# Presentation: 118072

## 

Development of a Remote External Repair Tool 
for Damaged or Defective 
Polyethylene (PE) Gas Pipe

Presented by
 Kenneth H. Green, President
Timberline Tool

**Development of a Remote External Repair Tool **
**for Damaged or Defective **
**Polyethylene (PE) Gas Pipe**
**Presented by**
** ****Kenneth H. Green****, President**
**Timberline Tool**

- Natural Gas Technologies 2005 Conference

## Introduction

**Since incorporating in 1989, Timberline has ****	****been developing innovative tools used by****	****natural gas utility operators to maintain****	****and repair PE pipe. **
**In 1999, Timberline began developing tools ****	****specifically****	****for repairing PE pipe in  ****	****keyhole situations. **
**Timberline tools are currently being used ****	****by natural gas utility operators worldwide.**

## Abstract

**Remote External Repair Tool **
**for 4-inch PE Gas Pipe**
**	**

**External repair methods for PE pipe are being investigated at ****	****Timberline Tool and Oregon State University under a ****	****cooperative agreement with DOE/NETL.**
**Current repair procedures require multiple excavations, isolation, ****	****and removal of the damaged section of pipe followed by fusing ****	****a new section of pipe into place.**
**This project will develop a new methodology and tool for ****	****externally repairing damage or defects on PE pipe by applying a ****	****repair patch over the compromised area.**
**This presentation reviews the initial design and development of ****	****the mechanical device and two chemical processes for repairing ****	****damaged PE pipe.**

## Background

**Natural Gas Delivery System**
**The use of PE pipe for natural gas transmission & distribution has ****	****been steadily growing in the U.S. and accounts for a majority of ****	****America’s natural gas distribution network.**
**The current delivery system consists of 650 thousand miles of ****	****underground PE piping in service for over 30 years.**
**It is important to keep the delivery system safe, reliable and efficient.**

**U.S. Natural Gas Pipelines**

## A Growing Need

**Maintaining a Growing Infrastructure**

**The U.S. Department of Transportation forecasts a 50% increase in the  ****	****demand for natural gas by 2020.**

**Need ****	****improved tools for ****	****maintenance & repair of ****	****PE pipe to keep up with ****	****the expected growth**
**This project responds ****	****directly to this need.**
**Goal is to help maintain ****	****the safety, reliability, and ****	****integrity of the U.S. natural ****	****gas delivery system**

## Operating Procedures

**Natural gas operators are ****	****turning to keyhole technology ****	****for increased safety and cost ****	****savings.**
**Since 1999, Timberline has ****	****been developing PE pipe ****	****repair tools for use in keyhole ****	**

## Repair Tool Development

- Repair Tool Development

**In 2003, Timberline received an award from the U.S. ****	****Department of Energy National Energy Technology ****	****Laboratory to develop a remote external repair tool ****	****for PE Pipe.**

**The focus of this research is to encapsulate the ****	****damaged area of the pipe and apply a chemical ****	****patch to permanently repair the pipe.**

**This project will develop a new method for ****	****repairing damaged or defective 4-inch PE pipe.**

## Repair Tool Team

**Cooperative Agreement with the Department of Energy                     National Energy Technology Laboratory**

## Repair Process

**Curved jaw fits the contour ****	****of the pipe as it closes. **
**Allows operator to fully ****	****enclose the damaged ****	****section of pipe with ****	****the ****	****repair patch.**
**Stops the flow of gas ****	****through the damaged pipe ****	****wall. **
**Permanently repairs the ****	****damaged area.**

## Technology Assessment

**Current repair procedures for PE gas pipe require multiple ****	****excavations, isolation, and removal of the damaged section of ****	****pipe followed by fusing a new section into place.**

## Repair Tool Design

**Lightweight & portable, **constructed of 	aluminum for mechanical operation by a single 	person.
**Remote operation **keeps operator away from 	leaking gas
**Top-down application** without the need to 	fasten the device under the pipe
**Operable in keyhole situations **without the 	need for squeeze-off.
**Curved jaw design** allows for encapsulation of 	the pipe.

## Safety Benefits

## Cost Savings

## Innovative Repair Tool Project

## Phase 1

**Phase 1 will be completed March 2005.**

**The project team will design, fabricate and perform in-****	****house and field tests on one or more repair tool ****	****configurations to determine the best functionality, ****	****safety and reliability for the repair tool.**

## Phase 2

**Phase 2 will be completed March 2006.**

**The project team will use information gained in     ****	****Phase 1 to guide the construction of one or more ****	****engineered prototype repair tools.  In-house and ****	****field tests will be performed on these engineered ****	****prototypes and laboratory tests will be performed ****	****on repaired 4-inch PE pipe sections.**

## Repair Concepts

**Concept 1:****  Polyethylene gel bonding uses a gel ****	****containing a bonding agent attached to a PE ****	****patch to join the surfaces of the PE patch material ****	****and the damaged PE pipe.**

**Concept 2:****  Polyethylene adhesives utilize structural ****	****plastic glues to join the surfaces of the PE patch and ****	****the damaged PE pipe.**

## Repair Concept 1

**Early shear test ****	****results show ****	****successful bonding ****	****of two HDPE samples. **

**Polyethylene gel bonding uses a gel containing a bonding ****	****agent attached to a PE patch to join the surfaces of the       ****	****PE patch material and the damaged PE pipe.**

**Compiled Gel Shear Tests**

## Repair Concept 1

**Gel creates a ****	****relatively seamless ****	****joint.**

**An ideal bond joint ****	****would be difficult to ****	****differentiate from this ****	****sample**

**SEM Bonded Cross Section**

## Repair Concept 2

**AD #1 and AD #2 cured at 80°C for 90 minutes in the ****	****Carver Press.  One AD #1 sample cured at 80 °C for 24 ****	****hours in the Carver Press.**

**Polyethylene adhesives utilize structural plastic glues to join ****	****the surfaces of the PE patch and the damaged PE ****	****pipe.**

## Repair Concept 2

**Sample 1 cured at 80°C for 90 minutes in Carver Press ****	****with 50 lbs pressure. Glass sphere broken during ****	****shear test.  1650x magnification.**

## Project Completion 

**The completion of the project will involve ****	****construction of an engineered prototype        ****	****for 4-inch diameter MDPE & HDPE pipe.  **

**Laboratory and field tests will be performed on ****	****the prototype and repaired pipe samples under ****	****well-defined testing and operating procedures ****	****of natural gas distribution systems.**

**The effectiveness of the design will be reviewed ****	****and modifications made in preparation for ****	****commercialization of the tool.**

## Acknowledgements

**This report was prepared with the support of the U.S.  Department of Energy, under Award No. DE-FC26-03NT41879.  However, any opinions, findings, conclusions, or recommendations expressed herein are those of the authors and do not necessarily reflect the views of the Department of Energy.**

**The authors thank the Department of Energy and the National Energy Technology Laboratory for their financial, technical, and administrative assistance in funding and managing this project.  The authors would also like to thank KeySpan Energy for all their support for this project.**

## For further information, contact Ken Green

**For further information, contact Ken Green**
**khg@timberlinetool.com**