D/Stream Pipeline Corrosion Defects & Remedy: Pipeline & Storage Tanks Integrity Assessment Workshop

n
Greater Nile Petroleum Operating Company Limited
D/Stream Pipeline
Corrosion Defects &
Remedy
Pipeline & Storage Tanks
Integrity Assessment
Workshop
5th December, 2007
Alsalam Rotana Hotel- Khartoum
GNPOC Pipeline:
Corrosion Defects & Remedy.
n
Great Nile Petroleum Operating Company Limited
GREATER NILE PETROLEUM
GNPOC Pipeline:
Corrosion Defects
& Remedy.
By: Pipeline Operations & Maintenance Department
December 2007.
Asset Integrity Workshop
5th December ,
GNPOC Pipeline:
n
Introduction:
In year 2001, intelligent pigging (IP) detected 2points metal loss depth
(ML) more than 40% and 130points with ML less than 40%.
5 points were repaired using Clock Spring Method that will be
discussed later.
In this year 2007, IP result showed serious corrosion defects in terms of
metal loss (ML) and severe welding anomaly (SWA) and general pitting
in total 20,233 points.
Details results of findings by CPP (China Petroleum Pipeline Bureau)
as shown in the next slides.
5th December ,
GNPOC Pipeline:
n
China Petroleum Pipeline

Bureau(CPP)
Inspection result comparison between 2001 and 2007
5th December ,
GNPOC Pipeline:
n
The following slides showed the inspection and remedial actions

being performed on the following KP locations.
a. KP (0 + 905m)
b. KP (0 + 917m)
c. KP (0 + 20m) to KP (0 +25m)
d. KP (0 + 320m)
In this presentation, we will showed on the severity of the
corrosion defect being observed on the pipeline surfaces at this
KP and what remedial action had been taken to rectify the
situation.
Note: Pipeline size and description:
28 x 10.72mmWT API 5L X65 pipe
3LPP (three layer polypropylene) coating.
5th December ,
GNPOC Pipeline:
n
1st September 2007:

Scenario of KP (0 + 905mm) location i.e. a swampy area before any civil
work commenced.
5th December ,
GNPOC Pipeline:
n
3rd September 2007:

Location of KP (0 + 905mm) before excavation being done. Note that the
swampy areas as shown in previous slide were dumped with dried black
clay and gravels before excavation can be proceed and total cost incurred
for such civil & excavation work was USD7,000 (USD seven thousand).
5th December ,
GNPOC Pipeline:
n
8th September 2007: Upon completion of excavating the KP (0 + 905mm)

location, the existing shrinkage sleeve on the welding joint area was
observed damaged, bulging in most areas where resulted water and damp
soil filled the gap between the sleeve and pipe surface areas.
5th December ,
GNPOC Pipeline:
n
Upon removal of the damage shrinkage sleeve condition,

the pipe surfaces and welding joint profiles were observed
to be severed pitted with severe Metal Loss (ML) and
under-bead welding profiles.
5th December ,
GNPOC Pipeline:
n
Other areas of the pipe surfaces that have been corrosive attack.
10
5th December ,
GNPOC Pipeline:
n
Upon completion of cleaning the corrosive defect areas by power brushes,

severe ML could be seen clearly.
11
5th December ,
GNPOC Pipeline:
n
Other affected ML areas observed.
12
5th December ,
GNPOC Pipeline:
n
Depth of the severe pitting surface that was accessible to be measured by

pitting gage (pipe pit gage) recorded approximately 0.230inch (5.8mm)
depth about 54% ML.
13
5th December ,
GNPOC Pipeline:
n
Thickness of pipe on the defect ML areas were measured on four (04)

severe locations that can be measured and the readings recorded were
between 4.7mm to 5.2mm thick.
14
5th December ,
GNPOC Pipeline:
n
The affected ML defect areas were thoroughly cleaned and fill with cold
weld compound materials as per manufacturer application methods and
left for curing and hardened.
Cold weld compound materials: DURAMETAL SUPER CA-HD RAPID
15
5th December ,
GNPOC Pipeline:
n
Fit up of the Type B fabricated welding sleeve upon curing of the cold
weld compound.
16
5th December ,
GNPOC Pipeline:
n
- Welding started after the Operating Pressure was reduced to the

minimum that possible and stabilized at 58Bar.
- Welding of the fabricated sleeve was done accordingly GNPOC WPS
No: 02, 03 and or 04.
- Work instruction & procedure for welding of the fabricated sleeve type
B were derived and followed for the welding of this sleeve.
17
5th December ,
GNPOC Pipeline:
n
Work Instruction & Procedure for Welding of the

Fabricated Sleeve Type B
Before welding of any welding sleeve on live pipeline can commence, the
operating pressure of the pipeline need to be reduced as per calculated
safe pressure level for welding onto in-service pipelines such as by using
the following formula:
P = 2S (t - c) 0.72 / D as per Pipeline Repair Manual by Pipeline Research
Council International Inc. (PRCI).
Where:
P = pressure (psi)
S = specific minimum yield strength of pipe (psi)
t = nominal pipe wall thickness (inch)
D = nominal pipe diameter (inch)
c = allowance for heated metal loss of strength, assume to be 2.4 based on
TD Williamson calculations.
18
5th December ,
GNPOC Pipeline:
n
Removed all coating material of the line pipe on the areas where
welding to be performed.
GNPOC Welding Procedure Specifications (WPS) No: 02 and 03 or
04 to be used for the welding of this fabricated sleeve type B.
Welding parameters, preheat temp, inter-pass temp and pipe wall
temperature to be monitor accordingly to the mentioned WPS
used.
Upon curing and hardened of the cold weld compound materials
(DURAMETAL-SUPER CA-HD RAPID), fit-up of the fabricated
welding sleeve type B to be done properly with accepted alignment
root gap to be achieved. Advisable to hold and tight up the two
portion of the this sleeve by the use of two numbers of chain
clamps, fiber strap clamps or any clamping devices.
19
5th December ,
GNPOC Pipeline:
n
Only Low Hydrogen Electrodes E 7018 to be used for welding of

these sleeves and ONLY use electrode E7018 that have been baked
at 300degC for 2hrs or as per recommended by the electrode
manufacturer.
Ensure that all E7018 electrodes that are to used during welding
are kept in a quiver (small portable oven) having a temperature of
70degC.
If there are gaps of more than 5mm between the fabricated
welding sleeve to the pipe surface circumferentially, advisable to
butter weld the pipe surface first using E 7018 size 3.2mm as per
GNPOC WPS no: 03, before welding of the mentioned sleeve to
the pipe can be performed.
20
5th December ,
GNPOC Pipeline:
n
Welding sequences if possible to be as follow:

a. Start and complete the longitudinal butt weld 2G position first.
b. Upon completion the longitudinal butt weld, then proceed with
the 3F circumferential fillet weld.
Preheat the welding joint areas to the temperature to a minimum
of 100degC before welding can start.
Monitor the pipe surface temperature near the welding pools to be
not more than what recorded in the above mentioned GNPOC
Approved WPS (s) i.e. must be <400degC.
Upon completion of welding, acceptance of the welding profiles to
be justified by visual inspection (VI) and in addition to VI, NDT
(non destructive test) either by Magnetic Particle Inspection
(MPI), Dye Penetrant Test (DPT) OR Ultrasonic Test (UT) to be
performed on the welding profile to confirm the acceptance of the
welding profiles.
21
5th December ,
GNPOC Pipeline:
n
Welding of 5F Circumferential Fillet position in progress.
22
5th December ,
GNPOC Pipeline:
n
Completion of welding the fabricated sleeve. Total welding time taken to

complete welding of this fabricated sleeve type B was approximately
5hours. Note that only two (02) welding machines and three (03) welders
were available to perform the welding job.
23
5th December ,
GNPOC Pipeline:
n
Upon completion of welding and visual inspection, Ultra-sonic Testing

(UT) was performed and result of UT was observed satisfactory.
24
5th December ,
GNPOC Pipeline:
n
Upon completion of NDT by Ultra-sonic Testing, application of Epoxy

Coating was done on all welding profile areas and exposed bare pipe surface.
Type of Epoxy Coating Material: Raychem S1239 Adhesive .
25
5th December ,
GNPOC Pipeline:
n
Upon curing time of the epoxy coating, the fabricated welding sleeve and
its nearby surrounding areas of the pipe were wrapped with the heat
shrinkable sleeve.
Type: RAYCHEM, HTLP 80, High Temperature (80degC)
26
5th December ,
GNPOC Pipeline:
n
Photos of repair job on

other locations.
27
5th December ,
GNPOC Pipeline:
n
Example of joint surface condition upon removal of shrinkable sleeve at

KP ( 0 + 917m)
28
5th December ,
GNPOC Pipeline:
n
Further removal of the 3LPP coating of the 28 existing pipe at

KP ( 0 + 917m).
29
5th December ,
GNPOC Pipeline:
n
Existing Heat Shrinkable Sleeve found wet after removed from the pipe
surface at KP ( 0 + 917m)
30
5th December ,
GNPOC Pipeline:
n
Location: KP (0 + 20m) to KP (0 + 25m)

Pipe Spool surface condition upon removal of shrinkable sleeve.
Note that these portions of pipe spool was only covered by shrinkable
sleeves ONLY.
31
5th December ,
GNPOC Pipeline:
n
Further example observed between KP (0 + 20m) to KP (0 + 25m)
32
5th December ,
GNPOC Pipeline:
n
33
5th December ,
GNPOC Pipeline:
n
34
5th December ,
GNPOC Pipeline:
n
NDT method using Magnetic Particle Inspection (MPI) performed upon

completion of welding of fabricated sleeve type B
at KP (0 + 20m)
35
5th December ,
GNPOC Pipeline:
n
Another photo for MPI in progress.
36
5th December ,
GNPOC Pipeline:
n
Existing Mechanical Clamp being removed at KP (0 + 320mm)
37
5th December ,
GNPOC Pipeline:
n
Upon removal of the present Mechanical Clamp at KP (0 + 320mm):

The condition of the cold weld material on the pipeline surface applied
earlier before installing a mechanical clamp being observed as shown in the
below photo. This area was thoroughly cleaned by using power brush &
hand grinder before fit-up of fabricated welding sleeve type B.
38
5th December ,
GNPOC Pipeline:
n
Optional Remedy Methods:

Besides welding of fabricated welding sleeve on the
corrosive defected areas, optional methods to be
considered are to execute the followings:
1) Installation of HT (High Temperature) Clock Spring
materials.
2) Installation of SpiderWrap (High Strength) HS
material.
39
5th December ,
GNPOC Pipeline:
40
n
5th December ,
n
CLOCK
Proven better, time after
time
SPRING
Clock Spring for the

reinforcement of
corrosion and
mechanical damage
restoring the pipe
integrity to its
pristine condition.
41
5th December ,
n
1.1.
2.2.
3.3.
CLOCK
Proven better,
SPRING
time after
time
time
Patented,
Patented,high-strength,
high-strength,
unidirectional
unidirectionalcomposite
composite
structure
structure
Patented,
Patented,fast
fastcuring,
curing,high
high
performance
two-part
performance two-part
adhesive
adhesivesystem
system
Extremely
Extremelyhigh
high
compressive
compressivestrength,
strength,
proprietary
proprietaryload
load
transferring
transferringcomponent.
component.
Once
Onceinstalled,
installed,the
thethree
three
elements
bond
together
elements bond togetherto
to
form
extraordinarily
form extraordinarily
strong
strongand
anddurable
durablerepair
repair
42
5th December ,
n
SPIDERWRAP HIGH STRENGTH (HS) WRAP

SpiderWrap HS is an innovative, high
strength piping remediation wrap. It consists of
a proprietary glass fiber reinforcement fabric,
factory impregnated with durable, moisture cured
polyurethane (MCU) resins.
SpiderWrap HS offers complete external piping
remediation, repair, reinforcement, and/or complete
hoop strength replacement to any size piping,
constructed of virtually any material, and its
flexibility
allows installation on any shape or configuration
Including elbows, manifolds, tees, reducers, bends .
SpiderWrap HS is an efficient, economical, easy to
use alternative to any other repair product, or
replacement.
SpiderWrap HS is a proven product, currently successfully used in numerous applications in many industries worldwide.
SpiderWrap HS is highly chemical resistant, non-conductive and temperature resistant to more than 650
deg. F. after cure.
43
5th December ,
GENERAL PREPARATION AND APPLICATION PROCEDURE
Clean pipe surface to as near white metal as possible

If pitting is present, fill pits with one of our specified epoxy fillers
Coat the surface to be wrapped with BD-563 Epoxy Base
Install the SpiderWrap HS to the calculated specified number of layers, wetting continuously
Pull each layer tightly and work into previous layer for bond
Smooth and wet continuously, then install 2 layers of the retaining stricture banding over the top layers to
assure a smooth finish and monolithic reinforcement
MECHANICAL PROPERTIES
Operating Temperature
Tensile Modulus
Tensile Strength
Flexural Modulus
Flexural Strength
Ply Thickness
Compressive Strength
Dielectric Strength
Working Time
Hardness
-65 to 650 F. after cure

3.8 x 106 psi
ASTM D3039
65,000 psi
ASTM D3039
3.6 x 106 psi
ASTM D3039
53,100 psi
ASTM D3039
.011 inches (11 mils)
28,500 psi
ASTM D3039
Non-conductive when cured (16,000 volts)
20-30 minutes, temperature dependent 85
shore D nominal
Load per ply per Inch or
width
Load per ply per Inch for

20 year+ life designs
425 pounds
Allowed for D.O.T. pipeline repairs under
49 CFR, Parts 192 and 195, as well as
being validated and certified for use under
the ASME PCC-2 Article for B31.3, B31.4
and B31.8.
Code Compliance
2 X 12
Available
Sizes
One year if stored between 40--83F and

aluminum packet is not punctured. Do not
use if product is hardened. Rotate stock for
best results.
Shelf Life
NO EFFECT
Chemical Resistance
(40 Day Immersion Test
715 pounds
Period)
Cure Time
Ammonia
Hydrochloric Acid
Diesel
MEK
Acetone
Crude Oil
Toluene
Ethyl Alcohol
Gasoline
Xylenes
Black liquor
Sulfuric Acid
1 hour at temperatures between 50--80F
10
3 X
30
4 X
15
4 X
30
4 X
50
6 X
60
10 X 60
10 X 120
3801 Kirby Drive, Suite 520, Houston TX 77098

Tel:
44
3 X
713-828-1318 Fax: 713-630-0560
5th December ,
GNPOC Pipeline:
n
THE END
Thank you for your kind
attention.
Shukran Jazilan.
Wassalam.
45
5th December ,

D/Stream Pipeline Corrosion Defects & Remedy: Pipeline & Storage Tanks Integrity Assessment Workshop

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

D/Stream Pipeline Corrosion Defects & Remedy: Pipeline & Storage Tanks Integrity Assessment Workshop

Uploaded by

Copyright:

Available Formats

n

Greater Nile Petroleum Operating Company Limited

GREATER NILE PETROLEUM

Asset Integrity Workshop

Asset Integrity Workshop

China Petroleum Pipeline

Inspection result comparison between 2001 and 2007

Asset Integrity Workshop

The following slides showed the inspection and remedial actions

Asset Integrity Workshop

1st September 2007:

Asset Integrity Workshop

3rd September 2007:

Asset Integrity Workshop

8th September 2007: Upon completion of excavating the KP (0 + 905mm)

Asset Integrity Workshop

Upon removal of the damage shrinkage sleeve condition,

Asset Integrity Workshop

Asset Integrity Workshop

Upon completion of cleaning the corrosive defect areas by power brushes,

Asset Integrity Workshop

Other affected ML areas observed.

Asset Integrity Workshop

Depth of the severe pitting surface that was accessible to be measured by

Asset Integrity Workshop

Thickness of pipe on the defect ML areas were measured on four (04)

Asset Integrity Workshop

Asset Integrity Workshop

Asset Integrity Workshop

- Welding started after the Operating Pressure was reduced to the

Asset Integrity Workshop

Work Instruction & Procedure for Welding of the

Asset Integrity Workshop

Asset Integrity Workshop

Only Low Hydrogen Electrodes E 7018 to be used for welding of

Asset Integrity Workshop

Welding sequences if possible to be as follow:

Welding of 5F Circumferential Fillet position in progress.

Asset Integrity Workshop

Completion of welding the fabricated sleeve. Total welding time taken to

Asset Integrity Workshop

Upon completion of welding and visual inspection, Ultra-sonic Testing

Asset Integrity Workshop

Upon completion of NDT by Ultra-sonic Testing, application of Epoxy

Asset Integrity Workshop

Asset Integrity Workshop

Photos of repair job on

Asset Integrity Workshop

Example of joint surface condition upon removal of shrinkable sleeve at

Asset Integrity Workshop

Further removal of the 3LPP coating of the 28 existing pipe at

Asset Integrity Workshop

Asset Integrity Workshop

Location: KP (0 + 20m) to KP (0 + 25m)

Asset Integrity Workshop

Further example observed between KP (0 + 20m) to KP (0 + 25m)

Asset Integrity Workshop

Further example observed between KP (0 + 20m) to KP (0 + 25m)

Asset Integrity Workshop

Further example observed between KP (0 + 20m) to KP (0 + 25m)

Asset Integrity Workshop

NDT method using Magnetic Particle Inspection (MPI) performed upon

Asset Integrity Workshop