composites repair arpa-e_v2.pdf · analysis of steel pipe with internal composite repair. modelling...
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Composites repairAllan C Manalo, Karu Karunasena and Sourish Banerjee
School of Civil Engineering and Surveying, Centre for Future MaterialsUniversity of Southern QueenslandToowoomba, Qld 4350, Australiae-mail: [email protected];
Braided shape-memory polymer composite liner:
Advanced materials for internal repair of steel pipes
Tri-axial braiding machine CFR-SMP Structure Fold and formed trenchless system (Bruce et al., 2006)
Novel particulate-filled (PF) polymer coating systems:
PF polymer coating
Failure of the composites
PF coated composite sleepers
Can be engineered to:• Adhere to steel pipe surfaces with no
surface preparation• Optimal viscosity to ensure
penetration but will flow from top of pipe to bottom prior to curing
• Minimal curing requirements• Compatible with future maintenance
and pipeline modifications• Optimal strength and high durability
Analysis of steel pipe with internal composite repair
Modelling of composite pipe-in-steel pipes
(a) Internal composite repair components and (b) superposition approach
At outer composite cylinder
Contact pressure at the internal composite repair and steel pipe interfaceAt inner composite cylinder
Failure index for inner and outer cylinder subjected to internal pressure Pi
1.50 mm3.50 mm
5.00 mm7.00 mm
9.00 mm
0.00
4.00 mm
8.00 mm
12.00 mm
16.00 mm
20.00 mm
0
5
10
15
20
25
20 30 40 50 60 70 80
Inte
rnal
Rep
air t
hick
ness
(mm
)
L.O.C (%)
X42 Steel-CFRPinternal repair(Pi=18.4 MPa)
X42 Steel-GFRPinternal repair(Pi=18.4 MPa)
0
10
20
30
40
50
60
0 10 20 30 40 50 60 70 80
Inte
rnal
pre
ssur
e co
rres
pond
s to
stee
l yie
ldin
g at
co
mm
on in
terf
ace
(MPa
)
L.O.C (%)
0
1 mm
2 mm
4 mm
6 mm
8 mm
10 mm
14 mm
18 mm
22 mm
Analysis of steel pipe with internal composite repair
Modelling of composite pipe-in-steel pipes
VM stress and Tsai Hill FI variation for 10 mm GFRP and CFRP internal composite repair systems
Required internal composite repair thicknesses for rectify operating pressure of 18.5 MPa for X42 steel
Internal composite repair design nomographs for 150ND pipe
Through thickness stress variation (hoop direction) against different bond coefficient (X42 150ND - 80% LOC, 2 mm CFRP internal repair, Pi =1MPa)
Methods for testing and analysis of repaired steel pipes
Material characterisation
Hydrostatic testing of repaired pipes (external and internal)
500 kN fatigue rigImpact rig Environmental chamber
Internal composite repair system
Axisymmetric external defect 0.5D axial with 50% LOC pipe
FE analysis and simulation