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Areas of specialty include assessing pipeline damage and evaluating composite repairs
B.S., M.S., and Ph.D. degrees from Texas A&M University in Mechanical Engineering
Disclaimer
Although Stress Engineering Services (SES) will discuss specific composite repair systems and products today, SES does not endorse any particular composite repair system. Users are encouraged to know and understand the capabilities and limitations of each composite repair system. SES has observed misrepresentation and incorrect distribution of technical data and information.
Todays Presentation
Background in pipeline evaluation and repairs Examples of when composites can be used to repair pipelines Background on the major pipeline repair systems using composite materials U.S. government regulations Guidelines for repair using composites and test program elements Repair of dents and gouges (mechanical damage) Long-term performance study Question & Answer Session
Metal wall loss (due to corrosion) Plain dents Mechanical damage (dents with a gouge) Re-rating pipeline system to achieve higher operating pressures Corrosion repair and replacement
Under insulation coating (UIC) Wear-resistant coatings (e.g. saddles) Underwater coatings
Wet lay-up systems (e.g. Armor Plate Pipe Wrap, Diamond Wrap, Aquawrap, Pipe Wrap A+, Diamond Wrap HP, I-Wrap)
Monolithic Can be applied to non-straight geometries Versatility in range of epoxy products (e.g.
Matrix types
Pre-cured Pre-impregnated (e.g. water-
Government Regulations
(from the U.S. Department of Transportation)
On January 13, 2000, Pipeline Safety: Gas and Hazardous Liquid Pipeline Repair, was issued by the RSPA of the Department of Transportation, went into effect. According to this document, the requirement for repairing corroded and dents in pipelines is as follows,
repaired by a method that reliable engineering tests and analyses show can permanently restore the serviceability of the pipe.
CORROSION REPAIR
Experimental Efforts
SES fabricated two test samples with a machined corrosion region in each
12.75-inch x 0.375-inch, Grade X42 75% deep corrosion with 8-inch x 6-inch
Strain gages installed on test samples and used to measure strains in the corroded section beneath the reinforced region during pressurization One sample pressurized to failure, while a second sample pressure cycled to failure (P=50% MAOP)
8 inches long
0.75-inch radius (at least)
0.375 inches
0.093 inches
(simulating 75% corrosion)
NOTE: Perform all machining 180 degrees from longitudinal ERW seam.
6 inches
Details on machining
(assume machined area is 8 inches long by 6 inches wide)
4500
Failure pressure of 4,254 psi
4000
3500 3000 2500 2000 1500 1000 500 0 0 5000 10000 Hoop Strain (microstrain)
(10,000 microstrain is equal to 1 percent strain) 1 Hoop 2 Hoop 3 Hoop 4 Hoop
15000
20000
Defect Classification
(and associated failure modes)
Plain dents Gouges (no denting present) Mechanical damage (dents with gouges) Rock dents (constrained) Failure modes/methods
Static overload or
Zone of Initiation/Propagation
that is from CSA Z662 for length limitation) also in current edition of ASME B31.8 in 851.42(c)(3)
Ductile material
stress more than 20% SMYS, dents greater than 2 percent of the nominal pipe diameter must be repaired using a method that permanently restores the serviceability of the pipe OR
the dent must be removed from the steel pipe
acceptable for repair of injurious dents or mechanical damage, unless proven through reliable engineering tests and analysis
100000
10000
Cycles to Failure
1000
2 1
Unground Ground Composite repairs plus grinding
0.0322*(D/t)
100
10
CURVE FITS Composite plus grinding: N = 36069e Ground: N = 188.92e 0.0714*(D/t) Unground: N = 29.594e 0.0731*(D/t)
Curve fit (unground) Curve fit (ground) Curve Fit (composite repairs plus grinding) 40 50 Pipe D/t Ratio 60 70 80 90 100
1 0 10 20 30
For the above reason, pipeline companies should be hesitant to define composite repairs as permanent repairs
Pump
10 year samples
5 year samples
Participation in 10-year study involves pipes to be removed and burst at 1, 2, 3, 5, 7.5, and 10 years 12 companies currently participating
3 year samples
2 year samples
1 year samples