High pressure containing repair alternatives
to a welded sleeve. Used by ExxonMobil, Chevron, Shell Oil.
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Website: www.fineoilcompany.com
Phone for technical questions: 817-240-6434
Fine Oil Trading Company
Pipeline Repair Products
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Website: www.fineoilcompany.com
Elbow repaired with Aquawrap
in less than one hour
Aquawrap requires no
field-mixing of cloth with resin
Soil to air interface repaired quickly, less than
one hour with Aquawrap 2”x10’ roll
44’ linear 10” pipe with 77% external corrosion
repaired with Aquawrap to reinforce the hoop
strength of the pipeline. No pressure reduction
and backfilled 45 minutes later
Pipeline Repair Photos
Odd Shape Pipeline Repair
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Website: www.fineoilcompany.com
External Corrosion Load transfer epoxy filler/primer Aquawrap 4” wide x 15’ long
roll installed right-out-of the
bag. No mixing of resin into
cloth required minutes prior
to install. Aquawrap’s resin
is pre-pregnated into cloth
during its manufacturing
process. We also have 2”&
3” wide rolls.
Blue wrap and perforate Remove blue 45 minutes
Swamp Pipeline Repair
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Website: www.fineoilcompany.com
Before repair lifted 8” pipe out of water 96’ repaired with Aquawrap in 3 hours, pipe lowered back into water same day
Swamp Pipeline Repair
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Website: www.fineoilcompany.com
Removing old coating
Sandblasting
Corrosion pitting
Aquawrap repair complete
Clamp, Welded Sleeve & Composite
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Website: www.fineoilcompany.com
Pig indicated 72% wall loss, sandblasting also discovered 85% & 98%
What do the government regulations say about using composite materials to repair pipelines?
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Website: www.fineoilcompany.com
The United States DOT has amended documentation (49 CFR Parts 192 and 195) allowing damaged piping to be "repaired by a method that reliable engineering tests and analyses show can permanently restore the serviceability of the pipe". Leaks can be repaired with composites like Aquawrap, as long as reliable engineering test has been conducted to prove it. Aquawrap can be used on leaks up to 60psi. In addition, ASME - not the law but an engineering recommendation, has amended their B31.4 piping code to include composites as a method to repair pipelines. This can be found in Section 451.6.2 of the 1998 edition of the B31.4 code. ASME has also formed a committee called “Post Construction Composite (PCC-2)” to set qualification standards for composites used to repair piping built under B31.1, B31.3, B31.4, and B31.8. The PCC-2 publishes a written repair document available to the public. The Aquawrap composite system has undergone engineering testing to prove it compliant by the following organizations:
• ASME B31G • ASME B31.4 • ASME PCC-2
• ASME B31.1 • ASME B31.8 • ISO/TS 24817 • ASME B31.3 • DOT 49 CFR Parts 192 and 195 • NSF/ANSI Standard 61
Aquawrap used to repair girth weld with corrosion
What role do composite materials play in repairing liquid and gas pipelines?
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Website: www.fineoilcompany.com
• Energy pipelines are weakened by external/internal corrosion, dents, gouges, buckles and wrinkles.
• Damaged pipelines that are repaired with a welded sleeve or clamp can require the pipeline to be shut down, which is costly.
• Composite technology is pressure containing and allows for in-service repair of pipelines.
Aquawrap used to repair bend with wrinkles and corrosion
Pipeline on BP ‘s offshore platform repaired with Aquawrap
What exactly is a composite?
A composite consist of two or more distinct materials that are combined together but remain uniquely identifiable in the mixture. The most common example is glass fibers mixed with a polymeric resin which is easy to distinguish, if one were to cut the fiberglass. This is not the same as making an alloy by mixing two distinct materials together where the individual components become indistinguishable.
Why are composites becoming so popular?
Composites have been an excellent repair method for years, but they are just now becoming "mainstream". As more composite repair systems are used on high profile applications, the more accepted they become. New technology coupled with excellent past performance have thrust composites into the limelight. Their relative low cost enables repair instead of replacement, which saves money for other investments.
How long have composites been used?
Composites have been used for over 40 years! Most composites were introduced into the aerospace industry, but have since had a powerful impact on many other markets: energy pipelines, sports equipment, race cars, boats, infrastructure components and countless other products have benefited from the advantages composites have to offer.
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Website: www.fineoilcompany.com
Bridge Column
Aquawrap Applied
Repair Complete
How long do composites last?
Composites can last a few years, or last fifty years, depending on the application. Just like any other material, they will degrade over time. Steel will rust, concrete will crack, paint will peel, and composites will lose their strength. Aquawrap’slong-term tests show that it will retain its strength over 50 years. Epoxy systems have a high initial strength, but weaken more over the long term. Both types of material have been in use in various applications for decades.
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Website: www.fineoilcompany.com
Aquawrap repaired corrosion & welding
Up-close photo of corrosion & welding anomalies
Rigid composite had trouble conforming to the damaged pipeline so the pipeline company called Aquawrap
Aquawrap used to repair gouge dent
Aquawrap used to repair several dents
Yes, polyurethane resin composite systems work best to repair pipelines with external defects of <80% wall loss, girth welds, dents, gouges, buckles and wrinkles. They can be used to repair leaks once the hole is plugged or the pipeline is shut down.
Internal defects can be repaired best with field impregnated epoxy resin composite systems, as they are more likely to hold a punch through leak. Sometimes it’s best to apply epoxy composite then apply polyurethane composite like Aquawrap over it to achieve more long-term strength. If line is leaking, it is best to shut down the system and plug the hole with a non-permeable epoxy putty, and then install the composite over it. However, active leaks can be plugged too, but wear a mask to insure that you don’t inhale a fatal gas. Composites should not be installed over active leaks until they have been plugged.
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Website: www.fineoilcompany.com
Are composites used to repair both external and internal piping defects?
On this particular job, we fixed 44 linear feet of 10” pipe that had 77% external
wall loss. We completed the repair using Aquawrap in one hour and backfilled
45 minutes later. Aquawrap can be wrapped in a spiral direction using 1”
overlap versus circumferential, thus allows long sections of pipeline to be
wrapped quickly using our 12” wide x 60 ft long rolls. Also, you don’t have to
butt the ends of each layer and it cures as one solid layer with no crevices. .
Spiral wrap technique saves time and money compared to
circumferential wrap technique used by field impregnated
wet lay-up and layered composite systems.
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Website: www.fineoilcompany.com
Wet lay-up composite systems:Two types
• Pre-impregnated (Aquawrap)• Field impregnated (Armor Plate, IWrap, Contour Wrap)
Both types use either e-glass or carbon fibers that are woven uni-axial or multi-axial depending on the amount of hoop and axial strength needed.
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Website: www.fineoilcompany.com
Pre-impregnated wet lay-up composites like Aquawrap require no mixing of the cloth just minutes prior to installation. Ready to wrap right out of the bag.
Field impregnated wet lay-up composites require cloth to be mixed just minutes prior to installation.
Pre-impregnated systems mix “polyurethane resin” into an e-glass or carbon fiber cloth at the factory. This ensures the resin is properly mixed in a temperature controlled environment by the manufacturer. This enables the wrap to be applied right out-of-the bag on the job site. However, you must spray water on the wrap when applying it to the pipe. Directly after applying the polyurethane wrap, apply three layers of blue plastic wrap and then perforate it to allow excess water to drain. Aquawrap has been removed from the pipe after it cured and no water has been found underneath the wrap. Alternatively, mixing epoxy resin into a cloth just minutes prior to field installation raises concerns about whether enough epoxy resin was applied and did the resin cure too quickly because of warm outside temperatures.
Field-impregnated systems mix “epoxy resin” into an e-glass or carbon fiber cloth just minutes before installation. (e.g. Armor Plate, Diamond Wrap, IWRAP) This system usually comes in one size, 12” wide, and takes much longer to install due to the mixing of resin and it has to be circumferentially wrapped. Also, epoxy resin doesn’t have as much long term strength as the polyurethane resin used in Aquawrap. These systems cost more than Aquawrap’s too.
Both systems cure as one solid mass leaving “no crevices” unlike layered systems. (AKA: “Monolithic”) Layered systems have suffered from crevices, which allow air and water to channel back to the anomaly and cause further corrosion underneath the wrap. Wet lay-up systems are easily applied on non-straight geometries unlike layered systems. (e.g. Tees, elbows, bends, welds and all odd shape lines)
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Website: www.fineoilcompany.com
Aquawrap requires no mixing of cloth, just start wrapping
Field impregnated requires clothto be mixed just before install
Comparison of the two types of wet lay-up composite
systems:
The Layered Composite System• Pre-cured in factory and very rigid• Ends must be butted flush against one another• Limited to repairing straight pipes because its
rigidness makes it difficult to confirm to odd shape lines • Not typically used for underwater application • Only comes in one size 12” wide and requires 8 layers • Takes much longer to install than wet lay-up systems
because resin must be applied on all 8 layers. Backfill hours later
• Must be circumferentially wrapped instead of spiral • Much tougher to install in crowded areas due to cinch bar• 8 layers cure with crevices and not as one solid layer
(e.g. Clock Spring and Wrapmaster)
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Website: www.fineoilcompany.com
Elbow repaired with Aquawrap.Spiral wrapped, no butting of ends.Installed very quickly and full coverage
Elbow repaired with layered systems. Limited coverage
Layered composite repair system best for straight pipe
Layered composite requires hammer and cinch bar. Extensive time required to install
ExxonMobil 8” line underwater that was hit by an anchor in the Caribbean Sea, causing a dent gouge
ExxonMobil 8” line was repaired using Aquawrap in 2006
BP’s offshore platform had heat exchanger repaired using Aquawrap in 2009
Chevron offshore platform in 2009 was repaired using Aquawrap
Offshore composite repairs successfully completed using Aquawrap
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Website: www.fineoilcompany.com
What kind of composite is Aquawrap?
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Website: www.fineoilcompany.com
50% Wall loss under Aquawrap - it was unaffected at 2,740 psi burst pressure test
Aquawrap is a low cost composite system for use in repair and reinforcement of existing mechanical systems, structures and piping. Furnished factory-impregnated with the proprietary polyurethane resin system, it is odorless and non-flammable. Aqua Wrap is ready to apply, right out of the bag and cures by way of a chemical reaction with field-applied water. When cured, it is a very durable, high strength material that is impervious to fuels and most chemicals, like Acetone, Diesel, Ethyl Alcohol, Gasoline, HCL, MEK, and Toluene. It permanently bonds to a wide variety of surfaces such as metals, composites, concrete, plastics, and wood. Aquawrap is a pressure containing composite repair system.
How should I prepare the surface before installing Aquawrap? For steel substrates, we recommend cleaning to at least a NACE II or SSPC-10 level. The better the cleaning and preparation, the better the wrap will bond/adhere to the pipe. For concrete surfaces, above and below the water line, all loose debris, coatings, marine growth, etc. must be removed. This can be done with high pressure water blasting or sand blasting. All surfaces need to be wiped clean prior to installation of any composite system.
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Website: www.fineoilcompany.com
Step 1:Sand blast or clean & abrade pipe surface per pipeline operator requirements to achieve bare metal. Do not wrap over old coating or rust because it might not be bonded well enough to the pipe so pressure can be transferred to Aquawrap. Make sure surface is a little rough to ensure a good anchor pattern.
Step 2: Fill voids by mixing white & black epoxies for 30 seconds or until grey, then fill voids completely so pressure can be transferred to Aquawrap. Will cure (tacky) in 3 minutes either above or below water.
Step 3: Primer area being wrapped and over grey filler in the voids too, by mixing yellow and blue epoxies for 60 seconds or until green, then pour and roll/brush onto pipe surface being wrapped. Allow 3 minutes to setup before wrapping Aquawrap over it. Don’t use this primer underwater.
Aquawrap’s Installation Process
Step 4: When applying Aquawrap to the pipe, constantly spray water on it. The number of layers will be determined by our calculator that is based on ASME PCC-2. Calculation are made by the manufacturer or the pipeline company, not by field installers. Above is circumferential wrap technique being used instead of spiral. Smooth each layer with your hands to ensure no wrinkles. Aquawrap comes in two thicknesses: 11 mills (G0-3) and 27 mills (G0-5). G0-3 does not require much smoothing but G0-5 needs to be feathered out, using your hands, from the middle to the outside as each layer is applied.
Step 5: Immediately after applying Aquawrap, wrap three layers of blue plastic wrap over it tightly, and perforate it so excess water will drain out. Aquawrap will soak up water needed to cure and displace the excess water. 45 minutes later remove blue plastic then back fill. If you reduced pressure because of defect then don’t pressure pipe back up for 24 hours because Aquawrap’s full cure takes that long. If above ground, then top-coat with UV resistant coating. Aquawrap has been cut open months later after curing, and no water or corrosion has been found underneath the wrap.
Aquawrap’s Installation Process
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Website: www.fineoilcompany.com
Does temperature have a significant effect on Aquawrap’s cure time?
Only in extreme temperatures such as, below 32 F (Unless using heating lamp in ditch) or above 288 F will effect Aquawrap’s curing time. It is important to note that epoxy resin wraps are very temperature sensitive, especially in warmer temperatures. Too much heat and epoxy systems will cure before being applied to the pipeline. Temperature has less of an effect on Aquawrap’spolyurethane resin system than the epoxy field mixed composite systems; however, they all have an upper and lower limit.
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Website: www.fineoilcompany.com
Aquawrap 45 minutes after install, now one solid layer with no crevices and ready to backfill. Metal bands placed around the ends so it will be pig detectable.
How long does it take Aquawrap to cure?
In most conditions, Aquawrap will cure in about one hour. This is cured to a point where the material is dry to the touch and then you can backfill. The wrap will "full properties" cure in 24 hours or less.
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Website: www.fineoilcompany.com
Immediately after wrapping the pipe, wrap three layers of blue plastic wrap and perforateit so excess water will drain out. Aquawrap will soak up water needed to cure for 45 minutes and displace the excess water.
Aquawrap 45 minutes after install, now one solid layer with no crevices.
Aquawrap Features: • Conforms to all shapes of pipe, clamps, sleeves, valves, welds• Versatile because it adheres well to both dry and wet surfaces• Easily installed underwater-fresh & salt, and in splash zone areas• Adheres well to metal, steel, concrete, wood, other composites• Contains pressures of any given liquid or gas pipeline system• Wrap in spiral direction- only 1” overlay, don’t have to butt ends• In-service repair, don’t have to lower line pressure, no hot work required • Cures as one solid layer, leaves no crevices• 50 year life, mechanically stronger than epoxy systems • Backfill in one hour after install• Wrap supplied in different widths and lengths
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Website: www.fineoilcompany.com
Aquawrap being spiral wrapped, 1” overlay,
takes little time to install. Don’t have to butt
ends of each layer. Backfill in one hour after
install.
Aquawrap is ready to apply right out of the
bag because cloth is already mixed with
polyurethane resin.
T-section of pipe no
trouble for Aquawrap
Aquawrap’s extensive engineering testing proves the following :
• Cures as one solid layer without crevices on the end sections of the repair. Thus, eliminates possible channeling of oxygen and moisture through crevices back to the anomaly. It won’t create a corrosion cell.
• It works well in salt or alkaline water and easily applied underwater and in splash zone areas.
• Non reactive to the general chemicals found around a pipeline:
Acetone, Diesel, Ethyl Alcohol, Gasoline, HCL, MEK, Toluene.
• Burst test proves its pressure containing capabilities for the MAOP of any given liquid or gas pipeline system.
• Cycle tested to prove it can handle millions of cycles.
• Creep rupture testing shows it has a life expectancy of 50 years.
• Aquawrap is a wet lay-up composite system impregnated with polyurethane resin compared to other wet lay-up systems impregnated with epoxy resin. Polyurethane resins have more long-term mechanical strength than epoxy resins, which become brittle over time.
Disadvantages: Don't install when outside temperatures are below freezing 32 F unless using a heating lamp in the ditch. Can't be applied over active leak until the leaking hole is plugged, which is fairly easy to do.
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Website: www.fineoilcompany.com
Column in Splash
Zone
Aquawrap applied
Aquawrap works well
in fresh & salt water
areas
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Website: www.fineoilcompany.com
Long section of pipeline in crowded area was easily repaired using Aquawrapbecause no cinch bar or hammer was needed. Also, repair was made in a few hours time using several 60 foot long rolls.
Aquawrap’s Advantages:
Unlike layered-composite systems, wet lay-up composite systems
like Aquawrap conform well to all shapes of pipelines
both onshore and offshore: Tees, elbows, bends, flanges, welds,
over sleeves & clamps. It is easily applied in the splash zone and
underwater.
Each layer of Aquawrap, also known as each ply, can be quickly
applied down the pipeline using only 1” or more overlay and still
cure as one solid layer, unlike the rigid layer or field impregnated
composite systems. Rigid composites cure with crevices that have
in some cases allowed oxygen and moisture to enter/channel
between layered composite systems layers allowing further
corrosion of the anomaly to continue underneath the wrap.
Aquawrap is supplied in many different widths and lengths, unlike
layered composite systems and the other wet lay-up systems that
are only supplied in one or two sizes, which eliminates waste of
purchased materials and allows for faster repairs.
Aquawrap has been used since 1991, has great long-term
strength, easiest and fastest to install than other composites and
cost less. It received a very positive evaluation by Dr. John Kiefner
in 2006 and underwent ASME’s PCC-2 testing criteria and
compliant per CFR 192 & 195.
2" Wide x 5-feet • 2" Wide x 12-feet 3" Wide x 10-feet • 3" Wide x 30-feet 4" Wide x 15-feet • 4" Wide x 30-feet • 4" Wide x 50-feet 6" Wide x 15-feet • 6" Wide x 30-feet • 6" Wide x 60-feet • 6" Wide x 90-feet 10" Wide x 30-feet • 10" Wide x 60-feet • 10" Wide x 90-feet 10" Wide x 120-feet 10" Wide x 150-feet12" Wide x 30-feet • 12" Wide x 60-feet • 12" Wide x 90-feet 12" Wide x 120-feet 12" Wide x 150-feet
Aquawrap
Temperature 33 F to 288 F
Working Time 30 minutes nominal, after water application
Cure Time 60 minutes nominal, after water application
Adhesion 1,000 psi (lap shear) to abraded carbon steel, using primer
Tensile Strength 54,000 psi for G-03 Fabric/694 lbs/per ply/per inch of width
123,000 psi C-14 Fabric/3,320 lbs/per ply/per inch of width
Compressive Strength 28,500 psi
Interlaminar Shear 2,900 psi
Chemical Resistant to acetone, MEK, toluene, gasoline, ethyl alcohol and
many others.
Aquawrap Sizes and Specifications:
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Website: www.fineoilcompany.com