125109910 chevron maintenance inspection procedures

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MAINTENANCE AND INSPECTION PROCEDURES Pipe Repair Chevron Pipe Line Company

PIPE REPAIR Procedure Number: MIP-403

COPYRIGHT 2005 Chevron Pipe Line Company. All Rights Reserved

Reviewed/Revised 9/05

MAINTENANCE AND INSPECTION PROCEDURES Pipe Repair Chevron Pipe Line Company

CONTENTS PIPE REPAIR MIP-403Section 1.0 2.0 3.0 4.0 5.0 Title Purpose Scope Prerequisites Process Overview Instructions 5.1 5.2 5.3 5.4 5.5 5.6 5.7 5.8 5.9 5.10 5.11 5.12 5.13 Evaluate and Classify the Extent of the Pipe Defect Select Repair Method Temporary Pipe Repairs Site Safety Plan and Work Over Permits and Notifications Pipe Preparation Patch Installation Mechanical Applied Full Encirclement Sleeves Full Encirclement Sleeve (Full Wrap) Composite Sleeve Document the Repair Backfilling Right-of-Way Clean Up, Restoration and Pipeline Marking Page 403 - 1 403 - 1 403 - 2 403 - 4 403 - 5 403 - 5 403 - 6 403 - 6 403 - 7 403 - 7 403 - 8 403 - 9 403-10 403-12 403-13 403-15 403-15 403-16

COPYRIGHT 2005 Chevron Pipe Line Company. All Rights Reserved

Reviewed/Revised 9/05

MAINTENANCE AND INSPECTION PROCEDURES Pipe Repair

6.0 7.0 8.0 Appendix A B C D

Roles and Responsibilities Reporting Requirements Documentation and Record Retention

403-18 403-17 403-19

Glossary Pipe Defects Pipe Repair Options Fiberglass Composite Repair Details

COPYRIGHT 2005 Chevron Pipe Line Company. All Rights Reserved

Reviewed/Revised 9/05

MAINTENANCE AND INSPECTION PROCEDURES Pipe Repair Chevron Pipe Line Company

1.0

PURPOSEassure pipe repairs are performed safely and properly; and comply with 49 CFR 192 and 195; in Texas, the Texas Railroad Commission, and applicable state pipeline safety regulations.

The purpose of this procedure is to:

2.02.1

SCOPEPersonnel Covered By This Procedure

This procedure applies to all personnel, Company and contractor, who are involved in pipe repairs to regulated pipelines operated and/or maintained by Chevron Pipe Line Company (CPL) or any of the other legal entities managed under the direction of CPL, herein after referred to as "Company".

2.2

Activities Covered By This Procedure

This procedure covers the repair of regulated non-leaking pipelines. Methods covered include: mechanical applied full encirclement installation; welded sleeve or welded full encirclement installation; and composite sleeve installation.

2.32.3.1 2.3.2

Activities Excluded From This ProcedureThis procedure does not cover pipe repair activities for non-regulated gathering facilities or pipelines. This procedure does not cover pipe repair activities mandated by local, state, county, or parish regulations. Refer to the System manual covering the location needing repair. This procedure does not cover repairs to leaking pipelines.

2.3.3

Page 403-1 COPYRIGHT 2005 Chevron Pipe Line Company. All Rights Reserved Reviewed/Revised 9/05

MAINTENANCE AND INSPECTION PROCEDURES Pipe Repair

2.4

References

For a list of reference documents and publications included in 49 CFR 192 and 195, refer to the latest edition of the U.S. Department of Transportation, CFR 49, Pipeline Regulations. References listed in 49 CFR 192 Appendix A and 49 CFR 195.3 include the following: API Specification 5L, "Specification for Line Pipe"; API Standard 1104, "Welding of Pipelines and Related Facilities"; ASME/ANSI B31.4, "Liquid Transportation Systems for Hydrocarbons, Liquid Petroleum Gas, Anhydrous Ammonia, and Alcohols"; and AMSE/ANSI B31.8, "Gas Transmission and Distribution Piping Systems".

3.03.13.1.1

PREREQUISITESPersonnel and Training RequirementsPersonnel performing this procedure must be: a) able to recognize and report pipeline damages or anomalies that warrant pipe repairs; b) Hazwoper trained and certified to level 3 to make pipe repairs; Note: Contractor personnel who will not perform any functions associated with "emergency response" situations are EXEMPT from this prerequisite.

c) capable of implementing pipe repairs in compliance with all regulatory requirements including 49 CFR 192 and 195; d) trained, qualified and experienced in making the specific pipe repairs being implemented; e) knowledgeable of the specific properties, characteristics and potential hazards of the gases or liquids contained in the pipelines requiring pipe repairs; f) qualified per API Standards 1104 for circumferential butt welds and API RP 1107 for in-service maintenance welding;

Page 403-2 COPYRIGHT 2005 Chevron Pipe Line Company. All Rights Reserved Reviewed/Revised 9/05

MAINTENANCE AND INSPECTION PROCEDURES Pipe Repair Chevron Pipe Line Company

g) familiar with the CPL-3 process (MIP-103) for data capture, documentation and reporting; h) knowledgeable and capable of complying with the safety procedures listed in section 3.2; i) trained and competent in the use of personal protective equipment; and j) qualified to perform this task under the CPL Operator Qualification (OQ) plan. 3.1.2 3.1.3 The Person-in-Charge must be Hazwoper trained and certified to Level 3 and/or Level 5. Personnel involved in excavations must be qualified as a "Competent Person." See Appendix A for definitions of Person-in-Charge and Competent Persons.

Note:

3.23.2.1 3.2.2

Safety RequirementsAll pipe repairs must be supervised by a qualified Person-in-Charge who is aware of the hazards and proper procedures for the type of repair being performed. Personnel performing pipe repairs must comply with the following procedures as applicable: a) Confined Space Entry (HES-201) b) Excavation (HES-202) c) Lockout/Tagout (HES-203) d) Hot Work Permits (HES-205) e) Respiratory Protection (HES-502) f) Gas Testing and Analysis (HES-209) g) Safe Handling of Asbestos Containing Material (HES-703) h) Safe Work Permit (HES-204) These and other safety procedures can be found in the HES Procedures manual.

3.2.3 3.2.4

Personnel performing pipe repairs must be fit tested and trained to use respiratory equipment. A job site safety plan must be completed prior to starting pipe repairs.

Page 403-3 COPYRIGHT 2005 Chevron Pipe Line Company. All Rights Reserved Reviewed/Revised 9/05

MAINTENANCE AND INSPECTION PROCEDURES Pipe Repair

3.3

Repair Material Requirements

All repair material must meet the design requirements for the system for which the material is used and be compatible with the product transported in the system.

Page 403-4 COPYRIGHT 2005 Chevron Pipe Line Company. All Rights Reserved Reviewed/Revised 9/05

MAINTENANCE AND INSPECTION PROCEDURES Pipe Repair Chevron Pipe Line Company

4.0

PROCESS OVERVIEWPipe repair needed

Install suitable temporary repair

Evaluate the pipe defect

Select type of permanent repair

Complete site safety plan

Notify appropriate agencies, landowners and one-call systems and obtain any necessary permits

Prepare the pipe for repair

Repair pipe

Document repair

Page 403-5 COPYRIGHT 2005 Chevron Pipe Line Company. All Rights Reserved Reviewed/Revised 9/05

MAINTENANCE AND INSPECTION PROCEDURES Pipe Repair

5.05.1

INSTRUCTIONSEvaluate and Classify the Extent of the Pipe Defect or Damage

When a pipe is determined to be damaged or defective, the Field Team Member performs the following steps: 5.1.1 Evaluate the damaged or defective pipe and classify the extent of the damage/defect (see Appendix A for definitions): 5.1.2 Leaking or non-leaking Severe Superficial Longitudinal extent Deep or shallow

Classify the type of damage or defect: a) b) c) d) e) f) Manufacturing defect Environmental/corrosion Construction caused Damaged by outside force Involves seam or girth weld Involves body of pipe only

5.1.3 5.1.4 5.1.5

Report findings to the Field Team leader. Determine type of repair best suitable for the pipe based on operational limitations, the extent of the damage, and the type of damage. Initiate a CPL-3 per MIP-103 for documentation.

5.25.2.1 5.2.2

Select Repair MethodIf a temporary repair is needed, see Section 5.3. Consult the matrix in Appendix C for an evaluation of permanent pipe repair options. Consider the following criteria before making a permanent repair:

Page 403-6 COPYRIGHT 2005 Chevron Pipe Line Company. All Rights Reserved Reviewed/Revised 9/05

MAINTENANCE AND INSPECTION PROCEDURES Pipe Repair a) b) c) d) e) f) g) 5.2.3 Regulatory compliance requirements; System downtime; Repair materials, labor and downtime costs; Scheduling; Safety; Best method of repair for the specific situation, and; Positive isolation or double block and bleed requirements. Chevron Pipe Line Company

The Asset Integrity Teams Pipeline Integrity Technologist, Technical Services Field Technical Support Representative or other subject matter expert assistance may be needed to select and develop the best repair technique based on: complexity/uniqueness of the repair technique; experience within the Field Team with similar repair techniques; and extent of the damage/defect to the pipeline.

The Field Team leader determines whether technical assistance is necessary, and if so, consults with the appropriate subject matter experts. 5.2.4 If the defect will be removed by hot tapping, refer to the Hot Tapping procedure (for liquids, Appendix 500A in the EPC General Procedures manual and for gas, Section 3.8 of the Core Gas Pipeline O & M manual). If the damaged or defective section of pipe will be replaced, refer to the Pipe Replacement procedure (MIP-404). Any repair method that varies from those listed within this document or that varies from the installation p

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