Technology From An Innovator’s ProspectiveDec 03, 2016 · Company) to develop a method to repair gouges on existing MDPE gas pipe lines. Responding to this particular RFP was our

Technology From An Innovator’s Prospective

Larry Cercone, Ph.D.

Director of Innovation, Oil, Gas and Industrial

Overview

What is InnovationInnovation can be defined simply as a "new idea, device or method”. However,

innovation is often viewed as the application of better solutions that meet new

requirements, unarticulated needs, or existing market needs.

What is an InnovatorThis is somewhat more difficult to define. An innovator can be anyone, but more than

likely, in our industry, is someone with knowledge of and experience. True innovators

get their hands dirty.

An innovator has many voices in their head, chemist, mathematician, physicist,

chemical engineer, mechanical engineer, testing technician, electrical controls

technician, machinist, marketing, management……………..and the list goes on.

An innovator’s job is NEVER 8 to 5. An innovator is always working on projects in their

mind, and sometime at very strange hours or social situations.

An innovator knows failure (hit rate).

Overview

Innovators who have influenced meKarl Stienmetz - Westinghouse

Nicola Tesla - Westinghouse

Fred Policelli - Hercules (ATK)

Enrico Fermi - University of Chicago

Where do innovative ideas come fromSales Group (The Business)

Customers

Vendors

Trade Shows

Observations

Dreams

What drivers control implementation of an innovationThe wants, is this something we really want?

The need, is the really needed?

The cost.

IP

BRAKETHROUGH INOVATIONS

ManagementWe want………………………………………………………….

InnovatorYou want WHAT………………WHEN?

ManagementHow much is to going to cost?

How long is it going to take?

InnovatorI don’t know.

I don’t know.

Breakthrough Innovations take time.


Thank you Far Side


90% of the solution to any problem is CLEARLY defining the knowns and unknowns.

Is the solution to the problem a brut force or an elegant solution.

Deal with the knowns first.

Think about the unknowns (Hopefully a Miracle Occurs).

Define the innovation needs

Is this materials only or materials and installation methodology.

Team members needed (a brief word).

Time line

From pencil on paper to product on a pipe.

Develop initial cost estimates, knowing those will change.

Be prepared to change directions. (Going down the rabbit hole)

Be prepared for failure.

A Real Innovative Project

THE PROBLEM AS PRESENTED

Develop a product and installation method to repair in-service

polyethylene gas pipe lines using composite materials. Can we do it?

The short answer is yes, we got to the moon, how much time and

money do I get?

Do you want this to be a brute force or elegant solution?

The Knowns and Unknowns

DEFINE THE SUBSTRAIT

Natural gas is transmitted and distributed in medium density polyethylene

pipe (MDPE). Through the years improvements have been made in the

polymer structure until we now use the familiar (MDPE 2406 GAS YELLOW)

MDPE pipe.

First Generation PE Pipe Current PE Pipe

Physical and Mechanical Properties of MDPE 2406 GAS YELLOW PIPE

MDPE 2406 GAS YELLOWPhysical Properties Test Method Values(3) English (SI)

Resin Properties

Melt Index (I2) @190°C/2.16 kg,

g/10 minASTM D 1238 >0.15

Flow Rate (I21) @190°C/21.60

kg, g/10 minASTM D 1238 9.5

Density (natural resin), g/cc ASTM D 792 0.94

Thermal Stability, °F (°C) ASTM D 3350 > 428 (> 220)

Mechanical Properties(4)

Tensile Strength at Yield, psi

(MPa)ASTM D 638 > 2600 (> 18)

Elongation at Break, % ASTM D 638 > 600

Flexural Modulus, psi (MPa)ASTM D 790, method

1, procedure B> 90,000 (> 620)Secant Modulus @ 2% strain, 0.5

in/min

Brittleness Temperature, °F (°C)ASTM D 746,

procedure A< -103 (<-76)

Slow Crack Growth PENT, hours ASTM F 1473 > 10,000

Pipe Properties(2)

Hydrostatic Strength @ 73° F

(23°C), psi (MPa)ASTM D 2837 1,250 (8.6)

Hydrostatic Strength @

140°F (60°C), psi (MPa)ASTM D 2837 1,000 (6.9)

Fusion Qualification:

Qualified to TR-33 Generic Procedure

* PE 2708 is also called PE 2406

under certain ASTM and AGA

specifications

What Will Bond to Polyethylene

Literature search (yes, some of us go to libraries and search).

Internet search.

Procure samples of likely candidates.

Test those samples.

Results, negative, negative, negative………………………..

Look for other alternatives.

THEN A MIRACLE OCCURS

THE BONDING OR TIE LAYER

After investigating possible candidates that could promote bonding to PE pipe, we

made a discovery from the electronics industry, that had the possibility of bonding

two dissimilar surfaces.

Since, in this case, it is not a chemical bonding solution, we first had to determine

how to heat-fuse the tie layer to the PE pipe.

THE BRUTE FORCE METHOD

The first trials were made using a hand held heat gun to fuse the tie

layer to the MDPE pipe.

The tie layer is 0.003” thick………………very difficult to handle.

Applying an even heat around the pipe circumference was

problematic at best.

Level of frustration at this point…………….HIGH!

Will It Actually Work

The Brute Force Test

4” Butt Joint Non Fused Tie Layer/Reinforcement

THE BRUTE FORCE TEST

Moral to the story is, you

really don’t need to spend

a lot of money to see if

something might actually

work.

ACTUAL TESTING STEP (real testing)

PATH FORWAD

RFP

Working closely with The Gas Technology Institute (GTI) in Chicago we responded to a

request for proposal submitted to GTI by OTD (Operations Technology Development

Company) to develop a method to repair gouges on existing MDPE gas pipe lines.

Responding to this particular RFP was our goal, but we could not respond until we had

potential for success.

The proposal was accepted and a testing program was defined.

Since the majority of the PE pipes that need to be repaired are 2” in diameter, it was

decided that all development and testing would be concentrated on that size.

THE CRITICAL STEPS

Installation Methodology

In our “Brute Force” phase we knew we would need to develop a device to install the

product with repeatable results, was easy to transport and easy to use.

Testing and Validation

Working with GTI, we developed a test matrix that, in accordance with the gas

industry’s requirements, would determine initial strength, durability and longevity of

the repair system.

INSTALLATION METHODOLOGY (The elegant solution)

First, we investigated the equipment currently used in the industry to repair

PE pipe.

Next, we investigated commercially available heating methods.

Keeping the installation a primary focus, we designed and built the prototype

machine based on our investigation.

Using the prototype device, we began the testing phase.

THE PROTOTYPE UNIT

THE PROTOTYPE UNITHEATER

OSSILATOR

CLAMP NOZZLE

THE TEST MATRIX

SAMPLE NO. DATE SAND (80 GRIT) CLEANFILL

DEFECTSANDING CLEAN ADHESIVE

TIME

(MIN)

TEMP

SETTINGA+ WRAP

142 104 - 024 4/2/2015 X X X X X X 4 10 X

142 104 - 025 4/2/2015 X X X X X X 4 10 X

142 104 - 026 4/2/2015 X X X X X X 6 9 X

142 104 - 027 4/2/2015 X X X X X X 6 9 X

142 104 - 028 4/2/2015 X X X X X X 6 9 X

142 104 - 029 4/2/2015 X X X X X X 6 9 X

142 104 - 030 4/2/2015 X X X X X X 6 9 X

142 104 - 031 4/3/2015 X X X X X X 6 9 X

142 104 - 032 4/3/2015 X X X X X X 6 9 X

142 104 - 033 4/3/2015 X X X X X X 6 9 X

142 104 - 034 4/3/2015 X X X X X X 6 9 X

142 104 - 035 4/3/2015 X X X X X X 6 9 X

142 104 - 036 4/3/2015 X X X X X X 6 9 X

142 104 - 037 4/3/2015 X X X X X X 6 9 X

142 104 - 038 4/6/2015 X X X X X X 6 9 X

142 104 - 039 4/6/2015 X X X X X X 6 9 X

142 104 - 040 4/6/2015 X X X X X X 6 9 X

142 104 - 041 4/6/2015 X X X X X X 6 9 X

142 104 - 042 4/6/2015 X X X X X X 6 9 X

142 104 - 043 4/6/2015 X X X X X X 6 9 X

142 104 - 044 4/6/2015 X X X X X X 6 9 X

142 104 - 045 4/6/2015 X X X X X X 6 9 X

142 104 - 046 4/6/2015 X X X X X X 6 9 X

CW-1 4/27/2015 X X X X X X 6 9 X

CW-2 4/27/2015 X X X X X X 6 9 X

CW-4 4/27/2015 X X X X X X 6 9 X

3 4/22/2015 X X N/A N/A X X 6 9 X

4 4/22/2015 X X N/A N/A X X 6 9 X

6 4/22/2015 X X N/A N/A X X 6 9 X

8 4/23/2015 X X N/A N/A X X 6 9 X

9 4/23/2015 X X N/A N/A X X 6 9 X

13 4/23/2015 X X N/A N/A X X 6 9 X

14 4/24/2015 X X N/A N/A X X 6 9 X

16 4/24/2015 X X N/A N/A X X 6 9 X

1 4/27/2015 X X N/A N/A N/A N/A N/A N/A X






TENSILE SAMPLES (BUTT JOINT) WITH ADHESIVE AND A+

TENSILE SAMPLES (BUTT JOINT) WITH NO ADHESIVE AND A+ BASELINE

Pressure Cycling Sample Preparation

Pressure Cycling Sample Preparation

TEST CHAMBER

TEST RESULTS (Bond Strength)

3319

3302

1268

4151

0 500 1000 1500 2000 2500 3000 3500 4000 4500

Control Pipe ( PE Pipe only)

Butt-fused Pipe (Using Current Butt FusionTechnology)

Butt Joint Made without Adhesive (PolyBurte™, No Adhesive)

Butt Joint Made with Adhesive (PolyBrute™ System)

PolyBrute™Tensile Peak Load (lb)

Peak Load (lb)

Test Method

• Rate Process Method (RPM)

• To validate the long-term performance of the repaired pipe samples an RPM test

program was devised and carried out. RPM is a technique for forecasting the long-

term performance of polyethylene (PE) piping materials. The method requires

hydrostatic pressure testing of pipe specimens at various pressures and

temperatures. The hydrostatic pressure testing was carried in general accordance

with PPI TN-16(2008) Rate Process Method for Projecting Performance of

Polyethylene Piping Components using the hydrostatic pressure test method

described in ASTM D1598. The pipe specimens were capped with free-end type end

closures, filled with deionized water, conditioned and tested in a water bath at

various pressures (hoop stress levels). The failure data obtained at all temperatures

are used to predict the performance of a pipe material at end-use temperature and

pressure conditions.

Results

RPM Data at 140°F (Actual & Shifted Data Points)

Results


Results


Results

Combined RPM Actual and Shifted Data Points

After four and one half years of development and testing,

MILLIKEN INFRASTRUCTURE is proud to announce

PolyBrute™

PolyBrute™ is a new system developed by Milliken Infrastructure to repair gouges

in MDPE gas pipe lines. The patented materials, process and equipment will add

another tool to the gas distribution industry that will allow the repair of gas

pipelines while in service without the need of traditional “squeeze off” and butt

fusion.

WHERE DO WE GO FROM HERE

• OTE Phase II test program.

• Design and build Version 2 of the PolyBrute™ fusion machine.

• Testing for active leak repair (permeation validation).

• Testing of “older” PE pipe currently in service.

• Testing “squeeze off” damage areas in existing pipes.

• Larger diameter pipe methodology.

• Extension of technology to HDPE pipe systems.

THE REWARDS FOR AN INOVATOR

Seeing Your Innovation Commercialized.

ACKNOWLEDGEMENT

• Genevieve Withers, Pipe Wrap, for perusing the opportunity with OTD and GTI and

believing in her development team.

• Jim Souza, Milliken Infrastructure, for his input in developing the technology.

• Dan Bomar Sr., Milliken Infrastructure, for his insight in the development of the

fusion machinery and field application techniques (and the use of his truck for

“brute force” testing).

• OTD for accepting our proposal for the repair of MDPE Pipes.

• GTI for their guidance during the testing program.

SUMMARY

Our industry, the rehabilitation of the nations infrastructure, has an infinite number of

innovations that are needed.

The permutations and combinations of materials running through the world’s piping

systems is almost infinite.

There is more work to be done by all of us.

Questions?

Documents

Technology From An Innovator’s ProspectiveDec 03, 2016 · Company) to develop a method to repair gouges on existing MDPE gas pipe lines. Responding to this particular RFP was our