12 Practical Aspects

CC Technologies
A DNV COMPANY
“Innovative Solutions”
Practical Aspects of Hot Tap and

Repair Sleeve Welding
Burnthrough Risk Summary

Prevention of Hydrogen Cracking
Welder/Procedure Qualification
Procedure Selection Example
Proper Electrode Handling
Control of Heat Input Levels
Inspection and Testing
THE MATERIALS JOINING EXPERTS
Primary Concerns
INNOVATIVE SOLUTIONS
Repair crew safety

¾ Avoiding “burnthrough” or “blow-out”
Resulting pipeline integrity
¾ Avoiding hydrogen cracking
Pipeline Repair/In-Service Welding – Practical Aspects Slide 2
Pipeline Repair/In-Service Welding Practical Aspects

Ver. 3.1 08/07 ©2007 Edison Welding Institute and CC Technologies, Inc.
Burnthrough Risk Summary
Burnthrough risk is extremely remote if wall thickness is

0.25 in. (6.4 mm) or greater, provided that low-hydrogen
electrodes and normal welding practice is used
Avoid excessively high heat input (e.g., excessively slow
travel speed) when welding onto thin-wall, low flow rate
pipelines
For a given heat input level, the use of smaller diameter
electrodes (lower current levels) is safer
Practical Aspects of Burnthrough Prevention

Measurement of pipe wall thickness

¾ Should be checked using ultrasonic testing equipment
Heat input control
¾ Conventional equipment (i.e., amp meter/tongs, voltmeter,
stopwatch, and linear scale), dedicated arc monitoring equipment,
or the run-out ratio scheme can be used
Have welder demonstrate proper heat input on scrap plate
prior to in-service welding

Avoiding Excessive Heat Input
For a given machine setting (current level), heat input is

high when travel speed is slow
Slow travel speed is required to bridge a large gap between
sleeve and pipe
Proper fit-up will preclude the need for excessively slow
travel speed
Weld metal buttering can be used to reduce gap when
other methods fail
Weld Metal Buttering


Prevention of Hydrogen Cracking
Eliminate at least one of the three conditions necessary for

its occurrence
For additional protection, eliminate more than one
Use properly qualified procedures in terms of:
¾ Hydrogen
¾ Microstructure
¾ Stress
Practical Application
Qualification and selection of procedures

¾ Example
Field welding
¾ Sequence
Control
¾ Control of heat input levels
¾ Preheating methods
Inspection and testing

Welder/Procedure Qualification
Simulate the ability of the in-service pipeline to remove heat

from the pipe wall
Realistic weld cooling rates
Realistic weld solidification characteristics
High pressure flow loops
Water-filled pipe section
Procedure Qualification Set-Up


Procedure Selection Example
Full-encirclement repair sleeve

API 5LX-52
16-in. (406.4-mm) diameter
0.250-in. (6.4-mm) wall thickness
Methane gas at 750 psi (5.17 MPa) and 30 ft/sec (9.14
m/sec) – 186 mmscfd
Low-hydrogen electrodes
Determine Chemical Composition

Mill test reports

In-situ measurement
Laboratory measurement of small sample
Statistical determination
¾ ⇒ Assume CEIIW ~ 0.40

In-situ measurement
Most portable devices are not capable of measuring carbon

content (Atomic No. 6) with sufficient accuracy
The most promising
device appears to be
the Belec Compact Port
Requires use of argon
flushed probe for
carbon analysis
Not widely available
in North America
www.belec.de
Laboratory Analysis of Small Sample

Removal of sample
¾ High-speed rotary file
¾ Free from contamination
¾ Remaining wall thickness no less than nominal thickness minus
API 5L limits (up to 12½%)
Qualified laboratory
¾ Combustion in oxygen
(LECO analyzer) for
Carbon (and Sulfur)
¾ Inductively Coupled Plasma
(ICP) method for other
elements

Statistical Determination – by Grade
Statistical Determination – by Year of

Manufacture INNOVATIVE SOLUTIONS

Statistical Data for TAPS
General Rules of Thumb

Vintage
¾ Modern – lower CE
¾ Older – higher or lower CE depending on grade
Manufacturing method
¾ ERW or SAW – lower CE
¾ Seamless – higher CE
Grade
¾ Higher strength (e.g., X70) – lower CE
¾ Intermediate strength (e.g., X52) – higher CE
¾ Lower strength (e.g., Grade B, X42) – probably lower CE, but may
be down-graded X52
Highest CE – 1950s vintage X52
Many, many exceptions to these rules

Determine Required Parameters
Battelle model
EWI method
PRCI Thermal Analysis Model
EWI Guidelines
Iterative procedure qualification trials
Battelle Model Example

Run cases for a range of heat inputs

¾ 15, 20, 25, 30, 35 kJ/in. (0.6, 0.8, 1.0, 1.2, and 1.4 kJ/mm)
Plot required heat input as a function of 800-500°C weld
cooling time
Determine required heat input for CEIIW ~ 0.40 material
¾ ⇒ 36 kJ/in. (1.4 kJ/mm)
Run additional case for 36 kJ/in. (1.4 kJ/mm) to evaluate
burnthrough risk

Battelle Model Example
EWI Method Example

Measure heat sink capacity

⇒ 28 seconds for methane gas at 750 psi (5.17 MPa) and
30 ft/sec (9.14 m/sec) for 0.250-in. (6.4-mm) wall thickness
Find plot of required heat input as a function of 800-500°C
weld cooling time for 0.250-in. (6.4-mm) wall thickness
Determine required heat input for CEIIW ~ 0.40 material
¾ ⇒ 32 kJ/in. (1.3 kJ/mm)

EWI Method Example
PRCI Model Example

Run cases for a range of heat inputs

¾ 15, 20, 25, 30, 35 kJ/in. (0.6, 0.8, 1.0, 1.2, and 1.4 kJ/mm)
Generate heat input selection curve
¾ Required heat input and HAZ hardness as a function of 800-500°C
weld cooling time
Determine maximum allowable hardness for <4 mm/100gm
and CEIIW ~ 0.40 material
¾ ⇒ 390 HV
Determine required heat input for maximum allowable
hardness (390 HV)
¾ ⇒ 23 kJ/in. (0.90 kJ/mm)

Critical Hardness Criteria
Critical HAZ Hardness vs. CEIIW for In-Service Welds

for Materials with > 0.10% C
450
Low hydrogen - < 4 ml/100
Critical HAZ hardness, HV
Low hydrogen - < 8 ml/100

Cellulosic-coated
400
350
300
250
0.2 0.3 0.4 0.5 0.6
Carbon equivalent, CEIIW
PRCI Model Example – 390 HV


PRCI Model Example – 350 HV
Guideline Example
1.6
1.4
Normalized volumetric flow rate, mmscfd/sq. in.
1.2
Category I -
Fast Cooling
1
15 kJ/in.
0.8 25 kJ/in.
40 kJ/in.
0.6
Category II -
Slow Cooling
0.4
0.2
0
0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5
Wall thickness, in.

Guideline Example
Low Hydrogen
(EXX18-type), What
Cellulosic-coated
GMAW, or electrodes/process
(EXX10-type)
Austenitic will be used?
(E309-type)
Are conditions favorable for Are conditions favorable for

No
hydrogen levels<=4mL/100gm? hydrogen levels <=8ml/100gm?
No
Yes Yes
Use Chart 1 Use Chart 2 Use Chart 3
Guideline Example
Chart 1
What is the wall

<=0.5" >0.5"
thickness?
What is the thermal

severity?
Category I (fast cooling) Category II (slow cooling)
What is the %C? What is the %C? What is the %C?
>0.10% >0.10% >0.10%

<=0.10% <=0.10% <=0.10%
What is the CEIIW? What is the CEIIW? What is the CEIIW?
<=0.35% <=0.42% <=0.50% <=0.35% <=0.42% <=0.50% <=0.35% <=0.42% <=0.50%
Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable Acceptable
procedure procedure procedure procedure procedure procedure procedure procedure procedure procedure procedure procedure
variations: variations: variations: variations: variations: variations: variations: variations: variations: variations: variations: variations:
A A A A A
B B B B B B B B
C C C C C C C E/C E/C E/C E/C
D1/D2 D1/D2 D1/D2 D1/D2 D1/D2 D1/D2 D1/D2 D1/D2 F/D1/D2 F/D1/D2 F/D1/D2 F/D1/D2
See Note 2 See Note 2 See Note 2 See Note 2 See Note 2 See Note 2 See Note 2 See Note 2
Note 1 - Reduce hydrogen level or thermal severity level

Note 2 - If wall thickness is <0.250" check burnthrough risk using Battelle Model.

Summary of Predictive Method Results
Battelle model
¾ 36 kJ/in. (1.4 kJ/mm)
EWI method
¾ 32 kJ/in. (1.3 kJ/mm)
PRCI Thermal Analysis Model – 390 HV
¾ 23 kJ/in. (0.9 kJ/mm)
PRCI Thermal Analysis Model – 350 HV
¾ 34 kJ/in. (1.3 kJ/mm)
EWI Guidelines
¾ 15 kJ/in. (0.6 kJ/mm)
9 Based on empirical data – least conservative
Select Qualified Procedure

Low-hydrogen electrodes
¾ EXX18 type
Covers minimum-required heat input
Qualified to the requirements of the appropriate code under
representative conditions

Field Welding Guidance
Proper electrode handling

Clean and dry pipe surface
Proper fit-up
Proper welding sequence
Monitoring of welding parameters
Hydrogen Level
Cellulosic-coated electrodes (EXX10-type)

Low- hydrogen electrodes (EXX18-type)
¾ Clean
¾ Dry
¾ Freshly-opened box
¾ Electrode holding ovens
¾ Special packaging

Electrode Storage
Stationary Electrode Ovens


Portable Electrode Ovens
Improper Storage

Improper Storage?
Special Packaging

Re-Drying of Low-Hydrogen Electrodes
Requires temperatures in excess of those attainable in

electrode holding ovens
[~650° F (350°C)]
Requires air circulation
(convection oven)
Follow manufacturers
instructions
Usually easier to start
over
Sleeve Fit-Up
Bolted lugs
Jacks and chains
Clamps
Can be used to pre-load sleeve
Not a substitute for pressure reduction (when required)

Jacks, Chains, and Clamps
Bolted Lugs

Jack and Chain
Clamps

Fit-Up on SAW and EFW Pipe
Remove weld reinforcement by grinding

¾ Only if inspected for defects prior to installation or if pressure is
reduced
Grind compensating groove in sleeve
¾ Thicker sleeve required
Use filler on either side of weld reinforcement
¾ Not for use with high force methods of fit-up
Position weld reinforcement in gap created by fillet welded
side strips
Longitudinal Seams
Single-V butt welds

¾ Backing strips
Fillet welded overlapping side strips
Welding procedure
Welding sequence

Backing Strips
Purpose is to prevent penetration into pipe wall

Mild or plain-carbon steel
~ 1/16-in. (1.6-mm) thick
Can be tack
welded to one
half of sleeve
Welding Sequence
Sleeve installation
¾ Thermal contraction of welds can improve sleeve fit
¾ Multiple welders - weld both sides simultaneously
¾ Single welder - alternate sides
Fillet welding
¾ Beads should be deposited
in such a way as to maximize
tempering (even for non-temper-
bead procedures)
9 Stack beads away from the
carrier pipe material
¾ Stringer beads are preferable to wide weave beads
9 Limit weaving to no more than one core wire diameter

Control of Heat Input Levels
Minimum-required or maximum-allowable heat input

Conventional equipment
¾ Amp meter/tongs
¾ Voltmeter
¾ Stopwatch
¾ Linear scale
Dedicated arc
monitoring
equipment
Run-out ratio
scheme
Run-Out Ratio Scheme

Simple method of controlling or measuring heat input levels

No need for measurement of voltage, current or travel
speed
For a given electrode diameter, the ratio of the length of
electrode consumed to the length of weld deposited is
proportional to the heat input
Tables given in BS 5135

Run-Out Ratios
L o w H y d r o g e n (E 7018, E 8018, E 9018)
1.6
1.5
w e ld b e a d le n g th / le n g th o f ro d b u r n e d
1.4
1.3
1.2
1.1
R u n o u t R a tio =
1 3/32"
0.9 1/8"
0.8 5/32"
0.7
0.6
0.5
0.4
0.3
e.g., 6 in. long weld deposited 0.2
using 10 in. of ⅛-in.-diameter 15 17 19 21 23 25 27 29 31 33 35 37 39
electrode => 25 kJ/in. H e a t I n p u t (kJ / in)
Temper Bead Sequence

Buttering
Pass No. 1
Buttering
Pass No. 2
Grinding
Fillet
Pass No. 1
Fillet
Pass No. 2
Fillet
Aprox. 1/16
Pass No. 3
in. (1-2 mm)
weld toe
spacing

Grinding of Buttering Passes
Preheating Methods
Flame
¾ Re-heating interval – welding time prior to reapplication
9 Measure time from maximum-allowable interpass temperature
(e.g., 400-450°F [200-230°C]) to minimum-required preheat
temperature (e.g., 200-250°F [90-120°C])
Electrical resistance
Induction

Preheating Methods
http://www.millerwelds.com/education/articles/story26.html
Fillet Weld Size

Repair Sleeves
Stopple fittings
Compensation for sleeve-end gaps
¾ Increase leg size by amount equal to gap

Inspection and Testing
During welding - monitoring of welding procedure and

welder technique
After welding - nondestructive testing
¾ Surface methods
¾ Volumetric methods
¾ Delay time
Confirmation weld scheme
Nondestructive Testing of In-Service Welds

In-service welds are more likely to contain hydrogen cracks

than other welds
Effective NDT is made difficult by the difficult-to-inspect
geometries associated with these welds
Amount of NDT given to these welds has historically been
minimal
Surface methods
¾ Penetrant testing (PT)
¾ Magnetic particle inspection (MPI)
Volumetric methods
¾ Radiographic testing (RT)
¾ Ultrasonic testing (UT)

Surface Methods
MPI performs significantly better than PT

¾ Some discontinuities may be located slightly below the surface
Particles in wet suspension vs. dry powders
¾ Particles in wet suspension technique is more sensitive
Fluorescent vs. visible (black over white contrast paint)
¾ Both techniques performed
equally well
¾ Choice of optimum technique
depends on illumination
conditions available
Volumetric Methods
UT is a likely better candidate that RT because RT is made

difficult by the complex geometries, gross thickness
changes, and the presence on liquid pipeline products
Effectiveness of UT depends on procedure variables
¾ Method used to set test sensitivity
¾ Choice of probe angles and scanning surfaces
¾ Criteria for evaluating and reporting discontinuities
Effectiveness also depends on operator skill

UT of In-Service Welds
Sleeve fillet welds

¾ Scans should be carried out on both pipe and sleeve surfaces using
at least 45-degree probes, and ideally 70-degree probes also
¾ General tendency to undersize discontinuity length
Branch groove welds
¾ Scanning should be carried out
on both branch and pipe surfaces
¾ Pipe toe cracking discontinuities
are best detected by 45-degree
probe scans on the pipe surface
Delay Time Prior to Inspection

Time required for hydrogen to diffuse to crack-susceptible

areas
Inspection should not occur immediately
¾ 48 to 72 hours (ideally) for some applications
Overnight delay (i.e., 12 hours) is generally sufficient for
pipeline repair welds

Confirmation Weld Scheme
Verify that the welding procedure used to make a hot tap

weld has been appropriate
Make weld onto the portion of the pipeline that will be
removed by the hot-tap cutter
¾ Mock-up of the welded connection must fits geometric constraints of
the hot-tap cutter
Perform mechanical testing and metallography after
removal
Perform chemical analysis of the pipe material
Confirmation Weld Scheme


Confirmation Welds
Coating and Backfill

Apply an effective coating system to prevent subsequent

corrosion
Make sure pipeline is adequately supported to prevent
significant secondary stresses


12 Practical Aspects

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CC Technologies

Practical Aspects of Hot Tap and

Burnthrough Risk Summary

THE MATERIALS JOINING EXPERTS

 Repair crew safety

Pipeline Repair/In-Service Welding – Practical Aspects Slide 2

Pipeline Repair/In-Service Welding Practical Aspects

 Burnthrough risk is extremely remote if wall thickness is

Pipeline Repair/In-Service Welding – Practical Aspects Slide 3

Practical Aspects of Burnthrough Prevention

 Measurement of pipe wall thickness

Pipeline Repair/In-Service Welding – Practical Aspects Slide 4

Pipeline Repair/In-Service Welding Practical Aspects

 For a given machine setting (current level), heat input is

Pipeline Repair/In-Service Welding – Practical Aspects Slide 5

Weld Metal Buttering

Pipeline Repair/In-Service Welding – Practical Aspects Slide 6

Pipeline Repair/In-Service Welding Practical Aspects

 Eliminate at least one of the three conditions necessary for

Pipeline Repair/In-Service Welding – Practical Aspects Slide 7

 Qualification and selection of procedures

Pipeline Repair/In-Service Welding – Practical Aspects Slide 8

Pipeline Repair/In-Service Welding Practical Aspects

 Simulate the ability of the in-service pipeline to remove heat

Pipeline Repair/In-Service Welding – Practical Aspects Slide 9

Procedure Qualification Set-Up

Pipeline Repair/In-Service Welding – Practical Aspects Slide 10

Pipeline Repair/In-Service Welding Practical Aspects

 Full-encirclement repair sleeve

Pipeline Repair/In-Service Welding – Practical Aspects Slide 11

Determine Chemical Composition

 Mill test reports

Pipeline Repair/In-Service Welding – Practical Aspects Slide 12

Pipeline Repair/In-Service Welding Practical Aspects

 Most portable devices are not capable of measuring carbon

Pipeline Repair/In-Service Welding – Practical Aspects Slide 13

Laboratory Analysis of Small Sample

Pipeline Repair/In-Service Welding – Practical Aspects Slide 14

Pipeline Repair/In-Service Welding Practical Aspects

Pipeline Repair/In-Service Welding – Practical Aspects Slide 15

Statistical Determination – by Year of

Pipeline Repair/In-Service Welding – Practical Aspects Slide 16

Pipeline Repair/In-Service Welding Practical Aspects

Pipeline Repair/In-Service Welding – Practical Aspects Slide 17

General Rules of Thumb

Pipeline Repair/In-Service Welding Practical Aspects

Pipeline Repair/In-Service Welding – Practical Aspects Slide 19

Battelle Model Example

 Run cases for a range of heat inputs

Pipeline Repair/In-Service Welding – Practical Aspects Slide 20

Pipeline Repair/In-Service Welding Practical Aspects

Pipeline Repair/In-Service Welding – Practical Aspects Slide 21

EWI Method Example

 Measure heat sink capacity

Pipeline Repair/In-Service Welding – Practical Aspects Slide 22

Pipeline Repair/In-Service Welding Practical Aspects

Pipeline Repair/In-Service Welding – Practical Aspects Slide 23

PRCI Model Example

 Run cases for a range of heat inputs

Pipeline Repair/In-Service Welding – Practical Aspects Slide 24

Pipeline Repair/In-Service Welding Practical Aspects

Critical HAZ Hardness vs. CEIIW for In-Service Welds

Low hydrogen - < 8 ml/100

Pipeline Repair/In-Service Welding – Practical Aspects Slide 25

Repair crew safety

Burnthrough risk is extremely remote if wall thickness is

Measurement of pipe wall thickness

For a given machine setting (current level), heat input is

Eliminate at least one of the three conditions necessary for

Qualification and selection of procedures

Simulate the ability of the in-service pipeline to remove heat

Full-encirclement repair sleeve

Mill test reports

Most portable devices are not capable of measuring carbon

Run cases for a range of heat inputs

Measure heat sink capacity

Run cases for a range of heat inputs

Proper electrode handling

Cellulosic-coated electrodes (EXX10-type)

Requires temperatures in excess of those attainable in

Remove weld reinforcement by grinding

Single-V butt welds

Purpose is to prevent penetration into pipe wall

Minimum-required or maximum-allowable heat input

Simple method of controlling or measuring heat input levels