| October 13-14, 2005 |
| 8:00am |
Registration, coffee |
| 8:30am-5:00pm |
Course |
| October 15, 2005 |
| 8:00am |
Coffee |
| 8:30am-12:00pm |
Course |
The various aspects of pipeline repair using weld and non-weld methods will be covered, as will the concerns for welding onto in-service pipelines and the approaches used to address them.
Who Should Attend
Pipeline engineers, Operations and Maintenance personnel, inspectors, and welders.
Lecturer
Bill Bruce is director of welding technology with CC Technologies. Prior to joining CCT, he was a technology leader at Edison Welding Institute and a senior engineer at Panhandle Eastern Pipeline Co. He is a member of the American Petroleum Institute API 1104 Committee and is the chairman of the Maintenance Welding Subcommittee.
All delegates will receive a detailed set of lecture notes containing more than 250 pages, providing an invaluable reference document after the course.
Continuing Education Units
Upon completion of the course, participants will be eligible to receive 1.4 Continuing Education Units (CEUs).
Course Program
Pipeline Repair Methods/InService Welding
• Introduction
• Incentives
• Primary Concerns
Defect Assessment Prior to Repair
• Reason for Assessment
• Types of pipeline defects
• Pressure Reduction Requirements
• Corrosion Measurement Methods
• Corrosion Assessment Methods
Selecting an Appropriate Repair Method
• Pipeline Repair Manual
• Detailed Selection Criteria
Burnthrough and Related Safety Concerns
• Factors Affecting Burnthrough
• Effect of Wall Thickness
• Effect of Heat Input
• Effect of Flow Rate/Pressure
• Avoiding Burnthrough
Hydrogen Cracking Concerns
• Recent significant incidents
• Common factor/recommendation
• Hydrogen cracking requirements
• Weld hydrogen levels
• Crack-susceptible weld
microstructures
• Welding residual stresses
• Welding metallurgy for carbon steels
• Welding processes
• Thermal cycles of welded joints
• Discontinuities and defects
• Prevention of hydrogen cracking
FullEncirclement Repair Sleeves
• FullEncirclement Sleeve Types
• Principle of Operation
• Assuring Effective Reinforcement
• Sleeve Design
• Sleeve Fabrication
Hot Tap Branch Connections
• Branch connection design
• Reinforcement types
• Integrally-reinforced
• Line replacement/stopping
• Pressure testing
Pipeline Repair by Weld Deposition
• Physical Concept
• History of Weld Deposition Repair
• Burnthrough Risk
• Integrity Restoration
• Practical Application
• External repair of internal wall loss
NonWelded Repairs
• Repair by Grinding
• Composite Repairs
• EpoxyFilled Shells
Code and Regulatory Requirements
• API 1104 Appendix B - In-Service Welding
• CSA Z662 requirements
• Code requirements for weld deposition repair
Procedure Selection for Hot Tap and Repair Sleeve Welding
• Burnthrough Risk Summary
• Prevention of Hydrogen Cracking
• Welding Procedure Options
• Welder/Procedure Qualification
• Predicting Required Heat Input
• Selecting an appropriate procedure
Practical Aspects of Hot Tap and Repair Sleeve Welding
• Practical aspects of avoiding burn-through
• Practical aspects of avoiding hydrogen cracking
• Qualification of welding procedures (API 1104)
• Qualification of welders (API 1104)
• Welding procedure selection examples
• Chemical composition determination
• Electrode (filler metal) selection
• Semiautomatic welding processes for maintenance welding
• Proper electrode handling
• Proper fit-up
• Proper welding sequence
• Control of heat input levels
• Inspection and testing
Lessons to be Learned from Past Pipeline Repair Incidents
• Reported Incidents
• PreviouslyUnreported Incidents
• Ten Commandments of InService Welding
