Furmanite Composite Repair Technology - · PDF fileFurmaniteFurmanite s’s engineered...

Furmanite’sFurmanite sengineered

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VALIDATIONVALIDATION

Dr Paul Hill CEngDirector – Furmanite Center of ExcellenceComposite Repairs

FurmaniteOperating in Over 40 CountriesOperating in Over 40 Countries

Corporate Headquarters:Furmanite Worldwide Inc. 2435 North Central Expressway Operating in Over 40 Countries Operating in Over 40 Countries

1800+ Employees1800+ EmployeesTurnover $300MTurnover $300M

ExpresswaySuite 700RichardsonTEXAS 7508075080USATel: 001 972 699 4000

Furmanite International LtdFurman HouseKendal LA9 6RUUKTel: +441539 729009E il l k@f iEmail: [email protected]

Furmanite B.V.Driemanssteeweg 1503084 CB R tt d3084 CB RotterdamNetherlandsTel: +31 (0)10 7420940Email: [email protected]

On-site servicesOn site services Leak sealing

Pipeline intervention Pipeline intervention

Valve repair

Composite repairp p

In-situ machining

Trevitest valve testing

Heat treatment

Metal disintegration

Controlled bolting/PSIM

SmartShim

FurmaSeal clamps

Passive fire protection

Composite repair technology

F it it Epoxy bond to pipe provides leak sealing and chemical and environmental resistance

FillerFurmanite composite repair technology Repairs based on fibre-

reinforced polymers (composites)

Repairs are fully engineered

No hot work required

No interruption to plant operation

Repairs can last life of plant Repairs can last life of plant

Lightweight repair kits are easy to transport and handle

Structural repair provided by fibre reinforcement

Materials formed to shape on site with no prefabrication

Repairs are close fitting and can be applied in confined spaces

D di t d t h l ti d d


Dedicated technology – meeting demands safely and economically

The emergency repair contingency solution

The low pressure strengthening and repair optioncontingency solution and repair option

For straightforward, compliant strengthening repairs

The high pressure strengthening and repair technology


Keep it in stock to deal with unexpected leaks

Quick and simple to install, high performance temporary repair Immerse in water wrap and Immerse in water, wrap and

allow to cure

Full strength in 30 minutes

Gives you time to implement a longer term strategy

Cost-effective – we’ll train your Cost-effective – we ll train your team to use it

FurmaFast bonds to all pipe materials and is resistant to many chemicalsy


Designed to strengthen and/or repair pipes where defects are not leakingnot leaking

Ideal where corrosion has reduced wall thickness below minimum allowableallowable

Can be used in splash zones, underwater and on wet surfaces

Available in range of widths and lengths to suit pipe sizes and defects

Validated in accordance with ISO TS Validated in accordance with ISO TS 24817 and ASME PPC-2 Article 4.1


Designed for repair and strengthening of pipes with through-wall damagethrough wall damage

The strength and stiffness of the glass fibre reinforcement makes this ideal for lower pressure orthis ideal for lower pressure or smaller diameter lines

Suitable for flat surfaces, tank ll t k fl i twalls, tank floors, pipes, tees,

reducers, elbows, etc

Supplied in accordance with ppISO TS 24817 and ASMEPCC-2 Article 4.1

Recommended for pressures up to 20 bar (300 psi)


High performance option for repair and strengthening where damage is through-wallwall

Ultimate strength and stiffness of carbon fibre enables applications from 10 bar (150 psi) to over 200 bar (3000 psi)(150 psi) to over 200 bar (3000 psi)

High bond strength and chemical resistance

Tested to prove long term suitability for pipeline repair

Ideal for local repair renovation of entire Ideal for local repair, renovation of entire lines or even corrosion protection

High performance, high pressure strengthening and repair technology for demanding applications

Demonstrating fitness for purpose of Composite repair technology

composite repairsHistory of Furmanite’s technology:

1994-8 Development programmes sponsored by Mobil and Shell

1999 Amerada Hess, BP, Elf, Shell and , , ,Texaco employ technology The advantages and potential of composite

repairs was clear, but guidance was necessary to ensure controlnecessary to ensure control

Shell and BP initiate project to develop design specifications and guidance notes

2000 Design guide released Significant test programme completed to

validate assumptions

2005 ASME PCC-2 Article 4.1 published

2006 ISO TS 24817 published ASME and ISO guidance is based on the S a d SO gu da ce s based o t e

guide produced in 2000

ASME PCC-2 Article 4 1 andComposite repair technology

ASME PCC 2 Article 4.1 and ISO TS 24817

Th id t i d t il d The guidance notes give detailed requirements for Specification of the repair

f i tperformance requirements Validation testing of the Repair

System Design justification for repair

thickness Training requirements for

i t llinstallers Key steps in installation

proceduresI i f l d i Inspection of completed repairs

In-service management of repairs

Validation RequirementsComposite repair technology

Validation Requirements The documents treat a repair system as

the combination of:the combination of: Pipe substrate Surface Preparation Method Repair materials

If one of the elements is changed, then requalification is required

The standard only provides a method to determine the thickness of composite required

It DOES NOT consider whether a composite repair is a wise choice

Specified Validation TestingComposite repair technology

Specified Validation TestingMaterial Property Test method

Mechanical properties Young’s modulus ISO 527 or ASTM D3039p p gPoisson’s ratio Shear modulus

Thermal expansion coefficient Glass transition temperature

ISO 527 or ASTM D3039ASTM D5379

ISO 11359 or ASTM D696ISO 11357-2, ISO 75 or ASTM D6604p

Barcol or shore hardness ,

BS EN 59, ISO 868 or ASTM D2583Adhesion strength Lap shear BS EN 1465 or ASTM D3165Performance data Long term strength (optional)

Energy release rate Detailed in guidelines 2&3

gyShort term pipe spool survival

test

Validation TestingComposite repair technology

Validation TestingFabric Carbon Carbon

Directional Properties Not Directional Hoop and Axialp pResin Type Standard Standard

Glass Transition Temperature, oC 88 88Stiffnes in hoop direction of pipe, GPa 34.7 59.5Stiffnes in axial direction of pipe, GPa 34.7 32.3

Poissons ratio 0.32 0.03Thermal expansion coefficient in

hoop direction of pipe, x10-6m/m/oC 11.7 10.7

Thermal expansion coefficient in axial direction of pipe, x10-6m/m/oC 11.7 20.9

Shear Modulus, GPa 2.27 2.27Shear Strength, MPa >10.0 >10.0

Thickness of each layer, mm 1.08 1.14

Fracture toughness of

bond, Jm-2

Carbon steel 102 102Stainless steel 87Duplex steels 87,Copper-Nickel 102

Fibre Type Glass Carbon CarbonDirectional Properties Not directional Hoop and axial Not directional

Standard Resin Tg<88°C

High temperature Resin Tg<153°C

Ultra High Temperature Resin Tg<230°C

Repair of PipelinesComposite repair technology

Repair of Pipelines Wide experience with high

pressure lines Above ground and buried lines

D i b d Design based on requirements of ISO TS 2481724817

Additional tests completed to demonstrate Long term performance in buried

environmentAbilit t i h i l Ability to repair mechanical damage

Long Term PerformanceComposite repair technology

g 3 year programme underway looking at

behaviour under cyclic loading/buried y glines

Three depths of corrosion 40 percent 60 percent 75 percent

Repaired samples were tested to MAOPP h d d 0% MAOP Pressure then reduced to 50% MAOP

Pressure cycled once per month as follows:

Bl d t Blow down to zero pressure 75 cycles from 50% MAOP to MAOP

(36% SMYS to 72% SMYS)

Burst tests completed at 12 monthBurst tests completed at 12 month intervals

Aim to demonstrate repaired area still as strong as original pipestrong as original pipe

12.75” x 0.375” Test SpoolsComposite repair technology

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

8 feet(center machined area on sample)

p

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

Break corners (all around)

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 inches75% corrosion: remaining wall of 0.093 inches

Note uniform wall in

6 inchesNOTE: Perform all machining 180 degreesfrom longitudinal ERW seam.

Details on machining

Note uniform wall inmachined region

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

Strain Gage InstallationComposite repair technology

Strain Gage Installation

G #4 i1

2 3

Gage #4 on repair

Repair ThicknessComposite repair technology

MAWP of pipe determined using ASME

Repair Thicknessp p g

B31G and similar calculations that allow for limited widths of defects (papers publishedlimited widths of defects (papers published by GRI/GTI)

The MAWP derived is input into equations in ISO TS 24817 to determine repair thickness pto restore original strength

Repair Thicknesses and lengthComposite repair technology

Repair thickness applied assumed defect profile

Repair Thicknesses and lengthDefect Depth Repair thickness

(Layers)assumed defect profile is flat (shape factor ‘1’) More conservative than

B31G

(Layers)40% 460% 6

B31G Better approximation of

actual defect

75% 8

Overlap derived from ISO TS 24817 to transfer load

Defect Depth

Repair overlap

Total Repair Lengthtransfer load

Gives full axial AND hoop reinforcement

Depth overlap (mm)

Length (mm)

40% 100 400hoop reinforcement (suitable for repair of girth welds)

60% 150 50075% 200 600

Application of RepairsComposite repair technology

Application of Repairs

Initial Burst Test ResultsComposite repair technology

Initial Burst Test Results

ResultsComposite repair technology

Results Pipe failed outside of repair

area Results demonstrate that

th i d i i tthe repaired pipe is stronger than the originalFatigue cycling will Fatigue cycling will demonstrate ability of composite to support steelcomposite to support steel and look at durability of the composite

Test Field LayoutComposite repair technology

Test Field LayoutValves and pressure gaugesPump Valves and pressure gauges installed to block off samples as appropriate.

7 5 year samples

10 year samplesPump

System ASystem A

System BSystem BColors denote

5 year samples

7.5 year samplesSystem CSystem C

System DSystem D

System ESystem E

System FSystem F

Colors denote different repair systems involved in test program.

3 year samples

System FSystem F

2 year samples

1 year samples

Field Work Photos (1/3)Composite repair technology

Field Work Photos (1/3)

ConclusionsComposite repair technology

Conclusions

Test work supports the theoretical assessments that have been used to date

Validates the 11 years service experience with the system

Repair of DentsComposite repair technology

Repair of DentsProgramme devised to look at:

Plain Dents Dents in girth weld Dents in ERW seam weld

Pipe: 12.75-inch x 0.188-inch, Grade X42 (D/t pe 5 c 0 88 c , G ade ( /similar to standard 36” line pipe)

Samples tested with and without repair toSamples tested with and without repair to demonstrate the benefit of the repairS l l d f 0 t MAOP (72% SMYS)Samples cycled from 0 to MAOP (72% SMYS) until failure or 250,000 cycles

Test Sample DetailsComposite repair technology

Test Sample DetailsPlain Dents (2) Dent in Girth Weld (2)

Gi th ld (2)

Side View of Pipe Sample (5 defects total)

ERW pipe seam

Girth welds (2)

p p ( )Dent in Seam Weld (2)

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

Notes:1. Six dent defects per sample (2 defects of each type).2. All six defects will be repaired.3. Strain gages to be installed beneath repairs (key performance indicator of the composite

reinforcement level).4. One unrepaired pipe sample will be prepared and tested (will serve as the reference data set).5. Samples will be cycled to failure – the performance of the composite repair will be based on its

ability to increase fatigue life over the unrepaired samples.

Generating Dent Photos (1/3)Composite repair technology

Generating Dent Photos (1/3)

Dent DetailsComposite repair technology

Dent Details Dent made by a 100mm spherical indenter Pipe indented to 15% of diameter (48mm) and pressurised to MAOPPipe indented to 15% of diameter (48mm) and pressurised to MAOP Pressure released and indenter withdrawn, pipe rebounds

All dents introduced into test spool in this manner 10 pressure cycles from 0 to MAOP applied10 pressure cycles from 0 to MAOP applied Final dent depth ~17mm (~5%) and dent length (along pipe) ~300mm Repair now applied

Derivation of Repair ThicknessComposite repair technology

Derivation of Repair Thickness

The effect of dents on pipeline strength is still s bject The effect of dents on pipeline strength is still subject to debate

No accepted method for analysing the significanceNo accepted method for analysing the significance However, it is relatively straightforward to propose a

repair thickness if a MAWP can be defined It was therefore assumed that the dent would have a similar

effect to corrosion equivalent to 80% wall loss The methods described for corrosion damage can then be g

applied This gave repairs of a practical thickness and a method to fit

with existing codesg Final repair thickness was 8 layers of carbon and repair

length of 600mm

Application of RepairsComposite repair technology

Application of Repairs

ResultsComposite repair technology

ResultsDent Location Cycles to Failure,

UnrepairedCycles survived

UnrepairedSeam Weld 6,205

All repairs survivedSeam Weld 7,018Plain Pipe 10 163 All repairs survived

261,742 cyclesPlain Pipe 10,163Plain Pipe 10,334Girth Weld 7,023Gi th W ld 24 996Girth Weld 24,996

Repairs did not fail within 250,000 cyclesy

Demonstrates suitability for repair of mechanical damage in gas transmission pipelines

SummaryComposite repair technology

Summary Furmanite have completedFurmanite have completed

the testing and validation required by ISO TS 24817 q y(and ASME PCC-2 Article 4.1)

In addition, specific tests have been completed for pipeline applications

Service experience includes corrosion damage and dents

Pi li R i E l


Pipeline Repair Examples

Overview of Design ProcessComposite repair technology

Overview of Design Process The guidance notes use the validation

d h li i d idata to assess each application to derive the repair thickness required

Two thicknesses to checkTwo thicknesses to check Thickness for loads due to pressure and

any structural loading Can include contribution of remaining steel or

rely on composite alone

Thickness to stop leaks Holes, cracks (circumferential or hoop) or slots

(large areas of debonding)

Factors then applied to account for

Factors then applied to account for geometry

Check the overlap required Select best fabric/resin combination

Information Required for theComposite repair technology

Information Required for the Assessment

Repair thickness varies with: Pipe diameter Geometry (tee, flange, elbow etc) Pressure (internal and external) for

service and installationT t ( d i ) f Temperature (max and min) for service and installation

Required service life Defect size Defect size Leaking/not leaking Amount of original pipe remaining Cause of degradationg

Large number of variables means a calculation is required for every application

Output from Design ProcessComposite repair technology

Output from Design Process

Thickness of repair Thickness of repair Expressed in number of

layers (plies) Overlap beyond damaged

region Material type Material type

Fibre and resin Cure requirements Best to summarise on

drawing and record keyinformation on thisduring application as a quality record

Sealing LeaksComposite repair technology

Sealing LeaksR i b d t d l ith l ki Repairs can be used to deal with leaking lines Defined as <1mm wall remaining at END OF LIFE

Not for sealing active (live) leaks Not for sealing active (live) leaks Performance is limited compared to

strengthening Unlikely to see good performance over 20 Unlikely to see good performance over 20

barg Larger defects (>25mm) may require

unreasonably thick repairsy p Fracture mechanics assessment of when

bond will fail Based on validation test results

Surface preparation very important Cleanliness Roughnessg


Leaks

Repair of VesselsComposite repair technology

Repair of Vessels Repair thickness derived in the same

way as for pipesway as for pipes Overlap length is driven by original

diameter, and so can become an issue on large diameterson large diameters Guidance notes allow overlap to be

calculated using an alternative l i ( l d f l tianalysis (closed-form solutions

assessing shear and peel generally used)

Overall structural rigidity of tank needs to be considered Not in scope of repair standard Vacuum loading often drives

thickness

InstallationComposite repair technology

Installation Quality records should be

k t d i th i t ll tikept during the installation These are simple but can

be used to demonstrate thebe used to demonstrate the repair installed is that designedTh d i l l i The design calculations and installation records can be used to justify using the j y grepair for longer service lives

InstallationComposite repair technology

Installation

C t f t h i i Competence of technicians installing the repair is key to ensuring good performance

Both documents give guidance on training and experience required, although the ISO is more d didemanding Requires a longer training

period (minimum two weeks, no minimum in ASME)

The validity of training is effectively 12 months from the last yrepair completed

Composite TechniciansComposite repair technology

Composite Technicians

ISO Training requirements are too generic for the type of work being undertakenF it h i l t d 5 l l kill t i Furmanite has implemented a 5-level skill matrix

Trainees start at Level 1E i i t ll ld b t L l 3 Experience installers would be at Level 3

Levels 4 and 5 are Supervisors with varying experience The requirements that must be achieved to move

between levels are formalisedTh kill l l i d f h j b i t i htf d t The skill level required for each job is straightforward to specify

Technician Qualification MatrixComposite repair technology

Technician Qualification Matrix

Composite Repair Technician Qualification MatrixLevel Title Training Experience Components Responsibility Resins Fibre/Fabric Pipe Condition Record Keeping Additional Requirements

1 Furmawrap Installer In-house course None Required Straights and bends 2nd man Water cured PU Glass Non-Leaking

(Type A repairs) NoneVisual inspection of trial application witnessed by

relevant trainer

2 Trained Technician In-house course None Required

Straights and bends and other

components under supervision

2nd man, fully supervised at all

times by Level 3 or higher

Standard Epoxy Glass and Quad Carbon

Non-Leaking (Type A repairs) None

Visual inspection of trial application witnessed by Level 4 or 5 Technician

3 Installation

HT & UHT resin (can be

completed in field Minimum of 12 supervised repairs including 3

Straights, bends and other components as

Able to work independently as Standard, HT

and UHT

Glass and Quad Leaking

(Type B

Completion of cutting and mixing record

sheets. Able to work

Type B qualification test completed and passed

C bilit f did t t3 Technician if all other requirements are

met)

repairs, including 3 complicated components

other components as directed part of a supervised

team

and UHT Epoxies Bidirectional

Carbon

(Type B Repairs) with Imperial and

metric units, volumes and mass

Capability of candidate to be confirmed by

assesment by Level 4 or 5 Technician

4 Lead T h i i Lead Tech course

Supervise installation of a minimum of 3 additional

i ( d t h f

Independent application of

t i l t

Able to complete site surveys and

supervise installation of repairs by teams f t th l

Standard, HT and UHT

Glass, Quad and

Bidi ti l

Leaking (Type B

Completion of quality documentation and

hold points related to repairs installed.

Methods of pipe defect assessment.

Capability of candidate to4 Technician Lead Tech course repairs (under watch of Level 4 or 5 Technician)

materials to any geometry

of up to three people (which must include at least one Level 3

Technician)

and UHT Epoxies Bidirectional

Carbon

(Type B Repairs)

repairs installed. Preparation of cutting plans. Inspection of

repairs


assesment by Level 4 or 5 Technician

5Advanced

Lead

Components may be repaired in orkshop if not

Supervise installation of a minimum of 3 additional

repairs on tees, nozzles or similar complicated

Independent application of

materials to an

Able to complete site surveys and

Standard, HT and UHT

Glass, Quad and

Bidirectional

Leaking (Type B

Completion of quality documentation and

hold points related to repairs installed.


assessment b Le el 5Technician workshop if not completed in field

similar complicated geometry under watch of

Level 5 Technician

materials to any geometry

ysupervise all repairs Epoxies Bidirectional

Carbon

( ypRepairs)

pPreparation of cutting plans. Inspection of

repairs

assessment by Level 5 Technician

Inspection and MaintenanceComposite repair technology

Inspection and Maintenance

Materials are inherently durable Visual inspection should show obvious damage Not currently possible to obtain information on whether

bond is still okayE i t d t i li thi i t bl i ti Experience to date implies this is not a problem – i.e. no time-dependent process of concern has been found in practice

Can inspect through the repairs to monitor the metal pipe p g p p pbeneath Eddy current techniques and radiography are the easiest to use Guided wave ultrasonics have also been successful

Experience to dateComposite repair technology

Experience to date

Pressures up to 209 bar

Temperatures from 50 to +210oC-50 to +210oC

Up to 18m diameter Live and offline repairs

Wid f Wide range of geometry

Wide range of chemicalschemicals

Lengths >100m Confined locations Pipes tanks vessels Pipes, tanks, vessels

and other components

SummaryComposite repair technology

Summary This presentation has outlined

the history and requirements ofthe history and requirements of the standards now available to guide use of composite repairs for extending the life of corrodedfor extending the life of corroded structures

The principles of the documents are based on extensiveare based on extensive experience of composites in industry and now have ~10 years of proven experienceof proven experience

The range of applications that can be considered has been illustrated by examplesillustrated by examples

Any questions?

Furmanite Composite Repair Technology - · PDF fileFurmaniteFurmanite s’s engineered...

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