Composite Repair Systems

Composite repair systems using composite wrap remain a constant repair option for industries requiring the repair and rehabilitation of piping systems. Various techniques and testing methods, which have the ability to handle different critical conditions onsite, are being developed in order to meet the demands of the industry. Composite wrap materials are recognized as a reliable and effective means of repairing corrosion damage, mitigating corrosion concerns and keeping critical piping systems in production.

Fundamentals of composite repair systems using composite wrap

While operating pressure is not always high, the chemicals and the elevated temperatures of some piping processes accelerate internal and external corrosion. In most cases, wall loss is severe and in many cases, it has become a safety hazard or is leaking. Through wall defects or complete wall loss and pinhole leaking is a regular occurrence within many facilities.

In order to repair these types of defects, a composite repair system must meet the minimum requirements and perform at the expected level under extreme conditions. Whilst numerous composite wrap materials are available on the market, there are few that have the testing and capability to perform at the elevated temperatures that may be experienced.

Types of composite repair systems

Layered systems and wet lay-up systems are general types of pipe repair systems used for composite repair. SealXpert^TM Wrap Seal PLUS^TM Fibreglass Wrap employs a fibreglass system that provides strength and stiffness, a resin matrix that is used to transfer the load between fibres. The wet lay-up system involves pre-impregnated fibreglass cloth that is activated in the flied by water.

An advantage composite repair system is that the cure state tends to be monolithic and can be used to cover a range of geometries, including tees, elbows, bends and even valves. When designing a repair system using composite wrap materials, engineers must consider both strength and stiffness. From a composite standpoint, strength relates to the tensile strength of a particular system, while stiffness relates to elastic modulus. For most conventional repair systems, there is a direct correlation.

For example, a uniaxial Fibreglass system will typically have an elastic modulus order of 5 x 10⁶ psi to 6 x 10⁶ psi. The strain to failure for E-glass is on the order of 2%. Therefore, one can conclude that typical failure stresses for uniaxial E-glass systems are between 100 ksi and 120 ksi.

Benefit of Composite Repair for Pipe and Tank Leaks Using Composite Wrap:

• Customized solution for through wall defects for pipes and tank walls
• Compliant installed by trained and certified applicators
• Engineering Calculation Report and Method of Statement for each repair
• ISO24817 and ASME PCC2 standards
• Provide excellent strength, bonding and chemical resistance
• Warranty for 20 years

Repair procedure using Composite Wrap for Pipe and Tank Leaks:

Benefit of Composite Repair for Pipeline Reinforcement Using Composite Wrap:

• Customized solution for thin wall defects for pipes and tank walls
• Compliant installed by trained and certified applicators
• Suitable for wall loss up to 80%
• Engineering Calculation Report and Method of Statement for each repair
• ISO24817 and ASME PCC2 standards
• Provide excellent strength, corrosion and chemical resistance
• Warranty for 20 years

Repair procedure using Composite Wrap for Pipeline Reinforcement:

Basic Pipe Reinforcement

Pipelines form the basis for the fluid transportation in all industries, starting from drinking water to corrosive, toxic and hazardous chemicals and gases. As pipeline deteriorates due to corrosion, erosion, etc., the pipe wall thickness will be reduced. Pipe corrosion put the owner at stake and pipe reinforcement system becomes critical and necessary when the pipelines carry complex chemicals that are flammable, corrosive or toxic.

Extreme conditions or high risk working scenarios can cause pipelines to experience damage and deterioration, which includes corrosion, external damage in the form of dents, leaks and the like. The costs for repairing/maintenance of pipelines would shoot up heavily if the pipeline needed to be shut down for such pipe repair operations. It is the greatest technical challenge for any industry to source for a cost-effective solution without any compromise in technology.

At SealXpert Products, we offer a range of proven maintenance and repair solutions in accordance to ISO 24817 and ASME PCC2 standards for pipe corrosion repair that are unique in pipeline services, minimizing or eliminating the need for total pipeline downtime.

Pipeline reinforcement of Crude Oil Pipeline

Some 6000 metres of an 8 inch crude oil transportation pipeline was severely corroded. The pipeline has been in operation for 30 years and needs to be repaired and rehabilitated regularly to ensure its integrity and prolong its service life under the design operating pressure of 350psig. The Wrap Seal PLUS corrosion repair and pipeline reinforcement system was used for the pipeline rehabilitation in this project after which fiberglass repair tapes were applied to reinforce the pipe wall thickness. This rehabilitation project was completed successfully in three months.

The pipe was surface prep via cold works to the required standards of at least ST3 and surface roughness of 80 microns. Next, Wrap Seal PLUS™ standard resin and activator was applied onto the pipe surface as a stop the corrosion. This is uniquely designed as a corrosion protection system for pipelines, vessels and storage tanks. It acts as a corrosion barrier, remediates and reinforces pipes and tanks. Finally, the pipeline reinforcement for the repair location was finally carried out with the wrapping of Wrap Seal PLUS fiberglass repair tape, in accordance to ASME PCC 2 standards and ISO 24817.

Repair procedure using Composite Wrap for Pipeline Reinforcement: