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Engineered Composite Solution

Proposal Packet

Date:08-February-2017

End User:

Distributor/Installer:

Product: DiamondWrap®

Repair Summary:

DiamondWrap®solutionisrecommendedforapplicationtothecustomer’sdamagedtanks.

Standard Used:

ASMEPCC-2Section4.1

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TableofContents

AnIntroductiontoCitadelTechnologiesEngineeredCompositeSolutions....................3SettingtheStandard.............................................................................................................................3CustomDesignedSolutions..............................................................................................................3

EngineeredCompositeSolutions........................................................................................................3ProductAdvantages:............................................................................................................................4

SurfacePreparationProcedures.........................................................................................................5InstallationInstructions..........................................................................................................................5Safety:.........................................................................................................................................................7ClothingandEquipment:...................................................................................................................7ColdWeather/ColdSubstrateProcedures................................................................................7MoistureProcedures...........................................................................................................................8

Cure..................................................................................................................................................................8CitadelTechnologiesClients.................................................................................................................9CaseStudy....................................................................................................................................................11

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AnIntroductiontoCitadelTechnologiesEngineeredCompositeSolutions Citadel Technologies’ composite products are among the most highly tested composite wraps on the market today. It is the goal of our company to maintain the highest integrity and engineering know-how of composites in the tank and pipe repair industry. With a long history of testing already behind them, Citadel products are continually tested in new ways and new products are developed to maintain the cutting edge in composite technology and knowledge.

SettingtheStandardThe ASME PCC-2 Article 4.1 is the ASME standard for governing the use of nonmetallic systems to repair tanks, vessels, piping, etc. Citadel Technologies has been apart of the ASME PCC-2 Article 4.1 committee since it was originally founded, and actively participates in advancing the breadth and depth of ASME’s composite repair standard for tanks and pipelines. Citadel not only contributes to the development of the ASME PCC-2 Article 4.1, but maintains compliance with the mandatory testing as well. As PCC-2 becomes increasingly utilized for the composite repair of corroded, eroded, and damaged systems, Citadel will continue to lead the composite repair industry.

CustomDesignedSolutionsCitadel Technologies employs PE’s, Master’s, and Bachelor’s engineers that are available around the clock to design each tank and pipe repair with the highest regard for safety and accuracy. The process begins with the collection of information on a one page engineering assessment form. Once this information is submitted to Citadel’s engineering team, they will use the ASME PCC-2 Article 4.1 and associated repair standards to design the exact composite repair required for the anomaly in question, providing the customer with assurance that they have a safe long-term repair installed on their corroded assets, every time.

EngineeredCompositeSolutionsCitadel Technologies has created the leading engineered composite solution (ECS) system used to rehabilitate and restore original operational strength to corroded and eroded tanks and vessels. The DiamondWrap® system is comprised of three components, each thoroughly and independently tested at both the university and national laboratory levels. The first component is a solid epoxy primer, which ensures complete bonding and load transfer

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between the repair and the substrate. The second component and most unique feature of the DiamondWrap® system, is its bi-directionally woven carbon-fiber material, which provides reinforcement in the hoop and axial directions and is the strongest available non- metallic repair on the market. The third part of the binding force in the system is the polymeric epoxy resin, which allows for uniform loading thoroughly the entire wrap. For repairs that require surfaces to be modified (e.g.: heavy pitting or irregular shapes), the high modulus filler can be applied. These components form an engineered composite system that is stronger than steel. The bi-directionally woven carbon-fiber material use with the DiamondWrap® composite system allows for negligible creep, ensuring a longer service life.

ProductAdvantages:Citadel Technologies´ DiamondWrap® saves time, labor, and equipment costs, while being a safer alternative to traditional repair methods. Tanks can be wrapped and repaired without welding. DiamondWrap® adheres to existing steel substrate and provides structural reinforcement, eliminating confined space cutting and grinding activities. Overhead repairs can be completed using scaffolding and personnel lift systems, dangerous overhead lifting and positioning of heavy steel plating is eliminated. DiamondWrap® contains no volatile organic compounds (VOCs) and requires no specialized personal protective equipment.

• Superior alternative to cut out/replacement. • Not limited by size – can install on all diameters of tanks. • Repairs all geometries quickly with ease: straight lengths, welded

seams, angles, valves, fittings, etc. • Adheres to carbon steel, stainless steel, alloys, PVC, FRP, and more. • High strength to weight ratio • Carbon fabric wrap has negligible creep, experiencing less than 1%

strain over a projected 100-year life. • Epoxy system has high chemical resistance – will not deteriorate if

exposed to internal contents of the tank. • Long service life – greater than 50 years. • No VOCs – no respirators or breathing PPE required for installation. • No welding and no hot works permits required. • Each anomaly is individually engineered – will have supporting

documentation from start to finish for every step in the process and the analysis behind each repair.

• Supplied as a complete kit, so there is no measuring or pouring in the field, and therefore a quality installation is assured every time.

• Extensively tested in lab, and verified with thousands of installations in the field.

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SurfacePreparationProceduresIn order for the proper bond strengths and adhesion to be achieved, surface preparation is a vital component of the application process. The recommendation outlined below is required for the proper and advertised bond strengths to be achieved with Citadel Technologies’ epoxy products. The desired result of the surface preparation is a clean, bare surface with a minimum anchor profile of 3 mils (0.003” or 0.076 mm.) Recommended Surface Preparation Standards:

• NACE 2 or equivalent (e.g. SSPC-SP-10) o Near-White Blast Cleaning – Removal of nearly all mill scale, rust, rust scale,

paint, or foreign matter by the use of abrasives propelled through nozzles or by centrifugal wheels, to the degree hereafter specified. A Near-White Blast Cleaned Surface Finish is defined as one from which all oil, grease, dirt, mill scale, rust, corrosion products, oxides, paint or other foreign matter have been completely removed from the surface except for very light shadows, very slight streaks or slight discolorations caused by rust stain, mill scale oxides, or light, tight residues of paint or coating that may remain.

o At least 95 percent of each square inch of surface area shall be free of all visible residues, and the remainder shall be limited to the light discoloration mentioned above.

o Chemical cleaners such as acetone or denatured alcohol should be used to remove any remaining fine blasting particles from the tank.

InstallationInstructionsDiamondWrap® has been certified to the ASME PCC2 Article 4.1 test standards and has completed all qualification testing for this specification. Surface Preparation:

• For full details, see Surface Preparations Procedure of this document • Ensure preparation has been completed to required minimums or greater as stated

for the ECS system being utilized. • Ensure surface preparation has been completed to the required length as stated in

this document. • Do not use any methods of surface preparation that will provide a polished finish. • The area to be wrapped should be prepared at least 2 inches wider than the fabric

on each end. You can tape off the area to be wrapped plus the 2 inches on either side; doing so will give you a clearly defined area that should be prepped.

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Applying CMF-1 Filler Putty (May not always be required):

• The filler putty smooths pits and rough spots and smooth transitions for even load transfer.

• Mix all of the putty hardener into the putty resin container. • Mix thoroughly using the stir stick. • Mix for a minimum of 1 or 2 minutes until the color is even and no marbling is

present. Make sure that all hardener is mixed thoroughly into the resin. Do not leave the cap on the mixed epoxies, as it will overheat, causing the epoxy to set up and be unusable.

• Using the same stir stick, or a putty knife (not included), smooth the filler putty into the area required and return the tank as close to the original geometry as possible.

• Tank may be wrapped immediately, unless the filler putty was applied very thick. In this case, allow the putty to set slightly before continuing with installation.

Applying Primer Epoxy:

• Pour the “Part B” hardener into the “Part A” resin container. • Mix thoroughly using the stir stick or mixer provided attached to a power drill. • Mix for a minimum of 1 or 2 minutes until the color is even and no marbling is

present. Make sure that all hardener is mixed thoroughly into the resin. • Using one of the brushes supplied, apply a thin layer of primer evenly over the

area that has been prepared (approximately 20 to 40 mils thick). • Use this material to fill voids, cracks and other surface irregularities so that there

will be no voids between the carbon cloth and the host substrate. For severe pitting where wall loss is significant, use CMF Filler Putty to fill the pits. Do not apply thicker than necessary on smooth areas. Doing so may cause the cloth to slip and misalign during wrapping.

Wetting the Fabric (Roller method):

• Pour the “Part B” hardener into the “Part A” resin container. • Shake vigorously for a minimum of 1 to 2 minutes until total mixing has

occurred. Do not leave the cap on the mixed epoxies, as it will overheat, causing the epoxy to set up and be unusable.

• Lay out the cloth on a clean, non-porous surface such as visqueen. • Pour a small amount of the mixed wetout epoxy over the piece(s) of cloth. • Using an adhesive roller or brush, distribute the mixed epoxy evenly over the

entire cloth insuring that all areas are wetted and no dry spots are present. • Roll the fabric in the length direction. This will insure that the fabric is

completely and evenly wetted. You may also roll the fabric onto a cardboard tube. Wrapping the Tank:

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• Center the cloth over the area to be wrapped. Using a gloved hand, lightly press the end of the cloth onto the tank.

• Using a gloved hand, smooth the cloth out, removing all air bubbles and smoothing out the edges.

• Repeat steps 1 and 2 for each piece of cloth. • Smooth out all of the edges, wrinkles, and bubbles to minimize any sharp edges

when the epoxy hardens. • You may use any remaining wet out epoxy as a glaze coat if so desired. • The normal set time for the repair is 2 to 3 hours at ~75ºF. All set times will vary

with ambient conditions. Set time may be accelerated by using an outside heat source such as a heater or a lamp.

Safety:Resin and hardener compounds used with DiamondWrap® are non-hazardous, however, some personnel may exhibit allergies associated with epoxies. Safety Data Sheets are provided with every product kit shipped.

ClothingandEquipment:Protective clothing is recommended during installation. Recommended clothing includes, but is not limited to: tyvek suit, coveralls, apron, rubber foot coverings, safety glasses or chemical splash goggles, and impervious gloves (vinyl, latex, or neoprene) to cover exposed areas of skin.

ColdWeather/ColdSubstrateProceduresInstallation of epoxy products at low temperatures is difficult and requires additional attention and procedures. The following is recommended to ensure proper installation and curing of DiamondWrap® in lower than optimal temperature environments. When the ambient installation temperature is below 4°C, all installation activities should be conducted in a temperature controlled environment. Portable building, tents, and external heat sources are typically used to achieve this. When the skin temperature of a substrate is below 4ºC DiamondWrap® can be applied as long as an external heat source is utilized to ensure a proper cure. Without an external heat source, it is not recommend to install on surfaces below 4°C. Below are several recommended techniques and equipment to achieve proper epoxy temperature:

• Enclose Installation area- Use tents or temporary containers around your workspace in conjunction with safe heat source.

• Enclose Wet-out Table area- Use tents or temporary containers around your Wet-out tables to keep epoxy warmer and more fluid for mixing and application.

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• Electric Blanket Heaters- Use Pipe or Barrel type blanket heaters to set the wrap after installation. Time of use for blanket heaters is dependent on ambient temperature and surface temperature. A minimum of 30 minutes is recommended.

• Electric Heaters- Use electric heaters in your workspace to increase ambient temperatures.

• Insulated Blankets- In some instances, after removing electric blankets, use insulated blankets or reflective blankets to retain heat longer.

MoistureProceduresSome applications may experience sweating or condensation after they have been cleaned due to environmental conditions. In those instances, DiamondWrap® may still be applied, but it is recommend to remove as much of the moisture with a clean dry towel prior to applying the CMF and fiber. The epoxy will displace small amounts of moisture formed after being toweled dry. If the condensation rate is sufficient that water is pouring/dripping off the substrate after cleaning and it is displacing epoxy, installation is not recommend until the environment conditions are changed to reduce condensation to a less profuse rate.

Cure Hardness testing confirms the quality of the epoxy mixing and quality of cure of the Hardnesstestingconfirmsthequalityoftheepoxymixingandqualityofcureoftherepair system. For Citadel Technologies’ composite repair systems the hardness should not be below 74 on a Shore D scale.

• Inspect the composite for raised or sharped edges. If sharped edges exist, they should be removed by grinding or sanding. It is possible for workers around the cured repair to be cut or injured if left untreated.

• Post-installation Inspection of the steel substrate can be performed using ultrasonic testers

• Other inspection techniques such as x-ray, low energy x-ray, laser, and guided wave have also been used with some success.

• Inspect for areas of dry fabric. If found, they can be corrected by lightly sanding and adding an extra glaze coat of wet out.

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CitadelTechnologiesClients

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ReplacewithSteel,orRepairwithDiamondWrap®-ACaseStudy

Introduction:

In2012,asyntheticfertilizerplantinCanadaapproachedCitadelTechnologieswithcorrosion and other anomalies in their largeUrea-Ammonia-Nitrate (UAN) tanks. Thetanks had cracking in the vertical welds.Nitrate embrittlement combined withimproper welding practice is suspected asbeing the cause of the Stress CorrosionCracking,orSCC.Thecracksrunhorizontally,originating in the vertical welds andextendingup toa few inches in length. Somehave traversed out past the heat-affectedzone.

Figure 1- Extensive corrosion on the floor of the tank

Various patches of worm holing andlocalized patches of internal corrosion wereobserved on the floor of the tank, aswell asgeneralwall loss on the underside floor. Thefoundation appears to have settled, therebyallowingthefloorplatesforflexupanddown.The floor plates all settle into locationwhenthetankisputbackintooperationandfilled. Therewere four courses to the tankwalls. Citadel engineersmadea site visit andrecommended a 3-ply taperedDiamondWrap® repair over the defectivewelds. The plant decided to stay with theconventional repair methods, and cut andreplacetheverticalweldsonthetank.

This proved to be a very involvedprocess. A rectangle approximately 1 meterby 3 meters was cut around each verticalweld. Then new steel was positioned intoplace and welded.Theywere soonmonthsbehind schedule, and hundreds ofthousandsofdollarsoverbudget.Theplantcalled Citadel Technologies again to take a

secondlookattheDiamondWrap®option.Citadel Technologies revived the

proposal.Thebottomthreecourseshadbeencompleted with the welding process. CitadelTechnologieswasbrought in towrap the topcourse (most difficult to access), and installwrapsatvarious locationsofwall lossonthetank.Thedesignwas finalized, andmaterialsweredispatchedwithinacoupleday.WorkCompleted: Citadel Technologies dispatched a 3-manteamconsistingofoneengineerandtwoskilledtechnicianstofacilitatetheinstallation.A couple local laborers assisted as well. Theworkcarriedoutonthetankincluded:1.Verticalweldpatches,interior

Citadel Technologies applied atapered3-plyrepairovereachofthecrackingvertical welds. This repair tapered from 3plies directly over theweld, down to 2 pliesandoutto1ply.Thiswouldprotectawidthof

Figure 2- Stress Corrosion Cracking in a weld

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upto16inchesoneachsideoftheweld,foratotal repair width of 32 inches. The goal ofthese repairs was to isolate the welds fromthe corrosion mechanism (UAN), andreinforce the repaired area. Thereinforcement from the DiamondWrap® isexpected to decrease the stressconcentrations found in the crack, and assistincrackarrest.

Figure 3- DiamondWrap® repairs installed over the

vertical welds on the top course2.Verticalweldpatches,exterior

A 4-ply tapered repair over each ofthe through-wallcrackedweldswas installedfortheexternalcracksontheWestUANtank.These repairswillnot isolate thewelds fromthe corrosion mechanism. The layup wouldbe similar to the 3-ply repairs proposed fortheinsideofthetank,withtheadditionofanextralayeroverthecenter.

Figure 4- Primer applied for an external patch

These external repairswere not expected to stop the crackpropagation.Theweldswillstillbeincontactwith the UAN. Also, the carbon fiber willdistribute lessoftheloadingbeingappliedtothe outside of the tank. However, theDiamondWrap® is still expected to containtheUANasabandaid-typepatch.Thiswillbea suitable short-term solution to contain theUAN in the tank until it can be taken out of

serviceforaninternalrepair.3.Floorpatch

A 2-ply DiamondWrap® repair wasinstalled for the general underside corrosionexperiencedonthefloorofthetank.Thefloortest patchwas a 50% overlap, 1-pass repair,coveringanareaof20’x50’.

Figure 6- 20'x50' floor patch

Figure 5- External patch over through-wall cracks

4.Chimeweld

A10’ longsectionofchimeweldwasinstalledwith2pliesofDiamondWrap®.Thesectionchosenhadasteelplateweldedontosupport the failing floor. Significant worm-hole corrosionwas present in this area. Thisrepair was installed with repair extendingabout 2’ up the sidewall and2’ into the tankonthefloor.

Figure 7- Chime weld repair Conclusion: Citadel Technologies successfully designed and implemented a DiamondWrap® repair on schedule and on budget when a traditional welded steel repair was going over budget and behind schedule. The DiamondWrap® repairs for the top course plus other locations were installed in two weeks; the other three courses had taken months. Citadel Technologies continues to partner with this chemical plant. The repairs on the UAN tanks were still in service as of Fall of 2016.