Professional Documents
Culture Documents
Project Overview
External corrosion on a 16 OD, API-5LX-42
cross country pipeline having 57% wall loss
within 4 foot wide region. Original pipe wall
was 0.281" and an MAOP of 1,062 psi
The Solution
Design a 20 year repair utilizing the A+ Wrap
System to restore the structural integrity of
the line back to pristine conditions.
Repair Method
Remove tape coating and sand blast to a NACE
#3 finish. The first step of repair is to fill the
anomaly with a load transfer epoxy putty.
Apply a corrosion barrier epoxy to the entire
repair zone prior to wrapping with A+ Wrap
using the cigar wrap method. Apply the
material until the calculated layers have been
achieved. Constrict and perforate, then allow
to cure for 2 hours. Top coat as applicable,
then back-fill.
THE PROBLEM:
The pipeline (at 750 psi) needed to be exposed
for the repair. The anomaly was 4.36 and wall
loss was approximately 45%.
THE SOLUTION:
A coffer dam was built and the water was
pumped out before digging down to
expose dented pipe. A+ Wrap System
was applied, then top coated and pipe was
reburied.
Project Overview
A Field Bend had external corrosion at the 6 - 9
O'Clock positions on a 16 OD, API-5LX-42 cross
country pipeline. The repair area encompassed a
9 Ft section having 62% wall loss. Original pipe
wall was 0.281" and an MAOP of 1,062 psi
The Solution
Design a 20 year repair utilizing the A+ Wrap
System to restore the structural integrity of the
line back to pristine conditions. The repair
required 18 layers (0.396" composite thickness).
Repair Method
Prep the pipe by removing any soft coating and
sand blast to a minimum of NACE #3 finish. Fill
the anomalies with a load transfer epoxy putty.
Apply a corrosion barrier epoxy to the entire
repair zone prior to wrapping with A+ Wrap
using the spiral wrap method. Apply the material
until the calculated layers have been achieved.
Constrict and perforate, then allow to cure for 2
hours. Top coat as applicable, then back-fill.
THE PROBLEM:
Dented caisson prevented proper operation and access
to pumping unit located within.
THE SOLUTION:
1. Abrade the caisson leg with sand
blasting.
2. Secure 24" dia x 180 deg x 36" long
FRP Sleeve with 12 bands.
(Note: The FRP Sleeve to be gasketed with
nitrile).
3. Apply EP-193 to create transitions around the FRP
Sleeve
4. Apply SplashBond all around the caisson .
5. Apply 6 layers of A+ W rap
(To extend 1 ft beyond both edges of the
sleeve).
6. Apply 6 layers of Pipe W rap (also has the 1 ft
extension).
7. Apply SplashBond over entire repair area.
Project Overview
During the excavation of an area within the Gas
Processing Plant, a backhoe struck two (2) 8"
process lines located adjacently within 4 feet of
each other. The 3rd Party mechanical damage
occurred during preparation for installation of
an additional process line that was to run
perpendicular to the damaged lines.
Dig
Di site - Gas Plant
The Solution
The A+ Wrap System was the selected material
of choice due to its ease of application and
structural strength. Based on the parameters
provided by the customer, a 12 layer (0.265"
material thickness) design was indicated to
ensure the continued integrity of the lines.
Ready to be back-fill
Project Overview
A large rehabilitation project by an Interstate Gas
Transmission company encompassed twenty-six
(26) miles of 14 Diameter pipe. The line had
been assessed by a High Resolution MFL
(Magnetic Flux Leakage) In-Line Inspection Tool.
The survey results indicated multiple regions with
sections having general corrosion anomalies
ranging from 35-65%.
The Solution
Based on the analysis conducted by PWLLC, the
repairs ranged from 14 layers (0.308" of material
thickness) for 35% wall loss to 26 layers (0.572" of
material thickness) for the 65% wall loss
conditions. The design is to provide a minimum of
a 20 year service in accordance with ASME PCC2 Standards.
To simplify things for the installation crews,
PWLLC provided the A+ Wrap System in kits for
the respective repair zones. This additional effort
enabled the installation crews to focus just on the
material application by removing the necessity for
individual layer counting.
Repair Method
Prep the pipe by removing any soft coating and
sand blast to a minimum of NACE #3 finish. Fill
the anomalies with a load transfer epoxy putty.
Apply a corrosion barrier epoxy to the entire repair
zone prior to wrapping with A+ Wrap using the
spiral wrap method. Apply the material until the
calculated layers have been achieved. Constrict
and perforate, then allow to cure for 2 hours. Top
coat as applicable, then back-fill.
"Marking" the repair zone
Primer Application
Complete application
Ready to rebury
Project Overview
A 24" O.D. AISI-106-B carbon steel Flare line
having both external and internal wall loss for a
total two hundred and twenty seven (227 ft) foot
section required structural reinforcement. The
line had a combined wall loss of 54% with an
original wall thickness of 0.375". The medium in
the line was dilute HF and propane having an
operating pressure of 285 psi.
The Solution
Based on the analysis conducted by PWLLC, the
repair required 12 layers (0.264" of material
thickness) of A+ Wrap to store the structural
integrity back to its pristine conditions. The
solution was deemed as a temporary repair as per
the ASME Standards. The design provided a 5
year service life.
Repair Method
Prep the pipe by hand tools to remove any soft
coating and etch the surface with 24 grit sanding
pads. Fill the anomalies with a load transfer
epoxy putty. Apply a corrosion barrier epoxy to
the entire repair zone prior to wrapping with A+
Wrap using the spiral wrap method. Apply the
material until the calculated layers have been
achieved. Constrict and perforate, then allow to
cure for 2 hours. Top coat edges of the repair to
add additional protection from potential moisture
ingress.
Project Overview
An underground 54" O.D. Grade B main water
feed line located in a concrete access tunnel had
extensive external corrosion due to constant
moisture droplets from the ceiling of the tunnel.
The line is direct fed from a Reservoir Dam and is
supported by 10 inch high concrete saddles
located approximately every 30 feet.
The 0.500" original wall had degraded by 50%.
The line operates at 55 psi in ambient
temperature. The designed repair required 26
layers (0.572" material thickness) of A+ Wrap
to restore structural integrity to a 392 foot long
section..
The Solution
Due to the restricted access of the lower half of
the pipe caused from the concrete saddles, it
required specifying the roll size of the A+ Wrap
to be 12" x 60 ft material. This particular size had
a diametric measurement sufficient for work
space. The A+ Wrap was selected because of
it performance capabilities on wet surfaces.
Repair Method
Prep the pipe by hand tools and sandblasting to
remove any soft coating and etch the surface with
24 grit sanding pads. Fill the anomalies with a
load transfer epoxy putty.
Applying primer
Applying A+ Wrap
Continue wrapping
Completed repair
Project Overview
An 8" O.D. riser at a meter station within a gas
plant had localized external corrosion at the "soil
to air interface" which is a common occurrence
due to the "wet-dry" conditions that the area is
exposed to during seasonal changes.
The external wall loss was minimal (less than
20% of original wall) and only required re-coating.
The SplashGard pipe protection system was
selected because this system was originally
designed for "wet-dry" conditions within the
splash zone area of off-shore platform risers.
The Solution
Due to the minimal wall loss, no structural
reinforcement was required thus SplashWrap I
was selected as the over-wrap material. The
repair consisted of 2 ft above and below transition
zone. The intended service life was a minimum of
5 years.
Repair Method
Applying SplashBond
Over-wrapped
Completed repair
Project Overview
Various piping sections developed Corrosion
Under Insulation (CUI) due to trapped moisture
within the insulating material around the pipe.
Although the corrosion appeared to be
aggressive, once the insulation was removed and
the piping surface was prepped, there was
minimal wall loss (less than 34%). Based on the
low operating pressure of the piping system (60
psi), the customer determined that only providing
a protective coating was required.
The
GenWrap System was selected because this
system prevents oxygen from reaching the pipe
surface. Without oxygen, a corrosion cell cannot
occur. This system is typically used on the top
side of off-shore platforms.
The Solution
All the insulation to be removed from the affected
area and the surfaces to be prepped by removing
all loose scale. The GenWrap System to be
applied and extended beyond the defect area.
Repair Method
Project Overview
A common problem that occurs with supported
piping sections is the development of crevice
corrosion at the interface of the pipe and the
support. This problem manifests itself from the
relative movement of the pipe in relation to the
support thus abrading the existing coating. This
action may be cause by the physical movement
of the pipe due to "fluid hammering" or the
expansion/contraction
from
temperature
variations.
In this repair, the movement was caused by "fluid
hammer" which breached the coating under the
support and creating a pocket that collected
moisture which helped cause the corrosion cell.
For this application, the patented Pipe Sock
(Patent #US 8,087,431 B2) should solve the
problem.
The Solution
The installation of the patented Pipe Sock will
eliminate the moisture capture zone by bonding to
the pipe and creating a "watershed" along with a
wear surface that is not the pipe. Designed
service life is 10 years.
Repair Method
Prep the pipe by hand tools to remove all rust,
scale and etch the surface with 24 grit sanding
pads. Attach the patented Pipe Sock to the
pipe with Black Magic polymer.
Project Overview
An Interstate Gas Transmission company
completed an ILI run using a High Resolution
MFL (Magnetic Flux Leakage) In-Line Inspection
Tool.
The survey results indicated multiple
regions with sections having general corrosion
anomalies ranging from 25-65%.
In working closely with PWLLC, PWLLC analyzed
the respective repair zones to determine the
amount of A+ Wrap required to restore the full
structural integrity of the line. This particular
repair was made on a 12" O.D. x 15 ft repair
section having the pipe grade as API-5LX-42,
with an original wall of 0.375". The system
design pressure was 2,470 psi with an MAOP of
1,778 psi for a Class 1 location designation.
The Solution
Designing the repair in accordance with ASME
PCC-2 & ISO 24817 resulted in 10 layer (0.22"
material thickness) design to restore the pipe back
to pristine condition. The design was based on a
20 year service life.
Sandblasting the repair zone
As part of the design approach, the repair zone
size was included and noted on the kits provided
to the installation crew. This results in assisting
the crew to focus specifically on applying the
materials and does not require them to count the
layers because by applying the materials provided
within the designated repair zone, the layer count
will come out correctly..
Repair Method
Prep the pipe by removing any soft coating and
sand blast to a minimum of NACE #3 finish. Fill
the anomalies with a load transfer epoxy putty.
Apply a corrosion barrier epoxy to the entire repair
zone prior to wrapping with A+ Wrap using the
spiral wrap method. Apply the material until the
calculated layers have been achieved. Constrict
and perforate, then allow to cure for 2 hours. Top
coat as applicable, then back-fill.
Measuring the anomaly
Applying constrictor
Completed repair
Completed repair
Project Details:
T he sites needing reinforcement were Pum ping
Stations 1 & 2 located in Hong Kong.
Pipe Diameters ranged f rom 24 thru 54 with a total
coverage area of 190.4 square meters.
Structural Reinforc em ent f or 50 year design lif e operating at
10 bar (145 psi) was required.
The areas that needed reinforcing are highlighted in yellow
on the supplied drawings on the next pages.
16
Draw ing #1
17
18
Project Details:
Solution Overview:
4 layers of A+W rap was used and covered 225 meters (738 f eet)
of 1.2 m (47.54 inch) diameter pipe.
After A+ W rap had cured (24 hours), a topically
applied intumescent Fire Resistant
coating was used to protect the pipe from future
brush fires.
Note: View shows an individual walking a section of the line. T he dark exterior m aterial on the coating
is debris and leaves fallen f rom trees.
19
THE PROBLEM:
Repair to go 6 above barnacle line.
THE SOLUTION:
Materials needed f or wrapping the pipe with 6
layers using A+ W rap as follows:
1 each - Overwrap (4 x 50 roll)
THE PROBLEM:
Very low efficiency of the dust collection
system due to holes and joint leakages.
Hole sizes ranged from 1 4 diameter.
Overall result: High operating costs with
minimal benefit.
THE SOLUTION:
26 FRP customized leak stop sleeves
were used over each wall defect,
overwrapped with A+ Wraps and topically
coated with epoxy to provide a requested
extended life of 10 years and UV
protection.
Repair involved 171 feet of horizontal
piping including 22 elbows varying in
diameters of between 12 and 18.
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Project Overview
12 Diameter main water line serving a
University.
The Problem
Completed Repair
The Solution
Repair method comprised of sealing the leak with
expanding
polyurethane foam
and
applying
FormaShield ET (Epoxy Fiberglass) System
Repair Method
The wooden dowel was cut off
to about (5mm)
above the pipe surface. Water leaked through the split
that ran up the center of the dowel, and this was
sealed by drilling out a hole using a (5mm) bit and
then sealing this with an expanding polyurethane.
The leaking area was cleaned using grit blasting with a
low pressure system. The pin holes were sealed using
a fast-curing epoxy putty. First, small balls (5mm)
diameter of putty were rolled and pushed in the holes
and held in place until they cured. Then larger balls
(10mm) diameter were flattened over these to support
them before the whole area was covered. To do this.
The putty was mixed and held in a ball until it started to
warm from the cure. It was then spread quickly over
the area where it rapidly turned solid. Finally the area
was faired smooth using a spreadable epoxy putty.
Solution Overview :
Repair method was comprised of sealing the pin hole leaks under
the clamp and encapsulating the entire clamp using Pipe W rap. Once
this was accomplished 3 feet of 4 inch line was wrapped to prevent
any further corrosion.
Repair Method:
Repair required a technician to work from a man lift to at a
height of 45 feet. The entire area was prepped as close to
near white metal as possible and then cleaned with acetone. Once
this was accomplished the leaks were repaired using Pipe W rap
EP400 epoxy putty applied directly to the pin holes.
The two-part Epoxy Putty was kneaded until heat
began generating from the putty. This indicated that the
putty was near setting up. At this point the putty was
pressed into the pin holes and held for approximately 5 minutes
until cured. Once all leaks were confirmed stopped, the entire
area was primed using Pipe W rap PPR epoxy primer and all
voids were filled to make sure of a smooth transition.
Project Overview
A 26" O.D. fresh water feed line for a Fish
Hatchery managed by the US Department of Fish
& Game developed multiple leaks within a section
of line running through a river. The line at the
river crossing was ductile iron and operating at 50
psi.
The operation of the line could not be interrupted
due to the impact on the hatchery. The initial
challenge was to divert the river to allow access
to the pipe for remediation. Once the river was
diverted, there were five (5) noticeable leaks from
holes that ranged in size from 1" to 3" in width.
The Solution
The product of choice for this type of active leak
defect is the RidgeBack because a compression
type seal is required that uniformly distributes the
compressive forces thus minimizing the possibility
of collapsing the pipe.
Repair Method
Position and secure the RidgeBack to each
active leak area per the provided procedures.
Tighten as required until the area is "drip free" for
a minimum of 30 minutes.
Use hand tools to prep the pipe by removing all
soft coating. Apply a corrosion barrier epoxy to
the entire repair zone prior to wrapping with Pipe
Wrap using the spiral wrap method. Apply the
material until the calculated layers have been
achieved. Allow to cure for 2 hours. Top coat as
applicable, then back-fill.
Installing RidgeBack
Close-up of installed
RidgeBack
Solution Overview:
Multi-sequence repair requiring depressurization of
the line utilizing A+ W rap in conjunction with epoxy
putty and rubber .
Repair Procedure:
Grinded all surfaces to clean steel. Installed thick
piece of rubber stopgap over defects.
The rubber pieces were secured with galvanized
banding strap. Traditional method of repair (filling
pipe with putty stick) was not used due to extremely
thin bottom.
Covered the sharp sections of banding material and
all transitions between welded plate to pipe, flange to
pipe and rubber piece to pipe with fast set epoxy
putty stick.
Installed epoxy adhesive over entire repair.
Due to location of repair area (tight against flange
with bolts every 2) a change was made from the
suggested spiral wrap over the patch and tight
against the flange. Two rolls were used making the
repair six layers thick. A spiral wrap was done
overlapping 2 of the hoop wrap with 3 rolls of
material over the rest of the repair.
Constrictor Wrap was applied over the material.
Line was recharged 2 hours after completion. The
temperature was of an estimated 78F.
THE PROBLEM:
Repair location was inside the leg of an oil and gas
production platform located in the Cook Inlet,
Alaska. The pipeline was DOT regulated and carried
produced fluids.
The platform leg had an inside diameter of 7 feet
and protected not just one 12 inch riser, but two
additional 12 inch risers, plus several other pipes
ranging in size from 1 inch to 6 inches.
Up out of
the hatch
after
preliminary
pipe
preparation.
THE SOLUTION:
The line was shut down and depressurized.
Divers descended inside the 7 foot diameter
platform leg and by blind feel sketched the
location of the various risers inside platform leg.
(See page 4).
Next, removal of sediment and water was
required before the area of metal loss could be
identified, cleaned and examined.
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ILI Report
ILI Report
Repair Schematic
Anom aly
area
sandblasted
to near
white m etal.
Coated elbow over wrapped with A+ W rap
The Problem
Cr evice
c or r os ion
r esult ed
f r om
c o n d e n s a t i o n s o a k in g t h e wo o d e n
s u p p or t , o ve r t i m e t h e con dens at io n
caused a 27 long def ect t o f or m . T he
c o r r o s i o n d eg r aded 45% of t he pip e
wa l l r e d u c i n g t h e m a xi m u m a l l o wab le
p r e s s u r e f r om 68 5 p s i t o 3 5 0 p s i.
Solution Overview
Based on the extent of the defect, the
repair was designed in accordance to
ASME PCC-2 standards which resulted in
18 layers of A+ W rap having an overall
repair thickness of 0.396. The repair was
complete from start to finish in 2 hours.
Primer-East Side
Finished
Repair-East
and West
Side
OVERVIEW:
Repair of a 24 O.D x 0.375 wall, water line
inside a refinery had 31 feet of external
corrosion and 3 areas with pin hole leaks. The
external corrosion on the pipe had a defect
depth of 60 percent wall loss.
THE PROBLEM:
Sandblast Pipe
Apply primer
Project Overview
Severe corrosion was determined at the lower portion of a
96 CW Return Line. Randomly selected UT measurements in the degraded area were performed to obtain a
baseline wall thickness of the 96 piping. From these
measurements, localized spots in corroded region are
below minimum wall thickness. Applying Pipe W raps
The Solution
Pipe - 96 Diameter located 1 story below ground level.
Repair was done using is A+ Wrap coated with PPR-2
Epoxy System Repair completed with RC-350 Rubber
Coating for an additional water barrier.
Repair Method
Pipe with beads of Black Magic followed by PPR-2
Project Overview
Our Client manufactures a special sequencing batch
reactor (SBR) system, demonstrating lower operating
costs and lower sludge production than conventional
SBRs, is providing greater than 99% removal of
organics for a 2.4 mgd wastewater treatment plant. Due
to trouble with internal nozzles the needed to cut two 8
inch holes in the 16 inch line to make repairs and then
seal the line. The close proximity of a smaller line
added to the difficulty of making the repair
The Solution
After reviewing the problem Pipe Wraps Formashield
was chosen for the repair due to its ability to be sized
to fit between the two lines and provide a repair that
would return the line to its original structural strength.
Repair Method
Step 1:
The first step in the repair after the internal repairs were
completed was to identify and prepare the repair zone
by abrading the entire area that was to have material
applied.
Step 2:
The second step of the repair was to apply epoxy
adhesive and place a fiberglass patch over the 8 hole,
fasten in place and allow to cure.
Step 3:
The third step of the repair was to apply epoxy putty
around the patch then coat the repair zone with Epoxy
paste and allow to set for a minimum of 15 minutes.
Step 4:
The final step in the repair was to wetout and apply
Formashield using 50%Overlap to provide 12 layers
over the center of the repair. Material was constricted,
lightly perforated and allowed to cure. The line was
returned to service 24 hours after start of repair.
Project Overview
Repair involves structural damage to a 6 GFE
Pipe that carries jet fuel from storage tanks to the
refueling area. Maintenance equipment had cut a
6 long hole in the elbow at ground level. Pressure
rating of the line is 150 PSI so the repair design
would be critical to assure at least original
pressure capability.
The Solution
Because standard pipe repair calculations would
not be accurate for this type of repair the design
was based on known parameters for this type of
pipe. Because of superior strength, ease of
application to this configuration, good service life
and excellent bonding characteristics
Formashield was chosen for the repair.
Repair Method
Step 1: The first step in the repair was to identify
the repair zone, in this case approximately a 15
long area and prep it using sandpaper to provide a
satisfactory anchor pattern.
AELD REPORT ACCOMPANYING THE AREA DURING THE ENTIRE BOARD REPAIR GW D-440
KM 5 +322 COVEN LINE OFFSHORE TERMINAL
REVISION CONTROL
Revision No. Date
0
Description
(DD I MM I YYY'I')
Documentation of the process.
271Jun I 2008
Developed:
Jotge Tormdo I Junior Engineer Integrity.
Reviewed I Approved:
carlos Vergara I Engineer lntegrity.
I. OBJECTIVE
Supply constraints In the field during the repair activities of system board siding GW0-440, located
Km 5 +322 OCENSA Offshore Line.In order to ensure and document this process.
2.
at
SCOPE
Field activities consisted of the permanent support to the process of implementation of ECO
Engineering Standard-IG-368-004-RP-056-E, for the completion of the repair ooating system
against extemal corrosion of the Board GW0-440 ,located at Km 5 +322 OCENSA Offshore Line.
3.
METHODOLOGY
The field visit took place between Monday June 16th and Monday June 23,2008 atTermlnal Covenas.
AELD REPORT ACCOMPANYING THE AREA DURING THE ENTIRE BOARD REPAIR GWD-440
KM 5 +322 COVEN LINE OFFSHORE TERMINAL
REVISION CONTROL
Revision No. Date
0
Description
(DD I MM I YYY'I')
Documentation of the process.
271Jun I 2008
Developed:
Jotge Tormdo I Junior Engineer Integrity.
Reviewed I Approved:
carlos Vergara I Engineer lntegrity.
I. OBJECTIVE
Supply constraints In the field during the repair activities of system board siding GW0-440, located
Km 5 +322 OCENSA Offshore Line.In order to ensure and document this process.
2.
at
SCOPE
Field activities consisted of the permanent support to the process of implementation of ECO
Engineering Standard-IG-368-004-RP-056-E, for the completion of the repair ooating system
against extemal corrosion of the Board GW0-440 ,located at Km 5 +322 OCENSA Offshore Line.
3.
METHODOLOGY
The field visit took place between Monday June 16th and Monday June 23,2008 atTermlnal Covenas.
Water Line
THE SOLUTION:
Since the coating was fusion
bond epoxy, minimal surface
preparation (abraded with sand
paper) was all that was required.
Next, PPR (epoxy primer) and 19
layers of A+ W rap were applied.
OVERVIEW:
FIGURE 1 Sketch of
Inspected Repair Zone
OVERVIEW:
Isometric Drawing Reference