Composite Wrap Lessons Learned from Natural Gas STAR EPA’s Natural Gas STAR Program, Pioneer...

Composite WrapComposite WrapLessons Learned Lessons Learned

from Natural Gas STARfrom Natural Gas STAR

EPA’s Natural Gas STAR Program,EPA’s Natural Gas STAR Program,

Pioneer Natural Resources USA, Inc., andPioneer Natural Resources USA, Inc., and

The Gas Processors AssociationThe Gas Processors Association

June 17, 2003June 17, 2003

Reducing Emissions, Increasing Efficiency, Maximizing Profits

Composite WrapComposite Wrap

Permanent On-Line Permanent On-Line Pipeline Repair Pipeline Repair

TechnologyTechnology

Source: Armor Plate


Methane LossesMethane Losses Technology DescriptionTechnology Description Methane RecoveryMethane Recovery Is Recovery Profitable?Is Recovery Profitable? Industry ExperienceIndustry Experience Discussion QuestionsDiscussion Questions



Use of 30 wrap Use of 30 wrap repairs versus line repairs versus line replacements could replacements could save 70,000 Mcf/yr save 70,000 Mcf/yr netting almost netting almost $130,000 in savings$130,000 in savings

Repairs with pipeline Repairs with pipeline in service average 2 in service average 2 days versus 5-7 days days versus 5-7 days for typical cut & weld for typical cut & weld pipe replacementspipe replacements


A QUICK & SAFE WAY to improve profitability &

AVOID VENTING METHANE!


Before January Before January 1313thth, 2000, 2000 repair repair methods were methods were restricted to restricted to replacement, or use replacement, or use of full encirclement of full encirclement steel sleeves steel sleeves welded in placewelded in place

And nowAnd now the steel the steel sleeve requirement sleeve requirement is amended to allow is amended to allow composite wrap composite wrap sleevessleeves



1.1. A high strength glass A high strength glass fiber composite or fiber composite or laminatelaminate

2.2. An adhesive or resin An adhesive or resin bonding systembonding system

3.3. A high-compressive-A high-compressive-strength load transfer strength load transfer filler compoundfiller compound

Composite WrapComposite WrapWhat Are They?What Are They?

Source: Clock Spring® Company L. P.


Composite WrapComposite WrapWhen to UseWhen to Use

Pipeline defects must be carefully analyzedPipeline defects must be carefully analyzed Follow industry standards: ASME B31G or Follow industry standards: ASME B31G or

RSTRENG (modified B31G)RSTRENG (modified B31G) Composite wrap vendors typically supply Composite wrap vendors typically supply

defect analysis and repair reporting softwaredefect analysis and repair reporting software Permanent repair for Permanent repair for

external, non-leaking external, non-leaking defectsdefects

Source: Armor Plate


Composite WrapComposite WrapSoftwareSoftware

Software will determine:Software will determine: if a repair is neededif a repair is needed if a composite wrap is suitableif a composite wrap is suitable or if a pipe replacement is requiredor if a pipe replacement is required

Defects up to 80% loss wall thickness can Defects up to 80% loss wall thickness can be repaired with composite wrap be repaired with composite wrap

There may be pressure and temperature There may be pressure and temperature restrictions on composite wraprestrictions on composite wrap


Composite WrapComposite WrapInstallation HistoryInstallation History

Tested extensivelyTested extensively Used commercially since 2000Used commercially since 2000 Many partner reported experiencesMany partner reported experiences In USA: 15 wraps butted side-by-In USA: 15 wraps butted side-by-

side have been used to repair lines side have been used to repair lines 16-30” in diameter and 800-900 psi16-30” in diameter and 800-900 psi

In Guatemala: 37 side-by-side In Guatemala: 37 side-by-side composite wrap sleeves have been composite wrap sleeves have been usedused

In USA: 22,000 sq. ft. applied in 9 In USA: 22,000 sq. ft. applied in 9 daysdays


Composite WrapComposite WrapInstallationInstallation

After excavation and pipe After excavation and pipe preparationpreparation

External defects are filled with External defects are filled with fillerfiller

Composite wrap wound around Composite wrap wound around pipe with adhesive or laminating pipe with adhesive or laminating agentsagents

Typically 2” of wrap must extend Typically 2” of wrap must extend beyond damagebeyond damage

After mandated drying or curing After mandated drying or curing time, excavation site refilledtime, excavation site refilled

While lines can be repaired at While lines can be repaired at full pressure, reducing pressure full pressure, reducing pressure improves quality of repairimproves quality of repair

Source: Armor Plate


Composite WrapComposite WrapEconomics & Environmental BenefitsEconomics & Environmental Benefits Quicker and less Quicker and less

expensiveexpensive Continuous pipeline Continuous pipeline

operationoperation No methane ventedNo methane vented Trained personnel Trained personnel

required versus required versus skilled laborskilled labor

Install at full line Install at full line pressure(reduced pressure(reduced pressure is pressure is recommended)recommended)

Installation takes Installation takes about 30 minutes; about 30 minutes; curing about 2 curing about 2 hourshours

Site access & Site access & preparation issues preparation issues minimizedminimized


Composite WrapComposite WrapDecision ProcessDecision Process

1.1. Determine suitability of composite wrap Determine suitability of composite wrap technique for repair optiontechnique for repair option

2.2. Calculate cost for composite wrap and Calculate cost for composite wrap and consider other benefits of on-line repairconsider other benefits of on-line repair

3.3. Estimate methane savingsEstimate methane savings

4.4. Calculate avoided costs of line replacementCalculate avoided costs of line replacement

5.5. Evaluate economicsEvaluate economics


Composite WrapComposite WrapStep1: Determine Suitable ApplicationStep1: Determine Suitable Application

Evaluate nature of defect and causal factorsEvaluate nature of defect and causal factors Evaluate operational needs and job site Evaluate operational needs and job site

factorsfactors Follow industry standards, such as ASME, Follow industry standards, such as ASME,

and your company engineering policies and and your company engineering policies and proceduresprocedures


Composite WrapComposite WrapStep 2: Cost of Wrap RepairStep 2: Cost of Wrap Repair

GIVEN: 6” non-leaking defect in 24” line @ 350 psiGIVEN: 6” non-leaking defect in 24” line @ 350 psi

Estimate: 16 hours to repairEstimate: 16 hours to repair

Cost of labor: Field Labor: 3 @$30/hr Cost of labor: Field Labor: 3 @$30/hr = $1,440 = $1,440 Eng Mgmt: 25% of $1,440 = $ 360Eng Mgmt: 25% of $1,440 = $ 360

Cost of Equipment: Wrap KitCost of Equipment: Wrap Kit = $ 900 = $ 900Backhoe & SandblasterBackhoe & Sandblaster = $ 750 = $ 750

Other: Permits/Inspection/MiscOther: Permits/Inspection/Misc = $1,650 = $1,650


Composite WrapComposite WrapStep 3: Estimate Methane SavingsStep 3: Estimate Methane Savings

Methane Savings = Emissions avoided from line replacementMethane Savings = Emissions avoided from line replacement

Volume of methane(Mcf) = (DVolume of methane(Mcf) = (D22*P*(L/1,000)*0.372)/1,000*P*(L/1,000)*0.372)/1,000 = 24*24*350(52,800/1,000)*0.372/1,000= 24*24*350(52,800/1,000)*0.372/1,000

= 3,960 Mcf @ $3/Mcf= 3,960 Mcf @ $3/Mcf

= $11,900= $11,900

Note: for 10 miles between block valves


Composite WrapComposite WrapStep 4: Calculate Purge Gas SavingsStep 4: Calculate Purge Gas Savings

Purge Gas saved = Purge Gas used during line replacementPurge Gas saved = Purge Gas used during line replacement

Volume of Purge Gas = [3.14*DVolume of Purge Gas = [3.14*D22*L/(4*144*1,000)]*1.2*L/(4*144*1,000)]*1.2 = [3.14*24*24*52,800/(4*144*1,000)]*1.2= [3.14*24*24*52,800/(4*144*1,000)]*1.2

= 200 Mcf @ $4/Mcf of nitrogen= 200 Mcf @ $4/Mcf of nitrogen

= $800= $800

Note: for 10 miles between block valves, assuming 20% wastage


Composite WrapComposite WrapStep 4(cont’d): Replacement Line CostStep 4(cont’d): Replacement Line Cost Given: 6” non-leaking defect in 24” line @ 350psiGiven: 6” non-leaking defect in 24” line @ 350psi

Assume: replace 6’ of line (3 times pipe diameter)Assume: replace 6’ of line (3 times pipe diameter)

Estimate: 40 hours to repairEstimate: 40 hours to repair

Cost of labor: Field labor: 4 @$30/hrCost of labor: Field labor: 4 @$30/hr = $4,800 = $4,800Eng Mgmt: 25% of $4,800 = $1,200Eng Mgmt: 25% of $4,800 = $1,200

Cost of Equipment: 6’ pipe @ $50/ftCost of Equipment: 6’ pipe @ $50/ft = $ 300 = $ 300 Backhoe, Welder & Crane = $3,700Backhoe, Welder & Crane = $3,700

Other: Permits/Inspection/MiscOther: Permits/Inspection/Misc = $4,500 = $4,500


Composite WrapComposite WrapStep 5: Evaluate the EconomicsStep 5: Evaluate the Economics

24” Line @ 350 psi

6” Defect

10 miles between shut off valves

Composite Wrap - $

Line Replacement - $

Methane Savings 11,900 none

Purge Gas 0 800

Labor 1,800 6,000

Equipment & Materials 1,650 4,000

Other 1,650 4,500

Total Cost of Repairs 5,100 15,300

Pay Back IMMEDIATE!!

INTANGIBLES:INTANGIBLES:

•SafetySafety

•Environmental Environmental impactsimpacts

•Site accessSite access

•Service Service interruptioninterruption


Composite WrapComposite WrapPartner ExperiencePartner Experience

300+ wraps on 10” or greater lines since 300+ wraps on 10” or greater lines since 19951995

Limits repairs to 4 butted wraps, then Limits repairs to 4 butted wraps, then replacesreplaces

20” defect in line near creek bed: limited 20” defect in line near creek bed: limited environmental exposure, wrapped in 2 environmental exposure, wrapped in 2 hours; total repair 2 days start to finish hours; total repair 2 days start to finish


Composite WrapComposite WrapPartner ExperiencePartner Experience

Primary considerationsPrimary considerations Can repair be done safely?Can repair be done safely? Can repair be done in service?Can repair be done in service? Can repair be done quickly?Can repair be done quickly?

Secondary considerations (but still important)Secondary considerations (but still important) Cost effectiveCost effective Methane emissions savingsMethane emissions savings


Composite Wrap Composite Wrap Lessons LearnedLessons Learned

Proven permanent Proven permanent repair for external repair for external defectsdefects

Temporary repair for Temporary repair for internal faultsinternal faults

In-service pipeline In-service pipeline repair methodologyrepair methodology

Ideal for urgent and Ideal for urgent and quick repairquick repair

Avoid service Avoid service disruptionsdisruptions

Cost effective versus Cost effective versus alternativesalternatives

Trained but not skilled Trained but not skilled crafts persons requiredcrafts persons required

Specialized welding Specialized welding and lifting equipment and lifting equipment not requirednot required

Minimizes access Minimizes access concernsconcerns

No delays awaiting No delays awaiting metal sleevemetal sleeve

Cathodic protection Cathodic protection remains functionalremains functional


Composite WrapComposite WrapLessons LearnedLessons Learned

METHANE EMISSIONS REDUCTIONS METHANE EMISSIONS REDUCTIONS save you money and reduce greenhouse save you money and reduce greenhouse gas emissionsgas emissions


Composite WrapComposite WrapContactsContacts

www.epa.gov/gasstar/www.epa.gov/gasstar/ EPA Natural Gas Star ManagersEPA Natural Gas Star Managers Vendors of composite wrap kitsVendors of composite wrap kits

Armor Plate, Inc.Armor Plate, Inc. http://www.armorplateonline.comhttp://www.armorplateonline.com

The Clock SpringThe Clock Spring® Company L.P.® Company L.P. http://www.clockspring.comhttp://www.clockspring.com

The StrongBack CorporationThe StrongBack Corporation http://www.strongbackcorp.comhttp://www.strongbackcorp.com

WrapMaster, Inc.WrapMaster, Inc. http://www.wrapm.comhttp://www.wrapm.com


Composite WrapComposite WrapDiscussion QuestionsDiscussion Questions

Has anyone used composite wrap repairs?Has anyone used composite wrap repairs? What are the barriers(technological, lack of What are the barriers(technological, lack of

information, regulatory, and etc.) that are information, regulatory, and etc.) that are preventing you from implementing this preventing you from implementing this technology?technology?

Would anyone like to elaborate on the Would anyone like to elaborate on the information provided in this presentation?information provided in this presentation?

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