Saep 79

Engineering Procedure
SAEP-79 31 October 2019

Subsea Pipeline Repair
Document Responsibility: Offshore Structures Standards Committee
Contents
1 Scope ................................................................ 2
2 Conflicts and Deviations .................................... 2
3 References ........................................................ 2
4 Definitions .......................................................... 4
5 General Requirements ....................................... 5
6 Pipeline Section Replacement ........................... 7
7 Repair Methods and Requirements ................... 8
8 Hyperbaric Welding Procedure Qualification ... 18
9 Subsea Flexibles ............................................. 19
10 Pressure Testing .............................................. 20
11 Coatings........................................................... 21
12 Cathodic Protection ......................................... 21
Revision Summary ............................................... 222
Appendix A - Damage Categorization

and Applicable Repair Methods ................. 23
Appendix B - Pipeline Repair Plan ......................... 24
Previous Issue: 9 May 2019 Next Planned Update: 17 January 2022

Page 1 of 24
Contact: (saleemqx)
©Saudi Aramco 2019. All rights reserved.
Saudi Aramco: Company General Use

Document Responsibility: Offshore Structures Standards Committee SAEP-79
Issue Date: 31 October 2019
Next Planned Update: 17 January 2022 Subsea Pipeline Repair
1 Scope
1.1 This SAEP describes the procedures to be followed for the repair of rigid subsea
pipelines.
1.2 The requirements are primarily for rigid pipelines, however, repair of subsea
flexibles is also discussed in Section 9.
1.3 The repair of offshore platform piping is not within the scope of this procedure
and is covered in SAEP-310.
1.4 The repair method for subsea pipeline shall be based on the most economical
and the most practical method/solution.
1.5 The repair methods and procedures set forth herein are the minimum
requirements and are not a release from the responsibility for prudent action that
circumstances make advisable.
1.6 The repair procedures shall comply with safety management processes outlined
in Company Safety Management System (SMS), Element #5, Asset Integrity.
2 Conflicts and Deviations
2.1 Any conflicts between this document and other applicable Mandatory Saudi
Aramco Engineering Requirements (MSAERs) shall be addressed to the
Engineering Support Department (ESD) Manager.
2.2 Any deviation from the requirements herein shall follow internal company
procedure SAEP-302, Waiver of a Saudi Aramco Engineering Requirement.
3 References
The requirements contained in the following documents apply to the extent specified in
this procedure.
3.1 Saudi Aramco References
Saudi Aramco Engineering Procedures

SAEP-302 Waiver of a Mandatory Saudi Aramco Engineering
Requirement
SAEP-37 Pipelines Residual Magnetism Removal
SAEP-306 Assessment of the Remaining Strength of Corroded
Pipes
©Saudi Aramco 2019. All rights reserved Page 2 of 24

SAEP-310 Piping and Pipeline Repair

SAEP-345 Composite Non-Metallic Repair Systems for
Pipelines and Pipework
Saudi Aramco Engineering Standards

SAES-A-004 General Requirements for Pressure Testing
SAES-H-002 Internal and External Coating for Steel Pipeline and
Piping
SAES-H-004 Protective Coating Selection and Application
Requirements for Offshore Structures and
Facilities
SAES-L-150 Pressure Testing of Piping and Pipelines
SAES-L-850 Design of Submarine Pipelines and Risers
SAES-W-012 Welding Requirements for Pipelines
SAES-X-300 Cathodic Protection of Marine Structures
Saudi Aramco Materials System Specification

01-SAMSS-012 Submarine Pipe Weight Coating
Saudi Aramco General Instructions

GI-0002.100 Work Permit System
GI-0002.102 Pressure Testing Safely
GI-0002.711 Fire and Safety Watch
GI-0006.012 Isolation, Lockout, and Use of Hold Tags
GI-0006.021 Safety Requirements for Abrasive Blast Cleaning
GI-0150.001 Asbestos Regulations
GI-1780.001 Atmosphere-Supplying Respirators
Saudi Aramco Inspection Procedure

00-SAIP-11 In-Service Inspection Requirements of Subsea Assets
Saudi Aramco Manuals
Saudi Aramco Construction Safety Manual
Saudi Aramco Crane Safety Handbook
3.2 Industry Codes and Standards


American Society of Mechanical Engineers

ASME B31.4 Liquid Transportation Systems for Hydrocarbons,
Liquid Petroleum Gas, Anhydrous Ammonia and
Alcohols
ASME B31.8 Gas Transmission and Distribution Piping Systems
ASME B31G Manual for Determining the Remaining Strength of
Corroded Pipelines
ASME SEC IX ASME Boiler and Pressure Vessel Code, Welding
and Brazing
ASME PCC-2 Repair of Pressure Equipment and Piping
American Petroleum Institute

API RP 1111 Design, Construction, Operation, and Maintenance
of Offshore Hydrocarbon Pipelines
API STD 1104 Standard for Welding Pipelines and Related
Facilities
API RP 579 Fitness-for-Service
Det Norske Veritas AS

DNV OS F101 Submarine Pipeline Systems
DNV RP F105 Free Spanning Pipelines
DNV RP F109 On-Bottom Stability Design of Submarine Pipelines
International Standards Organization

ISO 15589-2 Cathodic Protection of Pipeline Transportation
Systems - Part 2: Offshore Pipelines
ISO 24817 Composite Repairs for Pipework - Qualification and
Design, Installation, Testing and Inspection
Industry Practices
IMCA D 014 IMCA International Code of Practice for Offshore
Diving
4 Definitions
Demarcation Point: A point along the onshore portion of the line, established in the
Project Proposal, to mark the location at which the submarine pipeline ends as
referenced in the installation contract.


Free Span: A pipe segment which is not supported by the seabed due to uneven
seabed, pipeline crossings, tie-in to subsea structures, soil scouring, etc.
Pipeline Stabilization: The measures required to stabilize the pipeline on the seabed
during its design life.
Qualitative Risk Assessment: A method for understanding the risk of potential

hazards to an asset.
Subsea Pipelines: All lines used for the transportation of fluids and/or gases, installed
on or below the sea bed between an offshore facility and the demarcation point onshore
or another offshore facility.
Service Provider: The organization responsible for design, qualification, and

installation of the composite repair system.
5 General Requirements
5.1 Any repair methods that are not addressed in this procedure shall be reviewed and
approved by the Offshore Engineering Group of Consulting Services Department.
5.2 The adopted procedure shall ensure safe repair of subsea pipelines.
5.3 Prior to commencing any repair activities, subsea pipeline damage shall be
investigated and assessed considering that the extent of damage can vary from
insignificant to a fully buckled, ruptured or parted pipeline. The extent of
damage shall be classified as per following damage categories:
a) Minor Damage (D1): Damage not resulting in release of hydrocarbons or
water and not requiring repair.
b) Moderate Damage (D2): Damage not resulting in release of hydrocarbons
or water but requiring repair.
c) Major Damage (D3): Damage resulting in release of hydrocarbons or water.
The examples of various damage categories are included in Appendix A.

Major damage can further be classified as either with minor (R1) or major (R2)
release.
5.4 Defect assessment for metal loss shall be conducted in accordance with
SAEP-306. The severity of internal anomalies originating from in line
inspection shall be determined to establish the appropriate damage category.
Similar approach shall be used for wall thickness metal loss resulting from
external corrosion.


5.5 When the pipeline defects are not acceptable as per SAEP-306, pipeline pressure
derating shall be considered. Calculations shall be reviewed by the Offshore
Engineering Group of Consulting Services Department.
Commentary Note:
Pressure reduction provides a minimum level of assurance that the defect or

anomaly will not fail during the course of its examinations and repair.
5.6 Damage types falling under either moderate or major damage categories shall be
repaired as per the requirements of this procedure.
5.7 Subsea pipeline repair methods should be according to Table A-1, Appendix A.
Selection of the repair method should be evaluated based on the economics and
the practicality of the repair methods.
5.8 Pipeline damage/defects that are not addressed in Table A-1 should be reviewed
by the Offshore Engineering Group of Consulting Services Department.
5.9 A risk assessment shall be carried out by the proponent organization. It should
include but not limited to the assessment of defect types and location, design and
operating conditions, geometry, effect of impact and environmental loading.
5.10 Engineering calculations/analyses relevant to a given repair method should be

performed to ensure that the repair is performed in a safe and efficient manner.
5.11 Prior to commencing any repair work, a written procedure meeting all the
requirements outlined in Appendix B shall be developed. The procedure shall
be reviewed by the Offshore Engineering Group of Consulting Services
Department and approved by all parties involved in the repair activities.
5.11.1 The procedure shall comply with GI-0002.100, “Work Permit System,”
GI-0006.012, “Isolation, Lockout, and Use of Hold Tags,” and
GI-0002.711 “Fire and Safety Watch.”
5.11.2 The procedure shall include detailed requirements for safe working
conditions.
5.11.3 Repair shall be performed under qualified supervision by trained

personnel aware of and familiar with hazards to personnel, public, and
environment.
5.11.4 The procedure shall detail the safety measures associated with all
mechanized repair equipment.
5.11.5 The procedure shall include all required data such as pipe diameter, wall
thickness, grade, etc.

5.11.6 All repairs shall be tracked in accordance with Management of Change

Procedure of the operating organization.
5.12 Seabed preparation shall be performed either by jetting out the damaged area or
by excavation in case of hard seabed to locate the damage and to provide
sufficient access at the bottom of the pipeline during repair.
For hyperbaric welding operations, seabed preparations shall also be performed

for areas where welding habitats and pipeline handling frames (if required) will
be installed. Dredging must be of sufficient size and levelness for receiving the
equipment.
5.13 Concrete weight coating shall be removed from the subsea pipeline by water
blaster, sledge hammer or hydraulic jack hammer. Concrete coating removal
process shall be carefully controlled to avoid gouging on the pipeline.
5.14 External corrosion coating such as FBE shall be removed with grit blaster,
3M pads or wire wheel. Grinder shall not be used for the removal of corrosion
protection coating.
5.15 Pipeline shall be flushed/purged prior to cutting for section replacement.

Ultrasonic testing (UT) shall be used to inspect the pipeline to identify suitable
location (having sufficient wall thickness for welding and free of anomalies) for
cutting the pipe. In addition, after cutting the damaged section, pipeline shall be
cleaned internally at the ends.
6 Pipeline Section Replacement
6.1 Pipeline sections with cracks, rupture, severe damage (e.g., caused by dropped
objects) or with defects that cannot be repaired shall be removed or replaced.
6.2 Pipeline section replacement can be performed using any of the following
methods as appropriate:
a) Mechanical connectors
b) Pipeline lifting
c) Hyperbaric dry welding
The detailed requirements for each method are outlined in Section 7.
6.3 Prior to commencing any replacement activities, a procedure for pipeline

isolation and flushing or purging of hydrocarbon shall be developed according
to paragraph 5.11. If isolation plugs are used to isolate the pipeline they shall
provide a double pressure barrier (double block and bleed) to ensure higher
safety of divers performing the subsea work.

6.4 Pipeline cutting shall be performed with mechanical cutters such as diamond
wire, guillotine saw or travel cutter.
An engineering evaluation shall be conducted before performing pipeline cutting

as per paragraph 5.10.
6.5 The new replacement section shall meet the requirements of SAES-L-850 and
01-SAMSS-012.
6.6 The new replacement section shall be protected against internal/external

corrosion as per requirements outlined in SAES-H-002 and SAES-X-300.
6.7 If the pipeline replacement method as outlined in Section 7 requires hyperbaric

welding, the welding procedure shall be qualified according to Section 8.
6.8 For leaking girth welds, pipeline section replacement shall be performed as use
of alternative repair methods is not allowed.
7 Repair Methods and Requirements
7.1 Pipeline Repair Sleeves
7.1.1 Offshore repair sleeve may be used for leaks, severe internal corrosion
defects and for externally damaged pipeline resulting from external
corrosion or mechanical damage such as dents.
7.1.2 The suitability of repair sleeve for a given application shall be assured by
considering all relevant parameters.
7.1.2.1 The design strength (SMYS) of the repair sleeve shall be the
same or greater than the pipeline.
7.1.2.2 The working pressure of the selected sleeve shall be in line

with maximum allowable operating pressure (MAOP) or
design pressure of the pipeline.
7.1.2.3 The repair sleeve used to reinforce the externally damaged

pipeline shall provide the required level of reinforcement.
7.1.2.4 The sleeve design shall allow easier and faster installation
which will reduce the offshore repair time.
7.1.2.5 Hinges shall be provided on the body of the sleeve to help

divers with the installation.


7.1.2.6 For leaking pipeline, a steel or wooden plug shall be installed

prior to installing the repair sleeve.
7.1.3 Conversion of onshore repair sleeve for an offshore application as a

temporary repair can be acceptable provided all the requirements in
below sub-sections are met and reviewed by Offshore Engineering
Group of Consulting Services Department.
7.1.3.1 Vents shall be installed on the sleeve so that there is no

entrapped water inside (which can lead to internal corrosion)
while closing the fitting. Vent sizing and installation shall be
as per supplier’s recommendations. Vent welding procedure
shall be reviewed by Materials Engineering Group of
Consulting Services Department.
7.1.3.2 Marine epoxy coating (paint), plated studs and nuts and
sacrificial anodes shall also be provided to protect against
external corrosion.
7.1.3.3 Hinges shall be provided on the body of the sleeve to help

divers with the installation.
7.1.4 Repair sleeve shall not be used for leaking girth welds of subsea
pipelines.
7.2 Mechanical Connectors/Smart Flanges
7.2.1 Mechanical connectors can be used for pipeline section replacement and
shall be considered as the most preferable option.
7.2.2 For old pipelines having severe/excessive defects, mechanical connectors

shall be used to avoid the risk of further damage/rupture.
7.2.3 The installation of mechanical connectors shall adhere to vendor

recommendations to ensure optimum connector performance.
7.2.4 Swivel ring flanges shall be installed on spool piece (if needed) which
enables the diver to easily align the bolt holes of the swivel flange to the
other fixed flange on the mechanical connector.
7.2.5 Mechanical connectors shall have test ports which can be used to check
main seal integrity.
7.3 Pipeline Lifting


7.3.1 Pipeline section replacement can be carried out by lifting the pipeline to
the vessel provided that there are no severe/excessive defects in the
pipeline. This shall be confirmed based on the findings of the latest
in-line inspection (ILI) and external subsea inspection reports.
7.3.2 Lifting strategy shall be established taking into consideration the pipeline
data, extent of the damage and the pipeline condition during lifting,
e.g., empty or flooded.
7.3.2.1 Lifting the pipeline above sea level and performing the cutting
and repair on the vessel shall be the preferred option, if feasible.
7.3.2.2 Cutting the damaged pipeline section subsea and lifting each of
the pipeline end separately for subsequent repair activities can
also be performed.
7.3.2.3 After cutting the damaged pipeline section, bevel the pipe ends
and perform MPI and measure wall thickness prior to welding.
7.3.2.4 Fit-up the pipeline component (e.g., flanges) to the beveled

pipe ends for welding. Inspect fit-up to ensure root gap is
within welding specification tolerances.
7.3.2.5 Install external clamps for fine tuning the alignment to achieve
the required alignment.
7.3.2.6 Preheat the pipe using propane flame or heating blankets until
temperatures reaches the minimum preheat temperature
specified in the welding procedure specification.
7.3.2.7 If magnetic field greater than 2.0 mT (20 gauss) is detected,

install demagnetization coil onto pipeline and demagnetize
pipeline in accordance with SAEP-37.
7.3.2.8 Perform welding in accordance with the approved welding

procedure specification. Welding procedures and welders shall
be qualified in accordance with SAES-W-012.
7.3.2.9 Upon completion of weld, perform NDE in accordance with

SAES-W-012. If weld is unacceptable, repair shall be carried
out in accordance with SAES-W-012.
7.3.2.10 If completed weld is acceptable, for internally coated pipelines,

internal coating shall be field applied at the flange weld.
7.3.2.11 The flanged pipeline end shall be lowered back to the seabed.

7.3.2.12 The sections 7.3.2.3 to 7.3.2.10 above shall be repeated for the
other end of the pipeline.
7.3.2.13 Perform metrology measurement between the two flange faces.

Fabricate pup piece with flanges at both ends. Install the
fabricated pup piece and connect both flanged ends to the
pipeline by mechanical connection.
7.3.3 For internally coated pipelines, repair by section replacement shall only
be performed by flanged connections.
7.3.4 Pipeline lifting analysis shall be performed to determine the optimum

lifting curve configuration.
7.3.4.1 The capacity and location of lifting davits from stern of the
proposed vessel to be used for pipeline lifting shall be provided.
7.3.4.2 The pipeline dimensional and coatings data considering the

original design as well as current condition shall be considered.
The pipeline stresses during lifting shall be based on actual
remaining wall thickness and davit loads shall be based on
nominal pipe wall thickness.
7.3.4.3 The maximum longitudinal stress in the pipe wall shall be

limited to 80% of the SMYS (Specified Minimum Yield
Stress) during lifting.
7.3.4.4 Local buckling checks as per API RP 1111 and DNV OS F101
shall be performed to confirm that buckling of the pipeline will
not occur for the chosen lifting curve configuration.
7.3.4.5 The loads on the lifting davits shall be within the capacity of
lift davits.
7.3.4.6 Dynamic amplification factor shall be applied on the lifting

loads to account for hydrodynamic wave and current loads.
7.3.4.7 The number and capacity of buoyancy modules required to aid

pipeline lifting shall be specified, if applicable.
7.3.5 Lifting analysis shall be reviewed by Offshore Engineering Group of

Consulting Services Department prior to any repair activities.
7.4 Hyperbaric Dry Welding


Hyperbaric dry welding can be used for pipeline section replacement.

This involves welding in a chamber (habitat) where the water has been displaced
to create a dry environment for welding. The use of semi-dry underwater
welding or wet underwater welding for external welds during subsea pipeline
repairs shall be reviewed by Materials Engineering Group of Consulting
Services Department on a case by case basis.
7.4.1 Prior to hyperbaric welding activities, seabed preparation, rough cutting

of the pipeline damaged section using diamond wire cutter and recovery
of the damaged section to the vessel deck shall be completed as per
sections 4 and 5. Then, perform fine cut and beveling of the pipeline
ends using cutter/lathe or other suitable cutting/beveling machine.
Inspect the bevel profile and measure ovality, wall thickness and the
distance between the beveled pipe ends.
7.4.2 With the bevels completed and accepted, install welding plugs into the
pipeline ends to a distance of at least 500 mm and inflate plug seal.
7.4.3 On the vessel deck, prepare a pup piece with suitable length that will fit
between the pipeline ends, bevel both ends. NDT shall be carried out
on the pup piece prior to cutting and after beveling to ensure the bevel
ends are free of defects.
7.4.4 Install rigging on the pup piece and lower the pup pieces until it is
aligned with both ends of the beveled pipeline subsea. During
alignment, of the two ends, extreme caution should be used to ensure
bevel ends do not touch; which could results in damage to the bevels.
Once alignment is achieved, install temporary bevel protector such as
half shells over the ends.
7.4.5 Deploy habitat onto position over the welding ends, in accordance
with the approved habitat deployment procedures and lifting plan.
Extreme care must be taken to avoid contacting the pipes during
installation and risk damaging the pipe and bevels.
7.4.6 Perform additional dredging for habitat (if required). Do not over
dredge as excessive dredging will require concrete matrasses/sandbag
installation to raise the height of the habitat.
7.4.7 Once habitat is in position, displace (blowdown) water from the habitat.
Install welding and preheat umbilicals according to the habitat system
standard operating procedures.


7.4.8 The temporary bevel protection shall be removed and the welding plugs
shall be inflated. Final alignment shall be made by moving the pipe
ends, until root gap is within welding specification tolerances.
7.4.9 Install external clamps for fine tuning the alignment to achieve the
required alignment.
7.4.10 Install preheat blankets onto pipeline ends and pup piece and install
clamps over blankets to ensure full contact with underlying pipe.
7.4.11 If magnetic field greater than 20 gauss is detected, install

demagnetization coil onto pipeline and pup piece ends to demagnetize
the pipe and pup piece. Connect welding equipment ready to perform
welding.
7.4.12 Perform welding in accordance with the approved welding procedure

specification. Welding procedures for hyperbaric welding shall be
qualified in accordance with Section 7.
7.4.13 All operations including welding shall be monitored by a video system

that can be remotely controlled from the control station and the welding
area shall have continuous communication with the control station.
All relevant data such as welding parameters, preheat and interpass
temperature, etc., shall be monitored and recorded at the surface control
station under supervision by the welding supervisor.
7.4.14 On completion of weld, perform NDE in accordance with SAES-W-012.

If weld is unacceptable, weld repair shall be carried out in accordance
with SAES-W-012.
7.4.15 If completed weld is acceptable, welding habitat shall be tidied up,

tools replaced and contents made ready for recovery to vessel deck.
Umbilicals shall be disconnected. Connect habitat rigging to the crane
and recover habitat to deck.
7.4.16 Perform free span rectification, if any, in accordance with Section 7.7
and recover pipe handling frames (if applicable) to vessel deck.
7.4.17 Deflate welding plug seal then pressurize pipeline to send the welding
plugs to a plug receiving facility such as scraper receiver.
7.5 Composite Repair
7.5.1 Composite repair of subsea applications for both internal and external
corrosion is allowed as temporary repair only. The repair lifetime shall
be specified by the end user.

7.5.1.1 External Corrosion
The initial lifetime is limited to 2 years. If the proponent

intends to extend the lifetime until next shutdown, the new
time frame needs to be considered in the initial repair design
phase. However, the lifetime can be extended maximum up
to 3 more years and total 5 years provided that a proper
assessment was done on the composite repair by the vendor
after 2 years in service and the repair was found with no
anomalies. Regardless, the minimum design lifetime of the
repair shall be 2 years.
7.5.1.2 Internal Corrosion
The lifetime of the repair shall not exceed more than 1 year and
the minimum design lifetime of the repair shall be 2 years.
7.5.2 External Corrosion
7.5.2.1 Composite repair system can be used in subsea pipeline repair

suffering external corrosion provided that further corrosion is
prevented. The repair method is also applicable to external
damage such as minor gouges, fretting or wear.
7.5.2.2 For pipe fittings, such as, tees, reducers and flanges,
composite repair is not allowed. Composite system can be
used to repair bends where the service provider needs to
demonstrate previous track record.
7.5.2.3 Repairs to non-leaking, live piping systems are possible,

provided that the associated hazards are fully considered in
the risk assessment by the proponent and the service provider
agrees and accepts the associated risk.
7.5.2.4 If composite is used to repair gouges, all gouges shall be

removed by grinding. The remaining wall thickness after
gouge removal shall be assessed by the relevant defect
assessment code or Standard to determine the MAOP while
reviewed by the Offshore Engineering Group of Consulting
Services Department.
7.5.3 Internal Corrosion
7.5.3.1 Composite repair can be applied to pipeline suffering from

internal corrosion up to 50% metal loss, provided that a


fitness for service analysis is conducted and reviewed by

Offshore Engineering Group of CSD.
7.5.3.2 Composite system can be used to repair pipeline with internal

corrosion where the service provider needs to demonstrate
previous track record.
7.5.3.3 Repairing of pipe fittings, such as, tees, reducers, bends, and
flanges are not allowed.
7.5.3.4 For components with active internal corrosion the repair

laminate shall be designed based on the assumption through-
wall defect and the corrosion needs to be mitigated.
7.5.4 For pipelines with pinhole leak, composite repairs to live piping systems
are not allowed.
7.5.5 Composite repair is allowed where predicted number of pressure or other

loading cycles; e.g., thermal, is less than 7,000 over the design life.
7.5.6 Composite repair system shall be compatible with internal fluids and
external environments.
7.5.7 Composite repair qualification documentation shall be submitted by the

service provider if the vendors are not approved in the SAP System.
These documents shall be reviewed by CSD Nonmetallic Engineer to
ensure the suitability and compliance with relevant standard. As a
minimum the repair method shall be qualified either per SAEP-345 or
ASME PCC-2 or ISO 24817 while the environmental compatibility test
(subsea environment) from the service provider shall be obtained and
verified.
7.5.8 The service provider shall utilize the similar surface preparation as it
was used during the qualification and it should extend at least over the
whole surface onto which the repair laminate is to be applied.
7.5.9 If the pipeline is derated, either MAOP shall be stated by the

proponent on SIS sheets or calculated according to the requirements of
ASME B31G or API RP 579 and reviewed by Offshore Engineering
Group of Consulting Services Department.
7.5.10 Design of the repair laminate shall be based on two design cases,
i.e., Type A: pipeline not leaking but requires structural reinforcement
only or Type B: pipeline leaking and requires structural reinforcement.
A pipeline shall be considered to be leaking if the wall thickness at any


point of the affected area is determined to be less than 80% of wall

thickness at the end of its life.
7.5.11 Design temperature limit of the repair system shall follow the values
stated in Table 1, where Tg denotes to glass transition temperature and
HDT denotes to heat distortion temperature.
Table 1 - Service Temperature Limits for Repair Systems
Pipeline Leaking (Tm) Pipeline not Leaking (Tm)
Tg can be measured Tg – 30°C (54°F) Tg – 20°C (36°F)
Tg cannot be measured HDT – 20°C (36°F) HDT –15°C (27°F)
7.5.12 For repairs of leaking pipeline, the service provider shall demonstrate
that the repair system is capable of withstanding a low velocity 5 Joule
(44.3 inch-lb) impact. Under high probability of third party damage,
composite repair system shall be safeguarded by using additional wraps
or other methods recommended by the service provider.
7.5.13 The service provider shall demonstrate using a Standard Test

(e.g., ASTM G8) that repair on the steel pipeline is not susceptible to
disbondment under an imposed electrical current.
7.5.14 Design of repair system shall be reviewed by CSD Nonmetallic Engineer

while the system shall adhere to either SAEP-345 or ASME PCC-2 or
ISO 24817. Additionally, the design condition needs to be reviewed by
Offshore Engineering Group of CSD whether or not any lifting or
additional axial load needs to be considered in repair design.
7.5.15 Installation method shall be supplied by the service provider and it

should be reviewed jointly by the area and CSD responsible engineers
while ensuring that the method is properly followed. It should also
include materials storage, health and safety, quality assurance and
qualification of the applicator or installer.
Since the curing time is not long and it varies service provider to
provider, the diver must be properly trained to ensure on-time
completion of the job.
Resin shall be non-toxic and environmental friendly.
7.5.16 Upon completion of repair, the line shall be tested based on new MAOP
meeting the requirements of Section 10.


7.5.17 The repair system shall not impose any barrier to the internal inspection
of steel pipeline. This inspection issue shall be addressed in the design
phase especially in the repairing of the leaks.
7.5.18 The frequency of inspection (visual) should be determined in

accordance with the risk assessment. If defects are located then further
assessment will be required.
7.6 Concrete Mattresses
7.6.1 Concrete weight coating damage or complete loss shall be evaluated in

accordance with DNV RP F109, and if found critical, shall be
compensated by installation of concrete mattresses.
7.6.2 Individual or multiple concrete damage/loss extending along pipeline

length of less than 2 pipe joints (i.e., around 24 m) shall not be repaired.
7.6.3 The number and spacing of concrete mattresses along the pipeline
length shall be reviewed by Offshore Engineering Group of Consulting
Services Department. Concrete mattresses shall not be installed until
approved by Consulting Services Department.
7.6.4 Stacked concrete mattresses can be used to support/rectify free spans

exceeding allowable free span length.
7.6.5 Concrete mattresses shall be installed between the subsea cable, flexible
or umbilical crossing the pipeline and found in contact.
7.7 Subsea Supports
7.7.1 Free spans exceeding the allowable free span length shall be evaluated
prior to being corrected by installing subsea supports such as grout bags.
7.7.2 Local free span assessment shall be performed for each exceeding span
taking into consideration the applicable environmental (wave and
current), soil and effective axial force data at the span location in
accordance with DNV RP F105.
7.7.3 Allowable free span lengths provided in Table 1 and Table 2 of

00-SAIP-11 can be used for initial screening of pipelines for which
allowable span lengths are not available. The free span corrections
shall not be performed based on allowable span lengths provided in
00-SAIP-11.
7.7.4 Free spans corrections shall not be performed until approved by

Consulting Services Department.

7.7.5 Subsea supports at crossings not supporting the pipeline shall be

corrected to provide adequate support to the pipeline.
7.8 Repair couplings shall not be used for subsea pipeline repair due to
misalignment issues and the associated impact on seal performance.
7.9 The use of patches and partial encirclement half sleeves is prohibited for repair
of subsea pipelines.
8 Hyperbaric Welding Procedure Qualification
8.1 Welding procedure qualification shall be carried out under simulated hyperbaric
conditions using equipment and operating procedures similar to those to be used
during production welding.
8.2 Welding procedures and welders shall be qualified according to SAES-W-012.
8.3 Prior to welding, the test-pieces shall be inspected visually to ensure the beveled
edges and joint geometry conforms to the requirements of relevant welding
procedure specification.
8.4 During the welding procedure qualification test, the data in SAES-W-012 and
the following additional data shall be recorded or logged using the appropriate
data sheet, and shall form the basis of the welding procedure qualification
record:
a) Water depth
b) Habitat atmosphere (gas composition – argon, heliox, air or nitrox)
c) Habitat humidity and temperature
d) Joint fit-up and bevel geometry measurements
8.5 The power source and the technical specification for the welding system shall be
equivalent to the one used for production.
8.6 With increasing pressure (e.g., with increasing water depth), the voltage gradient
will increase. Small changes in arc length or operating depth result in
considerable changes in the monitored values of arc voltage. For calculations of
the heat input, the arc voltage shall be recorded at the position/point of welding
during qualification of the welding procedure and the difference between the
values and remote monitored values for use during production welding.
8.7 The essential variables for hyperbaric welding shall be according to

ASME SEC IX and SAES-W-012, with additional essential variables
according to DNV OS F101 Table C-8.


8.8 Completed test welds shall be subjected to 100% Radiography in accordance

with SAES-W-012 requirement. Such examination shall be carried out by
qualified personnel using the approved procedures.
8.9 Mechanical testing for weld procedure qualification shall be carried out in
accordance with ASME SEC IX. Such tests shall be carried out in approved
laboratory.
8.10 Welds within 19 mm or 3 times the wall thickness of the pipe from an existing
girth weld shall be inspected by radiography.
9 Subsea Flexibles
9.1 Damaged subsea flexibles shall not be replaced for their entire length instead
only the damaged section of the flexible shall be repaired. However, damage
spread over a long length or multiple damage location may require full
replacement.
9.2 Moderate Damage (D2)
9.2.1 Subsea flexible with moderate damage, i.e., without leak and with
localized deterioration (lighter cut) of the outer plastic sheath will not
require shutdown or isolation of the line.
If the polymer implant is required either in new installation or in an

already installed line, the repair work must be carried out as per specific
vendor’s recommendations.
9.2.2 If the extent of the damage is of an order of magnitude greater than the
OD of the flexible, then repair by means of offshore sleeve shall be
performed by the divers.
9.2.3 Due to small diameter of flexibles (typically up to 16”) the repair

sleeves are readily available ensuring faster repair.
9.2.4 Seabed preparation and coatings removal are not required for subsea
flexibles resulting in faster installation of repair sleeves.
9.2.5 Subsea flexibles categorized with moderate damage (D2) can be

repaired with/without the presence/involvement of flexible vendor.
9.3 Major Damage (D3)
9.3.1 Subsea flexible with major damage, i.e., release of hydrocarbon or

water will require shutdown and isolation of the line.


9.3.2 The leak location shall be immediately repaired temporarily using a

repair sleeve without waiting for the flexible vendor. This will
eliminate the pollution of environment and marine life.
9.3.3 Depending on the extent of the damage and the successful control of
leak provided by the repair sleeve, production can be restored.
9.3.4 For permanent repair and if the repair sleeve will not hold the leak
completely, the damaged section of the flexible shall be replaced by the
specific flexible vendor. The replaced section shall also be obtained
from the same vendor.
9.3.5 The damaged section of the flexible can be cut subsea and each end can
be lifted separately to the vessel. End fittings can then be installed at
each end and connected with the newly replaced section prior to
lowering it back into the position.
9.3.6 It is the responsibility of the operating department to ensure that the

spare length of flexible and end fittings are available so that the repair
can be performed in a timely and efficient manner.
10 Pressure Testing
10.1 Pressure testing is not required when subsea pipeline repairs are made for the
following scenarios:
a) Offshore repair sleeves installed for severe corrosion anomalies without any
leak.
b) Composite repair made for wall thickness metal loss due to corrosion
without any leak.
c) Concrete mattresses installed to compensate for weight coating loss.
d) Subsea supports installed either for free span corrections or at crossings.
10.2 When offshore repair sleeve/composite repair is used to fix subsea pipeline leak,
the hydrotest shall be according to SAES-A-004 and SAES-L-150.
10.3 If the new replacement section is to be hydrotested prior to installation (more

than one pipe joints welded together), the hydrotest shall be according to
SAES-A-004 and SAES-L-150.
10.4 When the pipeline system with replacement section is to be hydrotested, the test
shall be in full compliance with SAES-A-004 and SAES-L-150.


10.5 When the hydrotest is not practical, full compliance of SAES-A-004 shall be
adhered to along with the following requirements:
a) Verification of the pipe mechanical prosperities through the mill certificate.
b) Visually inspect all mill applied welds of the spiral or longitudinally welded
joint(s) of new pipe prior to installation in the pipeline.
c) Radiograph or ultrasonically check all suspect areas of the manufacturers'
welds found to be defective by visual inspection.
d) Repair all manufacturers weld defects and radiograph repairs to assure
defects are removed.
e) Visually inspect the pipe ends for proper bevel and evidence of no
laminations. Repair as required.
f) Radiograph all butt welds required to install the new pipeline section and
repair defects as required.
g) Provide and approve NDE In-Lieu-of Pressure Test.
11 Coatings
11.1 The selection and application of internal and external coating systems for subsea
pipelines shall be as per SAES-H-002 and SAES-H-004.
11.2 Refer to GI-0006.021, “Safety Requirements for Abrasive Blast Cleaning”,

when preparing pipe surfaces for coating using abrasive blast cleaning.
12 Cathodic Protection
12.1 When repairs are made due to external corrosion, the proponent cathodic
protection unit within the operating organization shall determine when and
where supplemental “Hot Spot” cathodic protection will be provided.
12.2 The design contractor shall collect/use details from previous diver/ROV surveys
about the pipeline to be replaced, including whether the corrosion is external or
internal, the length of the segment to be replaced, condition of the coating, age
of the pipeline, age of the anodes, remaining weight/life of the anodes, design
life of the pipeline and design life of the anodes.
12.3 Based on the data gathered, the operations/design contractor shall prepare a
CP anode replacement/upgrade proposal using ISO 15589-2 as a guideline to be
reviewed and approved by CSD on a case-by-case basis.


Revision Summary
17 January 2017 New Saudi Aramco Engineering Procedure that describes the procedures to be followed for
subsea pipeline repairs.
8 May 2019 Editorial revision as part of content confirmation assessment.
30 October 2019 Editorial revision to revise the Next Planned Update .


Appendix A - Damage Categorization and Applicable Repair Methods
Table A-1 - Subsea Pipeline Repair Methods1

Repair Methods
Damage Offshore Mechanical
Damage Type Pipeline Hyperbaric Composite Concrete Subsea
Category Repair End
Lifting Welding Repair2 Mattresses Supports
Sleeve2 Connector2
Internal Corrosion D2 Yes No No No Yes No No
External Corrosion D2 Yes No No No Yes No No
Dent D2/D3 Yes Yes Yes Yes Yes No No
Crack D2/D3 No Yes Yes Yes No No No
Leak D3 Yes No No No Yes No No
Rupture D3 No Yes Yes Yes No No No
Local Buckle D2 Yes Yes Yes Yes No No No
Global Buckle D2 No Yes Yes Yes No No No
Concrete Coating D2 No No No No No Yes No

Damage or Loss
D3 Yes Yes Yes Yes Yes No No
D2 No No No No No Yes Yes
Free Spans
D3 No Yes Yes Yes No No No
1
This table shall not be used without addressing the repair techniques limitations outlined in this procedure.
2
The repair fittings shall be from an approved source.
3
Pipeline damage/defects that are not addressed Table A-1 above shall be reviewed by the Offshore Engineering Group of
Consulting Services Department to select proper corrective actions.


Appendix B - Pipeline Repair Plan
Operations/Contractor shall develop a plan for subsea pipeline repair which shall be reviewed
by the Offshore Engineering Group of Consulting Services Department and approved by all
parties involved in the repair activities. The plan shall include the followings as minimum
where applicable:
1. Description of pipeline/s to be repaired.
2. Damage category based on subsea survey.
3. Safety considerations/ requirements such as risk assessment, LOTO, JSA, work permits,
use of specialized PPE, etc.
4. Engineering Calculations.
5. Selected repair method along with its justification.
6. Pipeline lifting analysis (applicable for pipeline repair by lifting only).
7. Seabed preparations.
8. Coatings removal method.
9. Pipeline isolation and cleaning procedure.
10. Cutting method (applicable for pipeline section replacement only).
11. Repair fittings.
12. Post-repair testing.


Saep 79

Uploaded by

Copyright:

Available Formats

You might also like

Saep 79

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Saep 79

Uploaded by

Copyright:

Available Formats

Engineering Procedure

SAEP-79 31 October 2019

Appendix A - Damage Categorization

Previous Issue: 9 May 2019 Next Planned Update: 17 January 2022

©Saudi Aramco 2019. All rights reserved.

Saudi Aramco: Company General Use

2 Conflicts and Deviations

3.1 Saudi Aramco References

Saudi Aramco Engineering Procedures

Saudi Aramco: Company General Use

SAEP-310 Piping and Pipeline Repair

Saudi Aramco Engineering Standards

Saudi Aramco Materials System Specification

Saudi Aramco General Instructions

Saudi Aramco Inspection Procedure

Saudi Aramco Manuals

Saudi Aramco Construction Safety Manual

Saudi Aramco Crane Safety Handbook

3.2 Industry Codes and Standards

Saudi Aramco: Company General Use

American Society of Mechanical Engineers

American Petroleum Institute

Det Norske Veritas AS

International Standards Organization

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

Qualitative Risk Assessment: A method for understanding the risk of potential

Service Provider: The organization responsible for design, qualification, and

The examples of various damage categories are included in Appendix A.

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

Pressure reduction provides a minimum level of assurance that the defect or

5.10 Engineering calculations/analyses relevant to a given repair method should be

5.11.3 Repair shall be performed under qualified supervision by trained

Saudi Aramco: Company General Use

5.11.6 All repairs shall be tracked in accordance with Management of Change

For hyperbaric welding operations, seabed preparations shall also be performed

5.15 Pipeline shall be flushed/purged prior to cutting for section replacement.

6 Pipeline Section Replacement

The detailed requirements for each method are outlined in Section 7.

6.3 Prior to commencing any replacement activities, a procedure for pipeline

Saudi Aramco: Company General Use

An engineering evaluation shall be conducted before performing pipeline cutting

6.6 The new replacement section shall be protected against internal/external

6.7 If the pipeline replacement method as outlined in Section 7 requires hyperbaric

7 Repair Methods and Requirements

7.1 Pipeline Repair Sleeves

7.1.2.2 The working pressure of the selected sleeve shall be in line

7.1.2.3 The repair sleeve used to reinforce the externally damaged

7.1.2.5 Hinges shall be provided on the body of the sleeve to help

Saudi Aramco: Company General Use

Saudi Aramco: Company General Use

7.1.2.6 For leaking pipeline, a steel or wooden plug shall be installed

7.1.3 Conversion of onshore repair sleeve for an offshore application as a

7.1.3.1 Vents shall be installed on the sleeve so that there is no

7.1.3.3 Hinges shall be provided on the body of the sleeve to help

7.2 Mechanical Connectors/Smart Flanges

7.2.2 For old pipelines having severe/excessive defects, mechanical connectors