Saep 310
Saep 310
Saep 310
1 Scope............................................................. 2
2 Applicable Documents................................... 2
3 Instructions.................................................... 4
1 Scope
This SAEP describes the procedures to be followed for the repair and maintenance of
onshore pipelines, as covered by ASME B31.4 and ASME B31.8. The methods and
procedures set forth herein are minimum requirements and are not a release from the
responsibility for prudent action that circumstances make advisable. Any deviation to
this SAEP requires the approval of the Manager, Consulting Services Department,
Dhahran.
2 Applicable Documents
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Document Responsibility: Piping SAEP-310
Issue Date: 30 November 2005
Next Planned Update: 1 April 2006 Pipeline Repair and Maintenance
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Document Responsibility: Piping SAEP-310
Issue Date: 30 November 2005
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3 Instructions
3.1 Safety
3.1.1.1 The detailed requirements for safe working conditions are too
extensive to cover in this instruction. The job supervisor shall
be familiar with all the safety equipment and existing
procedures applying to work in the vicinity of combustible and
poisonous products, and high energy systems. The following
requirements furnish a reminder to the job supervisor.
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3.1.2.5 Safe Routes of Exit. For excavations over 1219 mm deep, the
sides of the pits and trenches should be sloped back to the
natural repose of the soil to avoid a cave-in. Sides which
cannot be sloped to natural repose shall be shored adequately to
resist earth movement and protect workers. Minimum
requirements for shoring are shown in Std. Dwg. AB-036899.
Saudi Aramco Work Permit Form SA-924-4, "Confined Space
Entry" is required for excavations 4 ft and deeper. Also refer
to the "Saudi Aramco Construction Safety Manual".
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The following conditions are not exempt from the mandatory practices of
this section:
1) Line not cathodically protected.
2) Line section isolated by insulation flanges.
3) Cathodic protection rectifiers and generators shutdown.
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3.1.4.4 Venting & Draining. Balloons or mud packs are only safe
when an adequate means are provided for venting gases to a
place away from the open end of the pipe and monitoring
pressure in the line.
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Document Responsibility: Piping SAEP-310
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Formula No.1
2St(0.35)
Pmax. =
O.D.
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Document Responsibility: Piping SAEP-310
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Where:
Pmax. = MAOP of the pipeline during welding, (psig)
S = Specified minimum yield strength of the pipe, (psi)
t = Minimum measured wall thickness of the weld area, (in)
OD = Outside diameter of the pipe, (in)
Formula No. 2
2S(t − 0.10in.)F
Pmax =
O.D.
Where:
Pmax. = MAOP of the pipeline during welding, (psig)
S = Specified minimum yield strength of the pipe, (psi)
t = Minimum measured wall thickness of the weld area, (in.)
F = Design factor of the pipeline (Refer to SAES-L-003, paragraph
3.2)
OD = Outside diameter of the pipe, (in.)
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Document Responsibility: Piping SAEP-310
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NOTE: The minus 0.10 inch wall thickness takes into account the molten
and heat affected portion of the base metal which does not
contribute to pressure containment.
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3.2.1 Responsibilities
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If the decision is made to take the line out of service, the pipeline
operator at the site will inform the OSPAS Planner and obtain an
operating order to isolate the leak or repair location. If the repair is
sufficiently complex, the appropriate Pipelines Operations Engineering
Unit will draft a recommended procedure for the job.
For a pipeline crack, rupture or any other case which cannot be repaired
by hot tapping, patching or sleeving, the failed section shall be removed
by cold cutting and a replacement section installed. Sections of pipeline
can be removed during scheduled shut-down, or by using Stopples on
lines in operation. Refer to SAEP-315.
3.2.2.1 The repair of cracks, other than their complete removal, shall
be reviewed and approved by Consulting Services Department
(CSD).
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Formula No. 3
ts = tp(4Dp + 1)(SMYSp)/4[(Dp)(SMYSs)-2tp(SMYSp)]
Where:
Dp outside diameter of the pipeline (inches)
Ds outside diameter of the encirclement sleeve
(inches)
tp nominal wall thickness of the pipeline (inches)
ts nominal wall thickness of the encirclement
sleeve (inches)
SMYSp specified minimum yield strength of the
pipeline material (psi)
SMYSs specified minimum yield strength of the sleeve
material (psi)
3.2.4.1 Unless otherwise stated in this SAEP, the limits and disposition
of pipe surface defects shall be as established in ASME B31.4,
paragraph 451.6.2 and ASME B31.8, paragraph 851.4. Refer
also to ASME B31 G, "Manual for Determining the Remaining
Strength of Corroded Pipelines".
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3.2.5.1 Expose the full joint of pipe as well as a portion of the adjacent
joint on each side and determine the extent of the defect
indications. Continue exposing as much pipe as necessary until
the extent of the area with defect indications is determined.
The 15.24 m limit of exposed buried pipe as required in
paragraph 3.1.2.3 shall be observed.
3.2.5.2 Determine the size and depth of the defects with ultrasonic
testing. Ultrasonic indications may mean any of several things,
including on-going cracking, corrosion damage, the presence
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Document Responsibility: Piping SAEP-310
Issue Date: 30 November 2005
Next Planned Update: 1 April 2006 Pipeline Repair and Maintenance
3.2.5.3 The HIC decision tree, (Attachment 1), assesses the severity of
the hydrogen damage and provides recommendation for
corrective action. Assessment may require removal by Hot-
Tapping of coupons for metallurgical analysis. Refer to SAEP-
311. Hydrotesting, monitoring, increased inhibition, sleeving
or replacement of cracked areas may be required. No
corrective action shall be taken without the concurrence of the
Coordinator, Materials Engineering and Corrosion Control
Division, Consulting Services Department.
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Document Responsibility: Piping SAEP-310
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3.2.7.4 To minimize repair time on site, the flanges and the spool piece
should be internally coated prior to transportation to the site.
Remember, all field-applied epoxy paint type coatings require
multiple coats and curing times of up to 7 days before they can
be put into service. Refer to the SAES-H-101V Data Sheets.
3.3 Welding
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Document Responsibility: Piping SAEP-310
Issue Date: 30 November 2005
Next Planned Update: 1 April 2006 Pipeline Repair and Maintenance
Prior to any welding, the following paragraphs shall be reviewed and understood
by all personnel involved with the welding operation. Both the welder and
welding inspector shall be responsible for ensuring that all parameters of the
welding procedure are followed during the entire welding operation.
Compliance and verification by the Responsible Maintenance and Piping &
Valves Unit/M&CED/CSD shall be documented on the "Saudi Aramco Pipeline
Field Welding Checklist", (Attachment 2). Completed checklists shall be kept
on file by the Responsible Maintenance Unit for future reference.
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Document Responsibility: Piping SAEP-310
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3.3.2.3 Prior to fillet girth welding the sleeve to the pipe, a maximum
fit-up gap of 3.2 mm between the two surfaces shall not be
exceeded. If the fit-up gap exceeds 3.2 mm, a weld build-up
(buttering) shall be made at the deficient area to reduce the
distance. Do not start any fillet girth weld or tie-in weld until
the fit-up gap has been reduced to 3.2 mm or less.
3.3.2.4 If girth clamps are used to facilitate the positioning and fit-up
of the sleeves, the welder (s) shall deposit at least 9.6 mm or
25% of the weld thickness, whichever is greater, on both
longitudinal welds before removing the clamps.
3.3.3.3 On sleeve lengths equal to or greater than 1524 mm, both girth
welds may be welded simultaneously. For sleeve lengths less
than 1524 mm, one girth weld shall be completed and allowed
to cool before beginning the other. Refer to Std. Dwg. AB-
036262.
3.3.3.4 All passes on the girth fillet welds shall be in the following
sequence:
1) Weld from the 3:00 to 12:00 o'clock position.
2) Weld from the 6:00 to 9:00 o'clock position.
3) Weld from the 6:00 to 3:00 o'clock position.
4) Weld from the 9:00 to 12:00 o'clock position.
3.3.3.5 The girth fillet welds shall be full sized and blend in smoothly
with the pipe surface.
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Document Responsibility: Piping SAEP-310
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3.3.3.7 In cases where multiple sleeves are used, the adjoining sleeve
ends shall be beveled, before installation, to 37 ± 2½ degrees
without a land. A backing strip, as described in paragraph
3.3.3.2, shall be fit up to avoid fusion to the pipe in the root
gap. The root gap shall be 4.8 ± 1.6 mm. For two adjoining
sleeves, all of the longitudinal welds shall be completed before
the adjoining or either end girth welds are made to the carrier
pipe. The girth welds shall be made in order, from one end
towards the other end. For sections with more than two
adjoining sleeves, each additional sleeve shall be added in
sequence after completing the welds on the previous sleeve.
3.3.4.1 The maximum over-laying gap for all patches shall not exceed
3.2 mm.
3.3.5.1 The maximum electrode diameter for any pass shall be 3.2 mm.
3.3.5.3 The maximum excessive weld build-up above the pipe surface
shall be 1.6 mm. It is preferable to have the build-up flush
with the pipe surface. In any case, the build-up surface shall be
free from discontinuities which will show up during the
Magnetic Particle or Penetrant Testing (MT or PT) post weld
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Document Responsibility: Piping SAEP-310
Issue Date: 30 November 2005
Next Planned Update: 1 April 2006 Pipeline Repair and Maintenance
3.4.1 All welds made for the installation of pipe sleeving or patching for
pressure containment, and for weld metal build-up, shall have a final M.T. or
P.T. inspection.
3.4.2 Other than those welds which have been particularly chosen or randomly
selected in the repair procedure, additional inspection of any type on any
weld may be requested by inspection.
3.5.1 If the decision is made to hydrotest the new repair section(s) prior to
installation into the pipeline, the test pressure and duration shall be as
required for new pipe. Refer SAES-A-004. Duration of the test when
pipe and all welds are accessible shall be only as long as required to
visually inspect the pipe and all welds, but in no case less than 10
minutes.
3.5.2 If the decision is made to hydrotest the new repair section(s) after
installation into the pipeline, the test pressure and duration shall be as
provided in SAES-A-004, paragraph 6.2.5.
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Document Responsibility: Piping SAEP-310
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4) Visually inspect the pipe ends for proper bevel and evidence of no
laminations. Repair as required.
5) Radiograph all butt welds required to install the new pipeline
section and repair defects as required.
3.7.1 When repairs are made due to external corrosion, the appropriate
pipeline cathodic protection units shall determine when and where
supplemental "Hot Spot" cathodic protection will be used.
3.7.3 Anode requirements and installation details are found in Std. Dwgs.
AB-036478, "Magnesium Anode Installation at Pipeline Repair
Locations; Layout, Sections and Details", and AA-036352, "Details of
Installation of Galvanic Anodes for Road and Camel Crossing and
Pipeline Repair Locations".
3.7.4 Anode connections to the pipeline shall be Thermit welded as per Std.
Dwg. AB-036381, "Cathodic Protection; Thermit Welding of Cables to
Buried Pipe lines".
Revision Summary
30 November 2005 Revised the "Next Planned Update". Reaffirmed the contents of the document, and
reissued with no other changes.
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6 1 - 0.03 1 7.5
10 2 - 0.06 2 15
12 3 - 0.08 3 2.5
16 3 2 0.08 3 22.5
20 6 4 0.17 6 45
24 9 5 0.25 9 67.5
30 14 8 0.40 14 105
36 22 13 0.62 22 164.5
40 28 17 0.80 28 209.5
42 33 20 0.93 33 247
48 50 30 0.93 50 374
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3 2-3/4 20 02-958-074
4 3-5/8 18 02-958-078
6 5-1/2 10 02-958-082
8 7-1/2 5 02-958-086
10 9-1/2 3 02-958-090
12 11-1/2 2 02-958-094
NOTE: One pound per square inch gauge (1 psig) is equivalent to a column of water 704 mm (2.31 ft) high.
Table 4
Size Approx. Capacity
(in) (barrel/hr)
1 15 - 30
2 65 - 130
3 145 - 300
4 260 - 500
6 600 - 2000
8 1000 - 4000
EXAMPLE: Consider 609.6 m of 6 in flow line. Contents are approximately 2000/1000 x 6² = 72 barrels. A 2 in drain
should be provided.
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Notes for Attachment 1 – Hydrogen Induced Cracking (HIC) Decision Tree (Cont'd)
a) Once suspected hydrogen induced cracking (HIC) damage is located,it should be surveyed to determine the size and shape
of the damaged area, whether the suspected HIC occurs as small isolated spots or nearly continuous fields, and the depths
at which the suspected HIC is detected. Such surveys are normally conducted using ultrasonic examination.
b) Before assuming that the depth of a defect is less than 0.1 t, the area should be ultrasonically examined from both inside and
outside surfaces, when possible, to insure that additional areas of HIC at different depths are not masked from detection by
the near-surface defect.
c) Hydrogen blistering at mid-wall is a common anifestation of HIC. Such mid-wall blistering produces little strength loss unless
accompanied by Step-Wise Cracking (SWC), in which blisters are several different depths link up at shear steps.
d) Contact the CSD/ME&CCD/Materials Engineering Unit, for appropriate sample locations and for the metallographic
examination to detect SWC.
e) High, sharply crowned blisters may have SWC around the blister periphery which may be difficult to detect with ultrasonic
examination. Sample such areas as in note (d) to check for SWC.
f) Monitoring of items with HIC normally involves regular and frequent ultrasonic examination of the damaged area to determine
whether the HIC is growing or not. If the HIC continues to grow, periodic reassessment through the decision tree will be
necessary. Hydrogen evolution monitoring is used to check the inhibitor effectiveness in pipelines. In general, items with a
history of HIC should also be internally inspected more frequently than similar equipment free of HIC.
g) The inhibitor injection rates required for arresting HIC are much higher than those normally used for suppressing general
corrosion. Contact the CSD/ME&CCD, for specific application details.
h) It is assumed that arresting further HIC in plant piping, which cannot be coated in place and may be difficult to inhibit
effectively, may be uncertain and thus replacement will eventually be required. The urgency of replacement will vary widely
depending on operational circumstances and the extent of HIC damage. Consult the CSD/ME&CCD/MEU.
i) If blistering is extensive, of if SWC is observed, the residual strength of the item is best determined by a hydrostatic test at a
nominal stress of 90% of yield. After revalidation hydrotesting, vessels or cross-country pipelines with HIC may be continued
in service provided further HIC growth is arrested with coatings, inhibitors or both. Intensive monitoring may be required.
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Type of Weld
Line No. ________________ F.W.: ___________________
Butt Weld [ ] Weld Repair [ ]
O.D.: ___________Nom. Wall(1): ________ Grade ________ Sleeve [ ] Patch [ ]
Weld Build-Up [ ] Other [ ] ________
PRE-WELD INSPECTION
Check List Maintenance Sign-Off/Date Inspection Verification/Date
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