PSC Installation & Pipeline Constuction: SECOND END, FIELD PSC INSTALLATION

POSITIVE SEAL COUPLING QA/QC PROCEDURES:

1. The internal surface of each Positive Seal Coupling (PSC) shall be visually inspected for rust, dirt, sand, or any foreign matter. Rust and adhering contaminants shall be removed with a straight die power grinder tool using a circular wire brush. Only if power is not available, then hand wire brushes are allowed. Take extra precaution not to damage the SRG at the coupling’s pipe recess area. Remove any wheel brush debris or any foreign matter with a fine bristle paintbrush inside the coupling.

2. After removal of foreign matter, with the compressed air supply hose from the Jetair Hydraulic Power Unit (HPU), blow the interior of the PSC clean from the inside end.

3. Prior to pipe - PSC insertion, a specially formulated epoxy (HEMPADUR 8554) lubricant/sealant approved by Saudi Aramco (Ref. 02-SAIP-01) shall be applied inside the coupling with a minimum film thickness enough to spread over the required insertion depth and filling-in the serrations. The epoxy serves as a lubricant – preventing metal galling during coupling installation – and cures to form a secondary seal around the pipe end and throughout the PSC-pipe interfacial surface. A spreader made of plastic material can be used to spread the epoxy evenly. The allowable gel time for the epoxy should be observed during PSC insertion. It is not allowed to carry-on with the pipe-PSC insertion once the epoxy started to harden.
a. Use equally volume-sized measuring cups or ladles in preparing the epoxy compound. Ensure 1:1 mixing ratio by volume.
b. Ensure the epoxy components are thoroughly mixed by use of a stir stick or mechanical device inside a mixing bowl before applying the compound to the PSC’s internal surface.

4. After each pipe insertion into a PSC, a PSC Rep shall log on the SECOND END, FIELD PSC INSERTION form the maximum insertion (ram) pressure, the pipe slips pressure, the time of day, check off that a definite “bump-up” was observed or not, and the project cumulative and daily PSC installation counts. For the second end, field PSC make up, the maximum insertion pressure is the ram pressure just before bump up. A PSC Rep should also log any relevant comments in the NOTES column on the SEFPI form, such as when a new kit and quantity of lubricant/sealant is started in use.

5. Any excess epoxy gathered on the external edge of the coupling can be wiped-off with a rag and evenly spread.

6. It is not uncommon for the physical pipeline location of PSCs to differ from the chronological order that they were made up. So at available times during PSC pipeline construction or after construction is completed, walk the pipeline starting with the first PSC and log in the PSC location order for each PSC serial number. This location order number goes in the first column (left) on the subject form. This is important data to know exactly where each particular PSC actually is located.

LINE PIPE QA/QC PROCEDURES:

Refer to the PSC SYSTEM INSTALLATION QA/QC DATA form SECOND END (FIELD) PSC INSTALLATION OPERATIONS PIPE GRADE, SCHEDULE (WALL t),
& END SIZE/PREPARATION CONFORMANCE VERIFICATION IN YARD.

1. Visually check that each first end pipe end has been blast cleaned to nearwhite metal for at least the insertion depth (½ of the PSC length) and that the pipe end bevel corner has been ground off in accordance with Jetair dwg. No. 99-901, Pipe Bevel End Prep. Req. If these pipe end preparations are acceptable, check the appropriate form box relative to the pipe tally number. If any are not acceptable, they must be reblasted or reground.

2. Check the outside diameter (OD) of the 2nd end of each pipe joint along the ROW using the GO and NO-GO inspection rings. The GO and NO-GO rings’ inside diameters (ID) are machined to the line pipe OD tolerances of API 5L, Table 6.3 or to other appropriate line pipe end OD specifications. These over/under OD tolerances are shown on the QA/QC form. The NO-GO ring SHOULD NOT go on the end of the pipe. If it does not, put an acceptance check mark in the appropriate box on the form. If it does go on, then the pipe end is undersized and is rejected. The GO ring SHOULD go on the pipe end. If it does, put an acceptance check mark in the appropriate box on the form. If it does not go on, then the pipe end is oversized and is rejected. Usually, oversized and rejected pipe ends are caused by pipe ovalization. Determine the major oval pipe end axis with the GO ring and then measure this axis with a vernier caliper. Enter this OD value on the form in the appropriate “Rejected OD” column box.

3. When time permits, measure the rejected oversize end with a Pi (p) OD gauge tape to determine the average or “circular” OD and enter this value in the Notes column on the form. Advise the Prime Contractor and Client representative that often, ovalized pipe ends are as such only at and close to the pipe end and that cutting off the ovalized pipe end several inches back from the end may yield a pipe end OD that is within API specifications.

4. Check the wall thickness of each 1st end pipe end with the electronic, ultrasonic thickness meter. The wall thickness tolerances are to the specifications of API 5L, Table 6.3 and are given on the form under NOMINAL WALL. Log the wall thickness for each pipe end in the WALL t column on the form. Any thickness that out of specification causes rejection of that joint of pipe.

5. After a pipe end has passed all of the foregoing inspections, mark the insertion depth line on the outside of the pipe end. The 2nd end, field insertion
depth is determined by measuring the actual depth from the end of the PSC in to the inner face of the SRG. Upon marking the insertion depth line, log this
on the form.

6. Prior to pipe - PSC insertion, a portion from the lubricant/sealant mixture prepared to cover for each PSC and pipe-end combination requirement, shall also be applied at the externally blast-cleaned pipe end surface with a film thickness enough to spread to at least 3/4 of the marked insertion depth. A spreader made of plastic or light tin plate material can be used to spread the epoxy evenly. The allowable gel time for the epoxy should be observed during PSC insertion. It is not allowed to carry-on with the pipe-PSC insertion once the epoxy started to harden.

7. Use fabric slings only to handle the pipe. DO NOT use hooks in either the PSC or pipe ends.

8. The PSC Rep should make any relevant comments in the NOTES column on the form.