INTRODUCTION TOPipeline RepairSystems
INTRODUCTION TOPipeline Repair SystemsCONTENTSAbout Milliken InfrastructureSystems for Structural Integrity andCase Studies A+ Wrap™ System 4..........................................................................Atlas™ Carbon System........................................................... 12FormaShield® System.............................................................. 22Structural Repair AccessoriesILI Detection Technology..................................................30Systems for Corrosion PreventionPipe Sock™ System 32...................................................................Engineering Support Real Time Design-QuickCalc™....................................34Composite Repair Questionnaire........................... 35Milliken/ Pipe Wrap Design Package...............36 INTRODUCTION TO PIPELINE REPAIR SYSTEMS 1
Milliken Infrastructure Solutions At Milliken Infrastructure Solutions, LLC, we solve infrastructure challenges differently. More than just a materials provider, we partner with the industry to deliver smart, practical, innovative solutions. Our breadth of solutions rehabilitate, strengthen and protect infrastructure components. Backed by our engineering expertise and support, these systems install easier and faster than functional equivalents. Whether you are building new or repairing existing infrastructure, we can help you strengthen your structures to deliver the performance you need. Delivering Value Engineering Expertise • Assess challenges and recommend customized solutions • Leverage multiple technology platforms • Provide in-depth documentation and third-party validation Technical Support • Deliver in-field training and support • Provide responsive and on-demand service Project Optimization • Lower total project cost • Improve contractor productivity • Extend asset life cycle • Reduce installation time2 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
Systems forStructuralIntegrity INTRODUCTION TO PIPELINE REPAIR SYSTEMS 3
A+ Wrap™ Systemfor StructuralReinforcement4 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
Executive SummaryPipe Wrap®, LLC (Pipe Wrap) contracted Stress per the ASME PCC-2 design calculations. The testEngineering Services, Inc. (SES) to perform an sample is pressurized to failure to determine ifindependent technical assessment of their A+ the composite material has adequate strength toWrap composite repair system with respect to achieve a minimum test pressure. Qualification inthe qualification requirements of ASME PCC-2, this regard involves limit state testing to ascertainRepair of Pressure Equipment and Pipe, Article the ultimate capacity of a reinforced corrosion4.1, Nonmetallic Composite Repair Systems for section.Pipelines and Pipework: High-Risk Applications. Of particular interest to the current evaluation areThe ASME PCC-2 standard provides to Composite two tests that are critically important in terms of theManufacturers and Operators a comprehensive A+ Wrap performance qualification process.uniform approach for the proper design of compositerepair systems based on required coupon level The first test involved samples that were pressurizedmaterial properties testing, along with required for 1,000 hours (ASME PCC-2 Article 4.1, Mandatoryoverall system performance tests using full-scale Appendix V, Measurement of Performance Testtesting. Included within this review of the A+ Wrap Data). This test was used to establish the long-termcomposite repair system are details associated with design stress for the composite material of 20,369the requirements and tests designed to validate psi. From this value, the allowable stress for thethat the A+ Wrap system is adequately designed composite material of 10,184 psi was establishedfor its intended use in addition to accounting for the (0.5 x 20,369 psi).defect geometry for a particular service condition.The emphasis in the work performed by SES is on The second test, although not required by ASMEthe repair of corrosion defects in high pressure PCC-2, involved the systematic installation of straintransmission pipelines. gages positioned within each 3 layers of the A+ Wrap system used to repair a 75% deep corrosionIn addition to the full-scale testing conducted by defect in a 12.75-inch x 0.375-inch, Grade X42SES, Pipe Wrap®, LLC has performed numerous pipe. This test indirectly validates the coupon levelcoupon level tests to address performance variables composite properties and ensures that sufficientsuch as tensile strength, elastic modulus, heat design safety factors for the application. Duringdistortion temperature, long-term shear strength, pressurization to the design pressure of 72% SMYSand cathodic disbondment. Coupon tests are (1,778 psi), the maximum stress measured in anyimportant to qualify the components of a composite of the A+ Wrap composite layers was 4,086 psi.repair system before full-scale testing is performed. Using this maximum measured stress, the designHowever, coupon tests are not sufficient in and of margins of the mean tensile strength relative tothemselves to qualify a system. The qualification of the measured stress and allowable stress are 10.8a composite system per ASME PCC-2 requires full- (51,700 psi / 4,806 psi) and 5.1 (51,700 psi / 10,184scale testing to evaluate the total performance in psi), respectively. Another observation is that forthe repair of defects such as corrosion and dents. this particular repair, the current design used atAn example of full-scale testing involves the repair most 47% of the allowable stress (i.e. 4,806 psi /of a simulated corrosion in a pipe sample. The 10,184 psi). Because this particular corrosion defectcorroded test sample is repaired using a composite represents a severe condition, these design marginsmaterial having a specified thickness and length will be greater for less severe corrosion conditions. INTRODUCTION TO PIPELINE REPAIR SYSTEMS 5
Executive Summary continuedIn addition to the burst pressure tests performed service standpoint, Pipe Wrap, LLC has prepared theon the A+ Wrap that included testing involving the A+Wrap Calc calculator for determining the requiredinter-layer strain measurements, a pressure cycle thickness for repairing corroded pipes. This tool isfatigue test was performed in 2008 using a thinner based on the equations designated in ASME PCC-laminate on the same pipe and defect geometry 2. Therefore, by definition, the thickness of the A+where the sample was pressure cycled from 36% Wrap system will be in accordance with the ASMEto 72% SMYS. The hoop strain range measured PCC-2 standard. As a note, the A+ Wrap system hasbeneath the composite repair during cycling was been tested beyond the minimum requirements of900 microstrain (0.09 percent strain) before the ASME PCC-2. All data presented in this documentsample failed after 140,164 cycles. Although the represents first-time data. No additional testing wasresults are good, if the laminate thickness had been required beyond what has been presented due toperformed using the same number of layers as the either poor results or inadequate performance.aforementioned test, the number of cycles wouldhave most likely exceeded 200,000 cycles. Additionally, a comparison between the two internationally-recognized composite repairNumerous other tests have been conducted on the standards, ASME PCC-2 Article 4.1 and ISO 24817,A+ Wrap system including a study for the Minerals is included in this document. For all practicalManagement Service on the repair of offshore purposes the use of these two standards willrisers. Pipe Wrap® LLC has also participated in produce the same type of composite design. Hence,all of the composite repair programs sponsored a system such as the A+ Wrap system that meetsby the Pipeline Research Council International the requirements of PCC-2, by comparison satisfies(PRCI) including MATR-3-4 (3-year long-term the design requirements set forth in ISO 24817.performance), MATR-3-5 (dent repair), MATR-3-6 (10,000-hour subsea composite repair), and As a final comment - additional testing, such as theMATR-3-7 (repair of girth welds). pressure cycle testing and the inter- layer strain test, confirm the validity of the design and provideThe results for tests conducted on the A+ Wrap greater assurance that the A+ Wrap system issystem have met the minimum requirements beyond the minimum requirements set forth in thedesignated in the ASME PCC-2 Standard. From a ASME PCC-2 standard.6 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
Milliken Infrastructure Typical Uses A+ Wrap™ The A+ Wrap system is most commonly used for pipelines and piping systems suffering from corrosionWater Activated Composite Repair System or mechanical damage. Repairable defects include: OIL, GAS + INDUSTRIAL • External corrosion and pittingA+ Wrap is a high-strength fiberglass composite pre-impregnated with moisture cured • Dents, gouges and scratchespolyurethane resin. It is designed for simplification of installation for restoring the structuralstrength of degraded pipe with varying geometries. It is also able to be used for pressure • Manufactured defectscontainment under certain circumstances. BenefitsMECHANICAL PROPERTIES UNITS METHOD VALUE 51,800 (357) • Ready to useTensile Strength PSI, MPa ASTM D 3039 3.01 x 106 (20,753)Tensile Modulus PSI, MPa ASTM D 3039 0.077 • Water activated pre-impregnated fiber allowsPoisson's Ratio ASTM D 3039 for easy installation VALUETHERMAL PROPERTIES METHOD 0.2 um/m/°C • Can be applied on dry or wet surfaces, evenThermal Expansion ASTM E 831 underwater 205°C (400°F)Heat Distortion Temperature ASTM D 648 • Can be applied at temperatures up to 120°F 185°C (365°F) but works up to 365°FMax Operating Temperature ASME PCC-2 • Up to 30 minutes working time once pouch isApplication Temperature - -50°F up to 120°F opened (49°C with workingSYSTEM PROPERTIES temperature up to • Sets withing an hour and cures fully after 24Ply Thickness 365°F) hoursWorking TimeSet Time 22 mils (0.022 inches) • Used frequently as part of a custom designedCure Time 20 - 30 minutes repairShelf Life 1 hourStocked Sizes 24 hours • Conforms to any shape including elbows, tees, One Year @ 40 - 75°F flanges, bends & more Available in widths from 2 - 12 inchesBefore using any Milliken Infrastructure Solutions, LLC product, the user must review the most recent version of the product’s technical data sheet, material safety data sheet and other applicable documents, available at infrastructure.milliken.com or by calling 1-855-655-6750.Milliken Infrastructure Solutions, LLC is a subsidiary of Milliken & Company. The Milliken logo is registered by Milliken & Company and used under license by Milliken Infrastructure Solutions, LLC, all rights reserved. Technologyinfrastructure.milliken.com855-655-6750 INTRODUCTION TO PIPELINE REPAIR SYSTEMS 7
A+ Wrap™ System RepairNatural Gas PipelineCase Study #85 - Sinton, TXProject Overview External corrosion (.183” Deep x .512” Long x .315” Wide) and minor externalcorrosion (.020” Deep x 28’ Long) on a 24” OD Transmission pipeline. Nominalwall thickness of .28125” and Grade X-52 (52,000 SMYS). Design pressure 878PSI. Operating temp: Ambient (90°F).The SolutionMilliken/ Pipe Wrap designed a 20 year design life utilizing the A+ Wrap™ Systemwith 24 layers for 2 linear feet to restore the structural integrity of the pipe. As thearea was exposed 26 feet with minor pitting were found and was recommended towrap the minimum of 6 layers.Repair MethodBecause the repair is going to be made one (1) day after the pipe prep, the repairzone will be coated with an epoxy coating immediately after the 28 linear feet issandblasted to a NACE 3 finish. The next day, before starting the wrap, the coatingwas roughened with sandpaper and wiped clean with acetone. The repair zonewas identified with three sections. In the center, a two foot repair with 24 layersand on each side a 13 feet repair zone that will have 6 layers. EP400 filler wasused on the primary anomaly and EP420 filler material on the other 26 feet havingminor external pitting. Two certified trainees applied PPR on the entire repair zone.Then three other certified trainees applied the A+ Wrap™ System using the offsetmethod with 24 layers for 2 linear feet and 6 layers for 26 linear feet. The area wasconstricted and perforated. The total time for the repair from beginning repair tobackfilling required 5 hours. 8 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
A+ Wrap™ System RepairFuel LineCase Study #75 - South Pacific - USA TerritoryProject Overview A pipeline located in the South Pacific has been in service for over 40 years. During routine inline inspection of the pipeline, external corrosion was found in thestraight pipe and affected the pipelines circumferential and longitudinal welds. Thepipeline is a 24”-inch (609 mm) 0.250-inch (6.35 mm) wall, grade API-5LX-42pipe. The external corrosion extended 30’ and had approximately 66% wall lossand affected the operating pressure and required repair.The SolutionThe repair was designed for 20 years using A+ Wrap™ repair system. It wasselected as the repair of choice for one primary reason. It requires no “hot” work.On a high pressure pipeline this becomes a huge advantage as permitting andsafety concerns are minimized. When the repair was completed the A+ Wrap™system restored the structural integrity of the pipeline back to its pristine condition.Repair MethodRemove tape coating and sand blast to a NACE #3 finish. The first step of repairis to fill the anomaly with a load transfer epoxy putty. Apply a corrosion barrierepoxy to the entire repair zone prior to wrapping with A+ Wrap™ using the offsetmethod. Apply the material until the calculated layers have been achieved. Applymagnets on the outer ends of the repair for future smart pig detection. Constrictand perforate, then allow to cure for 2 hours. Top coat as applicable, then back-fill. INTRODUCTION TO PIPELINE REPAIR SYSTEMS 9
A+ Wrap™ System RepairDent RepairCase Study #74 - Pike River , Quebec Canada Media Blast Pipe to NACE 1Project Overview The Carbon Steel pipe that was used for this repair had an outside Measure repair zonediameter of 8 inches and a wall thickness of 0.188 inches. With a specifiedminimum yield stress of 42,000 psi, the initial design pressure for this pipe was determined to be 1800 psi. The Straight Pipe section suffered from 6% dent, with0% wall loss. Apply PPR CoatingThe Solution A+ Wrap™ system was selected for its ease of use and its superior strength. Natural Apply A+ Wrapgas pipeline repair zone was 24” and the ambient temp was 65-75°F. Overall repairwas designed for 50 years with 18 layers (.396”) over 24” repair zone. Operator used A+ Wrap™ and EP-420 paste products to make the repair.Repair MethodInstallers were trained and certified on A+ Wrap™ prior to repair. Installers 1stmedia blasted the pipe to a near white profile. Then EP 420 epoxy A&B was mixedand applied evenly to the dented area, then the area was completely coated withPPR and the installers applied the proper amount of A+ Wrap ™The wrap wasapplied opening one roll at a time using the spiral wrapping method was used,after 1 layer of A+ Wrap™ was installed at the beginning and end, ILI markermagnets were applied so repair could be identified during future ILI runs. Theremaining 17 layers were applied with tension to allow no wrinkles or voids. Nowconstrictor wrap was applied over A+ Wrap™ to constrict repair and assure properadhesion. Then the plastic wrap was perforated with a perforating tool allowing theCo2 and excess resin and water to migrate through the holes. Once the A+ Wrap™was cured and entire repair was finished gassing off, the constrictor was removedand a final top coat was applied over the entire repair area. Final A+ Wrap Perforate Constrictor Wrap Final Top Coat10 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
ASME PCC-2 & ISO 24817Certification Document for the A+ Wrap System PN113647CRA Prepared for Pipe Wrap, LLC Houston, Texas Prepared by: Dr. Chris Alexander, P.E. Principal Texas Registered Engineering Firm F-195 June 2011 (Revision 2) INTRODUCTION TO PIPELINE REPAIR SYSTEMS 11
Atlas™ Carbon Systemfor StructuralReinforcement12 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
Executive SummaryPipe Wrap, LLC (Pipe Wrap) contracted Stress to failure to determine if the composite materialEngineering Services, Inc. (SES) to perform an has adequate strength to achieve a minimum testindependent technical assessment of their Atlas pressure. Qualification in this regard involves limitCFE composite repair system with respect to thequalification requirements of ASME PCC-2-2011, state testing to ascertain the ultimate capacity of aRepair of Pressure Equipment and Pipe, Article reinforced corrosion section.4.1, Nonmetallic Composite Repair Systems forPipelines and Pipework: High-Risk Applications. In addition to the testing required by ASME PCC-2, before SES certifies a composite repair system twoThe ASME PCC-2 standard provides composite additional tests are required. Both involve the repairmanufacturers and operators with a comprehensive of pipe samples made using 12.75-inch x 0.375-uniform approach for the proper design of inch, Grade X42 pipe with 75% deep corrosion.composite repair systems based on required coupon The first test is a static pressure test to failure.material properties testing, along with assessing Strain gages are used to measure both strain inoverall system performance using full-scale the reinforced steel and also measure inter-layertesting. Included within this review of the Atlas strains in the composite material. The inter-layerCFE composite repair system is a comprehensive strains are used to compute hoop stresses that areassessment to validate that the Atlas CFE system compared to the composite design stresses peris adequately designed for its intended use in ASME PCC-2. The second test involves pressureaccordance with ASME PCC-2. The emphasis in the cycle testing a corrosion sample of the samework performed by SES is on the repair of corrosion configuration mentioned above to either failure or adefects in high pressure transmission pipelines. run-out condition (i.e. 250,000 cycles). In this test strain gages also provide useful information on theIn addition to full-scale testing conducted by SES predicted long-term performance of the repair.on the Atlas CFE system, Pipe Wrap, LLC performednumerous coupon tests to address performance The comments below provide specific insights onvariables including tensile strength, elastic the performance of the Atlas CFE system includingmodulus, glass transition temperature, long-term the ASME PCC-2 1,000 hour tests used to determineshear strength, and cathodic disbondment. Coupon the long-term strength of the composite materialtests are important to qualify the components of a and the two additional SES-required tests that werecomposite repair system before full-scale testing mentioned in the preceding paragraph. All of theseis performed. However, coupon tests are not tests are critically important in terms of qualifyingsufficient in and of themselves to qualify a system. the performance of the Atlas CFE system.The qualification of a composite system per ASMEPCC-2 requires full-scale testing to evaluate the • The first test of interest involved 12. 75-inchtotal performance of the system in repairing x 0.375-inch, Grade X42 samples that weredefects such as corrosion and dents. An example pressurized to 4,200 psi and held for 1,000 hoursof full-scale testing involves the repair of a simulated (ASME PCC-2 Article 4.1, Mandatory Appendixcorrosion in a pipe sample. The corroded test sample V, Measurement of Performance Test Data). Thisis repaired using a composite material having a test was used to establish the long-term designspecified thickness and length per the ASME PCC-2 stress for the composite material of 52,451 psi.design calculations. The test sample is pressurized From this value, the allowable stress for the composite material of 26,225 psi was established INTRODUCTION TO PIPELINE REPAIR SYSTEMS 13
Executive Summary continued (0.5 x 52,451 psi). Whenever the Atlas CFE is (212°F). The results of the tests are provided in installed to repair a pipeline, the stresses in the Appendix D; the tensile strength of Atlas CFE at composite material must be less than this value. 80.6°F was measured to be 213 ksi. This tensile strength corresponds to a safety factor of 14.2• The second test, although not required by ASME relative to the measured hoop stress of 15,053 PCC-2, involved the systematic installation psi at the design pressure (i.e. 213 ksi / 15.0 ksi = of strain gages positioned within designated 14.2). layers of the Atlas CFE system used to repair a 75% deep corrosion defect in a 12.75-inch x • The third test of specific interest was a pressure 0.375-inch, Grade X42 pipe. This test indirectly cycle fatigue test was performed to evaluate validates the coupon level composite properties the long-term performance of the Atlas CFE and ensures that sufficient design safety factors system considering cyclic pressure loading. for the application. During pressurization to Three samples were tested including composite the design pressure of 72% SMYS (1,778 psi), thicknesses of 1.243 inches, 0.571 inches, the maximum strain measured in the reinforced and 0.282 inches (the latter corresponds to corroded region was 2,259 με (10,000 με equals the thickness using the ASME PCC-2 design 1%strain). In comparison, the average hoop strain equations and is the basis for the following for the three participating carbon repair systems statements). The sample was pressure cycled in the PRCI MATR-3-4 long-term composite from 36% to 72% SMYS (890 to 1,780 psi). study was 2,524 με. The hoop strain range measured beneath the composite repair during cycling was on the order• In the composite inter-layer strain measurements, of 1,000 με (0.1 percent strain). The sample was the average inter-layer hoop strain was measured cycled to 320,000 cycles after which cycling to be 1,511 με. Using the elastic modulii of 9.7 Msi was terminated (i.e. no failure, run-out condition (circumferential) and 3.6 Msi (longitudinal), applied). For a typical gas pipeline cycling at a along with a Poisson’s ratio of 0.15 for the moderately aggressive condition (i.e. 337 cycles carbon material, the average hoop stress was per year at a pressure range of 36% SMYS)1, calculated to be 15,053 psi using the bi-axial this fatigue life corresponds to 48 years of stress equations for a composite material. This service if one applies a safety factor of 20 stress value is less than the design stress of to the experimental cycles to failure (320,000 26,225 psi (0.5 x 52,451 psi). Additionally, the cycles / 20 / 337 cycles per year = 48 years). measured composite hoop stress of 15,053 psi Correspondingly, the sample with the composite is 10% of the Atlas CFE short-term mean tensile thickness of 1.243 inches cycled 735,452 cycles strength of 151,000 psi. These results imply that without a failure. For the moderate pressure a safety factor 10.0 exists between the composite cycle condition this corresponds to 109 years of stress at design conditions and the actual (short- service. term) mean tensile strength of the material. Also, SES performed additional material testing to The results for testing conducted on the Atlas evaluate the strength of the Atlas CFE material as CFE system demonstrate that this composite a function of elevated temperature up to 100°C repair system meets the minimum requirements1 Kiefner J. F. et al, Estimating Fatigue Life for Pipeline Integrity Management, Paper No. IPC04-0167, Presented at the International Pipeline Conference,Calgary, Canada, October 4 – 8, 2008.14 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
Executive Summary continueddesignated in the ASME PCC-2-2011 Standard. This performance criteria. Additionally, with the selectedcertification requires that the Atlas CFE system tests the Atlas CFE system has been tested beyondbe designed in accordance with the requirements the minimum requirements of ASME PCC-2 toof ASME PCC-2-2011, specifically the minimum further validate the performance of the system asrequired composite thickness. Therefore, when listed in the table below.designed using the ASME PCC-2 minimum thicknessformulas, Atlas CFE will be within the ASME PCC-2Atlas CFE - ASME Qualification Test SummaryProperty Details Test Standard Test Results 0.015 inLayer Thickness 151,000 psi 1.60%Tensile Strength Longitudinal ASTM D 3039 9,700 ksi 27,800 psiUltimate Tensile Strain Longitudinal ASTM D 3039 1.40% 3,600 ksiYoung’s Modulus Longitudinal ASTM D 3039 0.15 960 ksiTensile Strength Transverse ASTM D 3039 52.5 2.08 x 10^-7 in/in/KUltimate Tensile Strain Transverse ASTM D 3039 7.35 x 10^-6 in/in/K 300°FYoung’s Modulus Transverse ASTM D 3039 152°F 198°FPoisson’s Ratio Longitudinal ASTM D 3039 52,451 psi SurvivedShear Modulus ASTM D 5379 Hardness Barcol Hardness ASTM D 2583 Thermal Expansion Coefficient Longitudinal ASTM E 831 Thermal Expansion Coefficient Transverse ASTM E 831 Tg - Wrap Atlas Epoxy ASTM E 1640 Tg - Filler EP400/EP913 ASTM E 1640 Tg - Adhesive PPR ASTM E 1640 Long Term Strength 1,000 hours ASME PCC-2 Spool Survival Test ASME PCC-2 Finally, a comparison between the two satisfies the design requirements set forth in ISOinternationally - recognized composite repair 24817.standards, ASME PCC-2 Article 4.1 and ISO24817, is included in this document (Appendix As a final comment - additional testing, such as theE). For all practical purposes the use of these two pressure cycle testing and the inter- layer strainstandards produces the same type of composite test, confirm the validity of the design and providedesign in repairing corrosion defects. Hence, a greater assurance that the design of the Atlas CFEsystem such as the Atlas CFE system that meets system is beyond the minimum requirements setthe requirements of ASME PCC-2, by comparison forth in the ASME PCC-2 standard. INTRODUCTION TO PIPELINE REPAIR SYSTEMS 15
Milliken InfrastructureAtlas™Carbon Fiber Composite Repair SystemOIL, GAS + INDUSTRIALAtlas™ is a high strength, high stiffness carbon fiber solution for on-site repair of piping Typical Uses structures. Atlas™ is designed for repairs requiring strain reduction due to dynamicloading conditions The Atlas™ system is most commonly used for pipelines and piping systems that have sufferedMECHANICAL UNITS ASTM TEST VALUES from corrosion or third party damages. PossiblePROPERTIES METHOD defects that can be repaired include: 151,000 (1,041) • External corrosion and pittingTensile Strength PSI, MPa D3039-00 9.7 x 106, (66,879) • Dents, gouges and scratches D3039-00 113,000 (779) • Welds and other manufacturing flawsTensile Modulus PSI, MPa D790-00 9.1 x 106, (62,742) • Wrinkle Bends D790-00 9.64 x 105 (6,647) • Crack Reinforcement (conditional cases)Flexural Strength PSI, MPa D5279-01 8,200 (56.5) D3165-07 53 BenefitsFlexural Modulus PSI, MPa D-2583 350°F (177°C) ISO 11357-2 .116 um/m/°F (.208 um/m/°C) • Site impregnatedShear Modulus PSI, MPa E831-6 .150 D3039-00 • Resin part A and part B come to the field pre-Interlaminar Shear Strength PSI, MPa measuredBarcol Hardness • Structural fabric is impregnated in the field with conventional equipmentGlass Transition • Restores pipe to original strengthThermal Expansion • Ideal application temperature up to 120 °FPoisson's Ratio (49 °C)PHYSICAL PROPERTIES (ACFE) • Independently certified to ASME-PCC-2 and ISO 24817 standardsStocked Width 12\" (30.5 cm) Complete Kit Includes% Resin content by weight 36 ± 3Fabric Orientation Bi-Axial 0° and 90° • Carbon FabricCure Ply Thickness 0.019 IN (19 mils) (0.48 mm) • Primer Kit • Constrictor WrapGENERAL PROPERTIES • Mixing Tools, GlovesMaximum Operating Temperature 314°F (157°C)Working Time (Dependent on Temperature) 40 Minutes @ AmbientSet Time 1 HourChemical Resistance Gasoline, MEK, Acetone, Toluene, Ethyl alcohol and other hydrocarbonsShelf Life One year from ship dateApplication Conditions Above 45°F (7°C) up to 120°F (49°C)Before using any Milliken Infrastructure Solutions, LLC product, the user must review the most recent version of the product’s technical data sheet, material safety data sheet and other applicable documents, available at infrastructure.milliken.com or by calling 1-855-655-6750.Milliken Infrastructure Solutions, LLC is a subsidiary of Milliken & Company. The Milliken logo is registered by Milliken & Company and used under license by Milliken Infrastructure Solutions, LLC, all rights reserved. Technologyinfrastructure.milliken.com855-655-675016 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
Atlas Carbon SystemGas Transmission LineCase Study #75 - USAProject OverviewAn emergency repair with 8’ of external corrosion on a 20” LGE transmissionpipeline needed to be repaired. The Pristine Design Pressure was 1,180 psi and theMAOP was 849 psi. Ambient temperature was 100°F. 50% Wall Loss.The SolutionPipe Wrap designed a 20 year repair requiring 8 layers of Atlas™ CFE with a repairthickness of 0.120” in accordance with ASME-PCC-2 Standards. Layer over layerwith a 1.5 inch overlap.Repair MethodThe pipe was sand blasted over the 8’ area and a solvent was used to removeany remaining particles. After identifying and marking the repair zone, EP-913 wasused to fill in all the anomalies and provide an adhesive layer. The Atlas™ Systemwas wetted with a two part epoxy resin and applied to the pipe until the calculatedlayers had been achieved. The 8-foot, 8 layer Atlas™ CFE repair was installed in aperiod of 1.5 hours. After a 2 hour cure, a top coat was used. INTRODUCTION TO PIPELINE REPAIR SYSTEMS 17
Atlas™ System Structural ReinforcementDiesel LineCase Study #62 - MexicoProject OverviewThe Carbon Steel pipe that was used for this repair had an outside diameter of16 inches and a wall thickness of 0.375 inches transferring 100% Diesel. With aspecified minimum yield stress of 30000 psi, the initial design pressure for this pipewas determined to be 1406 psi. The Straight Pipe section suffered from 92% wallloss with external corrosion. With a defect length of 1.5 inches the repair zone wascalculated to be 12 inches long.The SolutionWhen properly installed via the layer over layer method, this repair will restorethe pressure bearing capabilities to a design pressure of 1792 psi and a maximumallowable operating pressure of 717 psi. The repair length would have requiredencapsulating the flange. The customer opted for a shorter design life.Repair MethodTo provide the short term repair, the minimum repair thickness was set to ourcompany minimum allowable thickness of 0.09 inches. The Repair Methodconsisted of the following steps:• Identify Anomaly• Prep Surface• Apply Filler• Apply Primer• Apply CompositeUnique defect conditions, piping system components and installation techniqueswere then considered. The final recommended repair thickness was calculated as0.09 inches, or 6 layers of the Atlas PL system. Using the ASME PCC-2 and/or ISO24817 standards, the minimum repair thickness was determined by utilizing thePerformance Testing design equations.18 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
Atlas™ CFE Wrap System RepairNatural Gas PipelineCase Study #77 - Eunice, LA 1. View of repair zone and dentProject Overview 2. View of EP420 filler material applied to dent and long seamDent (.276” Deep x 8.45” Long x 5.7” Wide) on a 20” OD horizontal pipeline in thelongitudinal weld seam @ the 12:30 o’clock position. Nominal Wall Thickness of 3. FormaShield™ segment installed and.250” and Grade X- 52 (52,000 SMYS). placement of “Smart Pig Markers” inside the repairThe SolutionDesigned a 20 year design life utilizing the Atlas™ CFE Wrap System with 10layers for 2 linear feet to restore the structural integrity of the line back to pristineconditions.Repair MethodThree Technicians and 3.5 labor hours. Repair Area was grit-blasted the day before,primed and coated with an epoxy coating. Roughened the coating surface withsandpaper and wiped clean with Acetone. Applied EP420 as filler material forload transfer to dent and longitudinal weld. Applied PPR to entire repair zone. TheAtlas™ CFE Wrap System was applied using the offset method for 24 linear incheswith Smart Pig Markers. Applied Constrictor Wrap, perforated, allowed to cure for1.5 hours, removed Constrictor Wrap and top coat with PPR.6. Completed Atlas™ CFE Wrap System 5. Constrictor wrap applied and being 4. Completed installation of 10 repair perforated layers of carbon fiber repair INTRODUCTION TO PIPELINE REPAIR SYSTEMS 19
Atlas CFE Wrap™ System Natural Gas PipelineCase Study #24 - Near Ringgold, LA 1. View of 6 Wrinkle BendsProject Overview 2. Application of Filler Material at each Wrinkle Bend & Long SeamSix (6) Wrinkle Bends on the top of a 24” OD horizontal pipeline at a crossing about26” to 31.5” apart. No Corrosion. Distance from #1 Wrinkle Bend Center to #6 Wrinkle 3. Application of PPR Epoxy CoatingBend Center is 12.2’. Nominal Wall Thickness of .344” and Grade X-52 (52,000 SMYS).Operating Pressure of 875 psi.The SolutionDesigned a 20 year design life utilizing the Atlas CFE Wrap™ System with 20 layersfor 16 linear feet to restore the structural integrity of the pipeline back to pristineconditions.Repair MethodThe repair was completed in 13 productive hours by three (3) Milliken Pipe WrapTechnicians and three (3) Contract Personnel. Repair Area was grit-blasted and wipedclean with Acetone. Applied EP420 as filler material for load transfer at WrinkleBends and Long Seam. Applied PPR to entire repair zone. Applied layer of Fiberglasswith Smart Pig Markers. The 12” Wide Atlas CFE Wrap™ System was applied using thespiral method with 20 layers for 16 linear feet. Applied Constrictor Wrap, perforatedand allowed to cure. Removed Constrictor Wrap. Applied a Topcoat with PPR EpoxyCoating.Atlas Wrap: Lot #22700, #23700 & #23737EP420: Lot #AK15001 & #AK15004PPR: Lot #A1030H1030Resin: Lot #A032715-1, #A080615-2, #B022415-2 & #B060315-14. Application of Fiberglass Layer & 5. Application of Atlas CFE Wrap™ 6. Completed Atlas CFE Wrap™ Smart Pig Markers System System with Top Coat of PPR Epoxy Coating20 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
ASME PCC-2 & ISO 24817Certification Documentfor the Atlas CFE System PN 113647, Rev. 1 Prepared for Pipe Wrap, LLC Prepared by: _______________________________ Dr. Chris Alexander, P.E. Principal Reviewed by: _______________________________ Mr. Ron Scrivner Staff Consultant Firm Registration Number is F-195 September 2012REV DATE DESCRIPTION ORIGINATOR REVIEWER APPROVER1 9-19-12 Client Feedback Dr. Chris Alexander, P.E. Mr. Ron Scrivner Dr. Chris Alexander, P.E. Mr. Ron Scrivner Dr. Chris Alexander, P.E.0 August 2012 Client Review Dr. Chris Alexander, P.E. Page ii INTRODUCTION TO PIPELINE REPAIR SYSTEMS 21
FormaShield™ System for Structural Reinforcement22 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
Milliken InfrastructureFormaShield™ High Performance Epoxy Composite Repair SystemOIL, GAS + INDUSTRIALFormaShield® is a high-performance, high-strength fiberglass solution designed for Typical Uses pressure or leak containment of piping structures having internal or external defects. TheFormaShield® System is a reliable solution impregnated on-site with pre-measured resin kits. The FormaShield® system is generally used on piping systems suffering from corrosion orMECHANICAL PROPERTIES UNITS ASTM TEST VALUE mechanical damage. The system is suitable to METHOD repair the following: • External corrosion and pittingTensile Strength PSI, MPa D3039-00, 74,00 Hoop (510) • Dents, gouges and scratches A370, E8 17,900 Axial (123) • Welds and other manufacturing flawsTensile Modulus PSI, MPa D3039-00 3.1x106 (21,500) • Internal corrosion and erosion D790-00 84,200 (580)Flexural Strength PSI, MPa D790-00 3.0x106 (20,700) Benefits D5279-01 1.3x106 (9,100)Flexural Modulus PSI, MPa D3165-07 19,300 (133) • Site impregnated D-2240Shear Modulus PSI, MPa E1356 85 • Resin Part A and Part B come to the field pre- measuredInterlaminar Shear Strength PSI, MPa E831-6 350°F (177°C) • Structural fabric is impregnated in the fieldHardness, Shore D 8.7x10-6 (in/in/°F) with conventional equipment 15.6(in/in/°C)Glass Transition • Ideal application temperature up to 120 °F 0.37 (49 °C)Thermal Expansion Complete Kit IncludesPoisson's Ratio D3039-00 • Fiberglass FabricPHYSICAL PROPERTIES 4\", 6\" & 12\" (10cm, 15cm, 30.5cm)Stocked Width Tri-Axial • Resin- Parts A & BFabric Orientation 0.030 Inches (30 mils)(0.76 mm)Nominal Ply Thickness • Primer Kit • Constrictor Wrap • Mixing Tools, GlovesGENERAL PROPERTIESMaximum Operating Temperature 314 °F non leaking / 296 °F leakingWorking Time (Dependent on Temperature 40 Minutes @ AmbientSet Time 1 HourChemical Resistance Gasoline, Mek, Acetone, Toluene, Ethyl Alcohol and other hydrocarbonsShelf Life One year from ship dateApplication Conditions Above 55°F(13°C) up to 120°F (49°C)Cure Time 24-72 HoursBefore using any Milliken Infrastructure Solutions, LLC product, the user must review the most recent version of the product’s technical data sheet, material safety data sheet and other applicable documents, available at infrastructure.milliken.com or by calling 1-855-655-6750.Milliken Infrastructure Solutions, LLC is a subsidiary of Milliken & Company. The Milliken logo is registered by Milliken & Company and used under license by Milliken Infrastructure Solutions, LLC, all rights reserved. Technologyinfrastructure.milliken.com855-655-6750 INTRODUCTION TO PIPELINE REPAIR SYSTEMS 23
FormaShield™ ETWater LineCase Study #32 - Pasadena, TexasProject OverviewRepair of a 24” O.D x 0.375” wall, water line inside a refinery had 31 feet ofexternal corrosion and 3 areas with pin hole leaks. The external corrosion on thepipe had a defect depth of 60 percent wall loss.The ProblemExternal corrosion resulted from natural causes over a long period of timecaused minor pin hole leaks and external corrosion, over 31 feet to occur. Thecorrosion degraded 60% of the pipe wall.The SolutionBased on the extent of the defect, the repair was designed in accordance toASME PCC-2 standards which resulted in 6 layers of FormaShield™ of an overallrepair thickness of 0.20”. The repair was complete from start to finish in 3 days.The pipe was first blasted to near white metal and cleaned with MEK solvent.The 3 pin hole repairs were stop-gapped and held leak free for 1 full day. Theremaining 31 feet of corrosion was filled with proprietary epoxy putty, coatedwith PPR primer, then 6 layers of FormaShield™ was applied to the entire 34feet encapsulating the stop gaps.The pipe was then coated with a corrosion and UV resistant paint as a finishingcoat over the repair.As stipulated by the PCC-2 Standards, only certified installers were allowed toapply the product.24 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
FormaShield™ HT RepairSour Water LineCase Study #46 - New Mexico, USAProject Overview Pipe prior to RepairThe Client required a temporary repair of a leaking 12” sour water line that hadto remain in operation during the repair. This line operates at 190°F. Additionally,several clamps on the line would also require overwrapping.The SolutionAfter reviewing the problem Pipe Wraps’ FormaShield™ HT product whichutilizes a High Temperature resin was chosen for the repair due to its’ ability tobe applied at the elevated operating temperature and conformability to irregularshapes.Repair MethodThe first step in the repair was to cut off the clamp bolts flush with fastening nuts.A mold was then fabricated over the holding bolts on two of the clamps in orderto encapsulate with epoxy. The third clamp had epoxy putty molded around boltsbefore overwrapping.FormaShield™ HT resin was then mixed, Fabric wetted out and applied to thespecified number layers. Constrictor was applied until cure was complete thenremoved. Job was completed with no interruption of production.Completed Repair Lower and Center Section Wrap Encapsulation Molds INTRODUCTION TO PIPELINE REPAIR SYSTEMS 25
FormaShield™ SystemFiberglass Pipe Leak RepairCase Study #51- Alberta, Canada Top: 1” hole Bottom: Joint separationProject Overview EP-400 used to seal leak paths PPR used as adhesive layer• Leak repair on a 12” fiberglass pipe at a joint; two 1-inch holes that were drilled through the joint section.• Operating pressure 40 PSI• Max Design pressure 200 PSI• Operating Temp: ambient; 84°F• Conditions: Depressurized fiberglass pipeThe SolutionFour layers of the FormaShield™ system were used in conjunction with EP-400 andPPR to prevent future leaks. The total repair zone is 12 inches. The FormaShield™fabric is 6” wide to allow for easy installation over odd geometry. As this was anew repair method for the facility, a detailed step-by-step instruction package wascreated.Repair MethodThe pipe was depressurized and lightly abraded. Remaining water was slowlyevacuated through the leaks. Any remaining water was removed by solvent wiping.The EP-400 was used to plug the slot at the joint and seal the two 1-inch holes.Once hardened and deemed drip free for 30 minutes, PPR was applied. The PPRwas an adhesive between the FormaShield™ and the lightly abraded fiberglasspipe. The FormaShield™ fabric was then saturated and applied as instructed tothe repair. Once hardened, a top-coat of PPR was applied as a protective coating.Upon re-pressurization, no leaks were detected deeming this a very successfulrepair. Final FormaShield™ Repair26 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
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28 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
StructuralRepairAccessories INTRODUCTION TO PIPELINE REPAIR SYSTEMS 29
Milliken® Infrastructure Solutions Easy to install Continue wrapping within minutesILI Markers Mark direction of flow ILI Detection Technology OIL, GAS + INDUSTRIAL Patented ILI Detection Technology Designed for Composite Repairs• Stop digging up already repaired defects• Easily installs within the composite repair• Comprised of rare earth magnets• Easily detected with ILI tools• US Patent #2014004816• Each set comes with 4 magnets (1” x 1”)• Installed within a composite repair• Rounded corners and thin profile prevent stress concentration points• Does not corrode Group together for stronger signalBefore using any Milliken Infrastructure Solutions, LLC product, the user must review the most recent version of the product’s technical data sheet, material safety data sheet and other applicable documents, available at infrastructure.milliken.com or by calling 1-855-655-6750.Milliken Infrastructure Solutions, LLC is a subsidiary of Milliken & Company. The Milliken logo is registered by Milliken & Company and used under license by Milliken Infrastructure Solutions, LLC, all rights reserved. Technologyinfrastructure.milliken.com855-655-675030 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
Systems forCorrosionPrevention INTRODUCTION TO PIPELINE REPAIR SYSTEMS 31
Milliken InfrastructurePipe Sock™Crevice Corrosion Mitigation System OIL, GAS + INDUSTRIAL Typical Uses The Pipe Sock system, a patented technology (Patent #US08087431 B2), The system is ideal for all pipe supportis superior in performance to similar products, through its ability to resolve applications where metal-to-metal contactproblems associated with crevice corrosion resulting from coating failure and crevice corrosion can occur:due to direct metal-to-metal contact. It consists of pre-formed size specific • Wear Padsfiberglass wear pad and a protective modified syl polymer adhesive coating • Pipe Supportssystem (Black Magic™) resulting in a high strength crevice corrosion solution. • ClampsThe Pipe Sock system offers a complete non-intrusive piping remediation • Pipe Isolatorswith the flexibility of accommodating various temperature requirements. • Pipe Protectors • SleepersMechanical Properties - Wear Pad BenefitsPROPERTIES UNITS METHOD VALUESPad Color Gray • Stop crevice corrosion due to coatingPad Thickness Inches D3039 0.25 failuresTensile Strength PSI D3039 54,000Tensile Modulus PSI D3165-07 3.08 x 106 • East to install with minimal surfaceInterlaminar Shear Strength PSI D695 8,200 prepCompressive Strength PSI D-2583 28,500Barcol Hardness ISO 11357-2 53 • No mixing or special equipmentGlass Transition 302°F METHOD • Prevents metal-to-metal contactPhysical Properties - Adhesive VALUES DIN 53505 Black • Compatible with cathodic protectionPHYSICAL PROPERTIES UNITS DIN 53504 225 DIN 53505 420 StorageColor DIN 53482 65Elongation >398 18 month shelf life when stored at 80°F.Tensile Strength Shelf life may be extended when stored atHardness lower temperatures, but above 40°F.Volume Resistivity % PSI Shore D OHM inchGeneral Properties - AdhesiveMaximum Temperature Resistance 250°FShelf Life 18 months if stored between 40°F - 80°FApplication Conditions Temperatures between 41°F-95°FBefore using any Milliken Infrastructure Solutions, LLC product, the user must review the most recent version of the product’s technical data sheet, material safety data sheet and other applicable documents, available at infrastructure.milliken.com or by calling 1-855-655-6750.Milliken Infrastructure Solutions, LLC is a subsidiary of Milliken & Company. The Milliken logo is registered by Milliken & Company and used under license by Milliken Infrastructure Solutions, LLC, all rights reserved. Technologyinfrastructure.milliken.com855-655-675032 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
EngineeringSupport INTRODUCTION TO PIPELINE REPAIR SYSTEMS 33
Milliken® Infrastructure SolutionsQuickCalc™Real Time Design OIL, GAS + INDUSTRIALReal Time Design for Pipe Supports• Portable tablet with custom Pipe Wrap app• Patent pending, user friendly application• Design repairs to ASME PCC-2 standards• Record location and take photos• Instant Engineering power at the tip of your fingers• Fully record pipe and defect parameters• Can be customized for individual company needs• Quick access to product data and installer manuals• Automatic report E-mailing if enabled Instant design analysisGenerate full documentation Before using any Milliken Infrastructure Solutions, LLC product, the user must review the most recent version of the product’s technical data sheet, material safety data sheet and other applicable documents, available at infrastructure.milliken.com or by calling 1-855-655-6750. Milliken Infrastructure Solutions, LLC is a subsidiary of Milliken & Company. The Milliken logo is registered by Milliken & Company and used under license by Milliken Infrastructure Solutions, LLC, all rights reserved. Technologyinfrastructure.milliken.com855-655-675034 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
INTRODUCTION TO PIPELINE REPAIR SYSTEMS 35
36 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
Repair Project Summary #N/A In the following documentation, a report is presented for Example Compnay of ExampleCompany. Pipe Wrap Inc. was approached to design a composite repair for a Transmission pipeline.The repair was designed to structurally reinforce the remaining pipe wall with a 20 year design life. The Carbon Steel pipe that was used for this repair had an outside diameter of 30 inches anda wall thickness of 0.375 inches. With a specified minimum yield stress of 52000 psi, the initial designpressure for this pipe was determined to be 1300 psi. Using the factors below, a maximum allowableoperating pressure of 936 psi was calculated.The following design factors were taken into considerationDesign temperature : 150 °F Temperature design factor : 1.00 0.72Location type : Class 1 Class design factor : 1.00Pipe joint type : Welded Pipe joint Factor : The Straight Pipe section suffered from 50% wall loss with external corrosion. With a defectlength of 6 inches the repair zone was calculated to be 24 inches long. After consideringenvironmental conditions, it was determined that the A+ Wrap system would provide the bestcomposite repair. Using the ASME PCC-2 and/or ISO 24817 standards, the minimum repair thicknesswas determined by utilizing the Performance Testing design equations. The minimum repair thickness was calculated to be 0.55 inches. Unique defect conditions,piping system components and installation techniques were then considered. The finalrecommended repair thickness was calculated as 0.55 inches, or 25 layers of the A+ Wrap system. When properly installed via the layer over layer method, this repair will restore the pressurebearing capabilities to a design pressure of 2479 psi and a maximum allowable operating pressure of936 psi.This repair was designed by : June 29, 2015 0 INTRODUCTION TO PIPELINE REPAIR SYSTEMS 37
Defect Photos and InformationLocation : MLV 51-52 30 Line Date : 6/23/2015Info : Composite Repair QuestionnaireLocation : Date : Info : Location : Date : Info :38 INTRODUCTION TO PIPELINE REPAIR SYSTEMS Page 3
Defect Photos and InformationLocation : MLV 51-52 30 Line Date : 6/23/2015 Info : Defect PhotoLocation : Date : Info : Info : Date :Location : INTRODUCTION TO PIPELINE REPAIR SYSTEMS 39
40 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
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Design Input Parameters and Material Properties Transmission pipeline A+ Wrap Carbon Steel Pipe Parameters Composite Properties Geometric Conditions Generic PropertiesActual Outsdie Diameter 30.000 inches Ply Thickness 0.022 inchWall Thickness 0.375 inches Company Minimum Layer Count 6 Strength of Materials Strength of MaterialsTensile Modulus 30,000,000 psi Hoop Modulus (psi) 3,010,000 psiYield Strength 52,000 psi HoopTensile Strength (psi) 51,700 psiTensile Strength 66,000 psi Long Term Strength (psi) 36,190 psi Pressure Conditions Axial Modulus (psi) 1,400,000 psiOperating Pressure 1,000 psi Shear Modulus (psi) 185,000 psiInstallation Pressure 1,000 psi Bending Modulus (psi) 1,920,000 psiDesign Pressure of Pristine Pipe 1,300 psi Poisson's Ratio (v) 0.077MAOP of Pristine Pipe 936 psi Effective Poisson's (v^2) 0.05 Piping system components - Repair thickness increase factor Component Dimensions Component Multiplier FactorDiameter of branch pipe of Tee N/AThickness of Branch Pipe of Tee 0.000 inches Tee N/A Factor Used: inches BendWall Thickness of Flange 0.000 inches Flange N/A 1.00External Diameter of Reducer N/A Pipe Design Factors 0.000 inches Reducer Composite Design FactorsClass Design Factor 0.72 Temperature Factor 1.00Pipe Temperature Factor 1.00 Service Factor 0.50Pipe Joint Factor (PJF) 1.00 Defect Type Factor 1.00 Defect DimensionsPrimary Defect Type External Corrosion Corrosion Depth 0.188 inchesDefect Length 6.00 inches Remaining Wall 0.188 inchesDefect Width 6.00 inches Wall Loss 50.0%Leaking now or at end of life? No Parameters for leak repair only Defect Properties Composite Leak-Related PropertiesIs pipe being depressurized? No Is a Stop-Gap being used? NoNo Leak Present Energy Release Rate (γ)Defect Shape No Leak Adhesive Lap Shear Strength 0.346 psi*inch 2,826 psi 5.64E-06 °F-1 Thermal ConsiderationsComposite Hoop CTE 1.13E-05 °F-1 Glass Transition Temp. (Tg) 0Composite Axial CTE 402 °FSubstrate CTE Heat Distortion Temp. (THDT) 150 °F 6.00E-06 °F-1 System Design TemperatureInstallation Temperature 72 °F System Operating Temperature 72 °FTm : Service Temperature Limits for Repair systems Temperature Derating Factor Pipe Condition : leaking no leaking Service Temperature (Tm) : 375 °FFrom Tg Measurement : Temp. Differential (Tm-Td) : 225 °F From HDT Measurement : 357 375 Temperature Factor (fT) : 1.00Minimum Cure Temperature : 375 °F 0 °F System Design Temperature Allowable Repair Laminate Strains Initial Allowable StrainAllowable Strain εc0 0.25% c fTc0 Ts c (Equation 10 a)Hoop Direction Adjusted for Temperature (Equation 10 b) ffTTca00 wheTTre(ΔTss=0°F ca)Allowable Strain εc 0.25% ca Axial Direction Initial Allowable Strain εa0 0.10% Adjusted for Temperature a fTa0 T(s a) εa 0.10% where ΔT = 0°F42 INTRODUCTION TO PIPELINE REPAIR SYSTEMS Page 7 © 2014 Pipe Wrap Inc.
FINAL DESIGN OUTPUTS Final Repair Thickness Determination Repair Type Structural ReinforcementStructural Design Methodology (Hoop) : Performance TestingPCC 2 Recommended Thickness (Hoop) : Minimum structural reinforcement is calculated. Shows PCC 2 Recommended Thickness (Axial) : 0.550 inches methodology and minimum thickness results. 0.000 inches Axial loading assumed to be a non-issue Piping System Component Multiplier : 1.00 Added safety factor to component shape Calculated Minimal Repair Thickness : 0.550 inches Company Minimal Repair Thickness : 0.132 inches Largest thickness listed above. Based on minimum layers to ensure stress transfer. Defect Type Multiplier : 1.00 Added safety factor due to defect considerations Recommended Repar Thickness : 0.550 inches Largest thickness multiplied by added safety factors results in Corresponding Layer Count : 25 final repair thickness and layer count. 3.4.8 Axial Length of Repair Minimum length over defect edge 5.93 inches ( X 2 ) (Equation 16) Length of defect (Equation 17) 6.00 inches Sum of Lengths : 17.86 inches Surface Prep Multiplier : 1 (Sand Blasting - ideal) Pig Marker Detectibilty : 4.00 inches Total Length : 21.86 inches Pristine Pipe Pressure AnalysisDesign Pressure (of pipe)MAOP 1300 psi 3,000 936 psi 2,500 Damaged Pipe 1000 Pressure (psi) 2,000Re-rated Design Pressure 650 psi 1,500Re-rated MAOP 468 psi 1,000Operating Pressure 1000 psi Composite Only 1829 psi 500 Damaged Pipe Rehabbed PipeDesign Pressure 1317 psiEquivalent MAOP 0 2479 psi Rehabbed Pipe Prist1in0e0P0ipeDesign PressureMAOP (limited to pristine MAOP) Design Pressure (of pipe) MAOP Operating Pressure 936 psi Geometric Design Results Calculated Adjusted ValuesRecommended Roll WidthTotal Fabric Material Required 12 inches Recommended Roll Width 0 inchesTotal Fabric Material Used Total Fabric Material RequiredTotal Coating Material Required 407 sq. ft Total Fabric Material Used 407.10 sq. ftTotal Defect Volume 420 sq. ft 0 sq. ft 31.42 sq. ft Total Coating Material Req. 0.00 sq. ft 6.7 cubic inches Total Defect Volume Repair Material Results 0.0 cubic inches Material Calculated Quantity and Size Material Custom Design Quantity and SizeRolls of A+ Wrap 4 each - 12\" x 90ft Rolls of A+ Wrap 1 each - 12\" x 60ftFiller Material EP-400 2 each - 4 OZ StickCoating Material PPR 1 each - 2 Qt Kits 1 each - 1 Pt Kits © 2014 Pipe Wrap Inc. INTRODUCTION TO PIPELINE REPAIR SYSTEMS Page 8 43
Calculation of repair thickness and length3.4.3.1 Underlying Substrate Does Not Yield --- Repair thickness sufficient to prevent substrate from achieving yield stresses at design pressure Hoop Stress Axial Stress Ps: 468 psi F: 918,916 lbf tmin: 2.392 inches tmin: 1.125 inches# layer 109 # layer 52 trepair: 2.398 inches trepair: 1.144 inches tmin D Es P Ps tmin D Es 2DF2 Ps 2s Ec 2s Ea (Equation 3) (Equation 4)3.4.3.2 Underlying Substrate Yields --- Repair thickness sufficient to hold stress at design pressure, allows pipe to yield. Based on allowable strains. Hoop Stress Axial Stress tmin: 0.737 inches 0.006 7474.463226 tmin: 0.000 inches# layer 34 0.003 1.92E+04 # layer 0trepair: 0.748 inches 15000.000 -18220.51495 trepair: 0.000 inchesc PD s ts Plive D trepair 1 PD sts 2 E c t repair E c t repair 2 ( E c t repair E s t s ) a Ea 4 (Equation 5) (Equation 7)3.4.4 Repair Laminate Allowable Strains --- Assumes substrate provides no strength; repair thickness required to hold full stress at design pressure Hoop Stress Axial Stress tmin: 2.508 inches tmin: 6.465 inches# layer 115 # layer 294trepair: 2.530 inches trepair: 6.468 inches trepair 1 PD Fvca trepair 1 F PDvca c 2Ec DEc a DEa 2Ec (Equation 8) (Equation 9)3.4.5 Repair Laminate Allowable Stresses Determined by Performance Testing. --- Based on 1,000 hour elevated stress hold. Design Life of: 20.00 years Performance Factor: 0.50 Hoop Stress Hoop Stress; Include substrate support tmin: 1.077 inches tmin: 0.539 inches# layer 49 # layer 25trepair: 1.078 inches trepair: 0.550 inches t min PD 1 t repair PD t s s 1 2 f .slt 2 f . s lt (Equation 11) (Equation 12)3.4.6 Leaking Components --- Only used when system is leaking or expected to leak at before end of life.Defect Shape: No Leak Hole Diameter: 0 inchesCircular or Near-Circular Hole inches (Equation 13) coeff-a 5.1E+02 0.000 tmin: inches (Equation 14) coeff-b 0.0E+00 0.000 0.000 trepair: inches coeff-d 0.0E+00 inches delta 0.0E+00 0.000 Axial Slots (small width) coeff-a 5.12E+02 0.000 tmin: coeff-b 0.00E+00 0.000 coeff-d 0.00E+00 trepair: delta 0.00E+00Hoop Slots (small width) (Equation 14) coeff-a 5.12E+02 0.000 coeff-b 0.00E+00 0.000 tmin: inches coeff-d 0.00E+00 delta 0.000trepair: inches 0.00E+00 (Equation 15)Large Width Slots (Upper Bound) FALSE Max Pressure 855 tmin: inches For slot: #DIV/0!trepair: inches Leak Repair Thickness: 0.000 © 2014 Pipe Wrap Inc. Page 944 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
Additional Calculations3.4.10.1 External Loads --- Used when a vacuum is present or when concern of external soil pressure is present Soil Loading Vacuum Loads 0.072 lb/in.3PVacuum: 0 psi Soil unit weight: 0 inches 0.192 inches Buried depth: 9 tmin: 0.000 inches tmin:# layer 0 # layertrepair: 0.000 inches trepair: 0.198 inches ͵(ͳ − ������������ʹ)������������������������ ͳ͵ Ͷ ������������ ������������������������ʹ ͳ ������������ ʹ ʹ������������������������ ������������������������������������������������ ͵ ʹ������������������������ ������������������������ ʹ ͺ ͵ ʹ ͵(ͳ − ������������ʹ) ������������ ������������������������������������������������ ൌ ������������ ������������ ℎ − ℎ ������������������������������������������������������������ ൏ (Equation 19) (Equation 20)3.4.10.2 Cyclic Loading --- New performance factor used when cycles during design life exceeds 7,000. Non-leaking defects Leaking defectsRc: 1.000 (Pmin / Pmax) Rc: 1.000 (Pmin / Pmax) N: 0 (Cycle Count)N: 0 (Cycle Count)fc: 1.000 fc: 1.000 ������������������������ ൌ ���������������ʹ��������� (ͳ − ���������������ʹ��������� ) ǤͳͲͺ ������������ ൌ ͲǤ͵͵͵ ���������������ʹ��������� (ͳ − ���������������ʹ��������� ) ǤͳͲͺ ʹǤͺͺͺ������������������������������������(������������) − ʹǤͺͺͺ������������������������������������(������������) − (Equation 21) (Equation 22)Dent Calculations --- Assumes loss in remaining pipe strength based on dent depth to pipe diameter ratio SMYS Reduction Dent Depth: inches (assumed) d/D: psiStrength Loss: New SMYS:Where f (safety factor) = 2.5 Dent PristineTank Patch Repair --- Side of tank; designed to reinforce pressure containment. Horizontal Length of Repair Vertical Length or RepairDefect Length (Vertical) (L*2) : Defect Length (Horizontal) (L*2) : Modulus : 6.00 inches Horizonatal Modulus : 6.00 inches 1,400,000 psi 3,010,000 psi Strain Allowable : 0.10% Horizontal Strain Allowable : 0.25%Lap Shear Strength (τ) : Lap Shear Strength (τ) : 2,826 psi 2,826 psi������������������������������������������������������������ = ������������������������ ε������������ ������������������������������������������������������������������������������������ = 0.27 inches ������������������������������������������������������������ = ������������������������ ε������������ ������������������������������������������������������������������������������������ = 1.45 inches τ τ Ltaper = 2.75 inches Ltaper = 2.75 inches 14.41 inchesMinimum Repair Length : 12.04 inches Minimum Repair Length :Recommended Repair Length : Recommended Repair Length : 30 inches 30 inches30 FALSE Patch Area : 30 in. x 30 in.Tank Patch Repair --- Roof Kits, designed to hold a certain load. σFlexural : psi σ������������������������������������������������������������������������������������������������ = 3 ∗ ������������ ∗ ������������ Minimum Thickness : inchesLoad (P) : lbs 2 ∗ ������������ ∗ ������������⬚2 # Layer : inches Repair Thickness : Ply Sequencing EXAMPLE (first 4 layers shown) All wraps in the same \"layer\" should overlap 1 inch ||||||||||| ||||||||||| ||||||||||| ||||||||||| ||||||||||| ||||||||||| Horizontal Direction Horizontal Direction Horizontal Direction Horizontal Direction INTRODUCTION TO PIPELINE REPAIR SYSTEMS |---------------- 12 in. ----------------| Defect Center |---------------- 12 in. ----------------| 45 |---------------------------------------- 12 in. ----------------------------------------|
Installation Method for A+ WrapSurface preparation with Sand Blasting - ideal.Sandblast pipe to 2.5 mil profile (NACE 3 minimum) and ensure the removal all SHARP EDGES and softcoatings for repair zone. Solvent wipe.Apply the Load Transfer Filler, EP-400.Put on protective gloves and knead EP-400 epoxy putty until uniform in color. Apply to all voids and\"tented\" areas.Apply Base Coating of PPR.Measure equal parts, by volume, of the PPR-2 Coating material in a clean container. Mix thoroughlyand allow material set 10-20 minutes before applying to the pipe surface. Ensure a minimum of 30-mil coverage.A+ Wrap Preparation method.When ready to use, remove roll from foil pouch and submerse in water for approximately 1 minute.Apply the A+ Wrap repair.Begin wrapping around the pipe surface (“Repair Zone”) while applying uniform tension. When thematerial has overlapped itself, begin pulling tightly during the remainder of the application.Thoroughly saturate each layer of material with water during application.Completing the A+ Wrap installation.Using the provided constrictor wrap, tightly apply 4-6 layers extending over the repair. Perforate thesurface of the Compression Wrap (constrictor).Allow A+ Wrap system to cure.Allow to cure for 2 hours. System will appear to bubble through perforation; it is releasing CarbonDioxide. Once bubbles harden, remove constrictor wrap. System will continue to degas after beinghardened for several more hours.Apply Top Coating of PPR if neccessary.Measure equal parts, by volume, of the PPR-2 Coating material in a clean container. Mix thoroughlyand allow material set 10-20 minutes before applying to the pipe surface. Ensure a minimum of 30-mil coverage. © 2014 Pipe Wrap Inc. Page 1146 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
Quality Verification Form For A+ WrapINSTRUCTIONS: EACH ITEM LISTED REQUIRES VERIFICATION THAT THE STEP HAS BEEN COMPLETEDIN ACCORDANCE WITH THE APPLICATION PROCEDURE.Name of Technicians (Print): ______________________________Signatures: ____________________________________________Name of Company Representative (Print): ___________________Signatures: ____________________________________________Date of Application: ____________________________________NOTE - THE USE OF STANDARD PPE IS REQUIRED TO PROMOTE SAFETY1. THESE STEPS to be followed if a dent is detecteda. Depth of dent should be evaluated to assure it is acceptable for repairb. Once dent area has been cleaned by sandblasting NDE using Dye Penetrant or other acceptable method to assure that no cracks exist.c. If any stress cracks are detected they must be removed and re-inspected before proceeding.d. Proceed to step 2Name of Authorized Inspector (Print): _________________________________________Acceptable _______ Not Acceptable _______ Signature: __________________________2. Mark the ends of the designated repair zone. Unless otherwise specified, the center of the defect shall beconsidered to be the center of the repair zone.Initials ________________________3. Ensure NACE 3 abraded surface and ensure the removal all soft coatings.Initials ________________________4. Solvent wipe with acetone or MEK and allow to flash for 1-2 minutes.Initials ________________________5. THIS STEP ONLY FOR TEMPERATURES BELOW 40 ᵒF (5 ᵒC)Place the putty or paste, primer and rolls of A+ Wrap in a warm place for a minimum of 30 minutes. Leavematerials until ready for use.Initials ________________________ Start Time____________ End Time_____________6. Mix the load transfer Epoxy Putty by kneading (compressing it back and forth) for 2-3 minutes with the indexfinger and thumb until uniform in color and \"streak-free\". If Epoxy Paste material is used,mix equal volumes ofPart A & B until uniform in color without streaks.Initials ________________________ Batch Number_____________________7. Apply the load transfer filler to all defect areas with greater than 20% wall loss and blend to a smoothpipe contour. \"Tented areas\" are also to be considered.Initials ________________________ INTRODUCTION TO PIPELINE REPAIR SYSTEMS 47
8. Mix the adhesive in equal volumes of Part A & B until uniform in color without streaks.Initials ________________________ Batch Number_____________________9. Apply a thin layer of adhesive to the entire repair zone.Initials _____ __________________________10. THIS STEP ONLY WHEN ILI MARKERS (SMART PIG DETECTOR TABS) ARE USEDThe Detector Tab kits contain 4 each - ILI Markers which are placed at both ends of the repair. Read steps \"A\" thru \"E\", then proceed to Step 11 below.A. Apply a layer of the A+ Wrap™ onto the pipe Primer Coating.B. Apply a small swatch of additional coating onto the wrap where the detector tab(s) are to be located -approximately 1” from the edge.C. Firmly seat the Detector Tabs into the primer coat.D. Apply more primer coat to cover the Detector Tabs.E. Continue applying the A+ Wrap to the repair zone.Initial ___________________11. Apply the A+™ Wrap. Open ONLY ONE (1) ROLL AT A TIME. Open the pouch and submerse in a bucket ofwater for a minimum of one (1) minute. Wind two (2) wraps of the A+ Wrap™ around the pipe, then pulltightly. Ensure to liberally spray water on every layer of the A+ Wrap™ and keep constant tension on the rollduring application. In the event that the repair area is longer than the width of the roll – Employ the “Cigar Wrap”technique while ensuring that there is a minimum of a 50% overlap of the material. Begin the initial wrappingwith 2 layers (720°) before beginning the 50% overlap. Ensure there are 2 layers (720°) on the other end of therepair before reversing directions. Continue to apply A+ Wrap™ until the specified number of layers is completed.Initials ________________________12. Apply the Constrictor Wrap tightly around the A+ Wrap™ with a minimum of six (6) Layers.Initials ________________________13. Apply Minimal Pressure to Perforate the Constrictor Wrap using the perforating tool. This step is critical toensure that the composite material will sufficiently out-gas and to prevent void within the A+ Wrap™ material. Once theOnce the Constrictor Wrap is applied and perforated, inspect for “bulging spots”. This is an indication that theCompression Wrap has not been sufficiently perforated in that particular area. Re-perforate to correct.Initials ________________________14. Allow the materials to cure for a minimum of two (2) hours.�Initials ________________________ Start Time____________ End Time_____________15. After cure, remove the Constrictor Wrap, then use a Shore A Pencil Durometer Tester to measure the cure ofthe A+ WrapTM. The value to be a minimum of 72 on the Shore D Scale.Initials ________________________ Record Durometer Reading ______________16. Use either a Pi-Tape or Height Measurements to ensure that the correct material thickness has been applied.Initials ________________________ Repair Thickness ______________________17. Perform a basic Ultrasonic Test (Tap Test). Lightly \"tap\" the repaired surface. Listen for any flat or \"dead\"sounds. This will indicate the lack of intimate compaction of the repair (voids, delaminations or disbondedregion). Any localized area greater than 1\" x 1\" is unacceptable.�Initials ________________________ Acceptable/Unacceptable ______________________48 INTRODUCTION TO PIPELINE REPAIR SYSTEMS
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