Dimas Satya Lesmana S.T. 1

Transcription

1 The increased utilization acceptance of compos technology for piping pipelines repairs in the up, mid downstream sectors for maintaining asset integrity. Dimas Satya Lesmana S.T. 1 1Regio Manager (Asia Pacific), Clock Spring Company L.P. USA, dimasl@clockspring.com Abstract repairs are categorized as a recent innovation when it comes to repairing rehabilitating piping & pipelines with an increasing number of applications now in service. The use of compos technologies for repairing steel pipe has gained a large amount of support acceptance as a viable option for owners/operators. This acceptance has come because of compos repair system manufacturers completing thorough testing programs to qualify validate various compos repair systems compos archcture. This paper is to address the increased utilization acceptance of compos technology for the up, mid downstream operator the benefits of using compos materials as a methodology for temporary permanently repairing piping pipelines especially where harsh environment has been damaging the piping pipeline affecting its integrity. Technology When considering a repair for piping pipelines, compos repair may be one of the engineer repairs of choice. This technology can be a cost-effective method of improving safety while keeping maintenance cost down. Clock Spring Company is also aware that not all composs are of equal character pedigree that only Clock Spring meets the engineering testing guidelines established in recent code revisions. The distinctions between different types of composs used for pipeline repair are important, must be understood to ensure the compos repair selected will meet the rigorous specifications demed by sound engineering. There are many different types of compos pipe repair available on the market all of which are extremely different have undergone different levels of testing, research onward development. On the market, today there is a great deal of confusion as to which type of compos repair should be used on piping or pipelines with many choices of fiber, archcture resin available. type repairs are accepted in the ASME B31.4 B31.8 codes as being suitable for the repair of high pressure gas fluid pipelines but with the introduction of the ISO TS ASME PCC 2 article 4.1 guidelines many compos wrap type repairs have entered the market.

2 Application Consideration Two application techniques are available for the repair of pipelines using composs: first is the wraps (wet applied cloth) second is the (full-cure) system. Wraps - Wet Applied Cloth (Wet Wrap) This repair takes the form of a flexible cloth, woven from e-glass, which is impregnated with resin at the repair s. The e-glass provides the strength needed in the repair the resin provides the bonding matrix to hold the repair in place protect the glass from long-term effects of the environment. The disadvantages are obvious. The ratio of resin to glass, the degree of resin saturation, the alignment of the glass consistency of tension in the repair are difficult to control. Even the number of wraps is a variable that can be changed in the field. All mechanical properties are variable can be influenced by the installation process. Woven cloth can allow moisture to 'wick' into the compos weaken the repair. Effectiveness long-term performance are unpredictable. The advantage is that this repair technique can be used on irregular shapes fittings. Wet wrap is an effective repair for pipelines operating at less than 500 psi (3.5 MPa) for repairing fittings irregular shapes. It is most often applied in the downstream sector such as plants refineries where operating pressures are limd. Application (Full cure) Clock Spring eliminates all the variables of the wet wrap process. The compos sleeve is manufactured under controlled conditions. The fully cured compos sleeve is taken to the repair location secured to the pipe using adhesive. To ensure proper load transfer all defects voids under the compos sleeve are filled with a high compressive strength filler material. The ratio of glass to resin is accurately controlled monitored. The unidirectio glass strs are carefully positioned aligned to maximize strength in the hoop direction. The compos is squeezed, dried, heat-treated cured shipped as a completed unit to the repair location. All design variables are controlled. The mechanical properties of the compos sleeve are consistent well defined. The Clock Spring compos laminate layers are nomily inches thick have a glass fiber content ranging from 65 to 75 percent by weight (45 to 55 percent by volume). The Clock Spring compos sleeve material exhibits linear elastic behavior up to the point of failure in tension, typically 1.5 to 2 percent strain. Typical values of the elastic modulus are 5 x 10 6 psi in the fiber direction 1.4 x 10 6 psi in the transverse direction. Tensile strength is typically ksi. The coefficient of thermal expansion is 6.0 x 10-6 inch/inch/ F in the fiber direction 3.2 x 10-5 inch/inch/ F in the transverse direction. A completed repair will contain 8 wraps of compos. The adhesive has a lap shear strength of 1200 psi the filler a compressive strength of 8000 psi. Because all variables are well controlled the performance of the Clock Spring repair can be predicted. Without this predictable performance, long-term durability would be questionable. The full-cure compos sleeve (Clock Spring) is designed tested to ensure a minimum fifty-year life under worst-case environmental conditions of fully saturated soil.

3 Code Stard Review on Technology Engineer mostly refer piping repair system to API 570 / ASME B31.3 pipelines repair system into ASME B31.4 (for liquid) or B31.8 (for gas). Both of API ASME has establish code for compos or nonmetallic repair for piping or pipelines. Other supporting code is ISO PRCI (Pipeline Council Internatio). repairs have been successfully utilized by up, mid downstream operators from a small, medium to a large diameter piping pipeline to effectively return the integrity of the pipe using both Wrap System. Below is a table guideline for code stard reference for compos repairs for piping pipelines: Piping Type Code Section Type of Defe ct Pressure Equipment Piping API 570 Piping Inspec tion Code ASME PCC 2 Section Nonwelding s (On- Stream). Article 4.1 Nonmet allic Systems for Piping Pipewo rk: High- Risk Corr osion Inter Corr osion Type of Temp orary Only Temp orary /or Perma nent Type Wrap / Wrap / Piping Pipelines Pipelines Pipelines ISO ASME B31.4 (Liqui d Slurry) ASME B31.8 (Gas Trans missio n) Pipelin e Resear ch Counc il Intern atio (PRCI) REV 6 Applica tions All Section Table Accepta ble Pipeline Method s Table Accepta ble Threat Prevent ion Method s 3.4 Defect Using Reinfor cement s Table 1. Summa ry of repair options for various types of defects. Inter Corr osion corro sion 80% wall loss Non- Leaki ng Only Corr osion Inter Corr osion Temp orary /or Perma nent Perma nent up to 80% wall loss Perma nent up to 80% wall loss Perma nent up to 80% wall loss Table 1. Code Stard Review comparison Wrap / The above code stards have made significant influence in the acceptance of compos repair for piping pipelines

4 operator around the globe. Engineer have options to refer to the code stards to justified the use of compos technology as an alternative repair within their asset integrity management system. Case Study Application Upstream Case Study #1: Offshore 42 Skim Pile Leak Temporary corrosion due to harsh sea environment caused a leak on a 42 skim pile at the splash zone area in needs of temporary repair as per related code stard to maintain the integrity. The platform is in the Natuna Block. corrosion took place causing problems at any ferrous metal in the offshore platform. One of common issue that took place is corrosion within pipeline it s supporting area like deck plate. In some instance, corrosion at deck plate might migrated to any pipeline or piping system that is not well protected. In some case, main riser or main piping system that is goes through a deck plate may have severe corrosion issue. method at this pipeline defect will requires an engineered critical assessment (ECA) which must be done online without the need to shut down the system to avoid potential loss in daily oil gas lifting target. Following grit blasting surface preparation in accordance to industry stard guidelines a full cured compos laminate repair was applied to seal the leak reinforce the general corrosion area. The repair was completed within 1 day. Fig 2. Corrosion at deck plate area Figure 1. Completed 42 Skim Pile repair Upstream Case Study #2: Deck Plate Corrosion Problems Permanent Offshore operations throughout the world have facing many issue, corrosion is always a big concern in daily asset integrity issue. The salty atmosphere around is ideal for Following engineering design in accordance to ISO TS 24827,tThe obstacle at the repair zone (i.e. deck plate steel floor) needs to be removed by any means to allow the technician to do the repair application. The repair will require 6 layers to maintain the integrity with assumption 100% wall loss. Following the removal of the deck plate cleaning of the 16 pipe, the Clock Spring compos wrap system is installed over the defect zone to provide structural reinforcement on the pipeline.

5 Figure 4. Defect in the 32 pipeline also affecting the seam weld Following excavation manual surface preparation in accordance to industry stard guidelines a compos repair sleeve was applied to reinforce the damaged area. Fig 3. Clock Spring Contour installed The pipeline now has been restored rehabilitated back to its pristine conditions to maintain the integrity without interrupting the production operations. Midstream Case Study #1: 32 Mechanical Damage s Permanent An exter defect suspected due to mechanical damage by backhoe loader during pipeline installation was found after MFL inspection for a main 32 gas transmission line supplying gas from Sumatera to Java Indonesia an in needs of online permanent repair accepted by ASME B31.8 code to maintain the integrity. Figure 5. Installation of the 32 seam sleeve The repair was completed under the supervision of a Clock Spring installer within 1 day. Midstream Case Study #2: High Pressure Gas Transmission Line - Mechanical Defect During routine excavation the excavator accidentally hit a 28" main gas transmission line situated at in the middle of the Perawang jungle in Pekanbaru Riau, Indonesia. The excavator had "caught" the pipeline causing a significant mechanical defect with 8 meters of the pipeline being damaged. As the pipeline is the main supply to a local power station also to Singapore, it was critical the pipeline remained in operation, it was mid Summer with temperatures in excess of 39 o C a peak period for electricity supply. A large number of studies have been conducted concerning the suitability of full cure laminate compos sleeves for the

6 permanent repair of mechanical damage third party interference. The results of these studies have shown that repairs are acceptable as per ASME B31.8 Table Acceptable Threat Prevention Methods. extensive testing at Oxford Brookes University in accordance with ISO The repair will only perform as designed if adequate surface preparation is completed. It is recommended that good sections of pipe are blasted to a finish equivalent to SA 2 ½ (the axial extent taper), poorer sections of the pipe are cleaned by power brush to ST3. As much of the pipe as possible is cleaned to SA 2 ½ or equivalent as possible. Figure 6. Completed compos sleeve repair Downstream Case Study #1: Complex Geometry s Temporary This repair considers the reinforcement of 60 meters of multi Diameter - 36 to 72 pipe which involved geometry complex such as tee, bend, clamp, flanges, valve, bolt nuts. The lines are suffering from inter exter corrosion require a pressure containing compos repair to contain pressure when the inter corrosion goes through wall, lifetimes of 20 years are considered by the operator. This repair required using compos wraps technology in accordance to the guidelines of ISO TS The repair has been designed to the design pressure of the lines (11 Barg pressure). The repairs is completed using Clock Spring Contour s (CSC) bi-axial quad-axial fiber glass epoxy resin which has undergone Figure 4. Leaking Sea Water Line in need of repair Assessment of the s Derivations of Thickness Required Based on ISO TS The assessment has been undertaken based on guidance contained in ISO TS The repair designed is based on a pressure of 11 Barg a temperature of +35 C for a 20 years lifetime. The design has been based on the compos carrying circumferential (hoop) axial loadings, has also been calculated for the capacity to hle leaks through holes. The calculations completed are presented discussed below. The repair design was performed in accordance with section Design of repairs for through wall defects (defect type B) of the ISO document. The calculations used to establish the t (minimum thickness of

7 repair laminate required) value were equation 11 which is for circular of near circular defects equation 12 for circumferential slot type defects. Equation are to be partnered with Equation 6 Equation 7 of the ISO document the highest value of the 4 equations is the minimum thickness which should be applied as a repair. Copies of equations 11, 12, 6 7 are shown below: Equation 11: Equation 12: Equation 6 & 7: This solution considers a temperature range between C a maximum pressure of 11 Barg. The repair thickness should be the higher value of all the outputs from equations 11, 12, 6 7. Based on the calculation, a minimum repair thickness of 16.8 mm is required (8 layers) for a 20 year lifetime. A total of 9 layers should also be applied at bends location to conform with the ISO TS guidelines. The Application Proper surface preparation is essential for the repair to perform as required. As much of the pipe is reasonably practicable should be cleaned to SA 2 ½ (grit blasting), with the full axial extent taper prepared to Sa 2.5 with a roughness of 50 microns. Clock Spring advise that inspection should carry out further inspections of the pipe highlight areas which can cannot be cleaned by blasting. Areas too thin for blasting but thick enough for preparation should be cleaned by power-brush to ST3, areas which are excessively thin should be protected during the cleaning of the line. Clock Spring Contour (CSC) is the latest advanced compos repair technique from the Clock Spring Company. It is ideal for the repair of elbows, tees, reducers, nozzles other pipe components. The flexible repair technique allows materials to be tailored ons to enable repair of complex geometrical shapes commonly found in pipe systems. CSC has been developed is an engineered repair; each application is designed in accordance with industry stards (e.g. ISO TS ASME PCC-2 R&T Article 4.1). The Contour system provides a highly durable repair with excellent chemical resistance. Based on high-performance, non-woven glass fiber fabrics epoxy resin, Contour can provide protection from exter inter corrosion, replacement of strength for damaged pipes can seal leaking defects. Only installers who have been trained certified by a Clock Spring trainer are permitted to install any Clock Spring Contour product, in line with section 7 of ISO The application must follow the method statement of section 7.4 of ISO which describes the main procedures to be carried out prior to during the repair system application.

8 The repair of substrates using compos repair systems differs considerably from other repair techniques the quality of the installation depends strongly on satisfactory craftsmanship. Annex I of ISO outlines the basic skills experience required to install the repair. The sea water line repair installation was completed by Twenty (20) mans crew under the supervision of a Clock Spring installer within 21 days. Downstream Case Study #2: Leaking Oil line Temporary A major downstream refinery is having a 24 leaking crude oil pipeline. Following ASME B31.4 stard, a temporary repair was being taken by applying compos sleeve repair for a temporary 2 years lifetime. Following surface preparation by grit blasting, the leak was plugged using rubber plug patched using plastic steel putty. Figure 5. First 4 layers being installed Figure 7. Pinhole leak plugged using rubber plug The repair then apply 8 layers of Clock Spring compos sleeve repair kit was applied to reinforce the defect area. The installation was completed by three (3) mans crew under the supervision of a Clock Spring installer within 2 day. Figure 6. Completed repair at third week

9 Discussion Figure 8. Completed repairs Both compos wraps (wet applied cloth) compos sleeve (full-cure) system have a place in both piping pipeline maintenance. Engineer mostly refer piping repair system to API 570 / ASME B31.3 pipelines repair system into ASME B31.4 (for liquid) or B31.8 (for gas). Both of API ASME has establish code for compos or nonmetallic repair for piping or pipelines. Other supporting code is ISO PRCI (Pipeline Council Internatio). The compos wrap process is less sud to high-pressure repairs but has the advantage of being flexible suitable for repairing irregular shapes. The mechanical properties of the full cure compos sleeve can be controlled thus provide predictable performance long-term durability. is the most appropriate compos repair for highpressure pipelines. It is important to underst the design requirements of an effective compos repair the installation variables that can influence long-term performance. The mechanical properties of the compos, its archcture the method of installation can greatly affect the integrity life of the repair. Each repair must be tested validated independently. Defects such as inter exter corrosion, dents, gouges are regularly found in both upstream downstream sector. In the majority of cases these defects are minor have no impact on the integrity safety of the pipeline. But in some cases they can be significant a repair is necessary. Consequently, a reliable way of identifying defects that are critical, need repair is required. The twin requirements of security of supply, operating efficiency, mean that repairs should not be carried out if they are not required; hence, any method of identifying assessing critical defects must be accurate not excessively conservative. Furthermore, to ensure long term integrity, an appropriate repair must be selected. Selecting the appropriate repair technique is an important decision which requires an understing of the risks rewards associated with each compos repair alternative material archcture selected. Safety, permanency effectiveness are the primary drivers of this decision but cost can become an important issue. s, like Clock Spring, compete with older, more widely accepted welded repair techniques. These new repair options offer advantages over the more traditio repairs are both more cost effective are also the safest repair alternative. Nowaday, engineer have more repair alternative compared to the old times back at the 80 s. repair technology is becoming more more reliable developed under tight code stards. The ISO TS ASME PCC-2 R&T article 4.1 is the main source for designing the best compos repair. Please notice that all wet wrap compos repairs have to be designed spesifically as per pipeline operating design parameter which also consider the defect associated. The above case study application showed how we must carefully consider the code

10 design calculation involved with the repairs. This will also become an advantage in the future for the engineer as the design calculation supplied by the compos vendor will be the reliable source if there is any failure at the repair system in the future. Conclusions repairs may not be the right repair option every time but they are an important alternative that can be very effective in most repair cases they are now increased utilized for piping pipelines repairs in the up, mid downstream sectors for maintaining asset integrity. The above case study application showed how we must carefully consider the design calculation involved with the compos repairs choose the proper code stard applied. Defects found in piping pipeline systems at up, mid downstream sector can be temporarily or permanently repaired safely, quickly economically by using compos repair technology. Proper surface preparation is essential for the repair to perform as required. The repair of substrates using compos repair systems differs considerably from other repair techniques the quality of the installation depends strongly on satisfactory craftsmanship. As such, only installers who have been trained certified are permitted to install. BIOGRAPHY Dimas Satya Lesmana is a Chemical Engineer which is currently working as Regio Manager for Asia Pacific region at Clock Spring Company L.P. USA based in Indonesia. He was also a certified applicator the only one certified compos repairs trainer for Clock Spring Company L.P. in the region. References API Piping Inspection Code: In-service Inspection,, Alteration of Piping Systems, Fourth Edition, American Petroleum Institute, 2016 Addendum 1, May ASME B Pipeline Transportation Systems for Liquids Slurries. Table Acceptable Pipeline Methods, ASME B Gas Transmission Distribution Piping Systems. Table Acceptable Threat Prevention Methods, ASME PCC2 - of Pressure Equipment Piping - Article 4.1 Nonmetallic Systems for Piping Pipework: High-Risk Applications, Lesmana, D.S. - High Pressure Gas Transmission Pipeline using Clock Spring in Indonesia, Petromin Pipeliner Magazine, Jul-Sept 2010 Edition. Lesmana D.S. - Use of Clock Spring as a permanent means of pipeline repair. Rehabilitation of Pipelines Using Fiberreinforced Polymer (FRP) s. Vistasp M. Karbhari, Elsevier Books Publishing USA, May 23, 2015.

11 ISO/TS Petroleum, Petrochemical, Natural Gas Industries: s for Pipework - Qualification Design, Installation, Testing Inspection, Pipeline Research Council Internatio (PRCI) Updated Pipeline Manual, Rev 6 Defect Using Reinforcement s Table 1. Summary of repair options for various types of defects, The Gas Research Institute. GRI-97/0413 Evaluation of a System for of Mechanical Damage in Gas Transmission Lines. Gas Research Institute, 1998.