Composite Wrap for Non-leaking Pipeline Defects Lessons Learned from Natural Gas STAR Transmission...

Composite Wrap for Non-leaking Composite Wrap for Non-leaking Pipeline DefectsPipeline Defects

Lessons Learned Lessons Learned

from Natural Gas STARfrom Natural Gas STAR

Transmission Technology Transfer WorkshopTransmission Technology Transfer Workshop

Duke Energy Gas Transmission,Duke Energy Gas Transmission,

Interstate Natural Gas Association of America (INGAA) and Interstate Natural Gas Association of America (INGAA) and

EPA’s Natural Gas STAR ProgramEPA’s Natural Gas STAR Program

September 22, 2004September 22, 2004

Reducing Emissions, Increasing Efficiency, Maximizing Profits

Composite WrapComposite Wrap

Permanent On-Line Permanent On-Line Pipeline Repair Pipeline Repair

TechnologyTechnology

Source: Armor Plate


Use of 30 wrap repairs Use of 30 wrap repairs versus line replacements versus line replacements could save 70,000 could save 70,000 thousand cubic feet per thousand cubic feet per year (Mcf/yr) netting year (Mcf/yr) netting almost $130,000 in almost $130,000 in savingssavings

Repairs with pipeline in Repairs with pipeline in service average 2 days service average 2 days versus 5 to 7 days for versus 5 to 7 days for typical cut & weld pipe typical cut & weld pipe replacementsreplacements


A QUICK & SAFE WAY to improve profitability &

AVOID VENTING METHANE!


Before January 13Before January 13thth, , 20002000 repair methods repair methods were restricted to were restricted to replacement, or use of replacement, or use of full encirclement steel full encirclement steel sleeves welded in sleeves welded in placeplace

And nowAnd now the steel the steel sleeve requirement is sleeve requirement is amended to allow amended to allow composite wrap composite wrap sleevessleeves



1.1. A high-strength glass A high-strength glass fiber composite or fiber composite or laminatelaminate

2.2. An adhesive or resin An adhesive or resin bonding systembonding system

3.3. A high-compressive-A high-compressive-strength load transfer strength load transfer filler compoundfiller compound

Composite WrapComposite WrapWhat Are They?What Are They?

Source: Clock Spring® Company L. P.


Composite WrapComposite WrapSoftwareSoftware

Software will determine:Software will determine: If a repair is neededIf a repair is needed If a composite wrap is suitableIf a composite wrap is suitable Or if a pipe replacement is requiredOr if a pipe replacement is required

Defects up to 80% loss wall thickness can Defects up to 80% loss wall thickness can be repaired with composite wrap be repaired with composite wrap

There may be pressure and temperature There may be pressure and temperature restrictions on composite wraprestrictions on composite wrap


Composite WrapComposite WrapInstallationInstallation

After excavation and pipe After excavation and pipe preparationpreparation

External defects filled with fillerExternal defects filled with filler Composite wrap wound around Composite wrap wound around

pipe with adhesive or pipe with adhesive or laminating agentslaminating agents

Typically 2” of wrap must Typically 2” of wrap must extend beyond damageextend beyond damage

Excavation site refilled after Excavation site refilled after mandated curing timemandated curing time

Reducing pressure improves Reducing pressure improves quality of repairquality of repair

Source: Armor Plate


Composite WrapComposite WrapDecision ProcessDecision Process

1.1. Determine suitability of composite wrap Determine suitability of composite wrap technique for repair optiontechnique for repair option

2.2. Calculate cost for composite wrap and Calculate cost for composite wrap and consider other benefits of on-line repairconsider other benefits of on-line repair

3.3. Estimate methane savingsEstimate methane savings

4.4. Calculate avoided costs of line replacementCalculate avoided costs of line replacement

5.5. Evaluate economicsEvaluate economics


Composite WrapComposite WrapStep1: Determine Suitable ApplicationStep1: Determine Suitable Application

Evaluate nature of defect and causal factorsEvaluate nature of defect and causal factors

Evaluate operational needs and job site Evaluate operational needs and job site factorsfactors

Follow industry standards, such as ASME, Follow industry standards, such as ASME, and your company engineering policies and and your company engineering policies and proceduresprocedures


Composite WrapComposite WrapStep 2: Cost of Wrap RepairStep 2: Cost of Wrap Repair

GIVEN: 6” non-leaking defect in 24” line @ 350 pounds per GIVEN: 6” non-leaking defect in 24” line @ 350 pounds per square inch (psi)square inch (psi)

Estimate: 16 hours to repairEstimate: 16 hours to repair

Cost of labor: Field Labor: 3 men @$30/hr = $1,440Cost of labor: Field Labor: 3 men @$30/hr = $1,440 Eng Mgmt: 25% of $1,440 = $ 360Eng Mgmt: 25% of $1,440 = $ 360

Cost of Equipment: Wrap KitCost of Equipment: Wrap Kit = $ 900 = $ 900Backhoe & SandblasterBackhoe & Sandblaster = $ 750 = $ 750

Other: Permits/Inspection/MiscOther: Permits/Inspection/Misc = $1,650 = $1,650


Composite WrapComposite WrapStep 3: Estimate Methane SavingsStep 3: Estimate Methane Savings

Methane Savings = Emissions avoided from line replacementMethane Savings = Emissions avoided from line replacement

Volume of methane(Mcf) = (DVolume of methane(Mcf) = (D22*P*(L/1,000)*0.372)/1,000*P*(L/1,000)*0.372)/1,000 = 24*24*350(52,800/1,000)*0.372/1,000= 24*24*350(52,800/1,000)*0.372/1,000

= 3,960 Mcf @ $3/Mcf= 3,960 Mcf @ $3/Mcf

= $11,900= $11,900

Note: for 10 miles between block valvesNote: for 10 miles between block valves


Composite WrapComposite WrapStep 4: Calculate Purge Gas SavingsStep 4: Calculate Purge Gas Savings

Purge Gas saved = Purge Gas used during line replacementPurge Gas saved = Purge Gas used during line replacement

Volume of Purge Gas = [3.14*DVolume of Purge Gas = [3.14*D22*L/(4*144*1,000)]*1.2*L/(4*144*1,000)]*1.2 = [3.14*24*24*52,800/(4*144*1,000)]*1.2= [3.14*24*24*52,800/(4*144*1,000)]*1.2

= 200 Mcf @ $4/Mcf of nitrogen= 200 Mcf @ $4/Mcf of nitrogen

= $800= $800

Note: for 10 miles between block valves, assuming 20% wastageNote: for 10 miles between block valves, assuming 20% wastage


Composite WrapComposite WrapStep 4(cont’d): Replacement Line CostStep 4(cont’d): Replacement Line Cost

GIVEN: 6” non-leaking defect in 24” line @ 350 psiGIVEN: 6” non-leaking defect in 24” line @ 350 psi

Assume: replace 6’ of line (3 times pipe diameter)Assume: replace 6’ of line (3 times pipe diameter)

Estimate: 40 hours to repairEstimate: 40 hours to repair

Cost of labor: Field labor: 4 men @$30/hr = $4,800Cost of labor: Field labor: 4 men @$30/hr = $4,800 Eng Mgmt: 25% of $4,800 = $1,200Eng Mgmt: 25% of $4,800 = $1,200

Cost of Equipment: 6’ pipe @ $50/ftCost of Equipment: 6’ pipe @ $50/ft = $ 300 = $ 300 Backhoe, Welder & Crane = $3,700Backhoe, Welder & Crane = $3,700

Other: Permits/Inspection/MiscOther: Permits/Inspection/Misc = $4,500 = $4,500


Composite WrapComposite WrapStep 5: Evaluate the EconomicsStep 5: Evaluate the Economics

24” Line @ 350 psi

6” Defect10 miles between shut off valves

Composite Wrap - $

Line Replacement - $

Methane Savings 11,900 none

Purge Gas 0 800

Labor 1,800 6,000

Equipment & Materials 1,650 4,000

Other 1,650 4,500

Total Cost of Repairs 5,100 15,300

Pay Back IMMEDIATE!! None

INTANGIBLES:INTANGIBLES:

•SafetySafety

•Environmental Environmental impactsimpacts

•Site accessSite access

•Service interruptionService interruption


Composite WrapComposite WrapPartner ExperiencePartner Experience

300+ wraps on 10” or greater lines since 1995300+ wraps on 10” or greater lines since 1995 Up to 15 wraps have been butted side-by-side Up to 15 wraps have been butted side-by-side

in the U.S.in the U.S. 20’’ defect in line near creek bed: limited 20’’ defect in line near creek bed: limited

environmental exposure, wrapped in 2 hours; environmental exposure, wrapped in 2 hours; total repair 2 days start to finishtotal repair 2 days start to finish


Composite Wrap Composite Wrap Lessons LearnedLessons Learned

Proven permanent Proven permanent repair for external repair for external defectsdefects

Temporary repair for Temporary repair for internal faultsinternal faults

In-service pipeline In-service pipeline repair methodologyrepair methodology

Ideal for urgent and Ideal for urgent and quick repairquick repair

Avoid service Avoid service disruptionsdisruptions

Cost-effectiveCost-effective

Trained but not skilled Trained but not skilled crafts persons requiredcrafts persons required

Specialized welding Specialized welding and lifting equipment and lifting equipment not requirednot required

Minimizes access Minimizes access concernsconcerns

No delays awaiting No delays awaiting metal sleevemetal sleeve

Cathodic protection Cathodic protection remains functionalremains functional


Composite WrapComposite WrapContactsContacts

epa.gov/gasstarepa.gov/gasstar EPA Natural Gas STAR managersEPA Natural Gas STAR managers Vendors of composite wrap kitsVendors of composite wrap kits

Armor Plate, Inc.Armor Plate, Inc. http://www.armorplateonline.comhttp://www.armorplateonline.com

The Clock SpringThe Clock Spring® Company L.P.® Company L.P. http://www.clockspring.comhttp://www.clockspring.com

The StrongBack CorporationThe StrongBack Corporation http://www.strongbackcorp.comhttp://www.strongbackcorp.com

WrapMaster, Inc.WrapMaster, Inc. http://www.wrapm.comhttp://www.wrapm.com


Composite WrapComposite WrapDiscussion QuestionsDiscussion Questions

Has anyone used composite wrap repairs?Has anyone used composite wrap repairs?

What are the barriers(technological, lack of What are the barriers(technological, lack of information, regulatory, and etc.) that are information, regulatory, and etc.) that are preventing you from implementing this preventing you from implementing this technology?technology?

Would anyone like to elaborate on the Would anyone like to elaborate on the information provided in this presentation?information provided in this presentation?

Composite Wrap for Non-leaking Pipeline Defects Lessons Learned from Natural Gas STAR Transmission...

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