Repairing Crude Oil, Liquefied Petroleum Gas, and Product Pipelines

API RECOMMENDED PRACTICE 2200 FOURTH EDITION, SEPTEMBER 2010

Repairing Crude Oil, Liquefied Petroleum Gas, and Product Pipelines

Downstream Segment

API RECOMMENDED PRACTICE 2200 FOURTH EDITION, SEPTEMBER 2010

Special Notes

API publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.

Neither API nor any of API's employees, subcontractors, consultants, committees, or other assignees make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any use, or the results of such use, of any information or process disclosed in this publication. Neither API nor any of API's employees, subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights.

API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any authorities having jurisdiction with which this publication may conflict.

API publications are published to facilitate the broad availability of proven, sound engineering and operating practices. These publications are not intended to obviate the need for applying sound engineering judgment regarding when and where these publications should be utilized. The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices.

Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.

Classified areas may vary depending on the location, conditions, equipment, and substances involved in any given situation. Users of this Recommended Practice should consult with the appropriate authorities having jurisdiction.

Users of this Recommended Practice should not rely exclusively on the information contained in this document. Sound business, scientific, engineering, and safety judgment should be used in employing the information contained herein.

API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations to comply with authorities having jurisdiction.

Information concerning safety and health risks and proper precautions with respect to particular materials and conditions should be obtained from the employer, the manufacturer or supplier of that material, or the material safety data sheet.

All rights reserved. No part of this work may be reproduced, translated, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, NW, Washington, DC 20005.

Copyright © 2010 American Petroleum Institute

Foreword

This recommended practice was prepared under the auspices of the API Operations Technical Group (Pipeline). It is intended for use by API member companies and others to develop safe practices for the repair of pipelines in crude oil, liquefied petroleum gas, and product service. The information presented represents a consensus on desirable approaches to repairs.

The use of this recommended practice is entirely voluntary and is intended to apply to repairing of piping used in the transmission of crude petroleum, liquefied petroleum gases, petroleum products and where applicable to other pipeline systems.

This recommended practice represents the combined efforts of many engineers who are responsible for the design, construction and operation of pipelines and the committee appreciatively acknowledges their wholehearted and valuable assistance.

Nothing contained in any API publication is to be construed as granting any right, by implication or otherwise, for the manufacture, sale, or use of any method, apparatus, or product covered by letters patent. Neither should anything contained in the publication be construed as insuring anyone against liability for infringement of letters patent.

Shall: As used in a standard, “shall” denotes a minimum requirement in order to conform to the specification.

Should: As used in a standard, “should” denotes a recommendation or that which is advised but not required in order to conform to the specification.

This document was produced under API standardization procedures that ensure appropriate notification and participation in the developmental process and is designated as an API standard. Questions concerning the interpretation of the content of this publication or comments and questions concerning the procedures under which this publication was developed should be directed in writing to the Director of Standards, American Petroleum Institute, 1220 L Street, NW, Washington, DC 20005. Requests for permission to reproduce or translate all or any part of the material published herein should also be addressed to the director.

Generally, API standards are reviewed and revised, reaffirmed, or withdrawn at least every five years. A one-time extension of up to two years may be added to this review cycle. Status of the publication can be ascertained from the API Standards Department, telephone (202) 682-8000. A catalog of API publications and materials is published annually by API, 1220 L Street, NW, Washington, DC 20005.

Suggested revisions are invited and should be submitted to the Standards Department, API, 1220 L Street, NW, Washington, DC 20005, standards@api.org.

iii

Contents

Page

1. Scope 1

2. Normative References 1

3. Preliminary Knowledge 2

   1. Personnel 2

   2. Safety Procedures 2

4. Pre-departure Practices 2

   1. General 2

   2. Preplan Procedures 2

5. Site Hazard Assessment 3

   1. General 3

   2. Site Hazard Assessment Procedures 4

   3. Leak Site Area Assessment Procedures 4

6. Excavation 5

   1. General 5

   2. OSHA Construction Standard Checklist 5

7. Repair Practices 6

   1. General Repair Procedures 6

   2. Available Repair Methods 8

   3. Safe Repair Steps 8

8. Post-job Practices 10

9. Special Considerations for Liquefied Petroleum Gas (LPG)

   or Other Highly Volatile Liquids Pipelines 10

   1. Significant Characteristics and Their Related Problems 10

   2. Precautions 11

v

Repairing Crude Oil, Liquefied Petroleum Gas, and Product Pipelines

1. Scope

   This recommended practice (RP) discusses guidelines to safe practices while repairing in-service pipelines for crude oil, liquefied petroleum gas, highly volatile liquids and product service. Although it is recognized that the conditions of a particular job will necessitate an on-the-job approach, the observance of the suggestions in this document should improve the probability that repairs will be completed without accidents or injuries.

   
   

2. Normative References

The following referenced documents are indispensable for the application of this document. For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.

API Standard 1104, Welding of Pipelines and Related Facilities

API Recommended Practice 1117, Movement of In-Service Pipelines

API Standard 1160, Managing System Integrity of Hazardous Liquid Pipelines

API Publication 1161, Guidance Document for the Qualification of Liquid Pipeline Personnel

API Recommended Practice 1166, Excavation Monitoring and Observation

API Recommended Practice 2009, Safe Welding, Cutting, and Other Hot Work Practices in the Petroleum and Petrochemical Industries

API Recommended Practice 2201, Safe Hot Tapping Practices in the Petroleum and Petrochemical Industries

ASME B31.4 1, Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids

ASME B31G, Manual for Determining the Remaining Strength of Corroded Pipelines

ASME B31Q, Pipeline Personnel Qualification

ASME PCC-2, Repair of Pressure Equipment and Piping

ASME Sec IX, Boiler and Pressure Vessel Code

ASNT SNT-TC-1A 2, Personnel Qualification and Certification in Non-Destructive Testing

DOT Regulations 3, Title 49 Code of Federal Regulations Part 195: Transportation of Hazardous Liquids by Pipeline

OSHA Regulations 4, Title 29 Code of Federal Regulations Part 1910 and Part 1926

PRCI PR-218-9307 5, Pipeline Repair Manual

1. ASME International (formerly American Society of Mechanical Engineers), 3 Park Avenue, New York, New York 10016-5990, www.asme.org.

2. American Society for Nondestructive Testing, 1711 Arlingate Lane, P.O. Box 28518, Columbus, Ohio 43228, www.asnt.org.

3. Department of Transportation. The Code of Federal Regulations is available from the U.S. Government Printing Office, Washington, D.C. 20402. www.gpoaccess.gov

4. U.S. Department of Labor, Occupational Safety and Health Administration, 200 Constitution Avenue, NW, Washington, DC 20210, www.osha.gov.

1