Composite Wrap Composite Wrap Lessons Learned Lessons Learned from Natural Gas STAR from Natural Gas STAR EPA’s Natural Gas STAR Program, EPA’s Natural Gas STAR Program, Pioneer Natural Resources USA, Inc., Pioneer Natural Resources USA, Inc., and and The Gas Processors Association The Gas Processors Association June 17, 2003 June 17, 2003
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Composite Wrap Lessons Learned from Natural Gas STAR EPA’s Natural Gas STAR Program, Pioneer Natural Resources USA, Inc., and Pioneer Natural Resources.
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Use of 30 wrap Use of 30 wrap repairs versus line repairs versus line replacements could replacements could save 70,000 Mcf/yr save 70,000 Mcf/yr netting almost netting almost $130,000 in savings$130,000 in savings
Repairs with pipeline Repairs with pipeline in service average 2 in service average 2 days versus 5-7 days days versus 5-7 days for typical cut & weld for typical cut & weld pipe replacementspipe replacements
Before January Before January 1313thth, 2000, 2000 repair repair methods were methods were restricted to restricted to replacement, or use replacement, or use of full encirclement of full encirclement steel sleeves steel sleeves welded in placewelded in place
And nowAnd now the steel the steel sleeve requirement sleeve requirement is amended to allow is amended to allow composite wrap composite wrap sleevessleeves
Composite WrapComposite WrapWhen to UseWhen to Use
Pipeline defects must be carefully analyzedPipeline defects must be carefully analyzed Follow industry standards: ASME B31G or Follow industry standards: ASME B31G or
RSTRENG (modified B31G)RSTRENG (modified B31G) Composite wrap vendors typically supply Composite wrap vendors typically supply
defect analysis and repair reporting softwaredefect analysis and repair reporting software Permanent repair for Permanent repair for
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
After excavation and pipe After excavation and pipe preparationpreparation
External defects are filled with External defects are filled with fillerfiller
Composite wrap wound around Composite wrap wound around pipe with adhesive or laminating pipe with adhesive or laminating agentsagents
Typically 2” of wrap must extend Typically 2” of wrap must extend beyond damagebeyond damage
After mandated drying or curing After mandated drying or curing time, excavation site refilledtime, excavation site refilled
While lines can be repaired at While lines can be repaired at full pressure, reducing pressure full pressure, reducing pressure improves quality of repairimproves quality of repair
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
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
Composite WrapComposite WrapStep 2: Cost of Wrap RepairStep 2: Cost of Wrap Repair
GIVEN: 6” non-leaking defect in 24” line @ 350 psiGIVEN: 6” non-leaking defect in 24” line @ 350 psi
Estimate: 16 hours to repairEstimate: 16 hours to repair
Cost of labor: Field Labor: 3 @$30/hr Cost of labor: Field Labor: 3 @$30/hr = $1,440 = $1,440 Eng Mgmt: 25% of $1,440 = $ 360Eng Mgmt: 25% of $1,440 = $ 360
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% wastage
Composite WrapComposite WrapStep 4(cont’d): Replacement Line CostStep 4(cont’d): Replacement Line Cost Given: 6” non-leaking defect in 24” line @ 350psiGiven: 6” non-leaking defect in 24” line @ 350psi
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 @$30/hrCost of labor: Field labor: 4 @$30/hr = $4,800 = $4,800Eng Mgmt: 25% of $4,800 = $1,200Eng Mgmt: 25% of $4,800 = $1,200
300+ wraps on 10” or greater lines since 300+ wraps on 10” or greater lines since 19951995
Limits repairs to 4 butted wraps, then Limits repairs to 4 butted wraps, then replacesreplaces
20” defect in line near creek bed: limited 20” defect in line near creek bed: limited environmental exposure, wrapped in 2 environmental exposure, wrapped in 2 hours; total repair 2 days start to finish hours; total repair 2 days start to finish
Primary considerationsPrimary considerations Can repair be done safely?Can repair be done safely? Can repair be done in service?Can repair be done in service? Can repair be done quickly?Can repair be done quickly?
Secondary considerations (but still important)Secondary considerations (but still important) Cost effectiveCost effective Methane emissions savingsMethane emissions savings
METHANE EMISSIONS REDUCTIONS METHANE EMISSIONS REDUCTIONS save you money and reduce greenhouse save you money and reduce greenhouse gas emissionsgas emissions
www.epa.gov/gasstar/www.epa.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
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?