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Cold work surface preparation
Transcript of Ecoforce Marketing Slides_NEW2mail
Mission Statement
A Brief History of Cold Works
Composite Repair and Rehabilitation technology has been around for 30 Years
The greatest challenge was surface preparation was still considered “hot works” i.eSand Blast, Conventional Power Tools
To complete the portfolio and be 100% “cold works” solution provider, Safety Tools Allmet AS cold grinding and cutting technology was bundled together as a holistic solution.
Cold Works Process
Warranty Cycle begins
Project Completion and Hand Over
OSAT – On Site Acceptance Test
Run In Test
Testing and Commissioning
Customer Inspection
Curing Process
Application of Composite Repair
Customer Inspection
Surface Preparation using Ex Certified Cold Grinding Methods
Customer Approval Process
Pre – Work Safety Training
Pre – Work Testing
Risks Assessment
Customer enquiries to Sales Department
Revert to Sales on
alternative solution
Check operating pressure and temperature
Fill up engineering assessment form and submit
to Technical Department
Sales verify if defect is leaking or not
Leaking?
Yes
Leaking?
No
Prepare proposal and Site Survey
Perform risks assessment
and proposed solution
Refer customer to alternative solution of
check if operation can
be halted temporarily
for repair
Defect
within
Composite
Capability ?
No
Defect
within
Composite
Capability ?
Yes
Pressure and
Temperature
within
capability?
Yes
Pressure and
Temperature
within
capability? No
The importance of compliance and certifications in Oil and Gas
Are composites an established and compliant repair method according to ASME PCC-2?
Article 4.1 and 4.2 of ASME PCC-2 guidelines for post construction repairs using composite
What defines composite “long term repair” and temporary repair?
As a guideline, external corrosion not more than 80%
repaired with composites may be regarded as a long
term repair solution under condition that
all loose rust, contaminants are
removed and surface preparation
performed to required standard
What defines composite “long term repair” and temporary repair?
For external defects, all loose rust and contaminants must be removed and defect filled with suitable filler material for load
transfer to composite. The corrosion is assumed to have
halted and pipe’s design specifications restored.
This may be regarded as a long term solution because all
external corrosion has stopped and pipe’s integrity restored.
For internal corrosion, the defect may eventually become a through wall defect. As such, the composite
must be engineered to hold an eventual leaking defect.
Composites can be engineered to have a longer repair if the corrosion rate is known.
All sections with internal defects are affected by constant changes
and any repairs cannot be regarded as permanent.
However, if shutdown and replacement is not an option,
composites may still be the best solution.
A brief comparison between repair methods (Example: 1 metre section of 20 inch crude oil line with severe external corrosion wall loss
Replacement Program (Hot Works)
Hot Tapping and Bypass (Cold Works)
Stop Leak Mechanical clamps with compound
injection
Cold Works Surface Preparation and
Composite Rehabilitation
Cost Project > 1 million bahtLoss of production > 10
million baht a day
Project > 1 million 500,000 baht to 1 million baht
In general, only 10% to 15% of the other repair
methods
Duration More than 3 weeks More than 3 weeks At least 1 week 1 Day and service uninterrupted
Risks Stop Production and High Risks
Loss in Production Capability because bypass lines are
smaller in diameter
Extremely Heavy and can damage pipeline
Places between two clamps leaks may surface
No change in production capability
Effectiveness New pipe sections with original design. Same
material means corrosion problems will start again
Modified pipe runs and reduced capacity
Good for stop leak but does not provide engineered axial
reinforcementCompounds may enter the
pipe process
Composites can be engineered to meet or
exceed the original pipeline SMYS, MAOP,
Design Pressure and Tensile strength and
extremely lightweight
Service Life Crude Oil and Seawater will corrode carbon steel
Crude Oil and Seawater will corrode carbon steel
Needs to constantly refill compound when loss from
through hole defect
Composite systems are not affected by corrosion and
have minimum service life of 20 years
Surface preparation to optimize composite repair and halt further degradation
If grit blasting to SA2.5 is not permitted due to risks, surface preparation power tools must be tested to ensure they create the required surface profile for adhesion
All our explosion proof, EX certified tools for surface preparation are tested to ensure profile is optimized for composite repairs
We stress on the importance of surface preparation for all our composite applications.
“A leader in Cold Works
Composite Technology
with wide-ranging stocks
located at any of our
WRAP offices in APAC“
Perry Sim
(Managing Director)
Finance & Administration
Chong Cheu Peng
(Accounts
Executive)
Sharon Ng
(Account Manager)
Lim Chien Mei
(Operation & Admin
Manager)
Information Technology
Thailand
(Ecoforce
Thailand/WRAP
)
Australia
Sales & Engineering
Team
Logistic
Delson Moo
(IT Development)
Chaw Kuan Mun
(Warehouse Manager)
TBA
(Warehouse Asst.)
Indonesia BruneiSingapore
Perry Sim
(Regional Sales Director
& Technical Engineer)
Shang Loong
(Senior Technical
Engineer)
Leonard Lim
(Sales Engineer)
Orawan
Sanglertrattanakul
(Sales Manager)
Soemanto S.E
(Sales Engineer)
Spencer Jembat
(Sales Engineer)Rex Sim
(Business Manager &
Technical Engineer)
HSE Team
Alex Chow
HSE Officer
Vietnam
Khanh Vu
(Director)
Opportunities
4th
Spot problems that may lead to
eventual leakse.g pipe supports
5th
Leaking Defects requiring leak
sealing and reinforcement
1st
Pipelines Replacement
Programs
2nd
New projectsCorrosion
Protection Products
3rd
Post Construction Defects e.g welds,
metal fatigue
Market Sectors
Strong References available upon request
Refer Process line no.Design Operating
Remark
Pressure Temperature Pressure Temperature
DR10 1101-PG-A10219-16"-B6101-N89.5 120 68.5 28 Completed
DR17 1116-NG-160410-4"-B1101-N17.9 65 7.5 25 Completed
DR34 1119-HFG-190104-4"-B3101-N43.5 -29 / 175 30 50 Completed
DR43 1119-HFG-250134-3"-B3101-W43.5 -29 / 175 30 50 Completed
DR51 1106-DHPF-110918-18"-B1101-N17.9 65 0.06 30 Completed
Down stream of PV1744 1106-PG-060941-18"-B6101-N79 19 / 70 35 - 45 20 Completed
Up stream of PV1744 1106-PG-060941-18"-B6101-N79 19 / 70 70 50 Completed
Up stream of FV1745 1106-PG-060818-18"-B6101-N79 19 / 150 71 50 Completed
Down stream of FV1745 1106-PG-060932-18"-B6101-N79 19 / 70 70 50 Completed
DR 14 1106-PG-060941-18"-B6101-N79 19 / 70 70 50 Completed
INM 01 1106-PG-060941-18"-B6101-N79 19 / 70 70 50 Completed
INM 02 1106-PG-060941-18"-B6101-N79 19 / 70 70 50 Completed
Up stream of FV1745 1106-PG-060818-18"-B6101-N79 19 / 150 71 50 Completed
Down stream of FV1745 1106-PG-060932-18"-B6101-N79 19 / 70 70 50 Completed
INM 01 1106-PG-060932-18"-B6101-N79 19 / 70 70 50 Completed
INM 02 1106-PG-060932-18"-B6101-N79 19 / 70 70 50 Completed
Drain line 3" 1106-PG-060941-18"-B6101-N 79 19 / 70 35 - 45 20 Completed
By pass 2"
1106-PG-060941-18"-B6101-N79 19 / 70 35 - 45 20 Completed
Up stream of XV4008 1104-HFG-190128-3"B6101-N90 19 / 65 20 78 Completed
Up stream of PV4052A
1119-HFG-190105-3"-B3101-N36 5 / 65. 30 35 Completed
Down stream of PV4052A
1119-HFG-190221-6"-B1201-N11 .-15 / 65 8 25 Completed
DR 33 1119-HFG-190103-6"-B3101-N 36 5 / 65. 30 35 Completed
DR 36
1119-LFG-190205-6"-B1201-W11 19 / 65 7.5 46 Completed
PT of 1119-D-01
1119-HFG-190103-6"-B3101-N36 5 / 65. 30 35 Completed
Down stream of PV4011
1119-HFG-190101-6"-B3101-N36 5 / 65. 30 35 Completed
4 plies base carbon fibre and 1 ply encapsulating fiber over the 4 plies to finish. Leak point must be patched with steel putty first before application of composite repair system
Approximately 20” by 20” (near D, S7)
0102030405060
Work Days
Cost, 100K
Corrective Action Inspection Repair (CAIR)
1. Successful CAIR program designed to
intervene in the elimination stage
2. Results in 90% reduction of leaks.
3. 2010 to present – no unplanned shutdown as
a result of CAIR program.
In less than 24 hours, WRAP was able to
restore the integrity to a pipeline which
would have taken months to repair. The
turnkey solution is performed under a cold
work permit using state of the art tools.
Pipeline operates at full capacity in 24 hours.
Responsibility – All our customers’ projects are treated as unique and all work procedures are documented
Professionalism – We have the most proficient work method statement
Experience – 5 Years of solid experience with knowledge sharing amongst our APAC presence
Focus – We do only composites and composites is our only business
Understanding – We have pool of researchers and engineers pioneering in chemical engineering and materials engineering. We provide answers to our customers with full confidence
Integrity – We do not execute a job when the design considerations are over what is recommended or tested
Maintenance
supervisor
Maintenance Supervisors shall be in charge of the maintenance organisation setup. He is supported by a
group of highly trained and experienced supporting staff.
He shall be in charge of the Maintenance Team, liaise and coordinate with the customer when
maintenance operations have to be done on Site.
Quality engineer The quality engineer monitors the quality process on the maintenance actions. Systematic reviews by the
Quality Engineer ensure the expected level of quality during the maintenance activity
Technical support The technical support is available should any problems occur that cannot be resolved by the maintenance
team. The technical support can be any of the WRAP APAC entities.
Maintenance team The maintenance team shall report to the maintenance supervisor for the activities pertaining to the
maintenance of the System. They shall be involved in the corrective and preventive maintenance
activities. In order to achieve the required target, the team shall be contactable on a rotation shift for 24
hours operation throughout 365 days.
Note: The point of contact shall be Sales and Marketing Team, 24/7. The sales and marketing team shall
inform local team of the defect. If resources are occupied at time of report, resources will be drawn from any
of the APAC offices. The defect must be handled by the Technical Authority that executed the job.
