Download - MTT 989 composite overwrap repair system

composite overwrap repair systemMTT-989

using technology

MTT-989 is a novel pre-impregnated fibreglass, primer and top coat resin system for pipeline and infrastructure repairs, onshore and offshore.

Consists of multiaxial “E-Glassfibre” impregnated with proprietary underwater epoxy resin formulation, which provides effective corrosion and repair to metal, concrete, and composite infrastructure.

MTT-989 is the only repair system which cures underwater and in wet environments without any loss of adhesion or mechanical properties.

KEY BENEFITS• Effective corrosion barrier and protection• Extends pipeline life (e.g. thinned-wall pipelines)• Performs in accordance with ISO24817, ASMEPCC-2, and PTS31.40.60.12• Reduces maintenance costs• No hot work or welding required• Little or no shut down required• Designed to withstand underwater condition > 15years• Cost effective• Permanent repair

+ =The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053

what is MTT-989?

1 Clean surface of pipe or infrastructure

2 Fill holes or damage 3 Mix MTT-989 epoxy surface primer

4 apply MTT-989 epoxy surface primer

5 bandage wrap MTT-989 materials6 overwrap plastic consolidation film

The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053

how is MTT-989 applied?

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corrosion protection strengthening LEAK rEpAir


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what is MTT-989?target applications

Splash zone coating repairs

Onshore corrosion prevention and strengthening

Onshore pipeline coating repair (buried line)

Offshore process pipeline strengthening

Offshore process pipeline leak repair

Non-hydrocarbon vessel repair

To date MTT-989 has been applied and installed in 24 locations in South East Asia in 8 environmental conditions MTT-989-

Applications


SPLASH REPAIR ZONE

NON-HYDROCARBONPATCH REPAIR

ONSHORE CORROSION REPAIR FOR GAS

CORROSION PROTECTION FOR CRuDE

HYRDROCARBON LEAK REPAIR

NON-HYRDROCARBON LEAK REPAIR

MTT-989 performance

corrosion protection application

MTT-989

riser 1 riser 2 riser 3

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Dia – 10”; Length – 35”Repair length: 40”

Damage size: Dia – 10”; Length – 28”

Repair length: 40”

Repair length – 20”

Section to be wrap

DAMAGE SIZEDia–10”; Length –35”Repair length: 40”

DAMAGE SIZEDia–10”; Length –28”Repair length: 40”

REPAIR LENGTH –20”


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Section to be wrap

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Section to be wrap

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Section to be wrap

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Section to be wrap

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Section to be wrap

BEF

OR

EA

FTER

MTT-989 application 1three risers

ped

inspection work

The risers were inspected and one of three risers was opened up after 12 months (24/8/2011):> To check for signs of rust;> To verify signs of deterioration of the overwrap material.

TYPE OF INSPECTION

after 5 days

after 2 months

after 7 months

after 9 months

No abnormalities No abnormalities No abnormalities No abnormalities

VISUAL

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Type of Inspection After 5 days After 2

monthsAfter 7 months

After 9 months

Visual Inspection

No abnormalities

No abnormalities

No abnormalities

No abnormalities

Hardness (Shore D)

81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92

Adhesion(Dolly) MPa

3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12

• The risers were inspectedand one of three risers wasopened up after 12months (24/8/2011): To check for signs of rust; To verify signs of

deterioration on theoverwrap material.

hardness(ShoRE D) 81.17 ±1.72 77.30 ±2.21 75.50 ±4.43 80.00 ±2.92

adhesion(DoLLY) MPa 3.57±0.66 10.36 ±2.05 > 12 > 12


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After 9 months

Visual Inspection

No abnormalities

No abnormalities

No abnormalities

No abnormalities

Hardness (Shore D)

81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92

Adhesion(Dolly) MPa

3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12



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After 9 months

Visual Inspection

No abnormalities

No abnormalities

No abnormalities

No abnormalities

Hardness (Shore D)

81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92

Adhesion(Dolly) MPa

3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12



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After 9 months

Visual Inspection

No abnormalities

No abnormalities

No abnormalities

No abnormalities

Hardness (Shore D)

81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92

Adhesion(Dolly) MPa

3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12



8



After 9 months

Visual Inspection

No abnormalities

No abnormalities

No abnormalities

No abnormalities

Hardness (Shore D)

81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92

Adhesion(Dolly) MPa

3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12



8



After 9 months

Visual Inspection

No abnormalities

No abnormalities

No abnormalities

No abnormalities

Hardness (Shore D)

81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92

Adhesion(Dolly) MPa

3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12



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After 9 months

Visual Inspection

No abnormalities

No abnormalities

No abnormalities

No abnormalities

Hardness (Shore D)

81.17 ± 1.72 77.30 ± 2.21 75.50 ± 4.43 80.00 ± 2.92

Adhesion(Dolly) MPa

3.57 ± 0.66 10.36 ± 2.05 >> 12 >> 12



MTT-989 application 1

post one year

inspection prior to removal of paint

Paint removed

•Number of barnacles reduced since inspection in Month 9 demonstrating barnacles have no affinity or impact to MTT-989 surface condition•CVI and Dolly indicate MTT-989 had very good adhesion to riser, R1, similar to results on test plate

• Surfaces in good condition


• Population of barnacles reduced since inspection in Month 9 suggesting barnacles have no affinity or no impact to PIPEASSURE™

• CVI and Dolly indicate PIPEASSURE™ had very good adhesion to riser, R1, similar to results on test plate

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Inspection Prior to Removal of Paint

Paint Removed

• Surfaces in good condition• Population of barnacles reduced since inspection in Month 9 suggesting barnacles have no affinity or no impact to PIPEASSURE™

• CVI and Dolly indicate PIPEASSURE™ had very good adhesion to riser, R1, similar to results on test plate

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Inspection Prior to Removal of Paint

Paint Removed

• Surfaces in good condition


post one yearprior to removal of MTT-989

metal surface afterMTT-989 removed

Surface comparison between Riser 1 & Testplate after MTT-989 Removal


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Prior to Removal of PIPEASSURE™ Metal Surface after PIPEASSURE™ Removed

PIPEASSURE™ on R1 PIPEASSURE™ on Testplate

Surface comparison between Riser 1 & Test Plate after PIPEASSURE™ Removal

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MTT-989 on R1

MTT-989 on testplate

rust free

After removing MTT-989, no signs of rust are visable on the metal substrate. To date, MTT-989 has been applied and installed for

4 years. MTT-989 has been accepted as a standard composite re-pair system by PETRoNAS Malaysia based on PTS 31.40.60.12



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MTT-989 application 1re-application

MTT-989 successfully re-applied in the splash zone of oil platform riser

onshore field applications

MTT-989


SUBJECTMedium Steam

Description Condensate Steam Drum (15 years old)

Temperature ~90 deg. c

Pressure 0.2 bar

Types of defect Corrosion (3 locations)

Location of defect Bottom

Remarks Repair awaiting for Turn Around in 2014

MEDIUM

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Subject DescriptionMedium Steam

Description Condensate Steam Drum (15 years)


Pressure 0.2 bar


Location of defect on Bottom


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Subject DescriptionMedium Steam

Description Condensate Steam Drum (15 years)


Pressure 0.2 bar


Location of defect on Bottom


MTT-989 application 2high temperature


BEFORE REPAIR apply commercial putty to seal leaks

AFTER MTT-989 applied

Pa

tch

1P

atc

h 2

Pa

tch

2P

atc

h 3

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Before repair Apply commercial putty to seal leaks

After PipeAssure™ applied

Patc

h 1

Patc

h 2

Patc

h 2

Patc

h 3

Before and after repairs to condensate steam drum


corrosion protectionSUBJECT MEDIUM

Medium Crude oil

Diameter 30 inch

Temperature 30°C

Pressure 6 bar (<10bar)

Types of defect Corrosion under existing wrap (previously Fibaroll was applied –2006)

Location of defect on pipeline

4 & 5 o’clock position (defect possibly due to high humidity –close proximity to water/ moisture)

Length of repair 3.6 m

Remaining wall thickness 4 mm (original 12 mm)

REAPIR CHALLENGESLive repair on export pipeline (110,000 bbl/day of crude)

Section of repair is above water.

Partially submerged during high tide


corrosion protection& lEAK REPAIR

SUBJECT MEDIUM

Medium Water

Diameter 1.5-4 inch

Temperature 30°C

Pressure 6 bar (<10bar)

Types of defect Leak / corrosion protection

Defect 79 repair points including 17 leak points

repair CHALLENGEST joints at elevated areas

Multiple leak locations on a single pipe

Restricted access


MTT-989 applications 4 & 5


corrosion protection SUBJECT MEDIUM

Medium Water

Diameter 24 inch

Temperature 30°C

Pressure 45 bar (operating)

Types of defect Scratches and external metal loss

Defect length 1m

repair CHALLENGESRestricted working area

Live repair at 60 bar

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Damage due to excavation work

Wall thickness : 14.0 – 15.0 mmWall loss : 1.0 – 1.5 mm

Subject Description

Medium Hydrocarbon Gas

Diameter 1.5 inch – 4 inch

Temperature 30°C

Pressure 45 bar (operating)

Types of defect

Scratches (due to excavator work) & external metal loss

Defect Length 1 m

Challenges: Restricted working area.

Live repair at 60 bar


corrosion protection

SUBJECT MEDIUM

Diameter 12 inch

Types of defect External corrosion due to failed neoprene

Defect length 3m




strenthening and leak repair for high pressure facilities

REPAIR wORK AT TIONGB•Diameter: 6”•Repair length:400mm•Pressure: 207 bar (design), 140 bar (MAoP)•Temp: 110°C (design), 77°C (operating)

REPAIR wORK AT BEKOKA•50 repair points•Diameter: 4” to 10”•Pressure: 30 to 100 bar (operating)•Temp: 30°C -60°C (operating)

MCOT oNShoRE LEAK CoNTAINMENTDESCRIPTIoN•10 in @ 30C, 2barg, hydrocarbon, leak repair•Severe wall loss and pittings, limited access

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1

Highlights:

• Repair work at Tiong B• Diameter: 6” • Repair length:400mm• Pressure: 207 bar (design), 140

bar (MAOP)• Temp: 110°C (design), 77°C

(operating)

2

Highlights:

• Repair work at Bekok A• 50 repair points• Diameter: 4” to 10”• Pressure: 30 to 100 bar (operating)• Temp: 30°C - 60°C (operating)

ONSHORE LEAK CONTAINMENT

DESCRIPTION• 10 in @ 30 ⁰C, 2barg,

hydrocarbon, leak repair• Severe wall loss and

pittings, limited access• Repair length: 2 m

MCOT 11 October 2012

3

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1

Highlights:



(operating)

2

Highlights:







3

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1

Highlights:



(operating)

2

Highlights:







3


mtt-989DNV approved qualification certificates


MATERIALPROPERTIES

STRENGTHENING & LEAK

STRENGTHENING & LEAK

CORROSION PROTECTION

Longitudinal Tension( ASTM D 3039)

Transverse Tension( ASTM D 3039)

In plane Shear( ASTM D 5379)

Hardness (Shore D)( ASTM D 2583)

Tg( ASTM D 6604)

Coefficient of Thermal Expansion( ASTM E 831)

Lap Shear( ASTM E 831)

Defect Type A( ISO 24817)

Defect Type B(10mm)( ISO 24817)



Defect Type B + impact (25mm)( ISO 24817)

Salt Spray ( ASTM B 117 & D1654)

Salt Spray + Impact( ASTM B 117 & D1654 + D2794)

Adhesion ‘Dolly’ ( ASTM 4541)

Cathodic Disbondment(ASTM G8)

Accelerated Weathering(ASTM G26/ 155)

DNV Approved Qualification Test Program for corrosion resistance, strengthening and leak repair


CertifiCations oBtained in ComplianCe with iso 24817 standard:1. Material Properties (out-of-water)

2. Material Properties (in-water)

3. Adhesion Properties (out-of-water)

4. Adhesion Properties (in-water)

5. Dielectric

6. Cathodic Disbondment

7. Weathering Tests

8. Type A: Wall Loss (out-of-water)

9. Type A: Wall Loss (in-water), including unrepaired specimens

10. Type B: Leak (out-of-water)

11. Type B: Leak (in-water)

PETRoNAS MALAYSIA hAS SPECIFIED MTT-989 AS AN APPRoVED CoMPoSITE oVERWRAP REPAIR SYSTEM FoR PIPELINES AND PIPING

Third party qualitfications conducted by det norske Veritas Australia have been completed and certificates issued


tYpe a - 80% wall thinning• Demonstrate repair material capable to reinstate pipe back to design pressure• Survived design pressure (326 bar)• Excessive yielding of pipe when n-loaded to beyond 326 bar (and up to a max of 380 bar)

tYpe B –hole defeCt: 10mm, 15mm and 25mm• Test to measure fracture toughness –for hole in pipe defect 9 tested with three different holes sizes: 10, 15 and 25 mmResults:• 25 mm hole: Avg. failure at 87 bar• 15 mm hole: Avg. failure at 108 bar• 10 mm hole: Avg. failure at 333 bar* one failed at 240 bar; Two specimens did not fail at max. pressure of 380 bar!• Average fracture toughness valueof 96 J/m2 **** Excluding 10 mm hole

Demonstrate repair material capable to reinstate pipe back to design pressure

Survived design pressure (326 bar)

Excessive yielding of pipe when n-loaded to beyond 326 bar (and up to a max of 380 bar)

Pres

sure

(bar

)

Type A – 80% Wall thinning Type B – Hole defect: 10mm, 15mm and 25mm

Test to measure fracture toughness – for hole in pipe defect

9 tested with three different holes sizes: 10, 15 and 25 mm

Results:◦ 25 mm hole: Avg. failure at 87 bar◦ 15 mm hole: Avg. failure at 108 bar◦ 10 mm hole: Avg. failure at 333 bar

* One failed at 240 bar; Two specimens did not fail at max. pressure of 380 bar!

Average fracture toughness valueof 96 J/m2 ****Excluding 10 mm hole results

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Demonstrate repair material capable to reinstate pipe back to design pressure

Survived design pressure (326 bar)

Excessive yielding of pipe when n-loaded to beyond 326 bar (and up to a max of 380 bar)

Pres

sure

(bar

)

Type A – 80% Wall thinning Type B – Hole defect: 10mm, 15mm and 25mm

Test to measure fracture toughness – for hole in pipe defect

9 tested with three different holes sizes: 10, 15 and 25 mm

Results:◦ 25 mm hole: Avg. failure at 87 bar◦ 15 mm hole: Avg. failure at 108 bar◦ 10 mm hole: Avg. failure at 333 bar

* One failed at 240 bar; Two specimens did not fail at max. pressure of 380 bar!

Average fracture toughness valueof 96 J/m2 ****Excluding 10 mm hole results

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Qualification test results hydrostatic pressure

For technical enquries and licensed distrubtors contact The Specialty Group, 124-130 Cochranes Road, Moorabbin, VIC 3189 Australia Tel +61-3-9555 8766 Fax +61-3-9555 9053 Email: [email protected]

www.auscomposites.com.au

is a registered trademark PETRoNAS Ventures Sdn. Bhd

Specialty Coatings (Aust) Pty Ltd is the licensed manufacturer and global supplier of MTT -989 with ProAssure technology

Download - MTT 989 composite overwrap repair system

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