Composite Wrap for Nonleaking Pipeline Defects Lessons Learned

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

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 Reducing Emissions, Increasing Efficiency,

Composite Wrap Permanent On-Line Pipeline Repair Technology Source: Armor Plate Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 2

Composite Wrap p Use of 30 wrap repairs versus line replacements could save 70,

Composite Wrap p 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 A QUICK & SAFE WAY to improve profitability & AVOID VENTING METHANE! p Repairs with pipeline in service average 2 days versus 5 to 7 days for typical cut & weld pipe replacements Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 3

Composite Wrap p Before January 13 th, 2000 repair methods were restricted to replacement,

Composite Wrap p Before January 13 th, 2000 repair methods were restricted to replacement, or use of full encirclement steel sleeves welded in place p And now the steel sleeve requirement is amended to allow composite wrap sleeves Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 4

Composite Wrap What Are They? 1. A high-strength glass fiber composite or laminate 2.

Composite Wrap What Are They? 1. A high-strength glass fiber composite or laminate 2. An adhesive or resin bonding system 3. A high-compressivestrength load transfer filler compound Source: Clock Spring® Company L. P. Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 5

Composite Wrap Software will determine: u If a repair is needed u If a

Composite Wrap Software will determine: u If a repair is needed u If a composite wrap is suitable u Or if a pipe replacement is required p Defects up to 80% loss wall thickness can be repaired with composite wrap p There may be pressure and temperature restrictions on composite wrap Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 6

Composite Wrap Installation p After excavation and pipe preparation External defects filled with filler

Composite Wrap Installation p After excavation and pipe preparation External defects filled with filler u Composite wrap wound around pipe with adhesive or laminating agents u Typically 2” of wrap must extend beyond damage u Excavation site refilled after mandated curing time u Source: Armor Plate p Reducing pressure improves quality of repair Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 7

Composite Wrap Decision Process 1. Determine suitability of composite wrap technique for repair option

Composite Wrap Decision Process 1. Determine suitability of composite wrap technique for repair option 2. Calculate cost for composite wrap and consider other benefits of on-line repair 3. Estimate methane savings 4. Calculate avoided costs of line replacement 5. Evaluate economics Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 8

Composite Wrap Step 1: Determine Suitable Application p Evaluate nature of defect and causal

Composite Wrap Step 1: Determine Suitable Application p Evaluate nature of defect and causal factors p Evaluate operational needs and job site factors p Follow industry standards, such as ASME, and your company engineering policies and procedures Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 9

Composite Wrap Step 2: Cost of Wrap Repair GIVEN: 6” non-leaking defect in 24”

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 Backhoe & Sandblaster = $ 900 = $ 750 Other: Permits/Inspection/Misc = $1, 650 Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 10

Composite Wrap Step 3: Estimate Methane Savings = Emissions avoided from line replacement Volume

Composite Wrap Step 3: Estimate Methane Savings = Emissions avoided from line replacement Volume of methane(Mcf) = (D 2*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 Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 11

Composite Wrap Step 4: Calculate Purge Gas Savings Purge Gas saved = Purge Gas

Composite Wrap Step 4: Calculate Purge Gas Savings Purge Gas saved = Purge Gas used during line replacement Volume of Purge Gas = [3. 14*D 2*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 Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 12

Composite Wrap Step 4(cont’d): Replacement Line Cost GIVEN: 6” non-leaking defect in 24” line

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 Eng Mgmt: 25% of $4, 800 = $1, 200 Cost of Equipment: 6’ pipe @ $50/ft Backhoe, Welder & Crane = $ 300 = $3, 700 Other: Permits/Inspection/Misc = $4, 500 Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 13

Composite Wrap Step 5: Evaluate the Economics 24” Line @ 350 psi INTANGIBLES: 6”

Composite Wrap Step 5: Evaluate the Economics 24” Line @ 350 psi INTANGIBLES: 6” Defect 10 miles between shut off valves Composite Wrap - $ Line Replacement - $ 11, 900 none 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 IMMEDIATE!! None Methane Savings Purge Gas Pay Back • Safety • Environmental impacts • Site access • Service interruption Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 14

Composite Wrap Partner Experience p 300+ wraps on 10” or greater lines since 1995

Composite Wrap Partner Experience p 300+ wraps on 10” or greater lines since 1995 p Up to 15 wraps have been butted side-by-side in the U. S. p 20’’ defect in line near creek bed: limited environmental exposure, wrapped in 2 hours; total repair 2 days start to finish Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 15

Composite Wrap Lessons Learned p Proven permanent p p p repair for external defects

Composite Wrap Lessons Learned p Proven permanent p p p 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 p Trained but not skilled p p crafts persons required Specialized welding and lifting equipment not required Minimizes access concerns No delays awaiting metal sleeve Cathodic protection remains functional Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 16

Composite Wrap Contacts p epa. gov/gasstar p EPA Natural Gas STAR managers p Vendors

Composite Wrap Contacts p epa. gov/gasstar p EPA Natural Gas STAR managers p Vendors of composite wrap kits u Armor Plate, Inc. § http: //www. armorplateonline. com u The Clock Spring® Company L. P. § http: //www. clockspring. com u The Strong. Back Corporation § http: //www. strongbackcorp. com u Wrap. Master, Inc. § http: //www. wrapm. com Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 17

Composite Wrap Discussion Questions p Has anyone used composite wrap repairs? p What are

Composite Wrap Discussion Questions p Has anyone used composite wrap repairs? p What are the barriers(technological, lack of information, regulatory, and etc. ) that are preventing you from implementing this technology? p Would anyone like to elaborate on the information provided in this presentation? Reducing Emissions, Increasing Efficiency, Maximizing Profits Page 18

Composite Wrap for Nonleaking Pipeline Defects Lessons LearnedComposite Wrap for Nonleaking Pipeline Defects Lessons Learned
Defects Types of defects Point defects line defectsDefects Types of defects Point defects line defects
COMPOSITE SOLUTIONS COMPOSITE REPAIRS A composite wrap isCOMPOSITE SOLUTIONS COMPOSITE REPAIRS A composite wrap is
Timber Defects Defects n n n Defects inTimber Defects Defects n n n Defects in
COMPOSITE MATERIALS COMPOSITE MATERIALS A composite material canCOMPOSITE MATERIALS COMPOSITE MATERIALS A composite material can
UNITIV COMPOSITE CONSTRUCTION Composite Sections A composite sectionUNITIV COMPOSITE CONSTRUCTION Composite Sections A composite section
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