Piping Repair Case Study

48 Loading Line Permanent

Welded Repair

J onathan Brindley - Doosan Babcock
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48 Loading Line - Permanent Welded Repair
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Presentation Objectives

Demonstrate that a total solution delivered from one
contractor for integrity management through to
implementation makes sense
Educate that robust repair procedures save time,
money, and mitigate risk
Project Management
1 2 3
4
5
6
Process Elements
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Overview

Doosan Babcock approached by North Sea Oil and Gas Exploration and
Production company to assess a site repair.

Engineering investigation determined the repair could only be classed as
temporary

Alternative repair options presented.

Client selected welded sleeve repair.

Full EPC service provided by Doosan Babcock
Sleeve design
Weld procedure development
Site implementation





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Location

Storage and Processing Terminal.

Nominal Oil Process Capacity 375,000
Standard Barrels per Day

Oil storage capacity of 3.5m Barrels

Oil exported via single point mooring or jetty

Export J etty Line: Export Capacity: 80,000
Barrels per Hour

Responsible for over 40% of UK crude exports


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External Corrosion:
Routine inspection identified severe localised
external corrosion and pitting on main oil export
loading line.

The pipe was not fit for purpose; with an
immediate repair or replacement required to
continue operation.

Loss of availability of export loading line would of
cost the operator approx. $160 million per month
$40 million per week.






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Immediate Requirement
It was not possible to descale the worst
affected area due to the risk of a break in
containment. A fillet welded patch was installed
to contain the worst affected area.

A review of the repair was carried out to assess
suitability of use on other areas of corrosion.

Doosan Babcock contracted due to expertise
and experience of working with pipework
system issues and knowledge of current repair
codes and guidelines.





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Assessment of pre-existing patch repairs and areas of
external wall thinning

Stress analysis carried out using traditional hand calculations
and finite element analysis (FEA). Hand calculations allowed
maximum working pressures to be specified while FEA was
undertaken.

FFS Assessment utilised relevant codes, standards and
guidelines:
API579-1 / ASME FFS 2007 Fitness For Service (American
Petroleum Institute)
PD5500:2006 Specification for Unfired Fusion Welded Pressure
Vessels (British Standards Institute)
ASME B31.3 Process Piping Design (American Society of
Mechanical Engineers)
ASME PCC-2 Repair of Pressure Equipment & Piping
OTO 038/2001 Temporary/permanent pipe repair Guidelines
(Health & Safety Executive)

1. Fitness For Service (FFS) Assessment
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By studying the deformed shape of a patched pipe it is seen
that the patch causes a localised stiffening effect to the
shape of the pipe. This localised stiffening, in addition to the
bending moments resulting from the pipe and contents
weight, causes the pipe to distort it in such a way to induce
tension in the root of the weld.

Maximum working pressure of loading line limited due to
welded patch repair.

Repair codes do not recommend patch repairs for general
wall loss only localised making fillet welded patched
unsuitable for other defect areas.
Fitness For Service (FFS) Assessment Conclusions
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Fitness For Service (FFS) Assessment Conclusions
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Welded and composite repair options investigated
and presented to client.

Full encapsulation sleeve repairs with injected
grout filler chosen as most appropriate repair
Sleeve designed in accordance with substrate
design code ASME B31.3
Repair designed in accordance with guidance in
ASME PCC-2-2006 (Repair of Pressure
Equipment & Piping).

Full assurance engineering package provided to
client:
Static Stress Analysis of client pipe with addition
of repair sleeve weight.
Fatigue assessment due to cyclic operation of
loading line.
Buckling load calculations (Determine maximum
sleeve annulus integrity pressure test).
Brittle fracture assessment.


2. Permanent Repair Design & Assurance Engineering
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3 & 4. Weld Procedure Development & Qualification Tools
Plant Integrity
Technology
Risk assessment determined safest
condition for welding sleeve to substrate
was with loading line water filled no flow
condition.

Weld Procedure Specifications (WPS)
provided by Doosan Babcock Welding
Engineers

Weld designed with minimal pre-heat and no
post-weld heat treatment required due to
large internal volume of water at ambient
temperature.

Supplementary assurance testing in line
with API 1104 Appendix B In Service
Welding developed to support weld
Procedure Qualification Report (PQR).

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Bespoke measurement instrumentation
manufactured to capture outer diameter
(OD) and pipe ovality information during site
survey.

Each sleeve bespoke manufactured by
Service Technology fabricators utilising site
survey information to minimise fitting time on
site. Sleeves designed to encompass
existing patch repairs.

Doosan Babcock Construction department
provided site implementation team:
Welding Supervisor
Fitting Supervisor
Welders
Pipe Fitters

Sleeve welds non-destructively examined,
sleeve annulus pressure tested then injected
with polymeric grout to complete repair.

5 & 6. Sleeve Fabrication & Site Implementation
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Presentation Conclusions

A total solution delivered from one contractor for
integrity management through to implementation
makes sense
Robust repair procedures save time, money, and
mitigate risk
Project Management
1 2 3
4
5
6
Process Elements
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Customer Feedback







the design and assessment work you carried out for us was significant in achieving this end and we look forward
to working with you in future on these and other types of projects.
UK Operational Integrity Manager

and agree that this has been a significant piece of work completed within the schedule and within estimates. A
large effort has been put into the design work, project organisation and site implementation with no accidents or
incidents. Many thanks.
Onshore Operation Co-ordinator



A final thought from HSE Research Report RR509: Plant Ageing: Management of
Equipment Containing Hazardous Fluids or Pressure

Temporary repairs are often a source of trouble, they may very easily
become permanent even if not suitable for long term service. There is
also a risk that such repairs are done in a hurry, without full
assessment of implications.
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Questions