Pipeline Repair

PII - GE

Mike Brown
Presentation is to:

• Review the range of repair methods available

• Consider the applicability of these repair methods to

the various types of defect

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July, 2008
Pipeline Research Council International
• Updated Pipeline Repair Manual
> Based on published literature, vendor
literature, and a survey of industry
experience.
> A large number of documents were obtained
from the published literature and vendors.

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July, 2008
Pipeline Research Council International
Board of Director’s Companies
Southern California Gas Company
Saudi Aramco
Panhandle Energy
Gaz de France – R & D Division
N.V. Nederlandse Gasunie
Chevron Pipe Line Company
Columbia Gas Transmission Corp.
Pretrobras R & D Center
Texas Gas Transmission LLC
CenterPoint Energy Gas Transmission
Mississippi River Transmission Corp.
TransGas
Buckeye Partners
Total S.A.
Pacific Gas and Electric Company
Northern Plains Natural Gas Co.
Williams Gas Pipeline
TransCanada
TEPPCO
Enbridge Pipeline & Energy Partners
BP Exploration & Production
National Fuel Gas Supply Corp
National Grid Transco
Gulf South Pipeline Company, LP
Shell Pipeline Company LP
Dominion Transmission
ConocoPhillips Pipeline Company
Duke Energy Gas Transmission
ExxonMobil Pipeline Company
Colonial Pipeline Company
Marathon Pipe Line LLC
Gasum Oy
Explorer Pipeline Company
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July, 2008
PRCI Repair Manual

• Response to Discovery of an Anomaly or Defect

• Pipeline Repair Methods
• Appropriate Repairs for Various Kinds of Defects
• Guidelines for a Repair Procedure

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July, 2008
Pipeline Repair Methods

• The most commonly used methods

> Removal and replacement of the damaged section
> Grinding: reduce stress raisers / remove crack initiation sites
> Reinforcing with an encircling sleeve
> Placing a clamp or sealed sleeve over the defect
> Applying a composite wrap
> Weld deposition
> Applying a patch
> Hot tapping to remove the defect

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July, 2008
Removal/replacement of damaged section

• Hot Tie-In or Hot Repair

• Isolation by freeze plug

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Removal/replacement of damaged section

• Hot Tie-In or Hot Repair

• Isolation by freeze plug

A different repair is to use the hot tap machine

to cut out a defect, this is described first as an
introduction to Hot Tap Tie-In and Repair
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July, 2008
Hot Tap
• Uses a full encirclement tee, suitable for attachment
by welding to a pipeline for the purpose of making
hot tap or stopping-off connections
• Designed and constructed so that its connection to
a pipeline does not increase the membrane stress
level of the pipeline
• The cutting tool normally used to make a connection
is used to cut-out the defect
• The cutting tool should remove all of the defect

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July, 2008
Hot Tap

T D Williamson full
encirclement Tee

Picture from Team®

Industrial Services web site
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July, 2008
Removal/replacement of damaged section
• Isolation by hot tap

Replacement
pipe
Defective pipe
removed

Copyright T D Williamson, Inc.

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July, 2008
Grinding
• The removal of metal using a grinding tool to
produce a smooth contoured surface free of
defects.
• The stress concentrating effect of the defect or
imperfection is eliminated.
• All damaged or excessively hard or soft metal is
removed.
• The amount and distribution of removed metal
does not significantly reduce the pressure-carrying
capacity of the pipeline.

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July, 2008
Grinding
API 5L allows grinding between 8%
and 12.5% WT
ASME B31.4 applies same limits as
to corrosion
ASME B31.8 allows with various
limits
CSA Z662 allows with reference to
B31G& RSTRENG
Low power grinder
Caution with poor quality seam
welds (e.g. pre-1970 ERW)
Ensure cracking removed (mpi)

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July, 2008
Weld Deposition
Advantages Disadvantages
Quick Safety (welding on live line),
Inexpensive possibility of burn-through
Only welding consumables Accelerated cooling can
lead to hydrogen cracking
Detailed weld procedure /
possibly specialist
consumables required

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July, 2008
Full encirclement steel sleeves
• Widely used for onshore defects, since welding
is usually required. Infrequently used for
submerged features
• If used in cyclic service, fatigue performance
should be confirmed

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July, 2008
Full encirclement steel sleeves
• Type A Sleeves (Reinforcing)

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July, 2008
Encircling Sleeves
• Type A Sleeves (Reinforcing)
> To be effective the sleeve should:
– reinforce the defective area, restraining it
from bulging radially as much as possible
– be installed with a minimal gap between
the sleeve and the carrier pipe
– reduce pressure in the carrier pipe during
sleeve installation
– externally load the sleeve to force it to fit
tightly against the carrier pipe
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July, 2008
Encircling Sleeves
• Type A Sleeves (Reinforcing)
> To be effective the sleeve should:
– use a semi-liquid material that will fill and
harden in any gaps in the annular space
between the sleeve and the carrier pipe.
– apply special fit-up procedures for seam
welds.
• An alternative is to use special epoxy-filled shells.
• Pressure Reduction is essential if the defect being
repaired is at or near its predicted failure pressure at
the start of the repair operation.
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July, 2008
Encircling Sleeves
• Type A Sleeves (Reinforcing) – special case
> Steel compression sleeve
– the repaired section is maintained under
compressive hoop stress
– attractive for repairing longitudinally
oriented crack-like defects; without tensile
hoop stress there is no driving force for
crack growth

– CSA Z662(10) addresses the use of steel

compression sleeves.

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July, 2008
Encircling Sleeves
• Type A Sleeves (Reinforcing)
> Epoxy Filled Shell:
PROVIDES SUPPORT FOR
DEFECTS
TWO OVERSIZED STEEL HALF
SLEEVES JOINED BY WELDING OR
BOLTING
ANNULAR GAP FILLED WITH HIGH
STIFFNESS EPOXY GROUT
EXCELLENT BONDING OF EPOXY
GROUT AND STEEL (SLEEVES AND
PIPE)
CAN REPAIR MOST NON-LEAKING
DEFECTS OF ALL TYPES

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July, 2008
Encircling Sleeves
• Type A Sleeves (Reinforcing)
> Epoxy Filled Shell:
NO REQUIREMENT FOR ’LIVE
WELDING’
FULLY VALIDATED METHOD
IN USE NOW FOR OVER 15
YEARS
NO PRODUCT
INTERRUPTION
IN MANY CASES NO
PRESSURE REDUCTION
CONTINUAL DEVELOPMENT
INTERNAL CORROSION AND
SMALL LEAKING
DEFECTS ALSO
REPAIRABLE
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July, 2008
Encircling Sleeves
• Type B Sleeves: Pressure Containing or Capable of
Containing Pressure
> A full encirclement steel shell, welded down each
seam, the ends fillet welded to the carrier pipe.
> The ends are fillet welded to the carrier pipe and
so the sleeve is capable of carrying pressure. All
of the issues related to welding to an in-service
pipeline must be addressed.
> Since its ends are attached to the carrier pipe,
can also be used to strengthen circumferentially
oriented defects.
> Because the sleeve may contain pressure or
carry lateral loads, it must be designed and
fabricated to suit both of these roles. 22 /
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July, 2008
Encircling Sleeves
• Type B Sleeves: Pressure Containing or Capable of
Containing Pressure
Fillet welded to the
pipe wall

Picture taken from TDW website

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July, 2008
Composite Materials
• Composite sleeve
> For appropriate anomalies these can be a good choice of
repair both in terms of integrity and cost effectiveness.
> Composite repairs require lower skills, (than conventional
steel sleeve) are more rapidly installed, and are almost
always of lower overall cost.
> Appropriate training and qualification is essential to
ensure satisfactory installation of the repair, however
training can typically be completed within a few days.
> Gained regulatory acceptance in a number of regions for
certain applications. For example Clock Spring® has been
accepted as a permanent repair method for blunt wall-
loss defects by the U.S. Department of Transportation.

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July, 2008
Composite Sleeve
Clock Spring ® - detail from their website

• unidirectional composite wrap material

• 2-part polymer adhesive between wrap, pipe and layers of wrap
• a high compressive strength filler compound for load transfer.
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July, 2008
Composite Sleeve
• Armor Plate™ Pipe Wrap
(fibreglass epoxy sleeves)
> sized for specific pipe
diameters and defect
sizes
> made by successive
application of a number
of layers of the Armor
Fiber material.
> multiple layers may be Installing saturated cloth on the pipe
installed adjacent to one using the applicator. Armor Plate Inc.
another and overlapping Website
on alternate layers to
repair longer defects.

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July, 2008
Composite Sleeve
• StrongBack/Masterwrap; water-cured, fibre glass-
urethane composite
> developed for offshore applications the product
can be applied underwater.
> applied in the wet condition and then cured
> The resin used changes colour when the correct
mix has been achieved.
StrongBack Composite
Repair System.
StrongBack Website

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July, 2008
Composite Sleeve
• WrapMaster PermaWrap™; rigid polyester-fiberglass wrap
> in addition to using an adhesive between the layers of
wrap, the layers are mechanically interlocked, the system
does not rely only on the adhesive to secure the sleeve.
> the composite contains metallic material so is detectable
by an in-line inspection tool.
> As with Clock Spring®, PermaWrap™ can be used to
repair corrosion defects up to 80% of the wall thickness
deep and is a fast repair method.

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PermaWrapTM Installation - source of figures Wrapmaster Inc. GE /
July, 2008
Composite Sleeve
• There are other products, some will cure underwater

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July, 2008
Mechanical Clamp
• A temporary or permanent repair for non-leaking or
leaking defects often used in emergency applications
where repair needs to be achieved in a short time.
• Several types available from various vendors.
• Normally elastomeric seals to contain the pressure of
a leaking defect.
• Held on the pipeline by the
load exerted by the bolts
> in some cases the clamps
may be fillet welded to the
pipe like a Type B sleeve to
contain a leak if the seals fail.
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July, 2008
Leak Clamp – external corrosion pit
Lightweight metal bands with a single
draw bolt to tighten it onto the pipe.
Threaded fitting used to force a
neoprene cone into the leaking pit. Used
on isolated pits and usually considered
to be a temporary repair, which needs to
last only until a permanent repair can be
made.
To be used only if an engineering
analysis show that rupture of the
general corrosion around the leak is not
possible, or the pressure level is reduced
to a safe level until a permanent repair is
made.
Not be used to repair a selectively
corroded ERW or flash-welded
longitudinal seam.
Taken from PRCI manual
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July, 2008
Repair Procedure

Any pipeline operator should have in place an anomaly

assessment procedure which should include:
Inspection procedures and frequencies
An anomaly assessment procedure
Repair procedures

PRCI gives an example repair procedure – will not be

appropriate for all operators in all cases

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July, 2008
Repair Procedures

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July, 2008
National & Regulatory Guidance:
• API 1160: Repair methods suitability
PRIMARY REPAIR STRATEGIES
Anomalies Weld
Type A Type B Composite
Metal Hot Tap
Sleeve Sleeve Reinforcement
Deposition
Pipe seam Yes Yes Yes Yes No
External Girth weld Yes Yes Yes Yes No
Metal Loss
=<80% WT Pipe Body Yes Yes Yes Yes Yes
Bend Yes Yes Yes Yes Yes
Pipe seam No No Yes No No
Internal Girth weld No No Yes No No
Metal Loss
=<80% WT Pipe Body No No Yes No Yes
Bend No No Yes No Yes
Pipe seam Yes No Yes No No
External Girth weld Yes No Yes No No
Metal Loss Pipe Body Yes No Yes No Yes
>80% WT 34 /

Bend Yes No Yes No Yes GE /

July, 2008
 National & Regulatory Guidance:
• API 1160: Repair methods suitability
PRIMARY REPAIR STRATEGIES
Anomalies Weld
Type A Type B Composite
Metal Hot Tap
Sleeve Sleeve Reinforcement
Deposition
Pipe seam No No Yes No No
Internal Girth weld No No Yes No No
Metal Loss
>80% WT Pipe Body No No Yes No Yes
Bend No No Yes No Yes
Pipe seam No No Yes No No
Leaks, Girth weld No No Yes No No
Cracks, Arc
Pipe Body No No Yes No No
Burns and
Girth Weld Bend No No Yes No No
Flaws Thread Not
No No No No
Collar Practical

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July, 2008
 National & Regulatory Guidance:
• API 1160: Repair methods suitability
PRIMARY REPAIR STRATEGIES
Anomalies Weld Metal Type A Type B Composite
Hot Tap
Deposition Sleeve Sleeve Reinforcement
Pipe seam No Yes Yes No No
Dents with Girth weld No Yes Yes No No
Stress
Concentrators Pipe Body No Yes Yes No Yes
Bend No Yes Yes No Yes
Pipe seam No Yes Yes No No
Girth weld No Yes Yes No No
Plain Dents
Pipe Body No Yes Yes No Yes
Bend No Yes Yes No Yes

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July, 2008
Conclusions

•Safe dressing methods available for minor pipeline damage.

•Cut-outs will be rarely needed for non-leaking damage.
•Pipeline operators choose non-intrusive methods, do not require welding
to the live pipeline, are quick, safe and permanent.
•Composites and Epoxy Shell Repair (ESR), give the pipeline operator
cost-effective alternatives.
•ESR now available in kit form and training is available in defect
assessment & ESR installation techniques
•PII is able to offer solutions to almost all pipeline defect problems by
recommending any appropriate repair method.

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July, 2008