fine oil trading company pipeline repair...

High pressure containing repair alternatives

to a welded sleeve. Used by ExxonMobil, Chevron, Shell Oil.

Email: [email protected]

Website: www.fineoilcompany.com

Phone for technical questions: 817-240-6434

Fine Oil Trading Company

Pipeline Repair Products

mailto:[email protected]

http://www.fineoilcompany.com/



Elbow repaired with Aquawrap

in less than one hour

Aquawrap requires no

field-mixing of cloth with resin

Soil to air interface repaired quickly, less than

one hour with Aquawrap 2”x10’ roll

44’ linear 10” pipe with 77% external corrosion

repaired with Aquawrap to reinforce the hoop

strength of the pipeline. No pressure reduction

and backfilled 45 minutes later

Pipeline Repair Photos



Odd Shape Pipeline Repair



External Corrosion Load transfer epoxy filler/primer Aquawrap 4” wide x 15’ long

roll installed right-out-of the

bag. No mixing of resin into

cloth required minutes prior

to install. Aquawrap’s resin

is pre-pregnated into cloth

during its manufacturing

process. We also have 2”&

3” wide rolls.

Blue wrap and perforate Remove blue 45 minutes



Swamp Pipeline Repair



Before repair lifted 8” pipe out of water 96’ repaired with Aquawrap in 3 hours, pipe lowered back into water same day



Swamp Pipeline Repair



Removing old coating

Sandblasting

Corrosion pitting

Aquawrap repair complete



Clamp, Welded Sleeve & Composite



Pig indicated 72% wall loss, sandblasting also discovered 85% & 98%



What do the government regulations say about using composite materials to repair pipelines?



The United States DOT has amended documentation (49 CFR Parts 192 and 195) allowing damaged piping to be "repaired by a method that reliable engineering tests and analyses show can permanently restore the serviceability of the pipe". Leaks can be repaired with composites like Aquawrap, as long as reliable engineering test has been conducted to prove it. Aquawrap can be used on leaks up to 60psi. In addition, ASME - not the law but an engineering recommendation, has amended their B31.4 piping code to include composites as a method to repair pipelines. This can be found in Section 451.6.2 of the 1998 edition of the B31.4 code. ASME has also formed a committee called “Post Construction Composite (PCC-2)” to set qualification standards for composites used to repair piping built under B31.1, B31.3, B31.4, and B31.8. The PCC-2 publishes a written repair document available to the public. The Aquawrap composite system has undergone engineering testing to prove it compliant by the following organizations:

• ASME B31G • ASME B31.4 • ASME PCC-2

• ASME B31.1 • ASME B31.8 • ISO/TS 24817 • ASME B31.3 • DOT 49 CFR Parts 192 and 195 • NSF/ANSI Standard 61

Aquawrap used to repair girth weld with corrosion



What role do composite materials play in repairing liquid and gas pipelines?



• Energy pipelines are weakened by external/internal corrosion, dents, gouges, buckles and wrinkles.

• Damaged pipelines that are repaired with a welded sleeve or clamp can require the pipeline to be shut down, which is costly.

• Composite technology is pressure containing and allows for in-service repair of pipelines.

Aquawrap used to repair bend with wrinkles and corrosion

Pipeline on BP ‘s offshore platform repaired with Aquawrap



What exactly is a composite?

A composite consist of two or more distinct materials that are combined together but remain uniquely identifiable in the mixture. The most common example is glass fibers mixed with a polymeric resin which is easy to distinguish, if one were to cut the fiberglass. This is not the same as making an alloy by mixing two distinct materials together where the individual components become indistinguishable.

Why are composites becoming so popular?

Composites have been an excellent repair method for years, but they are just now becoming "mainstream". As more composite repair systems are used on high profile applications, the more accepted they become. New technology coupled with excellent past performance have thrust composites into the limelight. Their relative low cost enables repair instead of replacement, which saves money for other investments.

How long have composites been used?

Composites have been used for over 40 years! Most composites were introduced into the aerospace industry, but have since had a powerful impact on many other markets: energy pipelines, sports equipment, race cars, boats, infrastructure components and countless other products have benefited from the advantages composites have to offer.



Bridge Column

Aquawrap Applied

Repair Complete



How long do composites last?

Composites can last a few years, or last fifty years, depending on the application. Just like any other material, they will degrade over time. Steel will rust, concrete will crack, paint will peel, and composites will lose their strength. Aquawrap’slong-term tests show that it will retain its strength over 50 years. Epoxy systems have a high initial strength, but weaken more over the long term. Both types of material have been in use in various applications for decades.



Aquawrap repaired corrosion & welding

Up-close photo of corrosion & welding anomalies

Rigid composite had trouble conforming to the damaged pipeline so the pipeline company called Aquawrap



Aquawrap used to repair gouge dent

Aquawrap used to repair several dents

Yes, polyurethane resin composite systems work best to repair pipelines with external defects of <80% wall loss, girth welds, dents, gouges, buckles and wrinkles. They can be used to repair leaks once the hole is plugged or the pipeline is shut down.

Internal defects can be repaired best with field impregnated epoxy resin composite systems, as they are more likely to hold a punch through leak. Sometimes it’s best to apply epoxy composite then apply polyurethane composite like Aquawrap over it to achieve more long-term strength. If line is leaking, it is best to shut down the system and plug the hole with a non-permeable epoxy putty, and then install the composite over it. However, active leaks can be plugged too, but wear a mask to insure that you don’t inhale a fatal gas. Composites should not be installed over active leaks until they have been plugged.



Are composites used to repair both external and internal piping defects?



On this particular job, we fixed 44 linear feet of 10” pipe that had 77% external

wall loss. We completed the repair using Aquawrap in one hour and backfilled

45 minutes later. Aquawrap can be wrapped in a spiral direction using 1”

overlap versus circumferential, thus allows long sections of pipeline to be

wrapped quickly using our 12” wide x 60 ft long rolls. Also, you don’t have to

butt the ends of each layer and it cures as one solid layer with no crevices. .

Spiral wrap technique saves time and money compared to

circumferential wrap technique used by field impregnated

wet lay-up and layered composite systems.





Wet lay-up composite systems:Two types

• Pre-impregnated (Aquawrap)• Field impregnated (Armor Plate, IWrap, Contour Wrap)

Both types use either e-glass or carbon fibers that are woven uni-axial or multi-axial depending on the amount of hoop and axial strength needed.



Pre-impregnated wet lay-up composites like Aquawrap require no mixing of the cloth just minutes prior to installation. Ready to wrap right out of the bag.

Field impregnated wet lay-up composites require cloth to be mixed just minutes prior to installation.



Pre-impregnated systems mix “polyurethane resin” into an e-glass or carbon fiber cloth at the factory. This ensures the resin is properly mixed in a temperature controlled environment by the manufacturer. This enables the wrap to be applied right out-of-the bag on the job site. However, you must spray water on the wrap when applying it to the pipe. Directly after applying the polyurethane wrap, apply three layers of blue plastic wrap and then perforate it to allow excess water to drain. Aquawrap has been removed from the pipe after it cured and no water has been found underneath the wrap. Alternatively, mixing epoxy resin into a cloth just minutes prior to field installation raises concerns about whether enough epoxy resin was applied and did the resin cure too quickly because of warm outside temperatures.

Field-impregnated systems mix “epoxy resin” into an e-glass or carbon fiber cloth just minutes before installation. (e.g. Armor Plate, Diamond Wrap, IWRAP) This system usually comes in one size, 12” wide, and takes much longer to install due to the mixing of resin and it has to be circumferentially wrapped. Also, epoxy resin doesn’t have as much long term strength as the polyurethane resin used in Aquawrap. These systems cost more than Aquawrap’s too.

Both systems cure as one solid mass leaving “no crevices” unlike layered systems. (AKA: “Monolithic”) Layered systems have suffered from crevices, which allow air and water to channel back to the anomaly and cause further corrosion underneath the wrap. Wet lay-up systems are easily applied on non-straight geometries unlike layered systems. (e.g. Tees, elbows, bends, welds and all odd shape lines)



Aquawrap requires no mixing of cloth, just start wrapping

Field impregnated requires clothto be mixed just before install

Comparison of the two types of wet lay-up composite

systems:



The Layered Composite System• Pre-cured in factory and very rigid• Ends must be butted flush against one another• Limited to repairing straight pipes because its

rigidness makes it difficult to confirm to odd shape lines • Not typically used for underwater application • Only comes in one size 12” wide and requires 8 layers • Takes much longer to install than wet lay-up systems

because resin must be applied on all 8 layers. Backfill hours later

• Must be circumferentially wrapped instead of spiral • Much tougher to install in crowded areas due to cinch bar• 8 layers cure with crevices and not as one solid layer

(e.g. Clock Spring and Wrapmaster)



Elbow repaired with Aquawrap.Spiral wrapped, no butting of ends.Installed very quickly and full coverage

Elbow repaired with layered systems. Limited coverage

Layered composite repair system best for straight pipe

Layered composite requires hammer and cinch bar. Extensive time required to install



ExxonMobil 8” line underwater that was hit by an anchor in the Caribbean Sea, causing a dent gouge

ExxonMobil 8” line was repaired using Aquawrap in 2006

BP’s offshore platform had heat exchanger repaired using Aquawrap in 2009

Chevron offshore platform in 2009 was repaired using Aquawrap

Offshore composite repairs successfully completed using Aquawrap





What kind of composite is Aquawrap?



50% Wall loss under Aquawrap - it was unaffected at 2,740 psi burst pressure test

Aquawrap is a low cost composite system for use in repair and reinforcement of existing mechanical systems, structures and piping. Furnished factory-impregnated with the proprietary polyurethane resin system, it is odorless and non-flammable. Aqua Wrap is ready to apply, right out of the bag and cures by way of a chemical reaction with field-applied water. When cured, it is a very durable, high strength material that is impervious to fuels and most chemicals, like Acetone, Diesel, Ethyl Alcohol, Gasoline, HCL, MEK, and Toluene. It permanently bonds to a wide variety of surfaces such as metals, composites, concrete, plastics, and wood. Aquawrap is a pressure containing composite repair system.



How should I prepare the surface before installing Aquawrap? For steel substrates, we recommend cleaning to at least a NACE II or SSPC-10 level. The better the cleaning and preparation, the better the wrap will bond/adhere to the pipe. For concrete surfaces, above and below the water line, all loose debris, coatings, marine growth, etc. must be removed. This can be done with high pressure water blasting or sand blasting. All surfaces need to be wiped clean prior to installation of any composite system.



Step 1:Sand blast or clean & abrade pipe surface per pipeline operator requirements to achieve bare metal. Do not wrap over old coating or rust because it might not be bonded well enough to the pipe so pressure can be transferred to Aquawrap. Make sure surface is a little rough to ensure a good anchor pattern.

Step 2: Fill voids by mixing white & black epoxies for 30 seconds or until grey, then fill voids completely so pressure can be transferred to Aquawrap. Will cure (tacky) in 3 minutes either above or below water.

Step 3: Primer area being wrapped and over grey filler in the voids too, by mixing yellow and blue epoxies for 60 seconds or until green, then pour and roll/brush onto pipe surface being wrapped. Allow 3 minutes to setup before wrapping Aquawrap over it. Don’t use this primer underwater.

Aquawrap’s Installation Process



Step 4: When applying Aquawrap to the pipe, constantly spray water on it. The number of layers will be determined by our calculator that is based on ASME PCC-2. Calculation are made by the manufacturer or the pipeline company, not by field installers. Above is circumferential wrap technique being used instead of spiral. Smooth each layer with your hands to ensure no wrinkles. Aquawrap comes in two thicknesses: 11 mills (G0-3) and 27 mills (G0-5). G0-3 does not require much smoothing but G0-5 needs to be feathered out, using your hands, from the middle to the outside as each layer is applied.

Step 5: Immediately after applying Aquawrap, wrap three layers of blue plastic wrap over it tightly, and perforate it so excess water will drain out. Aquawrap will soak up water needed to cure and displace the excess water. 45 minutes later remove blue plastic then back fill. If you reduced pressure because of defect then don’t pressure pipe back up for 24 hours because Aquawrap’s full cure takes that long. If above ground, then top-coat with UV resistant coating. Aquawrap has been cut open months later after curing, and no water or corrosion has been found underneath the wrap.

Aquawrap’s Installation Process





Does temperature have a significant effect on Aquawrap’s cure time?

Only in extreme temperatures such as, below 32 F (Unless using heating lamp in ditch) or above 288 F will effect Aquawrap’s curing time. It is important to note that epoxy resin wraps are very temperature sensitive, especially in warmer temperatures. Too much heat and epoxy systems will cure before being applied to the pipeline. Temperature has less of an effect on Aquawrap’spolyurethane resin system than the epoxy field mixed composite systems; however, they all have an upper and lower limit.



Aquawrap 45 minutes after install, now one solid layer with no crevices and ready to backfill. Metal bands placed around the ends so it will be pig detectable.



How long does it take Aquawrap to cure?

In most conditions, Aquawrap will cure in about one hour. This is cured to a point where the material is dry to the touch and then you can backfill. The wrap will "full properties" cure in 24 hours or less.



Immediately after wrapping the pipe, wrap three layers of blue plastic wrap and perforateit so excess water will drain out. Aquawrap will soak up water needed to cure for 45 minutes and displace the excess water.

Aquawrap 45 minutes after install, now one solid layer with no crevices.



Aquawrap Features: • Conforms to all shapes of pipe, clamps, sleeves, valves, welds• Versatile because it adheres well to both dry and wet surfaces• Easily installed underwater-fresh & salt, and in splash zone areas• Adheres well to metal, steel, concrete, wood, other composites• Contains pressures of any given liquid or gas pipeline system• Wrap in spiral direction- only 1” overlay, don’t have to butt ends• In-service repair, don’t have to lower line pressure, no hot work required • Cures as one solid layer, leaves no crevices• 50 year life, mechanically stronger than epoxy systems • Backfill in one hour after install• Wrap supplied in different widths and lengths



Aquawrap being spiral wrapped, 1” overlay,

takes little time to install. Don’t have to butt

ends of each layer. Backfill in one hour after

install.

Aquawrap is ready to apply right out of the

bag because cloth is already mixed with

polyurethane resin.

T-section of pipe no

trouble for Aquawrap



Aquawrap’s extensive engineering testing proves the following :

• Cures as one solid layer without crevices on the end sections of the repair. Thus, eliminates possible channeling of oxygen and moisture through crevices back to the anomaly. It won’t create a corrosion cell.

• It works well in salt or alkaline water and easily applied underwater and in splash zone areas.

• Non reactive to the general chemicals found around a pipeline:

Acetone, Diesel, Ethyl Alcohol, Gasoline, HCL, MEK, Toluene.

• Burst test proves its pressure containing capabilities for the MAOP of any given liquid or gas pipeline system.

• Cycle tested to prove it can handle millions of cycles.

• Creep rupture testing shows it has a life expectancy of 50 years.

• Aquawrap is a wet lay-up composite system impregnated with polyurethane resin compared to other wet lay-up systems impregnated with epoxy resin. Polyurethane resins have more long-term mechanical strength than epoxy resins, which become brittle over time.

Disadvantages: Don't install when outside temperatures are below freezing 32 F unless using a heating lamp in the ditch. Can't be applied over active leak until the leaking hole is plugged, which is fairly easy to do.



Column in Splash

Zone

Aquawrap applied

Aquawrap works well

in fresh & salt water

areas





Long section of pipeline in crowded area was easily repaired using Aquawrapbecause no cinch bar or hammer was needed. Also, repair was made in a few hours time using several 60 foot long rolls.

Aquawrap’s Advantages:

Unlike layered-composite systems, wet lay-up composite systems

like Aquawrap conform well to all shapes of pipelines

both onshore and offshore: Tees, elbows, bends, flanges, welds,

over sleeves & clamps. It is easily applied in the splash zone and

underwater.

Each layer of Aquawrap, also known as each ply, can be quickly

applied down the pipeline using only 1” or more overlay and still

cure as one solid layer, unlike the rigid layer or field impregnated

composite systems. Rigid composites cure with crevices that have

in some cases allowed oxygen and moisture to enter/channel

between layered composite systems layers allowing further

corrosion of the anomaly to continue underneath the wrap.

Aquawrap is supplied in many different widths and lengths, unlike

layered composite systems and the other wet lay-up systems that

are only supplied in one or two sizes, which eliminates waste of

purchased materials and allows for faster repairs.

Aquawrap has been used since 1991, has great long-term

strength, easiest and fastest to install than other composites and

cost less. It received a very positive evaluation by Dr. John Kiefner

in 2006 and underwent ASME’s PCC-2 testing criteria and

compliant per CFR 192 & 195.



2" Wide x 5-feet • 2" Wide x 12-feet 3" Wide x 10-feet • 3" Wide x 30-feet 4" Wide x 15-feet • 4" Wide x 30-feet • 4" Wide x 50-feet 6" Wide x 15-feet • 6" Wide x 30-feet • 6" Wide x 60-feet • 6" Wide x 90-feet 10" Wide x 30-feet • 10" Wide x 60-feet • 10" Wide x 90-feet 10" Wide x 120-feet 10" Wide x 150-feet12" Wide x 30-feet • 12" Wide x 60-feet • 12" Wide x 90-feet 12" Wide x 120-feet 12" Wide x 150-feet

Aquawrap

Temperature 33 F to 288 F

Working Time 30 minutes nominal, after water application

Cure Time 60 minutes nominal, after water application

Adhesion 1,000 psi (lap shear) to abraded carbon steel, using primer

Tensile Strength 54,000 psi for G-03 Fabric/694 lbs/per ply/per inch of width

123,000 psi C-14 Fabric/3,320 lbs/per ply/per inch of width

Compressive Strength 28,500 psi

Interlaminar Shear 2,900 psi

Chemical Resistant to acetone, MEK, toluene, gasoline, ethyl alcohol and

many others.

Aquawrap Sizes and Specifications:





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