Pipeline Repair Methods/Inservice Welding Course

September 27, 2007

9am - 4pm

September 28, 2007

9am - 4pm

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.

Course 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.

Course Notes

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 (CEUs)

Upon completion of the course, participants will be eligible to receive 1.2 Continuing Education Units (CEUs).

Course Outline

DAY 1

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
• Welding Metallurgy 101
• 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
• IntegrallyReinforced

Pipeline Repair by Weld Deposition

• Physical Concept
• History of Weld Deposition Repair
• Burnthrough Risk
• Integrity Restoration
• Practical Application

NonWelded Repairs

• Repair by Grinding
• Composite Repairs
• Epoxy Filled Shells

Code and Regulatory Requirements

• Recent Changes to API 1104
• Code Requirements for Weld Deposition Repair

DAY 2

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

• Proper electrode handling
• Proper fitup
• Proper welding sequence
• Control of Heat Input Levels
• Inspection and Testing

Lessons to be Learned from Past Pipeline Repair Incidents

• Reported Incidents
• Previously Unreported Incidents
• Ten Commandments of InService Welding

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