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1Construction Issues
Northeast Gas Association
Spring Operations
Conference
April 2-3, 2020
Saratoga Hilton
Saratoga Springs, NY
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Safety – Where are you standing?
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Pipe on skids can move and fall.
You want to park where!
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Do you want to be under these
wires or near this equipment?
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Patch Stick Issues• Poor application practices.
• Soil stress can remove poorly installed patch stick
repairs.
• Heating the patch stick and dripping the product on the
coating holiday is not acceptable.
The photo shows a poorly
adhered patch stick repair.
This was found while
uncovering a newly built
pipeline.
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Manufacturer’s procedures for patch stick application
must be followed. The photo shows that a fingernail was
able to scratch off an applied patch stick repair
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Good patch stick application - notice heated/discolored
area around patch, this indicates that the pipe was heated
before and during patch stick application
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Patch Sticks are only for
pinhole or abrasion repair.
2 part epoxy should have
been used.
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Seriously!!!!
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2 part epoxy
• Follow manufacturers instructions
• Preparation required (Sanding = anchor pattern)
• Thoroughly mix product
• Use promptly
• If products starts to cure before application
the repair presents the appearance of the
next slide
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2 Part Epoxy
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Electronic Holiday Detection (Jeeping)
• Visual inspection must supplement jeeping
• Problems identified
– Bent defective spring
– Not identifying and repairing all “jeeps”
– Passing over visible holiday without the jeep sounding
– Based on experience, jeep voltage may need to be set as high as 3500v to detect coating defects
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Are the workmen finding coating holidays? Do the
workmen operating the jeep have time to find and
repair coating holidays?
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A bent jeep spring can miss coating holidays
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Duct tape can shield coating holidays
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• Manipulating
the jeep spring
over building
fiberboard
stuck to the
pipe is poor
practice
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Just jeeping at skids only on lowering in is not
usually per construction procedures
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• Look for
coating
holidays in
the ditch.
• Observing
these
indicates a
problem.
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Thin Film Epoxy Issues
• Insufficient heating (3M procedure specify
425 – 488 degrees F - lower temperatures
could mean improper curing)
• Over heating during application can be a
problem (the coating looks burnt and is
unacceptable)
• Poor sandblasting
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425°F to 488°F
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Gouges and Bending
• Gouges – consult procedures
• Acceptable wall thickness?
• < 1% diameter?
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Proper burial depth on bores?
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Is the pipeline buried deep enough
and protected from erosion?
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High Mechanized Defect Rate
• Causes
• Pipe sizing issues
• Inexperienced welders
• Start up issues
• X-ray or AUT falling behind eliminates
timely feed back. Feed back is a valuable
tool to improve weld quality.
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The welding procedure allows how much high-low?
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High Mechanized Defect Rate
• PHMSA Concerns:
• Having defects not an issue.
• Defect repair, NDT and tracking is an issue.
• Industry experience usually shows
10% defect rate on mechanized welding
7% for semi-automatic welding
5% on manual welding
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Laminations can be an issue especially
associated with an 80% waiver
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AUT, automated ultrasonic testing,
easily shows laminations
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Preheat
• Heating the weld joint before welding
• Temperature of the weld joint immediately
before the arc is struck.
• Procedures state Contact Pyrometer, or
Temperature Indicating Crayon
• Range of preheat values found in the
welding procedure
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Use of Temperature Indicating Crayon
• Temperature indicating crayons (Tempilstik) are specially formulated to melt at a specific temperature.
• On a cold pipe surface upon heating the mark changes color and melts at the specific temperature
• Used on a hot surface the crayon only indicates the temperature is greater than the specified temperature on the crayon if the crayon melts
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Use of Temperature Indicating Crayon
• Applying the crayon on an area adjacent to a weld joint and then heating with a propane torch directed on the mark will give a false temperature indication. In this case the flame heats the crayon mark faster than the pipe. The pipe will not be up to the required temperature.
• The crayon should be used after heating and two different temperature crayons may be necessary to determine the preheat is within the welding procedure.
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Temperature Indicating CrayonsThe crayon holder specifies the melt temperature.
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Preheat
• What should workman do if the weld joint is too cool? (add more
heat)
• What does welder do if the weld joint is too hot? (allow joint to cool)
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Interpass Temperature
• The temperature at a location near the start position of the welding arc(s) recorded immediately before initiating consecutive pass or passes. (from Appendix A)
• Minimum Inter-pass Temperature –generally preheat temperature
• Maximum Inter-pass Temperature –highest temperature allowed to start welding.
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• If the procedure states the Maximum Inter-
pass Temperature is 350 degrees F and
the pipe measures 360 degrees F – What
should welder do before starting to weld?
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Must follow welding procedure
• Some items to check
– Bevel configuration
– Electrodes – rods – filler metals
– Electrical parameters
– Speed of travel
– Weld dimensions
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Welding ProceduresThe procedure states 20 – 40 cfh shielding gas flow
rate. Does the photo show an acceptable value?
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Electrical Characteristics
• Values displayed on welding machines should be within the range of the WPS.
• Machine is not calibrated but usually close.
• If outside procedure use calibrated clamp-on.
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Welding
procedure
required
250°F
preheat
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Band Damage
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Welding Band Damage to Coating
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Inspection Requirements
• Large variation in inspector competency
• What are the inspectors responsibilities?
– Welding inspector must be knowledgeable and
competent
– Verify welding procedure is followed
– Observe
– Document
– Report
– Correct
– Work stoppage
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Seriously???
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Pipe on Solid Rock
Anomaly
Dig
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DCVG Dig on First Phase
Disbonded girth weld
coating – poor surface
preparation
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DCVG Dig
15 Holidays
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DCVG Dig
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DCVG Dig on First Phase – Girth Weld Coating
Mixed with Backfill
Wet Epoxy Mixed
with Backfill
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Protected from rocks in the ditch?
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Pipe Defect – Does remaining wall thickness meet
requirements of API 5L?
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Long Seam Location 195.212
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Grinding Remaining W.T.
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Hydrotest
• Procedures should include provisions for
cold weather testing (if not see next slide)
• Pressures should be maintained at least 8
hours for buried piping. Any pressure
decline should be investigated. A second
pressure test may be warranted. (See
chart of failed test)
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Chart shows pressure loss last 3 ½ hours
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Arc Burns
• Arc burns are not acceptable on high
pressure gas pipelines and liquid
pipelines.
• The following slides show that arc burns
can happen during internal back welding.
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The external weld was completed in the trench box. Then the welder
crawled inside and completed the back weld. This was a transition weld
between 0.740 and 0.486 wall thickness pipe. The welder struck the arc
multiple times inside the pipe and missed the bevel multiple times.
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Lessons Learned• Ineffective Contract Inspection - Much more Operator
Oversight Needed
• Some Jobs – Particularly Coating - are an Issue
• Mechanized Welding can Work Well – However, much
care and attention needed at Startup
• Some Spread Contractors Needed Extra Attention
• The Combination of Poor Inspection and a Contractor
Not Following Procedures Can Lead to Major Problems
• Deadline Urgency from the Operator is an Issue
• Contract Incentives for early completion
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Quiz
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Guess what’s wrong associated
with welder qualifications
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What is wrong with this coated girth
weld?
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What is wrong with this lowered-in
pipe?
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Guess what’s wrong with this?
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Any idea what happened?
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What’s up here? Who’s at fault?
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What is this?
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Anything out of the ordinary?
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What caused this coating damage
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What caused this reoccurring coating
defect?
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What’s up with this thin film epoxy coating ?
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The gauge measures
7/16”. Is this okay?
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Thoughts?
![Page 96: Northeast Gas Association Spring Operations Conference](https://reader034.vdocuments.us/reader034/viewer/2022050302/626ee2fb04c01e4de15fc2c6/html5/thumbnails/96.jpg)
Distribution isn’t left out!!
Guess what it says on the top?
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