Composite Repair forPlants WorkshopComposite Repair forPlants WorkshopHosted by Stress Engineering Services, Inc. | Houston, TexasWednesday, June 23, 2010 | 8:00 AM to 3:00 PM)Hosted by Stress Engineering Services, Inc. | Houston, TexasWednesday, June 23, 2010 | 8:00 AM to 3:00 PM)

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Workshop Sponsors Air Logistics, Inc. Armor Plate, Inc. Comptek Structural Composites Furmanite America Neptune Research, Inc. Pipe Wrap, LLC TechCorr USA, LLC TechnoPipe America / Walker Technical Resources Western Specialties Wrap Master

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Todays Agenda8:00 8:30 Meet, Greet, and Check-in8:30 8:45 Workshop Overview and Group Introductions

Safety Moment with Danny Krzywicki, Stress Engineering8:45 9:15 Composite review overview, Chris Alexander9:15 9:45 Paul Hill, Furmanite9:45 10:00 Break and Exhibit Time10:00 10:30 Simon Frost, Walker Technical Resources10:30 11:00 Tommy Precht, Armor Plate, Inc.11:00 11:30 Bart Davis, Neptune Research, Inc.11:30 12:30 Lunch and Exhibit12:30 1:00 Dean Damin, Invista (Informal Comments)1:00 1:30 James Teets / Jordan Addison, LyondellBasell (Informal Comments)1:30 2:00 Open Forum Discussion2:00 2:15 Wrap-up and Conclusion2:15 3:00 Exhibit Time and Optional Metallurgy and Testing Labs Tour

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Composite Review Overview Current industry standards Pipeline-sponsored Joint Industry Projects (JIPs)

MMS study on using composite materials offshoreLong-term buried pipe study (up to 10 years)Repair of dented pipelines

Issues for pipelines Issues for plants Composite Repair Users Group Where are we going?

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Current Industry Standards ASME PCC-2-2008

Repair of Pressure Equipment and Piping

ISO 24817:2006Petroleum, petrochemical and natural gas industries -- Composite repairs for pipework-- Qualification and design, installation, testing and inspection

Documents set a foundation for consistent, well-designed composite repairs

Emphasis on performance testing

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Joint Industry Projects

Minerals Management ServicesStudy to evaluate repair of offshore risersProgram budget of $180,000 (5 manufacturers)

PRCI long-term buried pipe study$400,000 from PRCI$1,440,000 contributions from 13 manufacturers

PRCI dented pipe study$100,000 from PRCI$310,00 contributions from 7 manufacturers

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Long-term Buried Pipe Study Program objective is to validate composite materials for

long-term (LT) service PRCI-sponsored program with co-funding from

manufacturers Twelve (13) companies participating in study

Five 10-year study participants (21 samples each)Eight 3-year study participants (12 samples each)

201 total 8-ft samples (162 are buried) Results are reported to PRCI anonymously, although

each manufacturer will receive their results (manufacturers encouraged to identify themselves)

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Program Specific Details Depths of corrosion

40 percent60 percent75 percent

Pressure cycling (P = 36% MAOP, 900 per year)

Recent testing has shown fatigue lives ranging from 20,000 to 500,000 cycles at this pressure level with 75% corrosion defects

Strain gage installation (monitored quarterly) Burst tests (Years 0, 1, 2, 3, 5, 7.5, and 10)

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12.75-inch x 0.375-inch, Grade X42 pipe (8-feet long)

8 inches long0.75-inch radius (at least)

0.375 inches Three (3) different corrosion levels:40% corrosion: remaining wall of 0.225 inches60% corrosion: remaining wall of 0.150 inches75% corrosion: remaining wall of 0.093 inches

Break corners (all around)

Details on machining(machined area is 8 inches long by 6 inches wide)

Note uniform wall inmachined region

6 inches

8 feet(center machined area on sample)

NOTE: Perform all machining 180 degreesfrom longitudinal ERW seam.

Test Sample Details

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Strain Gage Installation1

2 3

Gage #4 on repair

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Field Work Photos (1/3)

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Field Work Photos (2/3)

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Field Work Photos (3/3)

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Participants Armor Plate, Inc. (10 years) Air Logistics Corporation (3 years) Clock Spring Company, LLC (3 years) Citadel Technologies (10 years) EMS Group (10 years) Pipe Wrap, LLC (3 years) T.D. Williamson, Inc. (10 years) Walker Technical Resources Ltd. (3 years) Wrap Master (3 years) 3X Engineering (3 years) Furmanite (3 years) Neptune (3 years) Pipestream (10 years)

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Program Web Site(www.compositerepairstudy.com)

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PRCI Dented Pipe Study Nine (9) repair systems participating in study

2 rigid coil system (one E-glass & one steel)3 carbon systems4 E-glass systems

One unrepaired test sample served as baseline 60 total dents in study Program objective is to validate composite

materials for repairing dents

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Test Sample Details Program test matrix (60 total samples)

Plain dent (unrepaired)Dent interacting with girth weld (unrepaired)Dent interacting with ERW seam weld (unrepaired)Plain dent (repaired)Dent interacting with girth weld (repaired)Dent interacting with ERW seam weld (repaired)

Pipe: 12.75-inch x 0.188-inch, Grade X42 Measure strain using strain gages Cycle samples to failure (P=72% SMYS) Participants: Air Logistics, Armor Plate, Citadel, Pipe

Wrap A+, Furmanite, WrapMaster, and Pipestream (9 different systems - 8 have been tested)

SES PN118690

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Plain Dents (2)

Side View of Pipe Sample (6 defects total)

Top View of Pipe Sample(notice position of dents relative to welds)

ERW pipe seam

Girth welds (2)

Dent in Seam Weld (2)

Dent in Girth Weld (2)4-ft (typ)

28-ft (two 4-ft sections plus one 20-ft section)

Dented Pipeline Samples Strain Gage LocationsSamples fabricated using 12.75-inch x 0.188-inch, Grade X42 pipe material

Dent centerDent center

2-in

Gage #2Gage #2 Gage #3Gage #3 Gage #4Gage #4 Gage #5Gage #5 Gage #6Gage #6 Gage #7Gage #7

Gage #1 (24 inches from end)

Close-up View of Dented Region

(approximate region having minimum radius of curvature)

Notice orientationof bossets

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Generating Dent Photos (1/3)

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Generating Dent Photos (2/3)

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Generating Dent Photos (3/3)

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Cycles to Failure for Composite Repaired DentsDents initially 15% of OD installed in 12.75-inch x 0.188-inch, Grade X42 pipe using a 4-inch end cap. Dents installed with 72%SMYS pressure in pipe and cycled to failure at = 72% SMYS.

1,000

10,000

100,000

1,000,000

ERW-1 ERW-2 PD-1 PD-2 GW-1 GW-2Dent Type

(ERW: dent in ERW seam | PD: plain dent | GW: dent in girth weld)

Cyc

les

to F

ailu

re

Product AProduct BProduct CProduct DProduct EProduct FProduct GProduct HUnrepaired

250,000 cycles considered run-out

One system was pressure cycled to 358,470 cycles after which the ERW seam failed.

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Unique Issues for Pipelines

Wet soil environment (long-term performance) Forces generated by soil settlement Large pressures (i.e. large design stresses

permitted by ASME B31.4 and B31.8) Pressure cycling (sometimes aggressive with

large stress ranges) Third-party damage including dents and gouges Elevated design stresses (e.g. up to 80% of the

minimum yield stress)

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Unique Issues for Plants Safety issues due to close proximity of

personnel in plants (ASME B31.1 and B31.3) Elevated temperatures Under insulation corrosion Cyclic pressures and temperatures Bending, tension, and compression loads due to

thermal expansion (often cyclic) Repair of leaks Above ground (weather and UV exposure) Aggressive chemical environments

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Composite Repair Users Group

Formed to promote the safe use of properly-designed composite repair systems

Initial efforts driven by composite manufacturersDevelopment of by-laws with group objectivesMembership classesElected Officers / Executive Committee

Officially open for business to industry-at-large this September please come join us (we need your input)

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Where are we going?

Enhanced developments in terms of fiber materials and matrix polymers are expected

Greater acceptance and use of industry standards such as ASME PCC-2 / ISO 24817

Development of industry-sponsored JIPs to address issues specific to the plants

Utilize the resources and companies participating in the Composite Repair Users Group