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Pipeline Repair Methods, Hot-tapping, and In-service Welding
Led by Bill Bruce and Dr. Chris Alexander
September 20-21, 2023 | Online

Register before August 30, 2023 and save $200!

Day 1
  9am-1:40pm CDT  Course
Day 2
  9am-1:40pm CDT  Course


Course Syllabus

Day 1

Pipeline Repair Methods/Hot Tapping/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
  • Assessment of grinding defects

Welding Processes/Discontinuities and Defects

  • Arc welding processes
  • Consumable designations
  • Crack types and discontinuities vs. defects

Burnthrough and Related Safety Concerns

  • Factors affecting burnthrough
  • Effect of wall thickness
  • Effect of welding parameters
  • Effect of flow rate/pressure
  • Avoiding burnthrough
  • Related concerns

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
  • Thermal cycles of welded joints
  • Prevention of hydrogen cracking

FullEncirclement Repair Sleeves

  • Full encirclement sleeve types
  • Principal of operation
  • Assuring effective reinforcement
  • Sleeve design
  • Sleeve fabrication
  • Other Sleeve Types

Hot Tap Branch Connections

  • Branch connection design
  • Reinforcement types
  • Integrally reinforced
  • Line replacement/stopping
  • Pressure testing
  • Hot tapping through welds

Pipeline Repair by Weld Deposition

  • Physical concept
  • History of weld deposition repair
  • Burnthrough risk
  • Integrity restoration
  • Practical application
  • External repair of internal wall loss
  • Regulatory activities


Day 2

NonWelded Repairs and Commercial Repair Products

  • Repair by grinding
  • Bolton repair clamps
  • Fiberreinforced composite repairs
  • Epoxyfilled shells
  • Grouted tees
  • Steel sleeves vs. composite repairs

Selecting an Appropriate Repair Method

  • Pipeline repair manual
  • Detailed selection criteria
  • Repair option summary
  • Qualifying factors

Code and Regulatory Requirements

  • Procedure and Welder Qualification
  • History of API 1107/API 1104 Appendix B
  • Qualification of Procedures
  • InService Welder Qualification
  • Comparison with other codes (CSA Z662, AS28852, etc.)

Procedure Development and Selection for Hot Tap and Repair Sleeve Welding

  • Procedure options
  • History of weld cooling rate prediction
  • Predictive methods
  • HAZ hardness limits
  • Iterative procedure qualification trials
  • Procedure selection guidelines

Practical Aspects of Hot Tap and Repair Sleeve Welding

  • Practical aspects of avoiding burnthrough
  • Practical aspects of avoiding hydrogen cracking
  • Welding procedure selection examples
  • Chemical composition determination
  • Proper electrode handling
  • Proper fitup and welding sequence
  • Control of heat input levels
  • Inspection and testing

Alternative Welding Processes for InService Welding

  • Conventional processes
  • Alternative processes
  • Branch connection root pass welding
  • Cellulosiccoated electrode limitations

A Simple Approach to Hot Tap and Repair Sleeve Welding

  • Introduction
  • Five general rules of thumb
  • Prove it yourself

Lessons to be Learned from Past Pipeline Repair/Hot Tapping Incidents

  • Reported incidents
  • Previously unreported incidents
  • Ten commandments of inservice welding


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