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Repair Techniques for In Service and Out of Service Buried Pipelines

Technical Report · March 2017

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Repair Techniques for In Service and Out of Service Buried Pipelines

Project Report

Submitted by

AftabJanjua
UCID 10164727

Submitted to
Professor MA Farrokhzad

Department of Mechanical and Manufacturing Engineering

University of Calgary, (UofC)
 Table of Contents
1. Introduction .................................................................................................................................................. 1
2. Buried Pipeline ............................................................................................................................................. 2
3. Defect Categorization ................................................................................................................................... 2
3.1 Defect Location ......................................................................................................................................................... 3
3.2 Defect Severity.......................................................................................................................................................... 3
3.3 Kind of Repair............................................................................................................................................................ 3
4. Repair Techniques ....................................................................................................................................... 4
5. External Repair ............................................................................................................................................ 5
5.1 Grinding .................................................................................................................................................................... 5
5.2 Repair Patch .............................................................................................................................................................. 6
5.3 Full-Encirclement or Reinforcement Sleeves ............................................................................................................ 6
5.4 Composite Wrap ....................................................................................................................................................... 8
5.5 Weld Deposition Repair ............................................................................................................................................ 8
5.6 Mechanical Clamps ................................................................................................................................................... 9
5.7 Replacement ........................................................................................................................................................... 10
5.8 By Pass .................................................................................................................................................................... 11
5.8.1 Hot Tapping......................................................................................................................................................... 11
5.8.2 Tee Connection: .................................................................................................................................................. 12
6. Internal Repair ........................................................................................................................................... 12
6.1 Internal Liners ......................................................................................................................................................... 12
6.2 Sleeves .................................................................................................................................................................... 12
7. Selection of Repair Technique ................................................................................................................... 12
7.1 Pipeline Material..................................................................................................................................................... 13
7.2 Diameter and Thickness of Pipeline ....................................................................................................................... 13
7.3 Pipeline Location..................................................................................................................................................... 13
7.4 Pipeline Configuration ............................................................................................................................................ 13
7.5 Pipeline Operating Conditions ................................................................................................................................ 14
7.6 Pipeline Defects ...................................................................................................................................................... 14
8. Decision Making in Pipeline Repair ............................................................................................................ 14
8.1 Decision Tree Classification .................................................................................................................................... 14
8.2 Decision Rules ......................................................................................................................................................... 16

ii
Summary and Conclusion ................................................................................................................................. 16
References........................................................................................................................................................ 19

iii
 List of Figures

Figure 1 Defect Categorization ............................................................................................................................ 3

Figure 2 Pipeline Repair Techniques .................................................................................................................. 4
Figure 3 Full Reinforcement Sleeves .................................................................................................................. 7
Figure 4 Mechanical Clamps ............................................................................................................................. 10
Figure 5 Replacement Repair Technique classification ..................................................................................... 11
Figure 6 Decision Tree Classification of Repair Techniques ............................................................................. 15

iv
 List of Tables

Table 1 Repair Technique Selection for Defects............................................................................................... 18

Table 2 Properties of Repair Techniques ........................................................................................................ 18

v
 Abbreviations

ILI In Line Inspection

HAZ Heat Affected Zone

HIC Hydrogen Induced Cracking

AER Alberta Energy Regulator

FBE Fusion Bonded Epoxy

vi
 1. Introduction
Pipelines are used to transport gases, semi liquids and liquids from one place to another. Such pipelines
function at high operating temperatures and pressures. These service conditions deteriorate the integrity of
pipelines. Over the length of service, these pipelines undergo defects either due to built-in metallurgical flaws
and welding discontinuities or due to metal loss on interaction with surrounding environment. Additionally, most
of the pipelines designed for service life of up to 30 years are in service after lapse of 40 years. Therefore,
pipelines are continuously monitored for their integrity and any defect discovered is assessed through available
techniques e.g. in line inspection (ILI), hydrostatic testing etc. Any defects found on pipelines are quantified and
repaired to maintain the continuity of operation and avoid major losses incurred due to disruption or pipeline
blast. [1-5]

Canada has third largest oil reserves and exports almost two third of its crudes production to other countries.
There are about 1 million kilometers of pipelines to transport crudes and gases within Canada. Buried pipelines
are considered ideal for this purpose because these are economical, easier and quicker to install, use minimal
land and are considered safe for populated areas. Although, buried pipelines are preferred due to their added
advantages, yet these have huge consequences in terms of metal loss due to external corrosion, un-identified
leaks and soil movements due to snow thaw and dry and wet cycles. [2, 5]

Life cycle costs on pipeline integrity can be attributed to prevention, maintenance and repair costs. Prevention
and appraisal costs considerably reduce unnecessary spending on maintenance and repair. However, pipeline
repair can be reduced but cannot be eliminated through prevention strategy. A repair can be either preventive
or corrective or it can be adaptive and perfective activity. Adaptive repairs are performed to utilize the benefits
of advanced technology and resources e.g. upgradation of asphalt coated pipelines to FBE pipelines whereas
preventive maintenance is concerned with set of activities aimed at avoiding the need for corrective
maintenance by timely implementing preventive strategy and eliminating the root cause of a potential defect
before it occurs. None can deny the importance of continuous improvement in this era where quality
management is given prime importance. Perfective maintenance and repair is outcome of quality audits and
continuous improvements. [13,15,16]

Alberta energy regulator (AER) stresses the need for monitoring of pipelines and eradication of potential defects.
Most of the repairs in pipeline industry are concerned with preventive and corrective maintenance.
Organizations have fault monitoring and assessment measures in place to reduce the possibility of pipeline
incidents. This report will study available repair techniques for in service and out of service buried pipelines. [3]

1
 2. Buried Pipeline
Most of the pipelines used to transport crude oil and gases are buried within the soil due to economic benefits
and safe operation. However, integrity of buried pipelines is under continuous threat due to corrosive
environment, soil stress loading, dry and wet cycles and inadequate techniques to monitor huge lengths of
hidden pipelines. Despite extensive monitoring of pipelines, there exists possibility of potential defects resulting
in unwanted incidents causing monetary and human losses. Buried pipelines suffer internal as well as external
corrosion. Internal corrosion is mainly due to erosion whereas external corrosion can be due to multiple reasons
related to design concerns, bi metallic joins, corrosive environments, hydrogen intake and corrosion fatigue.
These factors are of huge concern for buried pipelines. Corrective and preventive repairs are carried out to
avoid the potential losses incurred due to above discussed concerns faced by buried pipelines. [5]

Pipelines transporting crudes and gases can switch between in service and out of service pipelines. An in
service pipeline is one that is active and functional or is an unused pipeline that transported hazardous liquids in
past but has not been declared as out of service. Whereas, an out of service pipeline is one that is inactive and
has been formally cleaned of hazardous liquids and has been formally declared as out of service. In pipeline
engineering related to transportation of crudes, oil and gas, any pipeline that is inactive for more than thirty
consecutive days is considered out of service. In case, there is major repair required on a pipeline or its
segment, it can be made inactive, repaired and then brought back to service. [6]

Repair methods for pipelines can also be classified on the bases of kind of corrosion. In cases of external
corrosion, there is a wider range of repair and mitigation techniques and designed is flexible to adopt suitable
repair due to ease of application and less complexity involved. However, in case of internal corrosion, there are
limited repair techniques that can be used to repair the defects. Since buried pipelines suffer both kinds of
corrosions, therefore, repair techniques for both kinds of defects are essentially considered for buried pipelines.
In case of internal defects, liner is mostly used to repair. However, if internal defect is accessible and can be
reached by operator, it is possible to use weld or sleeve patch. For external defects, any suitable repair
technique can be used. However, complex contours or inaccessible segments may limit repairing techniques. [7,
12]

3. Defect Categorization
Defect is any abnormality in structure due to environment, welding discontinuities or metallurgical flaws such
that it impairs normal functioning of pipeline. A defect in pipeline can be categorized on the basis of location,
size and kind of repair (see Fig 1). [8-12]

2
 Defects
Categorization

Defect Severity Defect Location Kind of Repair

Severe Internal Temporary

Normal External Permanent

Figure 1 Defect Categorization

3.1 Defect Location

Location of defect is an important parameter in making decision about suitable repair technique. In this regard,
two types of defects in a pipeline segment may occur i.e. internal and external. Wide range of repair techniques
is available for external defects. However, internal defects are mostly repaired using sleeves or liners. [8-,12]

3.2 Defect Severity

Defect severity can be determined based on its size and depth. A leaking defect or deep defect may cause
rupture and must be treated on emergency basis through temporary or permanent repair technique. [8-,12]

3.3 Kind of Repair

There are two basic modes of repair temporary arrangement and permanent repair are available. Temporary
arrangements are used to prepare for permanent arrangement. However, any repair supposed to be for less
than 5 years is considered temporary. Some sever defects required urgent and temporary response to avoid
any mishap. However, these are later treated using suitable permanent technique. [8-,12]

3
 4. Repair Techniques
Buried pipelines can be repaired using variety of repair techniques. In service pipelines require live repair to
avoid any break down of system. However, few techniques require pipelines to be brought out of service e.g.
replacement. Repair techniques are selected depending upon the system requirements. Such requirements can
be listed as under;

1. Where corrosion is source of defect, repair technique must prevent future corrosion along-with repairing
the defect.
2. Defect has reduced the strength of pipeline. Repair must also strengthen the pipeline along-with defect
repair.
3. Defect is leaking and repair must be capable to prevent fluid spillage.
4. Leaking defect has reduced the strength; pipe segment must be strengthened along-with leak repair.

Figure 2 Pipeline Repair Techniques

Although, there is variety of repair techniques available, a broad classification of these methods can be
illustrated as under;

Class A: If an anomaly or defect is found on pipeline surface, if possible, it can be grind. This process will
help in elimination of possible crack initiation
Class B: If it is not possible to grind the pipe, damaged part of pipeline can be reinforced through encircling
sleeve, clamp, composite wrap or placing a patch.

4
Class C: Alternatively, defects can be repaired through weld deposition or welded patch.
Class D: If repair is not possible for the damaged part of pipeline, it can be replaced with new pipe.

When there is no repair technique available to repair a defected segment of pipeline or when pipe is to be
repaired in service, it is possible to replace that segment with new pipeline. This classification is further
elaborated in Fig 2, where class D is not presented wilfully to separate it from other repair techniques. [10]

Pipeline repair activity is dependent upon monitoring and assessment of defects in pipelines. These defects are
identified through monitoring techniques. Once defects are identified, these are assesses, analyzed and
quantified to locate exact location of defected pipeline segment and suitable repair technique.

5. External Repair
External defect of pipeline are mostly accessible, if excavation of buried pipelines is possible. Due to
accessibility and ease of repair, many repair techniques are available that address defect directly. Although,
internal defect can also be repaired using external repair techniques such that defect is not indirectly repaired
externally. [8-12]

External repair techniques are discussed as under;

5.1 Grinding

Grinding is used for repair of service induced defects i.e. welding discontinuities or metallurgical flaws. It
eliminates stress concentration effects by removing excessively hard or soft metal such that pressure sustaining
capacity of pipeline is not compromised. Non-destructive techniques e.g. die penetrant or magnetic flux can be
used to assess the soundness of pipeline. Part of pipeline repaired through grinding does not required welding
if remaining thickness is within minimum allowable thickness. An important consideration during grinding is heat
dissipation to surrounding areas of defect that may sensitize or may impair grain structure of the adjacent
areas. [8-12] Some of the limitations attributed to depot of defected segment of pipeline are mentioned as
under;

1. Grinding is limited up to maximum depth of 40% of nominal wall thickness of defected pipeline.
2. For wall thickness up to 10%, there are no restrictions of length of grinding.
3. Above 10% up to 40% wall thickness, length of ground portion must be within allowable tolerance. If
there is area falling beyond the allowable tolerance, it must be considered as defect and should be
repaired using other techniques.
4. Defect deeper than 40 % of defect must not be ground and other repair techniques must be used.

Important considerations for grinding repair technique are;

5
 1. Micro cracks and stress concentrations can be repair through grinding
2. All repairs must be tested before putting pipe into service
3. Defect depth must be considered before selecting grinding operation
4. Any length of defect that is not within allowable limits must be repaired using other repair techniques

5.2 Repair Patch

Repair patch can be used to repair leaking and non-leaking defects. In case of leaking defects, these are used
to cover the defect by welding a patch on leaking segment. These are incapable to hold high pressures and
should not be used in high pressure pipelines. Non leaking defects can also be repaired using patches. In such
a case, these have design considerations similar to type A sleeves to be discussed later.[8-12] Disadvantages
include;

1. Corroded defect will spread in welded patches too, thus defect failure will not be arrested
2. Too much welding involved will raise issues related to soundness of weld, bimetallic corrosion etc.

5.3 Full-Encirclement or Reinforcement Sleeves

This is widely used method for general repair of damaged pipelines. Such sleeves are further classified into
type A and B sleeves. Although purpose of both types of sleeves is to reinforce the locally corroded area but
these differ in welds on end closures. Type A sleeves have no welded end closures whereas type B sleeves
have welded end closures. Damaged pipelines repaired with full encirclement sleeves can restore strength to
actual SMYS. However, this depends upon skillful design and fabrication of sleeves for damage pipeline. [8-12]

Type A sleeves are applied to the damage pipeline without welding end closures and are easier to install.
These sleeves reinforce the defected portion of the pipe but cannot contain pressure. Such sleeves are only
suitable for non-leaking defects due to their inability to withstand pressures generated by leaking liquids or
gases from pipeline. Normally, a sleeve comprises two halves of curved plates or pipe cylinders and these
halves are welded together after placement around the defected pipeline. Butt or fillet welding can be used to
join both halves. In case of butt welding, each half should be more than circumference of pipe to reduce gap
between halves. This consideration is not required for strip fillet weld. This technique can effective curtail small
defects without structural integrity design considerations. Some disadvantages of type A sleeve are;

1. As, it cannot effectively resist longitudinal stresses therefore cannot be used for circumferential defects.
2. As it cannot contain pressure, therefore, it cannot be used for leaking defects.
3. Due to creation of aeration cells because of spaces between metals, it is prone to crevice corrosion.
4. It cannot be used for defects that require axial strength.

6
 5. It can be used to arrest a defect but cannot prevent defect failure.

Figure 3 Full Reinforcement Sleeves

Type B sleeves also known as pressure contacting sleeves are essentially type A sleeves but have welded end
closures. These sleeves are used to avoid the limitations of type A sleeves. Ends of sleeves are fillet welded to
the pipe. Since welded sleeves can withstand pressures and longitudinal stresses, this helps to repair leaking
and circumferential defects. However, design considerations are important related to structural integrity and
operating pipeline pressure. Butt and seam welding can be used to weld end closures. However, butt weld is
preferred over seam weld due to its ability to withstand higher pressures. Additionally, elimination of spaces
between pipe and sleeve discourages crevice corrosion. Limitations of type B sleeves are;

1. Thickness and material grade of the sleeve should be similar to the base pipeline to avoid galvanic
corrosion.
2. Pressure carrying capacity of the sleeve should be equal the defected pipeline.

Some complex pipeline configurations and contouring applications require special purpose sleeves specifically
customized to repair damaged areas on pipeline. Couplings, girth welds, sleeves on sleeves and curved pipes
are typical examples of special applications. Disadvantages of type B sleeves are,

1. These are welded on the pipeline. Welding may deter integrity of pipeline
2. It may provide axial strength to some extent but will never prevent a defect to fail.
3. Sleeve will be equally affected by corrosion like base pipeline.

7
 5.4 Composite Wrap

With the advancement in technology, an alternative to full reinforcement sleeves emerged as composite
wrap. A composite wrap is a combination of different thermoset materials that provide desired mechanical
and physical properties to repair a pipeline defect. There are two main categories of composite sleeves i.e.
Wet Tape and Pre Fitted composite sleeves. Wet tape sleeves can be fitted and cured on site. This
flexibility makes them ideal for field applications due to ease in use. Secondly, these tapes can easily be
used on complex configurations, flanges, elbows and bends. However, pre fitted composite sleeves are
first moulded and cured and then these are used in field applications. Pre fitted composite sleeves can be
used on straight pipelines and are not considered ideal for bends and elbows. Thus wet tapes are flexible
in use as compared with pre fitted sleeves. Armor plate pipe wrap and techno wrap 2K sleeves are
examples of wet tape composite wraps whereas, clock spring sleeves are pre fitted composite wraps. [8-12]
Added advantages of composite wraps over other repair techniques are;

1. Composite sleeves are preferred due to easy and quick installation and low labour and repair costs
2. A composite wrap restores original strength of pipeline.
3. Composite sleeves withstand pipeline operating pressures as these are wrapped on the pipeline
and back up hold hoop stresses in the pipelines.
4. Composite wraps successfully arrest external corrosion at defect area by acting as coating.
5. Composites suffer aging problems and may require adequate testing before use as sleeves.

Disadvantages of composite wrap include;

1. These cannot be used for leaking defect.

2. These suffer from aging problem at elevated temperatures

Commonly used material for composite sleeves are fiberglass or carbon fiber composite. Since Composite
sleeves must be manufactured and tested according to set of requirements described in CSA Z662 for use
of composite sleeves. [8-12]

5.5 Weld Deposition Repair

Repairing of in service pipelines using weld deposition is a sensitive and safety critical activity and requires
skilled manpower and efficient process control. Weld deposition also known as weld overlay is an
alternative to encirclement sleeves or composite repair technique for in service pipelines. Weld deposition

8
can be successfully performed at difficult to reach and complicated configurations and is far better than
sleeves on contouring pipelines. This factor gives weld deposition supremacy over sleeves in repairing
defects. Weld deposition provides better corrosion and wear resistance than encirclement sleeves and
fiberglass reinforcements regarding galvanic, crevice and fretting corrosion. In weld deposition, such
materials as electrodes are selected for welding that are corrosion resistant and provide better wear
resistance. [8-12]

There are fewer design considerations in weld deposition and skilled workers are easily available. However,
there are few important metallurgical considerations about weld deposition. Firstly, weld deposition
generates heat affected zone that may disrupt grain structure and will cause bi- metallic corrosion.
Secondly, hydrogen absorption into pipeline from atmosphere, welding electrode or surrounding water if
electrode is wet may cause hydrogen induced cracking (HIC). Thirdly, welder’s negligence may cause
leakage if electrode penetrates in the pipeline and causes burn-through if thickness below the heat
affected zone is unable to curtain the pipe operating pressure. [8-12]

Success of weld direct deposition depends upon selection of compatible weld material and suitable
welding method, prevention of buildup of residual stresses in the pipeline, and skillful welding sequence
and weld layering or passes by the operator. Temper bead layering is normally used for weld deposition.
Temper bead weld technique is capable to alleviate heat affected zone hardening and eliminating the need
to use stress relieving after welding. This technique is specifically used for corrosion and wear resistant
steels to evade chromium depletion, path sensitization and hardening of heat affected zone (HAZ). This
technique applies first layer of weld metal by keeping the low heat input such that heat affected zone is not
hardened. In second layering of weld material, heat input is increased to relieve the hardening of first layer.
Successive low and high input of heats help to control hardening of heat affected zone. An operator can
use any of five available kinds of temper bead welds. [8]

5.6 Mechanical Clamps

High integrity pipelines are commonly repaired using mechanical clamps. Mechanical clamps are capable
to hold pipeline pressure and can be used for both leaking and non-leaking defects in pipeline. These
clamps can also be used for on-shore applications. There are two main categories of mechanical clamps
i.e. bolt-on clamps and leak clamps (see Fig 4).

9
Bolt-on clamps are used for leaking and non-leaking defects and permanent repair technique. In case of
leaking defects, bolt-on clamps are used to hold elastomeric seals used as repair patch adjacent to the
defected leaking segment. Such clamps are made thicker for elastomeric seals to hold pipeline pressure at
leaking defects. For non-leaking defects, bolt-on clamps provide desired strength to the defected
segments. Bolt-on clamps are equally useful for axial loads and can be used to repair circumferential
cracks. [8-12]

Figure 4 Mechanical Clamps

Leak clamps are used to repair leaking defects on pipelines. These can also be used to repair corrosion
pits. Bolt-on clamps can be used to transfer loads and avoid crack whereas leak clamps are used to repair
already leaking pipeline segments. Leak clamps are emergency response and are temporary repair
technique. These pipelines are later repaired using other techniques. In leak clamps, locating pins act as
fool proofing guides for seals and clamps are used to hold these seals. Important considerations for leak
clamps are reduction in pipeline pressure until leaking segment is permanently repaired and ensuring that
leaking defect will not cause rupture.

1. Seal degradation results in failure of mechanical clamps

2. Too much bulky compared with the defect and require much of design considerations.

5.7 Replacement

Last but not the least repair strategy is to replace the defected segment. Replacement is only repair
technique that requires pipeline to be out of service during repair. Replacement can be done either by

10
fitting new segment or through by-passing the defect. These are expensive and costly and may hinder live
repair of pipeline. [8-12]

Defected segment of pipeline is removed and replaced with a pre-tested new segment that is welded to in-
service pipeline. Considerations for pipeline replacement are;
1. Pipeline to be repaired must be isolated from the crude or gas transportation network during
replacement. Pipelines can be replaced through freeze plugs or hot tie in repairs.
2. Segment to be replaced must be inspected and tested before and after replacement for soundness
and ability to hold pipeline pressure.

Replacement

New Segment By Pass

Hot Tapping

Tee
Connection

Figure 5 Replacement Repair Technique classification

5.8 By Pass

Instead of replacing the defected segments, it is possible to by- pass the defect whilst pipeline is still in
service. Hot tapping valve and tee connection are two types of by-passing techniques in-practice in oil and
gas industry (see Fig 5).

5.8.1 Hot Tapping

Hot tapping is a by passing technique in which defected segment is replaced through hot tapping valve
and is used to repair in service pipelines.. Customized hot tapping clamps can be designed for on shore

11
and sub-sea applications. Hot tapping clamps are simple than mechanical clamps and can handle
pipelines with larger ovality. There are basic requirements for hot tapping. [8 -12]

1. Pipeline pressure must be reduced prior to inspection and repair by hot tapping.
2. Entire defected portion of the pipeline must be removed and replaced with hot tap valves.

5.8.2 Tee Connection:

Tee connection also termed as grouted tee connection is another by-pass repair technique. A Combination
of tee connections helps to isolate the defected segment and establishes new pipeline segment such that
pipeline is still active and online. Tee connections can also repair leaking defects in addition to by passing
the defect. This repair technique sustains the pipeline pressure by providing it adequate strength and
stiffness. [18, 19]

6. Internal Repair
Internal defects are distinct from external defects. Accessibility of internal defect is important factor in
selection of suitable repair technique. Although, external repair techniques can also be used for internal
repair but such a technique cannot prevent corroding defects. [14] Alternately, specified internal repair
techniques for internal defect repair include;

6.1 Internal Liners

Internal liners are used to repair internal defects impaired due to corrosion. This method necessitates
defected section to be brought out of service. Liners are inserted into defected pipelines. Length of liners is
limitation on repairs. Advantage of liners is that these arrest corrosion, provide strength to pipeline and
prevent axial cracks to some extent. [8, 14]

6.2 Sleeves

If defects are accessible, sleeves or weld patches can be used to repair defects. These techniques are
also discussed in section 5.2 and 5.3. [8, 14]

7. Selection of Repair Technique

Selection of appropriate repair technique depends upon number of parameters [9, 12]. These parameters
include;

1. Pipeline material

12
 2. Diameter and thickness of pipeline
3. Pipeline Location i.e. subsea, buried, onshore etc.
4. Pipeline structural configuration
5. Pipeline operating conditions
6. Defect characteristics

7.1 Pipeline Material

Selection of clamps, full reinforcement sleeves or welds depends upon the strength and grade of pipeline
material. Mechanical properties of pipeline material are used to decide proper repair technique with desired
characteristics. High strength steel cannot be welded and may require clamping, or encirclement sleeves.
[9, 12]

7.2 Diameter and Thickness of Pipeline

Thickness and diameter of pipeline are limiting factors in repair technique selection. There is a restriction
of grinding for a defect less than 40 percent of thickness. Similarly, burn through in weld deposition is
important consideration. Sleeves thickness and composite wrap layering is decided on the basis of
thickness. [9, 12]

Similarly, selection of clamping, encirclement sleeves or composite wrap is dependent upon operating
pressure of pipelines and pipeline operating pressure is dependent upon it diameter.

7.3 Pipeline Location

Sometimes pipelines are located at places that restrict welding or it is not possible to excavate. In such cases
limited options of repair are available. [9, 12]

7.4 Pipeline Configuration

Buried pipelines have additional stress design considerations than those on the ground. Similarly, on-shore and
deep sea applications have different design characteristics. Thus configuration of pipelines is decisive factors in
selection of appropriate repair technique. [9, 12]

13
 7.5 Pipeline Operating Conditions

A repair technique must ensure that pipeline will be able to withstand operating pressure and temperature
conditions. If a composite wrap is used, it must be able to withstand elevated temperatures. Similarly, repair
technique must be able to impart desired strength and stiffness to pipeline. [9, 12]

7.6 Pipeline Defects

Defect repair is strongly dependent upon complete information about the type of defect, its location and
size. Internal defect are treated differently than external defects. Similarly, a leaking defect has different
repair procedure than a non-leaking defect. Additionally, dents, pin holes, pits and welding discontinuities
or metallurgical flaws are treated differently. An axial defect requires strengthen pipeline against
transverse loading and transverse defect requires strengthening pipeline in axial loading. Similarly,
transvers, axial and circumferential defects require different repair techniques. Deeper and longer defects
are more sensitive and require immediate permanent repair whereas smaller defects can be repaired
through patches or grinding. [9, 12]

8. Decision Making in Pipeline Repair

Presently, in pipeline industry, expert judgement in selection of suitable repair technique is considered.
Expert judgment can be replaced by introducing artificial intelligence in decision making. In order to assist
in making decisions to select proper repair techniques, a decision making algorithm, rules or decision tree
can be devised. This may be helpful in automating decision making process. An algorithm developed using
these decision rules and trees can be used to make a window application for decision making using Java.
[8]

8.1 Decision Tree Classification

A model for decision making using decision tree classifications is given in Fig 6. Each node decides
outcome for next level. Decision trees simplify decision making process by providing visual or graphical
explanation of repair technique selection. Similarly, decision trees can be constructed for internal defects.
[8]

14
 Figure 6 Decision Tree Classification of Repair Techniques

15
 8.2 Decision Rules

It is possible to devise certain rules for decision making in pipeline repairs. These rules can also be
inferred from decision tree. If defect is external and depth is less than 40 percent than grinding else if less
than 80 percent than composite wrap else reinforcement sleeve

1. If defect is non-leaking than composite wrap else mechanical clamp or sleeve

2. If defect is non-leaking and operating pressure is high than mechanical clamps or sleeves else if
defect is leaking and pressure is low than leak clamps
3. If defect is internal, non-leaking and accessible than ‘patch’ else ‘liner’
4. If depth of defect is less than 80 percent but more than 40 percent of thickness than ‘sleeves’ or
‘clamps’ or ‘weld deposition’
5. If depth of defect is less than 40 percent of thickness than ‘grinding’
6. If pipeline is in service than all techniques except replacement for external defects

Summary and Conclusion

Pipeline repair techniques intend to bring a defected pipeline segment into service. However, a repair
technique selected might require a pipeline to be out of service for repair. Replacement of defected
segment with new pipe is an example of out of service repair. However, mechanical clamps, sleeves,
composite wraps and weld patches can be used while pipeline is in service. Some applications of these
techniques may require reduction in pipeline allowable pressure to avoid any major loss. Selection of
suitable repair technique depends upon the pipeline and defect characteristics [see Table 1]. Moreover,
desired properties in post repair pipeline also determine suitability of repair technique [see Table 2]. Axial
strength, corrosion prevention, axial, transverse and circumferential crack arrest, and ability to hold
allowable pipeline pressure are properties that are considered before selection of suitable repair technique.
Composite wrap have recently proved their worth in repairing pipelines but these are unable to withstand
axial loads. This lacks their ability to replace mechanical clamps or type B sleeves. Liners are mostly
considered best repair technique for internal repairs. [8-12] A leaking pipeline requires urgent response
and may be initially repaired through temporary arrangements and, later, strengthened using permanent
repair techniques. Replacement is not always possible due to cost involved and losses due to out of
service repair. By-passing techniques have proved to be successful in substituting replacement option for
pipeline repair. [17]

16
Internal defect repairs require pipeline to be out of service during repair. In external repair, it is mandatory
for replacement repair to bring the pipeline out of service. However, it depends upon the situation for other
external repair techniques, whether repair can be done in service or otherwise. However, these processes
support in service or live repair of pipelines.

Pipeline and defect characteristics can be used as input in decision making process with an output of
candidate repair strategies. Decision making process can use decision tree classification, and rules to
generate algorithms that can be automated for intelligent decision making using information technology. [8]

17
 Table 1 Repair Technique Selection for Defects

Defects vs Repair Full Mechanical

Grinding Patch Weld deposition Composite wrap Replacement
Technique Encirclement Clamps
Weld Discontinuity x x x x x x x
Pits x x x x x x x
Dents - - x x x x x
Stress Corrosion Cracking - - type B - - x x
Hydrogen Induced Cracking - - type B - - x x
Pitting Corrosion x - x x x x x

Table 2 Properties of Repair Techniques

Defects vs Repair Full Mechanical

Grinding Patch Weld deposition Composite wrap Replacement
Technique Encirclement Clamps
Axial Strength - - x - - x x
Permanent - - x x x - x
Design Complexity - - - x - x -
Weld Considerations NA x x x NA NA x
Defect
- - - - - - x
Failure Prevention
Field History x x x x x x x
Pipeline Strength - - x x x x x
Leak Repair - - x x - X x
Live Repair x x x x x x -

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 References
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