# Presentation: 334316

## Composite Wrap for Non-leaking Pipeline Defects

**Lessons Learned **
**from Natural Gas STAR**
**Transmission Technology Transfer Workshop**
**Duke Energy Gas Transmission,**
**Interstate Natural Gas Association of America (INGAA) and **
**EPA’s Natural Gas STAR Program**
**September 22, 2004**

## Composite Wrap

**Permanent On-Line Pipeline Repair Technology**

- Source: Armor Plate

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

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

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

**Composite Wrap**

**A QUICK & SAFE WAY **
**to improve profitability & **
** ****AVOID VENTING METHANE!**

## Before January 13th, 2000 repair methods were restricted to replacement, or use of full encirclement steel sleeves welded in place

**And now** the steel sleeve requirement is amended to allow composite wrap sleeves

**Composite Wrap**

## A high-strength glass fiber composite or laminate
An adhesive or resin bonding system
A high-compressive-strength load transfer filler compound

- An adhesive or resin bonding system
- A high-compressive-strength load transfer filler compound

**Composite Wrap****What Are They?**

## Composite WrapSoftware

- Software will determine:
**If a repair is needed**
**If a composite wrap is suitable**
**Or if a pipe replacement is required**
- Defects up to 80% loss wall thickness can be repaired with composite wrap
- There may be pressure and temperature restrictions on composite wrap

## Composite WrapInstallation

- After excavation and pipe preparation
**External defects filled with filler**
**Composite wrap wound around pipe with adhesive or laminating agents**
**Typically 2” of wrap must extend beyond damage**
**Excavation site refilled after mandated curing time**
- Reducing pressure improves quality of repair** **

- Source: Armor Plate

## Composite WrapDecision Process

- Determine suitability of composite wrap technique for repair option
- Calculate cost for composite wrap and consider other benefits of on-line repair
- Estimate methane savings
- Calculate avoided costs of line replacement
- Evaluate economics

## Composite WrapStep1:  Determine Suitable Application

- Evaluate nature of defect and causal factors
- Evaluate operational needs and job site factors
- Follow industry standards, such as ASME, and your company engineering policies and procedures

## Composite WrapStep 2: Cost of Wrap Repair 

- GIVEN: 6” non-leaking defect in 24” line @ 350 pounds per square inch (psi)
- Estimate: 16 hours to repair
- Cost of labor: Field Labor: 3 men @$30/hr = $1,440
- 	           Eng Mgmt: 25% of $1,440     = $   360
- Cost of Equipment: Wrap Kit		    = $  900
- 	Backhoe & Sandblaster	               = $  750
- Other: Permits/Inspection/Misc	               = $1,650

## Composite WrapStep 3: Estimate Methane Savings

- Methane Savings = Emissions avoided from line replacement
- Volume of methane(Mcf) = (D2*P*(L/1,000)*0.372)/1,000
- 		   = 24*24*350(52,800/1,000)*0.372/1,000
- 		   = 3,960 Mcf @ $3/Mcf
- 		   = $11,900
- Note: for 10 miles between block valves

## Composite WrapStep 4: Calculate Purge Gas Savings

- Purge Gas saved = Purge Gas used during line replacement
- Volume of Purge Gas = [3.14*D2*L/(4*144*1,000)]*1.2
- 	      = [3.14*24*24*52,800/(4*144*1,000)]*1.2
- 	      = 200 Mcf @ $4/Mcf of nitrogen
- 	      = $800
- Note: for 10 miles between block valves, assuming 20% wastage

## Composite WrapStep 4(cont’d): Replacement Line Cost 

- GIVEN: 6” non-leaking defect in 24” line @ 350 psi
- Assume: replace 6’ of line (3 times pipe diameter)
- Estimate: 40 hours to repair
- Cost of labor: Field labor: 4 men @$30/hr    = $4,800
- 		 Eng Mgmt: 25% of $4,800      = $1,200
- Cost of Equipment: 6’ pipe @ $50/ft	      = $   300
-                        Backhoe, Welder & Crane      = $3,700
- Other: Permits/Inspection/Misc	                 = $4,500

## Composite WrapStep 5: Evaluate the Economics  

| 24” Line @ 350 psi |  |  |
| --- | --- | --- |
| 6” Defect |  |  |
| 10 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:**
**Safety**
**Environmental impacts**
**Site access**
**Service interruption**

## Composite WrapPartner Experience

- 300+ wraps on 10” or greater lines since 1995
- Up to 15 wraps have been butted side-by-side in the U.S.
- 20’’ defect in line near creek bed: limited  environmental exposure, wrapped in 2 hours; total repair 2 days start to finish** **

## Composite Wrap Lessons Learned

- Proven permanent repair for external defects
- Temporary repair for internal faults
- In-service pipeline repair methodology
- Ideal for urgent and quick repair
- Avoid service disruptions
- Cost-effective

- Trained but not skilled crafts persons required
- Specialized welding and lifting equipment not required
- Minimizes access concerns
- No delays awaiting metal sleeve
- Cathodic protection remains functional

## Composite WrapContacts

- epa.gov/gasstar
- EPA Natural Gas STAR managers
- Vendors of composite wrap kits
**Armor Plate, Inc.**
**http://www.armorplateonline.com**
**The Clock Spring****® Company L.P.**
**http://www.clockspring.com**
**The StrongBack Corporation**
**http://www.strongbackcorp.com**
**WrapMaster, Inc.**
**http://www.wrapm.com**

## Composite WrapDiscussion Questions

- Has anyone used composite wrap repairs?
- What are the barriers(technological, lack of information, regulatory, and etc.) that are preventing you from implementing this technology?
- Would anyone like to elaborate on the information provided in this presentation?