United Energy Pakistan

Limited

PIPELINE REPAIR PROCEDURE

Document No: 301-203-095-WP-00177

Document No: Rev. No: Issue Date:

301-203-095-WP-00177 2 January 2012

PRO / 519 1 January, 2007
PRO / 519 0 June, 2004

Sponsored by: Endorsed by: Approved by:

Baber Akram Khokher / Muhammad M. Abdul Aleem / Zahid Ali Shah Syed Manzoor Hussain
Rashad Construction Team Leader Engineering Services Manager
Construction Support Engineer
United Energy Pakistan Limited

PIPELINE REPAIR PROCEDURE Rev. No.2

Muhammad Sajjad Zahoor

Technical Authority

TABLE OF CONTENTS

1. PURPOSE 3
2. SCOPE 3
3. CODES & STANDARDS 3
4. WHY REPAIRS ARE REQUIRED 4
5. TYPES OF DEFECTS 4
6. DEFECT DETECTION 4
7. DEFECT ASSESSMENT 5
8. REPAIR TYPES 5
8.1. COMPOSITE WRAP REPAIR 5
8.2. SPLIT SLEEVE 6
8.3. PLIDCO BOLTED SLEEVE 6
8.4. PLIDCO SMITH CLAMP 7
8.5. EPOXY FILLED SLEEVE 7
8.6. PUP-PIECE REPLACEMENT 7
9. SELECTION OF REPAIR METHOD 8
GENERAL PIPELINE REPAIR SEQUENCE 10
10. ATTENDING TO LEAKAGES / RUPTURES 11
ATTACHMENT-1 FACTORS TO BE CONSIDERED FOR PIPELINE REPAIRING 12
A-1.1.PIGGING CONSIDERATIONS 12
A-1.2.ISOLATION PLUGS 12
A-1.3.WELDING CONSIDERATIONS 13
ATTACHMENT-2 GENERAL SAFETY CONSIDERATIONS 14
ATTACHMENT-3 REPLACEMENT OF LEAKY PIPELINE SEGMENT 15
ATTACHMENT-4 INSTALLATION OF PLIDCO SMITH CLAMP+CAP 17
ATTACHMENT-5 INSTALLATION OF PLIDCO SPLIT SLEEVE 19
ATTACHMENT-6 INSTALLATION OF FULL ENCIRCELEMENT SPLIT SLEEVES 22
1. PRE-REQUISITES 23
2. EXECUTION 24
ATTACHMENT-7 COMPOSITE WRAP REPAIRS 26
ATTACHMENT-8 EPOXY FILLED SLEEVE 27
ATTACHMENT-9 MISCELLANEOUS REPAIRS 28
ATTACHMENT-10 REPAIR PROCEDURE FOR FIBER GLASS PIPELINES 29
1. FOR TUBULAR FIBER GLASS PIPES 29
2. FOR STAR FIBER GLASS PIPES 30

ABBREVIATIONS

CTL Construction Team Leader

DP Fully Depressurized
IP Internal Pressure

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PIPELINE REPAIR PROCEDURE Rev. No.2

IPE TL Integrity Planning & Execution Team Leader

NP Normal Pressure
OSM On-Shore Manager
QA/QC Quality Assurance / Quality Control Team Lead

1. PURPOSE

The purpose of this procedure is to ensure that all pipeline interventions and repairs
are carried out using a safe and approved technique based on applicable industry
codes & standards and relevant GDP-43-53, Group Defined Practice, Pipeline
Intervention and Repair; and fulfilling UEP HSE requirements.

2. SCOPE

The procedure outlines the responsibilities, practices and methodology that must
be followed while undertaking repairs of defected buried and above ground
pipelines to restore the integrity with the following techniques:

 Replacement of Leaky Pipeline Segment

 Installation of Plidco Clamps
 Installation of Split Plidco Bolted Sleeves
 Installation of Full Encirclement Sleeves
 Repair of Tubular and Star Fiber Glass Pipes
This procedure describes requisites for repairing of pipeline and piping defects
when the line is fully depressurized. For all repairs where it is assessed to maintain
a minimum flow and pressure conditions a specific procedure is to be developed by
a multidisciplinary team comprising of Construction, Operations and IPE and
authorized by Pipeline Technical Authority.
This procedure does not cover repair to internal and external coatings, repair to
fittings or valves, or restoration of damage to the surrounding environment in the
pipeline corridor.

3. CODES & STANDARDS

Pipeline repair shall be carried out in accordance with the relevant UEP guidelines
and industry codes of – Welding and testing requirements. The relevant industry
standards that must adhered to are as follows:

 ASME-B31.4a-1998- Pipeline Transportation Systems for Liquid Hydrocarbon and

Other Liquids.
 ASME-B31.8-1999 ASA code for Pressure Piping (Gas Transmission).

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PIPELINE REPAIR PROCEDURE Rev. No.2

 API 570 (Latest Edition) Piping Inspection code. Inspection, Repair, Alteration
and Re-rating of In service Piping Systems.
 API 1104 Standards for Welding Pipelines and Related Facilities.
 API 1107 Recommended Pipeline Maintenance Welding Practices.
 API 2200 Repairing Crude Oil, Liquefied Petroleum Gas and Products Pipelines.
 API-2201-Procedures for Welding on Hot Tapping on Equipment containing
flammables.
 NACE-RP-01-69 Recommended Practices, Control of External Corrosion or
Underground Piping Systems.
 NACE RP-0490-2001 Holiday Detection of Fusion-Bonded Epoxy External Pipeline
Coatings of 250 to 760 mm

 API Publication 2209 – Pipe Plugging Practices.

 ASME Section IX – Welding and Brazing Qualifications.
 GP 43-53 - Group Defined Practice, Pipeline Intervention and Repair.
 GP 43-52 - Guidance on Practice for Pipeline Inspection and Integrity
Assessment.
 B31G - 2009 Manual for Determining the Remaining Strength of Corroded
Pipelines: Supplement to ASME B31 Code for Pressure Piping.

4. WHY REPAIRS ARE REQUIRED

A pipeline is subjected to several operational, environmental, proximity and

external conditions during its operational life cycle that either deteriorate the
strength of base metal and consequently reduces its capacity to contain process
fluids within pipeline at normal operating envelop or cause the process fluid to
expose to environment by leakage / spillage from pin-hole or rupture.
A suitable repair method is required to restore the pipeline strength so that it can
be operated within normal operating envelope without further release of process
fluid.

5. TYPES OF DEFECTS

Based on the history, incident reporting, analysis of pipe material, process

conditions, operating parameters and environment following types of defects may
be reasonably anticipated during the operation phase:

a. Leakage due to internal corrosion

b. Leakage due to external corrosion as a result of coating damage
c. Damage due to Pilferage / external intervention
d. Dents and pipeline buckles caused by the impact of third party intrusion; like
earth moving equipment

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PIPELINE REPAIR PROCEDURE Rev. No.2

6. DEFECT DETECTION

6.1.Upon reported defect (leakage), Construction (CSE), LMS and Security will work
closely to establish accurately the geographical location of the defect to assess
accessibility of construction machinery. All relevant permissions will be
obtained by LMS.

6.2.Construction (CSE) in coordination with Production (OSM) will ensure isolation

and if required seek Engineering (FOE) inputs relating materials, process/
operation envelope.

6.3.If the line is buried then it should be exposed, preferably by manual excavation.

6.4.Identify the type of defect once the line is exposed.

6.5.Determine pipeline wall thickness by carrying out UT inspection for further

assessments and deciding suitable repair technique.

7. DEFECT ASSESSMENT

When a defect has been identified the level of impairment should be referred to the
Technical Authority for further reviews and assessment in the light of GDP 43-52
and further classification of defect as severe, significant or superficial.
Superficial: Defects that do not require repairs however need remedial
actions for mitigation, such as Pipeline coating damage, breaking or
settlement of pipe supports, water-logging conditions, ineffective CP
System, ineffective corrosion inhibitor, pipeline exposure due to soil
erosion.
Significant: Metal loss with calculated burst pressure less than 125% MAOP.
Metal loss with depth greater than 50% nominal wall thickness.
Gouge with depth greater than 40% nominal wall thickness.
Top of line dents with depth greater than 2% D.
Bottom of line dents with depth greater than 6% D.
Crack like defects with depth greater than 40% nominal wall thickness.
Severe: Metal loss with calculated burst pressure less than 110% MAOP.
Metal loss with depth greater than 80% nominal wall thickness.
Top of line dents with depth greater than 6% D.
Crack like defects with depth greater than 50% nominal wall thickness.

Reference: GDP- 43-52 - Inspection & Integrity Assessment of Pipeline System

Note: Top of line dents are located in the upper two thirds of the pipe between 8
o’clock and 4 o’clock. Bottom of line dents are located in the lower third of the pipe
between 4 o’clock and 8 o’clock.

Construction (CSE) in coordination with Production (OSM) will seek IPE and
Engineering inputs to determine nature of defect and decide suitable repair
technique in the light of table 7.1 (below) and procedural guidelines. In case nature
of defect falls outside defined boundaries then repair method will be decided in
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PIPELINE REPAIR PROCEDURE Rev. No.2

consultation with Pipeline Technical Authority after detailed assessments and

Engineering inputs.

8. REPAIR TYPES
8.1.COMPOSITE WRAP REPAIR (For Detail Refer Attachment-7)

Composite wrap is a permanent, cost-effective

pipeline repair technology, suitable for non-leaking
defects such as pits, dents, gouges, and external
corrosion. Composite wrap can be performed on an
operating pipeline without taking it out of service.
This repair technique is quick and generally less
costly than other repair options, and it permanently
restores the pressure-containing capability of the
pipe when properly installed.

For leaks and internal corrosions this repair method

can be applied only as a temporary repair and for
defects of pipe buckles, girth welds and seam welds this repairing technique is not
recommended.

8.2.SPLIT SLEEVE (For Detail Refer Attachment-6)

One of the most frequently used repair procedures involves the application of a full
encirclement welded split steel sleeve over the damaged area.

Full encirclement sleeves are of two types:

 Pressure-containing
 Non - pressure-containing

Pressure containing sleeve require that the ends of the sleeve be welded to the
pipeline around the circumference. The non-pressure-containing sleeves do not
have their ends welded to the pipeline.

Fully welded encirclement sleeves with longitudinal butt-welded seams are usually
installed to protect the line from damaging stresses, such as dents, gouges, or
scratches, which may lead to the bulging and eventual rupture of the pipe, to act as
a barrier from further external corrosion, and/ or to reinforce non leaking pipeline
segments suffering minimum design wall thickness violation (reduction in wall
thickness) due to loss of metal as a result of internal corrosion.

Assessment for residual wall thickness of pipeline is

essential to ensure that circumferential fillet welding
should be performed at location where remaining
wall thickness of pipe is sufficient to ensure that
burn-through or hydrogen-cracking does not occur in

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Document No: 301-203-095-WP-00177
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PIPELINE REPAIR PROCEDURE Rev. No.2

the fillet weld or carrier pipe. Qualified WPS and trained experienced welders are
required to perform the job.

For welding of circumferential welds the line should be fully de-pressurized and
isolated.

8.3.PLIDCO BOLTED SLEEVE (For Detail Refer Attachment-5)

They can be used for quick, temporary repairs without welding on urgently required
pipelines. However, sleeve pressure, temperature, and packing limitations must be
considered when installing un-welded sleeves, and the un-welded sleeve must be
removed for permanent repair preferably in approximately three months.

Plidco Split Sleeves are high in cost compared to other

methods of pipeline repair. Therefore, their use should
be restricted to those cases where speed of repair will
provide sufficient economic justification. They are
particularly attractive for permanent repair of small
leaks (no cracking evident) which cannot be plugged
readily and where downtime for draining oil from the line
is excessive.

When plidco bolted sleeve is removed from line for

permanent repair it can be returned to stock for future
use after replacement of inner packing.

Bolted Sleeves are not recommended for repair of external mechanical defects.

8.4.PLIDCO SMITH CLAMP (For Detail Refer Attachment-4)

The Smith Clamps are best suitable for repairing small

pinhole size 1/8” upto 1/4”and can be installed both on
temporary or permanent basis.

For temporary repairs the line can be pressurized to

normal operating pressure, conforming to
manufacturer’s recommendations, after cold installation
of clamp; however, the period for temporary installation
should not prolong for extended duration due to possible
corrosion of draw out band bearing small wall thickness.
As precaution temporary installation of plidco smith
clamp should not go beyond one month and preferably
be converted into permanent installation by welding of
Plidco Cap over Draw out Clamp within specified time.

Assessment for residual wall thickness of pipeline around pin-hole where weld cap
is to be welded is essential to avoid burn-through or hydrogen-cracking. Qualified
WPS and trained experienced welders are required to perform the job.

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PIPELINE REPAIR PROCEDURE Rev. No.2

8.5.EPOXY FILLED SLEEVE (For Detail Refer Attachment-8)

The repair comprises two oversized steel half-shells that are joined to encircle the
damaged area, leaving an annular gap. The annulus is sealed at each end of the
sleeve using a simply applied fast-setting material, and then filled at very low
pressure with a stiff epoxy-based compound.

Welding of sleeve with pipe is not required, and the process can be performed
without product interruption. The two sleeve halves are joined by welding or bolted
flange. Both methods can be used to repair all types of non-leaking defects,
including cracks, seam welds, dents, gouges, corrosion and manufacturing defects,
and bring the pipeline back to full working parameters.

Epoxy filled sleeves are not designed to repair leaks, however small pinhole leaks
can also be repaired using the Epoxy Filled Sleeve Repair, provided there is no
leakage of product during the installation or cure period of the epoxy (24 hours).

8.6.PUP-PIECE REPLACEMENT (For Detail Refer Attachment-3)

In case of leakage due to excessive corrosion inside or outside of the line, over an
extended area, replacement of defected segment is the only resort. The pipeline
should be taken out of service and repaired by removing the damaged section of
pipe.

Prior to the cutting / removal of damaged

section(s), the pipe should be depressurized and
drained of product (by Pigging or Flushing
operation). It is essential to ensure complete
isolation of system through closure of valves and
placement of blinds / spades in flanges upstream
and downstream of repair location. To avoid the
possibility of pressure build up in the line due to
rise in ambient temperature and heat of welding it
is important to keep open vent and bleeder valves.

Replacement of damaged portion of line with new pipe piece by cut out is the most
reliable repair technique as it completely eliminates the existence of defect.
However it requires maximum preparations and precautions for safe execution also
need extended time for actual repair also high production loss is associated with
this repair method.

9. SELECTION OF REPAIR METHOD

9.1.The primary purpose of any temporary or permanent repair shall be to

eliminate any further or potential future release of process fluid when
operating within the approved design envelope.

9.2.Endeavour should be to perform permanent repair as far as possible, unless

this is not immediately feasible. However a suitable temporary repair method
can be undertaken until such time that the permanent repair can be completed
but in no case the maximum duration of temporary repair shall be more than
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03 months for Plidco bolted Sleeve and 01 month for Plidco Smith Clamp.
Whereas a thorough risk assessment shall be performed by a multidisciplinary
team comprising of FOE and IPE lead by Pipeline TA keeping in view residual
strength of pipeline, operating parameters and integrity of repair technique
selected and decision shall be taken to decrease the validity of temporary
repair if deemed necessary.

9.3.All repairs should be consistent with following table.

Table 7.1 - Applicability of Repair Techniques

Reference: GDP 43-53 - Group Defined Practice, Pipeline Intervention and
Repair

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PIPELINE REPAIR PROCEDURE Rev. No.2

Repair
Split
Split Type
Weld Sleeve Epoxy- Plidco
Grindin Composite Sleeve Bolted Selectio
Defect Depositio (pressure filled Smith Cut Out
g Sleeve (reinforc Sleeve n
n containin Sleeve Clamp+Cap
e) Authorit
g)
y
Leak No No Yes No Yes No No Yes Yes IPE TL
(Temp only)
Pilferage No No No No No No Yes Yes * Yes OSM/ IPE
Clamp (Temp
only)
Internal No No Yes Yes Yes Yes No Yes Yes IPE TL
corrosion (Temp only) (Temp (Temp (Temp
only) only) only)
External Yes No Yes Yes Yes Yes No Yes Yes IPE TL
corrosion
Crack Yes No Yes Yes Yes Yes No No Yes CTL
(After
grinding)
Gouge Yes No Yes Yes Yes Yes No No Yes CTL
(Smooth)
Dent No No Yes Yes Yes Yes No No Yes CTL
(< 12,5%
wall)
Buckle No No No No No Yes No No Yes CTL

Girth Weld Yes No No No Yes No No No Yes QA/QC

Defect
Seam Yes No No No Yes Yes No Yes Yes QA/QC
Weld
Defect
IP During NA NP DP DP NP DP DP DP
Repair
Note:
1) Composite and Epoxy Filled Sleeves are for reference only; currently these sleeves are not available hence will not be considered
for pipeline repairs.
2) For repair of pilferage-hole the use of bolted Sleeve is not recommended as permanent repair where pigging of pipeline is required.
3) Refer to section 7.2 for validity of temporary repair.

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General Pipeline Repair Sequence

Defect Detection

Yes Significant / No
Severe Defect

Assess damage
Initiate Notifications Select repair
Mobilize for repair

On-line
Segment drain Repairabl
Segment isolate Schedule Repair No
e?

Assess damage
Yes Select repair Yes
Mobilize for repair

Repair defect
Inspect / Test / Certify

Demobilize
Re-commission
system

Permanent No Establish monitoring

Repair? Procure permanent fix

Yes

File report on
Defect and repair

Incident close-out
Lessons Learned Stop

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10. ATTENDING TO LEAKAGES / RUPTURES

An oil or gas line leakage or rupture should be dealt with according to the
Emergency Response Procedure. The role of the Construction team is to prepare
themselves by arranging manpower and materials at the site for repair of the
damage. The Construction team must not commence the job until relevant MoC is
obtained and Production, Lands and Security departments authorize the start of the
job. On receiving information of such an emergency the Construction Support
Engineer should act according to the procedure given below:

10.1. Obtain required size of

Emergency / Plidco clamp (mechanically fitted split sleeve), from warehouse,
and arrange installation to repair the leaks as per procedure noted in
Attachment-5.

10.2. In case of a rupture,

beyond the repair with Emergency / Plidco clamp, the defected section of
pipeline shall be replaced as per procedure detailed in Attachment-3.

10.3. Arrange and transport

required resources (including tools, portable generator, welding machine, etc.)
to the site.

10.4. Arrange with the

Production Department for the vacuum truck to be on site if required.

10.5. On reaching the site

the Construction crew should inform the Senior Lead Operator.

10.6. Before commencing

any activity it shall be ensured that the line is isolated and depressurized.

10.7. Re-open and redress the

trench by removing sand bags and ensuring proper side sloping / benching and
provision of escape route opposite to wind direction.

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PIPELINE REPAIR PROCEDURE Rev. No.2

ATTACHMENT-1

FACTORS TO BE CONSIDERED FOR PIPELINE REPAIRING

A-1.1. PIGGING CONSIDERATIONS

A pipeline defect that occurs due to certain protrusions (pilferage clamps) can restrict
the movement of pig and is unlikely to be assessed as acceptable without appropriate
repair.

a) Punching of pipe with pilferage clamp cone can create sharp metal protrusion inside
the pipe surface. Moreover the presence of pilferage clamp on pipeline poses risk
for pig stuck in the line or tearing of pig.

b) Poly pigs should not be used for pigging of line

where Plidco Bolted Sleeve is installed after
removal of pilferage clamp; however in case of
installation of Plidco Smith Clamp with Neoprene
Cone pigging of line with Poly Pig can be opted.

c) Where Plidco Bolted Split Sleeve need to be

installed for repair of pilferage-hole, other pig
types such as mandrel rubber disc pigs (picture
below) can be considered for pigging of line.

A-1.2. ISOLATION PLUGS

Plugging is any method, other than ordinary block valves or blinds, used to seal off or
isolate a line segment to prevent the entry of flammable, combustible or toxic liquids,

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vapors or gas into the work area. BP ME&P SPU Guidance on the Safe Use of Isolation
Plugs - Rev-A1 12/05/10 will be referred too; some of the salient plugging methods from
guidelines are re-produced here below:

A. PRESSURE RETAINING PLUGS: These are designed to hold pressure while being
used to isolate sections of line. Application of these types of plugs is associated
with high risks and need to be properly engineered and approved by appropriate
technical authority.

B. BARRIER PLUGS: Gas barrier plugs are intended only to seal off vapours and not
retain liquid or pressure. These are normally inserted manually and are only used
where pressure effects in the line can be completely eliminated. These plugs are
not recommended on LPG or other lines which contain similar volatile liquids or on
lines which cannot be positively isolated by closed and locked block valves, blinding
or disconnection from live lines.

a) Mechanical Seal Plugs: involves the

principle of having 2 steel discs compressing
a neoprene seal which is forced outwards
against the inside wall of the pipe to form a
seal. The centre section, or shaft, may contain
an opening to which a hose can be connected
to permit venting of any internal pressure or
liquid accumulation to be released at a
remote location. The plug is inserted into the
line according to its stem length. The sealing
ring should be at least 30 cm into the line so
that the welding operation does not compromise the seal.
Mechanical Seal Plugs can be used near flanges so that these can be retrieved
after completion of welding operation.

b) Mud Plugs: Bentonite Clay has been used to create a mud plug, acting as a
vapour / gas barrier on pipelines to allow hot work (welding, burning, grinding)
to be performed safely. Mud Plugs are used in situations where a long run of
pipe needs to be butt welded together and the positive isolation point (blind) is
some distance away from the weld.

The advantage of Bentonite is that it can be flushed out of a system by the

pipeline fluid leaving no restriction of residue. Sludge formation, drying and
improper installation of the mud plug however, can and has led to incidents
where the release of residual explosive or noxious gases has occurred into the
maintenance area.

Vents to be used between the isolation and the plug should be identified and
tagged. Checks to be made to ensure they are clear. Pressure upstream of the
mud plug should be monitored

The mud plug should be 2-4 ft long inside the line and shall be properly filled,
packed and leveled so that it completely adheres to the internal walls of the
pipe leaving no voids and leaving at least 12 inches and preferably 24-36 inches
unfilled open space from the pipe end. Mud plug shall be tamped until the plug
is firmly in place and does not move with the tamping

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After the plug has been installed it shall be visually checked by the supervisor
and Gas test shall be performed prior to commencing the hot work to check LEL
and ensure no leakage past the plug. Worksite shall be continuously monitored
for flammable and/or toxic gases and vapors throughout the task duration.

A-1.3. WELDING CONSIDERATIONS

Following steps will be considered for permanent repair of defect by welding on

pipelines:

a) To minimize burn through, the first weld pass to equipment or piping less than 1/4
in. (6.4 mm) thick should be made with a 3/32 in. (2.4 mm) or smaller diameter
welding electrode to limit heat input. Subsequent passes should be made with a 1/8
in. (3.2 mm) diameter electrode, or smaller if the metal thickness does not exceed
1/2 in. (12.7 mm).
Note: The use of low heat input levels can increase the risk of cracking in high
carbon equivalent materials.

b) The use of low hydrogen electrodes is mandatory to reduce the possibility of burn-
through and cracking when welding on high carbon-equivalency components.

c) Sufficient flow must be maintained for a sufficient time (approximately 30 minutes)

to ensure that any potentially explosive gas pockets in the line have been swept
clear of the weld area and then the line will be depressurized to zero pressure by
opening vent downstream or flaring the gas into flare. After attaining zero pressure
blow down valve will be closed for repair in “No Flow” conditions.

Note:
If it is required to weld on a live pipeline under pressure, a specific
procedure for the task shall be prepared by the multidisciplinary team
comprising of Construction, Operations and IPE and to be approved by
Technical Authority.

ATTACHMENT - 2

GENERAL SAFETY CONSIDERATIONS

All cold / hot work and welding repairs safe working practices must be followed with
strict adherence to UEP safety policies and procedures. These include to a minimum
the TRA & Permit to Work Procedure.

Following Safety Checks should be performed prior to starting a pipeline weld repair:

a. Perform site specific Level-II Risk Assessment and get the Risk Assessment
reviewed and approved by the relevant authority.

b. All works will be subject to ‘COW’ and ‘Permit to Work’.

c. Experienced contractors with appropriate personnel training and established

competence shall be used for performing the repair.

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d. Tool box talks shall be held prior to execution of works on site and all hazards
discussed / signed off by the performing authority.

e. Excavation Certificate is a must for addressing any buried pipeline intervention and
repair job, either hot or cold.

f. All mechanized repair equipment shall be located at a safe distance, preferably

upwind and in no case less than 50 feet from area of repair. Exceptions to the
above would be the use of cranes and side-booms, etc., which must be closer than
50 feet.

g. All pipeline intervention and repair jobs involving hot works will be done in the
presence of a dedicated standby vehicle and a certified medic. Work site access will
be developed for the movement of this dedicated vehicle.

h. All pipeline intervention jobs involving hot works will not proceed without the
availability of a fire trolley in addition to fire extinguishers and fire blankets on
location.

i. For all pipeline intervention jobs involving hot works presence of a certified Fire
watch, Construction representative and Production representative who is AGT is
mandatory until the entire job is finished.

j. An Authorized Gas Tester will perform explosive tests before giving go ahead for hot
works. During works execution explosive tests shall be taken and recorded every 15
minutes.

k. Switch off CP Rectifier before a cold cut is made or breaking of containment. Always
use Electro-Static-Charge Conductive Clamps (‘C” clamps) across the defective
segment of the line. The PI will ensure the contacts with the pipeline.

l. Metallic half cut drums will not be used in any circumstances to avoid static
discharge

m. Management of collected hydro carbons must be given due consideration.

Availability of a vacuum bowser is mandatory for any hot works on the line.

ATTACHMENT - 3

REPLACEMENT OF LEAKY PIPELINE SEGMENT

In case of leakage due to excessive corrosion inside or outside of the line, over an
extended area, replacement of defected segment is the only resort. The pipeline should
be taken out of service and repaired by removing the damaged section of pipe. Prior to
the cutting / removal of damaged section(s), the pipe should be depressurized and
drained of product (by Pigging or Flushing operation). P&IDs’ should be checked to
ensure complete isolation of the system through closure of valves and locating flanges
for placement of blinds / spades at up-stream and down-stream locations. Keep open
the vent or bleeder valves to avoid possibility of pressure buildup in the line. If it is not
possible to isolate and blind off the damaged section, than the line is to be
disconnected from both ends and taken out of service. Pipeline topographic drawings
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PIPELINE REPAIR PROCEDURE Rev. No.2

should also be consulted to anticipate the hydrocarbon release quantity once a cold cut
has been made. In case of unavailability of the profile drawings, preparations should
be made with respect to the worst case scenario.

A section of new pipe should be prepared from a length which has been tested at
pressure up to 1.5 times of its design pressure. Hydrostatic testing shall be carried out
in accordance with procedure PRO/514 and construction module CONST/019. The
replacement pipe section should be of the same (or higher) material grade, schedule
and wall thickness as the damaged pipe. The tie-in welds shall be subjected to
radiography before bringing the pipeline back into service.

Corrosion Engineering Team will ascertain the wall thickness and extent of pitted /
corroded area around damaged section ultrasonically and establish the length of
section to be replaced. However, the length of section to be replaced should not be
less than 1.5 times the diameter of pipe in any case.

On the authorization of a Work Permit the following procedure for repair should be
carried out:

a. Check that line is fully spaded with the conception of double block & bleeds
arrangement. All en-routed valves are tightly shut and locked or sealed [LOTO (Lock
out & Tagged out)].

b. Ensure that the line is depressurized and drained, and freed from hydrocarbons
with the help of pigging or flushing operations. Use drums and vacuum truck to
collect the drained / spilled oil or sludge to make the surroundings free from
hydrocarbon and to avoid any possible damage to the environment. In no case shall
spilled hydrocarbon be in the general vicinity of hot work. Oil saturated soil / sand
can be a fire hazard unless it is completely covered with clean soil / sand. An
alternative to covering with clean sand is to remove the oil-saturated sand. In the
case of spilled condensate, remove as much of the condensate saturated sand as
possible to a safe distance away from the hot work. Cover the excavated area with
clean sand and provide adequate cover with fire retardant material and provide
clean sand / soil over it. Only machinery with CI engines and with flame arrestors
should be allowed for works. Long boom reach excavators should be preferred.

c. If the line is buried, manually expose the line by excavating a suitable size bell hole,
in accordance with Excavation & Trenching procedure PRO/SFTY/016 making certain
to secure the sides from collapsing. For excavations over 4 feet deep, the sides of
the pits and trenches should be sloped back to the natural repose of the soil to
avoid a cave-in or benching / steps to be provided as per UEP Ground Disturbance
Procedure. Sides, which cannot be sloped to natural repose, shall be shored
adequately to resist earth movement and protect workers. Excavate to a workable
level, with a minimum clearance of 18 inches all around the pipe.

d. All mechanized repair equipment shall be located at a safe distance, preferably

upwind and in no case less than 50 feet from area of repair. Exceptions to the
above would be the use of cranes and side-booms, etc., which must be closer than
50 feet.

e. Cut out the defective length by cold cutting using a pipe cutter or cold cutter, and
collect the spilling oil / sludge in proper containers (half cut plastic drums) or use

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vacuum truck to avoid spillage and for proper disposal on designated location(s)
saving the environment.

f. Prepare the section of pipe to be inserted by grinding to a standard profile. Always

keep +ve or -ve margin giving due importance to thermal expansion b/c of weather
conditions.

g. Install drilling / Bentonite mud plugs at the pipe ends in accordance with API 2209.
In case of repairing above ground damaged pipe section a flanged spool piece can
be inserted or a wing plug can be used. In case of a buried line, Bentonite plug
should be more than 4’ long and placed as far as possible from the welds so that
minimum burnt gas pressure is developed during the root pass of the second joint
of the pipe piece. Welder should have this factor in mind before starting the pass. A
pre-fabricated mud pusher should be available on site. (In any circumstances the
mud or mechanical plug should not be considered as a pressure retaining device. It
is only a vapor seal. Once positive radiographic results are obtained the mud plugs
are required to be cracked by striking with mallets (wooden hammer)

h. Qualified weld procedures and welders would be used in accordance with the
applicable practices and design codes, based on the material certification data for
the existing and replacement line pipe material. Install the replacement pipe
section, perform explosive test (which shall be conducted by the Operations
Supervisor or his designated representative) prior to and during any welding /
grinding operations to ensure a hazardous free environment. If readings reach an
explosive level cease the hot work operation and take remedial action to rid the
area of the gas. Employ certified Safety Watch to keep vigil during the whole
operation especially during hot works. Continue explosive checks before and during
operation.

i. No more than two repairs per running pipe length (40 feet) should be carried out.
Anything over this parameter would require the renewal of that section.

j. Welding shall be carried out as per approved welding procedure. The new weld
joints shall be radiographed and accepted as per API – 1104.

k. For coated pipes, heat shrink sleeves shall be installed on the tie-in welds. The HSS
shall be installed after thoroughly cleaning and preparing the surface all around the
girth weld to a white metal finish i.e. SIS 2½ or equivalent, by using sand blasting
or if required with power brushing, in accordance with manufacturer’s
recommendations.

l. Holiday testing of the entire excavated section of the pipeline shall be carried out
after installation of the HSS.

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ATTACHMENT - 4
INSTALLATION OF PLIDCO SMITH CLAMP+CAP
Plidco Clamps (Smith Clamp or Draw out Clamp with plug & Plidco Cap) are used for
quick and safe repairs of leaking or ruptured pipelines and process lines. There are
various types with range of sizes and pressure ratings that can be selected from
Manufacturer’s specifications/ data to match the system requirements/ operating
conditions.

The Smith Clamps are best suitable for repairing small pinhole size 1/8” upto 1/4”and
can be installed both on temporary or permanent basis. For temporary repairs the line
can be pressurized to normal operating pressure, conforming to manufacturer’s
recommendations, after cold installation of clamp; however, the period for temporary
installtion should not prolong for extended duration due to possible corrosion of draw
out band bearing small wall thickness. As precaution temporary installation of plidco
smith clamp should not go beyond one month and preferably be converted into
permanent installation by welding of Plidco Cap over Draw out Clamp within specified
time.
The job execution comprises of following steps:
a. Manual excavation of pit. The pit can be widened up to the extent of (6’x 8’) to
facilitate welding of cap.

b. All coatings rust, and scale will be removed from the pipe surface, where the Plidco
Smith Clamp is to be assembled and cap is to be welded, ensuring that the contact
area is free of dents or pits in the seal area. (This may require weld reinforcements
to be ground flush with the surface of the pipe).
c. Adjust the Pilot Pin so that it protrudes ¼” beyond the packing cone. Adjust the
Force screw until the tip of the Packing cone is flush inside surface of the Plidco
Smith Clamp.

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d. Spread the Plidco Smith Clamp open sufficiently so that it can be assembled around
the pipe.

e. Use the Pilot Pin to locate the pin-hole leak.

f. Hold the Plidco Smith Clamp firmly in position until the Draw bolt and thrust Nuts
are snugged.

g. Tighten the Draw bolt to the torque value up to 25- 35 ft- lbs.

h. Remove the Pilot Pin prior to tightening the Force Screw.

i. Tighten the Force Screw to the torque value up to 70- 80 ft- lbs. (This completes the
temporary installation of the Plidco Smith Clamp, and after doing the necessary
coating repairs, and subsequent holiday testing, the line can be backfilled and
pressurized to normal operating pressures).

j. Welding

i) If the minimum wall thickness of the pipeline at the location of welding

is 0.25 inches or more and the possibility for formation of explosive
mixture inside the line has been precluded by maintaining sufficient
flow for at least one hour followed by depressurization of the line then
online welding can be performed at zero pressure and No Flow
conditions.

ii) If the wall thickness of the pipeline at the location of the welding is
less than 0.25 inch but equal or greater 0.2 inches, and or where the
hazard of formation of explosive mixture inside the line can not be
excluded; a specific procedure for welding on live line shall be
prepared and approved by technical authority, considering minimum

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flow and pressure requirements inside the pipeline to eliminate the

possibility of burn through or weld cracking.

iii) If the wall thickness is less than 0.2 inches then welding of caps should
be avoided unless or otherwise advised / approved by technical
authority.

k. Remove the 1/8” NPT pipe plug from the weld cap before welding.

l. Hold the weld cap over Plidco Smith Clamp and tack it into place on the Draw Band.

m. Weld the Cap to Draw Band.

n. Fillet welding, as per Company’s approved WPS # BP- F- 001(Fillet) employing low
hydrogen E 7018 electrodes, to weld the Cap with the pipe. Welding to be done
using 2.4 mm or 3.2 mm low hydrogen electrodes. The toes of the fillet weld shall
blend smoothly into the pipe surface. 3 to 4 weld passes will be applied to ensure
minimum fillet weld leg size equal to the pipe nominal wall thickness.

o. Preheat the pipe around Weld Cap up to 200 degree F (93 degree C) with the help
of torch. Temperature to be monitored with the help of pyrometer.

p. Welding inter-pass temperature shall be continuously monitored with the help of

pyrometer within 2 inches of weld cap to ensure that the temperature should not
rise above 225 deg F (107 degree C). Buna N packing has a temperature rating of
-30 deg C to 121 deg C.

q. After welding of Weld Cap, Notch & Break the Draw Band near the weld using a cold
Chisel.

r. Weld the Draw Band to the Pipe at the Break Points to complete the welding around
the cap.

s. Insert 1/8” NPT Pipe Plug in the vent hole and seal weld.

t. DPT and / or MPI of welding shall be performed to ensure quality of welding.

u. Apply epoxy paint around the cap and where coating defects/ damages observed.

v. Holiday testing of the entire excavated section.

w. Back filling.

x. Line to be pressurized to normal operating pressures.

ATTACHMENT - 5
INSTALLATION OF PLIDCO SPLIT
SLEEVE
Plidco Split Sleeves are used on blowouts or punctures which
cannot be readily sealed by plugs or patches. They shall not

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be used for repair of a defect if less than 70% of the design minimum pipe wall
thickness (around the total circumference) is left to resist axial forces, and they shall
not be used for reinforcement of non-leaking defects such as gouges, corrosion lakes,
etc. Reinforcement of non-leaking defects can be done inaccordance with
Attachment – 6 of this procedure.

They can also be used for quick, temporary repairs without welding on urgently
required pipelines. However, sleeve pressure, temperature, and packing limitations
must be considered when installing un-welded sleeves, and the un-welded sleeve must
be removed for permanent repair preferably in approximately three months.

Plidco Split Sleeves are high in cost compared to other methods of pipeline repair.
Therefore, their use should be restricted to those cases where speed of repair will
provide sufficient economic justification. They are particularly attractive for permanent
repair of small leaks (no cracking evident) which cannot be plugged readily and where
downtime for draining oil from the line is excessive.

The installation of Plidco Split Sleeve can be a temporary or permanent basis, and
executed as per following:

a. The line shall be exposed manually and a wider pit measuring 10’ x 6’ shall be
excavated for providing ample space for two welders to weld simultaneously on
both ends of sleeve.

b. All coatings, rust, and scale will be removed from the pipe surface, where the Plidco
Split-Sleeve is to be assembled. The area around the pipe should be thoroughly
cleaned, where the seals will come in contact with the pipe, ensuring that the
contact area is free of dents or pits in the seal area. (This may require weld
reinforcements to be ground flush with the surface of the pipe).

c. All bolts and nuts on the sleeve must be cleaned and lubricated.

d. Measurements will be taken so to centre the sleeve over the damaged portion of
the pipe. It will further be ensured that the packing at both ends of the sleeve seats
should rest on an undistorted, clean area of the pipe.

e. If welding is to be performed for permanent installation of Plidco Sleeve then the

pipe wall thickness in the vicinity of the fillet girth welds shall be checked by
ultrasonic testing (U.T.) to ensure adequate wall thickness around the girth weld
area.

f. Sleeve will be installed evenly on the pipe (For larger pipe diameters crane may be
required for handling/ placement of sleeve over the pipe). Place wooden planks to
support one half of the sleeve covering the lower half & place the other on the top
of it and tight the bolts manually to hold the sleeve over the pipe. The sleeve
should be rotated either before or after sliding into position so that any sharp edges
do not damage packing and that any bulges are centered in one of the halves.

g. Bolt tightening sequence starts at the centre bolts of each half and works outward.
Measurements of torque (Ft-lbs) should be taken during the tightening operation to
ensure that side bolts are tightened uniformly with torque wrench or with hand
wrenches. (Torque values to be referred from Manufacturer’s data depending upon
the bolt size. (This completes the temporary installation of the Plidco Split Sleeve,

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and after doing the necessary coating repairs, and subsequent holiday testing, the
line can be backfilled and pressurized to normal operating pressures).

h. Welding

i) If the minimum wall thickness of the pipeline at the location of welding

is 0.25 inches or more and the possibility for formation of explosive
mixture inside the line has been precluded by maintaining sufficient
flow for at least one hour followed by depressurization of the line the
online welding can be performed at zero pressure and No Flow
conditions.

ii) If the wall thickness of the pipeline at the location of the welding is
less than 0.25 inch but equal or greater 0.2 inches, and or where the
hazard of formation of explosive mixture inside the line can not be
excluded; a specific procedure for welding on live line shall be
prepared and approved by technical authority, considering minimum
flow and pressure requirements inside the pipeline to eliminate the
possibility of burn through or weld cracking.

iii) If the wall thickness is less than 0.2 inches then welding of bolted
sleeve should be avoided unless or otherwise advised / approved by
technical authority.

i. Preheat the pipe within the adjoining to Sleeve ends up to 200 degree F with the
help of torch. Temperature to be monitored with the help of pyrometer.

j. Welding to be done with welders on each end working in opposite quadrants at the
same time, using 2.4 mm or 3.2 mm low hydrogen electrodes in vertical up
progression. Where possible, use two welders at each end of the coupling to weld
on opposite quadrants simultaneously. All passes on the girth fillet weld shall be in
the following sequence:

 Weld from 3:00 to 12:00 o'clock position. 4 1

 Weld from 6:00 to 9:00 o'clock position.
 Weld from 6:00 to 3:00 o'clock position.
 Weld from 9:00 to 12:00 o'clock position.
2 3
k. The toes of the fillet weld shall blend smoothly into the pipe surface. 3 to 4 weld
passes will be applied to ensure minimum fillet weld leg size equal to the pipe
nominal wall thickness.

l. Fillet welding, as per Company’s approved WPS # BP- F- 001(Fillet) employing low
hydrogen E 7018 electrodes, to weld the Cap with the pipe. External coatings,
(including FBE), rust, and scale shall be completely removed in the welding area.

m. Welding inter-pass temperature shall be continuously monitored with the help of

pyrometer within 2 inches of sleeve end to ensure that the temperature should not
rise above 225 deg F (107 deg C). Buna N packing has a temperature rating of -30
deg C to 121 deg C.

n. After welding of sleeve ends the Sleeve Flanges (split ends) will be welded with 3
passes of 3.2 mm low-hydrogen electrodes to ensure seal.

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o. Bottom of nuts and stud ends will be seal welded with 2 passes using 2.4 mm or 3.2
mm low-hydrogen electrodes. The studs and nuts shall be cleaned with solvent
prior to welding. The studs will be torch cut from the back of the weld and file or
grind smooth to minimize coating and wrapping problems.

p. DPT and / or MPI of welding shall be performed to ensure quality of welding.

q. Wrapping of Polyken tape around the sleeve.

r. Holiday testing for repair of any possible coating damage.

s. Back filling of trench.

t. Line to be pressurized gradually to its normal operating pressures.

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ATTACHMENT - 6
INSTALLATION OF FULL ENCIRCELEMENT SPLIT SLEEVES

Carrier Pipe
Side seam
(Butt weld only,
Sleeve overlapping side strip
not recommended

End fillet weld

a. Fully welded encirclement sleeves with longitudinal butt-welded seams are usually
installed to protect the line from damaging stresses, such as dents, gouges, or
scratches, which may lead to the bulging and eventual rupture of the pipe, to act as
a barrier from further external corrosion, and/ or to reinforce non leaking pipeline
segments suffering minimum design wall thickness violation (reduction in wall
thickness) due to loss of metal as a result of internal corrosion.

b. Full encirclement sleeves can be of the pressure-containing or non- pressure-

containing type. The former require that the ends of the sleeve be welded to the
pipeline around the circumference. Qualified WPS are required to ensure that burn-
through or hydrogen-cracking does not occur in the fillet weld or carrier pipe. The
non-pressure-containing sleeves do not have their ends welded to the pipeline, but
they do provide structural support to the affected area.

c. A steel backing strip 1” wide and 1/16” thick shall be placed under and along the
length of the normal sleeve when doing the longitudinal welding. This will preclude
chances of burn-through of the pipe. The minimum length of fully welded
encirclement sleeves with longitudinal butt-welded seams shall be at least 4 inches.
There is no maximum length limitation and multiple sleeves may be used.

d. The need for welding on in-service lines has become a requirement for the repair or
modification of most pipeline systems .The greatest hazard encountered during
welding of sleeves on the live lines (pipeline under pressure) is the possibility of a
local "weld burn-through", sometimes called "weld metal blow-out", caused by the
heat of welding. Heat reduces the strength of the metal to support the hoop stress
created by the pressure in the pipe. One way to reduce the chances of "weld blow-
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out" is to reduce the pressure in the pipe during welding. Likewise, increasing the
wall thickness increases the capability of the pipe to sustain higher pressure and
reduces the chances of "weld metal blow-out". To sustain the maximum allowable
operating pressure of a pipeline, the minimum design thickness of a fully welded
encirclement sleeve, ts, shall be calculated using the following formulae:
1. ts = tp(4Dp + 1)(SMYSp)/4{Dp)(SMYSs)-(SMYSp)]
Where:
Dp outside diameter of the pipeline (inches)
Ds outside diameter of the encirclement sleeve (inches)
tp nominal wall thickness of the pipeline (inches)
ts nominal wall thickness of the encirclement sleeve (inches)
SMYSp specified minimum yield strength of the pipeline material
(psi)
SMYSs specified minimum yield strength of the sleeve material
(psi)
( D p )  ( P)
2. ts 
2  S 1  (.72)  P
Where:
ts = Minimum wall thickness of the sleeve.
S1= 100% minimum yield strength of sleeve
P= the maximum design pressure of the pipe and not the operating
pressure.
Dp= The outside diameter of the pipe the sleeve is being installed on (in
inches).

If the repair has been necessitated by a leak, then the minimum thickness of sleeve
should be 1.4141 times the nominal wall thickness of the line pipe being repaired.

1. PRE-REQUISITES

a. No pipe or other component may be installed in a pipeline system unless it has

been visually inspected at the site of installation to ensure that it is not damaged in
a manner that could impair its strength or reduce its serviceability.

b. A qualified welder in accordance with welding procedures qualified to produce

welds meeting the requirements of this subpart must perform welding. The quality
of the test welds used to qualify the procedure shall be determined by destructive
testing.

c. Each welding procedure must be recorded in detail, including the results of the
qualifying test. This record must be retained and followed whenever the procedure
is used.

d. Repairs to pipelines transporting hydrocarbons i.e. crude oil, refined products, LPG
products, or highly volatile liquids will be performed by personnel working under
qualified supervisors who are aware of and familiar with hazards to persons and
property.

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e. Full encirclement sleeves shall have a wall thickness equal to or greater than the
wall thickness of the pipe to which it will be installed.

f. Full encirclement sleeves shall have a minimum length equal to the nominal
diameter of the pipe, but not in any case less than 4 inches.
g. No welding repairs to the sleeve materials shall be acceptable. Sleeves shall be
provided free of dents, gouges, pits, laminations, hard spots or grind marks.

2. EXECUTION

a. Detailed assessment of the risks involved in the job (TRA) is mandatory prior to
execution. No hot job i.e. welding or grinding should commence until clearance /
hot work permit has been obtained from the Production.

b. Pipeline portion to be sleeved shall be bared off coat-wrap and cleaned at least 12
hours before commencement of welding.

c. It should be ensured that no leaks are evident at the area to be welded.

d. Repair personnel not required to directly perform the repair work should stand
clear, at least 50 feet or more away from the pipeline. The distance is dependent
on the pipeline contents, process conditions, and weather. Personnel should stand
upwind and be prepared to evacuate the area, if necessary, to a safe location
across wind. Fire watch personnel shall be located at the repair work area.

e. In case of buried pipelines special consideration shall be made during the

excavation of bell holes / trenches. Adherence to UEP’s Ground disturbance
procedure must be ensured.

f. Identify the area where the attachment is to be installed.

g. Identify the length of the attachment, i.e. repair sleeve.

h. Transfer and mark the length of the attachment onto the pipeline with soapstone or
another type of marking device.

i. Using a roundabout and some type of marking device, mark the entire
circumference of the pipe where the attachment ends are to be welded.

j. Score each of these roundabout marks on top of the pipeline with a half-round file
for approximately 1 to 2 inches with the circumference of the pipeline. This will
serve as a permanent reference mark for the attachment length.

k. Establish minimum pipe wall thickness to be welded, through engineered data, by

calculating the minimum wall thickness required by pipe specification tolerances.

l. If the defect is a dent, fill the dent area with an approved hardening filler material,
shaping the filler to the original pipe contour.

m. If the defect is a gouge / groove the defect shall be ground smooth to parent metal
taking care to assure that the root of the gouge / groove has been removed.
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n. Place the attachment on the pipeline and ensure that the ends of the attachment
coincide with the file and roundabout marks.

o. In case of isolated pitted spots markings will be made for 6” long normal sleeve
bands in such manner that the pit falls in the middle of the sleeve band.

p. In case of continuous pitting, marking will be made to place 6” long normal sleeve
bands at either end of the corroded section. The intermediate portion of complete
normal sleeve shall be marked.

q. The position of hot welds shall be at the ends of the corroded section i.e. the two
extremities of the 6" bond placed at the end of the corroded section. This position
shall be carefully selected after ensuring that the wall thickness of the pipe at that
position is according to the pipes specification of minimum thickness for welding.
Use of thickness tester is recommended.

r. Sleeves shall be positioned on the carrier pipe using ring-type sleeve clamps.

s. Safety clamps shall be fitted to the carrier pipe before commencing the hot welding
to prevent a running fracture in the pipe in case of a burn-through.

t. Sufficient flow must be maintained for a sufficient time to ensure that any
potentially explosive gas pockets in the line have been swept clear of the weld
area. Prior to the start of welding, it shall be ensured that the line has been
depressurized to zero pressure.

u. For any condition where depressurization of the line is not possible and it is
required to weld on line in running condition a specific procedure shall be
developed and approved by technical authority taking in consideration the
minimum and maximum flow and pressure conditions to exclude the possibility of
burn through and weld cracking.

v. In certain cases where there may be insufficient or interrupted flow, such as a flare
line, it is necessary to continually purge or flood the line with inert gas or
hydrocarbon gas to ensure that the line or equipment does not contain a flammable
mixture during the welding operation.

w. If the wall thickness is less than 0.2 inches than welding of split (full encirclement)
sleeve should be avoided unless or otherwise advised/ approved by technical
authority.

x. Two welders working simultaneously on either side of the sleeve shall make
longitudinal welds. Filling and capping shall be done starting from the center of the
sleeve and working out from the center.

y. Welding Sequence of Repair Sleeves

 The longitudinal welds on the sleeve shall be completely welded before
commencing with either girth weld.
 The welding sequence shall be such as to minimize the distortion and residual
stress in the sleeve and at the same time maintain an adequate inter pass
temperature.

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 On sleeve lengths equal to or greater than 5 feet, both girth welds may be
welded simultaneously. For sleeve lengths less than 5 feet, one girth weld shall
be completed and allowed to cool before beginning the other.
 All passes on the girth fillet welds shall be in the following sequence:
i. Weld from the 3:00 to 12:00 o'clock position.
4 1
ii. Weld from the 6:00 to 9:00 o'clock position.
iii. Weld from the 6:00 to 3:00 o'clock position.
iv. Weld from the 9:00 to 12:00 o'clock position. 2 3
z. The girth fillet welds shall be full sized and blend in smoothly with the pipe surface.

aa. For sleeving pipelines greater than 16-inch diameter, two welders shall be used on
opposite quadrants for each girth weld. In cases where multiple sleeves are used,
the adjoining sleeve ends shall be beveled, before installation, to 37 + 2 1/2 deg
without a land. A backing strip shall be fit up to avoid fusion to the pipe in the root
gap. The sleeve shall be cut to provide close fit-up dimensions for a root gap of
3/16” + 1/16” (4.8 + 1.6mm), and a maximum gap of 1/8” (3.2 mm) between the
pipe and sleeve surface around the entire circumference of the pipe. For two
adjoining sleeves, all of the longitudinal welds shall be completed before the
adjoining or either ends the carrier pipe.

ATTACHMENT - 7
COMPOSITE WRAP REPAIRS
Pipeline repair using Composite Wrap is included here only for reference as currently
this repair material is not available in stock and contractor personnel are not trained
for its application. However, this repair technique can be considered for future
application where repairing of pipeline would not be feasible by any other approved
techniques.

Composite wrap is a permanent, cost-effective pipeline repair technology, suitable for

non-leaking defects such as pits, dents, gouges, and external corrosion. Composite
wrap can be performed on an operating pipeline without taking it out of service. This
repair technique is quick and generally less costly than other repair options, and it
permanently restores the pressure-containing capability of the pipe when properly
installed.

Compared to traditional repair practices such as

pipeline replacement or installation of full
encirclement split sleeve, composite wrap repairs are
generally less expensive, time consuming, and labor
intensive. In the case of pipeline replacement,
composite wrap repair has additional advantages of
avoiding customer service interruptions and
eliminating hydrocarbon emissions associated with
the venting / draining of the damaged pipeline.

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Many variations of composite wrap systems are available. Examples include Clock
Spring®, StrongBack, Armor Plate®, and PermaWrapTM.

 Clock Spring® is a three-part system in which the sleeve itself is composed of

glass fibers and polyester resin.
 The StrongBack system is water activated, and can be applied to wet surfaces.
 Armor Plate® produces varieties of wrap systems that can be used in a wide
range of conditions including high or low pressure, high or subfreezing temperature,
and under water.
 PermaWrapTM (manufactured by WrapMaster, Inc.) has a feature to allow
detection of a previous wrap by a smart pig, so operators will not have to uncover
pipeline segments that have already been repaired.
 RES-Q Composite Wrap is a versatile solution to process piping defects where
clearance between pipes or supports is limited. It can be installed horizontally and
vertically, and it can conform to straight pipes, vessels, heat exchangers, tanks,
elbows, and even complex systems such as reducers, tees, and blind flanges.

For leaks and internal corrosions this repair method can be applied only as a temporary
repair and for defects of pipe buckles, girth welds and seam welds this repairing
technique is not recommended.

ATTACHMENT - 8
EPOXY FILLED SLEEVE
Pipeline repair using Epoxy filled Sleeve is included here only for reference as currently
material for this repair technique is not available in stock and contractor personnel are
not trained for its application. However, this repair technique can be considered for
future application where repairing of pipeline would not be feasible by any other
approved technique.

The repair comprises two oversized steel half-shells that are joined to encircle the
damaged area, leaving an annular gap. The annulus is sealed at each end of the sleeve
using a simply applied fast-setting material, and then filled at very low pressure with a
stiff epoxy-based compound.

The epoxy grout compound forms an excellent bond at both steel interfaces, providing
both axial and circumferential support. The combination of the steel outer shell and the
epoxy grout provides significant bulging restraint, thus removing or significantly
reducing the failure mechanism of defects.

Welding of sleeve with pipe is not required, and the process can be performed without
product interruption. The two sleeve halves are joined by welding or bolted flange.

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PIPELINE REPAIR PROCEDURE Rev. No.2

Both methods can be used to repair all types of non-leaking defects, including cracks,
seam welds, dents, gouges, corrosion and manufacturing defects, and bring the
pipeline back to full working parameters.

Backing strips are not needed since the shell can be spaced well off the pipeline for
welding.

Epoxy filled sleeves are not designed to repair leaks, however small pinhole leaks can
also be repaired using the Epoxy Filled Sleeve Repair, provided there is no leakage of
product during the installation or cure period of the epoxy (24 hours).

Application of epoxy grout is restricted for high temperature operating conditions.

Presently grout materials are available that can tolerate temperatures as high as 158
°F (70 °C). However in the future, materials suitable for temperatures as high as 212 °F
(100 °C) are expected to become available.

For safety reasons about 20% reduction of the operating pressure is recommended in
the course of sleeve installation (only for critical defects).

1 – Split sleeve
2 – Distance band
3 – Epoxy composition
4 – Filling/check threaded plugs
D – Defect; – Welds

ATTACHMENT - 9
MISCELLANEOUS REPAIRS
a. Stress risers such as sharp or deep scratches, gouges, and grooves shall be
removed by grinding. Grinding shall not be applied for the removal of material in
excess of 40% of the nominal wall thickness. Before removing pipe wall material, a
fitness-for-purpose analysis shall be performed based on actual and anticipated
pipe loads, material grade, and wall thickness to determine the maximum extent
and depth of material that may be removed, and the requirements for temporary or
permanent pressure reductions. This analysis shall include UT, MPI, and hardness
checks of the pipe wall (using calibrated instruments and competent technicians) to
confirm that no hidden features are present and verification of any localized hard
spots as a result of work hardening.

b. Dents that are in violation of the applicable Code shall be repaired by either
removal of the damaged section or by applying a fully welded encirclement sleeve
with butt straps. A dent of size greater than 6% OD needs to be cut out as it will
cause problems for pigging & exceeds code limits.
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PIPELINE REPAIR PROCEDURE Rev. No.2

ATTACHMENT - 10
REPAIR PROCEDURE FOR FIBER GLASS PIPELINES
The Work Permit Procedure shall be followed in strict compliance. All safety measures
as mentioned above in Attachment-2 to be strictly observed while carrying out the
repair of the pipelines.

Prior to the cutting / removal of damaged section(s), the pipe should be depressurized
and drained of product (by Pigging or Flushing operation). P&IDs’ should be checked to
ensure complete isolation of the system through closure

1. FOR TUBULAR FIBER GLASS PIPES

a. Draw a repair kit from warehouse (stock # H95-55-30V33IG4)

b. Expose the line by excavating a suitable size bell hole, in accordance with
Excavation & Trenching procedure PRO/SFTY/016 making certain to secure the
sides from collapsing. For excavations over 4 feet deep, the sides of the pits and
trenches should be sloped back to the natural repose of the soil to avoid a cave-
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PIPELINE REPAIR PROCEDURE Rev. No.2

in or benching / steps to be provided as per UEP Ground Disturbance Procedure.

Sides, which cannot be sloped to natural repose, shall be shored adequately to
resist earth movement and protect workers. Excavate to a workable level, with a
minimum clearance of 18 inches all around the pipe.

c. Cut the damaged pipe length in half and unscrew each half from the adjacent
pipe lengths. Entire damaged pipe length should be removed from the pipeline.
Cut Cut 2
1

Un screw
Un screw
Damaged area

d. Install repair pipe at the male end of existing pipeline ends (i.e. at point 1)

e. Install nipple at the female end of the existing pipeline end (i.e. at point 2)

f. Install flanges at both repair pipe end and nipple end

Repair Joint

Repair Flanges Nipple

pipe
g. Install gaskets (flexitallic) between flanges and tighten the bolts. Make
necessary arrangements for protection of stud bolts (use grease or epoxy
coating)

h. Backfilling

i. Line to be pressurized gradually to its normal operating pressures

2. FOR STAR FIBER GLASS PIPES

a. The repair of star fiber line pipe primarily involves the installation of a flange
set.

b. Expose the line by excavating a suitable size bell hole, in accordance with
Excavation & Trenching procedure PRO/SFTY/016 making certain to secure the
sides from collapsing. For excavations over 4 feet deep, the sides of the pits and
trenches should be sloped back to the natural repose of the soil to avoid a cave-
in or benching / steps to be provided as per UEP Ground Disturbance Procedure.
Sides, which cannot be sloped to natural repose, shall be shored adequately to
resist earth movement and protect workers. Excavate to a workable level, with a
minimum clearance of 18 inches all around the pipe.
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c. Consider the length of the damage. If the width of a set of flange will repair the
area, a nipple (long enough to repair the damaged area) and a coupling will be
required along with flange set.

d. Cut the damaged area of the pipe using hacksaw, taking into consideration the
total laying length of the parts needed to make the repair.

e. Depending on how long the damaged area is, an extra joint of pipe may be
required.

f. Rethread both square ends of the pipe using following procedure

Pipe preparation
I. Using the tapering tool, taper the pipe where threads will be prepared.
II. The taper should cover the entire length of the mold. Verify the mold to fit the
taper, there should be no looseness
III. Make sure all oil, mud, grease, finger prints, sand, dust, etc. are removed with
sand paper or solvent. If solvent is used, it must be dried before proceeding.
IV. Once cleaned, the bonding area should not be touched.

Mold preparation
V. Clean and warm factory supplied and approved thread mold to touch 100to
130 F

Thread Past Preparation

VI. Pour the entire bottle of amine hardener into the can of epoxy paint
VII. Using the stir stick, mix the amine hardener thoroughly into epoxy paste.
Mixing takes at least 2-3 minutes
VIII. The pot life for thoroughly mixed adhesive varies from 30 minutes (at 70 deg
F) to 10 minutes (at 100 deg F)
IX. The amine to thread paste ratio is 27 gram amine to 500 grams paste
(although the epoxy thread paste kits are pre-measured, this ratio can be
verified by using a scale)

Threading
X. Fill the thread mold with the mixed thread past using the stir stick
XI. Force the paste into the mold cavity by moving it across the thread, in one
direction from the small end of the mold to the large end
XII. Cover the full surface of the thread. Try to break or remove any air packets
present in the thread
XIII. Cover the tapered end of the pipe with approximately 1/8” of mixed epoxy
paste
XIV. Roll the paste around the tapered area in a fashion which assist breaking any
air pockets that are present
XV. Build a ¼” thickness bead of the paste around the small end of the taper to
assist in compression of trapped area
XVI. Using a stabbing motion, insert the large end of the thread mold onto the
tapered pipe, Shoved the mold in straight, smooth fashion
XVII. Once the surfaces touch, run the mold clockwise until the mold is locked onto
the tapered surface
XVIII. Thoroughly clean the excess epoxy paint from the front and rear of the mold

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XIX. Heat assisted curing to done to finalize the thread making. Application of the
heat for curing provides faster cure times and better chemical and physical
properties. Electric heat collars (250 deg F for 30 minutes, do not overlap) or
propane torch (apply to the end of mold first, then evenly heat mold, avoid
blistering pipe) heating methods can be used for heat assisted curing.

Mold removal
XX. Tap the mold lightly on all sides using a small hammer
XXI. Unscrew the mold using the strap wrench. Avoid using a pipe wrench since
this type wrench can bend the mold
XXII. Support the pipe during the mold removal such that it does not become over-
bend due to torque requirements
XXIII. Inspect threads, a fully cured thread should be shiny in appearance and
substantially free of voids

g. Install flanges on the field threaded ends. Use thread compound and/or Teflon
tape for making threaded connections.
h. Install gasket (flexitallic) and tighten the flange bolts. Make necessary
arrangements for protection of stud bolts (use grease or epoxy coating.
Nipple
Flange set
Coupling

Field threads
Damaged area Existing
Existing

i. Backfilling.

j. Line to be pressurized gradually to its normal operating pressures

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