

1eas in pipelines a# wadi %rossings are !ore %ri#i%al as #he leaing oil*gas is liel" #o spread #o a larger area #hrogh #he flood wa#er 7dring rain" seasons9. Dring non4rain" seasons, if #he wadi does no# %on#ain wa#er, nor!al !e#hods as des%ribed in Se%#ion /.$.- %an be sed #o %arr" o# repairs. For wadi #"pes  and C, #he %on%re#e %oa#ing o&er #he pipeline shall be re!o&ed and #he ne%essar" repair %arried o#. )f#er %o!ple#ion of #he repair wors, #he %o!ple#e se%#ional spool along wi#h #he asso%ia#ed slee&es shall be re%oa#ed wi#h %on%re#e in4si#. The %on%re#e %oa#ing shall be done in s%h a wa" #ha# #he slee&es do no# ge# da!aged de #o presen%e of gabions o&er #he!. In %ase if #he pipeline lea o%%rs in a li&e wadi 7for e8a!ple dring rain" season9, arrange!en#s shold be !ade #o di&er# #he wadi s#rea! and e&a%a#ion of re!aining wa#er in wadi prior #o s#ar#ing #he repair a%#i&i#". Following di&ersion, e&a%a#ion of wadi, #he repair shall be si!ilar #o #ha# of dr" wadi region e8plained abo&e. Con#inos e&a%a#ion of wa#er sing &a%! #r%s !igh# be reired dring repair a%#i&i#", in %ase if %on#inos ooing of wa#er is no#i%ed. emporary repair options are not recommended %or leas in 5adi crossings .

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"!,!7

Repair acti1ity procedures

The a%#i&i#ies de#ailed below shall for! par# of #he o&erall repair wors and shall be applied in %onjn%#ion wi#h #he pro%edre for %arr"ing o# #he spe%ifi% repairs de#ailed in Se%#ion /.$.@. "!,!7!# Procedure %or cleaning o% the de%ect area

The srfa%e of #he defe%#i&e area of #he pipeline shall be %leaned #o enable repair, welding, UT inspe%#ion e#%. The %leaning shall a%hie&e re!o&al of s%ale, rs#, %oa#ings and &ege#a#ion b" #he se of wire brshes, %hipping #ools or gri# blas#ing. The gri# blas#ing shall be per!i##ed onl" when re!aining wall #hi%ness of #he pipe is !ore #han / !!. +eferen%e shall be !ade #o SP42/-= for #his prpose. "!,!7!" &on%irmation o% suita'ility o% li1e pipeline %or permanent repair 5elding

The following %he%s shall be done #o %onfir! #he si#abili#" of #he li&e pipeline for #he prpose of welding:4 2. efore asse!bling #he repair fi##ings #o line pipe an l#rasoni% inspe%#ion shall be %ond%#ed #o %o&er a one e8#ending a !ini!! of 2!! on #he ei#her side of ea%h weld area #o %onfir! a !ini!! wall #hi%ness 7refer poin# no. / below9 and #o %he% for #he la!ina#ions. 1a!inar defe%#s e8%eeding =!! in an" dire%#ion and an" la!ina#ion no# parallel #o #he pipe srfa%e shall be na%%ep#able. Ul#rasoni% #es# #e%hnies shall be in a%%ordan%e wi#h )SM0 ' ar#i%le $ as spple!en#ed b" SP422>=. 1e&els of indi%a#ions reiring in&es#iga#ions are as follows:4 4 all refle%#ors gi&ing an indi%a#ion in e8%ess of /N D)C shall be in&es#iga#ed and e&ala#ed in a%%ordan%e wi#h #he a%%ep#an%e s#andard 7D)C  Dis#an%e )!pli#de Corre%#ion9. 4 all refle%#ors gi&ing an indi%a#ion in e8%ess of $N D)C shall be e&ala#ed and repor#ed. 4 all refle%#ors e8%eeding 2N D)C shall be %ase for reje%#ion. /. efore %arr"ing o# an" ind of weld repair on a li&e pipeline, i# shall be ensred #ha# dring #he welding opera#ion #he !a#erial in #he region of #he weld pool has sffi%ien# s#reng#h #o %on#ain safel" #he in#ernal pressre and a&oid a blow o#. The ris of blow o# is dependen# pon a %o!ple8 in#era%#ion of welding %ondi#ions, pipe !a#erial, pipe #hi%ness, pipe #e!pera#re and hoop s#ress. For !a#erial of "ield s#reng#h no# grea#er #han --@ MPa 73rade K4=$ as per )PI $19, opera#ing a# #e!pera#res of no# grea#er #han 5$ deg.C wi#h a hoop s#ress no# grea#er #han >/N of #he spe%ified !ini!! "ield s#ress, blow o# %an be pre&en#ed dring welding pro&ided #he !ini!! #hi%ness is no# less #han -.@!! 7referen%e shall be !ade #o )ppendi84/ and 5 of D0P 52.5@.=.29. The a%#al !ini!! wall #hi%ness shall be de#er!ined b" l#rasoni% #es#ing as spe%ified in poin# no. 2 abo&e. For o#her !a#erials or %ondi#ions, a !ini!! pipe #hi%ness shall be de#er!ined, based on ei#her spe%ifi% pre&ios e8perien%e and*or da#a fro! #rials.

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5. elding on li&e pipelines is prohibi#ed for #he following %ases:4 4 Mi8#res of gases or &apors wi#hin #heir fla!!able range or whi%h !a" be%o!e fla!!able as a resl# of hea# inp# in welding opera#ions. 4 68"gen enri%hed a#!ospheres in #he presen%e of h"dro%arbons whi%h !a" be presen# ei#her in #he a#!osphere or in #he deposi#s on #he inside srfa%e of #he pipe. 4 (o welding shall be perfor!ed on lined, %lad or in#ernall" %oa#ed pipes -. )##en#ion shall be paid #o %on#rolling #he pipe wall #e!pera#re dring #he welding #o a&oid de#eriora#ion of #he !i%ros#r%#re of #he pipe !a#erial de #o e8%essi&e hea# inp# resl#ing in e8%essi&e !e#al #e!pera#re. +eferen%e shall be !ade #o Clase 5.5./ of D0P 52.5@.=.2. $. The pressre in #he pipeline s"s#e! shall be &erified #o %onfir! #ha# i# does no# e8%eed #he !a8i!! allowable opera#ing pressre dring welding opera#ions. This shall be based on #he dera#ed pressre %ondi#ions ne%essar" whils# #he !a#erial is a# ele&a#ed #e!pera#re whils# welding. I# is also essen#ial #o pre&en# an" propaga#ion of an" ns#able %ra%s. The !a8i!! allowable opera#ing pressre dring welding shall be de#er!ined as per Clase 5.5.5 of D0P 52.5@.=.2. =. elding on a li&e pipeline nder no4flow or in#er!i##en# flow %ondi#ions shall no# be a##e!p#ed nless i# has been %onfir!ed #ha# no e8plosi&e or fla!!able !i8#re will de&elop dring welding opera#ions. In #his respe%# i# shall be %onfir!ed #ha# no ingress of o8"gen in #he line is possible. In %ases where #his reire!en# %anno# be !e#, ni#rogen prging 7de4%o!!issioning9 shall be done sing a !ini!! prge &elo%i#" of .-!*s. >. ) high liid flow sall" %ases rapid %ooling of #he weld area whi%h resl#s in hard !a#erial ones, whi%h are ss%ep#ible #o %ra%ing. Under #hese %ir%!s#an%es #he !ini!! in#er pass #e!pera#res !a" no# be a##ainable, resl#ing in ndesired !a#erial proper#ies. ) sgges#ed !a8i!! &elo%i#" for liid flow dring welding is 2.>$!*s. There is no res#ri%#ion on !a8i!! &elo%i#" for gas lines, sbje%# #o #he a##ain!en# of a%%ep#able in#er pass #e!pera#res. (o#e:4 For wall #hi%ness be#ween =.-!! and 2/.>!!, flow also in%reases #he weld %ooling ra#e and hen%e #he ris of %ra%ing. Mini!iing #he flow ra#e red%es #he ris of %ra%ing and of brn #hrogh. For !e#al #hi%ness grea#er #han 2/.>!!, #he effe%# of flow on bo#h weld %ooling ra#es and brn #hrogh are less signifi%an#.

"!,!7!3 Procedure %or 5eldinginspection %or emergency de%ect recti%ication

)ll e!ergen%" repair welding and inspe%#ion of welds on pressrised pipeline s"s#e!s, in%lding #he welding of slee&es, %la!ps shall be done as per SP422=> and D0P 52.5@.=.2 and sele%#ed appro&ed welding pro%edre. 6#her pre%a#ions needed dring welding in%lde:4 2. Carefl %on#rol of #he sie and shape of #he %ir%!feren#ial fille# welds. The sie of #he fille# weld shold be a# leas# 2.- #i!es #he wall #hi%ness of #he pipe a# #he weld area.

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/. Main#enan%e of a %on%a&e fa%ed fille# weld wi#h s#rea!lined blending in#o bo#h !e!bers. The s!oo#her and !ore s#rea!lined #he weld profile, #he grea#er #he resis#an%e #o fa#ige failre. 5. )&oiding no#%hes and nder%#s dring welding. -. Use of welding %ons!ables as indi%a#ed in appro&ed PS. $. Use of #e!pera#re %ra"ons or probe #her!o!e#ers, #o !oni#or hea# genera#ed dring welding or prehea#ing opera#ions, par#i%larl" near #he areas of #he sof# seals. If #he hea# genera#ed approa%hes #he #e!pera#re li!i# of #he seal !a#erial, whi%h is indi%a#ed on #he label, welding shold be dis%on#ined #o allow #he affe%#ed area #o %ool. =. 0nsring #ha# welding does no# o&erhea# #he seals. The welding shold be seen%ed so #ha# #he hea# is no# %on%en#ra#ed in one area. I# !a" be ne%essar" #o re4#ore #he s#d bol#s and n#s periodi%all" dring field welding be%ase weld %on#ra%#ion %ases #he! #o loosen. >. )&oiding brn #hrogh dring #he roo# rn. Firs# weld pass for pipelines wi#h a wall #hi%ness less #han =.-!! #hi% shold be a%hie&ed b" sing /.-!! or s!aller dia!e#er welding ele%#rode #o li!i# hea# inp#. @. For pipelines wi#h wall #hi%ness !ore #han 2/.>!!, where brn #hrogh is no# a pri!ar" %on%ern, %are shold be #aen b" a&oiding #he se of e8%essi&e welding %rren#. PD6 pre4alified welding pro%edres and welders 7P+42/>=, SP422>>9 shall be sed for welding on li&e pipelines #o a&oid dela" de #o pre4alifi%a#ion. Howe&er, in so!e s%enarios, in order #o %arr" o# weld repairs wi#ho# #he dela" #he following de&ia#ions are per!i##ed fro! SP422>>:4 2. If no re%ords are a&ailable, #he defe%#i&e line pipe shall be ass!ed #o be )PI $1 3rade , whi%h shall be sed for #he new repla%e!en# pipe if no !a#erial spe%ifi%a#ion re%ords are a&ailable. /. The pipeline engineer shall de%ide #he PS and PA+ #o be followed in %onsl#a#ion wi#h repair %on#ra%#or and welding engineer. elding %ondi#ions and rele&an# para!e#ers shall be no#ed and #es# pie%es shall be prepared on%e #he job is %o!ple#e. 5. 2N radiograph", UT and MPI shall be done on all e!ergen%" repair welds. -. )ll re%ords and #es# pie%e resl#s shall be re&iewed af#er #he repair, #o de#er!ine if #he !e#hod !ee#s #he reire!en#s of #he appli%a#ion. If dee!ed ne%essar", %##ing o# and repla%e!en# of na%%ep#able weld repairs shall be planned and e8e%#ed as per SP422>>. "!,!7!+ Procedure %or recoatingpainting o% the de%ect area

)f#er %o!ple#ion of #he repairs, #he defe%#i&e area shall be re%oa#ed * repain#ed as per SP42/-=.

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"!,!7!, Procedure %or sand padding and 'ac%illing o% the trench

2. S%reened sof# sand, free of ro% and foreign !a##er, shall be sed for sand padding. The !ini!! dep#h of padding below #he pipe shall be 5 !!. /. Hand sho&el and wooden hand4ra!!ing de&i%e shall be sed for #he pla%e!en# of sand nder #he pipe. 5. Sand shall be lowered in#o #he #ren%h wi#h a !e%hani%al sho&el and hand spread nifor!l" arond #he pipe. The dep#h of #he sand padding o&er #he #op of #he pipe shall be a# leas# 5 !!. Sand on #op of #he pipe shall be shaped #o #he na#ral angle of repose. -. S%reened e8%a&a#ed !a#erial fro! #he lo%a#ion shall be sed 7af#er #he re!o&al of an" ro% and bolders9 on #op of #he sand. In order no# #o da!age #he sand padding, #he ini#ial la"ers of final fill shall be %arefll" lowered in#o #he #ren%h fro! ea%h side b" !e%hani%al sho&el ensring #ha# #he ba%fill !a#erial is deposi#ed %arefll" #o a&oid dis#rbing #he sand padding. $. The !e%hani%al e8%a&a#or shall !ain#ain #he following minimum safe dis#an%es 7whi%h shall be %learl" !ared b" a line of bn#ing9 fro! #he edge of #he #ren%h: 4

+o%: dis#an%e fro! edge of #ren%h shall be 2. !e#re

4

Co!pa%#ed grond: dis#an%e fro! ba##ered edge of #ren%h shall be 2.$ !e#re

4

Sof# sand wi#h #ren%h sides ba##ered #o a !ini!! slope of /:2: dis#an%e shall be / !e#res.

=. )f#er %o!ple#ion of #he ini#ial ba%fill la"er, #he re!aining ba%fill shall be finished #o a le&el sligh#l" abo&e #he na#ral grade and shall be #horoghl" %o!pa%#ed b" !eans of a %o!pa%#ing &ibra#or. >. indrow shall be reins#a#ed, in%lding #he se%#ion sed for #e!porar" %rossings. here #he e8%a&a#ion %rosses wadis or di#%hes wi#h lined or o#herwise i!pro&ed srfa%es, #hese shall be reins#a#ed #o #heir original %on#or and %ondi#ion. +eferen%e shold also be !ade #o 0+D 5@422 and SP42/@ for de#ails on reins#a#e!en#. "!,!7!. Procedure %or de-commissioning isolation and draining1enting o% the pipeline %or de%ect repair :enting2raining o% the pipeline

Co!ple#e draining and &en#ing of #he pipeline is essen#ial in %ases of se%#ional repla%e!en# of a defe%#i&e por#ion of #he pipeline. For pipelines wi#h blo% &al&e s#a#ions draining %an be li!i#ed #o #he se%#ion be#ween #he blo% &al&es. here #here are no blo% &al&es, #he en#ire leng#h of #he pipeline shall be drained. For pipelines 5ithout 'loc 1al1e stations8 For s%h pipelines  !os# of #he flid is drained fro! #he pipeline dring #he depressrisa#ion pro%ess b" sh##ing down #he flow and opening #he &al&es a# #he re%ei&ing end s#a#ion. The re!aining flid %an be drained b" opening #he drain and &en# &al&es a# ea%h end. The drained flid shall be disposed of safel" #o pre&en# an" haard #o life or #he en&iron!en#. For an" residal

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flid #rapped in #he pipeline s%h as in areas of lower ele&a#ions, #he engineer4in4 %harge shall s#d" #he need for fr#her draining*&en#ing. This %an be a%%o!plished as follows:4 2. For liid lines, #he rp#red or leaing por#ion of #he pipeline shall be %o&ered #e!poraril" ei#her b" a slee&e or %o!posi#e reinfor%ing slee&e and pigging wi#h sof# pigs %arried o#, dri&en wi#h %o!pressed ni#rogen or wa#er, #o displa%e #he re!aining liid. )l#erna#i&el", #he #rapped liid %an be re!o&ed sing s%#ion p!ps. The s%#ion hose shall be inser#ed in#o #he pipeline ei#her #hrogh drain &al&es or #hrogh #he leaing por#ion and #he liid #ransferred #o a #aner. The se of s%#ion p!ps is li!i#ed depending pon #he %apa%i#" of #he p!p a&ailable and #he leng#h*#errain of #he pipeline and is onl" re%o!!ended for s!all leng#hs. )no#her !e#hod of draining #he liid line is b" flshing wi#h wa#er 7for general de#ails refer #o P+4 2>-9 /. For gas pipelines, an" re!aining #rapped gas %an be &en#ed b" prging wi#h iner# gas fro! one or bo#h ends of #he pipeline. 'en#ing of an" haardos gases shall onl" be allowed onl" #hrogh #he designa#ed &en#s and shall be si#abl" flared in a%%ordan%e wi#h s#andard safe#" pro%edres. For pipelines 5ith 'loc 1al1e stations8 For #hese pipelines onl" #he por#ion be#ween #he blo% &al&es needs #o be drained and &en#ed. This shall be done as follows:4

2. For liid lines, #he #rapped liid shall be drained o# #hrogh #he drain &al&es a# #he blo% &al&e s#a#ions. )n" re!aining liid %an be re!o&ed sing s%#ion p!ps. The s%#ion hose shall be %onne%#ed #o #he drain lines a# #he blo% &al&e s#a#ions. The %apa%i#" of #he s%#ion p!p shold be sffi%ien# #o drain appro8i!a#el" 5/ ! of pipeline  being #he !a8i!! leng#h be#ween #wo blo% &al&e s#a#ions. Flshing wi#h wa#er %an also be nder#aen #o re!o&e #he h"dro%arbon liid as spe%ified abo&e. /. For #he handling non4sor gases, %on#rolled &en#ing %an be done #o a#!osphere #hrogh #he &en#s pro&ided a# #he ' s#a#ions. )n" re!aining #rapped gas %an be &en#ed o# b" iner# gas prging fro! one or bo#h s#a#ions. 'en#ing of an" haardos gases shall onl" be allowed #hrogh designa#ed &en#s and shall be flared in a%%ordan%e wi#h s#andard safe#" pro%edres ei#her #hrogh #e!porar" !obile flare or as dire%#ed b" #he PD6 Safe#" 6ffi%er. (o#e: I# is also feasible #o drain and &en# #he pipeline b" ins#alling a ho# #ap #hrogh whi%h #he pipeline %on#en#s %an be drained, &en#ed or flared.

Isolation o% the pipeline

If dee!ed ne%essar", e&en af#er isola#ing and draining #he defe%#i&e se%#ion a# #he blo% &al&e s#a#ions, fr#her lo%alised isola#ion b" se of spe%ifi% pipeline isola#ion plgs s%h as P0 3rip 1o% Pipe Plgs, air plgs, !d*freee plgs or Hi fri%#ion pigs is re%o!!ended.

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For s!aller leng#hs where no blo% &al&e s#a#ions e8is#, #he pipeline shall be firs# de%o!!issioned and #hen #he defe%#i&e seg!en# is isola#ed sing air*!e%hani%al plgs*s#opples. Isola#ion of a defe%#i&e por#ion of a pipeline wi#ho# blo% &al&es is essen#ial #o pre&en# #he possibili#" of #rapped flid draining fro! o#her areas whils# repairs are in progress and also #o pre&en# #ransfer of welding f!es #o o#her seg!en#s of #he pipeline. The reire!en# of isola#ion for #hese pipelines shall be &erified b" 6pera#ions personnel and done in a%%ordan%e wi#h P+42>=. ote8- Ho# #apping #he line #o pro&ide a !eans of inser#ing #he plgs*s#opples #o isola#e #he defe%#i&e line se%#ion !a" affe%# a safe repair. Considera#ions shold be gi&en #o #he fa%#ors s%h as prod%# %hara%#eris#i%s, pipe %ondi#ion, #e!pera#res and reired differen#ial pressres #o ensre #ha# #he proper #"pe of plgs are sed and #ha# #heir holding %apa%i#" %an adea#el" resis# #he pressre #o be en%on#ered. 'arios #"pes of plgs #ha# %an be possibl" sed for isola#ion in%lde !d plgs, freee plgs and !e%hani%al*air plgs.

"!,!7!7 Emergency repair close out report

The prpose of #he %lose o# repor# is #o %ap#re all #he rele&an# a%#ions #aen #o iden#if" #he %ase of da!age, #he repair !e#hods sed and #o ser&e as feedba% #o %orre%# an" defi%ien%" and !ae f#re i!pro&e!en#s. The re%o!!ended #able of %on#en#s shall be as follows:4 2. Pipeline ser&i%e and de#ails 7flid #ranspor#ed, flow, opera#ing pressre, dia!e#er, wall #hi%ness, "ear bil# e#%.9 /. T"pe of defe%#, %ase and assess!en# of da!age 7safe#", en&iron!en# and loss of prod%#ion9 5. +epair !e#hod 7ad&an#ages and disad&an#ages9 -. )s bil# drawings re&isions. $. Con%lsions and la#eral re%o!!enda#ions, in%lding #he reire!en# #o dera#e #he pipeline af#er %o!ple#ion of repair if ne%essar". =. Feedba% #o pipeline e!ergen%" repair !anal. >. )n" o#her addi#ional %he%s or #es#s fond ne%essar" #o &erif" #he in#egri#" of #he pipeline. This repor# shall be in addi#ion #o an" o#her reire!en#s spe%ified in #he PD6 e!ergen%" pro%edres and HS0 <>42*P+42=.

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"!,!;

Emergency repair methods < &( pipelines

The following se%#ions %o&er #he &arios e!ergen%" repair !e#hods for CS pipelines. For ease of referen%e #he Plid%o S!i#h brand of repair !a#erials ha&e been o#ed in #his !anal. Howe&er, ei&alen# prod%#s a&ailable fro! o#her !anfa%#rers %an also be sed pro&ided #he" are an appro&ed &endor lis#ed in #he )'M0. "!,!;!# Plidco (mith = &lamp = >eld = &ap

Plid%o S!i#h E Cla!p is a #e!porar" repair sol#ion for !inor leas. The poin# of #he %one is %en#red e8a%#l" on #he hole, and for%e applied sing #he for%e s%rew #o sh# off #he lea. The draw bol#s a# #he bo##o! of #he fi##ing are sed #o hold #he %la!p in pla%e. The se of a welded Plid%o eld E Cap when sed in %onjn%#ion wi#h #he Plid%o S!i#h E Cla!p !aes #he repair per!anen#. +eferen%e shall be !ade #o )ppendi8 5 and - for de#ails.

Applications : 4

2. Plid%o S!i#h E Cla!ps are a&ailable in s#andard sies fro! 2.$J #o -@J /. The s#andard pressre ra#ing for Plid%o S!i#h E Cla!p and Plid%o eld E Cap is / psig 7Q25@ barg9. 5. Plid%o eld E Cap are a&ailable in s#andard sies fro! -J #o -@J -. elding of #he eld E Cap is reired for per!anen# repair $. Can #olera#e onl" !inor srfa%e irreglari#ies p #o E 2*5/J Procedure %or installation on li1e pipelines : 4

For #e!porar" repair: 2. /. 5. -. $.

'erif" #he pipeline as per Se%#ion /.$.5 0nsre all safe#" pre%a#ions as per Se%#ion $. Clean #he defe%# area as per Se%#ion /.$.>.2 Ins#all Plid%o S!i#h E Cla!p as per !anfa%#rers pro%edre Prepare de#ailed repor# as per Se%#ion /.$.>.>

For per!anen# repair %on#ine as follows: =. 'erif" and %onfir! #he si#abili#" of #he pipeline for welding as per Se%#ion /.$.>./ >. Ins#all Plid%o eld E Cap as per !anfa%#rers pro%edre @. eld #he Cap and inspe%# #he weld as per Se%#ion /.$.>.5. <. +e%oa#*pain# #he s"s#e! as per Se%#ion /.$.>.2. Sand padding and ba%filling as per Se%#ion /.$.>.$ 22. Prepare de#ailed repor# as per Se%#ion /.$.>.> "!,!;!" Plidco (plit = (lee1e

These %an be sed for #e!porar" and per!anen# repairs. The seal welded Plid%o Spli# E Slee&e is %onsidered as per!anen# repair sol#ion.

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ote: I# is preferable onl" #o se #his s"s#e! as a #e!porar" repair !e#hod be%ase of #he high %os#. I#

is re%o!!ended no# #o weld #he %la!p #o #he pipeline and #o repla%e i# as soon as pra%#i%able wi#h a per!anen# repair s%h as se%#ional repla%e!en# of #he defe%#i&e se%#ion.

The sie of #he slee&e #o be sed shall be sele%#ed based on #he dia!e#er of #he line pipe and #he leng#h of #he defe%#. The leng#h shall be s%h #ha# #he slee&e e8#ends a !ini!! of .2! be"ond #he defe%#. )dja%en# slee&es shall no# be pla%ed %loser #han one4half pipe dia!e#er fro! ea%h o#her. 6&er slee&es %an be sed #o %o&er defe%#s in areaRs adja%en# #o or be#ween #he slee&es. These shall be welded #o #he original slee&e sing alified welding pro%edres. The !ini!! reired wall #hi%ness and s#eel grade of #he slee&e shall be based on #he wall #hi%ness and design fa%#or applied #o #he pipeline. The slee&e #hi%ness shall be adea#el" in%reased #o %o!pensa#e for #he groo&e of #he ba%ing s#rips or sea!s of #he pipeline. The leng#h of slee&e shall no# be less #han .2!. +eferen%e shall be !ade #o )ppendi84/ for de#ails. Applications8

2. S#andard Plid%o spli# E slee&es are a&ailable for a woring pressre p #o 2 psig 7Q =< barg9. /. )&ailable in )PI pipe sies fro! 2.$J #o -@J 5. Higher woring pressre or longer leng#h slee&es %an be !ade #o order -. The slee&e shall no# be sed #o %ople pipes wi#ho# sffi%ien# end res#rain# be%ase i# does no# pro&ide an" longi#dinal res#rain# in an nwelded %ondi#ion. $. S#andard bod" !a#erials are ) 2= sea!less pipe, ) /2= CC %as# s#eel, ) $2= or ei&alen#. 6#her !a#erials are a&ailable on rees#. =. The seal %an #olera#e onl" !inor srfa%e irreglari#ies p #o E2*5/J >. The seals and girder rings on #he slee&e %an be da!aged b" %areless handling wi#h lif#ing de&i%es s%h as %hains, %ables or lif# #r% fors whi%h %an resl# in #he seals being dislo%a#ed fro! #he groo&e. @. The slee&es %an be field #es#ed p #o 2.$ #i!es #he design woring pressre. <. The slee&e shold be s#ored in a dr" en&iron!en# #o pre&en# #he npain#ed srfa%es fro! rs#ing. S#orage #e!pera#res shold no# e8%eed 2/ deg.F 7-< deg C9. The" shall be %o&ered wi#h dar pol"e#h"lene #o pro#e%# #he !a#erial fro! dire%# snligh#. I!properl" s#ored ni#s %an %ase #he seal !a#erial #o be%o!e bri##le and %ra%ed and #hs lose #he sealing proper#ies. Procedure %or installation on li1e line : 4

For #e!porar" repair: 2. /. 5. -. $.

'erif" #he pipeline as per Se%#ion /.$.5 0nsre all safe#" pre%a#ions as per Se%#ion $. Clean #he defe%# area as per Se%#ion /.$.>.2 Ins#all Plid%o Spli# E Slee&e as per !anfa%#rers pro%edre Prepare de#ailed repor# as per Se%#ion /.$.>.>

For per!anen# repair %on#ine as follows: =. 'erif" and %onfir! #he si#abili#" of #he pipeline for welding as per Se%#ion /.$.>./

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>. Seal weld #he ends, sides and bo##o! of n#s as per Se%#ion /.$.>.5 @. Inspe%# #he weld as per Se%#ion /.$.>.5. <. +e%oa#*pain# #he s"s#e! as per Se%#ion /.$.>.2. Sand padding and ba%filling as per Se%#ion /.$.>.$ 22. Prepare de#ailed repor# as per Se%#ion /.$.>.> "!,!;!3 (pool Piece 5ith Plidco >eld = End couplings

The ins#alla#ion of a spool pie%e sing Plid%o eld E 0nd %oplings reires sh#down and depressrisa#ion of #he pipeline. The #hi%ness and !a#erial grade of #he spool pie%e shall be #he sa!e as #ha# of #he line pipe and shall be de#er!ined sing #he ea#ions and safe#" fa%#ors as gi&en in SP42/22. The !a#erial shall %onfor! #o )PI $1 spe%ifi%a#ion. elding in %ases of neal wall #hi%nesses shall be done as per )SM0  52.- or 52.@ as appropria#e. +eferen%e shall be !ade #o )ppendi8 $ for de#ails. Plid%o weldEend %oplings %anno# ss#ain e8#ernal for%es s%h as #e!pera#re e8pansion and %on#ra%#ion, grond !o&e!en# e#%. Application: 4

2. This !e#hod of repair reires sh#down and depressrisa#ion of #he pipeline #o re!o&e #he defe%#i&e se%#ion wi#h %o!ple#e draining and isola#ion of #he prod%# fro! #he affe%#ed area. /. I# is a #i!e %ons!ing per!anen# pro%ess as %o!pared #o o#her !e#hods of repair as i# reires dis!an#ling and repla%e!en# of #he affe%#ed pie%e of #he line pipe. 5. Te!porar" repair for a period of no# !ore #han = !on#hs %an be a%hie&ed b" %la!ping and #igh#ening #he #hrs# s%rews wi#ho# welding #he %opling. -. Per!anen# repair is a%hie&ed b" welding #he %opling #o #he line pipe. This !a" reire addi#ional #i!e be%ase liid flow #hrogh #he pipeline will ha&e #o be re4 %o!!en%ed and safe %ondi#ions rea%hed #o per!i# welding. elding on a line nder no4flow or in#er!i##en# flow %ondi#ions shall no# be a##e!p#ed nless i# %an be posi#i&el" es#ablished #ha# no e8plosi&e or fla!!able !i8#re will de&elop dring #he welding opera#ion. $. here signifi%an# longi#dinal loads are presen# and i# is no# feasible #o weld #he %opling, addi#ional rows of %la!ping s%rews %an be pro&ided or #he Pild%o %la!p E +ing !a" be sed. =. S#andard sies are a&ailable fro! 2.$J #o -@J >. S#andard !a#erials are )42=, )42$, )4/@$, )4$2=. @. Coplings are si#able for an%hored pipeline join#s onl". <. The !odel of #he %opling !s# be sele%#ed #o #he sa!e pressre* #e!pera#re ra#ing as #he line pipe. 2. Coplings are si#able for #he !ini!! pipe wall #hi%nesses as spe%ified in Table /. Pipelines wi#h wall #hi%nesses less #han #hose spe%ified in #he #able will no# wi#hs#and #he for%e of #he %la!p s%rews and hen%e #his appli%a#ion will be nsi#able. )s a sol#ion, Plid%o Cla!p E +ing s hold be %onsidered. 22. The se of #hese %opling on elbows and bends is li!i#ed de #o #he possibili#" of pllo#s %ased b" e8#ernal and in#ernal for%es. 2/. For badl" !isaligned or o# of rond pipe, i# is helpfl #o grind a pilo# be&el wi#h a generos #aper on #he pipe. This shold eli!ina#e #he ris of da!age #o #he seals

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while ins#alling #he %opling o&er #he end of #he pipe. +efer #o )ppendi8 $ for de#ails. ominal pipe si?e )inch*

Min! 5all thicness ) mm*

-

=.

=

>.2

@

@./

2

<.5

2/

2.-

2-

22.2

2= ? larger

2/.>

a'le ": Mini!! pipe wall #hi%nesses for Plid%o eld E 0nd %oplings

Procedure %or installation : 4

For #e!porar" repair: 2. Sh#down #he pipeline s"s#e! /. 0nsre all safe#" pre%a#ions are in pla%e as per Se%#ion $. 5. Depressrise #he %o!ple#e pipeline s"s#e! #o a#!ospheri% pressre b" opening #he ne%essar" drain*&en# &al&es as per Se%#ion /.$.>.= -. 0nsre #ha# #he isola#ed se%#ion has been adea#el" drained and is free fro! an" #rapped flid as per Se%#ion /.$.>.= $. If reired, isola#e #he defe%#i&e se%#ion as per Se%#ion /.$.>.= =. Sele%# #he spool pie%e of wall #hi%ness and grade as spe%ified abo&e. >. H"dro4#es# #he spool pie%e separa#el" as per SP42/22 @. Clean #he defe%# area as per Se%#ion /.$.>.2 <. Cold %# #he defe%#i&e por#ion of #he pipeline as per general gidelines gi&en in P+422-= 2. Ins#all Plid%o eld E 0nd %opling as per !anfa%#rers re%o!!enda#ion 22. Slide #he spool pie%e in #he %opling and #igh#en #he s%rews 2/. Prepare de#ailed repor# as per Se%#ion /.$.>.> For per!anen# repair, %on#ine as follows: 25. +e4%o!!ission #he s"s#e!, &erif" and %onfir! #he si#abili#" of #he pipeline for welding as per Se%#ion /.$.>./ 2-. Seal weld #he %opling as per Se%#ion /.$.>.5 2$. Inspe%# #he weld as per Se%#ion /.$.>.5 2=. +e%oa#*pain# #he s"s#e! as per Se%#ion /.$.>.2>. Sand padding and ba%filling as per Se%#ion /.$.>.$ 2@. Prepare de#ailed repor# as per Se%#ion /.$.>.>

ote : Pild%o eld E 0nd %oplings onl" #aes in#o a%%on# #he for%es on a join# de #o #he in#ernal pressre and does no# %onsider addi#ional e8#ernal for%es lie #her!al e8pansion and %on#ra%#ion, nderwa#er %rren#s, grond !o&e!en# or %o!bina#ion #hereof. If an" of #hese addi#ional for%es are e8pe%#ed #o o%%r, i# is re%o!!ended #ha# ei#her #he %opling be welded or se of Plid%o Cla!p E +ing along wi#h Plid%o eld E 0nd is re%o!!ended

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"!,!;!+ Plidco Flange = Repair-Ring

These are sefl for s#opping leas #hrogh #he gase#s of #he flanges. Plid%o Flange E +epair +ings are ins#alled b" pla%ing #he #wo hal&es arond #he flange and sing s#ds and n#s #o draw #he! #oge#her. ol# leaage is s#opped b" inje%#ing a re%o!!ended sealan# wi#h a pressre gn. +eferen%e shall be !ade #o )ppendi84= for de#ails. Application4imitations: 4

2. /. 5. -. $. =.

Can be sed #o s#op #he leaage #hrogh #he gase# por#ion of #he flanges onl". )&ailable for s#andard flange sies J #o 2/J 2$ lb #o = lb Sealan# inje%#ion reired #o s#op leaage #hrogh #he bol#s. Pressre gn reired #o inje%# sealan# Canno# be sed #o %ople #he flanges and pro&ides no longi#dinal res#rain#. I# is onl" a #e!porar" !e#hod of repair.

Procedure: 4

2. /. 5. -. $. =. >. @. <. "!,!;!,

'erif" #he pipeline as per Se%#ion /.$.5 0nsre all safe#" pre%a#ions are in pla%e as per Se%#ion $. Clean #he defe%# area of #he leaing flange as per Se%#ion /.$.>.2 Ins#all Plid%o Flange E +epair +ing as per !anfa%#rers pro%edre Seal #he bol#s sing sealan# and pressre gn as per !anfa%#rers pro%edre Inspe%# #he s"s#e! &isall" +e%oa#*repain# #he area as per Se%#ion /.$.>.Pla%e sand padding and ba%fill as per Se%#ion /.$.>.$ Prepare de#ailed repor# as per Se%#ion /.$.>.> Plidco Flange-Repair = (plit-(lee1e

The Plid%o Flange +epair ESpli# Slee&e fll" en%apsla#es #he !a#ed flanges and seals #o #he pipe be"ond #he weld of #he flanges. The" are sefl for s#opping leas #hrogh an" por#ion of #he flanges. +eferen%e shall be !ade #o )ppendi8 > for de#ails. 4imitations: 4

2. I# is a #e!porar" !e#hod of repair. /. High %os#. Procedure: 4

2. /. 5. -. $. =. >. @.

'erif" #he pipeline as per Se%#ion /.$.5 0nsre all safe#" pre%a#ions are in pla%e as per Se%#ion $. Clean #he defe%# area of #he leaing flange as per Se%#ion /.$.>.2 Ins#all Plid%o Flange +epair E Spli# Slee&e as per !anfa%#rers pro%edre Inspe%# #he s"s#e! &isall" +e%oa#*repain# #he area as per Se%#ion /.$.>.Pla%e sand padding and ba%fill as per Se%#ion /.$.>.$ Prepare de#ailed repor# as per Se%#ion /.$.>.>

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"!,!;!. @ot apping

This !e#hod is sed #o re%#if" a defe%# in a pipeline in ser&i%e. ) ho# #ap fi##ing is ins#alled arond #he defe%#i&e seg!en# and #he defe%#i&e seg!en# is re!o&ed in #he sa!e wa" as re!o&ing a seg!en# fro! #he pipe wall for bran%h %onne%#ions sing #he ho# #ap !e#hod. I# %an also be sed for ins#alling a #e!porar" b"pass #o #he !ain line #o %arr" o# a se%#ional repla%e!en#. )ll reire!en#s as spe%ified in D0P 52.5@.=.2 shall appl" whils# %arr"ing o# #he ho# #apping. "!,!;!7 (ectional Replacement )5ithout couplings*

Se%#ional repla%e!en# is a per!anen# !e#hod of repair. Howe&er, #his reires depressrisa#ion of #he pipeline and sh#down of #he s"s#e!. The repla%e!en# pipe se%#ion shall ha&e s#reng#h of a# leas# #ha# of #he pipeline and shall !ee# #he reire!en#s of )PI $1 . The se%#ion shall be designed as per SP42/22 wi#h sa!e fa%#or of safe#" as sed for #he original pipeline and shall be h"dro #es#ed as per SP4 2/22 and D0P 52.-.-.5@4PD6 prior #o ins#alla#ion. The leng#h of #he repla%e!en# se%#ion shall no# be less #han half #he dia!e#er of #he pipeline or 5!!, whi%he&er is grea#er. (o se%#ion shall be ins#alled %loser #han 2$!! #o an e8is#ing weld. Application: 4

2.

This !e#hod is a #i!e %ons!ing pro%ess of repair de #o reiring sh#down and de4%o!!issioning of #he pipeline. /. The proper#ies of #he original pipeline need #o be nown #o de#er!ine #he proper#ies of #he repla%e!en# pipe !a#erial #o be sed. 5. The !e#hod reires end prepara#ion of #he e8is#ing pipeline for welding. The leng#h of #he pipe #o be %# o# shall be s%h #ha# in addi#ion #o repla%ing #he defe%#i&e se%#ion, #he wall #hi%ness where #he pipe is #o be joined is si#able for end prepara#ion and welding. Procedure: 4

2. Sh#down #he pipeline s"s#e! and #ransfer #he prod%# a# #he blo% &al&e or end s#a#ions /. 0nsre all safe#" pre%a#ions are in pla%e as per Se%#ion $. 5. Isola#e and de4%o!!ission #he se%#ion #o be repla%ed #o !ae #he se%#ion free fro! h"dro%arbons as per Se%#ion /.$.>.= -. Sele%# a spool pie%e of #he reired wall #hi%ness and grade as spe%ified abo&e. $. H"dro4#es# #he spool pie%e separa#el" as per SP42/22. =. Clean #he defe%# area as per Se%#ion /.$.>.2 >. Cold %# #he defe%#i&e se%#ion #o be repla%ed. @. Clean #he %# ends of #he pipeline #o be welded and prepare*be&el #he ends <. eld #he repla%e!en# se%#ion wi#h #he e8is#ing pipeline as per SP422>> 2. Inspe%# #he weld as per SP422>> 22. +e%oa#*repain# #he s"s#e! as per Se%#ion /.$.>.2/. Pla%e sand padding and ba%fill as per SP42/@ 25. +e4%o!!ission #he pipeline as per reire!en#s of SP42/22, &erif" and %onfir! if de4ra#ing of #he pipeline is reired.

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2-. Prepare de#ailed repor# as per Se%#ion /.$.>.> "!,!9

Minimum recommended tools and euipment

The repair %rews shall be eipped wi#h all si#able eip!en# as reired for #he spe%ifi% #"pe * !anfa%#re of #he pipeline being repaired and shall %arr" an adea#e range of fll" %o!pa#ible spare pipe and fi##ings. In addi#ion #he following #ools and %ons!ables shall be %arried: 2. /. 5. -. $. =. >.

Te!pera#re and rela#i&e h!idi#" !easring eip!en#s Measring #ape, sliding gage, pipe !arer 7pen9 e&elling Ma%hine in%hes 3rinders Sol&en# %leaner, %leaning rags PP0 7glo&es, e"e pro#e%#ion, ds# !as9

)n" addi#ional #ools* eip!en# reired shall be ad&ised b" #he engineer4in4%harge. "!.

&omposite Repair8 An Alternati1e Repair Method

Co!posi#e repair !e#hod is an p%o!ing #e%hnolog" for repair of %orrosion and #hrogh wall defe%#s in a pipeline. The %o!posi#e !a#erial %onsidered wi#hin #he do%!en#, are #hose wi#h glass 73+P9 or %arbon 7CF+P9 reinfor%e!en# in a pol"es#er, &in"l es#er or epo8" !a#ri8. These repairs %an be sed as an al#erna#i&e #o #he se of Me%hani%al Cla!p or Plid%o Spli# Slee&e for a leaing defe%# 7#hrogh wall defe%#s9, if designed, alified and applied in a%%ordan%e wi#h #he )SM0 %ode  (on Me#alli% Co!posi#e +epair S"s#e!s for Pipelines and Pipe wor: High +is )ppli%a#ions J wi#h in #he li!i#s of #he alifi%a#ion. The )SM0 ar#i%le is %rren#l" in re&iew. The )SM0 draf# reires a repair life#i!e #o be spe%ified, whi%h %an range fro! less #han / "ears p #o an#i%ipa#ed ser&i%e life of #he s"s#e!. The %o!posi#e repair shall be designed in s%h a !anner #ha# i# #aes in#o a%%on# #he f#re grow#h of #he defe%# for #he re!aining design life of #he pipeline. ) !ajor ad&an#age of #he !e#hod is #he rela#i&e ease of appli%a#ion, sing si!ple hand #ools wi#ho# an" welding. The %o!posi#e repair is !os# si#able where %la!p*slee&es %anno# be ins#alled de #o geo!e#ri% %ons#rain# e.g. bends, red%ers, T4pie%es e#%. For s#raigh# pipe se%#ions #his !e#hod %an be sed, in %ase si#able %la!p* slee&es are no# a&ailable a# #he #i!e of lea. For ea%h repair si#a#ion a ris assess!en# shall be %arried o#. The ris assess!en# shall in%lde %onsidera#ion of #he haards asso%ia#ed wi#h #he s"s#e! ser&i%e, #he a&ailabili#" of #he personnel wi#h #he ne%essar" sills, #he ease wi#h whi%h i# is pra%#i%able #o e8e%#e srfa%e prepara#ion opera#ions, #he a&ailabili#" of design da#a. 1ea before brea, inspe%#abili#", and perfor!an%e nder pse# and !ajor in%iden# si#a#ions in%lding fire, e8plosion, %ollision and en&iron!en#al loading.

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Manfa%#rer of %o!posi#e repair !a#erial shold pro&ide fll ins#alla#ion ins#r%#ions in%lding srfa%e prepara#ion, gri# blas#ing, ins#aller alifi%a#ions, la!ina#e la" p e#%. +epair shall be %arried o# in a%%ordan%e wi#h #he !anfa%#rers pro%edres and b" !anfa%#rer appro&ed and #rained personnel. The e" poin# #ha# !s# be %onsidered in design and appli%a#ion of bonded repair is #ha# #he %o!bina#ion of pipe !a#erial* srfa%e prepara#ion #e%hnie* %o!posi#e is #he basi% design ni#. Da#a deri&ed sing one se# of !a#erial %anno# be sed #o assis# in #he design of ano#her e&en if i# is onl" one of #he %o!ponen#s %o!prising #he arrange!en# #ha# has %hanged. The li!i#a#ions of #his !e#hod are #ha# i# needs a dr" and !e%hani%all" %lean srfa%e for a%hie&ing a drable bonded %onne%#ion be#ween pipe and la!ina#e. To a%hie&e #he reired dr" srfa%e, i# is ne%essar" #o plg #he lea on4line or depressrie #he line. The se%ond i!por#an# aspe%# of repair is srfa%e prepara#ion. Srfa%e prepara#ion a%#i&i#" in&ol&es re!o&al of loose debris and %orrosion prod%#s followed b" !e%hani%al abrasion. (or!all", ali#" of srfa%e prepara#ion shold be in %onfor!i#" wi#h S) / . For srfa%e prepara#ion sing gri#4blas#ing #e%hnie on li&e lines, all ne%essar" safe#" pre%a#ions shold be followed as per PD6 pro%edres. "!7

4e1el II Emergency 2e%ects- In0urious non leaing de%ects

These defe%#s are as des%ribed in se%#ion /./. The" ha&e a no!inal i!pa%# on #he prod%#i&i#" of #he pipeline de #o #he reire!en# for pressre red%#ion. +eferen%e is !ade #o SP42/5$ for possible repair op#ions and !e#hods for le&el4II e!ergen%" defe%#s. "!;

Repair organisation

The repair organisa#ion and %on#ingen%" plans for PD6 pipelines are gi&en in #he 0!ergen%" +esponse Do%!en#, Par#4III in #he following &ol!es:4 'ol!e45, Prod%#ion 6pera#ions, P+42== 4 Clase /.5.< 6il Pipeline Failre 4 Clase /.5.2 3as Pipeline Failre 'ol!e4-, Main 6il 1ine P+42=> 'ol!e4$, Ter!inal ? Tan Far! 6pera#ions, P+42=@ 'ol!e42-, 3o&ern!en# 3as S"s#e! Pipeline ? Ter!inals, P+42/-= 'ol!e42$, So#h 6!an 3as 1ine P+42/>$

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.0 Emergenc !e"airs for +lass !einforced $lastic +!$3 $i"elines 3!#

General

3+P pipelines for PD6 ha&e been %ons#r%#ed af#er sa#isfa%#or" and rigoros alifi%a#ion #es#s ha&e been %arried o# on #he 3+P s"s#e!s. Fr#her ali#" %he%s are !ade b" %arr"ing o# &isal inspe%#ion and pressre #es#ing prior #o %o!!issioning of #he s"s#e!. Mos# of #he 3+P pipelines are of bried #"pe. 3+P pipeline s"s#e!s %an sffer opera#ional defe%#s, whi%h !a" be %a#as#rophi% in na#re. This !anal iden#ifies #he possible %a#as#rophi% defe%#s, %a#egorised as e!ergen%" defe%#s, and spe%ifies #he appropria#e repair !e#hods. 3!"

(cope

This par# of #he do%!en# defines #he e!ergen%" defe%#s and #he repair respe%#i&e reire!en#s for 3+P pipelines. The e!ergen%" repairs for o#her non4!e#alli% pipelines in%lding HDP0 s"s#e!s are e8%lded fro! #he s%ope. IS6 2-=
&auses o% de%ects in an operating GRP pipeline system

The o%%rren%e of defe%#s in an opera#ing 3+P pipeline s"s#e! %an nor!all" be a##rib#ed #o ei#her one or a %o!bina#ion of #he following.

3!+

2

Third par#" in#erferen%e 7#he !os# %o!!on reason9

/

08%essi&e opera#ional loads*pse# %ondi#ions 7refer Se%#ion 5.- below9

2e%ects due to o1er pressurisation

The o&er pressrisa#ion of a 3+P pipeline s"s#e! de #o failre of #he o&er pressre pro#e%#ion s"s#e!s or e8%essi&e srge be"ond design li!i#s nor!all" leads #o weepage or rp#re of #he pipeline. If an" s%h si#a#ion o%%rs, i# is ad&ised #o repla%e #he %o!ple#e line or else fi#ness for prpose e&ala#ion shall be %arried o# as per !anfa%#rers re%o!!enda#ion. 3!,

2e%ect categorisation

The defe%# %a#egorisa#ion of 3+P Class4I pipelines is si!ilar #o #ha# of CS pipelines spe%ified in Se%#ion / of #his do%!en#, wi#h #he e8%ep#ion #ha# weeping defe%#s are in%lded in 1e&el42 e!ergen%" defe%#s.

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eeping defe%#s : 4 This is #he !os# %o!!on #"pe of 1e&el4I defe%# in a 3+P pipeline s"s#e!. I# !ainl" %ons#i##es seepage, swea#ing or pene#ra#ion of #he liid #hrogh #he wall of #he pipeline. In weeping #here is no apparen# &isal indi%a#ion of a defe%# in #he 3+P !a#erial and !ainl" o%%rs de #o dis#rban%e in #he fibre !a#ri8. I# is diffi%l# #o iden#if" #he !inor weeping defe%#s in bried 3+P pipelines 7Minor weeping %an onl" be iden#ified dring h"dro#es#ing9. 3!.

Repair o% 4e1el-I Emergency 2e%ects

The lea de#e%#ion, defe%# assess!en# !e#hods and !ajor a%#i&i#ies following repor#ing of a pipeline lea are si!ilar #o #hose indi%a#ed for CS pipelines a# se%#ion /.$ of #his do%!en#. 3!.!#

(hut do5n and pressure reduction

The need for sh##ing down #he pipeline s"s#e! for #he prpose of %arr"ing o# repair or inspe%#ion shall be de%ided b" #he lo%al area e!ergen%" %oordina#or in %onsl#a#ion wi#h senior pipeline personnel based on #he #"pe of defe%# and #he possible %onseen%es. The repair op#ions for 3+P pipelines are nor!all" #he repla%e!en# of #he defe%#i&e se%#ion and #herefore, sh#down, depressrisa#ion and draining of #he s"s#e! is ne%essar". In %ase, weeping of a pipeline de #o o&er pressrisa#ion is iden#ified an i!!edia#e sh#down of #he pipeline !s# be ini#ia#ed. If #he pipeline has been sh# down, re4pressrisa#ion shold be done wi#h e8#re!e %a#ion, s#eadil" in%reasing #he pressre wi#ho# srges, whi%h %old &ibra#e #he pipeline and #he asso%ia#ed fi##ings leading #o in#egri#" proble!s. The s"s#e! pressre af#er %o!ple#ion of #he repair shall be de%ided b" #he engineer4 in4%harge, depending pon #he #"pe of repair and shall be re%orded in #he %lose o# repor#. Manfa%#rers ad&i%e !s# also be #aen in#o a%%on#. 3!.!"

Repair options

The preferred op#ion of repair is #o #ae #he pipeline o# of ser&i%e, de%o!!ission and #he repla%e #he defe%#i&e se%#ion wi#h pipe !ee#ing #he reire!en#s of #he %odes and s#andards. Sele%#ion of join#ing !e#hod for se%#ional repla%e!en# shall be go&erned b" design pressre of #he pipeline. If design pressre of #he pipeline is less #han or eal #o - barg, la!ina#ed join# shall be sed. Se%#ional repla%e!en#, in #he pipelines ha&ing design pressre !ore #han - barg, shall be %arried o# sing flanged join#s.

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The following repair op#ions are re%o!!ended depending pon #he #"pe of defe%#. 7+efer Table 59. a'le 3 - (election o% emergency repair options - GRP pipelines ype o% 2e%ect

emporary repair Permanent repair location location Minor lea in s#raigh# (il Se%#ional repla%e!en# O por#ion Major lea in s#raigh# (il Se%#ional repla%e!en# por#ion eep in s#raigh# (il Se%#ional repla%e!en# O por#ion +p#re (il Se%#ional repla%e!en# 1eas in join#s and (il +epla%e!en# of #he fi##ing*join# fi##ings 1eaage #hrogh road (il Se%#ional repla%e!en# and wadi %rossings O Minor leas or lo%alised weeping defe%#s %an be repaired b" o&er wrapping p #o - barg design pressre. 3!.!3

Repair acti1ity procedures

The a%#i&i#ies de#ailed below shall for! par# of #he o&erall repair wors. 3!.!3!# &utting o% the Pipeline

The se%#ion of #he pipeline #o be repla%ed shall be !ini!! 2!! 7$!! on ei#her side of defe%#9 !ore #han #he leng#h of #he defe%# The pipe se%#ion #o be %# shold be !ared and %arefll" se%#ioned. The %ross se%#ion shall be s#raigh# and perpendi%lar #o #he pipe a8is, as #he join# reliabili#" depends #o a large e8#en# on #he sareness of #he %#. Pipe p #o 2 !! no!inal dia!e#er shall be sare #o wi#hin 2.$ !! whils# %#s on larger dia!e#er pipes shall be sare #o wi#hin 5. !!. The %##ing of glass fibre reinfor%ed plas#i% pipes %an be done b" !eans of a ha%saw or -J grinding dis% for dia!e#ers p #o 2 !!. Pipes of larger dia!e#er shold be %# b" grinding wi#h a diagri# or %arbornd!4grinding dis%. )l#erna#i&e eip!en# sed for %##ing shall be sbje%# #o #he !anfa%#rers appro&al prior #o s#ar# of wor. 3!.!3!" &leaning o% the de%ect area

The srfa%e of affe%#ed area of #he pipeline shall be %leaned #o allow for repair, inspe%#ion e#%. The pipe se%#ion !s# be free fro! oil, grease and ds#. )dea#e %leaning is essen#ial a# #he join# where #he e8is#ing pipeline is #o be bonded #o a new spool pie%e. Ds# re!o&al shall be %arried o# sing a %lean dr" brsh, dr" rag or %o!pressed air #ha# is dr" and free fro! oil. )ll srfa%es #o be adhesi&e bonded shall be %leaned

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sing a%e#one. The brsh or %lo#h #o be sed for %leaning shold be free fro! har!fl sbs#an%es. The %on#a%# srfa%e of #he e8is#ing pipeline #o be bonded shall be prepared in line wi#h join#ing pro%edre. Use of !e#al brshes or har!fl sol&en#s for %leaning of #hreaded join#s is no# ad&ised. 3!.!3!3 Emergency repair methods < GRE pipelines 3!.!3!3!# Repair o% leas in straight pipe section

The #"pe and na#re of #he defe%# shall di%#a#e #he repair pro%edre #o be followed. In %ase of !inor lea or lo%alised weeping de #o i!pa%# da!age is iden#ified in #he s#raigh# por#ion of #he pipeline, #hese defe%#s %an be repaired b" o&er wrapping, pro&ided #he design pressre of #he pipeline is less #han or eal #o - barg. In %ase, #he design pressre is - barg, se%#ional repla%e!en# shall be %arried o# for s%h leas. For !ajor lea*rp#re in s#raigh# se%#ion, se%#ional repla%e!en# shall be %arried o#. Pipeline se%#ion repla%e!en# in&ol&es %##ing o# of #he defe%#i&e por#ion and ins#alling a new spool pie%e of %o!pa#ible proper#ies #o #he e8is#ing pipeline. The sele%#ion of join#ing !e#hod depends on design pressre of #he pipeline. 1a!ina#ed join# shall be sed for joining #he new se%#ion wi#h e8is#ing pipeline p #o - barg design pressre. The alified pro%edre of la!ina#ed join# shall be sed for joining #he new se%#ion wi#h e8is#ing pipeline. The pipelines designed for !ore #han - barg pressre, are %ons#r%#ed sing #hreaded join#s, se%#ional repla%e!en# of s%h pipelines shall be %a rried o# sing flanged join#s as per Manfa%#rers repair pro%edres. +efer )ppendi8
For leas in fi##ings 7!inor*!ajor*rp#re*weep9, i# is re%o!!ended #o repla%e #he %o!ple#e fi##ing. +epla%e!en# of #he fi##ing in&ol&es #he sa!e pro%edres as spe%ified for s#raigh# se%#ions des%ribed in Se%#ion 5.=.5.5.2 3!.!3!3!3 Repair o% 0oint leas

+epair of leas #hrogh adhesi&e bonded, la!ina#ed, elas#o!eri% seal and #hreaded join#s ne%essi#a#es %##ing o# #he join#. ) pipe se%#ion %on#aining #he leaing join# shall be %# a# $ !! fro! #he leaing join# in bo#h ps#rea! and downs#rea! dire%#ions and a new pipe se%#ion shall be ins#alled. In %ase of flanged join#s, leas %an be %ased de #o #he wrong #"pe of gase# being fi##ed, a da!aged gase#, se of in%orre%# #ore for #igh#ening of #he flange bol#s, in%orre%# seen%e of #igh#ening of flange bol#s or ph"si%al da!age #o #he flange. For leas a##rib#ed #o gase#s, #he" shall be repla%ed b" #he %orre%# #"pe for #he appli%a#ion and #he flange bol#s #igh#ened #o #he !anfa%#rers re%o!!enda#ions.

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3!.!3!+ Procedure %or sand padding and 'ac%illing o% the trench

2. S%reened sof# sand, free of ro% and foreign !a##er, shall be sed for sand padding. The !ini!! %o!pa%#ed dep#h of padding below #he pipe shall be 2$ !!. /. Hand sho&el and wooden hand4ra!!ing de&i%e shall be sed for #he pla%e!en# of sand nder #he pipe. 5. Sand shall be lowered in#o #he #ren%h wi#h a !e%hani%al sho&el and hand spread nifor!l" arond #he pipe. The dep#h of #he sand padding o&er #he #op of #he pipe shall be a# leas# 5 !!. Sand on #op of #he pipe shall be shaped #o #he na#ral angle of repose. -. S%reened e8%a&a#ed !a#erial fro! #he lo%a#ion shall be sed 7af#er #he re!o&al of an" ro% and bolders9 on #op of #he sand. In order no# #o da!age #he sand padding, #he ini#ial la"ers of final fill shall be %arefll" lowered in#o #he #ren%h fro! ea%h side b" !e%hani%al sho&el ensring #ha# #he ba%fill !a#erial is deposi#ed %arefll" #o a&oid dis#rbing #he sand padding. $. The !e%hani%al e8%a&a#or shall !ain#ain #he following minimum safe dis#an%es 7whi%h shall be %learl" !ared b" a line of bn#ing9 fro! #he edge of #he #ren%h: 4

+o%: dis#an%e fro! edge of #ren%h shall be 2. !e#re

4

Co!pa%#ed grond: dis#an%e fro! ba##ered edge of #ren%h shall be 2.$ !e#re

4

Sof# sand wi#h #ren%h sides ba##ered #o a !ini!! slope of /:2: dis#an%e shall be / !e#res.

=. )f#er %o!ple#ion of #he ini#ial ba%fill la"er, #he re!aining ba%fill shall be finished #o a le&el sligh#l" abo&e #he na#ral grade and shall be #horoghl" %o!pa%#ed b" !eans of a %o!pa%#ing &ibra#or. >. indrow shall be reins#a#ed, in%lding #he se%#ion sed for #e!porar" %rossings. here #he e8%a&a#ion %rosses wadis or di#%hes wi#h lined or o#herwise i!pro&ed srfa%es, #hese shall be reins#a#ed #o #heir original %on#or and %ondi#ion. +eferen%e shold also be !ade #o 0+D 5@422 and SP42/-> for de#ails on reins#a#e!en#. 3!.!3!, 2etailed &lose /ut Repair Report

The %on#en#s of %loseo# repor# for 3+P pipelines shall be si!ilar #o #ha# of CS pipeline repairs %loseo# repor# indi%a#ed a# se%#ion /.$.>.> of #his do%!en#.

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3!7

Emergency Repair Procedure Buali%ication

Se%#ional repla%e!en# is #he onl" possible repair !e#hod for res#oring #he long #re! in#egri#" of #he pipeline. The la!in#ed join# shall be sed for %onne%#ing #he new se%#ion wi#h e8is#ing pipe s"#e!s for #he pipelines ha&ing design pressre less #han - barg. Si!ilarl", se%#ional repla%e!en# shall be %arried o# sing flanged join#, if design pressre of #he pipeline is !ore #han - barg. The alified and appro&ed join#ing pro%edre shold be sed for se%#ional repla%e!en# in all %ases. For pro%edre alifi%a#ion, PD6 shall engage one of #he for appro&ed 3+P &endors for pro%re!en# and sper&ision rela#ed a%#i&i#ies for #he e!ergen%" repair of #he 3+P pipelines. The appro&ed &endor shall de&elop a de#ailed repair pro%edre in%lding %leaningW %##ing and join#ing of #he e8i#ing pipeline wi#h new pipe se%#ion. This pro%edre along wi#h #es#ing plan shall be sb!i##ed #o PD6 for re&iew and appro&al. The alifi%a#ion #es#s shall be %arried o# wi#h all PD6 appro&ed 3+P !anfa%#rer pipes wi#h a &iew #o &erif" #he %o!pa#abili#" of resin #o be sed for la!ina#ed join#s. To !ini!ie #he e!ergen%" !a#erial, one fi# for allJ philosoph" is adop#ed. I# !eans highes# ra#ing pipe for a no!inal dia!e#er shall be pro%red fro! one of #he appro&ed &endor and sa!e pipe shall be sed for se%#ional repla%e!en# for all ra#ing for #ha# no!inal dia!e#er. 3!;

Buality Programme during Repair

The repair wors shall be %ond%#ed in a%%ordan%e wi#h #he ali#" !anage!en# s"s#e! as reired for IS6 <. ) high le&el of inspe%#ion shall be !ain#ained for all wors #o ensre %o!plian%e wi#h #he reire!en#s of #he rele&an# spe%ifi%a#ions and pro%edres. )ll repair wor shall be %arried o# nder #he sper&ision of appro&ed e!ergen%" repair %on#ra%#or who shall be responsible for !ain#aining %o!prehensi&e re%ords of #he repair a%#i&i#ies. 3!9

Emergency Repair Cit

The repair %rews shall be eipped wi#h all si#able eip!en# as reired for #he pipeline being repaired and shall %arr" an adea#e range of fll" %o!pa#ible spare pipe and fi##ings. In addi#ion #he following #ools and %ons!ables shall be %arried: 2. Te!pera#re and rela#i&e h!idi#" !easring eip!en#s /. Measring #ape, sliding gage, pipe !arer 7pen9 5. Pipe sha&ers 7as spplied b" #he pipe !anfa%#rer9 -. in%hes or Pllers, Cargo la#%hing bel#s and slings $. 3rinders and 3rinding Diss =. Drilling !a%hine and Flapper wheels 7gri# -4=9

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>. 0!er" Paper @. Sol&en Sol&en## %lean %leaner, er, %leani %leaning ng rags rags <. PP0 7glo 7glo&es &es,, e"e e"e pro#e%# pro#e%#ion ion,, ds# ds# !as9 !as9

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4.0 Emergenc Emergenc !e"air !e"air of #ubsea #ubsea Carbon Carbon #teel $i"elines $i"elines +!#

General

The in#egri#" of sb4sea pipeline s"s#e!s is &er" i!por#an# for #he opera#ors for e%ono!i%al, opera#ional and en&iron!en#al reasons. 6n%e %o!!issioned, #he sb4sea pipelines !s# gi&e %on#inos ser&i%e wi#h !ini!! in#errp#ion. Howe&er, sb!arine pipelines generall" are opera#ed in a highl" %orrosi&e and ina%%essible en&iron!e en&iron!en#. n#. PD6 opera#es opera#es a few sb4sea sb4sea e8por# e8por# pipelines pipelines for loading loading %rde oil and handling whi#e oil refiner" prod%#s #o #aners a# M)F area. The #o#al leng#h of sb!erged se%#ion of #hese pipelines is appro8i!a#el" $!. These in%lde • • • •

5J SM2 0as# 4 %rde e8por# pipeline. 5J SM2 es# es# 4 %rde e8por# pipeline. -J SM/ SM/ 4 %rde e8por# pipeline. 2J Prod%# lines  Shell !are# lines 7= nos SM*2*/*59.

The in#egri#" of %rde oil, prod%#4load prod%#4loading ing lines is highl" highl" i!por#an# i!por#an# fro! opera#ions opera#ions poin# of &iew. The %rde oil e8por# pipelines are !ainl" opera#ed nder gra&i#" flow %ond %ondi# i#io ions ns.. De De #o oper opera# a#io iona nall and and #an #aner er re reir ire! e!en en#s #s all all #he #he sb! sb!er erge ged d %rde*prod%# loading lines are %ri#i%al and #here is no spe%ifi% s#andb" line for %rde oil e8por#. )n" leas on #hese pipelines will ha&e a !ajor effe%# on #he !arine en&iron!en# and rep#a#ion wi#h longer4#er! effe%#s on loading opera#ionsW hen%e an" of #hese pipeline leas are reired #o be a##ended on e!ergen%" basis. This !anal iden#ifies #he possible %a#as#rophi% defe%#s 7le&elI defe%#s9 and spe%ifies #he appropria#e repair !e#hods for PD6 sb4sea pipelines. +!"

(cope

This par# of #he do%!en# de#ails #he possible e!ergen%" repair !e#hods for PD6 offshore loading lines. The defe%#s %onsidered are #hose #ha# %old be en%on#ered dring #he opera#ion of #he sb4sea pipelines. The #"pe of defe%#s, defe%# %lassifi%a#ion and %a#egorisa#ion of defe%#s, #he repair op#ions for sb4sea CS pipelines are si!ilar #o #ha# of bried onshore CS pipelines spe%ified in se%#ion /.. The addi#ional spe%ifi% reire!en#s for e!ergen%" repair of offshore se%#ions of loading lines are briefl" de#ailed in #his do%!en#. The sppor# fa%ili#ies reired for e!ergen%" repair of sb4sea pipelines, s%h as #e%hni%al #e%hni%al spe%ifi%a#ion spe%ifi%a#ion of reired fa%ili#ies on #he srfa%e sppor# sppor# &essel, di&ing di&ing e8per#ise reired for %arr"ing o# #he ne%essar" repair, spe%ifi% reire!en#s for nder wa#er %la!ping and h"perbari% welding e#%., are no# de#ailed in #his do%!en#.

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+!3

&auses o% o% 2e 2e%ects

The possible reasons for sb4sea pipeline defe%#s are 2. Thir Third d par par#" #" da!a da!age ge /. 08%essi 08%essi&e &e oper opera#i a#iona onall loads loads*err *errors ors 5. Corros Corrosion ion 7in#er 7in#ernal nal * e8#ern e8#ernal9 al9 -. Manfa Manfa%# %#rin ring g * %ons# %ons#r% r%#io #ion n defe%# defe%#ss +!+ +!+

4e1e 4e 1ell < I Emer Emerge genc ncy y 2e%e 2e%ect ctss

The !ajor a%#i&i#ies rela#ed #o 1e&el4I e!ergen%" repairs are %a#egorised in#o 2. 1ea ea de# de#e% e%#i #io on /. 1ea 1ea asses assess! s!en en## sr sr&e &e" " 5. De%ide #he repair repair op#ion op#ion based on da!age da!age assess!en# assess!en# sr&e" sr&e" -. Mobilia#io Mobilia#ion n of e!ergen%" e!ergen%" repair repair %rew, eip!en# eip!en# and %arr"o %arr"o# # #he repair wor wor (o#e: Poin#s 5 ? - ha&e ha&e been %o&ered in brief. brief.

+!+! !+!#

4ea 2ete 2etecction ion

I# is ne%essar" #o iden#if" #he lea lo%a#ion as soon as possible #o !ini!ie spill of h"dro%arbons and i!pa%# on #he en&iron!en#. The sb sea pipeline leas are di&ided in#o !inor leas and !ajor leas, whi%h is in line wi#h defe%# %a#egorisa#ion for onshore %arbon s#eel pipelines. The !inor !inor leas are !ainl" pinhole pinhole leas or %ra% leas. The pinhole pinhole lea is a s!all perfora#ion in #he pipe wall and is generall" #he resl# of ei#her %orrosion pi#s or weld defe% defe%#s #s or !a#e !a#eria riall defe% defe%#s #s or e8#e e8#ern rnal al da!a da!age ge.. ) s!all s!all pinh pinhol olee lea lea !a" !a" go nde#e%#ed for so!e #i!e n#il e&iden%e of oil poll#ion 7sigh#ed oil" sheen*la"ers in wa#er9 is obser&ed on #he wa#er srfa%e. The nsal dea#h of !arine life s%h as s!all fish e#%. in #he &i%ini#" of #he loading lines also indi%a#es sspe%#ed pipe lea. ) pinhole !a" o%%r below %orrosion s%ales*deposi#s or nder weigh# %oa#ing !aing #he de#e%#ion &er" diffi%l#. In #he %ase of a defini#e lea, #he da!age will be of s%h e8#en# #ha# pipeline %anno# re#ain re#ain #he line line pressr pressre. e. Pressr Pressree loss loss and en&iron en&iron!en !en#al #al poll#i poll#ion on are #he !ain %hara%#eris#i%s of !ajor pipeline leas. For iden#if"ing iden#if"ing #he sspe%#ed sspe%#ed lea, an e8perien%ed di&er shall ph"si%all" ph"si%all" inspe%# #he pipeline and sear%h for e&iden%e of a lea * sor%e of oil poll#ion. +e!o#e 6pera#ed 'essels 7+6'9 or !anned sb!ersibles %an also be engaged for lea de#e%#ion and repair a%#i&i#ies, in %ase #he safe#" of #he di&ers is in es#ion. Following iden#ifi%a#ion of lea lo%a#ion, #he defe%#i&e se%#ion shall be %learl" !ared sing bo"s. )f#er iden#if"ing #he lo%a#ion of #he lea, a preli!inar" inspe%#ion !s# be %arried o# as i%l" as possible #o iden#if" #he #"pe and e8#en# of #he da!age ss#ained #o #he

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pipeline. Under wa#er &ideo re%ording fa%ili#ies gi&e an added ad&an#age for anal"sis of pipeline da!age b" e8per#s. ased on #he preli!inar" inspe%#ion resl#s a ali#a#i&e assess!en# shall be !ade #o assess #he %ondi#ion of #he line 7leaing * nsafe * badl" da!aged9 in rela#ion #o #he safe#" of fr#her di&ing opera#ions. Hen%e #he preli!inar" inspe%#ion !s# be nder#aen wi#h e8#re!e %a#ion. +!+!"

4ea Assessment (ur1ey

)f#er %onfir!a#ion of #he presen%e and lo%a#ion of #he lea, #he ne8# s#ep in&ol&es #he assess!en# and %a#egorisa#ion of #he defe%# in#o !inor, !ajor or rp#re and e8ploring #he possible reasons for #he lea. This assess!en# is essen#ial #o de%ide pon #he repair pro%edre #o be adop#ed and #he safe#" !easres #o be #aen dring #he repair. The lea assess!en# sr&e" in&ol&es e8posre and de#ail inspe%#ion of #he defe%#i&e pipe se%#ion #o assess and re%ord #he %ondi#ion for sbseen# in#erpre#a#ion. The e8#ernal %on%re#e %oa#ing in #he defe%#i&e area shall be re!o&ed sing high4pressre wa#er je##ing. The defe%#i&e pipe se%#ion shall be %leaned #o an a%%ep#able le&el, whi%h is dependen# on #"pe of repair !e#hod. 08posing #he pipe for repair !a" reire e8%a&a#ion of #he srronding area. Sin%e #hese #ass reire e8#ensi&e srfa%e sppor#, #he" %an be %onsidered #oge#her and a single !obilisa#ion shall be !ade sing one &essel. I# shold be no#ed, #ha# #he spe%ial eip!en# sed and #he di&ing e8per#ise reired for #hese a%#i&i#ies shall be of #he highes# ali#". Sin%e #he preli!inar" inspe%#ion reires a rapid !obilisa#ion of di&ing %rew wi#h !ini!! dela", #he ser&i%es of #he sppor# &essel and di&ing %rew, a&ailable nder #he e8is#ing reglar !arine sppor# %on#ra%# shall be #ilied. Pro&ision e8is#s wi#hin #his %on#ra%# #o %all off addi#ional spe%ialis# !anpower and eip!en# a# shor# no#i%e. +!+!3

(hutdo5n and Pressure Reduction

The reire!en# of pressre red%#ion and sh# down depends pon se&eri#" of #he da!age, i!pli%a#ions of leaage on #he en&iron!en# and repair !e#hod #o be sed. Te!porar" repair of pinhole leas sing proprie#ar" slee&es or %la!ps %an be e8e%#ed wi#ho# pressre red%#ion. In %ase of a !ajor lea or rp#re, pipeline sh#down is ne%essar", #o !ini!ie en&iron!en#al poll#ion and for %arr"ing o# per!anen# repair 7se%#ional repla%e!en#9 in a safe !anner. +!+!+

Repair options

The %o!pan" philosoph", appli%able repair !e#hod, go&erning rles and regla#ions di%#a#e #he repair s#ra#eg". Depending on #he e8#en# of #he da!age fond, #he repair !a" reire ins#alla#ion of a repair %la!p or repla%e!en# of defe%#i&e se%#ion of pipe #iliing %onne%#ors or %oplings. The sele%#ion of repair !e#hod shall be based on pressre %on#ain!en# reire!en#s and %orrosi&i#" of in#ernal and e8#ernal en&iron!en#.

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Permanent Repairs

The preferred op#ion of per!anen# repair is #o de%o!!ission #he pipeline, %# #he defe%#i&e se%#ion and repla%e i# wi#h a new se%#ion. Howe&er, #his op#ion is seldo! e8er%ised de #o #he #i!e %ons#rain#, a&ailabili#" of resor%es and %os# in&ol&ed. For se%#ional repla%e!en#, !e%hani%al %onne%#ors shall be sed. The !ain ad&an#age of !e%hani%al %onne%#ors is #ha# #his !e#hod is fas# and nderwa#er 7h"perbari%9 welding %an be a&oided. The o#her per!anen# repair #e%hnies indi%a#ed for bried 7onshore9 CS pipelines are also appli%able for sb4sea pipelines. emporary Repairs

Plid%o Cla!p and slee&e or an" o#her si!ilar Co!pan" appro&ed brand slee&es are preferred for #e!porar" repair of sb4sea pipeline leas 7refer #o Table 2  Sele%#ion of e!ergen%" repair op#ions for CS pipelines9. The Plid%o Cla!p and slee&e has %la!ping srfa%es, whi%h grip #he o#side wall #o %on#er end4pll and a8ial s#resses. These #e!porar" repairs %an be a%%ep#ed as a per!anen# repair, sbje%#ed #o periodi% inspe%#ion of #hese slee&es following ins#alla#ion. In #he e&en# of pipeline rp#re, #he se%#ional repla%e!en# op#ion shall be sele%#ed. +!,

Resources

In order #o perfor! #he sb4sea inspe%#ion and lea repair a%#i&i#ies, an adea#e srfa%e &essel will be reired. The &essel shold ha&e following !ain fea#res. •

3ood seawor#hiness rela#ed #o i#s o&erall di!ensions and hll for!. ) #"pi%al fla# bo##o! barge for e!ergen%" repair of sb4sea pipelines shall be of 2$ #o /$ fee# long wi#h &alid %er#ifi%a#ion for hll, !a%hiner", safe#" eip!en# for offshore opera#ions. For shallow wa#er appli%a#ions ei#her a ;a%4p or shallow wa#er fla# bo##o! barge %an be sed.

•

The &essel de% %rane %apa%i#" !s# be in e8%ess of e8pe%#ed loads 7for lowering, lif#ing of pipe se%#ions, repair slee&es, %la!ps e#%.9. The reire!en# will depend pon #he #"pe of repair and sie of defe%#i&e pipeline. The %rane !s# be ra#ed for offshore se and !s# be eipped #o assis# di&er opera#ions down #o $ !e#ers wa#er dep#h.

•

3eneral %ons#r%#ion %apabili#ies shold in%lde nder wa#er welding and %##ing gear #oge#her wi#h worshop * repair fa%ili#ies. The &essel shold ha&e a well4#rained and in#egra#ed %rew fa!iliar wi#h #he wor and #he %ons#r%#ion, repair opera#ions.

•

Posi#ioning s"s#e!s #o allow #he &essel #o a%%ra#el" fi8 i#s posi#ion rela#i&e #o nown referen%es and #o #he pipeline on #he seabed.

•

Co!!ni%a#ions !s# be good and in preferen%e in%lde #ele8, as well as nor!al !arine side band 'HF*UHF and walie4#alie eip!en#.

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hils# #he %o!pan" !ain#enan%e barge GFahal2 flfils !os# of #he reire!en#s abo&e, ss#ained opera#ions !a" reire #he ser&i%es of addi#ional spe%ialis# eip!en#. i#h a &iew #o #a%le an" e!ergen%" si#a#ions wi#h #he sb4sea loading lines a# M)F area, #he sor%es of reired resor%es for #a%ling an" e!ergen%" repair wor needs #o be iden#ified and #he rele&an# repair pro%edres shold be !ade a&ailable for read" referen%e.

.0

Emergenc #toc' %aterials ,!#

Philosophy

The following philosoph" has been adop#ed #o es#ablish #he an#i#ies of e!ergen%" s#o% !a#erial. For CS pipelines, all %lass4I pipelines shall be di&ided in#o differen# grops based on pipe dia!e#er and lo%a#ion of #he pipeline. Presen#l", e!ergen%" !a#erials are s#ored a# for lo%a#ions. These lo%a#ions are (i!r, Mar!l, Fahd and M)F. )ll %lass4I pipelines are reglarl" !oni#ored and inspe%#ed b" IP and UT. The inspe%#ion freen%" depends on #he presen# %ondi#ion of #he pipeline, e8pe%#ed %orrosion ra#e and ris asso%ia#ed wi#h #he pipeline. )ll iden#ified defe%#s, whi%h are #hrea#ening #he in#egri#" of #he pipeline, are repaired in a planned !anner and %han%es of an" #hird par#" da!age #o #he pipeline are !ini!al. Considering all #hese aspe%#s, #he probabili#" of leaage in a %lass4I pipeline is !ini!!, so i# is %on%lded #ha# e!ergen%" !a#erials shall be s#ored for one e&en# a# ea%h lo%a#ion for ea%h dia!e#er. )n e&en# in%ldes a pinhole lea, a !ajor lea and a rp#re. +eire!en# of an" addi#ional e!ergen%" !a#erial shall be dis%ssed wi#h PD6 on %ase #o %ase basis. The Plid%o Spli# Slee&es 7or si!ilar9 shall be pro%red for highes# ra#ing pipeline for ea%h dia!e#er. Howe&er, a&ailable Plid%o S!i#h Cla!p %an be sed for !inor leas if adja%en# area has sffi%ien# wall #hi%ness. In f#re, no Plid%o S!i#h Cla!p shall be pro%red. For se%#ional repla%e!en# in %arbon s#eel pipeline, i# is proposed #ha# 5 pipe join#s for ea%h dia!e#er a# e&er" lo%a#ion shall be s#o%ed fro! a&ailable pipe !a#erial. The wall #hi%ness and grade of pipe !a#erial shall be sele%#ed in s%h a !anner #ha# sele%#ed pipes %an be sed for se%#ional repla%e!en# in all pipelines of sa!e dia!e#er a# #ha# lo%a#ion wi#ho# an" %o!pa#ibili#" isse. For 3+0 pipelines, i# is de%ided #ha# se%#ional repla%e!en# shall be %arried o# sing la!ina#ed join#s p #o - barg and flanged spool pie%es shall be sed for se%#ional repla%e!en# for lines opera#ing a# !ore #han - barg. Minor leas shall be repaired b" o&er wrapping p #o a design pressre of - barg. ,!"

4oaction and Buantities o% Emergency (toc Materials

The 0!ergen%" S#o% Ma#erials are lo%a#ed in following s#ores. • (i!r •

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Mar!l MPS

GU-379 Pipeline Emergency Repair Manual •

Fahd M1PS

•

Mina )l Fahal

•

(i!r

The lis# of re%o!!ended e!ergen%" !a#erials is a##a%hed as )ppendi8 @.

5.0

#afet .!#

(a%ety reuirements during repair o% emergency de%ects

I# is #he responsibili#" of #he engineer4in4%harge #o ensre #he repair opera#ions are %arried o# in a %on#rolled and safe !anner. The engineer4in4%harge shall prepare a spe%ifi% a%#ion plan indi%a#ing #he da!age iden#ified, #he repair !e#hod #o be sed in line wi#h #his !anal. )ll pre%a#ions and safe#" !easres #o be #aen shall also be spe%ified in #he plan. The plan shall %on#ain #he following !ini!! infor!a#ion: 4 o o o

o

o o

o o

(a!e and #elephone n!ber of #he PD6 %o!!ander on #he s%ene. 1o%a#ion of defe%# Defe%# %a#egoria#ion*#"pe as per Se%#ion /./ for CS and Se%#ion 5.$ for 3+P and SP42/5$ Pipeline ser&i%e and de#ails 7flid #ranspor#ed, !a#erial grade, 6D, opera#ing pressre, wall #hi%ness9 +epair !e#hod 7repair op#ion, #ools reired, PS9 +epair !a#erial reired 7lis#, lo%a#ion and responsible par#" for arranging and #ranspor#ing #he repair !a#erial9 De#ails of %on#ra%#or who will %arr" o# #he repair 7na!e*#elephone9 Safe#" pre%a#ions, in%lding a&ailabili#" of adea#e fire pro#e%#ion eip!en#.

The repair opera#ions shold pro%eed onl" af#er #he reisi#e safe#" pre%a#ions for dealing wi#h an" e!ergen%" in%lding fire, e8plosion or spill ha&e been dl" adop#ed. The re%o!!ended safe#" !easres shall be based on #he #"pe of defe%# and #he le&el of lea as o#lined in SP42>$ and HS0 <>425. For raising an e!ergen%" alar! #he PD6 e!ergen%" response do%!en#s shall be followed. These do%!en#s o#line #he %on#ingen%" plans and safe#" !easres #o be adop#ed. )ll ne%essar" no#ifi%a#ion and repor#ing shall be done as per HS0 <>42 and as des%ribed in Se%#ion /.$.>.> abo&e. The personnel in&ol&ed in #he repair shall be pro&ided wi#h adea#e personnel pro#e%#ion eip!en# in line wi#h SP42/5- and S+D4S42 and shall wor #o #he Gdd" 7non4woring alone9 s"s#e! as o#lined in P+42@2. For welding on li&e lines, #he po#en#ial for fire is grea#er and #herefore #he wearing of fire resis#an# %lo#hing is essen#ial. In %ases of repairs #o a leaing pipeline, a haard assess!en# !s# be done i!!edia#el" and a worsi#e safe#" plan prod%ed. ) haard one shold be es#ablished b" de#er!ining #he a!on# of h"dro%arbon &apors in #he area. Infor!a#ion %on#ained in #he !a#erial da#a shee# for #he prod%# shold be %onsl#ed #o de#er!ine #he &ola#ili#" and #o8i%i#" %hara%#eris#i%. )n area assess!en# shall e8plore #he following !ini!! aspe%#s: 2. The fla!!abili#" le&el in #he area shold be %he%ed wi#h a %o!bs#ible gas de#e%#or. )#!ospheres abo&e 2N of #he lower e8plosi&e li!i# 71019 shall be

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de%lared haardos and a%%ess shold be res#ri%#ed. Those abo&e $N 101 shall no# be en#ered. /. To8i%i#" #es#ing shold be !ade wi#h dire%# reading ins#r!en#s #ha# in%lde %olori!e#ri% #bes. This will de#er!ine #he #"pe of #he pro#e%#i&e eip!en# reired for all personnel woring in #he area. 5. If #he repair is #o be done in a %onfined spa%e s%h as a #ren%h, #he o8"gen le&el !s# be %he%ed and !oni#ored. -.

The fla!!able haard one !s# be de!ar%a#ed #o prohibi# !o&e!en# of eip!en# and o#her igni#ion sor%es in#o #he one.

6#her essen#ial safe#" !easres #ha# shall be followed in%lde:4 2. If #he haard area e8#ends in#o pbli% areas, all ne%essar" warning signs and res#ri%#ed a%%ess !s# be p# in pla%e. /. The lea si#e shold be barri%aded and !ared #o pre&en# #he possibili#" of a%%iden#s or injries. 5. 0le%#ri%al ear#hing bonds !s# be pro&ided de #o #he possibili#" of an ele%#ri%al po#en#ial on #he pipeline. -. efore s#ar# of ho# wor, an" h"dro%arbon sa#ra#ed ear#h shold be re!o&ed. $. The e8%a&a#ion and i#s srronding area shold be #es#ed and %on#inosl" !oni#ored wi#h %o!bs#ible gas de#e%#ors or o8"gen !oni#ors or bo#h #o ensre #he a#!osphere re!ains safe. )dea#e &en#ila#ion is essen#ial #hrogho# #he wor dra#ion. In addi#ion, #he following safe#" !easres are spe%ifi%all" appli%able for 3+P pipeline repair wors :4 2. Under no %ir%!s#an%es shold brning eip!en# be sed for 3+P repair wors /. Spe%ial pre%a#ions shall be #aen when woring wi#h resins, %ring agen#s, and %a#al"s#s whi%h %an prod%e irri#a#ion when allowed #o %o!e in#o %on#a%# wi#h #he e"es or sin. )dea#e personnel pro#e%#ion !s# be worn e.g. fa%e !ass, safe#" glasses, rbber glo&es and barrier %rea!s. 5. )n" a%%iden#all" %on#a!ina#ed sin area shall be #horoghl" washed wi#h soap and wa#er. -. Spe%ial pre%a#ions shall be #aen #o pre&en# inhala#ion of #he glass fibre ds#. $. )ll redndan# %o!ponen#s shall be %orre%#l" disposed. .!"

Accidental releases

0&er" effor# shall be !ade #o %on#ain an" spill or a%%iden#al release, red%e #he %on#a!ina#ed area and #o di&er# #he oil awa" fro! sensi#i&e areas s%h as wadis, &illages, fa%ili#ies and sor%es of igni#ion. In %ases of spills #he !e#hods and pro%edres o#lined in P+4 2@-, P+42@<, SP4 2$ and SP42> shall be followed. ) spill shold be di&er#ed awa" fro! sensi#i&e areas where possible b" %##ing drainage %hannels fro! #he lea si#e #o a spe%iall" dg pi# or a bnded %olle%#ion poin#

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a# leas# $! awa" fro! #he area so #he oil %an be %olle%#ed in a safe and %on#rolled !anner. If ne%essar", addi#ional pi#s or bnded areas shold be %ons#r%#ed #o #ae an" o&erflow. Par#i%lar a##en#ion shall be #aen #o ensre #ha# #he oil does no# flow in#o a falaj s"s#e! as #his %old allow #he oil #o #ra&el a %onsiderable dis#an%e and %on#a!ina#e popla#ed*agri%l#ral areas.

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6.0

!eferences If no re&ision or isse da#e is !en#ioned referen%e shall be !ade #o #he la#es# re&ision in for%e a# #he #i!e of isse of #his Manal P2/ Engineering Re%erence 2ocuments

0+D 5@422

3idelines for 08%a&a#ion and oring arond 1i&e Pipelines

P2/ (peci%ications

SP42$ SP42= SP42> SP42< SP422/ SP42>$ SP422=> SP422>= SP422>> SP42/@ SP42/2 SP42/22 SP42/5SP42/5$ SP42/-=

0!issions #o )#!osphere HS0 spe%ifi%a#ion 4 )eos 0fflen#s Spe%ifi%a#ion for )%%iden#al +eleases #o 1and and a#er as#e Manage!en# Si#e Prepara#ion, )bandon!en# and +es#ora#ion Spe%ifi%a#ion for Fire and 08plosion +is Manage!en# Spe%ifi%a#ion for elding on Pressrised Pipes 7)!end!en#s* Spple!en#s #o D0P 5.2.=.59 (on4Des#r%#i&e 08a!ina#ion 7)!end!en#*Spple!en# #o )SM0 '9 elding of Class I Pipelines 7)!end!en#s*Spple!en#s #o )PI 22-9 Pipeline Cons#r%#ion Spe%ifi%a#ion Pipeline 6pera#ions and Main#enan%e Pipeline 0ngineering Heal#h, Safe#" and 0n&iron!en# Spe%ifi%a#ion 7PP09 D0P 52.-.=.2/4PD6 Pipeline +epairs 7)!end!en#s*Spple!en#s #o )SM0  52.- and  52.@9 Spe%ifi%a#ion for Pain#ing and Coa#ing of 6il and 3as Prod%#ion Fa%ili#ies

P2/ Procedures

P+4222 P+42= P+42== P+42=> P+42=@ P+42>2 P+42>5 P+42>P+42>= P+42@2 P+42@/ P+42@P+42@< P+422-= P+42/-= P+42/>$

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Pipeline +e!edial ors HS0 Manage!en# Pro%edre X Co!!ni%a#ing ? +epor#ing 0!ergen%" +esponse Do%!en# Se%#ion /II, Con#ingen%" Plan, 'ol. III Prod%#ion 6pera#ion 0!ergen%" +esponse Do%!en# 0!ergen%" +esponse Do%!en# Flow 1ine Sspension*)bandon!en# 3as Freeing, Prging and 1ea Tes#ing of Pro%ess 0ip!en# Flshing Flow 1ines Isola#ion of Pro%ess 0ip!en#s The Gdd" S"s#e! Pro%edre Pipeline Pigging Pro%edre Spills Clean4p and Si#e +es#ora#ion Pro%edre Spillage +epor#ing Pro%edre Flow 1ine Cold C##ing Pro%edre 0!ergen%" +esponse Do%!en# 0!ergen%" +esponse Do%!en#


P+42/>= P+42$=

S#d Pro%edre Aalifi%a#ion +e%ord for elding on #o Pressrised Pipes Pipeline Ho# Tap Manage!en# Pro%edre

P2/ Guidelines

3U4/>5

Per!i# #o or S"s#e!

P2/ @(E (tandards

HS0 <>42 HS0 <>425 S+D4S42 S+D4S45

In%iden# (o#ifi%a#ion, In&es#iga#ion, +epor#ing and Follow p F0+M Fa%ili#" Plan 3ideline S#andard for +espira#or" Pro#e%#i&e 0ip!en#s S#andards and 3idan%e for Personnel H"drogen Slphide Moni#ors

P2/ Policy

P145

PD6 0!ergen%" +esponse Poli%"

2EP

52.5@.=.2 52.-.5.5 52.-.5.52 52.-.-.5@ 52.-.=.22

Ho#4Tapping on pipelines, Piping and 0ip!en# 1ine Pipe for se in 6il and 3as 6pera#ions Under (on4sor Condi#ion 1ine Pipe for se in 6il and 3as 6pera#ions Under Sor Condi#ion H"dros#a#i% Pressre Tes#ing of (ew Pipelines Pipeline 1ea De#e%#ion

International (tandards

)SM0  52.- Pipeline Transpor#a#ion S"s#e!s for 1iid H"dro%arbons and 6#her 1iids )SM0  52.@ 3as Trans!ission Pipelines )PI +P 22> Pipeline Main#enan%e elding Pra%#i%es )PI +P // +epairing Crde 6il, 1iefied Pe#role! 3as, and Prod%# Pipelines )PI +P //2 Safe Ho# Tapping Pra%#i%es in #he Pe#role! ? Pe#ro%he!i%al Inds#ries )PI S#d. 22- elding of Pipelines and +ela#ed Fa%ili#ies )PI $1 Spe%ifi%a#ion for 1ine Pipe Re%erences speci%ic to GRP pipelines

D0P 52.-.2.2<

3+P Pipelines and Piping S"s#e!s ))!end!en#s* Spple!en# #o IS6 2-=2$<:2<@< Design and Cons#r%#ion of 3lass +einfor%ed Plas#i%s 73+P9 piping s"s#e!s for indi&idal plan#s or si#es )PI 2$1+ 1ow Pressre Fiberglass 1ine Pipe )PI 2$H+ Spe%ifi%a#ion for High Pressre Fibre 3lass 1ine Pipe SP42/-> Cons#r%#ion of Pipeline S"s#e!s in (on4Me#alli% Ma#erials IS6 2-=
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AppendiD-#8 Mechanical methods to 'e used in installation o% slee1es

Repair sleeve

Pipe

&ug and bolt method

Hydraulic jack Hi-yield chain link

Wood skid

Repair sleeve halves with side strips shown Pipe Wood skid

#tandard method

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Chain clam" method


AppendiD-"8 Plidco (plit = (lee1e

Studs & nuts in position

Test ports

End thrust studs

End sealing mechanism

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AppendiD-38 Plidco (mith = &lamp

orce-screw with cone

!lamp

"raw-#olt

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AppendiD-+8 Plidco >eld = &ap

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AppendiD-,8 FiDing arrangement %or Plidco >eld = End

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AppendiD-.8 Plidco Flange = Repair Ring

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AppendiD-78 Plidco Flange < Repair = (plit (lee1e

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AppendiD-; 8 4ist o% Emergency Materials )#. Pages*

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AppendiD-9 8 Manu%acturer Instructions

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$&I)CO C&A%$ 7 !I+ I#TA&&ATIO I#T!8CTIO# (AFE &@E&C 4I( • •

•

•

+ead and follow #hese ins#r%#ions %arefll". Do no# e8%eed #he !a8i!! end res#rain# indi%a#ed on #he label of #he Plid%o Cla!p E +ing. ) Plid%o Cla!p E +ing is designed for a spe%ifi%, longi#dinal and res#rain# in ni#s of for%e. 'erif" #he !a8i!! end res#rain# indi%a#ed on #he label is sffi%ien# #o resis# #he %o!bina#ion of h"dros#a#i%, d"na!i%, e8#ernal and #her!al ind%ed for%es. Do no# e8%eed #he !a8i!! #e!pera#re indi%a#ed on #he label of #he Plid%o Cla!p E +ing. The !a8i!! #e!pera#re indi%a#ed on #he label refers onl" #o #he sele%#ion of an allowable s#ress sed in #he design of #he Plid%o Cla!p E +ing. I# does no# i!pl" #he Plid%o Cla!p E +ing is %apable of resis#ing #her!al for%es asso%ia#ed wi#h raising #he #e!pera#re of #he pipeline #o #he !a8i!! #e!pera#re indi%a#ed on #he label. Please refer #o design end res#rain#J des%ribed earlier. If ne%essar", please %onsl# Plid%o Depar#!en# 2 for fr#her de#ail. If #he pipeline has been sh# down, repressring shold be done wi#h e8#re!e %a#ion. +e4pressring shold be a%%o!plished slowl" and s#eadil" wi#ho# srges, whi%h %old &ibra#e #he pipeline and fi##ing. Inds#r" %odes and s#andards are a good sor%e of infor!a#ion on #his sbje%#. Do no# e8%eed #he !a8i!! end res#rain# indi%a#ed on #he label as des%ribed earlier. Personnel shold no# be allowed near #he ins#alla#ion n#il #he Plid%o Cla!p E +ing has been pro&en. &4AMP = RIG &/MP/E(

Page $> of >=


PIPE PREPARAI/

2. +e!o&e all %oa#ings, rs# and s%ale fro! #he pipe srfa%e where #he Plid%o Cla!p E+ing will %on#a%# #he pipe. /. Sr&e" #he o#side of #he pipe #o %onfir! a %ir%lar %ross se%#ion, par#i%larl" in #he area of #he %la!ping se%#ion. This area shold be a s!oo#h %r&ed srfa%e wi#ho# inden#a#ions of fla# spo#s #ha# %old ad&ersel" affe%# proper gripping. 5. ) ring gage shold be sed for sb!erged pipelines where &isibili#" is li!i#ed. Plid%o has a&ailable ring gages #ha# %an a%%ra#el" sr&e" #he %ross se%#ional shape of #he pipe. -. The bol#ing for%e genera#ed when asse!bling #he #wo hal&es is %apable of shaping !inor o#4of4rond pipe. Ma8i!! allowable o&ali#" is appro8i!a#el" $N, depending on #he pipe wall #hi%ness. Fla# spo#s are &er" diffi%l# #o reshape and bol#ing for%e shold no# be relied on #o %orre%# fla##ened or inden#ed areas. $. Clean and lbri%a#e all Plid%o Cla!p E +ing. S#d bol#s and n#s. Pro&e free and eas" n# rnning prior #o ins#alla#ion. I(A44AI/

Careless handling %an da!age Cla!p E +ing. 1if#ing de&i%es s%h as %hains, %ables or lif# #r% fors shold no# %on#a%# #he %la!ping se%#ions. 2. )sse!ble #he Plid%o Cla!p E +ing loosel" on #he pipe, %en#ered o&er #he repair fi##ing, !aing %er#ain #he "ellow pain#ed ends are !a#%hed. There shold be appro8i!a#el" #hree 759 in%hes be#ween #he Plid%o Cla!p E +ing and #he repair fi##ing. See Cla!p E +ing %o!ponen#s. /. i#h #he #ie s#d bol# lgs in align!en#, inser# #he #ie s#d bol#. Hand #igh#en a n# on ea%h side of #he lgs. 5. )ll %la!ping s#d bol#s and n#s shold be nifor!l" #ored as indi%a#ed in #he Plid%o Tore Char# #he bes# resl#s are ob#ained b" !ain#aining an eal gap be#ween #he sidebars while #igh#ening The s#d bol#s. The sidebars will be gapped appro8i!a#el" Y #o  in%h. -. The #ie s#d bol# n#s need onl" be sng. ) high pre4s#ress on #he #ie s#d bol#s is ndesirable. $. To %o!ple#e asse!bl", #he %la!ping s#d bol#s shold be re%he%ed a# #he re%o!!ended #ore. )n in%rease in #ore on one s#d bol# %an %ase a de%rease in #ore on neighboring s#d bol#s. FIE42 E(IG

The Plid%o Cla!p E +ing is %apable of being field #es#ed p #o 2 #i!es i#s !a8i!! end res#rained indi%a#ed on #he label of #he Plid%o Cla!p E +ing. The %o!bina#ion of

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h"dros#a#i%, d"na!i%, e8#ernal and #her!al ind%ed for%ed an#i%ipa#ed dring #es#ing !s# be %onsidered. (/RAGE

Plid%o Cla!p E +ing shold be s#ored in a dr" en&iron!en# #o pre&en# an" npain#ed srfa%es rs#ing. P4I2&/ /RBUE &@AR (o!inal dia!e#er of s#d bol#s 7 in%hes9

ren%h 6pening a%ross fla#s

Cla!ping S#dbol# Tore 'alesO .@ Cf F#4lbs

.2$ Cf (!

f#4lbs

(!

$/,$ psi pre4s#ress $*@22 [442 >*@< 2@ 242*@@ 242*-44@ 245*@@ 242*/44@ 24$*@@ 245*-44@ 24>*@@ /@ /42*-@ /42*/44@

<$ 22@ 2= 2=/ /= /@ /$< 5/@ --= 5@$ -< ==$=2 >2< <>$ >@/ 2@ 25=@ 2$$ 25=@ 2@$$ 25@/ 2@ /--2 2>$@ /5/ 52/2 ///= /$@ 5=55 - 55= ---=/$ -@/= =-2/ @=<===@@@= 2/-@ ->,$ psi pre4s#ress /45*-@ -42*$<-> @=2>@> 2-=/@ 5@ -4$*@ >@2= 2$<@ 2-/2@ 2 /-=5< 542*/44@ $45*@ 2/->@ 2=<5<@ 545*-@ $45*2$5@ /@$= /@2- 5@2$> -@ =42*@ 2@=<< /$5$$ 5-/=/ -=-= 5>,$ psi pre4s#ress -42*-@ =42*/ 2>>5$ /-$ 5/$- --2/5 -42*/44@ =4>*@ /2@/ /@$@= 5@>/5 $/$@ -45*-@ >42*/-@// 55=$< -$=-5 =2@<2 $@ >4$*@ /@<@5 5<5/ $55->/55$42*-@ @ 55$@$ -$$5< =2@=@5@@> $42*/44@ @45*@ 5@=-> $/-$ >2/-$ <==< $45*-@ @45*--2<$ $<=2 2/$>@5 Tore &ales shown in #he #able represen# #wo differen# %oeffi%ien#s of fri%#ion 7Cf9W .@ and .2$. hen Cf eals .@, i# is ass!ed #he s#ds and n#s are %lean, free rnning, free of ob&ios flaws and lbri%a#ed wi#h a high grade graphi#e4oil #hread lbri%an#. hen Cf eals .2$, i# is ass!ed #he s#ds and n#s are %lean, free rnning, free of ob&ios flaws and lbri%a#ed wi#h a ligh# weigh# Ma%hine oil. The #ore &ales are safe !ini!!s and represen# appro8i!a#el" #he bol# pre4s#ress &ales lis#ed in #he #able.

Page $< of >=

242*2= 242*24>*2= 24$*@ 2425*2= / /45*2= /45*@ /4<*2= /45*/42$*2= 542*@ 542*/ 54>*@

> 2/ 2= >>> 22< 2/<= 2=-5 /55 /->@ 5$= -<2-


$&I)CO ,E&) 7 E)# I#TA&&ATIO I#T!8CTIO# (AFE &@E&C 4I( • • •

+ead and follow #hese ins#r%#ions %arefll". e absol#el" %er#ain #ha# #he %orre%# seal !a#erial has been sele%#ed for #he in#ended se. De#er!ine #he #"pe of join# #ha# #he Plid%o eld E 0nds %opling is e8pe%#ed #o %onne%#. See 7a9 and 7b9 below and de#er!ine #he appropria#e ra#ing fro! #he ra#ings lis#ed on #he label of #he Plid%o eld E0nds %opling. 7a9 Pipe (o# an%hored ) join# in whi%h #he pipe ends %old !o&e when sbje%#ed #o in#ernal or e8#ernal for%es, s%h as in#ernal pressre, #e!pera#re e8pansion and %on#ra%#ion, nderwa#er %rren#s, grond !o&e!en# or an" %o!bina#ion #hereof. The assigned Plid%o eld E 0nds Pipe (o# )n%hored ra#ing %onsiders onl" #he end for%e %rea#ed b" #he in#ernal pressre. I# does no# %onsider an" addi#ional e8#ernal for%es s%h as #e!pera#re e8pansion and %on#ra%#ion, nderwa#er %rren#s, grond !o&e!en# or an" %o!bina#ion #hereof. These addi#ional e8#ernal for%es !s# be de#er!ined. If an" of #hese for%es %anno# be res#rained b" %s#o!er pro&en #e%hnies, a Plid%o Cla!p E +ing shold be sed. 7b9 )n%hored pipe ) join# in whi%h #he pipe ends wold no# !o&e when sbje%#ed #o #hese sa!e for%es. Plid%o eld E 0nds )n%hored pipe ra#ing is #he !a8i!! pressre a# whi%h #he pipeline %an be opera#ed. I# ass!es #ha# #he pipeline is si#abl" )n%hored b" welding, b" #he se of an appropria#el" ra#ed Plid%o Cla!p E +ing or b" o#her %s#o!er pro&en #e%hnies.

•

6bser&e #he pressre and #e!pera#re ra#ings on #he label of #he Plid%o eld E 0nds %opling. Do no# e8%eed #he !a8i!! appropria#e pressre indi%a#ed on #he ni#. Minimum Pipe >all hicness For Plidco >eld = Ends ominal Pipe (i?e )inches * 2 / / 5 = @ 2 2/ 22= ? larger

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>all hicness )inches * ./ ./2@ ./>= ./5> ./5> ./@ .5// .5=$ .-< .-5@ .$

GU-379 Pipeline Emergency Repair Manual • •

•

•

Pipe wall #hi%ness less #han #hose lis#ed !a" be pshed inward b" #he for%e of #he %la!p s%rews. ) Plid%o Cla!p E +ing shold be %onsidered whene&er wall #hi%ness is less #han #hose lis#ed. ) Plid%o Cla!p E +ing shold also be %onsidered where high e8#ernal for%es 7s%h as nderwa#er Crren#s or #her!al %on#ra%#ions9 are an#i%ipa#ed, e&en if #he pipe has an adea#e wall #hi%ness. Pipelines shold be %arefll" blo%ed a# elbows and bends #o pre&en# pllo#s %ased b" in#ernal and e8#ernal for%esW or a Plid%o Cla!p E +ing shold be sed. Pipeline shold be e&enl" sppor#ed before re4pressring. Follow appli%able 52 %odes dring re4pressring. If #he Plid%o eld E 0nds %opling is welded or a si#able Plid%o Cla!pE +ing is sed, i# %an be %onsidered an an%hored join#. PIPE PREPARAI/

2. The pipe srfa%e in #he area of #he repair shold be %lean, free of %oa#ing and brrs and lbri%a#ed #o pre&en# abrasion #o #he seal. /. For badl" !isaligned or o# of rond pipe, i# is helpfl grind a pilo# be&el wi#h a generos #aper on #he pipe. This wold be eli!ina#e #he ris of da!age #o #he seal while slipping #he Plid%o eld E 0nds %opling o&er #he end of #he pipe 7See Figre 29

I(A44AI/

The seal %an be da!aged b" %areless handling. 1if#ing de&i%es s%h as %hains, %ables or lif# #r%s fors shold no# %on#a%# #he seal. Failre #o do so %an resl# in #he seal being da!aged or plled fro! i#s groo&es. 2. Measre and re%ord di!ension DJ as shown in Figre 5. This will be needed la#er if #he Plid%o eld E 0nds is welded #o #he pipe. /. Coa# all e8posed srfa%es of #he seal !a#erial wi#h a lbri%an#. The following %har# indi%a#es #he lbri%an#s #ha# are re%o!!ended for #he &arios seal !a#erials. I# !s# be de#er!ine #ha# #he lbri%an# is %o!pa#ible wi#h #he prod%# in #he pipeline. na4(

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), , C

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'i#on Sili%one (eoprene )flas Teflon Be&lar Pe#role! based lbri%an#  ) Sili%one based lbri%an#   3l"%erin based lbri%an#  C

), , C C , C ), , C ), , C ), , C

/$ \F -$ \F /$ \F /$ \F $ \F >$ \F

5. Slide #he pipe in#o #he Plid%o elds E 0nds %opling %o!ple#el". Mar on #he pipe one4half #he Plid%o eld E 0nds %oplings leng#h fro! #he !iddle of gap 7re%o!!ended gap no# #o e8%eed [ in%h9. Slide #he eld E 0nds %opling ba% #o #he !ar #o di&ide #he %opling eall" o&er #he join#. 7See Figre /9.

-. Cla!p s%rews ha&e %ase hardened %p poin#s whi%h are sed #o se%re #he %opling #o #he pipe. The shans are !ild s#eel and fll" weldable. Cla!p s%rews shold be #igh#ened e&enl", !ain#aining an eal spa%e be#ween #he pipe and #he %opling sing #he re%o!!ended #ore &ales. Cla!p s%rews are designed for #he assigned Plid%o eld E 0nds (o# an%hored ra#ing whi%h %onsiders onl" #he end for%e %rea#ed b" #he in#ernal pressre. Cla!p s%rews do no# %onsider an" addi#ional e8#ernal for%es or s#resses i!posed on #he pipeline. $. )%%ra#e %la!p s%rew #ore &ales are &er" i!por#an# when #he Plid%o eld E 0nds %opling is sed on a pipeline join# #ha# is (6T )(CH6+0D. Do no# e8%eed #he Pipe (o# )n%hored +a#ing lis#ed on #he label of #he Plid%o eld E 0nds n#il sbseen# welding has been %o!ple#ed.

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=. Che% all %la!p s%rews #o !ae %er#ain ea%h has re%ei&ed a# leas# #he !ini!! #ore spe%ified in %har# below. Cp poin# Cla!p S%rews $*@422 [42

Mini!! Tore f#4lbf 2 2$

(! 25= /-

>. Thrs# s%rews a%#i&a#e #he seals. The" are !ade of !ild %arbon s#eel and are fll" weldable. The" shold be #igh#ened gradall" and nifor!l" arond #he %ir%!feren%e. Firs#, sng all #he #hrs# s%rews fir!l". Then ad&an%e ea%h #hrs# s%rew abo# 2*@ of a #rn before pro%eedings #o an adja%en# #hrs# s%rew. I# will be ne%essar" #o !ae !an" %ir%i#s arond #he %opling before %o!ple#ing #he #hrs# s%rew #ore opera#ion. Use re%o!!ended #ore &ales in #he %har# below. Thrs# S%rews 5*@42= 425 $*@422

Tore +ange f#4lbf /4/$ 54- >4@

(! /@45-24$$ <$42<

@. ) final #ore range, shown in #he %har# abo&e, will be adea#e #o %o!ple#e #he asse!bl". <. +epressring af#er #he repair shold be done wi#h e8#re!e %a#ionW slowl" and s#eadil" wi#ho# srges, whi%h %old &ibra#e #he pipeline and fi##ing. Inds#r" %odes and s#andards are a good sor%e of infor!a#ion on #his sbje%#. 6pera#ing pressre !s# no# e8%eed #he !a8i!! appropria#e Pipe )n%hored or Pipe (o# )n%hored +a#ing. Personnel shold no# be allowed near #he ins#alla#ion n#il #he seal has been pro&en. FIE42 >E42IG I(RU&I/(

Pipeline shold be fll and nderflow. Use absol#el" dr" ele%#rodes, whi%h are of eal or grea#er #ensile s#reng#h #han #he pipe. Carefll" %on#rol #he sie and shape of #he %ir%!feren#ial fille# weld. The weld is reired #o an%hor #he join# and gi&e longi#dinal s#abili#" #o #he pipeline. The sie of #he fille# weld shold be a# leas# 2.- #i!es #he wall #hi%ness of #he pipe. This ass!es a 2. join# effi%ien%". There !a" be need #o sele%# a differen# join# effi%ien%" based on le&el of inspe%#ion or "or %o!pan"s welding poli%". S#ri&e for a %on%a&e fa%ed fille# weld wi#h s#rea!lined blending in#o bo#h !e!bersW a&oid no#%hes and nder%#s. The s!oo#her and !ore s#rea!lined #he weld, #he grea#er #he resis#an%e #o fa#ige failre. The wors# Possible shape wold be a hea&" reinfor%ed %on&e8 weld wi#h an nder%#. I!proper weld shape %an lead #o rapid fa#ige failre, whi%h %an %ase leaage, rp#re or e8plosion wi#h a##endan# serios %onseen%es.

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elders and weld pro%edres shold be alified in a%%ordan%e wi#h )PI s#andard 22-, elding of Pipelines and +ela#ed Fa%ili#iesJ or +P 22>, +e%o!!ended Pipeline Main#enan%e elding Pra%#i%esJ la#es# edi#ion. )PI 22- and 22> ha&e eas" #o follow dire%#ions for pro%edre alifi%a#ion. Plid%o en%orage #he se of low h"drogen ele%#rodes 704KK2@9 be%ase of #heir high resis#an%e #o !ois#re pi%4p and h"drogen %ra%ing. Shielded !e#al ar% welding 7S)9 filler !e#als lis#ed in )PI 22- and 22> in%lde #he %elllose %oa#ed ele%#rodes 704KK2 series9 whi%h are of#en preferred be%ase of #he e8%ellen# downhill welding %hara%#eris#i%s. There are a%%ep#able filler !e#al, pro&ided #he" are pro&en b" pro%edre alifi%a#ion. I# is &er" i!por#an# #ha# #he field welding pro%edre %losel" follow #he essen#ial &ariables of #he alified pro%edre so #ha# #he ali#" of #he field weld is represen#ed b" #he ph"si%al #es#s perfor!ed on #he pro%edre alifi%a#ion #es# spe%i!en. Di!ension DJ as !easred dring #he ini#ial Ins#alla#ion, !a" now be sed #o !ar off lo%a#ions )J and J as shown in Figre 5. These lo%a#ions are #he sa!e dis#an%e fro! #he weld as #he seal lo%a#ion CJ. To pre&en# da!age #o #he seals, !oni#or #he hea# genera#ed b" welding or prehea#ing, par#i%larl" a# lo%a#ion )J and J, b" sing #e!pera#re %ra"ons or probe #her!o!e#ers. If #he hea# genera#ed approa%hes #he #e!pera#re li!i# of #he seal !a#erial, whi%h is indi%a#ed on #he label and in #he seal lbri%a#ion %har#, welding shold be dis%on#ined or seen%ed #o ano#her par# of #he fi##ing so #ha# #he affe%#ed area has a %han%e #o %ool. >E42IG (EBUE&E

2. Ca#ion shold be obser&ed so #ha# welding or pre hea#ing does no# o&erhea# #he seals. Seen%e #he welding so #ha# #he hea# is no# %on%en#ra#ed in one area. /. Thrs# S%rews shold be %# or brned off flsh. S#ar# wi#h #he fille# weld #o #he pipe arond %ir%!feren%e and in%lde seal welding #he #hrs# s%rews. 7See Figre 59. 5. C# or brn off %la!p S%rews appro8i!a#el" 5*2=J abo&e #he o#side srfa%e of #he %opling and seal weld. 6ne %la!p s%rew near #he #op !a" be re!o&ed #o ser&e as a &en# while welding and also as a final #es# poin# for leaage. 7See Figre 59

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FIE42 E(IG

The Plid%o eld E0nds %opling %an be field #es#ed p #o 2  #i!es #he appropria#e pipe )n%hored or Pipe (o# )n%hored + a#ing. (/RAGE I(RU&I/(

Plid%o eld E0nds %opling shold be s#ored in a dr" en&iron!en# #o pre&en# #he npain#ed srfa%es fro! rs#ing. S#orage #e!pera#res shold no# e8%eed 2/ $F 7-< \C9. Co&er wi#h a dar pol"e#h"lene #o eep #he dire%# sn ligh# fro! #he seals. I# is bes# #o e8%lde %on#a!ina#ion, ligh#, oone and radia#ion. I!properl" s#ored Plid%o eld E 0nds %oplings %an %ase #he gase# !a#erial #o be%o!e %ra%ed and bri##le and lose i#s abili#" #o seal.

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$&I)CO #$&IT 7 #&EE9E I#TA&&ATIO I#T!8CTIO# (AFE &@E&C 4I( • •

•

• •

+ead and follow #hese ins#r%#ions %arefll". The Plid%o Spli# E Slee&e shold ne&er be sed #o %ople pipe nless sffi%ien# end res#rain# is pro&ided s%h as wi#h #he Plid%o Cla!p E +ing. The Plid%o Spli# ESlee&e has no end res#rain# in i#s nwelded %ondi#ion, and if so #ilied %old resl# in e8plosion, fire, dea#h, personal injr", proper#" da!age and*or har! #o en&iron!en#. 6bser&e woring pressre and #e!pera#re on #he label of #he Plid%o Spli# E Slee&e. Do no# e8%eed !a8i!! woring pressre or #e!pera#re as indi%a#ed on #he ni#. hen repairing an a%#i&e lea, e8#re!e %are !s# be #aen #o gard personnel. Se&ere injr" or dea#h %old resl#. If #he pipeline has been sh# down, repressring #o #es# #he seals af#er repair shold be done wi#h e8#re!e %a#ion. +e4pressring shold be a%%o!plished slowl" and s#eadil" wi#ho# srges, whi%h %old &ibra#e #he pipeline and fi##ing. Inds#r" %odes and s#andards are a good sor%e of infor!a#ion on #his sbje%#. Do no# e8%eed #he !a8i!! woring pressre. Personnel shold no# be allowed near #he repair n#il #he seal has been pro&en. PIPE PREPARAI/

2. +e!o&e all %oa#ings, rs# and s%ale fro! #he pipe srfa%e where #he %ir%!feren#ial seals of #he Plid%o Spli# ESlee&e will %on#a%# #he pipe. /. The seal %an #olera#e !inor srfa%e irreglari#ies p #o ± 2*5/J. I(A44AI/

The seals and 3irder +ings %an be da!aged b" %areless handling. 1if#ing de&i%es s%h as %hains, %ables or lif# #r% fors shold no# %on#a%# #he seals or girder +ings. Con#a%# %an resl# #he seals being plled fro! #heir groo&es. 7See Figre 29 2. Coa# all e8posed srfa%es of #he seals wi#h a lbri%an#. The following %har# indi%a#es #he lbri%an#s #ha# are re%o!!ended for &arios seals. Pe#role! based lbri%an# : Sili%one based lbri%an# : 3l"%erine based lbri%an# : na4 ( 'i#on Sili%one 0#h"lene Prop"lene (eoprene )flas Teflon Be&lar

)  C ), , C ), , C C , C , C ), , C ), , C ), , C

The %s#o!er !s# de#er!ine if #he lbri%an# is %o!pa#ible wi#h #he prod%# in #he pipeline.

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/. Clean and lbri%a#e all s#d bol#s and n#s, and pro&e free and eas" n# rnning prior #o ins#alla#ion. 5. )sse!ble #he Plid%o Spli#E Slee&e arond #he pipe !aing sre #he "ellow pain#ed ends are !a#%hed and #ha# #he fi##ing is %en#ered o&er #he lea and da!aged area as !%h as possible. So!e#i!es i# is helpfl #o loosel" asse!ble

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#he Plid%o Spli# E Slee&e #o one side of #he lea, #hen reposi#ion i# %en#ered o&er #he lea. -. )ll s#d bol#s and n#s shold be nifor!l" #ored as indi%a#ed b" #he Plid%o Spli# ESlee&e Tore Char#. The bes# resl#s are ob#ained b" !ain#aining an eal gap all arond be#ween side bars while #igh#ening #he s#dbol#s. $. To %o!ple#e asse!bl", )11 s#d bol#s shold be re%he%ed a# #he re%o!!ended #ore. Beep in !ind, #he sligh#es# in%rease in #ore on one s#dbol# %an %ase a de%rease in #ore on neighboring s#dbol#s. =. The side bars are grapped appro8i!a#el" 2*@J when #he Plid%o Spli# ESlee&e is fll" #igh#ened. FIE42 >E42IG I(RU&I/(

If #he pipeline has been sh#down, repressring #o #es# #he seals af#er repair shold be done wi#h e8#re!e %a#ion. +epressring shold be a%%o!plished slowl" and s#eadil" wi#ho# srges whi%h %old &ibra#e #he pipeline and fi##ing. Inds#r" %odes and s#andards are a good sor%e of infor!a#ion on #his sbje%#. Do no# e8%eed !a8i!! woring pressre. Personnel shold no# be allowed near #he repair n#il #he seal has been pro&en. Use absol#el" dr" ele%#rodes whi%h are eal or grea#er #ensile s#reng#h #han #he pipe. Carefll" %on#rol #he sie and shape of #he %ir%!feren#ial fille# welds. The sie of #he fille# welds shold be a# leas# 2.- #i!es #he wall #hi%ness of #he pipe. This ass!es a 2. join# effi%ien%". S#ri&e for a %on%a&e fille# weld, wi#h s#rea!lined blending in#o bo#h !e!bersW a&oid no#%hes and nder%#s. I!proper weld shape %an lead #o rapid fa#ige failre whi%h %an %ase leaage, rp#re or e8plosion wi#h a##endan# serios %onseen%es. elders and weld pro%edres shold be alified in a%%ordan%e wi#h )PI S#andard 22-  elding of Pipelines and rela#ed Fa%ili#ies,J or +P 22>  +e%o!!ended Pipeline Main#enan%e elding Pra%#i%es,J la#es# edi#ion. )PI 22- and 22> ha&e eas"4#o4follow dire%#ions for pro%edre alifi%a#ion. Plid%o en%orage #he se of low h"drogen ele%#rodes 7 04KK2@9 be%ase of #heir high resis#an%e #o !ois#re pi%4p and h"drogen %ra%ing. The" are also #he preferred ele%#rode for seals welding #he s#d bol#s and n#s. Shielded !e#al ar% welding 7SM)9 filler !e#als lis#ed in )PI 22- and 22> in%lde #he %elllose %oa#ed ele%#rodes 704KK29 series whi%h are of#en preferred be%ase of #he e8%ellen# downhill welding %hara%#eris#i%s. These are a%%ep#able filler, !e#als, pro&ided #he" are pro&en b" pro%edre alifi%a#ion. Celllose %oa#ed ele%#rodes are no# re%o!!ended for seal welding #he s#d bol#s and n#s. I# is &er" i!por#an# #ha# #he field welding pro%edre %losel" follow #he essen#ial &ariables of #he alified pro%edre so #ha# #he ali#" of #he field weld is represen#ed b" #he ph"si%al #es#s perfor!ed on #he pro%edre alifi%a#ion spe%i!en. Moni#or #he hea# genera#ed b" welding or prehea#ing, par#i%larl" near #he area of #he seals, b" sing #e!pera#re %ra"ons or probe #her!o!e#er. If #he hea# genera#ed approa%hes #he #e!pera#re li!i# of #he seal !a#erial whi%h is indi%a#ed on #he label,

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welding shold be dis%on#ined or seen%ed #o ano#her par# of #he fi##ing so #ha# #he affe%#ed area has a %han%e #o %ool. Seal welding #he grade 4> s#dbol#s of a Plid%o Spli# E Slee&e is #he !os# diffi%l# phase of field welding. The" are !ade of )ISI -2- s#eel wi#h a high %arbon ei&alen%e. " sing low h"drogen ele%#rodes 7 04KK2@9 and a !odes# prehea# 7 do no# e8%eed / degree F9, #he proble! of h"drogen %ra%ing and pin holes %an be red%ed. The prehea# will dr" o# na" !ois#re, oil da!pness or #hread lbri%an# #ha# !a" be presen# in #he seal weld area. >E42IG (EBUE&E

2. Ca#ion shold be obser&ed so #ha# welding does no# o&erhea# #he seals. Seen%e #he welding so #ha# #he hea# is no# %on%en#ra#ed in one area. I# will be ne%essar" #o re4#ore #he s#dbol#s and n#s periodi%all" dring field welding be%ase weld %on#ra%#ion %ases #he! #o loosen. /. Fille#4weld ends #o pipe 5. Seal4weld side openings -. +e4#ore s#d bol#s and n#s $. Seal4weld arond bo##o!s of n#s #o side bars. =. Seal weld n#s #o s#dbol#s.

FIE42 E(IG @E P4I2&/ (P4I= (4EE:E

The Plid%o Spli# E Slee&e %an be field #es#ed p #o 2  #i!es i#s design woring pressre. (/RAGE I(RU&I/(

Plid%o Spli# E Slee&es shold be s#ored in a dr" en&iron!en# #o pre&en# #he npain#ed srfa%es fro! rs#ing. S#orage #e!pera#res shold no# e8%eed 2/ $ 7-< \C9. Co&er wi#h a dar pol"e#h"lene #o eep #he dire%# sn ligh# fro! #he seals. I# is bes# #o e8%lde %on#a!ina#ion, ligh#, oone and radia#ion. I!properl" s#ored Plid%o Spli# E Slee&es %an %ase #he seal !a#erial #o be%o!e %ra%ed and bri##le and lose i#s abili#" #o seal. P4I2&/ (P4I = (4EE:E /RBUE &@AR (o!inal

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ren%h

Cla!ping S#dbol# 7Tore 'alesO9


dia!e#er of s#d bol#s 7 in%hes9 $*@22 [442 >*@< 2@ 242*@@ 242*-@ 245*@@ 242*/@ 24$*@@ 245*-@ 24>*@@ /@ /42*-44@ /42*/@

6pening a%ross fla#s

242*2= 242*24>*2= 24$*@ 2425*2= / /45*2= /45*@ /4<*2= /45*/42$*2= 542*@ 542*/ 54>*@

.@ Cf f#4lbs

55 $> <2 25$ 2<> />5> -@$ =2> >@/ <=@ 22@ 2=<$ /5-

f#4lbs

.2$ Cf (!

/$, psi pre4s#ress -$ $= >> <@ 2/5 2$= 2@5 /55 /=> 5-/ 5>/ -@ $/ =$2 =$@ @$> @5> 2<= 2= 25<2525 2>5 2= /22= //<@ 5$5 52>5 -/52

>= 255 /2/ 52= -==$2 @@5 22=/ 2-@= 2@< /5-= /@=< -2- $>5>

(!

/5 psi pre4s#ress /45*-44@ -42*/@@ 5<$//>@5 5@ -4$*@ 5>@$ $255 =@@$ <55= 542*-44@ $ -@/= =$-$ @><< 22<52 542*/@ $45*@ =-5 @2<225> 2-<=> 545*-@ $45*>--> 2<< 25=/= 2@->> -@ =42*@ <$$ 2//>@ 2=$< //-<> 2@,@ psi pre4s#ress -42*-@ =42*/ @@<2 2/>$ 2=525 //2/ -42*/@ =4>*@ 2$=< 2-552 2<-25 /=5/-45*-@ >42*2/--2=@>//@@/ 52/@ $@ >4$*@ 2-$5 2<>5 /=>-5 5=/=5 $42*-@ @ 2=@5> //@5 522-/$$ $42*/@ @45*@ 2<5>$ /=/>/ 5$>2> -@-55 $45*-@ @45*//2$= 5--@>5 $$-/$ =@ <42*@ /$2<2 5-2= -=$=5$< Tore &ales shown in #he #able represen# #wo differen# %oeffi%ien#s of fri%#ion 7Cf9W .@ and .2$. hen Cf eals .@, i# is ass!ed #he s#ds and n#s are %lean, free rnning, free of ob&ios flaws and lbri%a#ed wi#h a high grade graphi#e4oil #hread lbri%an#. hen Cf eals .2$, i# is ass!ed #he s#ds and n#s are %lean, free rnning, free of ob&ios flaws and lbri%a#ed wi#h a ligh# weigh# !a%hine oil. The #ore &ales are safe !ini!!s and represen# appro8i!a#el" #he bol# pre4s#ress &ales lis#ed in #he #able.

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$&I)CO F&A+E 7 !E$AI!-!I+ I#TA&&ATIO I#T!8CTIO# (AFE &@E&C 4I( • • • • •

• •

+ead and follow #hese ins#r%#ions %arefll". The Plid%o Flange E+epair +ing !a" be sed wi#h #he pipeline in opera#ion or sh#down. e absol#el" %er#ain #ha# #he %orre%# seal !a#erial has been sele%#ed for #he in#ended se. The Plid%o Flange E +epair +ing shold ne&er be sed #o %ople flanges. (o end res#rain# is pro&ided wi#h #he Plid%o Flange E +epair +ing. 6bser&e woring pressre and #e!pera#re on #he label of #he Plid%o Flange E +epair +ing. Do no# e8%eed #he !a8i!! woring pressre or #e!pera#re as indi%a#ed on #he ni#. 'erif" #he #igh#ness of all #hreaded &en#s and %onne%#ions. hen ins#alling a Plid%o Flange E +epair +ing on non4leaing flanges sb!erged nder wa#er 7or an" liid9, Plid%o s#rongl" re%o!!ends #he &en#s be open dring ins#alla#ion #o pre&en# e8%essi&e pressre bildp wi#hin #he fi##ing de #o h"drali% lo%. PREPARAI/

2. +e!o&e all %oa#ings, rs# and s%ale fro! #he flange srfa%e where #he %ir%!feren#ial seals of #he Plid%o Flange E +epair +ing will %on#a%# #he flange. The seal %an #olera#e !inor srfa%e irreglari#ies p #o ± 2*5/J. /. Mae sre #he gap be#ween #he flanges is %lear #o #he flange s#d bol#s. 5. Clean and lbri%a#e all Plid%o Flange E +epair +ing s#d and n#s. Pro&e free and eas" n# rnning prior #o ins#alla#ion. -. Coa# all e8posed srfa%es of #he sealing !a#erial wi#h lbri%an#. The following %har# indi%a#es #he lbri%an#s #ha# are re%o!!ended and #he !a8i!! #e!pera#re li!i# for &arios seals. The %s#o!er !s# de#er!ine if #he lbri%an# is %o!pa#ible wi#h #he prod%# in #he pipeline. Pe#role! based lbri%an# Sili%one based lbri%an# 3l"%erine based lbri%an# na4 ( 'i#on Sili%one (eoprene )flas Teflon Be&lar

: : :

)  C ), , C ), , C C , C ), , C ), , C ), , C

//$ degree F /$ degree F -$ degree F /$ degree F /$ degree F $ degree F >$ degree F

I(A44AI/

The seal and 3irder +ings %an be da!aged b" %areless handling. 1if#ing de&i%es s%h as %hains, %ables or lif# #r% fors shold no# %on#a%# #he seals or girder +ings. Con#a%# %an resl# #he seals being plled fro! #heir groo&es.

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2.

/. 5. -. $.

)sse!ble #he Plid%o Flange E +epair +ing arond #he flanges !aing %er#ain #he fi##ing is %en#ered o&er #he gap be#ween #he flanges and #ha# #he "ellow pain#ed ends are !a#%hing. )sse!ble #he s#ds and n#s hand #igh#. )ll s#d bol#s and n#s shold be nifor!l" #ored as indi%a#ed b" #he Plid%o Tore Char#. The #ore &ales shown appl" p #o and in%lding > degree F. The bes# resl#s are ob#ained b" !ain#aining an eal gap be#ween #he side bars while #igh#ening #he bol#s. To %o!ple#e asse!bl", #he s#d bol#s shold be re%he%ed a# #he re%o!!ended #ore. The side bars are gapped appro8i!a#el" 2*@J #o 5*2=J when #he Plid%o Flange E +epair +ing is fll" #igh#ened. P4I2&/ /RBUE &@AR

(o!inal dia!e#er of s#d bol#s 7 in%hes9

ren%h 6pening a%ross fla#s

Cla!ping S#dbol# Tore 'alesO

$*@22 [442 >*@< 244@ 242*@@ 242*-44@ 245*@@ 242*/44@ 24$*@@ 245*-44@ 24>*@44@ /44@ /42*-44@ /42*/44@

242*2= 242*24>*2= 24$*@ 2425*2= / /45*2= /45*@ /42*/ /45*/42$*2= 542*@ 542*/ 54>*@

55 $> <2 25$ 2<> />5> -@$ =2> >@/ <=@ 22@ 2=<$ /5-

/45*-44@ 544@ 542*-44@ 542*/44@

-42*-4$*@ $ $45*@

525 -22$/-= =$=@

.@ Cf f#4lbs

(! f#4lbs /$, psi pre4s#ress -$ $= >> <@ 2/5 2$= 2@5 /55 /=> 5-/ 5>/ -@ $/ =$2 =$@ @$> @5> 2<= 2= 25<2525 2>5 2= /22= //<@ 5$5 52>5 -/52 -/-$$>< >22@<=

$=>@ >-@<$=22<<>

.2$ Cf (! >= 255 /2/ 52= -==$2 @@5 22=/ 2-@= 2@< /5-= /@=< -2- $>5> >=<< 22-@ 2/<=< 2=/=@

Tore &ales shown in #he #able represen# #wo differen# %oeffi%ien#s of fri%#ion 7Cf9W .@ and .2$. hen Cf eals .@, i# is ass!ed #he s#ds and n#s are %lean, free rnning, free of ob&ios flaws and lbri%a#ed wi#h a high grade graphi#e4oil #hread lbri%an#. hen Cf eals .2$, i# is ass!ed #he s#ds and n#s are %lean, free rnning, free of ob&ios flaws and lbri%a#ed wi#h a ligh# weigh# Ma%hine oil. The #ore &ales are safe !ini!!s and represen# appro8i!a#el" #he bol# pre4s#ress &ales lis#ed in #he #able.

(EA4A IE&I/

6ne or !ore sealan# %o%s are spplied wi#h ea%h Plid%o Flange E +epair +ing. These !a" be sed for &en#ing b" re!o&ing #he b##on heads while #he %o%s are %losed. 6pen #he sealan# %o%s #o allow prod%# #o &en# while bol#ing, if desired. Close %o%s and re4ins#all b##on heads. e sre %o%s are open before inje%#ing sealan#.

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Conne%# a sealan# gn #o fi##ing and inje%# sealan# #hrogh all b##on head fi##ings a li##le a# a #i!e n#il #he Plid%o Flange E +epair +ing is fll. 1eaage will sall" slow down #o a whisper #hrogh #he flange bol#s. Inje%#ion shold pro%eed slowl", inje%#ing a li##le a# a #i!e #hrogh #he b##on head neares# #he lea n#il #o#al seal off is a##ained. So!e#i!es a #o#al seal off is ins#an#, in whi%h %ase all sealan# inje%#ion shold be s#opped. 6bser&e for a while #o see if a lea de&elops. 3enerall" #he leaage will red%e #o whispers and #he ra#e of sealan# inje%#ion shold be red%ed propor#iona#el". ) good rle #o re!e!ber is when #he ra#e of leaage de%reases #he ra#e of sealan# inje%#ion shold be de%reased. 6f#en, dring #he final phases of seal off, #here is an i!plse #o p!p sealan# ealosl". This does no# alwa"s gi&e desirable resl#s. The %onfined sealan#, ha&ing no where #o go, is for%ed o# a pre&iosl" sealed bol# hole or gase#. 6%%asionall" #he srfa%es #o be sealed are nreasonabl" gapped or badl" %orroded. These !a" reire sealan#s whi%h are &er" %oarse and whi%h %anno# be p!ped #hrogh #he res#ri%#ion of s#andard b##on heads. These sealan#s %an be inje%#ed dire%#l" #hrogh #he sealan# %o%. (/RAGE I(RU&I/(

Plid%o Flange E +epair4+ing shold be s#ored in a dr" en&iron!en# #o pre&en# #he npain#ed srfa%es fro! rs#ing. S#orage #e!pera#res shold no# e8%eed 2/ $ 7-< \C9. Co&er wi#h a dar pol"e#h"lene #o eep #he dire%# sn ligh# fro! #he seals. I# is bes# #o e8%lde %on#a!ina#ion, ligh# oone and radia#ion. I!properl" s#ored Plid%o Spli# E Slee&es %an %ase #he seal !a#erial #o be%o!e %ra%ed and bri##le and lose i#s abili#" #o seal.

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GRE REPAIR PR/&U2RE( 8 (MI@ FIER Introduction

The repair of S#ar line pipe pri!aril" in&ol&es #he ins#alla#ion of a flange se#. 1ower pressre prod%#s offer al#erna#i&e !e#hods #o flange se#s, b# are li!i#ed in pressre ra#ing. The following are #he repair !e#hods and #he li!i#a#ions of ea%h: &AUI/8 Mae sre #ha# #he line is properl" &en#ed prior #o s#ar#ing repair wor. Flange (et

Pri!aril" for )PI @rd prod%#s ] $ PSI. Se# in%ldes / flanges, n#s, bol#s, washers and gase#s. Depending on #he lo%a#ion of #he lea, a de%ision !s# be !ade as #o how #o re%onne%# #he line wi#h #he flanges. The se of a !ini!! leng#h nipple !a" be reired #o ins#all #he flange se#.

• • • •

/PI/(8

2. Mae se of #he nda!aged pipe b" re#hreading #he ends in #he field allowing for #he flange se#. +eferen%e #he field #hread ra#ing %har# /.@./ of #he +e%o!!ended Ins#alla#ion Pra%#i%es for #he proper #hreading !e#hod #o !ain#ain #he s"s#e! pressre ra#ing. /. If e8#ra pipe is a&ailable, repla%e #he da!aged join# wi#h a new join# whi%h %an be shor#ened in #he field #o !ae roo! for #he flange se# and a !ini!! leng#h nipple. The pressre ra#ing of #he s"s#e! %an be !ain#ained sing #his s"s#e! on an" )PI @rd prod%#. 5. Pr%hase a prefabri%a#ed repair join# designed #o !e%hani%all" repla%e a fll 7<.2- M#rs. no!inal9 join# of pipe and !ae roo! for a flange se#. This !e#hod wors for )PI @rd. /PI/ /E PR/&E2URE8 Consider #he leng#h of #he da!age. If #he wid#h of a se# of flanges will repair • #he area, a nipple 7long enogh #o repair #he da!aged area9 and a %opling will be reired along wi#h #he flange se#. C# #he da!aged area of #he pipe sing a ha%saw, #aing in#o %onsidera#ion • #he #o#al la"ing leng#h of #he par#s needed #o !ae #he repair. Depending on how long #he da!aged area is, an e8#ra join# of pipe !a" be • reired. +e#hread bo#h sare %# ends or bell 8 !ale adap#ers. •

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Figure 1

/PI/ >/ PR/&E2URE8 C# #he da!aged join# sing a ha%saw. • +e!o&e bo#h re!aining ends sing 7/9 S#ar !e#al fri%#ion wren%hes. • +epla%e wi#h a new join# of pipe. • Shor#en #he join# as reired #o fi# #he flange se# and a !ini!! leng#h nipple. • Do no# %# #he pipe in #he pipe bod", onl" in #he pse# area. • Field #hread #he pipe. • Ins#all #he flange se#. •

Figure 2

/PI/ @REE PR/&E2URE8 C# #he da!aged join# of pipe sing a ha%saw. • +e!o&e bo#h re!aining ends sing 7/9 S#ar !e#al fri%#ion wren%hes. • +epla%e #he da!aged join# wi#h #he spe%ial leng#h repair join#s. • Ins#all #he flange se#. •

Figure 

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GU-379_Pipeline_Emergency_Repair_Manual.doc

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