1、Repairing Hazardous Liquid PipelinesAPI RECOMMENDED PRACTICE 2200 FIFTH EDITION, SEPTEMBER 2015Special NotesAPI 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 a
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3、he results of such use, of any information or process disclosed in this publication. Neither API nor any of APIs 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 des
4、iring 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
5、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
6、 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
7、 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 dep
8、ending 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 do
9、cument. Sound business, scientific, engineering, and safety judgment should be used in employing the information contained herein.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,
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11、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, “shal
12、l” 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 ap
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15、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 b
16、y 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, standardsapi.org.iiiContentsPage1 Scope . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Normative References. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Acronyms and Abbreviations . . . . . . . . . . . . . .
18、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Preliminary Knowledge. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.1 Personnel . . . . . . . . . . . . . .
19、. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24.2 Safety Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 Pr
20、e-departure Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21、 . . . . . . . . . . . . . . . 25.2 Preplan Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Site Hazard Assessment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22、 . . . . . . . . . . . . . . . . . . . . . . . . . . 36.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.2 Site Hazard Assessment Procedures . . . . . . . . . . . . . . . . .
23、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36.3 Leak Site Area Assessment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Excavation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57.2 OSHA Construction Stand
25、ard Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Repair Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.1 General R
26、epair Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68.2 Available Repair Methods. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27、. . . 88.3 Safe Repair Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Post-job Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
28、 . . . . . . . . . . . . . . . . . 1010 Special Considerations for Liquefied Petroleum Gas (LPG) or Other Highly Volatile Liquids Pipelines 1110.1 Significant Characteristics and Their Related Problems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1110.2 Precautions .
29、 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Bibliography . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30、. . . . . . . . . . . . . 12v1Repairing Hazardous Liquid Pipelines1 ScopeThis recommended practice (RP) discusses guidelines for safe practices while repairing in-service pipelines for hazardous liquids. Although it is recognized that the conditions of a particular job will necessitate an on-the-job
31、 approach, the observance of the suggestions in this document should improve the probability that repairs will be completed without accidents or injuries.2 Normative ReferencesThe following referenced documents are indispensable for the application of this document. For dated references, only the ed
32、ition cited applies. For undated references, the latest edition of the referenced document (including any amendments) applies.API Standard 1104, Welding of Pipelines and Related FacilitiesASME B31.4 1, Pipeline Transportation Systems for Liquid Hydrocarbons and Other Liquids ASME B31G, Manual for De
33、termining the Remaining Strength of Corroded PipelinesASME Section IX, Boiler and Pressure Vessel CodeASNT SNT-TC-1A 2, Personnel Qualification and Certification in Non-Destructive TestingPRCIPR-218-9307 3, Pipeline Repair Manual3 Acronyms and AbbreviationsFor the purposes of this document, the foll
34、owing acronyms and abbreviations apply.OQ operator qualificationLOTO lockout/tagoutPEL personal exposure limitPPE personal protective equipmentLEL lower explosive limitHVL high volatile liquidsNDT nondestructive testingLPG liquefied petroleum gas1ASME International, 2 Park Avenue, New York, New York
35、 10016-5990, www.asme.org.2American Society for Nondestructive Testing, 1711 Arlingate Lane, P.O. Box 28518, Columbus, Ohio 43228, www.asnt.org.3Pipeline Research Council International, Inc., 1401 Wilson Boulevard, Suite 1101, Arlington, Virginia 22209, www.prci.org.2 API RECOMMENDED PRACTICE 22004
36、Preliminary Knowledge4.1 PersonnelQualified oversight is a prerequisite to the successful implementation of pipeline repair practices. Regulatory requirements for the qualification of pipeline personnel performing repair activities are covered in DOT Regulation 49 CFR 195.501 through 195.509 of Subp
37、art G (Operations and Maintenance). Guidance for the development and implementation of operator qualification (OQ) programs and procedures are given in ASME B31Q, Pipeline Personnel Qualification, and in API 1161, Guidance Document for the Qualification of Liquid Pipeline Personnel. Personnel workin
38、g on pipeline repairs must understand the importance of careful planning to ensure safe and efficient practices and procedures. Employees and contractors should be briefed on-site about specific repairs and safety procedures. Only personnel with the proper training, experience and demonstrated skill
39、s should be allowed to perform pipeline repairs.4.2 Safety Procedures Repair personnel shall have a basic knowledge of safety procedures that includes, but is not limited to, lockout/tagout (LOTO); confined space; workers right-to-know; personal protective equipment; excavation and trenching; fire p
40、revention and protection; emergency response; atmospheric testing devices; hot work; work permitting; respiratory protection; hydrogen sulfide; hearing conservation; first aid; hazardous substances; fall protection; ergonomics; electrical hazards; and abrasive blasting; Regulations to protect worker
41、 safety are covered in OSHA 29 CFR 1910 (operations) and 29 CFR 1926 (construction). The company person or designee with overall responsibility for the repair should review previous testing and repair files to determine the presence or absence of asbestos-containing pipe coatings, lead-based paint,
42、or other substances requiring special attention. If coatings are identified to contain hazardous substances, special work practices designed by the companys health and safety department to mitigate employee exposure should be used. Additional handling and disposal requirements may be specified by lo
43、cal, state, or federal agencies, consult regulations in your area to determine and develop appropriate handling procedures.In addition, the company person or designee with overall responsibility for the repair should be knowledgeable about the most recent Department of Transportation Alert Notices a
44、nd National Transportation Safety Board recommendations related to pipelines as they may pertain to the specific repair situation.5 Pre-departure Practices 5.1 General When piping revisions, replacements, or repairs are needed, the goal is to safely and efficiently complete the work. Work shall incl
45、ude in-service and out of service repairs. To ensure the safe and efficient completion of the repair project, the proper preplanning and groundwork shall be accomplished before any work is done. 5.2 Preplan Procedures The preplan should include the following steps. a) Consult and comply with all app
46、licable laws and regulations. b) Notify “ONE CALL” service, if provided in the area or, if not, contact the owners of the buried facilities directly, giving notice of the work and allowing ample time for other buried facilities to be located and marked. (811 National One Call number.)c) Evaluate rep
47、orted damage and determine if a Safety-related Condition Report should be filed with the Department of Transportation. REPAIRING HAZARDOUS LIQUID PIPELINES 3d) Evaluate reported damage and determine appropriate repair method required to mitigate the condition.e) Develop a written work plan that incl
48、udes the proper repair procedure, drain-down or isolation procedures and appropriate equipment required to complete the repair project safely and efficiently. f) Determine pipeline operating characteristics required during the repair project. Determine if pipeline pressure de-rating and/or shut down
49、 is required to complete the repair project safely. g) Obtain any required permits, including landowner, local government, other regulatory agencies, company general and hot work permits, if required. h) Ensure all tools and safety equipment is in good working order. i) Brief all line repair personnel on the proper safety procedures and preplan requirements. j) Notify personnel at the control center and discuss the line repair plans. Pipeline flow conditions, such as pressure and flow rate at the site of the repair, should be considered prior to the actual initiation of the repair. In s
