GU-379 Pipeline Emergency Repair Manual

GU-379 Pipeline Emergency Repair Manual
Authorised For Issue --/--/----
Signed:........................................................................................
M. Zadjali, UIP
CFDH Pipelines
The following is a brief summary of the 5 most recent revisions to this document. Details of all revisions
prior to these are held on file by the issuing department.
Version No.
Rev. 4.0
Rev. 3.2
Date
Nov 2004
April 2001
Feb. 2001
Author
UEL/1
R Harris
OIP/31
UEL/1
Scope/ Remarks
GRP pipeline section added. Document re-formatted.
Electronic copy of Emergency Materials List (Appendix 13)
added.
Designed as BCD Guideline. Minor textual changes to adapt to
GU- format and reference updated. Technical content not
reviewed.
Rev. 3.1
Rev. 3
June 1999
OIP/4
Updated to reflect changes in responsibilities due to asset based

organisation and reformatted to new template.
Rev. 2
Mar 1995
AEF/631
Page 2 of 76
Table Of Content
Authorised For Issue --/--/----.........................................................................................2
1.0
Introduction.....................................................................................................................
1.1
Objective.................................................................................................................5
1.2
Scope.......................................................................................................................5
1.3
Applicable Standards..............................................................................................6
1.4
Definitions and Abbreviations................................................................................6
1.5
Distribution/Target Audience..................................................................................7
1.6
Document Structure................................................................................................7
1.7
Review & Improvement..........................................................................................8
2.0
Emergency Repairs for Carbon Steel Pipelines...........................................................
2.1
Scope.......................................................................................................................9
2.2
Types of defects and its causes................................................................................9
2.3
Causes of Emergency Defects...............................................................................10
2.4
Types of Level I Emergency Defects....................................................................10
2.5
Level-I Emergency Defects...................................................................................11
2.6
Composite Repair: An Alternative Repair Method...............................................29
2.7
Level II Emergency Defects- Injurious non leaking defects.................................30
2.8
Repair organisation...............................................................................................30
3.0
Emergency Repairs for Glass Reinforced Plastic (GRP) Pipelines.........................
3.1
General..................................................................................................................31
3.2
Scope.....................................................................................................................31
3.3
Causes of defects in an operating GRP pipeline system.......................................31
3.4
Defects due to over pressurisation........................................................................31
3.5
Defect categorisation.............................................................................................31
3.6
Repair of Level-I Emergency Defects...................................................................32
3.7
Emergency Repair Procedure Qualification..........................................................36
3.8
Quality Programme during Repair........................................................................36
3.9
Emergency Repair Kit...........................................................................................36
4.0
Emergency Repair of Subsea Carbon Steel Pipelines..............................................
4.1
General..................................................................................................................38
4.2
Scope.....................................................................................................................38
4.3
Causes of Defects..................................................................................................39
4.4
Level I Emergency Defects...............................................................................39
4.5
Resources..............................................................................................................41
5.0
Emergency Stock Materials.........................................................................................
5.1
Philosophy.............................................................................................................42
5.2
Loaction and Quantities of Emergency Stock Materials.......................................42
6.0
Safety..............................................................................................................................
6.1
Safety requirements during repair of emergency defects......................................43
6.2
Accidental releases................................................................................................44
7.0
References......................................................................................................................
Page 3 of 76
Appendix-1
Appendix-2
Appendix-3
Appendix-4
Appendix 5
Appendix 6
Appendix-7
Appendix-8
Appendix-9
Appendix-10
Page 4 of 76
Mechanical methods to be used in installation of sleeves

Plidco Split + Sleeve
Plidco Smith + Clamp
Plidco Weld + Cap
Fixing arrangements for Plidco Weld + End
Plidco Flange + Repair Ring
Plidco Flange Repair + Split Sleeve
List of Emergency Material
Manufacturer Instructions
User Comment Form
1.0 Introduction
1.1
Objective
The objective of this manual is to provide a structured approach for emergency repairs
to Carbon steel pipelines, GRP off-plot pipelines and subsea pipelines.
The main purpose of an emergency repair is to restore the structural integrity of the
pipeline in the most efficient manner, to avoid further damage to health, safety and the
environment and to resume the operation without any further loss in production. In
this regard expediency is a more important factor than achieving the cheapest capital
cost of the repair itself, particularly as the time saved due to fast repair will lead to
lower losses in production throughput of the pipeline.
An emergency repair differs from a planned repair in that the time available for
assessment of the best course of action, material supply and execution time are
limited by the need for resumption of production.
The main purpose of the manual is to define the guidelines and requirements for
emergency repairs in order to reduce the execution time in the assessment of the
emergency scenario and deciding the best course of action. The manual gives
practical repair and maintenance solutions to various potential emergency situations.
The manual provides the user with information to select and execute a suitable repair
method for a given pipeline damage scenario. It is not possible to foresee every
condition that may arise in the event of a pipeline requiring repairs and, therefore, the
exact course of action to be taken must be decided upon by the engineer in charge of
the repair.
In the event of an emergency situation, reference shall be made to the PDO
Emergency Procedures. These procedures provide information essential to the
Emergency Controller when making decisions and formulating an action plan to
control and rectify a wide range of emergency situations.
1.2
Scope
This document covers the emergency repairs of off-plot pipelines. The
recommendations covered pertain to both aboveground and underground Carbon steel
and GRP pipelines. Repair of subsea carbon steel pipelines is briefly covered in this
document. The repair methods specified in this manual can be used for repair of all
classes of pipelines as defined in section 3.2.5 of SP-1211. However, the emergency
material is stocked for class-I pipelines only.
This document covers emergency scenarios for the off-plot portion of a pipeline
outside the plant boundary. On plot emergency repairs including those related to
scraper traps, bypass lines and other related on plot facilities are excluded. These
latter repairs shall form part of the plant repair/shutdown manual.
The document covers emergency repairs for internally and externally coated/lined
pipelines but repairs to cathodic protection systems are excluded.
Page 5 of 76
Only leakage emergency scenarios are covered in this manual. For non-leaking
injurious defects, reference is made to requisite DEP/PDO standards. The scope of the
manual is taken from the point where the leak has been identified and located. It also
briefly covers the aspect of detection or identification of the defects by reference to
the relevant DEP / Standards.
1.3
Applicable Standards
The list of applicable standards, specifications, codes, guidelines and procedures are
indicated in section 6.0 of this document.
1.4
1.4.1
Definitions and Abbreviations

General Definitions
Contractor - The party that has a contract with the Company for providing work
(including emergency repairs), equipment, material, services (including consulting

services) and manpower. Contractor shall be read to also include sub-contractor
and parties providing support to contractors and sub-contractors. The company may
undertake all or part of the duties of the contractor.
Company - is Petroleum Development of Oman LLC. The company may include an
agent or consultant authorised to act on behalf of the company.

Shall - indicates a requirement.
Should - indicates a recommendation.
May - indicates a possible course of action.

1.4.2
Specific Definitions
Defect: - a flaw which may have a deleterious effect on the structural integrity of the
pipeline.
Emergency: - a critical condition that may endanger life, environment and/or assets.
Injurious defect: - a defect which requires removal, repair or derating of the pipeline.
Permanent repair: - a repair that makes a pipeline safe for continuous service for the
remaining period of its design life at its maximum allowable operating pressure or at a
reduced pressure.
Temporary repair: - a repair that makes a pipeline safe for service for a limited
period of minimum 3 months.
Leaking cracks: - Stress induced separation of the pipe material, which, without any
other influence, is insufficient in extent to cause complete rupture. The cracks usually
occur due to excessive straining during the initial mechanical formation of the pipe or
as a result of micro-structural sensitivity to certain environments, which are often high
in hydrogen or sulphur content, in combination with tensile stresses. Cracks may be
found in the girth welds, seam welds or in the pipe body.
Page 6 of 76
Prompt action: Consists of dispatching qualified personnel without delay for

evaluating and, where necessary, abating the existing or probable hazard.
1.4.3
1.5
Abbreviations
API
American Petroleum Institute.
ANSI
American National Standards Institute
ASME
American Society of Mechanical Engineers
DEP
Design and Engineering Practice (SHELL documents)
HIC
Hydrogen Induced Cracking
MPI
Magnetic Particle Inspection
NPS
Nominal Pipe Size
SCC
Stress Corrosion Cracking
UT
Ultrasonic Testing
Distribution/Target Audience
The document is intended for use by PDO and all other parties involved in the
pipeline maintenance and emergency repairs as a basic guideline for the emergency
repair of pipelines. Typical parties include operators, design consultants, construction
contractors, inspection, repair and maintenance contractors, certifying agencies and
authorities.
1.6
Document Structure
The document comprises of the following sections:
1.
Introduction
2.
Emergency repairs for Carbon steel pipelines
3.
Emergency repairs for GRP pipelines
4.
Emergency repairs for Subsea CS pipelines
5.
Safety
6.
References
The sections will be further sub-divided to cover the relevant technical / safety
considerations, procedures and planning required to meet the objectives of the
manual. References at the back of the manual will include relevant reference material.
The document is intended for use by PDO and all other parties involved in the
pipeline maintenance and emergency repairs as a basic guideline for the emergency
repair of pipelines. Typical parties include operators, design consultants, construction
contractors, inspection, repair and maintenance contractors, certifying agencies and
authorities.
Page 7 of 76
1.7
Review & Improvement

These Guidelines will be reviewed and updated once every three years. The review
authority will be CFDH Pipelines. No changes will be made without the approval of
the Custodian (CFDH Pipelines).
Page 8 of 76
2.0 Emergency Repairs for Carbon Steel Pipelines

2.1
Scope
This part of the document defines emergency repair requirements for carbon steel
pipelines. The pipelines covered are for diameters ranging from 4 to 48, wall
thickness ranging from 4.8mm to 20.06mm and steel grades conforming to API 5L up
to Grade X-70. It excludes the repair details for other metallic pipelines e.g. ductile
iron, duplex material etc.
The subjects addressed in this part of the document contain information regarding
assessment of an emergency defect, inspection, repair methods and the safety
requirements to be followed during repair.
2.2
Types of defects and its causes

The possible repair methods are, to a large extent, dictated by the type of the defect.
The various types of defects in a pipeline system can be classified on the basis of
availability of time required for repair, the resources required to deal with the repair
and the consequences. These are classified in the following two main types: Emergency defects:- a defect in the pipeline that has a deleterious effect on the
health, safety, environment and/or production. Such defects in a pipeline system are
those, which require immediate and prompt action and also need specialised
procedures, equipment, manpower and supplies to protect the public safety or
property from an existing or potential hazard.
Emergency defects can be further categorised Level 1 and Level 2.
Level I emergency defects: - All leaking defects in Class I pipelines are classified
as Level I emergency defects. These Level I emergency defects pose an
immediate threat to the health, safety, environment and production and therefore
needs to be rectified on an immediate basis with prompt action. The period
between reporting of a defect and the repair shall be kept as short as practicable.
Level II emergency defects: - All non-leaking injurious defects as defined in SP1235 in Class I pipelines are defined as Level II emergency defects. These
defects do not pose an immediate threat to health, safety, environment and
production. However, the extent of damage to the pipeline system is such that
these defects can at any time become leaking defects. Therefore the time
available for carrying out repairs for such defects is more than the time available
in Level I emergency defects, but is less than the time available for nonemergency defects.
Non-Emergency defects: - a defect which, in its present state, does not have any
immediate impact on the health, safety, environment and/or production. However,
such defects can if not rectified, have the potential to become emergency defects and
thereof need planned repair. The time available for carrying out repairs for such
defects is more than the time available in cases of emergency defects. Therefore, no
specialised procedures and resources are required.
Page 9 of 76
Such defects can be repaired in a planned manner, but must also be rectified in a
timely manner to ensure that do not become emergency defects.
P i p e l in e D e f e c t s
E m e rg e n c y D e fe c ts
M in o r L e ak
N o n -E m e rg e n c y D e fe c ts
L e v e l-I
L e v e l - II
L e a k in g In ju r io u s D e fe c ts
N o n L e a k in g In ju r io u s D e fe c ts
(A s p e r S P -1 2 3 5 )
M a jo r L e a k
R u p tu re
P i p e M i ll D e f e c t s
G i r t h W e l d D e f e c ts
D e n ts
C r a c k s /A r c B u r n s
S p a llin g , G o u g e s , G r o o v e s
G e n e r a l /L o c a l M e t a l L o s s
Fig. 1: Summary of pipeline defects
2.3
Causes of Emergency Defects

The occurrence of emergency defects in the pipeline system can be attributed to one
or a combination of the following causes: 1. Third party interference
2. Manufacturing/construction/design/material defects
3. Excessive operational loads/errors
4. Geo-technical forces
5. Corrosion/sensitivity to environment
The most common reasons for pipeline failures are third party interference or
corrosion.
2.4
Types of Level I Emergency Defects

Level I emergency defects can be further categorised based on the type of leaks into: Minor Leak
A leak (also called a pinhole leak), where the largest dimension of

the leaking hole is < 3mm.
Major Leak
A leak, where the largest dimension of the leak hole is > 3mm but
less than 60% of the outer diameter of the line pipe
Rupture
A rupture is a defect where the largest dimension of the leak hole

is >60% of the outer diameter of the line pipe. In these cases, the
pressure in the pipeline system is drastically reduced and also, the
leakage rate from the defect is high.
Page 10 of 76
In addition to the above, leaks occurring from flanges/ flanged fittings, valves etc.,
shall also be considered as Level I emergency defects.
Repair methods adopted for Level I emergency defects will depend on the nature of
the leak and location at which the leak occurs. Leaks occurring in pipeline systems in
the vicinity of road and wadi crossings shall require different repair methods than the
leaks reported from other areas.
2.5
Level-I Emergency Defects

The events/activities related to Level I emergency defects can be categorised under
following four main headings: 1. Detection of defect/leak
2. Perform damage/leak assessment survey
3. Analyse damage assessment survey and decide upon repair options
4. Mobilise emergency repair equipment/contractors and commence repair works as
per procedures outlined in this manual.
Note: This manual places greater emphasis points 3 & 4 above. Points 1 & 2 have only been covered in
brief.
2.5.1
Detection/identification of leak
Timely detection/identification of leaks is essential to prevent catastrophic effects of
the leak. For detailed guidelines on the leak detection, reference shall be made to DEP
31.40.60.11 and PR-1066 (Clause 2.3.9 and 2.3.10).
Identification of suspected leaks, unless it has been sighted and reported by 3 rd party/
PDO surveillance team or in the absence of a suitable leak detection technique, will
involve patrolling (walking, driving or flying) the pipeline to identify evidence of one
or more of the following:
1. Vegetation disturbances - visual observation to detect abnormal or unusual
indications in vegetation, e.g. an area of dead vegetation or a build up of frost on
the ground
2. Visual identification of fluid spillage
3. A loud whistling sound associated with a leak in a high pressure pipeline system
4. Smell of the fluid being transported in the leaking pipeline
5. Possible shortness of breath in the area of a leak
6. Fire near a pipeline facility
Other essential warnings signs of a leak include a reduction in the pressure or
discharge flow rate in the pipeline system, which cannot be explained by the analysis
of the regular operating conditions. A drastic reduction in pressure normally indicates
the presence of rupture in the pipeline and requires an immediate shut down of the
system. The extent of pressure reduction in the system is nominal in cases of major
leaks whereas it may be unnoticeable for cases of minor leaks.
Page 11 of 76
Once a suspected leak is confirmed, identification of the exact location of the leak
involves mobilisation of crews with leak detection equipment such as gas detectors,
ultrasonic leak detection tools etc. This phase will also involve exposing the pipeline
at probable locations of a leak to ascertain the exact location. All necessary safety
measures as required and specified in the later parts of this document shall be adopted
during the operation.
For leakage survey procedures, leakage pinpointing, equipment and test methods for
gas leakage, reference shall be made to appendix-M of ASME B 31.8-2003.
2.5.2
Defect/Leak Assessment/Inspection
Once the leak has been detected and located it should be accessed and categorised in
accordance with Section 2.4 of this manual. Assessment and categorisation is essential
in deciding on the repair procedure and safety methods to be adopted during the
repair.
In the absence of readily available inspection tools or due to the lack of time, leak
assessment/inspection for buried pipeline is normally done by digging at the location
of the leak and reaching the leak position on the pipeline. The probable locations of
the leaks are identified in the previous phase of leak detection. Suitable safety
measures as detailed in Section 5.0 shall be implemented before start of digging.
Excavation for live pipelines shall be done as per ERD 38-11. Excavation at the
damaged portion of pipeline shall be carried out with due regard to trench stability
and safe egress.
In cases where the leak has been detected by inspection tools, no digging may be
required at this stage as the results produced from the inspection tests normally detail
the type, size and assessment of the defect/leak. These inspection results shall be
further interpreted/assessed by trained personnel to classify the leak into major, minor
or rupture, the reason for leak and to propose the strategy to be followed in the repair
of these defects.
On reaching the location of the leak, further visual inspection shall be done to assess
and categorise the damage. All loose wrapping shall be removed and the damaged
area shall be cleaned of all traces of mud and extraneous matter.
2.5.3
Shut down and pressure reduction

Under normal circumstances, no shutdown is required for cases of minor leaks as the
repair can be done on a running pipeline except in cases of pipelines transporting
excessively sour or hazardous fluid and passing through areas of higher location
classes (class 3 and 4 as per SP-1211). Shutting down or pressure reduction during
minor leaks becomes essential in the following cases: 1. Risk of growth of the defect at locations with stresses other than those due to
internal pressure only e.g. at locations of soil movement or settlement or
inadequate pipe support conditions etc.
2. Presence of defect (leak) in critical location
3. Use of hot work for the repair (may require decommissioning of the pipeline)
Page 12 of 76
4. The leak, although minor, will still result in unacceptable safety situation or an
environmental impact.
However it is essential that the operating pressure of the system be reduced for all
cases of minor leaks to a maximum of 80% of the operating pressure at the time of
defect reporting to ensure safe repair operations. Specific care shall be exercised for
cases of downhills of a liquid line where the required pressure reduction of more than
80% due to static head of the liquid. The criteria and extent of the pressure reduction
shall be verified by the engineer-in-charge. Settings of safeguarding instruments shall
be adjusted to maintain the pressure reduction during repair period.
Note: The pressure reduction recommended above is the reduction required at the time of repair. The
pressures at which the pipeline system shall be operated after accomplishment of repair shall be
decided by the engineer-in-charge in its close out report. For down hill sections where the 80%
reduction criteria could not be met due to static head, the engineer in charge shall decide the
operating pressure during repair period.
In cases involving hazardous major leaks, it is recommended to shutdown the system

to avoid any disastrous consequences during the repair works, to prevent any growth
in the defect and to prevent any increase in threat to health, safety or the environment.
The decision for shutting down the pipeline shall be taken by the local emergency
coordinator who must carefully assess the risk and consequences involved and the
loss in production on account of a shutdown.
In cases involving rupture, the pipeline system will incur a serious pressure drop in
the area of the rupture resulting in excessive loss of product. In these situations,
shutting down the system should be carried out immediately to avoid further damage,
control the risk and avoid further loss of product. Repairs in these cases normally
require sectional replacement.
If the pipeline has been shut down, repressurising for testing after the repair should be
done with extreme caution. Repressurising should be accomplished slowly and
steadily without surges to avoid vibration of the pipeline and fittings. No personnel
should be allowed near the repair until the test has been completed. Other safety
measures as detailed in the later parts of this document shall be adopted during such
repairs.
2.5.4
Repair options
The preferred option for a permanent repair is to completely decommission the
pipeline, then cut out and replace the section of pipe containing the defect. However,
this option is rarely used due to the time constraints.
The preferred repair options for Level I emergency defects can be classified into: Temporary repair options: - These provide temporary relief to the defects in the
pipeline system but have to be removed and replaced with more permanent
alternatives during a planned shutdown or as soon as practically possible. Such
methods are employed to reduce the down time of the pipeline. A temporary repair is
recommended only when the loss of production caused by the time needed to execute
a permanent repair is such that it justifies the cost involved in both the temporary
repair and the subsequent planned permanent repair.
Page 13 of 76
Permanent repair options: - These provide permanent relief to the defects, enabling
the normal operating pressure of the system to be maintained for the remaining design
life. A temporary repair should be replaced with a permanent repair method within a
period of 3 months (as per SP 1210). Any further extension beyond 3 months shall be
subject to demonstration of performance with confidence and written approval from
competent authority (CFDH pipelines).
Once the defect has been categorised and located the following repair options are
recommended depending upon the type of defect. (Refer Table 1).
Table - 1: Selection of emergency repair options - CS pipelines
Type of defect
Minor leak
Temporary repair option
Permanent repair option
Plidco Smith+Clamp,
Plidco Split + Sleeve or similar
Composite Repair****
Plidco Smith+Clamp+
Plidco Weld+Cap
Plidco Split + Sleeve (duly
welded) or similar
Sectional replacement*
Major leak
Plidco Split + Sleeve or similar Plidco Split + Sleeve (duly
welded) or similar
Sectional replacement
Leaking cracks
Plidco Split+Sleeve** or similar Sectional replacement
Rupture
NIL
Leakage through flange Plidco Flange + Repair-Ring
Plidco Flange-Repair + SplitSleeve*** or similar
Leakage through valve Nil
Valve replacement/repair as per
manufacturers recommendation
Leaks in road crossings
See Section 2.5.6
Leaks in wadi
crossings
Note: Plidco brand repair materials are indicated in the table for reference purpose only. All Plidco
equivalent PDO approved brand repair materials can also be used for emergency repair.
*
**
***
****
Page 14 of 76
Sectional replacement can also be achieved using Plidco weld+end couplings.

Refer to details given below in Section 2.5.8.3.
The length of split sleeve shall be suitable for the length of crack. The welded
split sleeve cannot be considered as a permanent repair due to possible
propagation of crack during the service.
Not applicable for valve flanges
Composite repair can be used with in the limits of qualification in accordance
to ASME Code. Please Refer Section 2.6.
2.5.5
Repair of internal PE lined pipelines

The PE lined pipelines may develop leaks either due to 3 rd party interference to such
an extent that the liner is also damaged or in-service failure of liner and subsequent
corrosion of the pipeline. The leaks in these lines shall be temporarily repaired using
Plidco split sleeves or mechanical clamp in an emergency situation.
The temporarily repaired sections of these internal PE lined pipelines shall be
replaced by a permanent alternative method within 3 months period as per section
2.4.5.3 of SP-1210. The flange-to-flange sectional replacement including replacement
of damaged liner is the only recommended permanent method of repair for PE lined
pipelines.
2.5.6
Repair options for leaks at areas of road and wadi crossings

The repair options specified in Section 2.5.4 are applicable for pipeline leaks at road
crossings subject to the condition that open cut repair is feasible for such roads, e.g.
traffic diversion during the repair works should not lead to any major disruption.
Temporary repair options for leaks in these areas are not recommended due to the
following associated disadvantages:1. The temporary repair options do not enable the complete structural integrity of the
pipeline to be restored. This is more critical in areas of road crossings.
2. Temporary repairs are short term and will ultimately have to be replaced with
more permanent repairs which will require further closure of the road for open
cutting.
For roads where open cut is not possible, e.g. on a major road, the repair works shall
be done using boring/drilling to avoid disrupting the traffic movement. In such cases a
casing pipe, along with the sectional spool piece, shall be laid using thrust/auger
boring. The sectional pipe shall be joined to the main line using Pildco Weld + End
Couplings or welding as shown in Figure-2 .
Page 15 of 76
Figure 2: Sectional replacement of defective pipeline at road crossings
Leaks in pipelines at wadi crossings are more critical as the leaking oil/gas is likely to
spread to a larger area through the flood water (during rainy seasons).
During non-rainy seasons, if the wadi does not contain water, normal methods as
described in Section 2.5.4 can be used to carry out repairs. For wadi types B and C,
the concrete coating over the pipeline shall be removed and the necessary repair
carried out. After completion of the repair works, the complete sectional spool along
with the associated sleeves shall be recoated with concrete in-situ. The concrete
coating shall be done in such a way that the sleeves do not get damaged due to
presence of gabions over them.
In case if the pipeline leak occurs in a live wadi (for example during rainy season),
arrangements should be made to divert the wadi stream and evacuation of remaining
water in wadi prior to starting the repair activity. Following diversion, evacuation of
wadi, the repair shall be similar to that of dry wadi region explained above.
Continuous evacuation of water using vacuum trucks might be required during repair
activity, in case if continuous oozing of water is noticed.
Temporary repair options are not recommended for leaks in wadi crossings.
Page 16 of 76
2.5.7
Repair activity procedures

The activities detailed below shall form part of the overall repair works and shall be
applied in conjunction with the procedure for carrying out the specific repairs detailed
in Section 2.5.8.
2.5.7.1 Procedure for cleaning of the defect area

The surface of the defective area of the pipeline shall be cleaned to enable repair,
welding, UT inspection etc. The cleaning shall achieve removal of scale, rust,
coatings and vegetation by the use of wire brushes, chipping tools or grit blasting. The
grit blasting shall be permitted only when remaining wall thickness of the pipe is
more than 2 mm. Reference shall be made to SP-1246 for this purpose.
2.5.7.2 Confirmation of suitability of live pipeline for permanent repair welding
The following checks shall be done to confirm the suitability of the live pipeline for
the purpose of welding:1. Before assembling the repair fittings to line pipe an ultrasonic inspection shall be
conducted to cover a zone extending a minimum of 100mm on the either side of
each weld area to confirm a minimum wall thickness (refer point no. 2 below) and
to check for the laminations. Laminar defects exceeding 6mm in any direction and
any lamination not parallel to the pipe surface shall be unacceptable. Ultrasonic
test techniques shall be in accordance with ASME V article 5 as supplemented by
SP-1176.
Levels of indications requiring investigations are as follows:- all reflectors giving an indication in excess of 20% DAC shall be investigated
and evaluated in accordance with the acceptance standard (DAC = Distance
Amplitude Correction).
- all reflectors giving an indication in excess of 50% DAC shall be evaluated and
reported.
- all reflectors exceeding 100% DAC shall be cause for rejection.
2. Before carrying out any kind of weld repair on a live pipeline, it shall be ensured
that during the welding operation the material in the region of the weld pool has
sufficient strength to contain safely the internal pressure and avoid a blow out.
The risk of blow out is dependent upon a complex interaction of welding
conditions, pipe material, pipe thickness, pipe temperature and hoop stress. For
material of yield strength not greater than 448 MPa (Grade X-65 as per API 5L),
operating at temperatures of not greater than 350 deg.C with a hoop stress not
greater than 72% of the specified minimum yield stress, blow out can be
prevented during welding provided the minimum thickness is not less than 4.8mm
(reference shall be made to Appendix-2 and 3 of DEP 31.38.60.10). The actual
minimum wall thickness shall be determined by ultrasonic testing as specified in
point no. 1 above. For other materials or conditions, a minimum pipe thickness
shall be determined, based on either specific previous experience and/or data from
trials.
Page 17 of 76
3. Welding on live pipelines is prohibited for the following cases:- Mixtures of gases or vapours within their flammable range or which may
become flammable as a result of heat input in welding operations.
- Oxygen enriched atmospheres in the presence of hydrocarbons which may be
present either in the atmosphere or in the deposits on the inside surface of the
pipe.
- No welding shall be performed on lined, clad or internally coated pipes
4. Attention shall be paid to controlling the pipe wall temperature during the welding
to avoid deterioration of the microstructure of the pipe material due to excessive
heat input resulting in excessive metal temperature. Reference shall be made to
Clause 3.3.2 of DEP 31.38.60.10.
5. The pressure in the pipeline system shall be verified to confirm that it does not
exceed the maximum allowable operating pressure during welding operations.
This shall be based on the derated pressure conditions necessary whilst the
material is at elevated temperature whilst welding. It is also essential to prevent
any propagation of any unstable cracks. The maximum allowable operating
pressure during welding shall be determined as per Clause 3.3.3 of DEP
31.38.60.10.
6. Welding on a live pipeline under no-flow or intermittent flow conditions shall not
be attempted unless it has been confirmed that no explosive or flammable mixture
will develop during welding operations. In this respect it shall be confirmed that
no ingress of oxygen in the line is possible. In cases where this requirement
cannot be met, nitrogen purging (de-commissioning) shall be done using a
minimum purge velocity of 0.4m/s.
7. A high liquid flow usually causes rapid cooling of the weld area which results in
hard material zones, which are susceptible to cracking. Under these circumstances
the minimum inter pass temperatures may not be attainable, resulting in undesired
material properties. A suggested maximum velocity for liquid flow during welding
is 1.75m/s. There is no restriction on maximum velocity for gas lines, subject to
the attainment of acceptable inter pass temperatures.
Note:- For wall thickness between 6.4mm and 12.7mm, flow also increases the weld cooling rate
and hence the risk of cracking. Minimizing the flow rate reduces the risk of cracking and of burn
through. For metal thickness greater than 12.7mm, the effect of flow on both weld cooling rates
and burn through are less significant.
2.5.7.3 Procedure for welding/inspection for emergency defect rectification

All emergency repair welding and inspection of welds on pressurised pipeline
systems, including the welding of sleeves, clamps shall be done as per SP-1167 and
DEP 31.38.60.10 and selected approved welding procedure. Other precautions needed
during welding include:1. Careful control of the size and shape of the circumferential fillet welds. The size
of the fillet weld should be at least 1.4 times the wall thickness of the pipe at the
weld area.
Page 18 of 76
2. Maintenance of a concave faced fillet weld with streamlined blending into both
members. The smoother and more streamlined the weld profile, the greater the
resistance to fatigue failure.
3. Avoiding notches and undercuts during welding.
4. Use of welding consumables as indicated in approved WPS.
5. Use of temperature crayons or probe thermometers, to monitor heat generated
during welding or preheating operations, particularly near the areas of the soft
seals. If the heat generated approaches the temperature limit of the seal material,
which is indicated on the label, welding should be discontinued to allow the
affected area to cool.
6. Ensuring that welding does not overheat the seals. The welding should be
sequenced so that the heat is not concentrated in one area. It may be necessary to
re-torque the stud bolts and nuts periodically during field welding because weld
contraction causes them to loosen.
7. Avoiding burn through during the root run. First weld pass for pipelines with a
wall thickness less than 6.4mm thick should be achieved by using 2.4mm or
smaller diameter welding electrode to limit heat input.
8. For pipelines with wall thickness more than 12.7mm, where burn through is not a
primary concern, care should be taken by avoiding the use of excessive welding
current.
PDO pre-qualified welding procedures and welders (PR-1276, SP-1177) shall be used
for welding on live pipelines to avoid delay due to pre-qualification. However, in
some scenarios, in order to carry out weld repairs without the delay the following
deviations are permitted from SP-1177:1. If no records are available, the defective line pipe shall be assumed to be API 5L
Grade B, which shall be used for the new replacement pipe if no material
specification records are available.
2. The pipeline engineer shall decide the WPS and PQR to be followed in
consultation with repair contractor and welding engineer. Welding conditions and
relevant parameters shall be noted and test pieces shall be prepared once the job is
complete.
3. 100% radiography, UT and MPI shall be done on all emergency repair welds.
4. All records and test piece results shall be reviewed after the repair, to determine if
the method meets the requirements of the application. If deemed necessary,
cutting out and replacement of unacceptable weld repairs shall be planned and
executed as per SP-1177.
2.5.7.4 Procedure for recoating/painting of the defect area
After completion of the repairs, the defective area shall be recoated / repainted as per
SP-1246.
Page 19 of 76
2.5.7.5 Procedure for sand padding and backfilling of the trench

1. Screened soft sand, free of rock and foreign matter, shall be used for sand
padding. The minimum depth of padding below the pipe shall be 300 mm.
2. Hand shovel and wooden hand-ramming device shall be used for the placement
of sand under the pipe.
3. Sand shall be lowered into the trench with a mechanical shovel and hand spread
uniformly around the pipe. The depth of the sand padding over the top of the
pipe shall be at least 300 mm. Sand on top of the pipe shall be shaped to the
natural angle of repose.
4. Screened excavated material from the location shall be used (after the removal
of any rock and boulders) on top of the sand. In order not to damage the sand
padding, the initial layers of final fill shall be carefully lowered into the trench
from each side by mechanical shovel ensuring that the backfill material is
deposited carefully to avoid disturbing the sand padding.
5. The mechanical excavator shall maintain the following minimum safe distances
(which shall be clearly marked by a line of bunting) from the edge of the trench:
-
Rock: distance from edge of trench shall be 1.0 metre
Compacted ground: distance from battered edge of trench shall be 1.5

metre
Soft sand with trench sides battered to a minimum slope of 2:1:

distance shall be 2 metres.
6. After completion of the initial backfill layer, the remaining backfill shall be
finished to a level slightly above the natural grade and shall be thoroughly
compacted by means of a compacting vibrator.
7. Windrow shall be reinstated, including the section used for temporary crossings.
Where the excavation crosses wadis or ditches with lined or otherwise improved
surfaces, these shall be reinstated to their original contour and condition.
Reference should also be made to ERD 38-11 and SP-1208 for details on
reinstatement.
2.5.7.6 Procedure for de-commissioning, isolation and draining/venting of the pipeline
for defect repair
Venting/Draining of the pipeline
Complete draining and venting of the pipeline is essential in cases of sectional
replacement of a defective portion of the pipeline. For pipelines with block valve
stations draining can be limited to the section between the block valves. Where there
are no block valves, the entire length of the pipeline shall be drained.
For pipelines without block valve stations: For such pipelines, most of the fluid is
drained from the pipeline during the depressurisation process by shutting down the
flow and opening the valves at the receiving end station. The remaining fluid can be
drained by opening the drain and vent valves at each end. The drained fluid shall be
disposed of safely to prevent any hazard to life or the environment. For any residual
Page 20 of 76
fluid trapped in the pipeline such as in areas of lower elevations, the engineer-incharge shall study the need for further draining/venting. This can be accomplished as
follows:1. For liquid lines, the ruptured or leaking portion of the pipeline shall be covered
temporarily either by a sleeve or composite reinforcing sleeve and pigging with
soft pigs carried out, driven with compressed nitrogen or water, to displace the
remaining liquid.
Alternatively, the trapped liquid can be removed using suction pumps. The suction
hose shall be inserted into the pipeline either through drain valves or through the
leaking portion and the liquid transferred to a tanker. The use of suction pumps is
limited depending upon the capacity of the pump available and the length/terrain
of the pipeline and is only recommended for small lengths. Another method of
draining the liquid line is by flushing with water (for general details refer to PR1074)
2. For gas pipelines, any remaining trapped gas can be vented by purging with inert
gas from one or both ends of the pipeline. Venting of any hazardous gases shall
only be allowed only through the designated vents and shall be suitably flared in
accordance with standard safety procedures.
For pipelines with block valve stations: For these pipelines, only the portion
between the block valves needs to be drained and vented. This shall be done as
follows:1. For liquid lines, the trapped liquid shall be drained out through the drain valves at
the block valve stations. Any remaining liquid can be removed using suction
pumps. The suction hose shall be connected to the drain lines at the block valve
stations. The capacity of the suction pump should be sufficient to drain
approximately 32 km of pipeline being the maximum length between two block
valve stations. Flushing with water can also be undertaken to remove the
hydrocarbon liquid as specified above.
2. For the handling non-sour gases, controlled venting can be done to atmosphere
through the vents provided at the BV stations. Any remaining trapped gas can be
vented out by inert gas purging from one or both stations. Venting of any
hazardous gases shall only be allowed through designated vents and shall be flared
in accordance with standard safety procedures either through temporary mobile
flare or as directed by the PDO Safety Officer.
Note: It is also feasible to drain and vent the pipeline by installing a hot tap through which the pipeline
contents can be drained, vented or flared.
Isolation of the pipeline

If deemed necessary, even after isolating and draining the defective section at the
block valve stations, further localised isolation by use of specific pipeline isolation
plugs such as PE Grip Lock Pipe Plugs, air plugs, mud/freeze plugs or Hi friction pigs
is recommended.
Page 21 of 76
For smaller lengths where no block valve stations exist, the pipeline shall be first
decommissioned and then the defective segment is isolated using air/mechanical
plugs/stopples. Isolation of a defective portion of a pipeline without block valves is
essential to prevent the possibility of trapped fluid draining from other areas whilst
repairs are in progress and also to prevent transfer of welding fumes to other segments
of the pipeline. The requirement of isolation for these pipelines shall be verified by
Operations personnel and done in accordance with PR-1076.
Note:- Hot tapping the line to provide a means of inserting the plugs/stopples to isolate the defective
line section may affect a safe repair. Considerations should be given to the factors such as
product characteristics, pipe condition, temperatures and required differential pressures to
ensure that the proper type of plugs are used and that their holding capacity can adequately
resist the pressure to be encountered. Various types of plugs that can be possibly used for
isolation include mud plugs, freeze plugs and mechanical/air plugs.
2.5.7.7 Emergency repair close out report

The purpose of the close out report is to capture all the relevant actions taken to
identify the cause of damage, the repair methods used and to serve as feedback to
correct any deficiency and make future improvements. The recommended table of
contents shall be as follows:1. Pipeline service and details (fluid transported, flow, operating pressure, diameter,
wall thickness, year built etc.)
2. Type of defect, cause and assessment of damage (safety, environment and loss of
production)
3. Repair method (advantages and disadvantages)
4. As built drawings revisions.
5. Conclusions and lateral recommendations, including the requirement to derate the
pipeline after completion of repair if necessary.
6. Feedback to pipeline emergency repair manual.
7. Any other additional checks or tests found necessary to verify the integrity of the
pipeline.
This report shall be in addition to any other requirements specified in the PDO
emergency procedures and HSE 97-01/PR-1060.
Page 22 of 76
2.5.8
Emergency repair methods CS pipelines

The following sections cover the various emergency repair methods for CS pipelines.
For ease of reference the Plidco Smith brand of repair materials have been quoted in
this manual. However, equivalent products available from other manufacturers can
also be used provided they are an approved vendor listed in the AVME.
2.5.8.1 Plidco Smith + Clamp + Weld + Cap

Plidco Smith + Clamp is a temporary repair solution for minor leaks. The point of the
cone is centred exactly on the hole, and force applied using the force screw to shut off
the leak. The draw bolts at the bottom of the fitting are used to hold the clamp in
place. The use of a welded Plidco Weld + Cap when used in conjunction with the
Plidco Smith + Clamp makes the repair permanent. Reference shall be made to
Appendix 3 and 4 for details.
Applications : 1. Plidco Smith + Clamps are available in standard sizes from 1.5 to 48
2. The standard pressure rating for Plidco Smith + Clamp and Plidco Weld + Cap is
2000 psig (~138 barg).
3. Plidco Weld + Cap are available in standard sizes from 4 to 48
4. Welding of the Weld + Cap is required for permanent repair
5. Can tolerate only minor surface irregularities up to + 1/32
Procedure for installation on live pipelines: For temporary repair:
1.
2.
3.
4.
5.
Verify the pipeline as per Section 2.5.3

Ensure all safety precautions as per Section 5.0
Clean the defect area as per Section 2.5.7.1
Install Plidco Smith + Clamp as per manufacturers procedure
Prepare detailed report as per Section 2.5.7.7
For permanent repair continue as follows:

6. Verify and confirm the suitability of the pipeline for welding as per Section
2.5.7.2
7. Install Plidco Weld + Cap as per manufacturers procedure
8. Weld the Cap and inspect the weld as per Section 2.5.7.3.
9. Recoat/paint the system as per Section 2.5.7.4
10. Sand padding and backfilling as per Section 2.5.7.5
11. Prepare detailed report as per Section 2.5.7.7
2.5.8.2 Plidco Split + Sleeve
These can be used for temporary and permanent repairs. The seal welded Plidco Split
+ Sleeve is considered as permanent repair solution.
Page 23 of 76

Note: It is preferable only to use this system as a temporary repair method because of the high cost. It
is recommended not to weld the clamp to the pipeline and to replace it as soon as practicable
with a permanent repair such as sectional replacement of the defective section.
The size of the sleeve to be used shall be selected based on the diameter of the line
pipe and the length of the defect. The length shall be such that the sleeve extends a
minimum of 0.1m beyond the defect. Adjacent sleeves shall not be placed closer than
one-half pipe diameter from each other. Over sleeves can be used to cover defects in
area`s adjacent to or between the sleeves. These shall be welded to the original sleeve
using qualified welding procedures. The minimum required wall thickness and steel
grade of the sleeve shall be based on the wall thickness and design factor applied to
the pipeline. The sleeve thickness shall be adequately increased to compensate for the
groove of the backing strips or seams of the pipeline. The length of sleeve shall not be
less than 0.1m. Reference shall be made to Appendix-2 for details.
Applications:
1. Standard Plidco split + sleeves are available for a working pressure up to 1000
psig (~ 69 barg).
2. Available in API pipe sizes from 1.5 to 48
3. Higher working pressure or longer length sleeves can be made to order
4. The sleeve shall not be used to couple pipes without sufficient end restraint
because it does not provide any longitudinal restraint in an unwelded condition.
5. Standard body materials are A 106 seamless pipe, A 216 WCC cast steel, A 516 or
equivalent. Other materials are available on request.
6. The seal can tolerate only minor surface irregularities up to +1/32
7. The seals and girder rings on the sleeve can be damaged by careless handling with
lifting devices such as chains, cables or lift truck forks which can result in the
seals being dislocated from the groove.
8. The sleeves can be field tested up to 1.5 times the design working pressure.
9. The sleeve should be stored in a dry environment to prevent the unpainted
surfaces from rusting. Storage temperatures should not exceed 120 deg.F (49 deg
C). They shall be covered with dark polyethylene to protect the material from
direct sunlight. Improperly stored units can cause the seal material to become
brittle and cracked and thus lose the sealing properties.
Procedure for installation on live line: For temporary repair:
1.
2.
3.
4.
5.

Ensure all safety precautions as per Section 5.0
Clean the defect area as per Section 2.5.7.1
Install Plidco Split + Sleeve as per manufacturers procedure
For permanent repair continue as follows:

6. Verify and confirm the suitability of the pipeline for welding as per Section
2.5.7.2
Page 24 of 76
7. Seal weld the ends, sides and bottom of nuts as per Section 2.5.7.3
8. Inspect the weld as per Section 2.5.7.3.
2.5.8.3 Spool Piece with Plidco Weld + End couplings
The installation of a spool piece using Plidco Weld + End couplings requires
shutdown and depressurisation of the pipeline. The thickness and material grade of
the spool piece shall be the same as that of the line pipe and shall be determined using
the equations and safety factors as given in SP-1211. The material shall conform to
API 5L specification. Welding in cases of unequal wall thicknesses shall be done as
per ASME B 31.4 or 31.8 as appropriate. Reference shall be made to Appendix 5 for
details.
Plidco weld+end couplings cannot sustain external forces such as temperature
expansion and contraction, ground movement etc.
Application: 1. This method of repair requires shutdown and depressurisation of the pipeline to
remove the defective section with complete draining and isolation of the product
from the affected area.
2. It is a time consuming permanent process as compared to other methods of repair
as it requires dismantling and replacement of the affected piece of the line pipe.
3. Temporary repair for a period of not more than 6 months can be achieved by
clamping and tightening the thrust screws without welding the coupling.
4. Permanent repair is achieved by welding the coupling to the line pipe. This may
require additional time because liquid flow through the pipeline will have to be recommenced and safe conditions reached to permit welding. Welding on a line
under no-flow or intermittent flow conditions shall not be attempted unless it can
be positively established that no explosive or flammable mixture will develop
during the welding operation.
5. Where significant longitudinal loads are present and it is not feasible to weld the
coupling, additional rows of clamping screws can be provided or the Pildco clamp
+ Ring may be used.
6. Standard sizes are available from 1.5 to 48
7. Standard materials are A-106, A-105, A-285, A-516.
8. Couplings are suitable for anchored pipeline joints only.
9. The model of the coupling must be selected to the same pressure/ temperature
rating as the line pipe.
10. Couplings are suitable for the minimum pipe wall thicknesses as specified in
Table 2. Pipelines with wall thicknesses less than those specified in the table will
not withstand the force of the clamp screws and hence this application will be
unsuitable. As a solution, Plidco Clamp + Ring should be considered.
11. The use of these coupling on elbows and bends is limited due to the possibility of
pullouts caused by external and internal forces.
12. For badly misaligned or out of round pipe, it is helpful to grind a pilot bevel with
a generous taper on the pipe. This should eliminate the risk of damage to the seals
Page 25 of 76
while installing the coupling over the end of the pipe. Refer to Appendix 5 for
details.
Nominal pipe size (inch)
4
6
8
10
12
14
16 & larger
Min. wall thickness ( mm)

6.0
7.1
8.2
9.3
10.4
11.1
12.7
Table 2: Minimum pipe wall thicknesses for Plidco Weld + End couplings
Procedure for installation: For temporary repair:

1. Shutdown the pipeline system
2. Ensure all safety precautions are in place as per Section 5.0
3. Depressurise the complete pipeline system to atmospheric pressure by opening the
necessary drain/vent valves as per Section 2.5.7.6
4. Ensure that the isolated section has been adequately drained and is free from any
trapped fluid as per Section 2.5.7.6
5. If required, isolate the defective section as per Section 2.5.7.6
6. Select the spool piece of wall thickness and grade as specified above.
7. Hydro-test the spool piece separately as per SP-1211
8. Clean the defect area as per Section 2.5.7.1
9. Cold cut the defective portion of the pipeline as per general guidelines given in
PR-1146
10. Install Plidco Weld + End coupling as per manufacturers recommendation
11. Slide the spool piece in the coupling and tighten the screws
For permanent repair, continue as follows:
13. Re-commission the system, verify and confirm the suitability of the pipeline for
welding as per Section 2.5.7.2
14. Seal weld the coupling as per Section 2.5.7.3
15. Inspect the weld as per Section 2.5.7.3
Note : Pildco Weld + End couplings only takes into account the forces on a joint due to the internal
pressure and does not consider additional external forces like thermal expansion and contraction,
underwater currents, ground movement or combination thereof. If any of these additional forces
are expected to occur, it is recommended that either the coupling be welded or use of Plidco
Clamp + Ring along with Plidco Weld + End is recommended
Page 26 of 76
2.5.8.4 Plidco Flange + Repair-Ring

These are useful for stopping leaks through the gaskets of the flanges. Plidco Flange +
Repair Rings are installed by placing the two halves around the flange and using studs
and nuts to draw them together. Bolt leakage is stopped by injecting a recommended
sealant with a pressure gun. Reference shall be made to Appendix-6 for details.
Application/Limitations: 1.
2.
3.
4.
5.
6.
Can be used to stop the leakage through the gasket portion of the flanges only.
Available for standard flange sizes to 12 150 lb to 600 lb
Sealant injection required to stop leakage through the bolts.
Pressure gun required to inject sealant
Cannot be used to couple the flanges and provides no longitudinal restraint.
It is only a temporary method of repair.
Procedure: 1.
2.
3.
4.
5.
6.
7.
8.
9.
2.5.8.5

Ensure all safety precautions are in place as per Section 5.0
Clean the defect area of the leaking flange as per Section 2.5.7.1
Install Plidco Flange + Repair Ring as per manufacturers procedure
Seal the bolts using sealant and pressure gun as per manufacturers procedure
Inspect the system visually
Recoat/repaint the area as per Section 2.5.7.4
Place sand padding and backfill as per Section 2.5.7.5
Plidco Flange-Repair + Split-Sleeve
The Plidco Flange Repair +Split Sleeve fully encapsulates the mated flanges and seals
to the pipe beyond the weld of the flanges. They are useful for stopping leaks through
any portion of the flanges. Reference shall be made to Appendix 7 for details.
Limitations: 1. It is a temporary method of repair.
2. High cost.
Procedure: 1.
2.
3.
4.
5.
6.
7.
8.

Ensure all safety precautions are in place as per Section 5.0
Clean the defect area of the leaking flange as per Section 2.5.7.1
Install Plidco Flange Repair + Split Sleeve as per manufacturers procedure
Inspect the system visually
Recoat/repaint the area as per Section 2.5.7.4
Place sand padding and backfill as per Section 2.5.7.5
Page 27 of 76
2.5.8.6 Hot Tapping

This method is used to rectify a defect in a pipeline in service. A hot tap fitting is
installed around the defective segment and the defective segment is removed in the
same way as removing a segment from the pipe wall for branch connections using the
hot tap method. It can also be used for installing a temporary bypass to the main line
to carry out a sectional replacement.
All requirements as specified in DEP 31.38.60.10 shall apply whilst carrying out the
hot tapping.
2.5.8.7 Sectional Replacement (without couplings)
Sectional replacement is a permanent method of repair. However, this requires
depressurisation of the pipeline and shutdown of the system. The replacement pipe
section shall have strength of at least that of the pipeline and shall meet the
requirements of API 5L . The section shall be designed as per SP-1211 with same
factor of safety as used for the original pipeline and shall be hydro tested as per SP1211 and DEP 31.40.40.38-PDO prior to installation. The length of the replacement
section shall not be less than half the diameter of the pipeline or 300mm, whichever is
greater. No section shall be installed closer than 150mm to an existing weld.
Application: 1.
This method is a time consuming process of repair due to requiring

shutdown and de-commissioning of the pipeline.
2.
The properties of the original pipeline need to be known to determine the
properties of the replacement pipe material to be used.
3.
The method requires end preparation of the existing pipeline for
welding. The length of the pipe to be cut out shall be such that in addition to
replacing the defective section, the wall thickness where the pipe is to be joined is
suitable for end preparation and welding.
Procedure: 1. Shutdown the pipeline system and transfer the product at the block valve or end
stations
2. Ensure all safety precautions are in place as per Section 5.0
3. Isolate and de-commission the section to be replaced to make the section free
from hydrocarbons as per Section 2.5.7.6
4. Select a spool piece of the required wall thickness and grade as specified above.
5. Hydro-test the spool piece separately as per SP-1211.
6. Clean the defect area as per Section 2.5.7.1
7. Cold cut the defective section to be replaced.
8. Clean the cut ends of the pipeline to be welded and prepare/bevel the ends
9. Weld the replacement section with the existing pipeline as per SP-1177
10. Inspect the weld as per SP-1177
11. Recoat/repaint the system as per Section 2.5.7.4
12. Place sand padding and backfill as per SP-1208
13. Re-commission the pipeline as per requirements of SP-1211, verify and confirm if
de-rating of the pipeline is required.
Page 28 of 76

2.5.9
Minimum recommended tools and equipment

The repair crews shall be equipped with all suitable equipment as required for the
specific type / manufacture of the pipeline being repaired and shall carry an adequate
range of fully compatible spare pipe and fittings.
In addition the following tools and consumables shall be carried:
1.
2.
3.
4.
5.
6.
7.
Temperature and relative humidity measuring equipments

Measuring tape, sliding gauge, pipe marker (pen)
Bevelling Machine
Winches
Grinders
Solvent cleaner, cleaning rags
PPE (gloves, eye protection, dust mask)
Any additional tools/ equipment required shall be advised by the engineer-in-charge.

2.6
Composite Repair: An Alternative Repair Method

Composite repair method is an upcoming technology for repair of corrosion and
through wall defects in a pipeline. The composite material considered within the
document, are those with glass (GRP) or carbon (CFRP) reinforcement in a polyester,
vinyl ester or epoxy matrix. These repairs can be used as an alternative to the use of
Mechanical Clamp or Plidco Split Sleeve for a leaking defect (through wall defects),
if designed, qualified and applied in accordance with the ASME code Non Metallic
Composite Repair Systems for Pipelines and Pipe work: High Risk Applications
with in the limits of the qualification. The ASME article is currently in review.
The ASME draft requires a repair lifetime to be specified, which can range from less
than 2 years up to anticipated service life of the system. The composite repair shall be
designed in such a manner that it takes into account the future growth of the defect for
the remaining design life of the pipeline.
A major advantage of the method is the relative ease of application, using simple hand
tools without any welding. The composite repair is most suitable where clamp/sleeves
cannot be installed due to geometric constraint e.g. bends, reducers, T-pieces etc. For
straight pipe sections this method can be used, in case suitable clamp/ sleeves are not
available at the time of leak.
For each repair situation a risk assessment shall be carried out. The risk assessment
shall include consideration of the hazards associated with the system service, the
availability of the personnel with the necessary skills, the ease with which it is
practicable to execute surface preparation operations, the availability of design data.
Leak before break, inspectability, and performance under upset and major incident
situations including fire, explosion, collision and environmental loading.
Page 29 of 76
Manufacturer of composite repair material should provide full installation instructions

including surface preparation, grit blasting, installer qualifications, laminate lay up
etc.
Repair shall be carried out in accordance with the manufacturers procedures and by
manufacturer approved and trained personnel.
The key point that must be considered in design and application of bonded repair is
that the combination of pipe material/ surface preparation technique/ composite is the
basic design unit. Data derived using one set of material cannot be used to assist in
the design of another even if it is only one of the components comprising the
arrangement that has changed.
The limitations of this method are that it needs a dry and mechanically clean surface
for achieving a durable bonded connection between pipe and laminate. To achieve the
required dry surface, it is necessary to plug the leak on-line or depressurize the line.
The second important aspect of repair is surface preparation. Surface preparation
activity involves removal of loose debris and corrosion products followed by
mechanical abrasion. Normally, quality of surface preparation should be in
conformity with SA 2 . For surface preparation using grit-blasting technique on live
lines, all necessary safety precautions should be followed as per PDO procedures.
2.7
Level II Emergency Defects- Injurious non leaking defects

These defects are as described in section 2.2. They have a nominal impact on the
productivity of the pipeline due to the requirement for pressure reduction. Reference
is made to SP-1235 for possible repair options and methods for level-II emergency
defects.
2.8
Repair organisation
The repair organisation and contingency plans for PDO pipelines are given in the
Emergency Response Document, Part-III in the following volumes:Volume-3, Production Operations, PR-1066
- Clause 2.3.9 Oil Pipeline Failure
- Clause 2.3.10 Gas Pipeline Failure
Volume-4, Main Oil Line PR-1067
Volume-5, Terminal & Tank Farm Operations, PR-1068
Volume-14, Government Gas System Pipeline & Terminals, PR-1246
Volume-15, South Oman Gas Line PR-1275
Page 30 of 76
3.0 Emergency Repairs for Glass Reinforced Plastic (GRP)

Pipelines
3.1
General
GRP pipelines for PDO have been constructed after satisfactory and rigorous
qualification tests have been carried out on the GRP systems. Further quality checks
are made by carrying out visual inspection and pressure testing prior to
commissioning of the system. Most of the GRP pipelines are of buried type.
GRP pipeline systems can suffer operational defects, which may be catastrophic in
nature. This manual identifies the possible catastrophic defects, categorised as
emergency defects, and specifies the appropriate repair methods.
3.2
Scope
This part of the document defines the emergency defects and the repair respective
requirements for GRP pipelines. The emergency repairs for other non-metallic
pipelines including HDPE systems are excluded from the scope.
ISO 14692 (part 1 to 4) and DEP 31.40.10.19, GRP Pipelines and Piping Systems
(Amendments/Supplements to ISO 14692) form the basis for this document.
The defects considered are those that could be encountered during the operation of the
GRP pipelines. Defects detected during the manufacturing, installation, testing and
commissioning stages are excluded from this manual.
3.3
Causes of defects in an operating GRP pipeline system

The occurrence of defects in an operating GRP pipeline system can normally be
attributed to either one or a combination of the following.
3.4
Third party interference (the most common reason)
Excessive operational loads/upset conditions (refer Section 3.4 below)
Defects due to over pressurisation

The over pressurisation of a GRP pipeline system due to failure of the over pressure
protection systems or excessive surge beyond design limits normally leads to weepage
or rupture of the pipeline. If any such situation occurs, it is advised to replace the
complete line or else fitness for purpose evaluation shall be carried out as per
manufacturers recommendation.
3.5
Defect categorisation
The defect categorisation of GRP Class-I pipelines is similar to that of CS pipelines
specified in Section 2 of this document, with the exception that weeping defects are
included in Level-1 emergency defects.
Page 31 of 76
Weeping defects : - This is the most common type of Level-I defect in a GRP pipeline
system. It mainly constitutes seepage, sweating or penetration of the liquid through
the wall of the pipeline. In weeping there is no apparent visual indication of a defect
in the GRP material and mainly occurs due to disturbance in the fibre matrix. It is
difficult to identify the minor weeping defects in buried GRP pipelines (Minor
weeping can only be identified during hydrotesting).
3.6
Repair of Level-I Emergency Defects

The leak detection, defect assessment methods and major activities following
reporting of a pipeline leak are similar to those indicated for CS pipelines at section
2.5 of this document.
3.6.1
Shut down and pressure reduction

The need for shutting down the pipeline system for the purpose of carrying out repair
or inspection shall be decided by the local area emergency coordinator in consultation
with senior pipeline personnel based on the type of defect and the possible
consequences. The repair options for GRP pipelines are normally the replacement of
the defective section and therefore, shutdown, depressurisation and draining of the
system is necessary.
In case, weeping of a pipeline due to over pressurisation is identified an immediate
shutdown of the pipeline must be initiated.
If the pipeline has been shut down, re-pressurisation should be done with extreme
caution, steadily increasing the pressure without surges, which could vibrate the
pipeline and the associated fittings leading to integrity problems.
The system pressure after completion of the repair shall be decided by the engineerin-charge, depending upon the type of repair and shall be recorded in the close out
report. Manufacturers advice must also be taken into account.
3.6.2
Repair options
The preferred option of repair is to take the pipeline out of service, decommission and
the replace the defective section with pipe meeting the requirements of the codes and
standards.
Selection of jointing method for sectional replacement shall be governed by design
pressure of the pipeline. If design pressure of the pipeline is less than or equal to 40
barg, laminated joint shall be used. Sectional replacement, in the pipelines having
design pressure more than 40 barg, shall be carried out using flanged joints.
Page 32 of 76
The following repair options are recommended depending upon the type of defect.
(Refer Table 3).
Table 3 - Selection of emergency repair options - GRP pipelines
Type of Defect
Temporary
location
Nil
repair
Permanent repair location
Minor leak in straight

Sectional replacement *
portion
Major leak in straight Nil
portion
Weep in straight
Nil
Sectional replacement *
portion
Rupture
Nil
Leaks in joints and
Nil
Replacement of the fitting/joint
fittings
Leakage through road Nil
and wadi crossings
* Minor leaks or localised weeping defects can be repaired by over wrapping up to
40 barg design pressure.
3.6.3
Repair activity procedures

The activities detailed below shall form part of the overall repair works.
3.6.3.1 Cutting of the Pipeline

The section of the pipeline to be replaced shall be minimum 1000mm (500mm on
either side of defect) more than the length of the defect
The pipe section to be cut should be marked and carefully sectioned. The cross
section shall be straight and perpendicular to the pipe axis, as the joint reliability
depends to a large extent on the squareness of the cut. Pipe up to 100 mm nominal
diameter shall be square to within 1.5 mm whilst cuts on larger diameter pipes shall
be square to within 3.0 mm.
The cutting of glass fibre reinforced plastic pipes can be done by means of a hacksaw
or 4 grinding disc for diameters up to 100 mm. Pipes of larger diameter should be
cut by grinding with a diagrit or carborundum-grinding disc. Alternative equipment
used for cutting shall be subject to the manufacturers approval prior to start of work.
3.6.3.2 Cleaning of the defect area
The surface of affected area of the pipeline shall be cleaned to allow for repair,
inspection etc. The pipe section must be free from oil, grease and dust. Adequate
cleaning is essential at the joint where the existing pipeline is to be bonded to a new
spool piece.
Dust removal shall be carried out using a clean dry brush, dry rag or compressed air
that is dry and free from oil. All surfaces to be adhesive bonded shall be cleaned
Page 33 of 76
using acetone. The brush or cloth to be used for cleaning should be free from harmful
substances. The contact surface of the existing pipeline to be bonded shall be prepared
in line with jointing procedure. Use of metal brushes or harmful solvents for cleaning
of threaded joints is not advised.
3.6.3.3 Emergency repair methods GRE pipelines
3.6.3.3.1 Repair of leaks in straight pipe section
The type and nature of the defect shall dictate the repair procedure to be followed.
In case of minor leak or localised weeping due to impact damage is identified in the
straight portion of the pipeline, these defects can be repaired by over wrapping,
provided the design pressure of the pipeline is less than or equal to 40 barg. In case,
the design pressure is >40 barg, sectional replacement shall be carried out for such
leaks.
For major leak/rupture in straight section, sectional replacement shall be carried out.
Pipeline section replacement involves cutting out of the defective portion and
installing a new spool piece of compatible properties to the existing pipeline.
The selection of jointing method depends on design pressure of the pipeline.
Laminated joint shall be used for joining the new section with existing pipeline up to
40 barg design pressure. The qualified procedure of laminated joint shall be used for
joining the new section with existing pipeline.
The pipelines designed for more than 40 barg pressure, are constructed using threaded
joints, sectional replacement of such pipelines shall be carried out using flanged joints
as per Manufacturers repair procedures. [Refer Appendix 9].
3.6.3.3.2 Repair of leaks in GRP pipe fittings
For leaks in fittings (minor/major/rupture/weep), it is recommended to replace the
complete fitting. Replacement of the fitting involves the same procedures as specified
for straight sections described in Section 3.6.3.3.1
3.6.3.3.3 Repair of joint leaks
Repair of leaks through adhesive bonded, laminated, elastomeric seal and threaded
joints necessitates cutting out the joint. A pipe section containing the leaking joint
shall be cut at 500 mm from the leaking joint in both upstream and downstream
directions and a new pipe section shall be installed.
In case of flanged joints, leaks can be caused due to the wrong type of gasket being
fitted, a damaged gasket, use of incorrect torque for tightening of the flange bolts,
incorrect sequence of tightening of flange bolts or physical damage to the flange. For
leaks attributed to gaskets, they shall be replaced by the correct type for the
application and the flange bolts tightened to the manufacturers recommendations.
Page 34 of 76
3.6.3.4 Procedure for sand padding and backfilling of the trench

1. Screened soft sand, free of rock and foreign matter, shall be used for sand
padding. The minimum compacted depth of padding below the pipe shall be 150
mm.
2. Hand shovel and wooden hand-ramming device shall be used for the placement
of sand under the pipe.
3. Sand shall be lowered into the trench with a mechanical shovel and hand spread
uniformly around the pipe. The depth of the sand padding over the top of the
pipe shall be at least 300 mm. Sand on top of the pipe shall be shaped to the
natural angle of repose.
4. Screened excavated material from the location shall be used (after the removal
of any rock and boulders) on top of the sand. In order not to damage the sand
padding, the initial layers of final fill shall be carefully lowered into the trench
from each side by mechanical shovel ensuring that the backfill material is
deposited carefully to avoid disturbing the sand padding.
5. The mechanical excavator shall maintain the following minimum safe distances
(which shall be clearly marked by a line of bunting) from the edge of the trench:
-
Rock: distance from edge of trench shall be 1.0 metre
Compacted ground: distance from battered edge of trench shall be 1.5

metre
Soft sand with trench sides battered to a minimum slope of 2:1:

distance shall be 2 metres.
6. After completion of the initial backfill layer, the remaining backfill shall be
finished to a level slightly above the natural grade and shall be thoroughly
compacted by means of a compacting vibrator.
7. Windrow shall be reinstated, including the section used for temporary crossings.
Where the excavation crosses wadis or ditches with lined or otherwise improved
surfaces, these shall be reinstated to their original contour and condition.
Reference should also be made to ERD 38-11 and SP-1247 for details on
reinstatement.
3.6.3.5 Detailed Close Out Repair Report
The contents of closeout report for GRP pipelines shall be similar to that of CS
pipeline repairs closeout report indicated at section 2.5.7.7 of this document.
Page 35 of 76
3.7
Emergency Repair Procedure Qualification

Sectional replacement is the only possible repair method for restoring the long trem
integrity of the pipeline. The laminted joint shall be used for connecting the new
section with existing pipe sytems for the pipelines having design pressure less than
40 barg. Similarly, sectional replacement shall be carried out using flanged joint, if
design pressure of the pipeline is more than 40 barg. The qualified and approved
jointing procedure should be used for sectional replacement in all cases.
For procedure qualification, PDO shall engage one of the four approved GRP
vendors for procurement and supervision related activities for the emergency repair
of the GRP pipelines. The approved vendor shall develop a detailed repair
procedure including cleaning; cutting and jointing of the exiting pipeline with new
pipe section. This procedure along with testing plan shall be submitted to PDO for
review and approval. The qualification tests shall be carried out with all PDO
approved GRP manufacturer pipes with a view to verify the compatability of resin
to be used for laminated joints.
To minimize the emergency material, one fit for all philosophy is adopted. It
means highest rating pipe for a nominal diameter shall be procured from one of the
approved vendor and same pipe shall be used for sectional replacement for all rating
for that nominal diameter.
3.8
Quality Programme during Repair

The repair works shall be conducted in accordance with the quality management
system as required for ISO 9000. A high level of inspection shall be maintained for all
works to ensure compliance with the requirements of the relevant specifications and
procedures.
All repair work shall be carried out under the supervision of approved emergency
repair contractor who shall be responsible for maintaining comprehensive records of
the repair activities.
3.9
Emergency Repair Kit

The repair crews shall be equipped with all suitable equipment as required for the
pipeline being repaired and shall carry an adequate range of fully compatible spare
pipe and fittings.
In addition the following tools and consumables shall be carried:
1. Temperature and relative humidity measuring equipments
2. Measuring tape, sliding gauge, pipe marker (pen)
3. Pipe shavers (as supplied by the pipe manufacturer)
4. Winches or Pullers, Cargo latching belts and slings
5. Grinders and Grinding Disks
6. Drilling machine and Flapper wheels (grit 40-60)
Page 36 of 76
7. Emery Paper
8. Solvent cleaner, cleaning rags
9. PPE (gloves, eye protection, dust mask)
Page 37 of 76
4.0 Emergency Repair of Subsea Carbon Steel Pipelines

4.1
General
The integrity of sub-sea pipeline systems is very important for the operators for
economical, operational and environmental reasons. Once commissioned, the sub-sea
pipelines must give continuous service with minimum interruption. However,
submarine pipelines generally are operated in a highly corrosive and inaccessible
environment. PDO operates a few sub-sea export pipelines for loading crude oil and
handling white oil refinery products to tankers at MAF area. The total length of
submerged section of these pipelines is approximately 5000m. These include
30 SBM1 East - crude export pipeline.

30 SBM1 West - crude export pipeline.
40 SBM2 - crude export pipeline.
10 Product lines Shell market lines (6 nos SBM/1/2/3).
The integrity of crude oil, product-loading lines is highly important from operations
point of view. The crude oil export pipelines are mainly operated under gravity flow
conditions. Due to operational and tanker requirements all the submerged
crude/product loading lines are critical and there is no specific standby line for crude
oil export. Any leaks on these pipelines will have a major effect on the marine
environment and reputation with longer-term effects on loading operations; hence any
of these pipeline leaks are required to be attended on emergency basis.
This manual identifies the possible catastrophic defects (levelI defects) and specifies
the appropriate repair methods for PDO sub-sea pipelines.
4.2
Scope
This part of the document details the possible emergency repair methods for PDO
offshore loading lines. The defects considered are those that could be encountered
during the operation of the sub-sea pipelines.
The type of defects, defect classification and categorisation of defects, the repair
options for sub-sea CS pipelines are similar to that of buried onshore CS pipelines
specified in section 2.0. The additional specific requirements for emergency repair of
offshore sections of loading lines are briefly detailed in this document.
The support facilities required for emergency repair of sub-sea pipelines, such as
technical specification of required facilities on the surface support vessel, diving
expertise required for carrying out the necessary repair, specific requirements for
under water clamping and hyperbaric welding etc., are not detailed in this document.
Page 38 of 76
4.3
Causes of Defects
The possible reasons for sub-sea pipeline defects are
1. Third party damage
2. Excessive operational loads/errors
3. Corrosion (internal / external)
4. Manufacturing / construction defects
4.4
Level I Emergency Defects

The major activities related to Level-I emergency repairs are categorised into
1. Leak detection
2. Leak assessment survey
3. Decide the repair option based on damage assessment survey
4. Mobilization of emergency repair crew, equipment and carryout the repair work
Note: Points 3 & 4 have been covered in brief.
4.4.1
Leak Detection
It is necessary to identify the leak location as soon as possible to minimize spill of
hydrocarbons and impact on the environment. The sub sea pipeline leaks are divided
into minor leaks and major leaks, which is in line with defect categorisation for
onshore carbon steel pipelines.
The minor leaks are mainly pinhole leaks or crack leaks. The pinhole leak is a small
perforation in the pipe wall and is generally the result of either corrosion pits or weld
defects or material defects or external damage. A small pinhole leak may go
undetected for some time until evidence of oil pollution (sighted oily sheen/layers in
water) is observed on the water surface. The unusual death of marine life such as
small fish etc. in the vicinity of the loading lines also indicates suspected pipe leak. A
pinhole may occur below corrosion scales/deposits or under weight coating making
the detection very difficult.
In the case of a definite leak, the damage will be of such extent that pipeline cannot
retain the line pressure. Pressure loss and environmental pollution are the main
characteristics of major pipeline leaks.
For identifying the suspected leak, an experienced diver shall physically inspect the
pipeline and search for evidence of a leak / source of oil pollution. Remote Operated
Vessels (ROV) or manned submersibles can also be engaged for leak detection and
repair activities, in case the safety of the divers is in question. Following identification
of leak location, the defective section shall be clearly marked using buoys.
After identifying the location of the leak, a preliminary inspection must be carried out
as quickly as possible to identify the type and extent of the damage sustained to the
Page 39 of 76
pipeline. Under water video recording facilities give an added advantage for analysis
of pipeline damage by experts. Based on the preliminary inspection results a
qualitative assessment shall be made to assess the condition of the line (leaking /
unsafe / badly damaged) in relation to the safety of further diving operations. Hence
the preliminary inspection must be undertaken with extreme caution.
4.4.2
Leak Assessment Survey

After confirmation of the presence and location of the leak, the next step involves the
assessment and categorisation of the defect into minor, major or rupture and exploring
the possible reasons for the leak. This assessment is essential to decide upon the repair
procedure to be adopted and the safety measures to be taken during the repair.
The leak assessment survey involves exposure and detail inspection of the defective
pipe section to assess and record the condition for subsequent interpretation. The
external concrete coating in the defective area shall be removed using high-pressure
water jetting. The defective pipe section shall be cleaned to an acceptable level, which
is dependent on type of repair method. Exposing the pipe for repair may require
excavation of the surrounding area.
Since these tasks require extensive surface support, they can be considered together
and a single mobilisation shall be made using one vessel. It should be noted, that the
special equipment used and the diving expertise required for these activities shall be
of the highest quality. Since the preliminary inspection requires a rapid mobilisation
of diving crew with minimum delay, the services of the support vessel and diving
crew, available under the existing regular marine support contract shall be utilized.
Provision exists within this contract to call off additional specialist manpower and
equipment at short notice.
4.4.3
Shutdown and Pressure Reduction

The requirement of pressure reduction and shut down depends upon severity of the
damage, implications of leakage on the environment and repair method to be used.
Temporary repair of pinhole leaks using proprietary sleeves or clamps can be
executed without pressure reduction. In case of a major leak or rupture, pipeline
shutdown is necessary, to minimize environmental pollution and for carrying out
permanent repair (sectional replacement) in a safe manner.
4.4.4
Repair options
The company philosophy, applicable repair method, governing rules and regulations
dictate the repair strategy. Depending on the extent of the damage found, the repair
may require installation of a repair clamp or replacement of defective section of pipe
utilizing connectors or couplings. The selection of repair method shall be based on
pressure containment requirements and corrosivity of internal and external
environment.
Page 40 of 76
Permanent Repairs
The preferred option of permanent repair is to decommission the pipeline, cut the
defective section and replace it with a new section. However, this option is seldom
exercised due to the time constraint, availability of resources and cost involved.
For sectional replacement, mechanical connectors shall be used. The main advantage
of mechanical connectors is that this method is fast and underwater (hyperbaric)
welding can be avoided. The other permanent repair techniques indicated for buried
(onshore) CS pipelines are also applicable for sub-sea pipelines.
Temporary Repairs
Plidco Clamp and sleeve or any other similar Company approved brand sleeves are
preferred for temporary repair of sub-sea pipeline leaks (refer to Table 1 Selection
of emergency repair options for CS pipelines). The Plidco Clamp and sleeve has
clamping surfaces, which grip the outside wall to counter end-pull and axial stresses.
These temporary repairs can be accepted as a permanent repair, subjected to periodic
inspection of these sleeves following installation.
In the event of pipeline rupture, the sectional replacement option shall be selected.
4.5
Resources
In order to perform the sub-sea inspection and leak repair activities, an adequate
surface vessel will be required. The vessel should have following main features.
Good seaworthiness related to its overall dimensions and hull form. A

typical flat bottom barge for emergency repair of sub-sea pipelines shall be
of 150 to 250 feet long with valid certification for hull, machinery, safety
equipment for offshore operations. For shallow water applications either a
Jack-up or shallow water flat bottom barge can be used.
The vessel deck crane capacity must be in excess of expected loads (for
lowering, lifting of pipe sections, repair sleeves, clamps etc.). The
requirement will depend upon the type of repair and size of defective
pipeline. The crane must be rated for offshore use and must be equipped to
assist diver operations down to 50 meters water depth.
General construction capabilities should include under water welding and

cutting gear together with workshop / repair facilities. The vessel should
have a well-trained and integrated crew familiar with the work and the
construction, repair operations.
Positioning systems to allow the vessel to accurately fix its position relative
to known references and to the pipeline on the seabed.
Communications must be good and in preference include telex, as well as

normal marine side band VHF/UHF and walkie-talkie equipment.
Page 41 of 76
Whilst the company maintenance barge Fahal1 fulfils most of the requirements
above, sustained operations may require the services of additional specialist
equipment.
With a view to tackle any emergency situations with the sub-sea loading lines at MAF
area, the sources of required resources for tackling any emergency repair work needs
to be identified and the relevant repair procedures should be made available for ready
reference.
5.0
Emergency Stock Materials

5.1
Philosophy
The following philosophy has been adopted to establish the quantities of emergency
stock material.
For CS pipelines, all class-I pipelines shall be divided into different groups based on
pipe diameter and location of the pipeline. Presently, emergency materials are stored
at four locations. These locations are Nimr, Marmul, Fahud and MAF. All class-I
pipelines are regularly monitored and inspected by IP and UT. The inspection
frequency depends on the present condition of the pipeline, expected corrosion rate
and risk associated with the pipeline. All identified defects, which are threatening the
integrity of the pipeline, are repaired in a planned manner and chances of any third
party damage to the pipeline are minimal. Considering all these aspects, the
probability of leakage in a class-I pipeline is minimum, so it is concluded that
emergency materials shall be stored for one event at each location for each diameter.
An event includes a pinhole leak, a major leak and a rupture. Requirement of any
additional emergency material shall be discussed with PDO on case to case basis. The
Plidco Split Sleeves (or similar) shall be procured for highest rating pipeline for each
diameter. However, available Plidco Smith Clamp can be used for minor leaks if
adjacent area has sufficient wall thickness. In future, no Plidco Smith Clamp shall be
procured.
For sectional replacement in carbon steel pipeline, it is proposed that 3 pipe joints for
each diameter at every location shall be stocked from available pipe material. The
wall thickness and grade of pipe material shall be selected in such a manner that
selected pipes can be used for sectional replacement in all pipelines of same diameter
at that location without any compatibility issue.
For GRE pipelines, it is decided that sectional replacement shall be carried out using
laminated joints up to 40 barg and flanged spool pieces shall be used for sectional
replacement for lines operating at more than 40 barg. Minor leaks shall be repaired by
over wrapping up to a design pressure of 40 barg.
5.2
Loaction and Quantities of Emergency Stock Materials

The Emergency Stock Materials are located in following stores.
Nimr
Page 42 of 76
Marmul MPS
Fahud MLPS
Mina Al Fahal
Nimr
The list of recommended emergency materials is attached as Appendix 8.
6.0
Safety
6.1
Safety requirements during repair of emergency defects

It is the responsibility of the engineer-in-charge to ensure the repair operations are
carried out in a controlled and safe manner. The engineer-in-charge shall prepare a
specific action plan indicating the damage identified, the repair method to be used in
line with this manual. All precautions and safety measures to be taken shall also be
specified in the plan. The plan shall contain the following minimum information: o Name and telephone number of the PDO commander on the scene.
o Location of defect
o Defect categorization/type as per Section 2.2 for CS and Section 3.5 for GRP and
SP-1235
o Pipeline service and details (fluid transported, material grade, OD, operating
pressure, wall thickness)
o Repair method (repair option, tools required, WPS)
o Repair material required (list, location and responsible party for arranging and
transporting the repair material)
o Details of contractor who will carry out the repair (name/telephone)
o Safety precautions, including availability of adequate fire protection equipment.
The repair operations should proceed only after the requisite safety precautions for
dealing with any emergency including fire, explosion or spill have been duly adopted.
The recommended safety measures shall be based on the type of defect and the level
of leak as outlined in SP-1075 and HSE 97-13. For raising an emergency alarm the
PDO emergency response documents shall be followed. These documents outline the
contingency plans and safety measures to be adopted.
All necessary notification and reporting shall be done as per HSE 97-01 and as
described in Section 2.5.7.7 above. The personnel involved in the repair shall be
provided with adequate personnel protection equipment in line with SP-1234 and
SRD-S-01 and shall work to the Buddy (non-working alone) system as outlined in
PR-1081. For welding on live lines, the potential for fire is greater and therefore the
wearing of fire resistant clothing is essential.
In cases of repairs to a leaking pipeline, a hazard assessment must be done
immediately and a worksite safety plan produced. A hazard zone should be
established by determining the amount of hydrocarbon vapours in the area.
Information contained in the material data sheet for the product should be consulted to
determine the volatility and toxicity characteristic. An area assessment shall explore
the following minimum aspects:
1. The flammability level in the area should be checked with a combustible gas
detector. Atmospheres above 10% of the lower explosive limit (LEL) shall be
Page 43 of 76
declared hazardous and access should be restricted. Those above 50% LEL shall
not be entered.
2. Toxicity testing should be made with direct reading instruments that include
colorimetric tubes. This will determine the type of the protective equipment
required for all personnel working in the area.
3. If the repair is to be done in a confined space such as a trench, the oxygen level
must be checked and monitored.
4.
The flammable hazard zone must be demarcated to prohibit movement of

equipment and other ignition sources into the zone.
Other essential safety measures that shall be followed include:1. If the hazard area extends into public areas, all necessary warning signs and
restricted access must be put in place.
2. The leak site should be barricaded and marked to prevent the possibility of
accidents or injuries.
3. Electrical earthing bonds must be provided due to the possibility of an electrical
potential on the pipeline.
4. Before start of hot work, any hydrocarbon saturated earth should be removed.
5. The excavation and its surrounding area should be tested and continuously
monitored with combustible gas detectors or oxygen monitors or both to ensure
the atmosphere remains safe. Adequate ventilation is essential throughout the
work duration.
In addition, the following safety measures are specifically applicable for GRP pipeline
repair works :1. Under no circumstances should burning equipment be used for GRP repair works
2. Special precautions shall be taken when working with resins, curing agents, and
catalysts which can produce irritation when allowed to come into contact with the
eyes or skin. Adequate personnel protection must be worn e.g. face masks, safety
glasses, rubber gloves and barrier creams.
3. Any accidentally contaminated skin area shall be thoroughly washed with soap
and water.
4. Special precautions shall be taken to prevent inhalation of the glass fibre dust.
5. All redundant components shall be correctly disposed.
6.2
Accidental releases
Every effort shall be made to contain any spill or accidental release, reduce the
contaminated area and to divert the oil away from sensitive areas such as wadis,
villages, facilities and sources of ignition.
In cases of spills the methods and procedures outlined in PR- 1084, PR-1089, SP1005 and SP-1007 shall be followed.
A spill should be diverted away from sensitive areas where possible by cutting
drainage channels from the leak site to a specially dug pit or a bunded collection point
Page 44 of 76
at least 50m away from the area so the oil can be collected in a safe and controlled
manner. If necessary, additional pits or bunded areas should be constructed to take any
overflow. Particular attention shall be taken to ensure that the oil does not flow into a
falaj system as this could allow the oil to travel a considerable distance and
contaminate populated/agricultural areas.
Page 45 of 76
7.0
References
If no revision or issue date is mentioned reference shall be made to the latest revision
in force at the time of issue of this Manual
PDO Engineering Reference Documents
ERD 38-11
Guidelines for Excavation and Working around Live Pipelines
PDO Specifications
SP-1005
SP-1006
SP-1007
SP-1009
SP-1012
SP-1075
SP-1167
Emissions to Atmosphere
HSE specification - Aqueous Effluents
Specification for Accidental Releases to Land and Water
Waste Management
Site Preparation, Abandonment and Restoration
Specification for Fire and Explosion Risk Management
Specification for Welding on Pressurised Pipes (Amendments/
Supplements to DEP 30.10.60.30)
SP-1176
Non-Destructive Examination (Amendment/Supplement to ASME V)
SP-1177
Welding of Class I Pipelines (Amendments/Supplements to API 1104)
SP-1208
Pipeline Construction Specification
SP-1210
Pipeline Operations and Maintenance
SP-1211
Pipeline Engineering
SP-1234
Health, Safety and Environment Specification (PPE)
SP-1235
DEP 31.40.60.12-PDO Pipeline Repairs (Amendments/Supplements to
ASME B 31.4 and B 31.8)
SP-1246
Specification for Painting and Coating of Oil and Gas Production
Facilities
PDO Procedures
PR-1011
PR-1060
PR-1066
PR-1067
PR-1068
PR-1071
PR-1073
PR-1074
PR-1076
PR-1081
PR-1082
PR-1084
PR-1089
PR-1146
PR-1246
PR-1275
Page 46 of 76
Pipeline Remedial Works

HSE Management Procedure _ Communicating & Reporting
Emergency Response Document Section 2II, Contingency Plan, Vol.
III Production Operation
Emergency Response Document
Flow Line Suspension/Abandonment
Gas Freezing, Purging and Leak Testing of Process Equipment
Flushing Flow Lines
Isolation of Process Equipments
The Buddy System Procedure
Pipeline Pigging Procedure
Spills Clean-up and Site Restoration Procedure
Spillage Reporting Procedure
Flow Line Cold Cutting Procedure
PR-1276
PR-1506
Std Procedure Qualification Record for Welding on to Pressurised

Pipes
Pipeline Hot Tap Management Procedure
PDO Guidelines
GU-273
Permit to Work System
PDO HSE Standards

HSE 97-01
HSE 97-13
SRD-S-01
SRD-S-03
Incident Notification, Investigation, Reporting and Follow up

FERM Facility Plan Guideline
Standard for Respiratory Protective Equipments
Standards and Guidance for Personnel Hydrogen Sulphide Monitors
PDO Policy
PL-30
PDO Emergency Response Policy
DEP
31.38.60.10
31.40.30.30
31.40.30.31
31.40.40.38
31.40.60.11
Hot-Tapping on pipelines, Piping and Equipment

Line Pipe for use in Oil and Gas Operations Under Non-sour Condition
Line Pipe for use in Oil and Gas Operations Under Sour Condition
Hydrostatic Pressure Testing of New Pipelines
Pipeline Leak Detection
International Standards
ASME B 31.4 Pipeline Transportation Systems for Liquid Hydrocarbons and Other
Liquids
ASME B 31.8 Gas Transmission Pipelines
API RP 1107 Pipeline Maintenance Welding Practices
API RP 2200 Repairing Crude Oil, Liquefied Petroleum Gas, and Product Pipelines
API RP 2201 Safe Hot Tapping Practices in the Petroleum & Petrochemical
Industries
API Std. 1104 Welding of Pipelines and Related Facilities
API 5L
Specification for Line Pipe
References specific to GRP pipelines
DEP 31.40.10.19
GRP Pipelines and Piping Systems (Amendments/

Supplement to ISO 14692 )
BS 7159:1989
Design and Construction of Glass Reinforced Plastics (GRP)
piping systems for individual plants or sites
API 15LR
Low Pressure Fiberglass Line Pipe
API 15HR
Specification for High Pressure Fibre Glass Line Pipe
SP-1247
Construction of Pipeline Systems in Non-Metallic Materials
ISO 14692 Dec 2002 :Part 1 to 4: Petroleum and Natural Gas Industries- GRP Piping
Page 47 of 76
Appendix-1: Mechanical methods to be used in installation of sleeves
Repair sleeve
Pipe
Lug and bolt method
Hydraulic jack
Hi-yield
chain link
Wood skid
Repair sleeve
halves with
side strips shown
Pipe
Wood skid
Standard method
Page 48 of 76
Chain clamp method
Appendix-2: Plidco Split + Sleeve
Studs & nuts

in position
Test ports
End thrust studs
End sealing
mechanism
Page 49 of 76
Appendix-3: Plidco Smith + Clamp
Force-screw with cone
Clamp
Draw-bolt
Page 50 of 76
Appendix-4: Plidco Weld + Cap
Page 51 of 76
Appendix-5: Fixing arrangement for Plidco Weld + End
Page 52 of 76
Appendix-6: Plidco Flange + Repair Ring
Page 53 of 76
Appendix-7: Plidco Flange Repair + Split Sleeve
Page 54 of 76
Appendix-8 : List of Emergency Materials (16 Pages)
Page 55 of 76
Appendix-9 : Manufacturer Instructions
Page 56 of 76
PLIDCO CLAMP + RING INSTALLATION INSTRUCTIONS

SAFETY CHECK LIST
Read and follow these instructions carefully.

Do not exceed the maximum end restraint indicated on the label of the Plidco
Clamp + Ring. A Plidco Clamp + Ring is designed for a specific, longitudinal
and restraint in units of force. Verify the maximum end restraint indicated on the
label is sufficient to resist the combination of hydrostatic, dynamic, external and
thermal induced forces.
Do not exceed the maximum temperature indicated on the label of the Plidco
Clamp + Ring. The maximum temperature indicated on the label refers only to
the selection of an allowable stress used in the design of the Plidco Clamp +
Ring. It does not imply the Plidco Clamp + Ring is capable of resisting thermal
forces associated with raising the temperature of the pipeline to the maximum
temperature indicated on the label. Please refer to design end restraint
described earlier. If necessary, please consult Plidco Department 100 for further
detail.
If the pipeline has been shut down, repressuring should be done with extreme
caution. Re-pressuring should be accomplished slowly and steadily without
surges, which could vibrate the pipeline and fitting. Industry codes and
standards are a good source of information on this subject. Do not exceed the
maximum end restraint indicated on the label as described earlier. Personnel
should not be allowed near the installation until the Plidco Clamp + Ring has
been proven.
CLAMP + RING COMPONENTS
Page 57 of 76
PIPE PREPARATION
1. Remove all coatings, rust and scale from the pipe surface where the Plidco
Clamp +Ring will contact the pipe.
2. Survey the outside of the pipe to confirm a circular cross section, particularly in
the area of the clamping section. This area should be a smooth curved surface
without indentations of flat spots that could adversely affect proper gripping.
3. A ring gauge should be used for submerged pipelines where visibility is limited.
Plidco has available ring gauges that can accurately survey the cross sectional
shape of the pipe.
4. The bolting force generated when assembling the two halves is capable of
shaping minor out-of-round pipe. Maximum allowable ovality is approximately
5%, depending on the pipe wall thickness. Flat spots are very difficult to reshape
and bolting force should not be relied on to correct flattened or indented areas.
5. Clean and lubricate all Plidco Clamp + Ring. Stud bolts and nuts. Prove free
and easy nut running prior to installation.
INSTALLATION
Careless handling can damage Clamp + Ring. Lifting devices such as chains, cables
or lift truck forks should not contact the clamping sections.
1. Assemble the Plidco Clamp + Ring loosely on the pipe, centered over the repair
fitting, making certain the yellow painted ends are matched. There should be
approximately three (3) inches between the Plidco Clamp + Ring and the repair
fitting. See Clamp + Ring components.
2. With the tie stud bolt lugs in alignment, insert the tie stud bolt. Hand tighten a
nut on each side of the lugs.
3. All clamping stud bolts and nuts should be uniformly torqued as indicated in
the Plidco Torque Chart the best results are obtained by maintaining an equal
gap between the sidebars while tightening The stud bolts. The sidebars will be
gapped approximately to inch.
4. The tie stud bolt nuts need only be snug. A high pre-stress on the tie stud bolts
is undesirable.
5. To complete assembly, the clamping stud bolts should be rechecked at the
recommended torque. An increase in torque on one stud bolt can cause a
decrease in torque on neighboring stud bolts.
FIELD TESTING
The Plidco Clamp + Ring is capable of being field tested up to 1 times its maximum
end restrained indicated on the label of the Plidco Clamp + Ring. The combination of
Page 58 of 76
hydrostatic, dynamic, external and thermal induced forced anticipated during testing
must be considered.
STORAGE
Plidco Clamp + Ring should be stored in a dry environment to prevent any unpainted
surfaces rusting.
PLIDCO TORQUE CHART
Nominal
diameter of stud
bolts
( inches)
Wrench
Opening
across flats
Clamping Studbolt Torque Values*

0.08 Cf
Ft-lbs
0.15 Cf
Nm
ft-lbs
Nm
52,500 psi pre-stress

5/811
--10
7/89
18
1-1/88
1-1/4--8
1-3/88
1-1/2--8
1-5/88
1-3/4--8
1-7/88
28
2-1/48
2-1/2--8
95
118
160
162
206
280
259
328
446
385
490
664
561
719
975
782
1008
1368
1055
1368
1855
1382
1800
2441
1758
2302
3121
2226
2928
3969
2758
3633
4927
3360
4444
6025
4826
6412
8694
6664
8886
12048
2-3/48
4-1/4
5947
8064
10787
14628
38
4-5/8
7816
10598
14218
19280
3-1/48
5
9966
13514
18170
24639
3-1/2--8
5-3/8
12478
16921
22794
30908
3-3/48
5-3/4
15380
20856
28140
38157
48
6-1/8
18699
25355
34262
46460
4-1/48
6-1/2
17735
24050
32540
44123
4-1/2--8
6-7/8
21082
28586
38723
52508
4-3/48
7-1/4
24822
33659
45643
61891
58
7-5/8
28983
39302
53344
72334
5-1/48
8
33585
45539
61864
83887
5-1/2--8
8-3/8
38647
52405
71245
96609
5-3/48
8-3/4
44195
59929
81529
110556
68
9-1/8
50249
68139
92761
125783
Torque values shown in the table represent two different coefficients of friction (Cf); 0.08 and 0.15. When
Cf equals 0.08, it is assumed the studs and nuts are clean, free running, free of obvious flaws and
lubricated with a high grade graphite-oil thread lubricant. When Cf equals 0.15, it is assumed the studs
and nuts are clean, free running, free of obvious flaws and lubricated with a light weight Machine oil. The
torque values are safe minimums and represent approximately the bolt pre-stress values listed in the table.
Page 59 of 76
1-1/16
1-1/4
1-7/16
1-5/8
1-13/16
2
2-3/16
2-3/8
2-9/16
2-3/4
2-15/16
3-1/8
3-1/2
3-7/8
70
120
192
284
414
576
777
1019
1296
1643
2033
2478
3560
4914
PLIDCO WELD + ENDS INSTALLATION INSTRUCTIONS

SAFETY CHECK LIST

Be absolutely certain that the correct seal material has been selected for the
intended use.
Determine the type of joint that the Plidco Weld + Ends coupling is expected to
connect. See (a) and (b) below and determine the appropriate rating from the
ratings listed on the label of the Plidco Weld +Ends coupling.
(a) Pipe Not anchored
A joint in which the pipe ends could move when subjected to internal or
external forces, such as internal pressure, temperature expansion and
contraction, underwater currents, ground movement or any combination
thereof. The assigned Plidco Weld + Ends Pipe Not Anchored rating
considers only the end force created by the internal pressure. It does not
consider any additional external forces such as temperature expansion and
contraction, underwater currents, ground movement or any combination
thereof. These additional external forces must be determined. If any of these
forces cannot be restrained by customer proven techniques, a Plidco Clamp
+ Ring should be used.
(b) Anchored pipe
A joint in which the pipe ends would not move when subjected to these same
forces. Plidco Weld + Ends Anchored pipe rating is the maximum pressure at
which the pipeline can be operated. It assumes that the pipeline is suitably
Anchored by welding, by the use of an appropriately rated Plidco Clamp +
Ring or by other customer proven techniques.
Observe the pressure and temperature ratings on the label of the Plidco Weld +
Ends coupling. Do not exceed the maximum appropriate pressure indicated on
the unit.
Minimum Pipe Wall Thickness For Plidco Weld + Ends
Nominal Pipe Size (inches )
1
2
2
3
4
6
8
10
12
14
16 & larger
Page 60 of 76
Wall Thickness (inches )

0.200
0.218
0.276
0.237
0.237
0.280
0.322
0.365
0.409
0.438
0.500
Pipe wall thickness less than those listed may be pushed inward by the force of
the clamp screws.
A Plidco Clamp + Ring should be considered whenever wall thickness is less
than those listed. A Plidco Clamp + Ring should also be considered where high
external forces (such as underwater Currents or thermal contractions) are
anticipated, even if the pipe has an adequate wall thickness.
Pipelines should be carefully blocked at elbows and bends to prevent pullouts
caused by internal and external forces; or a Plidco Clamp + Ring should be
used. Pipeline should be evenly supported before re-pressuring. Follow
applicable B31 codes during re-pressuring.
If the Plidco Weld + Ends coupling is welded or a suitable Plidco Clamp+ Ring
is used, it can be considered an anchored joint.
PIPE PREPARATION
1. The pipe surface in the area of the repair should be clean, free of coating and
burrs and lubricated to prevent abrasion to the seal.
2. For badly misaligned or out of round pipe, it is helpful grind a pilot bevel with
a generous taper on the pipe. This would be eliminate the risk of damage to the
seal while slipping the Plidco Weld + Ends coupling over the end of the pipe
(See Figure 1)
INSTALLATION
The seal can be damaged by careless handling. Lifting devices such as chains, cables
or lift trucks forks should not contact the seal. Failure to do so can result in the seal
being damaged or pulled from its grooves.
1. Measure and record dimension D as shown in Figure 3. This will be needed
later if the Plidco Weld + Ends is welded to the pipe.
2. Coat all exposed surfaces of the seal material with a lubricant. The following
chart indicates the lubricants that are recommended for the various seal
materials. It must be determine that the lubricant is compatible with the product
in the pipeline.
Buna-N
Page 61 of 76
A, B, C
225 F
Viton
Silicone
Neoprene
Aflas
Teflon
Kevlar
Petroleum based lubricant = A
Silicone based lubricant = B
Glycerin based lubricant = C
A, B, C
C
B, C
A, B, C
A, B, C
A, B, C
250 F
450 F
250 F
250 F
500 F
750 F
3. Slide the pipe into the Plidco Welds + Ends coupling completely. Mark on the
pipe one-half the Plidco Weld + Ends couplings length from the middle of gap
(recommended gap not to exceed inch). Slide the Weld + Ends coupling back
to the mark to divide the coupling equally over the joint. (See Figure 2).
4. Clamp screws have case hardened cup points which are used to secure the
coupling to the pipe. The shanks are mild steel and fully weldable. Clamp
screws should be tightened evenly, maintaining an equal space between the pipe
and the coupling using the recommended torque values. Clamp screws are
designed for the assigned Plidco Weld + Ends Not anchored rating which
considers only the end force created by the internal pressure. Clamp screws do
not consider any additional external forces or stresses imposed on the pipeline.
5. Accurate clamp screw torque values are very important when the Plidco Weld +
Ends coupling is used on a pipeline joint that is NOT ANCHORED. Do not
exceed the Pipe Not Anchored Rating listed on the label of the Plidco Weld +
Ends until subsequent welding has been completed.
Page 62 of 76
6. Check all clamp screws to make certain each has received at least the minimum
torque specified in chart below.
Cup point
Clamp Screws
5/8-11
-10
Minimum Torque
ft-lbf
100
150
Nm
136
240
7. Thrust screws activate the seals. They are made of mild carbon steel and are
fully weldable. They should be tightened gradually and uniformly around the
circumference. First, snug all the thrust screws firmly. Then advance each thrust
screw about 1/8 of a turn before proceedings to an adjacent thrust screw. It will
be necessary to make many circuits around the coupling before completing the
thrust screw torque operation. Use recommended torque values in the chart
below.
Thrust Screws
3/8-16
-13
5/8-11
Torque Range
ft-lbf
20-25
30-40
70-80
Nm
28-34
41-55
95-109
8. A final torque range, shown in the chart above, will be adequate to complete the
assembly.
9. Repressuring after the repair should be done with extreme caution; slowly and
steadily without surges, which could vibrate the pipeline and fitting. Industry
codes and standards are a good source of information on this subject. Operating
pressure must not exceed the maximum appropriate Pipe Anchored or Pipe Not
Anchored Rating. Personnel should not be allowed near the installation until the
seal has been proven.
FIELD WELDING INSTRUCTIONS
Pipeline should be full and underflow. Use absolutely dry electrodes, which are of
equal or greater tensile strength than the pipe. Carefully control the size and shape
of the circumferential fillet weld. The weld is required to anchor the joint and give
longitudinal stability to the pipeline.
The size of the fillet weld should be at least 1.4 times the wall thickness of the pipe.
This assumes a 1.0 joint efficiency. There may be need to select a different joint
efficiency based on level of inspection or your companys welding policy. Strive for
a concave faced fillet weld with streamlined blending into both members; avoid
notches and undercuts.
The smoother and more streamlined the weld, the greater the resistance to fatigue
failure. The worst Possible shape would be a heavy reinforced convex weld with an
undercut. Improper weld shape can lead to rapid fatigue failure, which can cause
leakage, rupture or explosion with attendant serious consequences.
Page 63 of 76
Welders and weld procedures should be qualified in accordance with API standard
1104, Welding of Pipelines and Related Facilities or RP 1107, Recommended
Pipeline Maintenance Welding Practices latest edition. API 1104 and 1107 have
easy to follow directions for procedure qualification.
Plidco encourage the use of low hydrogen electrodes (E-XX18) because of their
high resistance to moisture pick-up and hydrogen cracking. Shielded metal arc
welding (SWAW) filler metals listed in API 1104 and 1107 include the cellulose
coated electrodes (E-XX10 series) which are often preferred because of the
excellent downhill welding characteristics. There are acceptable filler metal,
provided they are proven by procedure qualification.
It is very important that the field welding procedure closely follow the essential
variables of the qualified procedure so that the quality of the field weld is
represented by the physical tests performed on the procedure qualification test
specimen.
Dimension D as measured during the initial Installation, may now be used to
mark off locations A and B as shown in Figure 3. These locations are the same
distance from the weld as the seal location C. To prevent damage to the seals,
monitor the heat generated by welding or preheating, particularly at location A
and B, by using temperature crayons or probe thermometers. If the heat generated
approaches the temperature limit of the seal material, which is indicated on the label
and in the seal lubrication chart, welding should be discontinued or sequenced to
another part of the fitting so that the affected area has a chance to cool.
WELDING SEQUENCE
1. Caution should be observed so that welding or pre heating does not overheat
the seals. Sequence the welding so that the heat is not concentrated in one area.
2. Thrust Screws should be cut or burned off flush. Start with the fillet weld to the
pipe around circumference and include seal welding the thrust screws. (See
Figure 3).
3. Cut or burn off clamp Screws approximately 3/16 above the outside surface of
the coupling and seal weld. One clamp screw near the top may be removed to
serve as a vent while welding and also as a final test point for leakage. (See
Figure 3)
Page 64 of 76
FIELD TESTING
The Plidco Weld +Ends coupling can be field tested up to 1 times the
appropriate pipe Anchored or Pipe Not Anchored Rating.
STORAGE INSTRUCTIONS
Plidco Weld +Ends coupling should be stored in a dry environment to prevent the
unpainted surfaces from rusting. Storage temperatures should not exceed 120 F
(49 C). Cover with a dark polyethylene to keep the direct sun light from the seals.
It is best to exclude contamination, light, ozone and radiation. Improperly stored
Plidco Weld + Ends couplings can cause the gasket material to become cracked and
brittle and lose its ability to seal.
Page 65 of 76
PLIDCO SPLIT + SLEEVE INSTALLATION INSTRUCTIONS

SAFETY CHECK LIST

The Plidco Split + Sleeve should never be used to couple pipe unless sufficient
end restraint is provided such as with the Plidco Clamp + Ring. The Plidco Split
+Sleeve has no end restraint in its unwelded condition, and if so utilized could
result in explosion, fire, death, personal injury, property damage and/or harm to
environment.
Observe working pressure and temperature on the label of the Plidco Split +
Sleeve. Do not exceed maximum working pressure or temperature as indicated
on the unit.
When repairing an active leak, extreme care must be taken to guard personnel.
Severe injury or death could result.
If the pipeline has been shut down, repressuring to test the seals after repair
should be done with extreme caution. Re-pressuring should be accomplished
slowly and steadily without surges, which could vibrate the pipeline and fitting.
Industry codes and standards are a good source of information on this subject.
Do not exceed the maximum working pressure. Personnel should not be allowed
near the repair until the seal has been proven.
PIPE PREPARATION
1. Remove all coatings, rust and scale from the pipe surface where the
circumferential seals of the Plidco Split +Sleeve will contact the pipe.
2. The seal can tolerate minor surface irregularities up to 1/32.
INSTALLATION
The seals and Girder Rings can be damaged by careless handling. Lifting devices
such as chains, cables or lift truck forks should not contact the seals or girder Rings.
Contact can result the seals being pulled from their grooves. (See Figure 1)
1. Coat all exposed surfaces of the seals with a lubricant. The following chart
indicates the lubricants that are recommended for various seals.
Petroleum based lubricant
:
Silicone based lubricant
:
Glycerine based lubricant
:
Buna- N
Viton
Silicone
Ethylene Propylene
Neoprene
Aflas
Teflon
Kevlar
A
B
C
A, B, C
A, B, C
C
B, C
B, C
A, B, C
A, B, C
A, B, C
The customer must determine if the lubricant is compatible with the product in
the pipeline.
Page 66 of 76
2. Clean and lubricate all stud bolts and nuts, and prove free and easy nut running
prior to installation.
3. Assemble the Plidco Split+ Sleeve around the pipe making sure the yellow
painted ends are matched and that the fitting is centered over the leak and
damaged area as much as possible. Sometimes it is helpful to loosely assemble
Page 67 of 76
the Plidco Split + Sleeve to one side of the leak, then reposition it centered over
the leak.
4. All stud bolts and nuts should be uniformly torqued as indicated by the Plidco
Split +Sleeve Torque Chart. The best results are obtained by maintaining an
equal gap all around between side bars while tightening the studbolts.
5. To complete assembly, ALL stud bolts should be rechecked at the
recommended torque. Keep in mind, the slightest increase in torque on one
studbolt can cause a decrease in torque on neighboring studbolts.
6. The side bars are grapped approximately 1/8 when the Plidco Split +Sleeve is
fully tightened.
FIELD WELDING INSTRUCTIONS
If the pipeline has been shutdown, repressuring to test the seals after repair should
be done with extreme caution. Repressuring should be accomplished slowly and
steadily without surges which could vibrate the pipeline and fitting. Industry codes
and standards are a good source of information on this subject. Do not exceed
maximum working pressure. Personnel should not be allowed near the repair until
the seal has been proven.
Use absolutely dry electrodes which are equal or greater tensile strength than the
pipe. Carefully control the size and shape of the circumferential fillet welds. The
size of the fillet welds should be at least 1.4 times the wall thickness of the pipe.
This assumes a 1.0 joint efficiency. Strive for a concave fillet weld, with
streamlined blending into both members; avoid notches and undercuts. Improper
weld shape can lead to rapid fatigue failure which can cause leakage, rupture or
explosion with attendant serious consequences.
Welders and weld procedures should be qualified in accordance with API Standard
1104 Welding of Pipelines and related Facilities, or RP 1107 Recommended
Pipeline Maintenance Welding Practices, latest edition. API 1104 and 1107 have
easy-to-follow directions for procedure qualification.
Plidco encourage the use of low hydrogen electrodes ( E-XX18) because of their
high resistance to moisture pick-up and hydrogen cracking. They are also the
preferred electrode for seals welding the stud bolts and nuts.
Shielded metal arc welding (SMAW) filler metals listed in API 1104 and 1107
include the cellulose coated electrodes (E-XX10) series which are often preferred
because of the excellent downhill welding characteristics. These are acceptable
filler, metals, provided they are proven by procedure qualification. Cellulose coated
electrodes are not recommended for seal welding the stud bolts and nuts.
It is very important that the field welding procedure closely follow the essential
variables of the qualified procedure so that the quality of the field weld is
represented by the physical tests performed on the procedure qualification
specimen.
Monitor the heat generated by welding or preheating, particularly near the area of
the seals, by using temperature crayons or probe thermometer. If the heat generated
approaches the temperature limit of the seal material which is indicated on the label,
Page 68 of 76
welding should be discontinued or sequenced to another part of the fitting so that

the affected area has a chance to cool.
Seal welding the grade B-7 studbolts of a Plidco Split + Sleeve is the most difficult
phase of field welding. They are made of AISI 4140 steel with a high carbon
equivalence. By using low hydrogen electrodes ( E-XX18) and a modest preheat
( do not exceed 200 degree F), the problem of hydrogen cracking and pin holes can
be reduced. The preheat will dry out nay moisture, oil dampness or thread lubricant
that may be present in the seal weld area.
WELDING SEQUENCE
1. Caution should be observed so that welding does not overheat the seals.
Sequence the welding so that the heat is not concentrated in one area. It will be
necessary to re-torque the studbolts and nuts periodically during field welding
because weld contraction causes them to loosen.
2. Fillet-weld ends to pipe
3. Seal-weld side openings
4. Re-torque stud bolts and nuts
5. Seal-weld around bottoms of nuts to side bars.
6. Seal weld nuts to studbolts.
FIELD TESTING THE PLIDCO SPLIT+ SLEEVE

The Plidco Split + Sleeve can be field tested up to 1 times its design working
pressure.
Plidco Split + Sleeves should be stored in a dry environment to prevent the
It is best to exclude contamination, light, ozone and radiation. Improperly stored
Plidco Split + Sleeves can cause the seal material to become cracked and brittle and
lose its ability to seal.
PLIDCO SPLIT + SLEEVE TORQUE CHART
Nominal
Page 69 of 76
Wrench
Clamping Studbolt (Torque Values*)

diameter of stud
bolts
( inches)
Opening
across flats
0.08 Cf
ft-lbs
0.15 Cf
Nm
ft-lbs
Nm

45
56
76
77
98
133
123
156
212
183
233
316
267
342
464
372
480
651
502
651
883
658
857
1162
837
1096
1486
1060
1394
1890
1313
1730
2346
1600
2116
2869
2298
3053
4140
3173
4231
5737
23000 psi pre-stress
2-3/4--8
4-1/4
2880
3904
5224
7083
38
4-5/8
3785
5133
6885
9336
3-1/4--8
5
4826
6545
8799
11931
3-1/28
5-3/8
6043
8194
11037
14967
3-3/48
5-3/4
7447
10099
13626
18477
48
6-1/8
9055
12278
16590
22497
4-1/48
6-1/2
8891
12075
16313
22120
4-1/28
6-7/8
10569
14331
19413
26324
4-3/48
7-1/4
12444
16874
22882
31028
58
7-5/8
14530
19703
26743
36263
5-1/48
8
16837
22830
31014
42055
5-1/28
8-3/8
19375
26272
35717
48433
5-3/48
8-3/4
22156
30044
40873
55425
68
9-1/8
25191
34160
46504
63059
Torque values shown in the table represent two different coefficients of friction (Cf); 0.08 and 0.15.
When Cf equals 0.08, it is assumed the studs and nuts are clean, free running, free of obvious flaws
and lubricated with a high grade graphite-oil thread lubricant. When Cf equals 0.15, it is assumed
the studs and nuts are clean, free running, free of obvious flaws and lubricated with a light weight
machine oil. The torque values are safe minimums and represent approximately the bolt pre-stress
values listed in the table.
5/811
--10
7/89
18
1-1/88
1-1/48
1-3/88
1-1/28
1-5/88
1-3/48
1-7/88
28
2-1/4--8
2-1/28
Page 70 of 76
1-1/16
1-1/4
1-7/16
1-5/8
1-13/16
2
2-3/16
2-3/8
2-9/16
2-3/4
2-15/16
3-1/8
3-1/2
3-7/8
33
57
91
135
197
274
370
485
617
782
968
1180
1695
2340
PLIDCO FLANGE + REPAIR-RING INSTALLATION INSTRUCTIONS

SAFETY CHECK LIST

The Plidco Flange +Repair Ring may be used with the pipeline in operation or
shutdown.
Be absolutely certain that the correct seal material has been selected for the
intended use.
The Plidco Flange + Repair Ring should never be used to couple flanges. No
end restraint is provided with the Plidco Flange + Repair Ring.
Observe working pressure and temperature on the label of the Plidco Flange +
Repair Ring. Do not exceed the maximum working pressure or temperature as
indicated on the unit.
Verify the tightness of all threaded vents and connections.
When installing a Plidco Flange + Repair Ring on non-leaking flanges
submerged under water (or any liquid), Plidco strongly recommends the vents
be open during installation to prevent excessive pressure buildup within the
fitting due to hydraulic lock.
PREPARATION
1. Remove all coatings, rust and scale from the flange surface where the
circumferential seals of the Plidco Flange + Repair Ring will contact the flange.
The seal can tolerate minor surface irregularities up to 1/32.
2. Make sure the gap between the flanges is clear to the flange stud bolts.
3. Clean and lubricate all Plidco Flange + Repair Ring stud and nuts. Prove free
and easy nut running prior to installation.
4. Coat all exposed surfaces of the sealing material with lubricant. The following
chart indicates the lubricants that are recommended and the maximum
temperature limit for various seals. The customer must determine if the lubricant
is compatible with the product in the pipeline.
Petroleum based lubricant
Silicone based lubricant
Glycerine based lubricant
Buna- N
Viton
Silicone
Neoprene
Aflas
Teflon
Kevlar
:
:
:
A
B
C
A, B, C
A, B, C
C
B, C
A, B, C
A, B, C
A, B, C
225 degree F
250 degree F
450 degree F
250 degree F
250 degree F
500 degree F
750 degree F
INSTALLATION
The seal and Girder Rings can be damaged by careless handling. Lifting devices
such as chains, cables or lift truck forks should not contact the seals or girder Rings.
Contact can result the seals being pulled from their grooves.
Page 71 of 76
1.
2.
3.
4.
5.
Assemble the Plidco Flange + Repair Ring around the flanges making certain
the fitting is centered over the gap between the flanges and that the yellow
painted ends are matching.
Assemble the studs and nuts hand tight.
All stud bolts and nuts should be uniformly torqued as indicated by the Plidco
Torque Chart. The torque values shown apply up to and including 700 degree F.
The best results are obtained by maintaining an equal gap between the side bars
while tightening the bolts.
To complete assembly, the stud bolts should be rechecked at the recommended
torque. The side bars are gapped approximately 1/8 to 3/16 when the Plidco
Flange + Repair Ring is fully tightened.
PLIDCO TORQUE CHART
Nominal
diameter of stud
bolts
( inches)
Wrench
Opening
across flats
5/811
--10
7/89
1--8
1-1/88
1-1/4--8
1-3/88
1-1/2--8
1-5/88
1-3/4--8
1-7/8--8
2--8
2-1/4--8
2-1/2--8
2-3/4--8
3--8
3-1/4--8
3-1/2--8
1-1/16
1-1/4
1-7/16
1-5/8
1-13/16
2
2-3/16
2-3/8
2-1/2
2-3/4
2-15/16
3-1/8
3-1/2
3-7/8
4-1/4
4-5/8
5
5-3/8
Clamping Studbolt
Torque Values*
0.08 Cf
ft-lbs
33
57
91
135
197
274
370
485
617
782
968
1180
1695
2340
3130
4114
5246
6568
0.15 Cf
Nm
ft-lbs
45
56
77
98
123
156
183
233
267
342
372
480
502
651
658
857
837
1096
1060
1394
1313
1730
1600
2116
2298
3053
3173
4231
4244
5678
5579
7484
7114
9564
8906
11997
Nm
76
133
212
316
464
651
883
1162
1486
1890
2346
2869
4140
5737
7699
10148
12969
16268
Torque values shown in the table represent two different coefficients of friction (Cf); 0.08 and 0.15.
When Cf equals 0.08, it is assumed the studs and nuts are clean, free running, free of obvious flaws
and lubricated with a high grade graphite-oil thread lubricant. When Cf equals 0.15, it is assumed
the studs and nuts are clean, free running, free of obvious flaws and lubricated with a light weight
Machine oil. The torque values are safe minimums and represent approximately the bolt pre-stress
values listed in the table.
SEALANT INJECTION
One or more sealant cocks are supplied with each Plidco Flange + Repair Ring.
These may be used for venting by removing the button heads while the cocks are
closed. Open the sealant cocks to allow product to vent while bolting, if desired.
Close cocks and re-install button heads. Be sure cocks are open before injecting
sealant.
Page 72 of 76
Connect a sealant gun to fitting and inject sealant through all button head fittings a
little at a time until the Plidco Flange + Repair Ring is full. Leakage will usually
slow down to a whisper through the flange bolts.
Injection should proceed slowly, injecting a little at a time through the button head
nearest the leak until total seal off is attained. Sometimes a total seal off is instant,
in which case all sealant injection should be stopped. Observe for a while to see if a
leak develops. Generally the leakage will reduce to whispers and the rate of sealant
injection should be reduced proportionately.
A good rule to remember is when the rate of leakage decreases the rate of sealant
injection should be decreased. Often, during the final phases of seal off, there is an
impulse to pump sealant zealously. This does not always give desirable results. The
confined sealant, having no where to go, is forced out a previously sealed bolt hole
or gasket.
Occasionally the surfaces to be sealed are unreasonably gapped or badly corroded.
These may require sealants which are very coarse and which cannot be pumped
through the restriction of standard button heads. These sealants can be injected
directly through the sealant cock.
Plidco Flange + Repair-Ring should be stored in a dry environment to prevent the
It is best to exclude contamination, light ozone and radiation. Improperly stored
Plidco Split + Sleeves can cause the seal material to become cracked and brittle and
lose its ability to seal.
Page 73 of 76
GRE REPAIR PROCUDRES : SMITH FIBER

Introduction
The repair of Star line pipe primarily involves the installation of a flange set. Lower
pressure products offer alternative methods to flange sets, but are limited in pressure
rating. The following are the repair methods and the limitations of each:
CAUTION: Make sure that the line is properly vented prior to starting repair work.
Flange Set
Primarily for API 8rd products 500 PSI.

Set includes 2 flanges, nuts, bolts, washers and gaskets.
Depending on the location of the leak, a decision must be made as to how
to reconnect the line with the flanges.
The use of a minimum length nipple may be required to install the flange
set.
OPTIONS:
1. Make use of the undamaged pipe by rethreading the ends in the field
allowing for the flange set. Reference the field thread rating chart 2.8.2 of
the Recommended Installation Practices for the proper threading method to
maintain the system pressure rating.
2. If extra pipe is available, replace the damaged joint with a new joint which
can be shortened in the field to make room for the flange set and a minimum
length nipple. The pressure rating of the system can be maintained using
this system on any API 8rd product.
3. Purchase a prefabricated repair joint designed to mechanically replace a full
(9.14 Mtrs. nominal) joint of pipe and make room for a flange set. This
method works for API 8rd.
OPTION ONE PROCEDURE:
Consider the length of the damage. If the width of a set of flanges will repair
the area, a nipple (long enough to repair the damaged area) and a coupling
will be required along with the flange set.
Cut the damaged area of the pipe using a hacksaw, taking into consideration
the total laying length of the parts needed to make the repair.
Depending on how long the damaged area is, an extra joint of pipe may be
required.
Rethread both square cut ends or bell x male adapters.
Page 74 of 76
Figure 1
OPTION TWO PROCEDURE:
Cut the damaged joint using a hacksaw.
Remove both remaining ends using (2) Star metal friction wrenches.
Replace with a new joint of pipe.
Shorten the joint as required to fit the flange set and a minimum length nipple.
Do not cut the pipe in the pipe body, only in the upset area.
Field thread the pipe.
Install the flange set.

Figure 2
OPTION THREE PROCEDURE:
Cut the damaged joint of pipe using a hacksaw.
Remove both remaining ends using (2) Star metal friction wrenches.
Replace the damaged joint with the special length repair joints.
Install the flange set.

Figure 3
Page 75 of 76
Appendix-10 : User Comment Form

User Comment Form
If you find something that is incorrect, ambiguous or could be better in this document, write your comments
and suggestions on this form. Send the form to the Document Control Section (DCS). They make a record of
your comment and send the form to the correct CFDH. The form has spaces for your personal details. This
lets DCS or the CFDH ask you about your comments and tell you about the decision.
Title:
Issue Date:
Specification
Details
Number:
Page Number:
Heading Number:
Figure Number:
Comments:
Suggestions:
Users personal details
Name:
Ref.
Ind.:
Signature:
Date:
Phone:
Document Control Section Actions

Date:
Comment
Number:
CFDH
Ref. Ind.:
Recd.:
CFDH Actions
Recd.
Decision:
Date:
Reject:
Accept, revise at next issue:
Accept, issue temporary amendment
Comments:
Page 76 of 76
To CFDH:
Inits.:
Ref.
Ind.:
Date:

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