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Analysis of leak repair testing requirements in ASME PCC-2 and ISO 24817

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Corrosion in metallic industrial equipment, pipework, and vessels, when left unchecked, can lead to the full deterioration of wall-thickness. The presence of through-wall defects may lead to loss of production and costly shutdowns, in addition to environmental and safety hazards. One solution to this issue is the installation of a repair system using composite materials, which are durable for decades, easy to install, and a cost-effective to deploy option for bringing industrial equipment back to operation, even after a leak is detected. Internationally recognized organizations, such as ASME and ISO, set the rules for the design methodology, material testing, and training of personnel for this type of repair method.

Product Number: 51323-18934-SG
Author: Pedro Bordieri, Casey Whalen, Hanna Ford
Publication Date: 2023
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$20.00
$20.00

Part of the testing program that composite repair systems are required to undergo for qualification is the installation on pipes with various hole sizes and subsequent pressure tests. The objective of these tests is to determine the lower confidence level of the energy release rate (γLCL) of the repair system. A requirement set by the standards for calculating γLCL is that the failure must occur on the edges of the repair, rather than through its thickness. However, the layer count of the composite repair may be thicker than predicted mathematically in order to have consistent through-edge failure mode. This paper reviews recent testing programs that evaluated the leak sealing capabilities of composite repairs with various thicknesses and compares the results to estimated values, regardless of failure mode. The objective of this study is to determine if, under specific scenarios, repair thicknesses less than the minimum required to pass the test can be used effectively and conservatively. The results will be compared to mathematical estimates that also highlight some key differences between the ASME PCC-2 and ISO 24817 standards.

Part of the testing program that composite repair systems are required to undergo for qualification is the installation on pipes with various hole sizes and subsequent pressure tests. The objective of these tests is to determine the lower confidence level of the energy release rate (γLCL) of the repair system. A requirement set by the standards for calculating γLCL is that the failure must occur on the edges of the repair, rather than through its thickness. However, the layer count of the composite repair may be thicker than predicted mathematically in order to have consistent through-edge failure mode. This paper reviews recent testing programs that evaluated the leak sealing capabilities of composite repairs with various thicknesses and compares the results to estimated values, regardless of failure mode. The objective of this study is to determine if, under specific scenarios, repair thicknesses less than the minimum required to pass the test can be used effectively and conservatively. The results will be compared to mathematical estimates that also highlight some key differences between the ASME PCC-2 and ISO 24817 standards.

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For almost three decades composite repair technology has provided valuable alternatives to operating companies in maintaining the integrity of their high-pressure gas and liquid pipeline systems. Early adopters of the technology helped to push the usage of these beneficial materials to where they are today. As with all technology increased usage drives increased scope of usage and there have been extensive and comprehensive full-scale testing programs dedicated to pushing the boundaries and opening new defect repair options. These have been funded jointly by industry and manufacturers and have yielded successful results further showcasing the full range of benefits that composite materials can provide. Benefitting from this history and background allows for a better repair option based on experience and lessons learned. Development of new technologies methods and materials has been ongoing and results show improvements may be made by using lessons learned in conjunction with technologies now available.The contents of this paper focus and provide details on the development of specialized composite technologies for reinforcing anomalies such as corrosion and dents subjected to aggressive operating conditions. Additionally small-scale coupon-level testing results are used to characterize the effects of constitutive component changes in order to take the next steps prior to full-scaling including burst and cyclic pressure testing. Information is included on the initial design process used by engineers to optimize reinforcements using constitutive properties and insights from previous testing and research programs to guide the advancements in the understanding of the materials. Detailed test results and industry comparisons are included with information on how both coupon-level and full-scale test results can be used to assist operators in repairing and maintaining their pipeline systems using optimized composite reinforcing technologies.
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Key qualification and testing requirements, as well as a full implementation process as outlined within the ASME PCC-22, Article 4.1, Nonmetallic Composite Repair Systems: High Risk Applications.
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