Fiber Reinforced Polymer Upgrades for Large Pipelines. Anna Pridmore, PhD Vice President- Pipeline Solutions Structural Technologies
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1 Fiber Reinfrced Plymer Upgrades fr Large Pipelines Anna Pridmre, PhD Vice President- Pipeline Slutins Structural Technlgies
2 Agenda Inspectin Methds evlutin Repair Optins analysis Carbn Fiber technical verview Prject verview: 144-inch PCCP Prject verview: 36 & 42-inch steel pipeline Advancements in surface preparatin Overcming peratinal challenges Cnclusins
3 State f the Art Prducts Engineering Supprt Services Specialty Cntracting Slutins that integrate prducts, engineering, and cnstructin
4 Prducts & Systems Strengthening Frce Prtectin Pipe Repair & Upgrade Crrsin Cntrl Misture Cntrl Cncrete Restratin Equipment Fundatins Pst Tensining Engineering Supprt Investigative Cnditin Assessment Engineering Prduct Custmizatin Design Assist Specialty Full Design State f the Art Prducts Engineered Slutins
5 Pre-Stressed Cncrete Cylinder Pipe (PCCP) verview Key pints: Certain types f pre-stressing wires susceptible t failure Installed in ft sectins, ften referred t as spls, which lends well t segmental r targeted repairs Current inspectin technlgy and wner behavir, typically repairing suspect segments
6 Other Pipe types failure mdes verview Other cncrete cracking due t surge pressure damage, crrded reinfrcement steel, age r sil settlement factrs Metallic crrsin f pipeline due t sil chemistry, age r ther factrs causing sectin lss (wall thinning) and can lead t leaks Plymer based cracking due t surge pressure damage, age r sil settlement issues
7 Pipeline Inspectin Methds Electrmagnetics 1. Visual & sunding Determines severely deterirated pipe areas 2. In-line acustics Determines leaks in the pipe 3. Electrmagnetics Determines prestressing wire breaks in PCCP 4. Impact ech Determines cncrete integrity r metallic wall thickness 5. Magnetic flux leakage Determines metallic pipe wall lss Impact Ech 6. Crrelatrs - Determines leaks in the pipe and average pipe wall thickness
8 Repair Optins Analysis What are the alternatives? 1. Dig & replace new pipe 2. Steel slip-lining 3. Prtective catings 4. Structural lining CFRP 5. External pst-tensining
9 Carbn Fiber Technical Overview FRP = Fiber Reinfrced Plymer Carbn Fiber prvides structural strength. Epxy resin prvides durability.
10 Carbn Fiber Technical Overview 36-inches and abve diameter fr buried pipe, n size limitatins fr expsed piping Fluid type - water and waste water Internal pressures - up t 400psi External lads n limit Hst pipe materials - mst any material including PCCP, reinfrced cncrete, steel, cast irn, ductile irn, and plymer based piping systems Temperature limit 130F Schedule need minimum 4 day cnstructin windw
11 Carbn Fiber Technical Overview Durability ICC cmpliance Testing requirements Full-scale testing Resin system Wet lay-up methd Lng-term lab testing Minimum field applicatins
12 Carbn Fiber Technical Overview ICC AC-125 Durability Matrix ENVIRONMENTAL DURABILITY TEST RELEVANT SPECIFICATIONS TEST CONDITIONS TEST DURATION MINIMUM PERCENT RETENTION Hurs 1,000 3,000 Water resistance ASTM D 2247 ASTM E percent, 100 ± 2 F Full-scale testing 1,000, 3,000 and 10,000 hurs Saltwater resistance ASTM D 1141 ASTM C 581 Alkali resistance ASTM C 581 Immersin at 73 ± 2 F Immersin in Ca (CO3) at ph = 9.5 & 73 ± 3 F 1,000, 3,000 and 10,000 hurs 1,000 and 3,000 hurs Dry heat resistance ASTM D ± 5 F 1,000 and 3,000 hurs
13 Carbn Fiber Technical Overview Design Cnsideratins Overview Internal wrking pressure Internal wrking-plus-transient pressure Weight f pipe and fluid Earth lad abve the pipe Live lads at the grund surface Full-scale testing External pressure due t grundwater abve the pipe Negative pressure inside the pipe What is the desired service life?
14 Carbn Fiber Technical Overview End cnnectin detailing Full-scale testing
15 Prject Overview: 36 & 42-inch steel pipeline Nuclear Facility in United States Circulating Water System cnsists f 36 & 42-inch carbn steel pipelines Thinning wall sectins and limited thru-wall leaks were detected during inspectin
16 Prject Overview: 36 & 42-inch steel pipeline Prject Scpe: Carbn fiber reinfrced plymer (CFRP) cmpsite lining f 255 cntinuus lineal feet f 36 & 42-inch carbn steel pipe during 2013 utage Unique Prject Challenges: Extremely pr cnditin f substrate Sequencing peratins activity in small diameter pipeline Crdinatin f weld repairs during peratins Changes in elevatin and slpe cnditins within scpe area
17 Prject Overview: 36 & 42-inch steel pipeline
18 Advances in Surface Preparatin Befre After 36 & 42-inch steel pipeline prject
19 Prject Challenges: 36 & 42-inch steel pipeline Pipe Primer Interir cat Clse-up installatin Prject sequencing during installatin due t limited access within 36-inch pipe Carbn Fiber Installatin Glass Fiber installatin Spnge-Jet Set-up Final CFRP layer & tpcat
20 Backgrund- Quality Cntrl Prgram Multiple QA/QC Persnnel 3 rd Party inspectr Full time Quality Assurance Manager Multiple Owner Representatives Dcumentatin fr each stage f implementatin Material verificatin Surface preparatin Mixing and saturatin CFRP liner installatin End details and special detailing Tp cat Final cure
21 FRP Cmpsite Systems Next Generatin Installatin Overview Reinfrcing Steel
22 FRP Cmpsite Systems Next Generatin StrngPIPE Hybrid FRP System Descriptin StrngPIPE System Legend 1. 1 st Glass FRP Layer (lngitudinal) 2. High Str. Steel Wire 3. Plymer Matrix Existing Pipe nd Glass FRP Layer (lngitudinal) 1 5. Flexible Tpcat
23 Thank yu! Questins? Anna Pridmre, PhD VP- Pipeline Slutins Structural Technlgies, LLC
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