furmanite composite repair technology - · pdf filefurmanitefurmanite s’s engineered...
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Furmanite’sFurmanite sengineered
it icomposite repair technologygy
VALIDATIONVALIDATION
Dr Paul Hill CEngDirector – Furmanite Center of ExcellenceComposite Repairs
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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]
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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
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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
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D di t d t h l ti d d
Composite repair technology
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
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Composite 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
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Composite repair technology
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
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Composite repair technology
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)
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Composite repair technology
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
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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
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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
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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
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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
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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
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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
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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
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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)
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Strain Gage InstallationComposite repair technology
Strain Gage Installation
G #4 i1
2 3
Gage #4 on repair
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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
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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
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Application of RepairsComposite repair technology
Application of Repairs
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Initial Burst Test ResultsComposite repair technology
Initial Burst Test Results
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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
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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
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Field Work Photos (1/3)Composite repair technology
Field Work Photos (1/3)
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Field Work Photos (2/3)Composite repair technology
Field Work Photos (2/3)
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Field Work Photos (3/3)Composite repair technology
Field Work Photos (3/3)
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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
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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
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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.
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Generating Dent Photos (1/3)Composite repair technology
Generating Dent Photos (1/3)
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Generating Dent Photos (2/3)Composite repair technology
Generating Dent Photos (2/3)
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Generating Dent Photos (3/3)Composite repair technology
Generating Dent Photos (3/3)
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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
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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
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Application of RepairsComposite repair technology
Application of Repairs
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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
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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
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Pi li R i E l
Composite repair technology
Pipeline Repair Examples
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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
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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
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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
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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
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Composite repair technology
Leaks
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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
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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
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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
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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
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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
Capability of candidate to be confirmed by
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.
Capability of candidate to be confirmed by
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
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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
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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
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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?