Development and Evaluation of a Steel-Composite Hybrid Composite Repair System

2012 ◽  
Author(s):  
Chris Alexander ◽  
Carl Brooks
Keyword(s):  
Composite Materials ◽  
Hybrid System ◽  
Hybrid Composite ◽  
Carbon Materials ◽  
Repair System ◽  
Glass Composite ◽  
Composite Repair ◽  
Cyclic Pressure ◽  
Steel Composite ◽  
Repair Systems

Composite materials are widely recognized as a resource for repairing damaged pipelines. The fibers in conventional composite repair systems typically incorporate E-glass and carbon materials. To provide greater levels of reinforcement a system was developed that incorporates steel half shells and an E-glass composite repair system. In comparison with other competing composite technologies, the hybrid system has a significant capacity to reduce strain in corroded pipeline to a level that has not been seen previously. Specifically, the hybrid system was used to reinforce a pipe sample having 75% corrosion subjected to cyclic pressure at 36% SMYS. This sample cycled 767,816 times before a leak failure developed. Furthermore, recent testing has demonstrated that the hybrid system actually places the pipeline in compression during installation. This paper will provide results on a series of specifically-designed tests to evaluate the performance of the hybrid system and the implications in relation to the service of actual pipelines.

Repair of High Pressure Pipe Fittings Using Composite Materials

2010 ◽  
Author(s):  
Julian Bedoya ◽  
Chris Alexander ◽  
Tommy Precht
Keyword(s):  
Composite Materials ◽  
Structural Integrity ◽  
Burst Pressure ◽  
Metal Loss ◽  
Repair System ◽  
Composite Repair ◽  
Main Challenge ◽  
Repair Systems ◽  
Pipe Fittings ◽  
Original Metal

Pipelines and piping frequently suffer from metal loss that threatens their integrity and serviceability. Multiple repair options exist for straight sections of pipe; however, repair options for pipe fittings such as elbows and tees are typically limited to composite repair systems, or section replacement. The latter method can be costly as it often requires at least a partial shut down of the pipeline while the section is replaced. A composite repair system however, can be performed in place during operations at a greatly reduced cost. The main challenge with the composite repair system is the required demonstrated ability to restore integrity and serviceability to the same level as the original metal system. Over the past 10 years, Stress Engineering Services, Inc. has been greatly involved in evaluating the ability of many composite repair systems to restore the original pipeline structural integrity by testing methods and analysis methods. The current paper investigated the ability of the Armor Plate Pipe Wrap (APPW) system to restore the burst pressure of tee and elbow pipe fittings with 60% metal loss to that of a nominal thickness system. In this program four full scale burst tests were conducted: on 12-inch nominal pipe size (NPS) Y52 tee and elbow pipe fittings. All four fittings had 60% metal loss; two were repaired with APPW, and the other two were not repaired. Prior to burst testing, elastic plastic finite element analyses (FEA) were performed to adequately size the repair thickness. The results of the FEA calculations predicted the restoration of the burst pressures of the repaired fittings up to a 1.6% agreement with the actual burst pressure results. Furthermore, the burst pressure of the 60% metal loss tee was increased from 3,059 psi (unrepaired) to 4,617 psi, or a 51% improvement. The burst pressure of the 60% metal loss elbow was increased from 2,610 psi to 4,625 psi, or a 77% improvement. Both the analysis and testing results demonstrated that composite materials can restore the pressure integrity of corroded tee and elbow pipe fittings.

Advanced Insights on Composite Repairs

2012 ◽  
Author(s):  
Chris Alexander ◽  
Jim Souza
Keyword(s):  
Composite Materials ◽  
Test Sample ◽  
Repair System ◽  
Strain Gages ◽  
Composite Repair ◽  
Pressure Cycling ◽  
Repair Systems ◽  
Long Term Performance ◽  
Term Performance

In response to inquiries from pipeline operators regarding the long-term performance of composite materials, manufacturers have performed additional tests to evaluate the performance of their composite repair systems. Insights were gained through these additional tests that demonstrated the long-term worthiness of the composite system. Of particular importance were two types of tests. The first involved the application of strain gages between layers of the composite repair system that was used to reinforce a corroded pipe test sample. As the sample was pressurized the strain gages permitted a comparison between the measured values and design stresses per the ASME PCC-2 design code. The second series of tests involved pressure cycling a 75% corroded sample to failure. In addition to the inter-layer strain measurements, the pressure cycling provides an important insight regarding the long-term performance of the composite repair. This paper addresses how the ASME PCC-2 Code, along with additional well-designed tests, can be used to design a composite repair system to ensure that it adequately reinforces a given defect. As composite materials are being used to repair pipeline anomalies beyond the corrosion-only defects, it is essential that pipeline operators utilize a systematic approach for ensuring the long-term performance of composite repair systems.

Design of Pipeline Composite Repairs: From Lab Scale Tests to FEA and Full Scale Testing

2014 ◽  
Author(s):  
Remy Her ◽  
Jacques Renard ◽  
Vincent Gaffard ◽  
Yves Favry ◽  
Paul Wiet
Keyword(s):  
Finite Element ◽  
Full Scale ◽  
Combined Loading ◽  
Material Strength ◽  
Repair System ◽  
Loading Conditions ◽  
Original Design ◽  
Composite Repair ◽  
Repair Systems ◽  
Composite Properties

Composite repair systems are used for many years to restore locally the pipe strength where it has been affected by damage such as wall thickness reduction due to corrosion, dent, lamination or cracks. Composite repair systems are commonly qualified, designed and installed according to ASME PCC2 code or ISO 24817 standard requirements. In both of these codes, the Maximum Allowable Working Pressure (MAWP) of the damaged section must be determined to design the composite repair. To do so, codes such as ASME B31G for example for corrosion, are used. The composite repair systems is designed to “bridge the gap” between the MAWP of the damaged pipe and the original design pressure. The main weakness of available approaches is their applicability to combined loading conditions and various types of defects. The objective of this work is to set-up a “universal” methodology to design the composite repair by finite element calculations with directly taking into consideration the loading conditions and the influence of the defect on pipe strength (whatever its geometry and type). First a program of mechanical tests is defined to allow determining all the composite properties necessary to run the finite elements calculations. It consists in compression and tensile tests in various directions to account for the composite anisotropy and of Arcan tests to determine steel to composite interface behaviors in tension and shear. In parallel, a full scale burst test is performed on a repaired pipe section where a local wall thinning is previously machined. For this test, the composite repair was designed according to ISO 24817. Then, a finite element model integrating damaged pipe and composite repair system is built. It allowed simulating the test, comparing the results with experiments and validating damage models implemented to capture the various possible types of failures. In addition, sensitivity analysis considering composite properties variations evidenced by experiments are run. The composite behavior considered in this study is not time dependent. No degradation of the composite material strength due to ageing is taking into account. The roadmap for the next steps of this work is to clearly identify the ageing mechanisms, to perform tests in relevant conditions and to introduce ageing effects in the design process (and in particular in the composite constitutive laws).

Advanced Techniques for Establishing Long-Term Performance of Composite Repair Systems

2014 ◽  
Author(s):  
Chris Alexander
Keyword(s):  
The United States ◽  
Operating Conditions ◽  
Repair System ◽  
Composite Repair ◽  
Design Life ◽  
Repair Systems ◽  
Long Term Performance ◽  
Term Performance ◽  
Composite Repairs

Although composite materials are used to repair and reinforce a variety of anomalies in high pressure transmission gas and liquid pipelines, there continues to be widespread debate regarding what constitutes a long-term composite repair. The United States regulations require that composite repairs must be able to permanently restore the serviceability of the repaired pipeline, while in contrast the Canadian regulations take a more prescriptive approach by integrating the ASME PCC-2 and ISO 24817 composite repair standards along with a requirement for establishing a 50-year design life. In this paper the author provides a framework for what should be considered in qualifying a composite repair system for long-term performance by focusing on the critical technical aspects associated with a sound composite repair. The presentation includes a discussion on establishing an appropriate composite design stress using the existing standards, using full-scale testing to ensure that stresses in the repair do not exceed the designated composite design stresses, and guidance for operators in how to properly integrate their pipeline operating conditions to establish a design life. By implementing the recommendations presented in this paper, operators will be equipped with a resource for objectively evaluating the composite repair systems used to repair their pipeline systems.

Composite Repair Performance at Elevated Temperatures

2014 ◽  
Author(s):  
Chris Alexander ◽  
Jim Souza ◽  
Casey Whalen
Keyword(s):  
Composite Materials ◽  
Elevated Temperatures ◽  
Critical Role ◽  
Ambient Conditions ◽  
Composite Repair ◽  
Repair Materials ◽  
Performance Curves ◽  
Repair Systems ◽  
Composite Repairs

For the better part of the past 20 years composite materials have been used to repair damaged piping and pressurized components in plants, refineries, and pipelines. The use of composite materials has been accompanied by comprehensive research programs focused on the development and assessment of using composite technology for restoring integrity to damaged piping and pressurized components. Of particular interest are composite repair standards such as ISO 24817 and ASME PCC-2 that provide technical guidance in how to properly design composite repair systems. The vast body of research completed to date has involved assessments at ambient conditions; however, at the present time there is significant interest in evaluating the performance of composite repair materials at elevated temperatures. This paper is focused on the topic of high temperature composite repairs and addresses the critical role of utilizing temperature-based mechanical properties to establish a composite repair design. The backbone of this effort is the development of composite performance curves that correlate change in strength as a function of temperature. A discussion on supporting full-scale pressure test results are included, along with guidance for users in how to properly design composite repair systems for applications at elevated temperatures.

Efficiency Assessment of the Composite Materials Repair Systems Intended for Corrosion Damaged Pipelines

2019 ◽  
Author(s):  
Andrei Dumitrescu ◽  
Alin Diniţă
Keyword(s):  
Mechanical Properties ◽  
Composite Material ◽  
Finite Elements ◽  
Numerical Models ◽  
Plastic Region ◽  
Research Work ◽  
Repair System ◽  
Composite Repair ◽  
Erosion Processes ◽  
Repair Systems

Abstract This paper presents the results of the research work carried out by the authors in order to evaluate the efficiency of the composite material wraps/sleeves (made of a polymeric matrix and reinforcing fabric) used to repair steel pipelines carrying hydrocarbons upon which local metal loss defects (generated by corrosion and/or erosion processes) have been detected. The pipeline repair technologies consisting of the application of composite material wraps are perceived as being advantageous alternative solutions for substituting the conventional technologies, which require welding operations to be performed in the pipe areas with defects. The efficiency of the composite repair systems has been investigated by assessing the reinforcement effects (the restoration level of the damaged pipe mechanical strength) generated by the applied composite wraps as a function of their geometry and mechanical properties. To that purpose, numerical models based on finite elements have been developed and certified by comparing them with the results of several experimental programs previously performed by the authors. Finite elements simulations have also been conducted in the plastic region, taking into account material non-linearity. The calculation methods proposed in literature (among which a method previously developed by the authors) to define the composite wrap dimensions (thickness and length) for a given pipe have also been investigated and compared to our numerical results in order to select the most adequate solution for the design of the composite repair system. The optimal values for the mechanical properties of the composite material used by the repair system have also been defined.

Cathodic Disbondment Testing Comparison of Carbon Fiber, Fiberglass, and Hybrid Composite Repair Systems for Pipelines

2012 ◽  
Author(s):  
Matthew A. Green ◽  
Larry Deaton ◽  
Christopher J. Lazzara
Keyword(s):  
Cathodic Protection ◽  
Repair System ◽  
Fiber Types ◽  
Preventative Measure ◽  
Composite Repair ◽  
Protection Systems ◽  
Repair Systems ◽  
Cathodic Protection System ◽  
Internal Pressures ◽  
The Impact

Composite repair systems are being successfully and heavily utilized for the repair of a wide variety of pipeline systems operating at high internal pressures worldwide. Many of these pipelines employ cathodic protection systems as a preventative measure of insuring that the pipeline does not corrode. Even with advanced cathodic protection systems, there are still times that a pipeline may become damaged or corroded and composite repair systems are a popular choice. In order to qualify a composite repair system for use on a cathodically protected pipeline, the repair system must undergo specific testing to insure that there will be no issues of disbondment of the composite due to the cathodic protection system. This paper discusses the testing of composite repair systems with varying fiber types, resins, and installation methods. Results have been gathered for several repair system options and indicate that there is variance in the results depending on the above mentioned variables. The results of each of these systems and the impact of the fibers utilized will be discussed and conclusions made as to the effect of cathodic protection on each.

Long-Term Duration of Composite Repair Systems for Pipeline Defects

2021 ◽  
Vol 1035 ◽  
pp. 870-877
Author(s):  
Lian Xun Ming ◽  
Deng Zun Yao ◽  
Bin Chen ◽  
Zhen Heng Teng ◽  
Lin Wang
Keyword(s):  
Composite Materials ◽  
Water Immersion ◽  
Prediction Equation ◽  
Field Application ◽  
Composite Repair ◽  
Micro Cracks ◽  
Aging Properties ◽  
Repair Systems ◽  
Hydrolysis Of

Composite repair systems of buried pipeline will be affected by moisture and other factors due to anti-corrosion and construction problems. These environmental factors will reduce the service life of the composite system. In this paper, the performance of composite and interface between composite and steel under the action of water were studied. It was found that the formation of micro-cracks on the surface of composite materials and the hydrolysis of epoxy resin were the important reasons for the Performance degradation. Moreover, the aging properties of composite materials and their interfaces under water immersion were analyzed by residual strength theory, and the life prediction equation of composite materials and interfaces were obtained, which can be useful to the field application of composite repair systems.

Performance of a Composite Repair System for Externally Corroded Metallic Pipe Using Numerical Model

2014 ◽  
Author(s):  
Abul Fazal M. Arif ◽  
M. Anis ◽  
A. Al-Omari
Keyword(s):  
Composite Material ◽  
Composite Materials ◽  
Numerical Model ◽  
Fiber Orientation ◽  
Surface Preparation ◽  
Metal Loss ◽  
Repair System ◽  
Operating Pressure ◽  
Composite Repair ◽  
Field Quality

Traditionally, corroded pipelines with metal loss defects have been repaired by replacing the defective areas with metallic pipe segments or by welding on metallic sleeves. Considering the technical and economic advantages of composite materials, literature shows that these defects can be repaired or reinforced with a composite sleeve system. In these systems, epoxy filler is used to fill the corrosion defect followed by wrapping the piping segment with concentric coils of composite material. However several challenges need to be met to obtain the desired repair quality. The major considerations are surface preparation, reduction in operating pressure for the repair, the duration required (e.g. for curing of the composite material) for the composite repair to share the load from the pipe, and the most important is the in-field quality assessment and to ensure consistency between several repairs. In this work, a numerical model is developed to investigate the performance of composite repair systems and compare with the traditional metallic welded sleeve. The effect of fiber orientation, repair sleeve thickness, material and installation pressure have been studied. Results show the potential of composite repair system in replacing the existing welded metallic non-pressure containing sleeve for metallic pipelines.

Repair of Dents Subjected to Cyclic Pressure Service Using Composite Materials

2010 ◽  
Author(s):  
Chris Alexander ◽  
Julian Bedoya
Keyword(s):  
Composite Materials ◽  
Extensive Study ◽  
Life Extension ◽  
Composite Repair ◽  
The Past ◽  
Extensive Evaluation ◽  
Research Organizations ◽  
Repair Systems ◽  
Primary Focus ◽  
Girth Welds

For the better part of the past 15 years composite materials have been used to repair corrosion in high pressure gas and liquid transmission pipelines. This method of repair is widely accepted throughout the pipeline industry because of the extensive evaluation efforts performed by composite repair manufacturers, operators, and research organizations. Pipeline damage comes in different forms, one of which involves dents that include plain dents, dents in girth welds and dents in seam welds. An extensive study has been performed over the past several years involving multiple composite manufacturers who installed their repair systems on the above mentioned dent types. The primary focus of the current study was to evaluate the level of reinforcement provided by composite materials in repairing dented pipelines. The test samples were pressure cycled to failure to determine the level of life extension provided by the composite materials relative to a set of unrepaired test samples. Several of the repaired dents in the study did not fail even after 250,000 pressure cycles were applied at a range of 72% SMYS. The results of this study clearly demonstrate the significant potential that composite repair systems have, when properly designed and installed, to restore the integrity of damaged pipelines to ensure long-term service.

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