Loctite® Composite Repair System – Pipe Repair Introduction, training overview and target
Bernd Hammer; Dec 3-4, 2014
Workshop Introduction: Loctite® Composite Repair System 2 2
1. Workshop Agenda
2. Introduction of Composite Repair System – Pipe Repair -
3. Product Management Information
4. Technical data
5. Approval, calculation tool and applicator certification
6. Marketing support material: Illustrations, brochure, video and article
7. Training overview and target
8. Basic skills, experience and validity of qualification (installer and supervisor)
9. Benefits of Composite Repair System (general & Loctite system)
10.References and application areas
Table of Contents
Workshop Introduction: Loctite® Composite Repair System 3 3
Wednesday , Dec 3 at Xiang Mao
Composite Repair System – Pipe Repair - 1. Workshop Agenda
Time Description Who
09:00 Theory
- Introduction, training overview
and target, market & marketing
Bernd
10:00
10:30
Theory
- Definition, H&S, tool and products to be used
Communication break
Ged
All
10:45 Theory
- Repair process (A & B Repair)
Ged
11:45 Practical session 1
- Surface preparation (Demonstration Sample)
- Type A : Rebuilding surface
Ged/Tom
12:30 Lunch All
13:15 Practical session 2
- Type A & B : Reinforcement
Tom/Ged
14:45 Communication break All
15:00 Theory
- Repair process components
Ged
15:30 Practical session 3
- Reinforcement of components
Ged
16:30 Communication break All
16:45 Meeting room
- Debriefing: Type A & B
Ged
17:15 Finish of Day 1 All
Workshop Introduction: Loctite® Composite Repair System 4 4
Thursday , Dec 4 at Xiang Mao
Composite Repair System – Pipe Repair - 1. Workshop Agenda
Time Description Who
09:00 Meeting room
- Recap and questions from Day 1
Ged/All
09:30
10:30
Practical session 4
- Demonstration Sample Preparation
Communication break
Tom/Ged
All
10:45 Theory
- Supervisor responsibilities including
Calculation Tool & quality control
– inspection method
Ged
11:45 Practical session 5
- Protect repair area
(Top Coat application Demonstration Piece)
Ged/Tom
12:45 Lunch All
13:30 Exam
- Theory
All
14:00 Communication break &
End of pipe certification workshop
All
14:10 Next action steps Bernd
14:30 Market roll out & business John
15:00 Finish of training All
Workshop Introduction: Loctite® Composite Repair System 5
Composite Repair System: Pipe Repair 2. Introduction
“The Composite Repair System, Pipe Repair ” is
a repair system developed according the ISO
Standard 24817 ( = Petrochemical and natural
gas industries – composite repair for pipe work)
The pipe repair system consists of a 2 C Epoxy
and reinforcement fibre
The application will be carried out on the
“outside of pipes” in case of corrosion and
through - wall defects
It can be used on pipes and pressure equipment
in power plants, waster water plants and
refineries & petrochemical plants
Workshop Introduction: Loctite® Composite Repair System 6
Composite Repair System: Pipe Repair 2. Introduction
The “Composite Repair System” consists of:
2 Component Epoxy
Fibre (mixed with glass & carbon)
+ =
In addition a top coat with:
Loctite 7255 Sprayable Ceramic Grey
(As UV and fire retardant coating; Protective
coat against outside exposure)
= >
Workshop Introduction: Loctite® Composite Repair System 7
Composite Repair System: Pipe Repair 2. Introduction
Industries where no standard is required: Power plant and waste water
Petroleum, petrochemical and natural gas industry: It is only possible to
carry out a pipe repair with an approved repair solution
Different state of pipes: Corroded pipes and pipes with through – wall
defects
According to the defect and application area, different repair methods are
possible and different classes are required:
The repair method:
• Repair of corroded
pipes
• Repair of through
wall defects
Workshop Introduction: Loctite® Composite Repair System 8
ISO global (2006) DIN CEN ISO/TS European (2011)
(European & German harmonization) (Compliance to ASME PCC -2)
Composite Repair System: Pipe Repair 2. Introduction: The ISO / TS Standard
Workshop Introduction: Loctite® Composite Repair System 9 9
Composite Repair system is available under the following grade codes
A) Loctite 7210 = Epoxy (A&B) + Spatulas Single pack size of resin: 1kg Qty. per carton: 6 x 1kg of resin + 6 spatulas
B) Loctite 5085 = Reinforcement Fiber
1 roll á 30m (120mm in width) packed in a single carton
Composite Repair System: Pipe Repair 3. Product management information
Workshop Introduction: Loctite® Composite Repair System 10 10
A) Loctite 7210 (Epoxy + Spatula)
B) Loctite 5085 (Fiber)
NOTE:
Both epoxy and fiber are available as separate items
this is to keep flexibility for additional business
Composite Repair System: Pipe Repair 3. Product management information
Product Pack Size Language
version
Language IDH MOQ
(CON)
Loctite® 7210 1kg EDFN UK, DE, FR, NL 1634917 1kg KIT A&B
EPIG ES, PT, IT, GR 1638401 1kg KIT A&B
SFDN SE, FI, DA, NO 1638421 1kg KIT A&B
Loctite® 5085 1 Roll á 30m EN EN 1647020 1 Roll á 30m 1
6*
Workshop Introduction: Loctite® Composite Repair System 11
Loctite® Composite Repair System – Pipe Repair 4. Technical Data
Product 7210 5085 3478 7255 7515
Type 2C Epoxy Glass-Carbon
Fiber Tape 2C Epoxy 2C Epoxy
Corrosion
Inhibitor
Colour Beige Grey Grey Green / Grey Brown
Viscosity 33 Pa.s
(Plate-plate at 40 sec-1,
@25°C)
n/a Putty
5 Pa.s (Brookfield @25°C,
spindle 7, speed 100
rpm)
Liquid
Mix Ratio by
weight 100 : 16 n/a 100 : 21 100 : 50 n/a
Mix Ratio by
volume 3,125 : 1 n/a 4 : 1 2 : 1 n/a
Shelf Life 18 Months 120 Months 24 Months 18 Months 12 Months
Pot Life
(at 25°C) 35 - 40 Minutes n/a 20 Minutes 40 Minutes n/a
Package Size 1 KG 1 roll á 30 M 453 G / 3,5 KG 900 ML / 30 KG 5 L / 20 L
Workshop Introduction: Loctite® Composite Repair System 12
ISO/TS 24817 certified by Germanischer Lloyd:
Loctite ® Composite Repair System – Pipe Repair
Calculation Tool
Certified training of applicators
Composite Repair System: Pipe Repair 4. Approval, calculation tool and applicator certification
Merge of GL & DNV in 2013:
New approval with GL & DNV Logo will follow
Workshop Introduction: Loctite® Composite Repair System 13
• Loctite Composite Repair System for reduced wall-thickness („Defect Type A“)
Loctite® Composite Repair System – Pipe Repair Certificate: Defect type - Reduced Wall thickness
Workshop Introduction: Loctite® Composite Repair System 14
• Loctite Composite Repair System for through-wall defects („Defect Type B“)
Loctite® Composite Repair System – Pipe Repair Certificate: Defect type - Through-wall
Workshop Introduction: Loctite® Composite Repair System 15
• Loctite Composite Repair System for Straight pipes and complex geometries
Flanges, T-Pieces, Reducers and Bends
Loctite® Composite Repair System – Pipe Repair Certificate: Geometry – Pipe Components
Workshop Introduction: Loctite® Composite Repair System 16
• Loctite Composite Repair System for Vessels, tanks and
pipes of large diameter (>600 mm)
Loctite® Composite Repair System – Pipe Repair Certificate: Geometry – Vessels and tanks
D> 600 mm
Workshop Introduction: Loctite® Composite Repair System 17
Composite Repair System: Pipe Repair 5. Approval, calculation tool and applicator certification
Full approval we will achieve with:
Qualified repair solution (ISO 24817 A or A&B)
Handing out to our customer in petrochemical industry
Calculation tool (approved from GL)
To calculate how to carry out the repair in dependence of many parameter
In order to have a documentation of the most important characteristic of the
repair
Applicator Training
Repair method should only be carried out from experienced applicator
That applicator still need to be trained in theory and practical part (e.g.
application method of repair)
Training according the standard ISO 24817 – Trainer to be certified from GL
Workshop Introduction: Loctite® Composite Repair System 18
Roll out plan 2013 2014
Q2 Q3 Q4 Q1 Q2 Q3 Q4
GL Certification – A
GL Certification – B
A & B Approval
• B approval in place
(through wall defects)
• Patch Method
• Certified calculation tool
A Approval
• Full A approval in place
(corrosion
• Components approval
Completion of
approval (2014)
• Scale up 5 mm
• Surface preparation
• Additional substrates
(stainless steel)
• Improve impregnation
Composite Repair System: Pipe Repair 5. Approval, calculation tool and applicator certification
Workshop Introduction: Loctite® Composite Repair System 19
Current situation:
• Full A approval achieved (Q1 – 2013)
• Approval for complex geometries: Bends – T-joints – etc (Q4-2013)
• B approval in place (Q1-2014)
• NEW: Tank & pressure vessel approval – Patch method (Q2-2014)
• NEW: Merge of GL & DNV
• NEW: Calculation tool: Certified by GL & DNV (Q2-2014)
• Transferring approval (acceptance): Lloyd`s Register & TÜV
Approval available Currently approaching:
Composite Repair System: Pipe Repair 5. Approval, calculation tool and applicator certification
Workshop Introduction: Loctite® Composite Repair System 20
Calculation tool:
Calculation of number of wraps
and length of repair
Repair is depending on many
parameters like repair class, kind
of defect, repair lifetime or
system to repair
Calculation tool will be certified
from GL
Composite Repair System: Pipe Repair 5. Approval, calculation tool and applicator certification
Workshop Introduction: Loctite® Composite Repair System 21 21
4 Loctite® 7255
Sprayable Ceramic
3 Loctite® 7210 & 5085
Composite Repair
2 Loctite® 3478
Superior Metal
1 Loctite® 7515
Surface Preparation
Repair System:
Composite Repair System – Pipe Repair 6. Marketing Support: Illustration, Flyer & Video
Workshop Introduction: Loctite® Composite Repair System 22 22
Illustrations for two different kind of repairs:
Repair of corroded pipe & pipeline (A = none through wall defect)
Repair of cracks and holes (B = through wall defect)
Corroded pipes Holes and cracks
Composite Repair System – Pipe Repair 6. Marketing Support: Illustration, Flyer & Video
Workshop Introduction: Loctite® Composite Repair System 23 23
Composite Repair System – Pipe Repair 6. Marketing Support: Illustration, Flyer & Video
2 page flyer
Workshop Introduction: Loctite® Composite Repair System 24
Two detailed technical video; One for A and one for B Approval –
(Corrosion & Through wall defects)
Composite Repair System – Pipe Repair 6. Marketing Support: Illustration, Flyer & Video
Workshop Introduction: Loctite® Composite Repair System 25 25
Composite Repair System – Pipe Repair 6. Marketing Support: Customer Presentation
• 34 page customer presentation, linked with technical video & pressure testing
• In general used for customer introduction, providing a good overview of the
repair system and technical detail for supervisor, engineers and maintenance
managers
Workshop Introduction: Loctite® Composite Repair System 26 26
http://www.gl-nobledenton.com/en/1336.php
Composite Repair System – Pipe Repair 6. Marketing Support: GL Article (external)
Workshop Introduction: Loctite® Composite Repair System 27 27
Press article available: UK & German version
Composite Repair System – Pipe Repair 6. Marketing Support: Adhesive Technology News
Workshop Introduction: Loctite® Composite Repair System 28 28
http://www.loctite.co.uk/pipe-repair-8890.htm
Composite Repair System – Pipe Repair 6. Marketing Support: Internet site
29
• Display for pipe available to support local activities (exhibition &
customer presentations
• New: Additional 5 pcs large diameter pipe displays
Workshop Introduction: Loctite® Composite Repair System
Composite Repair System – Pipe Repair 6. Displays
Workshop Introduction: Loctite® Composite Repair System 30
Composite Repair System: Pipe Repair 7. Training overview and target
Explain the Henkel Composite repair system It is not just a product, it is a full system
Training to handle Henkel composite repair system
You will have to practice all steps Fulfill requirement for qualification as applicator
According to ISO/TS 24817 Training approved by GL on: Theoretical knowledge & Practical
ability (= Theoretical + practical test) Practical test (according ISO/TS 24817 – annex I §I.4)
On pipes that you will repair (lab. Session) including: - Visual qualification - Pressure test qualification - Instant test pressure up to leakage
Workshop Introduction: Loctite® Composite Repair System 31
Composite Repair System: Pipe Repair 8. Basics skills, experience and validity of qualification
Requirements for installer and supervisor ISO/TS 24817 Annex I
Basic skills and experience:
Installer shall be minimum 18 years of age
Minimum of two years experience in repair and maintaining with
pipe related system (Polymer Composite experience); Or having
supervised 12 repair applications;
In house & on site training of at least two weeks in duration in sum
Validity of qualification:
Type specific qualification is valid for a period of one year
Requalification is necessary after not having carried out a repair
for longer than one year
Workshop Introduction: Loctite® Composite Repair System 32
Composite Repair System: Pipe Repair 8. Basics skills, experience and validity of qualification
Support & training on site with Henkel MRO Specialists
Surface Engineering Solutions
Henkel certified “applicator training”
Advanced Module:
Composite Repair System
– Pipe Repair –
Requires SES Training
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September 2, 2016 Loctite® Composite Repair System – Pipe Repair 33
Composite Repair System for Pipework 9. Benefits
• No need to replace pipes
• Cost efficient repair method in comparison to
welding
• In situ repair method, avoidance or reduction of plant
shut down time
• „Cold Repair Method“ and no heat required in
comparison to welding (Ex – zone repair method)
• Repair of complex geometries, for example flanges
and bends
• Certified solution: Repair System, Calculation Tool
and Installer Training
• Increase pipe lifetime by up to 20 years
September 2, 2016 Loctite® Composite Repair System – Pipe Repair 34
Application:
•Industry: Refinery / UK
•Process.: Crude oil / buried pipe / 35 bar design
pressure; Class 3
•Kind of repair: A Repair– corroded pipe – 20 years
lifetime extension
•12“ (305 mm) diameter; 4 Layer (7,1 mm
Thickness); 600 mm repair width,
Costs in comparison:
•Welding (material & labor): 13.000 €
•Plant shut down during welding: 2 days / 159.000 €
•Henkel Repair System: 2.500 € (material & labor)
Composite Repair System for Pipework 9. Benefits: Cost comparison
2. September 2016 Loctite Composite Reparatursystem – Rohrreparaturen 35
• Full certified system by GL & DNV: Repair System,
Calculation Tool, Applicator & Supervisor Workshop
• Especially developed System according ISO/TS 24817
• High value & comfortable calculation tool, based on C
programming
• All areas of pipe work: Complex geometries, like
flanges and T – Joints (certified and approved)
• Safe and improved surface preparation and opening of
process window: Loctite 7515 Corrosion Inhibitor
• High elongation @ break of repair system to withstand
all needs of dynamic loads
• Henkel: European & global available product solution
and also support in all regions with our maintenance
specialists in project planning and application
Composite Repair System for Pipework 9. Benefits: Specialties of Loctite System
Workshop Introduction: Loctite® Composite Repair System 36 36
Composite Repair System – Pipe Repair 10. Application Areas & Industries
Refinery &
Petrochemical
Industry
Oil & Gas
Water Utilities
Power Plants:
Hydroelectric
Nuclear
Gas fired
Oil fired
Workshop Introduction: Loctite® Composite Repair System 37 37
Refinery & Petrochemical Industry
Composite Repair System – Pipe Repair 10. Application Areas & Industries
Workshop Introduction: Loctite® Composite Repair System 38
Composite Repair System – Pipe Repair 10. Application Areas & Industries
Refinery & Petrochemical Industry
Workshop Introduction: Loctite® Composite Repair System 39 39
Gas Pipes & Pipelines
Advantage: Repair without plant shut down –
in situ repair
Composite Repair System – Pipe Repair 10. Application Areas & Industries
Workshop Introduction: Loctite® Composite Repair System 40 40
Composite Repair System – Pipe Repair 10. Application Areas & Industries
Water pipes for hydrolectric power plants
Workshop Introduction: Loctite® Composite Repair System 41
Composite Repair System – Pipe Repair 10. Application Areas & Industries
Off Shore Pipe & Pipeline: Processing Hydrocarbons
Workshop Introduction: Loctite® Composite Repair System 42
Composite Repair System – Pipe Repair 10. Application Areas & Industries
Power Plant
Thank you!