mtt 989 composite overwrap repair system
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composite overwrap repair systemMTT-989
using technology
MTT-989 is a novel pre-impregnated fibreglass, primer and top coat resin system for pipeline and infrastructure repairs, onshore and offshore.
Consists of multiaxial “E-Glassfibre” impregnated with proprietary underwater epoxy resin formulation, which provides effective corrosion and repair to metal, concrete, and composite infrastructure.
MTT-989 is the only repair system which cures underwater and in wet environments without any loss of adhesion or mechanical properties.
KEY BENEFITS• Effective corrosion barrier and protection• Extends pipeline life (e.g. thinned-wall pipelines)• Performs in accordance with ISO24817, ASMEPCC-2, and PTS31.40.60.12• Reduces maintenance costs• No hot work or welding required• Little or no shut down required• Designed to withstand underwater condition > 15years• Cost effective• Permanent repair
+ =The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
what is MTT-989?
1 Clean surface of pipe or infrastructure
2 Fill holes or damage 3 Mix MTT-989 epoxy surface primer
4 apply MTT-989 epoxy surface primer
5 bandage wrap MTT-989 materials6 overwrap plastic consolidation film
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
how is MTT-989 applied?
3
corrosion protection strengthening LEAK rEpAir
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
33
what is MTT-989?target applications
Splash zone coating repairs
Onshore corrosion prevention and strengthening
Onshore pipeline coating repair (buried line)
Offshore process pipeline strengthening
Offshore process pipeline leak repair
Non-hydrocarbon vessel repair
To date MTT-989 has been applied and installed in 24 locations in South East Asia in 8 environmental conditions MTT-989-
Applications
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
SPLASH REPAIR ZONE
NON-HYDROCARBONPATCH REPAIR
ONSHORE CORROSION REPAIR FOR GAS
CORROSION PROTECTION FOR CRuDE
HYRDROCARBON LEAK REPAIR
NON-HYRDROCARBON LEAK REPAIR
MTT-989 performance
corrosion protection application
MTT-989
riser 1 riser 2 riser 3
7
Dia – 10”; Length – 35”Repair length: 40”
Damage size: Dia – 10”; Length – 28”
Repair length: 40”
Repair length – 20”
Section to be wrap
DAMAGE SIZEDia–10”; Length –35”Repair length: 40”
DAMAGE SIZEDia–10”; Length –28”Repair length: 40”
REPAIR LENGTH –20”
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
7
Dia – 10”; Length – 35”Repair length: 40”
Damage size: Dia – 10”; Length – 28”
Repair length: 40”
Repair length – 20”
Section to be wrap
7
Dia – 10”; Length – 35”Repair length: 40”
Damage size: Dia – 10”; Length – 28”
Repair length: 40”
Repair length – 20”
Section to be wrap
7
Dia – 10”; Length – 35”Repair length: 40”
Damage size: Dia – 10”; Length – 28”
Repair length: 40”
Repair length – 20”
Section to be wrap
7
Dia – 10”; Length – 35”Repair length: 40”
Damage size: Dia – 10”; Length – 28”
Repair length: 40”
Repair length – 20”
Section to be wrap
7
Dia – 10”; Length – 35”Repair length: 40”
Damage size: Dia – 10”; Length – 28”
Repair length: 40”
Repair length – 20”
Section to be wrap
BEF
OR
EA
FTER
MTT-989 application 1three risers
ped
inspection work
The risers were inspected and one of three risers was opened up after 12 months (24/8/2011):> To check for signs of rust;> To verify signs of deterioration of the overwrap material.
TYPE OF INSPECTION
after 5 days
after 2 months
after 7 months
after 9 months
No abnormalities No abnormalities No abnormalities No abnormalities
VISUAL
8
Type of Inspection After 5 days After 2
monthsAfter 7 months
After 9 months
Visual Inspection
No abnormalities
No abnormalities
No abnormalities
No abnormalities
Hardness (Shore D)
81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92
Adhesion(Dolly) MPa
3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12
• The risers were inspectedand one of three risers wasopened up after 12months (24/8/2011): To check for signs of rust; To verify signs of
deterioration on theoverwrap material.
hardness(ShoRE D) 81.17 ±1.72 77.30 ±2.21 75.50 ±4.43 80.00 ±2.92
adhesion(DoLLY) MPa 3.57±0.66 10.36 ±2.05 > 12 > 12
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
8
Type of Inspection After 5 days After 2
monthsAfter 7 months
After 9 months
Visual Inspection
No abnormalities
No abnormalities
No abnormalities
No abnormalities
Hardness (Shore D)
81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92
Adhesion(Dolly) MPa
3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12
• The risers were inspectedand one of three risers wasopened up after 12months (24/8/2011): To check for signs of rust; To verify signs of
deterioration on theoverwrap material.
8
Type of Inspection After 5 days After 2
monthsAfter 7 months
After 9 months
Visual Inspection
No abnormalities
No abnormalities
No abnormalities
No abnormalities
Hardness (Shore D)
81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92
Adhesion(Dolly) MPa
3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12
• The risers were inspectedand one of three risers wasopened up after 12months (24/8/2011): To check for signs of rust; To verify signs of
deterioration on theoverwrap material.
8
Type of Inspection After 5 days After 2
monthsAfter 7 months
After 9 months
Visual Inspection
No abnormalities
No abnormalities
No abnormalities
No abnormalities
Hardness (Shore D)
81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92
Adhesion(Dolly) MPa
3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12
• The risers were inspectedand one of three risers wasopened up after 12months (24/8/2011): To check for signs of rust; To verify signs of
deterioration on theoverwrap material.
8
Type of Inspection After 5 days After 2
monthsAfter 7 months
After 9 months
Visual Inspection
No abnormalities
No abnormalities
No abnormalities
No abnormalities
Hardness (Shore D)
81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92
Adhesion(Dolly) MPa
3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12
• The risers were inspectedand one of three risers wasopened up after 12months (24/8/2011): To check for signs of rust; To verify signs of
deterioration on theoverwrap material.
8
Type of Inspection After 5 days After 2
monthsAfter 7 months
After 9 months
Visual Inspection
No abnormalities
No abnormalities
No abnormalities
No abnormalities
Hardness (Shore D)
81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92
Adhesion(Dolly) MPa
3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12
• The risers were inspectedand one of three risers wasopened up after 12months (24/8/2011): To check for signs of rust; To verify signs of
deterioration on theoverwrap material.
8
Type of Inspection After 5 days After 2
monthsAfter 7 months
After 9 months
Visual Inspection
No abnormalities
No abnormalities
No abnormalities
No abnormalities
Hardness (Shore D)
81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92
Adhesion(Dolly) MPa
3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12
• The risers were inspectedand one of three risers wasopened up after 12months (24/8/2011): To check for signs of rust; To verify signs of
deterioration on theoverwrap material.
MTT-989 application 1
post one year
inspection prior to removal of paint
Paint removed
•Number of barnacles reduced since inspection in Month 9 demonstrating barnacles have no affinity or impact to MTT-989 surface condition•CVI and Dolly indicate MTT-989 had very good adhesion to riser, R1, similar to results on test plate
• Surfaces in good condition
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
• Population of barnacles reduced since inspection in Month 9 suggesting barnacles have no affinity or no impact to PIPEASSURE™
• CVI and Dolly indicate PIPEASSURE™ had very good adhesion to riser, R1, similar to results on test plate
9
Inspection Prior to Removal of Paint
Paint Removed
• Surfaces in good condition• Population of barnacles reduced since inspection in Month 9 suggesting barnacles have no affinity or no impact to PIPEASSURE™
• CVI and Dolly indicate PIPEASSURE™ had very good adhesion to riser, R1, similar to results on test plate
9
Inspection Prior to Removal of Paint
Paint Removed
• Surfaces in good condition
MTT-989 application 1
post one yearprior to removal of MTT-989
metal surface afterMTT-989 removed
Surface comparison between Riser 1 & Testplate after MTT-989 Removal
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
10
Prior to Removal of PIPEASSURE™ Metal Surface after PIPEASSURE™ Removed
PIPEASSURE™ on R1 PIPEASSURE™ on Testplate
Surface comparison between Riser 1 & Test Plate after PIPEASSURE™ Removal
10
Prior to Removal of PIPEASSURE™ Metal Surface after PIPEASSURE™ Removed
PIPEASSURE™ on R1 PIPEASSURE™ on Testplate
Surface comparison between Riser 1 & Test Plate after PIPEASSURE™ Removal
10
Prior to Removal of PIPEASSURE™ Metal Surface after PIPEASSURE™ Removed
PIPEASSURE™ on R1 PIPEASSURE™ on Testplate
Surface comparison between Riser 1 & Test Plate after PIPEASSURE™ Removal
10
Prior to Removal of PIPEASSURE™ Metal Surface after PIPEASSURE™ Removed
PIPEASSURE™ on R1 PIPEASSURE™ on Testplate
Surface comparison between Riser 1 & Test Plate after PIPEASSURE™ Removal
10
Prior to Removal of PIPEASSURE™ Metal Surface after PIPEASSURE™ Removed
PIPEASSURE™ on R1 PIPEASSURE™ on Testplate
Surface comparison between Riser 1 & Test Plate after PIPEASSURE™ Removal
MTT-989 application 1
MTT-989 on R1
MTT-989 on testplate
rust free
After removing MTT-989, no signs of rust are visable on the metal substrate. To date, MTT-989 has been applied and installed for
4 years. MTT-989 has been accepted as a standard composite re-pair system by PETRoNAS Malaysia based on PTS 31.40.60.12
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
MTT-989 application 1
12
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
MTT-989 application 1re-application
MTT-989 successfully re-applied in the splash zone of oil platform riser
onshore field applications
MTT-989
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
SUBJECTMedium Steam
Description Condensate Steam Drum (15 years old)
Temperature ~90 deg. c
Pressure 0.2 bar
Types of defect Corrosion (3 locations)
Location of defect Bottom
Remarks Repair awaiting for Turn Around in 2014
MEDIUM
14
Subject DescriptionMedium Steam
Description Condensate Steam Drum (15 years)
Temperature ~90 deg. c
Pressure 0.2 bar
Types of defect Corrosion (3 locations)
Location of defect on Bottom
Remarks Repair awaiting for Turn Around in 2014
14
Subject DescriptionMedium Steam
Description Condensate Steam Drum (15 years)
Temperature ~90 deg. c
Pressure 0.2 bar
Types of defect Corrosion (3 locations)
Location of defect on Bottom
Remarks Repair awaiting for Turn Around in 2014
MTT-989 application 2high temperature
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
BEFORE REPAIR apply commercial putty to seal leaks
AFTER MTT-989 applied
Pa
tch
1P
atc
h 2
Pa
tch
2P
atc
h 3
15
Before repair Apply commercial putty to seal leaks
After PipeAssure™ applied
Patc
h 1
Patc
h 2
Patc
h 2
Patc
h 3
Before and after repairs to condensate steam drum
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
corrosion protectionSUBJECT MEDIUM
Medium Crude oil
Diameter 30 inch
Temperature 30°C
Pressure 6 bar (<10bar)
Types of defect Corrosion under existing wrap (previously Fibaroll was applied –2006)
Location of defect on pipeline
4 & 5 o’clock position (defect possibly due to high humidity –close proximity to water/ moisture)
Length of repair 3.6 m
Remaining wall thickness 4 mm (original 12 mm)
REAPIR CHALLENGESLive repair on export pipeline (110,000 bbl/day of crude)
Section of repair is above water.
Partially submerged during high tide
MTT-989 application 3
corrosion protection& lEAK REPAIR
SUBJECT MEDIUM
Medium Water
Diameter 1.5-4 inch
Temperature 30°C
Pressure 6 bar (<10bar)
Types of defect Leak / corrosion protection
Defect 79 repair points including 17 leak points
repair CHALLENGEST joints at elevated areas
Multiple leak locations on a single pipe
Restricted access
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
MTT-989 applications 4 & 5
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
corrosion protection SUBJECT MEDIUM
Medium Water
Diameter 24 inch
Temperature 30°C
Pressure 45 bar (operating)
Types of defect Scratches and external metal loss
Defect length 1m
repair CHALLENGESRestricted working area
Live repair at 60 bar
19
Damage due to excavation work
Wall thickness : 14.0 – 15.0 mmWall loss : 1.0 – 1.5 mm
Subject Description
Medium Hydrocarbon Gas
Diameter 1.5 inch – 4 inch
Temperature 30°C
Pressure 45 bar (operating)
Types of defect
Scratches (due to excavator work) & external metal loss
Defect Length 1 m
Challenges: Restricted working area.
Live repair at 60 bar
MTT-989 application 6
corrosion protection
SUBJECT MEDIUM
Diameter 12 inch
Types of defect External corrosion due to failed neoprene
Defect length 3m
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
MTT-989 application 7
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
strenthening and leak repair for high pressure facilities
REPAIR wORK AT TIONGB•Diameter: 6”•Repair length:400mm•Pressure: 207 bar (design), 140 bar (MAoP)•Temp: 110°C (design), 77°C (operating)
REPAIR wORK AT BEKOKA•50 repair points•Diameter: 4” to 10”•Pressure: 30 to 100 bar (operating)•Temp: 30°C -60°C (operating)
MCOT oNShoRE LEAK CoNTAINMENTDESCRIPTIoN•10 in @ 30C, 2barg, hydrocarbon, leak repair•Severe wall loss and pittings, limited access
21
1
Highlights:
• Repair work at Tiong B• Diameter: 6” • Repair length:400mm• Pressure: 207 bar (design), 140
bar (MAOP)• Temp: 110°C (design), 77°C
(operating)
2
Highlights:
• Repair work at Bekok A• 50 repair points• Diameter: 4” to 10”• Pressure: 30 to 100 bar (operating)• Temp: 30°C - 60°C (operating)
ONSHORE LEAK CONTAINMENT
DESCRIPTION• 10 in @ 30 ⁰C, 2barg,
hydrocarbon, leak repair• Severe wall loss and
pittings, limited access• Repair length: 2 m
MCOT 11 October 2012
3
21
1
Highlights:
• Repair work at Tiong B• Diameter: 6” • Repair length:400mm• Pressure: 207 bar (design), 140
bar (MAOP)• Temp: 110°C (design), 77°C
(operating)
2
Highlights:
• Repair work at Bekok A• 50 repair points• Diameter: 4” to 10”• Pressure: 30 to 100 bar (operating)• Temp: 30°C - 60°C (operating)
ONSHORE LEAK CONTAINMENT
DESCRIPTION• 10 in @ 30 ⁰C, 2barg,
hydrocarbon, leak repair• Severe wall loss and
pittings, limited access• Repair length: 2 m
MCOT 11 October 2012
3
21
1
Highlights:
• Repair work at Tiong B• Diameter: 6” • Repair length:400mm• Pressure: 207 bar (design), 140
bar (MAOP)• Temp: 110°C (design), 77°C
(operating)
2
Highlights:
• Repair work at Bekok A• 50 repair points• Diameter: 4” to 10”• Pressure: 30 to 100 bar (operating)• Temp: 30°C - 60°C (operating)
ONSHORE LEAK CONTAINMENT
DESCRIPTION• 10 in @ 30 ⁰C, 2barg,
hydrocarbon, leak repair• Severe wall loss and
pittings, limited access• Repair length: 2 m
MCOT 11 October 2012
3
MTT-989 application 8
mtt-989DNV approved qualification certificates
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
MATERIALPROPERTIES
STRENGTHENING & LEAK
STRENGTHENING & LEAK
CORROSION PROTECTION
Longitudinal Tension( ASTM D 3039)
Transverse Tension( ASTM D 3039)
In plane Shear( ASTM D 5379)
Hardness (Shore D)( ASTM D 2583)
Tg( ASTM D 6604)
Coefficient of Thermal Expansion( ASTM E 831)
Lap Shear( ASTM E 831)
Defect Type A( ISO 24817)
Defect Type B(10mm)( ISO 24817)
Defect Type B(15mm)( ISO 24817)
Defect Type B(25mm)( ISO 24817)
Defect Type B + impact (25mm)( ISO 24817)
Salt Spray ( ASTM B 117 & D1654)
Salt Spray + Impact( ASTM B 117 & D1654 + D2794)
Adhesion ‘Dolly’ ( ASTM 4541)
Cathodic Disbondment(ASTM G8)
Accelerated Weathering(ASTM G26/ 155)
DNV Approved Qualification Test Program for corrosion resistance, strengthening and leak repair
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
CertifiCations oBtained in ComplianCe with iso 24817 standard:1. Material Properties (out-of-water)
2. Material Properties (in-water)
3. Adhesion Properties (out-of-water)
4. Adhesion Properties (in-water)
5. Dielectric
6. Cathodic Disbondment
7. Weathering Tests
8. Type A: Wall Loss (out-of-water)
9. Type A: Wall Loss (in-water), including unrepaired specimens
10. Type B: Leak (out-of-water)
11. Type B: Leak (in-water)
PETRoNAS MALAYSIA hAS SPECIFIED MTT-989 AS AN APPRoVED CoMPoSITE oVERWRAP REPAIR SYSTEM FoR PIPELINES AND PIPING
Third party qualitfications conducted by det norske Veritas Australia have been completed and certificates issued
The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053
tYpe a - 80% wall thinning• Demonstrate repair material capable to reinstate pipe back to design pressure• Survived design pressure (326 bar)• Excessive yielding of pipe when n-loaded to beyond 326 bar (and up to a max of 380 bar)
tYpe B –hole defeCt: 10mm, 15mm and 25mm• Test to measure fracture toughness –for hole in pipe defect 9 tested with three different holes sizes: 10, 15 and 25 mmResults:• 25 mm hole: Avg. failure at 87 bar• 15 mm hole: Avg. failure at 108 bar• 10 mm hole: Avg. failure at 333 bar* one failed at 240 bar; Two specimens did not fail at max. pressure of 380 bar!• Average fracture toughness valueof 96 J/m2 **** Excluding 10 mm hole
Demonstrate repair material capable to reinstate pipe back to design pressure
Survived design pressure (326 bar)
Excessive yielding of pipe when n-loaded to beyond 326 bar (and up to a max of 380 bar)
Pres
sure
(bar
)
Type A – 80% Wall thinning Type B – Hole defect: 10mm, 15mm and 25mm
Test to measure fracture toughness – for hole in pipe defect
9 tested with three different holes sizes: 10, 15 and 25 mm
Results:◦ 25 mm hole: Avg. failure at 87 bar◦ 15 mm hole: Avg. failure at 108 bar◦ 10 mm hole: Avg. failure at 333 bar
* One failed at 240 bar; Two specimens did not fail at max. pressure of 380 bar!
Average fracture toughness valueof 96 J/m2 ****Excluding 10 mm hole results
25
Demonstrate repair material capable to reinstate pipe back to design pressure
Survived design pressure (326 bar)
Excessive yielding of pipe when n-loaded to beyond 326 bar (and up to a max of 380 bar)
Pres
sure
(bar
)
Type A – 80% Wall thinning Type B – Hole defect: 10mm, 15mm and 25mm
Test to measure fracture toughness – for hole in pipe defect
9 tested with three different holes sizes: 10, 15 and 25 mm
Results:◦ 25 mm hole: Avg. failure at 87 bar◦ 15 mm hole: Avg. failure at 108 bar◦ 10 mm hole: Avg. failure at 333 bar
* One failed at 240 bar; Two specimens did not fail at max. pressure of 380 bar!
Average fracture toughness valueof 96 J/m2 ****Excluding 10 mm hole results
25
Qualification test results hydrostatic pressure
For technical enquries and licensed distrubtors contact The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053 Email: sales@specialty.com.au
www.auscomposites.com.au
is a registered trademark PETRoNAS Ventures Sdn. Bhd
Specialty Coatings (Aust) Pty Ltd is the licensed manufacturer and global supplier of MTT -989 with ProAssure technology
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