Case Study-R12 12 (2)

General Case Studies

Pipe Wrap, LLC

15832 W est Hardy Rd.

Suite 600

Houston, TX 77060

Tel: 281-999-7100 USA

www.piperepair.net

http://www.piperepair.net/

Case Study # 1- 16" Gas Transmission Line

A+ Wrap™ Repair South Texas - USA

Project Overview External corrosion on a 16” OD, API-5LX-42 cross country pipeline having 57% wall loss within 4 foot wide region. Original pipe wall was 0.281" and an MAOP of 1,062 psi The Solution Design a 20 year repair utilizing the A+ Wrap™ System to restore the structural integrity of the line back to pristine conditions. Repair Method Remove tape coating and sand blast to a NACE #3 finish. The first step of repair is to fill the anomaly with a load transfer epoxy putty. Apply a corrosion barrier epoxy to the entire repair zone prior to wrapping with A+ Wrap™ using the cigar wrap method. Apply the material until the calculated layers have been achieved. Constrict and perforate, then allow to cure for 2 hours. Top coat as applicable, then back-fill.

Case Study #2- Sub Sea Level Bayou Repair

Damaged Gas Transmission Line

Louisiana, USA

OVERVIEW: A 22” gas transmission pipeline12’ below sea level in a bayou, had been hit by a boat anchor and required structural repair.

Coffer dam built to expose

damaged pipe

THE PROBLEM: The pipeline (at 750 psi) needed to be exposed

for the repair. The anomaly was 4.36” and wall

loss was approximately 45%.

THE SOLUTION: A coffer dam was built and the water was

pumped out before digging down to

expose dented pipe. A+ Wrap System

was applied, then top coated and pipe was

reburied.

Wrapping 3 foot of pipe

Pipe ready for topcoat

View of Constrictor Wrap

Case Study # 3- 16" Field Bend Repair Gas Transmission Line

A+ Wrap™ System South Texas - USA

Project Overview A Field Bend had external corrosion at the 6 - 9 O'Clock positions on a 16” OD, API-5LX-42 cross country pipeline. The repair area encompassed a 9 Ft section having 62% wall loss. Original pipe wall was 0.281" and an MAOP of 1,062 psi

The Solution Design a 20 year repair utilizing the A+ Wrap™ System to restore the structural integrity of the line back to pristine conditions. The repair required 18 layers (0.396" composite thickness).

Repair Method Prep the pipe by removing any soft coating and sand blast to a minimum of NACE #3 finish. Fill the anomalies with a load transfer epoxy putty. Apply a corrosion barrier epoxy to the entire repair zone prior to wrapping with A+ Wrap™ using the spiral wrap method. Apply the material until the calculated layers have been achieved. Constrict and perforate, then allow to cure for 2 hours. Top coat as applicable, then back-fill.

Case Study # 4- Oil Rig Caisson Repair

Offshore Oil Rig 24”

Caisson Repair

Gulf of Mexico, USA

THE PROBLEM: Dented caisson prevented proper operation and access

to pumping unit located within.

THE SOLUTION: 1. Abrade the caisson leg with sand

blasting.

2. Secure 24" dia x 180 deg x 36" long

FRP Sleeve with 12 bands.

(Note: The FRP Sleeve to be gasketed with nitrile).

3. Apply EP-193 to create transitions around the FRP Sleeve

4. Apply SplashBond all around the caisson .

5. Apply 6 layers of A+ W rap

(To extend 1 ft beyond both edges of the sleeve).

6. Apply 6 layers of Pipe W rap (also has the 1 ft extension).

7. Apply SplashBond over entire repair area.

Case Study #4-Oil Rig Caisson Repair


Caisson Repair

Gulf of Mexico, USA

SWLP-B Caisson – Current State: Front View

Dented Area (Area of maximum curvature change)

Case Study #4-Oil Rig Caisson Repair


Caisson Repair

Gulf of Mexico, USA

SWLP-B Caisson – Current State: Front View

Case Study #5 Riser Repair Offshore Platform

Production Platform

Offshore Eastern Canada

OVERVIEW: A 3” MEG line with various

configurations needed coating

replacement.

THE PROBLEM: Several areas including an elbow

where epoxy coating was

corroding , system operating at

73°C.

THE SOLUTION: Pipe was sandblasted to near

white metal.

GenWrap™ polyolefinic corrosive

inhibitive under wrap was cut to

size to form over damaged

areas, then overwrapped with

MCU outer wrap for containment

and mechanical protection.

Preparing corroded elbow

repair zone

Applying GenWrap™ Overwrap

Case Study # 6 - Gouge Repairs at a Gas Plant

A+ Wrap™ System - Mechanical Damage North Texas - USA

Project Overview During the excavation of an area within the Gas Processing Plant, a backhoe struck two (2) 8" process lines located adjacently within 4 feet of each other. The 3rd Party mechanical damage occurred during preparation for installation of an additional process line that was to run perpendicular to the damaged lines.

Both pipes were 8" pipe, API-5LX-46, 0.344" wall and operating at 860 psi. The resultant damage was a 0.4" wide x 8" long gouge with 40% wall loss on one pipe section and a 0.12" wide x 1" long gouge with 35% wall loss on the other pipe section.

The Solution The A+ Wrap™ System was the selected material of choice due to its ease of application and structural strength. Based on the parameters provided by the customer, a 12 layer (0.265" material thickness) design was indicated to ensure the continued integrity of the lines.

Inspection of the lines via Dye Penetrant Testing verified that "no cracks" existed in the damaged areas. An important requirement was stipulated for preparation of the gouged areas and that was the removal of all sharp edges to ensure the elimination of potential stress concentrations.

Additionally, because the pipe coating was fusion bonded epoxy, sandblasting was not required. Abrading the existing coating with sandpaper is sufficient.

Di

Dig site - Gas Plant

Distance between pipe sections

View of 0.4" wide x 8" long gouge

Case Study # 6 - Cont.

Repair Method Whenever mechanical damage occurs, the line must be checked to ensure there are no cracks. Once this is confirmed, the primary task in preparing to repair a gouge type defect is to remove "all sharp edges".

The pipe is coated with FBE, so the repair zone only requires lightly abrading the surface with 24-80 grit sandpaper. Fill the anomalies with a load transfer epoxy putty. Apply a corrosion barrier epoxy to the entire repair zone prior to wrapping with A+ Wrap™ using the spiral wrap method. Apply the material until the calculated layers have been achieved. Constrict and perforate, then allow to cure for 2 hours. Top coat as applicable, then back-fill.

View of 0.1" wide x 1" long gouge

Removing "sharp edges"

Putty applied to gouge Abraded surface ready for putty


Applying primer to pipe Continue applying primer

Repairs constrictor wrapped Repairs curing for 2 hours

Ready to be back-fill

Case Study # 7- 14" Natural Gas Transmission Pipeline

A+ Wrap™ Repair Victoria, Texas - USA

Project Overview A large rehabilitation project by an Interstate Gas Transmission company encompassed twenty-six (26) miles of 14” Diameter pipe. The line had been assessed by a High Resolution MFL (Magnetic Flux Leakage) In-Line Inspection Tool. The survey results indicated multiple regions with sections having general corrosion anomalies ranging from 35-65%. The Gas Transmission Company worked closely with PWLLC by providing the pigging log and having PWLLC analyze the respective repair zones to determine the amount of A+ Wrap™ required to restore full structural integrity of the line. The pipe grade was an API-5LX-42, schedule 30 (0.375" original wall). Since it was a Class 1 line, it had 1,620 psi.

The Solution Based on the analysis conducted by PWLLC, the repairs ranged from 14 layers (0.308" of material thickness) for 35% wall loss to 26 layers (0.572" of material thickness) for the 65% wall loss conditions. The design is to provide a minimum of a 20 year service in accordance with ASME PCC-2 Standards.

To simplify things for the installation crews, PWLLC provided the A+ Wrap™ System in kits for the respective repair zones. This additional effort enabled the installation crews to focus just on the material application by removing the necessity for individual layer counting.

Measuring the repair zone

Pipe surface before prep

After Sandblast to NACE 3

Case Study # 7- Cont.


Applying Load Transfer Putty

Encapsulating ILI Marker

"Marking" the repair zone

Primer Application

Begin applying A+ Wrap™

Case Study # 7- Cont.

Spray & apply with 50% overlap

Begin constrictor wrap

"Lightly" perforate constrictor

Complete application

Pull constrictor tightly

Ready to rebury

Case Study # 8 - 24" Flare Line Repair

A+ Wrap™ Repair Tennessee - USA

Project Overview A 24" O.D. AISI-106-B carbon steel Flare line having both external and internal wall loss for a total two hundred and twenty seven (227 ft) foot section required structural reinforcement. The line had a combined wall loss of 54% with an original wall thickness of 0.375". The medium in the line was dilute HF and propane having an operating pressure of 285 psi.

The Solution Based on the analysis conducted by PWLLC, the repair required 12 layers (0.264" of material thickness) of A+ Wrap™ to store the structural integrity back to its pristine conditions. The solution was deemed as a temporary repair as per the ASME Standards. The design provided a 5 year service life.

The complete repair from surface prep to final wrap was accomplished in 21 days without interruption of the refineries process.

Repair Method Prep the pipe by hand tools to remove any soft coating and etch the surface with 24 grit sanding pads. Fill the anomalies with a load transfer epoxy putty. Apply a corrosion barrier epoxy to the entire repair zone prior to wrapping with A+ Wrap™ using the spiral wrap method. Apply the material until the calculated layers have been achieved. Constrict and perforate, then allow to cure for 2 hours. Top coat edges of the repair to add additional protection from potential moisture ingress.

View Elbow Transition

Repaired Branch Connection

Wide View of Entire Repair

Case Study # 9 - 54" Municipal Water Line

A+ Wrap™ Repair San Juan, Puerto Rico - USA Territory

Project Overview An underground 54" O.D. Grade B main water feed line located in a concrete access tunnel had extensive external corrosion due to constant moisture droplets from the ceiling of the tunnel. The line is direct fed from a Reservoir Dam and is supported by 10 inch high concrete saddles located approximately every 30 feet. The 0.500" original wall had degraded by 50%. The line operates at 55 psi in ambient temperature. The designed repair required 26 layers (0.572" material thickness) of A+ Wrap™ to restore structural integrity to a 392 foot long section..

The Solution Due to the restricted access of the lower half of the pipe caused from the concrete saddles, it required specifying the roll size of the A+ Wrap™ to be 12" x 60 ft material. This particular size had a diametric measurement sufficient for work space. The A+ Wrap™ was selected because of it performance capabilities on wet surfaces.

The repair approach was to reinforce the sections between the concrete saddles, then lift the pipe (after materials were properly cured) and apply the materials to the saddle support areas.

The entire repair from surface prep to final wrap was completed in 20 days.

Repair Method Prep the pipe by hand tools and sandblasting to remove any soft coating and etch the surface with 24 grit sanding pads. Fill the anomalies with a load transfer epoxy putty.

View of pipe towards the Dam

View of pipe towards the exit

Preparing to prep the pipe

Applying primer Primer to larger area

Applying A+ Wrap™ Continue wrapping

Case Study # 9 - cont.

Repair Method - cont Apply a corrosion barrier epoxy to the entire repair zone prior to wrapping with A+ Wrap™ using the spiral wrap method. Apply the material until the calculated layers have been achieved. Constrict and perforate, then allow to cure for 2 hours. Top coat edges of the repair to add additional protection from potential moisture ingress.

Applying putty

Completed repair

Case Study # 10 - 8" Riser Repair - Soil to Air Interface

SplashGard™ Repair Bakersfield, California - USA

Project Overview An 8" O.D. riser at a meter station within a gas plant had localized external corrosion at the "soil to air interface" which is a common occurrence due to the "wet-dry" conditions that the area is exposed to during seasonal changes.

The external wall loss was minimal (less than 20% of original wall) and only required re-coating. The SplashGard™ pipe protection system was selected because this system was originally designed for "wet-dry" conditions within the splash zone area of off-shore platform risers.

The Solution Due to the minimal wall loss, no structural reinforcement was required thus SplashWrap I was selected as the over-wrap material. The repair consisted of 2 ft above and below transition zone. The intended service life was a minimum of 5 years.

Repair Method Prep the pipe by hand tools to remove any soft coating and etch the surface with 24 grit sanding pads. Fill the anomalies with a load transfer epoxy putty. Apply the SplashBond™ corrosion barrier epoxy to the entire repair zone prior to wrapping with SplashWrap™. Allow to cure for 2 hours, then top coat with SplashBond™.

Prepped repair zone

Applying SplashBond™

Over-wrapped

Completed repair

Case Study # 11 - Corrosion Under Insulation Repair

GenWrap™ Repair Boston, Massachusetts - USA

Project Overview Various piping sections developed Corrosion Under Insulation (CUI) due to trapped moisture within the insulating material around the pipe. Although the corrosion appeared to be aggressive, once the insulation was removed and the piping surface was prepped, there was minimal wall loss (less than 34%). Based on the low operating pressure of the piping system (60 psi), the customer determined that only providing a protective coating was required. The GenWrap™ System was selected because this system prevents oxygen from reaching the pipe surface. Without oxygen, a corrosion cell cannot occur. This system is typically used on the top side of off-shore platforms.

The Solution All the insulation to be removed from the affected area and the surfaces to be prepped by removing all loose scale. The GenWrap™ System to be applied and extended beyond the defect area.

Repair Method Prep the pipe by hand tools to remove all rust, scale and etch the surface with 24 grit sanding pads. Apply the the GenWrap™ Underwrap and then the GenWrap™ Outerwrap. Both materials to be applied spirally in opposing directions.

Initial view of CUI

Corroded elbow - insulation

removed

Repaired Elbow section

View of repaired

reducing pipe

section

Case Study # 12 - 6" Pipe - Crevice Corrosion Repair

Pipe Sock™ Repair Long Beach, California - USA

Project Overview A common problem that occurs with supported piping sections is the development of crevice corrosion at the interface of the pipe and the support. This problem manifests itself from the relative movement of the pipe in relation to the support thus abrading the existing coating. This action may be cause by the physical movement of the pipe due to "fluid hammering" or the expansion/contraction from temperature variations.

In this repair, the movement was caused by "fluid hammer" which breached the coating under the support and creating a pocket that collected moisture which helped cause the corrosion cell. For this application, the patented Pipe Sock™ (Patent #US 8,087,431 B2) should solve the problem.

The Solution The installation of the patented Pipe Sock™ will eliminate the moisture capture zone by bonding to the pipe and creating a "watershed" along with a wear surface that is not the pipe. Designed service life is 10 years.

Repair Method Prep the pipe by hand tools to remove all rust, scale and etch the surface with 24 grit sanding pads. Attach the patented Pipe Sock™ to the pipe with Black Magic polymer.

Developing access under

support

Initial positioning of Pipe Sock

Final positioning of Pipe Sock Close-up of

Installed Pipe Sock

Exposed pipe with wax coating

removed

Sandblasting the repair zone

Measuring repair zone

Case Study # 13 - 12" Natural Gas Transmission Pipeline

A+ Wrap™ Repair South Texas - USA

Project Overview An Interstate Gas Transmission company completed an ILI run using a High Resolution MFL (Magnetic Flux Leakage) In-Line Inspection Tool. The survey results indicated multiple regions with sections having general corrosion anomalies ranging from 25-65%. In working closely with PWLLC, PWLLC analyzed the respective repair zones to determine the amount of A+ Wrap™ required to restore the full structural integrity of the line. This particular repair was made on a 12" O.D. x 15 ft repair section having the pipe grade as API-5LX-42, with an original wall of 0.375". The system design pressure was 2,470 psi with an MAOP of 1,778 psi for a Class 1 location designation.

The Solution Designing the repair in accordance with ASME PCC-2 & ISO 24817 resulted in 10 layer (0.22" material thickness) design to restore the pipe back to pristine condition. The design was based on a 20 year service life.

As part of the design approach, the repair zone size was included and noted on the kits provided to the installation crew. This results in assisting the crew to focus specifically on applying the materials and does not require them to count the layers because by applying the materials provided within the designated repair zone, the layer count will come out correctly..

Kneading the putty

Measuring the anomaly

Applying the primer

Completing primer application Begin wrapping A+ Wrap and

spraying water during the

application



Complete wrapping process Applying constrictor

Perforating the constrictor Completed repair


Case Study #14- Underwater Repair

Underwater In-Situ SplashGard Application

Offshore Norway

THE PROBLEM:

A 6” diameter submerged pipeline20 meters below

sea level had 25 meters failed concrete coating.

THE SOLUTION:

It was necessary to clean the pipeline of loose

corrosion product. The SplashBond h a d t o

b e m i x e d topside, then placed in buckets,

brought down and applied at approximately 30 mil

thickness. The repair was completed by applying

4 layers of SplashWrap followed by a topcoat of

SplashBond.

Completed repair

16

Case Study #15 - Fresh Water Pump Station

Project Overview:

The Water Supplies Department in Hong Kong is

responsible for m aintaining the pipe repair work within the

district.

Water supply facilities such as, water treatm ent plants

were look ing f or new m aterial to repair and strengthen

the water pipe externally, in particular those large diam

eter pipes inside the water treatm ent work s.

Project Details:

T he sites needing reinforcement were Pum ping Stations 1 & 2 located in Hong Kong.

Pipe Diameters ranged f rom 24” thru 54” with a total

coverage area of 190.4 square meters.

Structural Reinforc em ent f or 50 year design lif e operating at

10 bar (145 psi) was required.

The areas that needed reinforcing are highlighted in yellow

on the supplied drawings on the next pages.

For the areas of Y’s, T’s and against flanges the contingenc y was sm aller rolls sizes were used.

17

Case Study #15 - Fresh Water Pump Station

Table 1

Draw ing #1

18

Case Study #15 - Fresh Water Pump Stations

View s of Repair in Progress

Primer application for preparation of continuing repair of Site M3

Application of A+ Wrap over the

primer undercoat

Application of A+ Wrap over the primer undercoat

19

Case Study # 16- Fire Proofing Rural Water Line

Project Overview:

Pipeline pictured is located in Shek Kong –

Hong Kong China. Due to a brush fire, the

external bitumen protection was burnt entirely.

Pipe W rap LLC was asked to provide a

replacement protective coating that would

enable the protection of the piping under the

same conditions.

Project Details: • The site is located in Shek Kong.

• Each concrete pier about 16 m.

• The pipeline OD is 1.2 meter. The length

(225 meter).

Solution Overview:

View of Repair Site

4 layers of A+W rap was used and covered 225 meters (738 f eet)

of 1.2 m (47.54 inch) diameter pipe.

After A+ W rap had cured (24 hours), a topically

applied intumescent Fire Resistant

coating was used to protect the pipe from future

brush fires.

View of completed Repair

4 layers of PWAP with Fire Resistant Coating

Note: View shows an individual walking a section of the line. T he dark exterior m aterial on the coating

is debris and leaves fallen f rom trees.

Case Study #17-Riser Splash Zone Repair

Riser Coating Repair Mendicant Island Louisiana , USA

OVERVIEW: Badly corroded pipe under pier in need of coating

repair at the Splash Zone.

Pipe - 16” Diameter x .281 wall, API-5LX-42

Design Pressure = 1,475 psi; MAOP = 590 psi.

Recommended repair is the SplashGard™

Coating System (a two-step corrosion barrier

system composed of an adhesive undercoating

and a fiberglass outer wrap), specifically

developed for off shore risers.

THE PROBLEM: Repair to go 6’ above barnacle line.

THE SOLUTION: Materials needed f or wrapping the pipe with 6

layers using A+ W rap™ as follows:

• 1 each - Overwrap (4” x 50’ roll)

• 1 each - SplashBond Epoxy Coating (2-gal kit)

• 1 each - EP913-2Q Epoxy Paste (2 qt kit)

• 2 each - AK25 Application Kits

• 1 each - Constrictor Wrap Small (5” x 600’)

Risers were coated and wrapped using the

SplashGard™ Coating System (a two-step

corrosion barrier system composed of an

adhesive under coating and a fiberglass outer

wrap), specifically developed for offshore risers. View of completed repair using 6

layers of the SplashGard System

Case Study #18 – Air Products & Chemicals

Dust Collector Structural Rehabilitation

California, USA

OVERVIEW: Structural Repair for Dust Collector

Piping.

See piping schematics below

Client Contact: Arun Mahabirsingh Plant Engineer Air Products Manufacturing Corporation email: [email protected]

THE PROBLEM: Very low efficiency of the dust collection system due to holes and joint leakages. Hole sizes ranged from 1” – 4” diameter.

Overall result: High operating costs with minimal benefit.

THE SOLUTION: 26 FRP customized leak stop sleeves were used over each wall defect, overwrapped with A+ Wraps and topically coated with epoxy to provide a requested extended life of 10 years and UV protection.

Repair involved 171 feet of horizontal piping including 22 elbows varying in diameters of between 12” and 18”.

Area 1 - View of Dust Collector pipe

before repair.

Area 1 - View of Dust Collector pipe after repair.

Area 2 - View of before and after Dust Collector structural repair.

mailto:[email protected]

Case Study #18 - Air Products & Chemicals


California, USA

Area 3 - View of duct

before repair.

Area 3 - View of duct after using

the A+ Wrap™ System.

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Case Study #18- Air Products & Chemicals


California, USA

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Case Study #18- Air Products & Chemicals Dust Collector Structural Rehabilitation California, USA

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Case Study #18 - Air Products & Chemicals


California, USA

Aerial view of Facility Before

Aerial view of Facility After

Case Study # 19– Water Line Leak Repair

Combination Pipe Wrap™ & A+ Wrap™ Repair

Project Overview

12” Diameter main water line serving a

University.

The Problem

Thru-Wall crack in 12” Transite Pipe due to lateral soil pressure.

Solution Overview

Combination Composite System Repair utilizing Epoxy Putty, Stop Gap Clamp, Pipe Wrap and A+ W rap.

This approach contains the leak along with providing structural integrity.

Repair Procedure The surface was prepped. Putty was applied to the crack to “near-net” profile. The Stop Gap clamp was installed. PPR-2 was then applied to the surface. There were 6 layers of Pipe Wrap applied as well as 8 layers of A+ Wrap. The constrictor wrap was applied and allowed to cure for 2 hours.

View of radial crack

Side view of defect

Completed Repair

Case Study #20 – Penstock Pipe Repair

A+ Wrap Repair

Project Overview: 60”Diameter penstock pipe with a 4” stub out.

The Problem: Thin wall due to corrosion, through wall holes.

Solution Overview : Customized leak repair made up of 5 layers designed to meet the customers’ requirements f or a maximum 2 year service lif e.

Area 2 – Front View of 60” Diameter

penstock before repair.

Area 1 – View of 4” Stub out before repair.

Area 3 – Side view of 4” Stub out before repair.

Area 4 – View of preparation of pipe by blast cleaning.

Area 5 – View o f fully exposed and clean 60” Diameter penstock pipe.

Case Study #20 – Penstock Pipe Repair

Area 6 – View of Epoxy application. Area 7 – View o f completed primer application.

Area 8 – Beginning of A+ Wrap application on 4” Stub out.

Area 9 – Near completion of A + Wrap application.

Area 10 – View of perforated constrictor wrap.

Area 11 – View of completed repair.

Case Study # 21 - Blast Furnace Cooling Water Lines

Project Overview Leaks and thinning pipe wall on a 24” line. Severe

external corrosion had been caused by corrosive

solution dripping onto pipe surface. Concern was

greatest at four tees, where numerous leaks had

formed, the largest having been sealed with wooden

dowels. There was concern that any work on the pipe

could lead to a major rupture. The pipe was operating

at 100 psi (7bar) and 100°F (40°C)

The Solution Repair method comprised of sealing the leak with

expanding polyurethane foam and applying

FormaShield ET (Epoxy – Fiberglass) System

Repair Method The wooden dowel was cut off to about ¼ “ (5mm)

above the pipe surface. Water leaked through the split

that ran up the center of the dowel, and this was

sealed by drilling out a hole using a ¼ “ (5mm) bit and

then sealing this with an expanding polyurethane.

The leaking area was cleaned using grit blasting with a

low pressure system. The pin holes were sealed using

a fast-curing epoxy putty. First, small balls ¼” (5mm)

diameter of putty were rolled and pushed in the holes

and held in place until they cured. Then larger balls ½”

(10mm) diameter were flattened over these to support

them before the whole area was covered. To do this.

The putty was mixed and held in a ball until it started to

warm from the cure. It was then spread quickly over

the area where it rapidly turned solid. Finally the area

was faired smooth using a spreadable epoxy putty.

The repaired area was left overnight to confirm the

putty had sealed the leaks.

Four (4) layers of FormaShield ET were then applied

over the tee. This supports the putty and bonds

strongly to the pipe, protecting it from further corrosion.

View of Leaking Pipe

Pipe Prep outside Defect Zone

Close-up of Putty application

Completed Repair

Case Study #22—Vessel Relief Line 4 Inch Line and Clamp Repair Using Pipe Wrap®

Project Overview : Repair of a 4” line on the outside of a natural gas storage vessel. Included in the repair is an area under the clamp that holds the line in place that has extensive corrosion and pin hole leaks

caused by water being trapped f or an extended period of time. Area

to be repaired will be the side of the vessel, the clamp and

the 4 inch line.

Solution Overview : Repair method was comprised of sealing the pin hole leaks under the clamp and encapsulating the entire clamp using Pipe W rap®. Once

this was accomplished 3 feet of 4 inch line was wrapped to prevent any further corrosion.

Repair Method: Repair required a technician to work from a man lift to at a

height of 45 feet. The entire area was prepped as close to

near white metal as possible and then cleaned with acetone. Once this was accomplished the leaks were repaired using Pipe W rap EP400 epoxy putty applied directly to the pin holes.

The two-part Epoxy Putty was kneaded until heat

began generating from the putty. This indicated that the

putty was near setting up. At this point the putty was

pressed into the pin holes and held for approximately 5 minutes until cured. Once all leaks were confirmed stopped, the entire area was primed using Pipe W rap PPR epoxy primer and all voids were filled to make sure of a smooth transition.

The next step was to apply 8 layers of Pipe W rap® to encapsulate the entire clamp and 3 linear feet of 4 inch pipe. Once the repair was cured the vessel was placed back into service. Work was accomplished within an 8 hour

period. This completed the repair.

4” 45’ Elevated Pipe

.237 Original W all Thickness

Corrosion Under Clamp

Repair Cleaned and Primed

Six Layers of Pipe W rap

A+™ to complete repair

Water pooling due to active

leaks

Strapping attempting to stop

flow

Temporary Dam to allow

access to pipe

Case Study # 23 - 26" Fresh Water Line - Active Leak Repair

RidgeBack™ Repair Northern Arizona - USA

Project Overview A 26" O.D. fresh water feed line for a Fish Hatchery managed by the US Department of Fish & Game developed multiple leaks within a section of line running through a river. The line at the river crossing was ductile iron and operating at 50 psi. The operation of the line could not be interrupted due to the impact on the hatchery. The initial challenge was to divert the river to allow access to the pipe for remediation. Once the river was diverted, there were five (5) noticeable leaks from holes that ranged in size from 1" to 3" in width. The existing coating on the pipe was a mastic rubber tape which easily flaked off. An additional problem incurred was the very limited ability to conduct surface preparation.

The Solution The product of choice for this type of active leak defect is the RidgeBack™ because a compression type seal is required that uniformly distributes the compressive forces thus minimizing the possibility of collapsing the pipe.

Metal clamps had been tried by the contractor, but did not succeed because the tightening process of the clamps did collapse the pipe sections.

As an additional prevention method for future leaks the Pipe Wrap® system was incorporated in the regions between the active leaks. This consisted of a primer and 24 layers of material (0.528" material thickness) utilized.

3rd leak area

2nd leak area - close-up of

make shift clamp

Attempt at wooden plugs

Close-up of installed

RidgeBack™

Installing RidgeBack™


Repair Method Position and secure the RidgeBack™ to each active leak area per the provided procedures. Tighten as required until the area is "drip free" for a minimum of 30 minutes.

Use hand tools to prep the pipe by removing all soft coating. Apply a corrosion barrier epoxy to the entire repair zone prior to wrapping with Pipe Wrap® using the spiral wrap method. Apply the material until the calculated layers have been achieved. Allow to cure for 2 hours. Top coat as applicable, then back-fill.

Over-wrapping the RidgeBack™

Repair approximately 75%

complete

Applying Pipe Wrap

Top coating wrapped area Repairing 2nd section

Require final top coat


Case Study #24- Offshore Leak Repair

Offshore Platform

Lift Pump Piping Repair

Gulf of Mexico, USA

OVERVIEW: Leak repairs on seawater lift piping

located on and offshore Truss SPAR.

THE PROBLEM: The three alternating stainless steel

piping sections supplying seawater

ballast for the SPAR were corroding in

a variety of locations and had active

leaks in all three lines.

There were approximately 39 leaking

areas in both the pipe runs and tees

on the three 10” lines (A, B, and C)

(Photo 1). All piping was 14’ above the deck. It was difficult to be sure of the exact number as some of the leaks were covered with a variety of clamps, tapes or screws.

THE SOLUTION: Erect scaffolding so there is a safe work area for the 2 man crew. Schedule alternating shutdowns and depressurize individual lines, working on them one at a time.

Remove all existing repairs (clamps, tapes, screws, etc.).

Prepare all three pipelines using a side grinder to remove the rust and scale build up, bringing the pipe down to bare metal. Solvent wipe prior to application of epoxies.

Case Study #24- Offshore Leak Repair

Offshore Platform

Lift Pump Piping Repair

Gulf of Mexico, USA

On line A, fill the holes and anomalies

with 2 part epoxy putty, apply 2 part

epoxy primer 360˚ circumferentially, and

overlap repair zone axially by 3-4 inches.

Next, wrap with 24 layers of Pipe W

rap™.

On lines B & C, after preparing the

entire line, fill the holes and anomalies

with 2 part epoxy putty, then apply the

2 part epoxy paste from 3 o’clock to the

9 o’clock position, as all previous leaks

appeared to be in the bottom 180˚ of the

piping. This is in anticipation of new leak

zones developing . Next, apply 2 part

epoxy primer to remainder of bare piping,

and finish with 24 layers of Pipe W rap™.

Case Study #25– Cooling Tower Line Repair

Delaware, USA

Project Overview

12” return water line from chiller unit. The Problem:

The repair of thru wall defects near flange on a 12”

carbon steel cooling tower waterline operating at

140 psi and 90°F. View of Thru wall defects

Solution Overview: Multi-sequence repair requiring depressurization of

the line utilizing A+ W rap in conjunction with epoxy

putty and rubber .

Repair Procedure: Grinded all surfaces to clean steel. Installed ¼’ thick

piece of rubber stopgap over defects.

The rubber pieces were secured with galvanized

banding strap. Traditional method of repair (filling

pipe with putty stick) was not used due to extremely

thin bottom.

Covered the sharp sections of banding material and

all transitions between welded plate to pipe, flange to

pipe and rubber piece to pipe with fast set epoxy

putty stick.

Installed epoxy adhesive over entire repair.

Due to location of repair area (tight against flange

with bolts every 2”) a change was made from the

suggested spiral wrap over the patch and tight

against the flange. Two rolls were used making the

repair six layers thick. A spiral wrap was done

overlapping 2” of the hoop wrap with 3 rolls of

material over the rest of the repair.

Constrictor Wrap was applied over the material.

Line was recharged 2 hours after completion. The

temperature was of an estimated 78°F.

Pipe prepped for repair

Repair Applied and Curing

View of Completed Repair

34

Case Study #26– Gas Pipeline Dent Repair

Midstream Transmission Pipeline Dent Repair 2010

Project Overview:

Dent Repair to Midstream Liquid Transmission Pipeline in wet conditions in Louisiana, USA.

The Problem:

Dented pipe w ith all sharp edges ground out before filler material applied.

Dent filled w ith putty ready for Primer Coat.

Mechanical damage to Transmission pipeline 6.625 OD,0.188” wt. and X42.

Anomaly was a Dent 2.7” long, 1.9” wide, 0.12” depth at 11:16 O’Clock position.

Solution Overview:

The use of the A+ W rap System with Smart Pig Markers.

The A+ W rap System is an alternative to welding a sleeve or cut-out of the dented pipe area.

A+ W rap is suited for wet conditions.

The repair took 2 hours to complete.

View of Primer ap plied to repair

area. Completed A+ Wrap repair w ith

constrictor w rap during cure.

Case Study #27- Active Leak Repair-Gas Line

Gas Storage Area 1

Project Overview: A 6” gas pipeline had pinhole leaks, where metal

clamps have been previously installed, that required

the arrest of leaks with an approved leak repair

system.

The Problem: Leaks and minimum corrosion at two 6 O’Clock

locations of the pipe about 2’ above ground. The first

leaking pinhole was 0.3mm with a repair area of

6” and the two more leaking pinholes were 0.2mm

with a repair area of 12”, with a minimal operating

temperature and pressure. The pipe has anti-

corrosion paint as coating.

Solution Overview: The Active Leak Repair Kit (ALRK) is a three

component system for leak and corrosion protection.

Kits are specific to repair each area on the pipeline. First the leak on the pipe was arrested using

QuikStrap and then the remaining repair zone was

prepped using sandpaper and a metal file to near

white finish. Then the EP913-2 epoxy was applied for

corrosion protection before wrapping with Pipe W rap

for containment and mechanical protection. A final

layer of the epoxy was applied as a topcoat.

Epoxy putty, (EP407), was applied prior to the

QuikStrap step for additional protection.

Case Study #28 – Offshore Production Platform

Unique Emergency Offshore Riser Repair Cook Inlet , Alaska USA

OVERVIEW:

Due to the PHMSA denial of a special permit shortly after the Deepwater Horizon tragedy, the platform operator was out of compliance, subject to enforcement and was forced to immediately shut down.

An emergency structural repair for a liquid production line having a bend located inside of a support leg on an offshore production platform offered many challenges.

THE PROBLEM:

Repair location was inside the leg of an oil and gas production platform located in the Cook Inlet,

Alaska. The pipeline was DOT regulated and carried produced fluids.

The platform leg had an inside diameter of 7 feet and protected not just one 12 inch riser, but two additional 12 inch risers, plus several other pipes ranging in size from 1 inch to 6 inches.

Work space was limited inside and the metal loss location identified by ILI tool inspection was 100 feet from the top of one of the 12 inch diameter risers under 30 - 60 feet of water depending on the tide.

View inside platform leg.

Diver ready to enter platform leg casing.

Visibility was non-existent because the leg was flooded with salt water and silt from many years of tidal action. Water temperature ranged from 40° to 45ºF.

The outside pipe surface temperature was 37ºF. Cure time of the proposed composite repair was temperature dependent.

The riser had been de-rated from the original operational pressure to 340 psig and this pressure would be maintained as the maximum operational pressure for continued service.

The 12” pipe was Grade B, original wall thickness

0.500 inches and had a maximum wall loss of 69% due to external corrosion.

Up out of

the hatch

after

preliminary

pipe

preparation.

Down the hatch.


THE PROBLEM Continued:

Defect was located on a bend in the pipeline;

the bend radius was 24’ - 3”.

Defect was 10 ft. in length beginning 6 inches

from the entry of the pipe into support leg.

Primary defect was located plus 7 feet from the

entry of the support leg.

The repair needed to comply with DOT

requirements (in compliance with ASME PCC-2

Repair Standard for Non-Metallic Repairs). In

addition, the crew needed to be trained and

certified onsite to complete the repair.

Pig marker delectability was also a concern

for future ILI inspections to show that the

anomaly had already been repaired.

THE SOLUTION: The line was shut down and depressurized.

Divers descended inside the 7 foot diameter

platform leg and by blind feel sketched the

location of the various risers inside platform leg.

(See page 4).

Next, removal of sediment and water was

required before the area of metal loss could be

identified, cleaned and examined.

Remote Access Technicians (RAT) then needed

to be trained topside by Pipe W rap, LLC as the

composite repair was designed to DOT

Standards.

A certified Pipe W rap LLC trainer was utilized for

instruction and application procedures and

supervision.

First round of pipe prep

Preliminary pipe prep

Final pipe prep

Primer Coat mixing to send down hatch


THE SOLUTION continued:

The repair was designed to return piping to full strength from 69% wall loss using

26 layers of wrap.

Curing was assisted by forced heated air down to the bottom of the riser. This resulted in raising the pipe temperature to 95ºF for 12 hours.

A PHMSA representative and the Director of Technology from Pipe W rap LLC were on-site to observe, assist and ensure compliance with the riser repair.

Prior to product installation, a certified NACE inspector went down-hole to verify surface preparation requirements.

Technicians installed Pipe W rap LLC’s exclusively licensed patented pig marker into the repair in the direction of oil flow.

(See page 5.)

Due to the critical nature and location of the repair , a project specific QC sign- off was employed for each major step.

Once the repair cured to the required hardness (minimum of 85 shore A scale), the PHMSA representative agreed that the riser had been adequately repaired and platform was restarted.

Oil is again flowing through the seafloor pipeline and the repaired riser is compliant with 49 CFR Part 195.

Splashbond Epoxy Primer ready to

be sent down hatch in bucket

Splashbond Epoxy applied ready to

be overwrapped

A+ W rap applied for structural repair

Inspection of Cure Hardness


Sketches made by Diver inside platform leg

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Repair Schematic

Case Study #29 –Elbow Repair Transmission Pipeline

Gas Transmission Pipeline Elbow Repair 2010

Project Overview : Structural repair needed for a 10.75” OD 90º Elbow with 40% wall loss due to external corrosion.

The Problem: Immediate repair needed to be conformable, easy to apply, safe and durable. This DOT regulated high pressure gas transmission pipeline had general corrosion with 40% wall loss and needed pig detection for later pig runs.

Defect depth was 0.200 inches Defect width was 8.40 inches Defect Length was 28 inches.

Solution Overview: The A+ Wrap System with Pig Detectible Markers provided a repair thickness of .320 inches based on design calculations.

A UV protective topcoat was applied after constrictor wrap had been removed.

Anom aly area

sandblasted to near

white m etal.

Coated elbow over wrapped with A+ W rap

W rapping conform able A+ W rap.

Continuation of wrapping process.

Cured repair to be topically coated f or UV protection. Removing constrictor wrap after 1 hour.

Case Study # 30 – 24” Natural Gas Line Repair

A+ Wrap™ Repair-Kenner, LA

Project Overview

Repair of a 24” O.D., .500” wall X-46 Natural Gas line at a metering station. The line had

27” of corrosion that gathered under pipe support at the 6 oclock position that caused

45% wall loss.

The Problem C r e v i c e c o r r o s i o n r e s u l t e d f r o m c o n d e n s a t i o n s o a k i n g t h e w o o d e n s u p p o r t , o v e r t i m e t h e c o n d e n s a t i o n c a u s e d a 2 7 ” l o n g d e f e c t t o f o r m . T h e c o r r o s i o n d e g r a d e d 4 5 % o f t h e p i p e w a l l r e d u c i n g t h e m a x i m u m a l l o w a b l e p r e s s u r e f r om 68 5 p s i t o 3 5 0 p s i.

Solution Overview

Based on the extent of the defect, the repair was designed in accordance to ASME PCC-2 standards which resulted in 18 layers of A+ W rap™ having an overall repair thickness of 0.396”. The repair was complete from start to finish in 2 hours.

The pipe was media blasted to near white metal and cleaned with MEK solvent, corrosion was filled with EP400 epoxy putty and then coated with PPR primer. A+ W rap™ was applied 31” f rom right to left. T he pipe was then coated with a corrosion and UV resistant paint as a finishing coat over the repair. As stipulated by the Standards, only certified installers are allowed to apply the product .

24” Pipeline with corrosion

Primer-East Side

Primer-West Side

Finished

Repair-East

and West

Side

Case Study #31 – 6” Vertical Caustic Line

Formashield™ ET Repair Pasadena Texas

PROJECT OVERVIEW:

18 linear foot repair of a 6” x 0.281” wall Grade

B carbon steel caustic line at ambient

temperature.

THE PROBLEM:

The line had external corrosion with 65% wall

loss at ambient temperature; there was also a

leak that was present around a 6” clamp.

THE SOLUTION:

The repair was designed in accordance to

ASME PCC-2 standards. Presence of caustic in

the line required Formashield™ System be

used.

Based on the extent of the defect area, 6 layers

of Formashield™ were required for an overall

repair thickness of 0.17”. EP913 epoxy filler

and EP400 epoxy putty were used to

encapsulate the clamp.

The entire repair area was prepped using a

non-sparking grinder as well as wire brushes.

Pin hole leaks surrounding the clamp were filled

in using EP400 epoxy putty. All sharp edges

were ground away. A form was then built to

encapsulate the clamp and filled in using EP913

epoxy filler. The next day after determining the

area was leak free, the rest of the 6 inch pipe

was prepped using the same methods listed

above.

The pipe was primed using PPR-2 and the

required 6 layers of Formashield™ applied

spirally. Then the entire area was wrapped in

constrictor banding. After all material was fully

cured, the constrictor banding was removed

and the area was coated with an epoxy UV

topcoat.

Case Study #32 – Formashield™

Formashield™ ET Pasadena Texas

OVERVIEW:

Repair of a 24” O.D x 0.375” wall, water line

inside a refinery had 31 feet of external

corrosion and 3 areas with pin hole leaks. The

external corrosion on the pipe had a defect

depth of 60 percent wall loss.

THE PROBLEM:

External corrosion resulted from natural causes

over a long period of time caused minor pin hole

leaks and external corrosion, over 31 feet to

occur. The corrosion degraded 60% of the pipe

wall.

THE SOLUTION:

Based on the extent of the defect, the repair

was designed in accordance to ASME PCC-2

standards which resulted in 6 layers of

Formashield™ of an overall repair thickness

of 0.20”. The repair was complete from start

to finish in 3 days.

The pipe was first blasted to near white metal

and cleaned with MEK solvent. The 3 pin hole

repairs were stop- gapped and held leak free

for 1 full day. The remaining 31 feet of

corrosion was filled with proprietary epoxy

putty, coated with PPR primer, then 6 layers

of Formashield™ was applied to the entire 34

feet encapsulating the stop gaps.

The pipe was then coated with a corrosion

and UV resistant paint as a finishing coat

over the repair.

As stipulated by the PCC-2 Standards, only

certified installers were allowed to apply the

product.

Sandblast Pipe

Apply primer

Wrap prepared section

Top coat for UV resistance

Case Study # 33- 96” Water Pipe

A+ Wrap™ Repair Nuclear Plant, Byron IL

Project Overview Severe corrosion was determined at the lower portion of a 96” CW Return Line. Randomly selected UT measurements in the degraded area were performed to obtain a baseline wall thickness of the 96” piping. From these measurements, localized spots in corroded region are below minimum wall thickness. Applying Pipe W rap’s

A+ W rap™ will re-establish margin by restoring pipe strength, Installation of the Pipe W rap material will be from the floor 18” up on the 96” pipe, completely around a 4” stub and, out to the valve on 6” lines 1CW 20AA/B/C/D.

A 2-part elastomeric coating was applied to the wrap and the floor to seal the interface between the wrap and the floor. The wrap is validated through testing for use under the ASME PCC-2 Article 4.1 2006 for B31.1, B31.3, B31.4, and B31.8

The Solution

Pipe - 96” Diameter located 1 story below ground level. Repair was done using is A+ Wrap™ coated with PPR-2™ Epoxy System Repair completed with RC-350™ Rubber Coating for an additional water barrier.

Repair Method

Repair was done with no down time and completed in less than 2 days. Pipe was wrapped with 12 layers of A+ Wrap™ for 1

st 10” and

an additional 5 layers for remaining 8”. Photo shows A+ Wrap™ overwrapped with constrictor wrap.

View of 96” Water Pipe before Repair

12 Layers with A+ Wrap™

Pipe with beads of Black Magic™ followed by PPR-2

Final view of completed repair

Case Study # 34- Special Sequencing Batch Reactor Waste Water Piping Smithville, TN

Project Overview Our Client manufactures a special sequencing batch

reactor (SBR) system, demonstrating lower operating costs and lower sludge production than conventional SBRs, is providing greater than 99% removal of organics for a 2.4 mgd wastewater treatment plant. Due to trouble with internal nozzles the needed to cut two 8 inch holes in the 16 inch line to make repairs and then seal the line. The close proximity of a smaller line added to the difficulty of making the repair

The Solution After reviewing the problem Pipe Wraps’ Formashield was chosen for the repair due to its’ ability to be sized to fit between the two lines and provide a repair that would return the line to its’ original structural strength.

Repair Method Step 1:

The first step in the repair after the internal repairs were

completed was to identify and prepare the repair zone

by abrading the entire area that was to have material

applied.

Case Study # 34- Special Sequencing Batch Reactor

Waste Water Process Piping Smithville, TN

Step 2:

The second step of the repair was to apply epoxy adhesive and place a fiberglass patch over the 8” hole, fasten in place and allow to cure.

Step 3:

The third step of the repair was to apply epoxy putty around the patch then coat the repair zone with Epoxy paste and allow to set for a minimum of 15 minutes.

Step 4:

The final step in the repair was to wetout and apply Formashield using 50%Overlap to provide 12 layers over the center of the repair. Material was constricted, lightly perforated and allowed to cure. The line was returned to service 24 hours after start of repair.

Case Study # 35-Jet Fuel Line Skytanking, USA

Formashield™ New River Airport, New River NC

Project Overview Repair involves structural damage to a 6” GFE Pipe that carries jet fuel from storage tanks to the refueling area. Maintenance equipment had cut a 6” long hole in the elbow at ground level. Pressure rating of the line is 150 PSI so the repair design would be critical to assure at least original pressure capability.

The Solution

Because standard pipe repair calculations would

not be accurate for this type of repair the design

was based on known parameters for this type of

pipe. Because of superior strength, ease of

application to this configuration, good service life

and excellent bonding characteristics

Formashield™ was chosen for the repair.

Repair Method Step 1: The first step in the repair was to identify the repair zone, in this case approximately a 15” long area and prep it using sandpaper to provide a satisfactory anchor pattern.



Step2: The second step of the repair was to apply epoxy putty to the damaged area to create a

seal/load transfer. Putty is contoured then allowed

to harden.

Step 3: The next step of the repair was to mix and

apply epoxy paste to the entire repair zone and

allow to set until it has reached the consistency of

“cold honey”.

Step 4: At this point the pre-measured epoxy resin

was mixed and applied to the Formashield cloth.

Cloth was rolled up and moved from wet=out area

to the repair. For this particular repair 2” wide cloth

was used for ease of application to the curved

surface of the elbow.



Step 5: 10 layers if Formashield™ cloth was

applied to the repair zone using the “Spiral Wrap”

method with 50% overlap. After wrapping was

complete, a constrictor wrap was applied and

lightly perforated to allow for out-gassing and for

the release of excess resin. Repair was allowed to

cure for 2 hours and then constrictor wrap was

removed.

Step 6: Exterior of repair was coated with Epoxy

Primer and entire repair was allowed to cure for 12

hours. Line was put back in service and functioned

perfectly.

Case Study #36- Production Platform Export Riser

GenWrap™ Production Platform

Offshore Eastern Canada

OVERVIEW: An 18” export riser had areas where

existing neoprene rubber coating was

cracking and needed patching using an

approved corrosion barrier system.

THE PROBLEM: Corrosion under cracked neoprene on a 18”

OD riser about 15 feet above water line.

Pitted area was 330.2 mm (13”) x 50.8mm

(2”), operating temperature 73C-78C.

The neoprene coating was 2mm (79 mils)

thick.

THE SOLUTION: GenWrap™ had been laboratory

tested (per Exxon Mobil protocol ) to

have no disbondment , so a field trial

using the two-component corrosion

inhibitive system composed was

custom kitted to repair each area on

the W T riser.

First the pipe was sandblasted to

near white metal, then GenWrap™

polyolefinic corrosive inhibitive under

wrap was cut to size to form over

damaged areas, then overwrapped

with MCU outerwrap for containment

and mechanical protection.

Corrosion under failed neoprene coating on 18” riser

View of completed repair

Case Study #37- Crude Oil Pipeline Repair

Submerged Concrete Coated Crude Oil Pipeline Repair Offshore Columbia

OVERVIEW

Concrete coating on a submerged (15

meters) 48” diameter crude oil pipe

had been scratched and cracked by a

dragging anchor.

THE PROBLEM: Failed concrete coating from

mechanical damage in 15 meter deep

water in 2 separate locations

compromised carbon steel pipe

underneath.

At almost 50 feet deep, all materials

needed to be mixed topside, and

brought down to ocean floor using

weighted buckets. Murky conditions

with limited visibility.

THE SOLUTION: Divers removed damaged concrete,

then measured the concrete thickness

to replace coating. After measuring

the thickness of the existing cracked

concrete coating, a stainless steel

enclosure was fabricated to surround

repair areas to tie the existing concrete

OD on either side of repair zone. The

enclosure was secured with tie-downs

and epoxy aggregate was injected into

an annulus at the top of the stainless

steel enclosure. Final step was to

overwrap the enclosure with A+ Wrap

and topically coat with SplashBond.


INITIAL APPLICATION OF RESIN

FINAL FILL APPLICATION SHROUD

Mixing of com ponents A and B, SplashBond resin. Gravel to the Mix

Mix Epoxy Resin and Gravel Final Appearance of fill material

FINAL FILL APPLICATION

Enlistment of divers Final Photos.

AELD REPORT ACCOMPANYING THE AREA DURING THE ENTIRE BOARD REPAIR GW D-440

KM 5 +322 COVEN LINE OFFSHORE TERMINAL

REVISION CONTROL Revision No. Date

(DD I MM I YYY'I')

Description

0 271Jun I 2008 Documentation of the process.

Developed:

Jotge Tormdo I Junior Engineer Integrity.

ReviewedI Approved:

carlos Vergara I Engineer lntegrity.

I. OBJECTIVE

Supply constraints In the field during the repair activities of system board siding GW0-440, located at Km 5 +322 OCENSA Offshore Line.In order to ensure and document this process.

2. SCOPE

Field activities consisted of the permanent support to the process of implementation of ECO Engineering Standard-IG-368-004-RP-056-E, for the completion of the repair ooating system

against extemal corrosion of the Board GW0-440 ,located at Km 5 +322 OCENSA Offshore Line.

3. METHODOLOGY

The field visit took place between Monday June 16th and Monday June 23,2008 atTermlnal Covenas.


Submerged Concrete Coated Crude Oil Pipeline Repair Offshore Columbia

OVERVIEW

Concrete coating on a submerged (15

meters) 48” diameter crude oil pipe

had been scratched and cracked by a

dragging anchor.

THE PROBLEM: Failed concrete coating from

mechanical damage in 15 meter deep

water in 2 separate locations

compromised carbon steel pipe

underneath.

At almost 50 feet deep, all materials

needed to be mixed topside, and

brought down to ocean floor using

weighted buckets. Murky conditions

with limited visibility.

THE SOLUTION: Divers removed damaged concrete,

then measured the concrete thickness

to replace coating. After measuring

the thickness of the existing cracked

concrete coating, a stainless steel

enclosure was fabricated to surround

repair areas to tie the existing concrete

OD on either side of repair zone. The

enclosure was secured with tie-downs

and epoxy aggregate was injected into

an annulus at the top of the stainless

steel enclosure. Final step was to

overwrap the enclosure with A+ Wrap

and topically coat with SplashBond.


INITIAL APPLICATION OF RESIN

FINAL FILL APPLICATION SHROUD

Mixing of components A and B, SplashBond resin. Gravel to the Mix

Mix Epoxy Resin and Gravel Final Appearance of fill material

FINAL FILL APPLICATION

Enlistment of divers Final Photos.

AELD REPORT ACCOMPANYING THE AREA DURING THE ENTIRE BOARD REPAIR GWD-440 KM 5 +322 COVEN LINE OFFSHORE TERMINAL

REVISION CONTROL Revision No. Date

(DD I MM I YYY'I')

Description

0 271Jun I 2008 Documentation of the process.

Developed:

Jotge Tormdo I Junior Engineer Integrity.

ReviewedI Approved:

carlos Vergara I Engineer lntegrity.

I. OBJECTIVE

Supply constraints In the field during the repair activities of system board siding GW0-440, located at Km 5 +322 OCENSA Offshore Line.In order to ensure and document this process.

2. SCOPE

Field activities consisted of the permanent support to the process of implementation of ECO Engineering Standard-IG-368-004-RP-056-E, for the completion of the repair ooating system

against extemal corrosion of the Board GW0-440 ,located at Km 5 +322 OCENSA Offshore Line.

3. METHODOLOGY

The field visit took place between Monday June 16th and Monday June 23,2008 atTermlnal Covenas.

Case Study #39- Underwater Dent Repair

Offshore Malaysia

OVERVIEW: A 24” concrete coated X60 submersed

gas pipeline was caliper pigged that

identified three dent anomalies.

THE PROBLEM: The pipeline lay on the sea bed with

nominal wall thickness of 15.9 mm and

the three defects were located in a 2

meter section.

The water depth was 25 meters,

expected free spanning and surrounding

in Dregs condition.

THE SOLUTION: Concrete coating was removed for bare

surface area ready for wrapping.

SplashGard was utilized to ensure the

structural integrity of damage caused

from anchors.

Case # 39- Underwater Dent Repair cont'd

Case # 39- Underwater Dent Repair cont'd

Case Study #40- Production Platform Water Line

Production Platform Water Line with Leaks

Offshore West Africa

OVERVIEW: Production facility operating 250

miles offshore with a 24” carbon

steel line experiencing internal

corrosion.

THE PROBLEM: Personnel from Pipe Wrap, LLC

needed to inspect sections of

UT’d pipe that needed structural

wrapping. The produced water lines

had an operating pressure of 62 psi

with a defect area of 84” with 3 mm

(.118”) remaining wall on Grade B

(original 9.52 mm (.375”) wall

thickness.

Sections of pipe that needed

structural wrapping had an I beam

with 6.0 mm clearance above

component 53. As a result,

wrapping could only be performed

area illustrated in Figure 1. (see next page for Sketch of Inspected Repair Zone).

THE SOLUTION: Since the coating was fusion

bond epoxy, minimal surface

preparation (abraded with sand

paper) was all that was required.

Next, PPR (epoxy primer) and 19

layers of A+ W rap were applied.

Photo 1 – I Beam Obstruction

Photo 2 – View of Repair Zone

Photo 3 – Bottom View of I-Beam


Production Platform Produced

Water Line with Leaks


OVERVIEW: FIGURE 1 – Sketch of Inspected Repair Zone

See next page for Isometric Drawing Reference


Production Platform

Produced Water Line with Leaks


OVERVIEW: Isometric Drawing Reference

See next page for additional photos of repair


Production Platform



Photo 4 – View of Prepped Pipe

Photo 5 – View after Repair


Production Platform



Photo 6 – Upstream View of Repair

Photo 7 – Ground View of Completed Repair

Case Study #41- Production Platform Piping

Production Platform Piping Gulf of Mexico, USA

Outside and Topside Platform Deck

Facilities

THE PROBLEM: Pipe line to be repaired ranged in diameters

of 6”, 4” and 3” Schedule 40 to Schedule 80,

Grade B. With an operating temperature of

40° F minimum to 100° F maximum and an

operating pressure of 50 psi. Four layers of

A+ W rap™ were applied to the pipe bodies

with less than 80% wall loss.

Repairs were to be done while the system

was operating. Some lines were actively

leaking.

THE SOLUTION: W here the pipe works had leaks (100%

wall loss) a mechanical clamp was applied

to defect and over wrapped with 15 layers of

Pipe Wrap™ and then reinforced with 4

layers of A+ Wrap™. Girth welds with less

than 80 % wall loss were repaired using

8 layers of A+ W rap.

Girth welds that leaked (100% wall loss)

were clamped first and then over wrapped

with 15 layers of Pipe Wrap™ and 8 layers of

A+ Wrap™ to provide additional axial

stiffness.

Documents

Case Study-R12 12 (2)