Pipeline Composite Repair Presentation - Louisiana · PDF fileprepreg and burst tested to...

Presented on Monday, May 16, 2011by: Gregg Crow

Pipeline Composite Repair Presentation

What is a Composite?

Two or more materials combined in such a way that the individual materials are easily distinguishable.

A common example of a composite is concrete. It consists of a binder (cement) and a reinforcement (gravel and rebar). Concrete is a three-phase composite.

Created by Gregg Crow - 817-240-6434

Composite repairs odd-

shape line quickly.

How long have composites been used?

1940’s – aerospace, military, marine, sporting goods, electronic industries and they appeared in the pipeline industry in late 1980s.


Corroded bridge

column on DOT

highway

Wet-layup prepregnated

composite used for structural

reinforcement repair

Composite repair

completed

Does the DOT approve of pipeline composite repair technology?

• Prior to 2000, only ClockSpring’s rigid composite system was allowed through an issued waiver.

• Effective January 13, 2000, the DOT published


within CFR 192.713 or 195.585 (Google it): “Repaired by a method that Reliable engineering tests and analyses show that can

permanently restore the serviceability of the pipe”.

(Therefore, any composite can be used if it has engineering testing like

ASME’s PCC-2, but not limited to, as PRCI, GRI, Battelle, SWRI and many others

listed on the next page have established composite testing criteria:)

ASME Post Construction Committee (PCC-2) – 16 composite testing criteria

ASME B31.4 & .8 – specifies composites can be used on <80% general corrosion

pitting, and on some dents, gouges, wrinkles, etc that are still piggable.

Note: NACE certification is not required to install a composite because they are not

considered a coating but a mechanical reinforcement repair. Though, most composite

manufacturers should require completion of their OQ install or train-the-trainer classes.

Composite Testing and Research

• ASME’s Post Construction Committee (PCC-2) established 16 composite repair engineering tests.

• Gas Research Institute (GRI)

• Southwest Research Institute (San Antonio,TX)

• Battelle Columbus Division (Columbus, Ohio)

• Kiefner & Associates, Inc.

• Stress Engineering

• Pipeline Research Council International (PRCI)


Regulations don’t specify engineering testing entity

Why has the energy pipeline industry started using composites to reinforce hoop/pressure containing

strength on metal wall loss & mechanical damage?

• Alternative to repairing a pipeline with a welded

sleeve or cut-out. ASME recommends using only

<80% general corrosion pitting, and on some dents,

gouges, wrinkles, etc that are still piggable.

• In-service repair – don’t have to lower the

pressure to install.

• Faster to install – about 1/3 of the time compared

to a welded sleeve.

• Non-conductive to CP except carbon fiber

composites.

• Wet-layup composite systems are excellent for odd

shape pipeline sections – bends, elbows, tees,

weld-o-lets, etc.

• Often the most economical way to repair a

pipeline.


Wet layup- spiral wrapped, cures

as one-solid-mass and can

backfill one hour later. Requires

no field mixing of resin into cloth

and no cinch bars or hammers.

Types of Composite Systems? Wet Layup –

field impregnatedRigid/Layerd/PreCuredWet Layup –

prepregnated


Resin mixed into cloth

minutes prior to install

Apply right out of the bag Tightening it up Each layer must be mixed

with resin before applying

Elbow repair Resin applied between

each layer

Pipeline Composite Repair Materials?

• Fibers – E-glass, carbon, aramid(Unidirectional – hoop stress or biaxial woven – hoop & axial stress)

• Matrix – meaning resins: epoxy, polyester, vinyl ester, phenolicpolyurethane.

Fibers provide the reinforcement, like rebar and gravel do for concrete. The matrix, like cement used in concrete, is what holds the fibers/reinforcement in place and allows the transfer of the load/pressure throughout the fibers/reinforcement.


Wet-layup prepreg – apply right out of

bag. Resin comes mixed into cloth

Have to mix resin into cloth in the

field. You don’t with wet-layup

prepreg.

Fiber Patterns


Unidirectional – provides

hoop strength only

Biaxial Woven – provides

hoop and axial strength.

Which Composite is the strongest?

Most composites used in the energy pipeline market place have undergone 3rd-party engineering fatigue testing to prove they can last anywhere from 25-50 years as a permanent pipeline field repair. Ask the composite manufacturer for their engineering testing results; such as, ASME Post Construction Committee (PCC-2).

50% defect wrapped with wet-layup

prepreg and burst tested to failure. Good

section of pipe failed and wet-layup did

not. Created by Gregg Crow - 817-240-6434

What types of energy pipeline defects can be repaired with composites?

• External Corrosion – <80% wall loss on any shape of pipeline.

• Internal Corrosion – not recommended, because no way to seal off corrosive environment as on

external corrosion with 100% solids epoxy before reinforcing hoop strength with a composite.

• Dents or Gouges – if the pipeline is still piggable (recommended to grind gouges smooth)


Pipeline defects repaired with composites


Girt Weld Wrinkles on bend

Corrosion pitting, welding defects

Vertical – soil-to-air Weld-O-Let

Weld-o-let


Soil-to-air composite repairs

Wet-layup prepregnated Soil to air interface corrosion repaired quickly 2”x10’ roll.


Wet-layup the girth welds prior to bore, tested on pull head. :


Before wrapped

Wrapped

After pulled through bore

Typically – powercrete epoxy

Wet-layup easily repairs odd-shape pipe.

Created by Gregg Crow Phone: 817-240-6434

External Corrosion Load transfer epoxy filler/primer Composite 4” wide x 15’ long roll

installed right-out-of the bag. No

mixing of resin into cloth

required, minutes prior to install.

Composite’s resin is pre-

pregnated into cloth during its

manufacturing process. Also,

there are 2” and 3” wide rolls

ranging in lengths of 10’-30’.

Blue wrap and perforate Remove blue anytime after 45

minutes.


Elbow repaired with composite

in less than one hour

Wet-layup ready to apply right

out of the bag, requires no

field-mixing of cloth with epoxy

resin minutes prior to install

Soil to air interface repair in one hour , 2”x10’

roll

44’ linear 10” pipe with 77% external corrosion

repaired with wet-layup, in one hour, to

reinforce hoop strength. No pressure reduction

& backfilled one hour later

Wet-layup Pipeline Repair Photos

Wet-layup Swamp Pipeline Repair


Before repair lifted 8” pipe out of water 96’ repaired with composite in 3 hours, pipe lowered back into water same day

Swamp Pipeline Repair


Removing old coating

Sandblasting

Corrosion pitting, wrapped with wet-layup

Wet-layup repair complete

Dehy44.5”OD wrapped with wet-

layup repair


Pipe anomaly where support

bracket was cut off. Sand

blasted to achieve bare metal

and a good anchor pattern for

repair materials to adhere.

A butyl rubber patch was placed over

anomaly and adjacent leaking crack.

Leaks < 60 psi in-service or blown

down.


Biaxial-woven fiberglass cloth was pregnated with a hydrocarbon

chemical resistance two-part epoxy then placed over the butyl

rubber tape patch to serve as a backup patch.


Coat sand-blasted area with non-

permeable two-part epoxy.

Immediately after wrapping

composite around the pipe, apply 3

layers of the blue plastic then

perforate it so composite will displace

water and Co2, which is the bi-

product from the chemical reaction of

moisture and the factory prepreg

polyurethane resin in the composite.


45 minutes later, remove blue plastic and the mechanical

reinforced composite is setup. It can be an in-service

repair on leaks up to < 60 psi.


ExxonMobil 8” line underwater that was hit by an anchor in the Caribbean Sea, causing a dent gouge

ExxonMobil 8” line was repaired using composite in 2006

BP’s offshore platform had heat exchanger repaired using wet-layup prepreg composite in 2009

Chevron offshore platform in 2009 was repaired using wet-layup prepreg composite

Offshore composite repairs successfully completed using composite


How long does it take to install a composite and then how long until it can be backfilled?

Wet Layup

field impregnated

Wet Layup

prepregnatedRigid/Layerd/Precured

Spiral or circumferentially

wrapped. Quickest to

install on any shape of

pipe: tee, elbow,

transition piping. Ready

to backfill 1 hour after

install.

Only circumferentially

wrapped. Takes longer to

install than wet-layup prepreg

because resin has to be

mixed into cloth. Must wait

several hours before

backfilling.

Only circumferentially

wrapped and limited to

straight pipe repairs. Takes

longer to install than both

wet-layups. Must wait a few

hours before backfilling.


How many layers do I need to apply?

• Most composite manufacturers have a spread-sheet calculator that uses Barlow's formula, Rstreng and factors in the mechanical strength that each layer of their composite system provides, per their 3rd-party engineering testing results.

• Make sure their calculator factors in the degradation of their composite wrap’s materials. They might only need 4 layers today to contain your actual MOP, but 20 years from now that same material might only have 70% of its strength remaining.

• Most composite manufacturers have performed 3rd

party testing to determine the degradation of their composite wrap’s materials.


How far past the defect must you wrap?

• ASME Post Construction Committee-2

formula:

Length of the defect plus

2 X 2.5 X SQRT of (OD X Wall Thickness )

2


Are Composites Pig Detectable?

• Composite wraps are identifiable by a pig when placing a metal band around the end of each end of the composite wrap.

• Or, some operators place a washer under the last layer, and at the same orientation on the pipeline.


Place metal bands around each

end of the repair so it will be

smart-pig detectable.

Do composites breach the CathodicProtection?

• Composites that adhere well to the pipeline’s surface provide a good barrier between the anomaly and corrosive environment, so no CP should be needed underneath the repair area.

• However, if the composite separates from the pipe allowing moisture/oxygen to channel underneath it, and the composite material is too resistant/dielectric to allow CP to push through it, then you will have CP Shielding.

• To prevent a corrosion cell, at least top-coat the ends of the composite repair with a non-permeable coating that will not allow moisture or oxygen to channel back underneath the sides of the composite, which would cause the anomaly to further corrode and eventually cause a leak underneath the composite repair.


For steel substrates, it’s recommend cleaning to bare metal, NACE II or SSPC-10 level. The better the cleaning and preparation, the better the wrap will bond/adhere to the pipe. For concrete surfaces, above and below the water line, all loose debris, coatings, marine growth, etc. must be removed. This can be done with high pressure water blasting or sand blasting.


Step 2: Fill all voids with 2-part load-transfer epoxy, and coat the entire area being wrapped.

Installation Process

Step 1: Sand Blast –NACE II Near White Finish. Or, at least don’t wrap over old coating and rough up surface to ensure anchor pattern.

Step 3 spiral wrapping technique installed quickly.

Step 5: Immediately after applying, wrap three layers of the plastic wrap over it tightly, and perforate it so excess water will drain out. 45 minutes later remove plastic then back fill.

Installation Process


Step 6:45 minutes after install, now one solid layer and ready to backfill. Metal bands placed around the ends so it will be pig detectable.

What lengths and widths are available for each composite systems?

Wet Layup –

prepregnated

Wet Layup –

field impregnated

Rigid/Layerd/Full Cure -

Supplied in 2“,3" 4“, 5”, 6" , 8”,10“, 12" wide X 10’, 20’,

25’, 30’, 50’, 60’, 90’, 120’ long rolls and installed

continuously and can be circumferentially or spiral

wrapped.

Typically supplied in 12” wide

One roll of cloth for each layer must be wetted with

resin and installed separately and only

circumferentially wrapped.

Typically supplied in 12” wide

Have to apply resin between each layer and only

circumferentially wrapped.


Cost comparison of composite systems used to repair pipelines:

Wet Layup –

prepregnated

Wet Layup –

field impregnated

Rigid/Layerd/Full Cure -

More expensive

Least expensive

Most expensive


Factors to consider when choosing a composite:

• Engineering testing - 3rd-party engineering testing? DOT requires that composites

have “Reliable Engineering Testing” before being used on a regulated line.

• DOT regs and ASME Codes – read and understand them, don’t rely on composite

manufacturers.

• Type of defect – wet-layup will conform to both straight and odd shaped pipelines, and

the rigid/layer/pre-cured systems are typically limited to straight pipelines.

• Life of repair – how long do you need the repair to last? 25 year? 50 Years?

• Length of repair – how many linear/axial inches or feet do you need repaired? Wet

layup pre-pregnated systems come in many different widths so you only buy near the

exact amount of material needed. Field impregnated and rigid/layer/pre-cured systems

only come in 12” wide and often rigid systems require 8 layers when only 4 are needed.

• Costs – wet-layup systems are cheaper than rigid systems, especially pre-pregnated.

• Carbon wraps – don’t apply directly against the steel pipeline, because it’s more

positive than steel and will thus cause corrosion. Insulate with a two-part non-permeable

epoxy or a layer of fiberglass wrap before applying onto pipeline.

• CP shielding – how dielectric is the composite?


Installation Procedure:

Step 1: Wear gloves and protective eye wear. Read MSDS!

Step 2: Drill 3/16” holes into sleeves to pour two-part epoxy resin.

Step 3: Pour .7 gallon of epoxy curing agent into the two-gallon container

already partially filled with 1.3 gallons of epoxy base agent.

Step 4: Mix epoxy for 2 minutes using a Home Depot battery drill with a paint

mixer drill bit.

Step 5: Pour mixed epoxy into the drilled-hole to fill annulus.

Description: Epoxy is 100% solids, low viscosity epoxy resin especially formulated for

maximum penetration into voids or porous surfaces. It is water tolerant and

able to displace water from wet surfaces to form a strong bond. Our epoxy is

NonHazmat for shipping without restrictions by air, sea or land. 2-4 hour cure

time depending on temperature. Seal welded with ½”plugs.

Materials Needed:

1) .7 gallon of epoxy curing agent supplied in one-gallon container.

2) 1.3 gallon of epoxy base agent supplied in two- gallon container.

3) Home Depot style battery drill with paint mixer drill bit.

4) 3/16” drill bit to drill and access the space between sleeve and pipe.

5) Wear protective gloves and glasses when handling epoxy.

Installation procedure for injecting

non-permeable two-part epoxy into

annulus of pumpkin sleeves:


Thank You

Gregg Crow

Phone: 817-240-6434

Email: [email protected]: www.myoilpatch.com


Pipeline Composite Repair Presentation

mailto:[email protected]

http://www.myoilpatch.com/

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