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
Page 2Reducing Emissions, Increasing Efficiency, Maximizing Profits
Composite WrapComposite Wrap
Permanent On-Line Permanent On-Line Pipeline Repair Pipeline Repair
TechnologyTechnology
Source: Armor Plate
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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
Composite WrapComposite Wrap
A QUICK & SAFE WAY to improve profitability &
AVOID VENTING METHANE!
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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
Composite WrapComposite Wrap
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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.
Page 6Reducing Emissions, Increasing Efficiency, Maximizing Profits
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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
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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
Page 18Reducing Emissions, Increasing Efficiency, Maximizing Profits
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?