Professional Documents
Culture Documents
\
|
=
2
(1)
For axial stresses due to internal pressure, bending and axial thrust the minimum thickness
for a repair laminate, t
min
(m), is given by:
|
.
|
\
|
|
|
.
|
\
|
=
s
a
s
min
P
D
F
E
E
s
D
t
2
2
2
(2)==
==
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=
The design repair thickness shall be the maximum value determined from Equations (1) and
(2).
Where the purpose of the composite repair is to increase the rating of an undamaged
section of pipe the value of P
s
shall be the original MAWP.
Where the purpose of the composite repair is to strengthen an undamaged section of pipe to
carry additional bending or other axial loads the value of F should be taken to be the
increased total axial load requirement and the value of P
s
shall be the original MAWP.
It is recognised that in this design option the amount of load carried by the composite is
modest. It is likely that this design method will be used as part of the assessment of leaking
pipes (in conjunction with Section 9.4).
Use of the MAWP for the steel pipe should ensure that the steel does not exceed yield
during operation or hydrotest so that the assumptions used in the derivation of Equations (1)
and (2) regarding load distribution will remain valid.
For pipelines Equations (3) or (4) should be used. In the derivation of these equations it is
assumed that the underlying substrate does yield and the repair is limited by the design or
allowable strain of the composite. Only hoop loading is considered in determining the
minimum wall thickness of the repair laminate.
For hoop stresses due to internal pressure the minimum thickness for a repair laminate, t
min
(m), is given by:
) t E t E (
D P
t E
t
s
t E
PD
s s min c
live
min c
s
min c
c
+
=
2 2
(3)
If the repair is applied at zero internal pressure, i.e. P
live
= 0, then Equation (3) can be
rearranged to give;
|
.
|
\
|
=
s
c c
min
st
PD
E
t
2
1
(4)
The design repair thickness, t
design
, shall be taken as the value determined from either
Equations (3) or (4).
The assumptions made in deriving Equations (3) and (4) are that the substrate material is
elastic, perfectly plastic, i.e. no strain hardening and that no defect assessment is performed
other than use of the minimum remaining wall thickness (of the substrate) to infer the internal
pressure at the point of substrate yield.
9.2 Design based on composite allowable strains
Use of the design method in this section is appropriate if the contribution of the steel pipe to
is to be ignored in the calculation for load carrying capability and if short term material
properties are to be used.
For hoop stresses due to internal pressure the minimum thickness for a repair laminate, t
min
(m), is given by:
==
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=
|
|
.
|
\
|
=
c c c
min
E D
F
E
PD
t
1
2
1
(5)
For axial stresses due to internal pressure, bending and axial thrust the minimum thickness
for a repair laminate, t
min
(m), is given by:
|
|
.
|
\
|
=
c a a
min
E
PD
E D
F
t
2
1 1
(6)==
Material Type Class 1 Class 2 Class 3
Repair lifetime (years) 2 10 20 2 10 20 2 10 20
For E
a
> 0.5 E
c
For E
a
< 0.5 E
c
- circumferential
- axial
0.40%
0.40%
0.25%
0.32%
0.32%
0.16%
0.25%
0.25%
0.10%
0.35%
0.35%
0.10%
0.30%
0.30%
0.10%
0.25%
0.25%
0.10%
0.30%
0.30%
0.10%
0.27%
0.27%
0.10%
0.25%
0.25%
0.10%
Note: For Class 3 detailed consideration between the owner/user and supplier is required.
Table 4: Allowable strains for composite laminates as a function of repair lifetime
Table 4 is used in the following manner. For example, for a Class 2 repair design lifetime of
8 years with (E
a
< 0.5 E
c
), then the allowable strains are taken from the next highest repair
lifetime, i.e. 10 years, implying the allowable circumferential and axial strains are 0.3% and
0.1% respectively.
The design repair thickness, t
design
, shall be the maximum value determined from Equations
(5) and (6).
For occasional loads, Class 1 minimum repair lifetime (1 year) strains may be used.
Occasional loads are defined as those that occur during short term, rarely occurring events,
typically less than 10 times in the life of the component and each duration less than 30 min.
The data presented in Table 4 for GRP assumes that the strain to failure of the un-reinforced
resin is greater than 2%. For resin systems where the strain to failure is less than 2%
special consideration is required. It is also assumed that the strain to failure of the repair
laminate is at least 4 times that taken from Table 4 and used in design. The strain to failure
can be derived from the test carried out to determine the tensile properties of the laminate
(ISO 527 or equivalent).
Some suppliers may choose to use laminate analysis to calculate modulus values for
laminates built up from a series of different layers. This is satisfactory provided that the
results from the analysis have been fully validated using measured data.
The strains given in Table 4 are typical of those used in the design of composite components
(see for example prEN 13121). The values are based on those required for long term
performance.
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9.3 Design based on repair allowable stresses
determined by performance testing
Use of the design method in this section is appropriate if performance based test data is
available.
Appendix 5 provides three methods for the determination of long term failure stress (or
strain).
If allowance for the pipe is not to be included, then Equation (7) shall be used.
For hoop stresses due to internal pressure the minimum repair laminate thickness, t
min
, is
given by:
|
|
.
|
\
|
=
lt perf
min
s f
PD
t
.
1
2
(7)
For axial stresses due to internal pressure, bending and axial thrust the minimum repair
laminate thickness, t
min
, is given by Equation (2) or (6) as appropriate.
The design repair laminate thickness, t
design
, shall be the greater of the values determined.
If allowance for the pipe is to be included, then Equation (8) shall be used.
For hoop stresses due to internal pressure the design repair laminate thickness, t
design
, is
given by:
( )
|
|
.
|
\
|
=
lt perf
s design
s . f
s t
PD
t
1
2
(8)
The service factor f
perf
is obtained from Table 5.
Test Data Class 1 Class 2 Class 3
Repair lifetime (years) 2 10 20 2 10 20 2 10 20
1000 hour data
Design life data
0.83
1
0.65
0.83
0.5
0.67
0.67
0.83
0.58
0.75
0.5
0.67
0.6
0.75
0.55
0.71
0.5
0.67
Note: For Class 3 detailed consideration between the owner/user and supplier is required.
Table 5: Service factor, f
perf
, for performance data of repair systems
The basis behind the performance bases design method is that established for GRP pipe
work systems. ISO 14692 provides further information. The 1000 hr duration for survival
testing has been selected, as at this time modes of failure tend to be more typical of those
over long time periods.
==
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9.4 Additional requirements for leaking pipes
Use of the design method in this section is appropriate if the pipe is leaking or deemed to be
leaking at the end of its life. The requirements of this section are in addition to those
described in Sections 9.1, 9.2 or 9.3.
A pipe shall be considered to be leaking if the wall thickness at any point of the affected area
is determined to be less than 1 mm at the end of its life.
For a circular or near circular defect the minimum thickness for a repair laminate, t
min
(m), is
calculated using:
+
)
`
=
2 4
3
2
2
64
3 1
512
3 1
d
Gt
d d
t E
) (
f f P
min min
leak T
(9)
Where the design incorporates a plug to allow the repair of a live line the procedure
described in this section should still be used. The tests carried out to determine the value of
(Appendix 4) should be conducted on the whole assembly including any plug arrangement.
Equation (9) is valid for defect sizes Dt d 6 (AEAT - 75484).
As the defect becomes large curvature of the pipe wall becomes important.
For non-circular defects that have an aspect ratio < 5 Equation (9) should be used where the
value of d (effective defect diameter) is selected such that it contains the defect.
For non-circular defects that have an aspect ratio > 5 Equation (10), (11) or Equation (12)
should be used where the value of W (effective slot width) is selected appropriate to the
aspect ratio.
For a circumferential slot type defect, where the axial width of the slot, W (m), satisfies;
min
Dt . W 65 1 , the minimum thickness for a repair laminate, t
min
(m), is calculated using;
+
|
.
|
\
|
+
+
)
`
=
2 4
3
2
2
1
2 5
4
16
3
4 24
1 1
W
) ( Gt
W W
t E
) (
f f P
min min
leak T
(10)
For a circumferential slot type defect, where the width of the slot, W (m), satisfies;
min
Dt . W 65 1 > , the minimum thickness for a repair laminate, t
min
(m), is calculated using;
==
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=
min
leak T
Et
D
f f
P 8
2
= (11)
For an axial slot type defect, where the circumferential width of the slot, W=D/2 (m), the
minimum thickness for a repair laminate, t
min
(m), is calculated using;
(
(
(
+
+ +
=
6
3
4
4
3
4 2
2
11520
2
4
384 8
1
min min
c
leak T
t
)
G
E
( D
t
D D
E
) (
f f P (12)
The value of the service factor, f
leak
, shall be set to;
) t ( .
leak
* . f
1 016 0
10 666 0
=
where t is the specified design lifetime in years.
Where long term performance test data is available according to Appendix 7, then the
service factor , f
leak
, shall be set to;
f leak
D f 666 . 0 =
The design repair thickness, t
design
, shall be the maximum value of the minimum repair
thickness determined from Equation (9), (10), (11) or (12) and the design repair thickness
derived in either Sections 9.1, 9.2 or 9.3.
Further information on the design method given in this section may be obtained from R
Mableson et al, Refurbishment of Steel Tubulars using Composite Materials, Rehabilitation
of Piping and Infrastructure Conf, University of Newcastle, 1999.
Where the repair laminate is anisotropic, i.e. the properties of the material are different in the
axial and circumferential directions, the value of E and
2
in Equations (9) to (12) should be
taken as (E
a
.E
c
)
0.5
and (
ac
.
ca
) respectively.
For very small defects such that d<<t
min
the bending contribution to the deformation of the
repair laminate becomes insignificant and the second term in the denominators of Equations
(9) to (12) can be ignored. Under these conditions Equations (9) to (12) simplify to:
d
E
f f P
leak T
) 1 (
2
2
=
and
W
E
f f P
leak T
4
) 1 (
2
2
=
respectively.
As the axial extent or size of the defect increases the response of the repair laminate will
change from that for a plate or beam under transverse loading to that for a cylindrical shell
under membrane loading. The latter circumstance is represented by Equation (11). For
large defects the response of the repair laminate becomes independent of defect size.
==
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9.5 Axial extent of repair
The design thickness of the repair laminate shall extend beyond the damaged region in the
pipe by the larger of 0.05 m or L
over
(m), where L
over
is given by;
For slot type defects Dt L
over
2 = (13)
For circular type defects Dt . d d L
over
5 0 4 < = where (14)
If the equality in Equation (14) is not satisfied then Equation (13) shall be used. Appendix 8
presents a look-up table of axial extent of repair as a function of both diameter and defect
size.
The total axial length of the repair, L (m), is given by,
taper defect over
L L L L 2 2 + + = (15)
Care shall be taken to ensure that the discontinuity in thickness at the edge of the repair is
designed such that the local stresses in this region are minimised. This is especially the
case where the stress in the steel is allowed to exceed its allowable in the repair section,
(Section 9.1). A minimum taper of at least 5:1 is recommended.
A check on the axial extent of the repair is required to ensure that the applied axial load can
be transferred from the substrate to the repair. Equation (16) describes this check or
inequality, which must be satisfied.
repair a a
over
t E
L > (16)
For most repair systems where the short-term strain to failure of the repair laminate is
greater than 1% then Equation (16) is generally satisfied. The concern primarily is with very
stiff, low strain to failure repair systems.
Where the geometry of the section to be repaired is such that it is not possible to achieve the
required axial extent of overlay, L
over
, this shall be considered as follows.
To account for the limited axial extent (i.e. less than 0.05 m) of available substrate (L
available
)
the design repair thickness, t
design
, determined from Sections 9.1, 9.2, 9.3 or 9.4 shall be
increased by the repair thickness increase factor, f
th,overlay
, defined as;
min overlay , th design
/
available
over
overlay , th
t f t
L
L
f =
|
|
.
|
\
|
= implying
3 2
(17)
A detailed engineering stress analysis of the adhesive layer demonstrating that the axial load
can be transmitted between the repair and the substrate shall be performed. The analysis
shall demonstrate that the average principal stress is less than 3 times the average principal
stress value from lap shear test data (BS EN 1465).
==
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The minimum axial extent of available overlay length that repairs can be applied to is defined
as either L
available
shall be at least 0.025 m or f
th,overlay
shall be no greater than 2.5.
When there is limited axial extent of available substrate it will not be possible to taper the
repair laminate. For this case the transition between the repair laminate and the restraining
substrate, e.g. flange face, should be a smooth as possible to minimise stress
concentrations.
The total axial extent of the repair for reduced axial extent is therefore;
2 1 , available , available defect
available taper defect over
L L L L
L L L L L
+ + =
+ + + =
extent, axial reduced sided two For
extent, axial reduced side one For
(18)
where the larger of the two values of f
th,overlay
is taken to determine the design thickness of
the repair, Equation (18).
==
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=
10. ELEVATED TEMPERATURES
The maximum service temperature within the scope of this document is 100
o
C. Higher
service temperatures may be considered but will require appropriate qualification testing at
this elevated temperature.
For service temperatures greater than 40
o
C individual laminate systems shall not be used at
temperatures higher than the glass transition (T
g
) less 30
o
C in the case of epoxies or higher
than the heat distortion temperature (HDT) less 20
o
C in the case of polyesters and vinyl
esters. For resin systems which do not exhibit a clear transition point, i.e. a significant
reduction in mechanical properties at elevated temperatures, e.g. polyurethane, then a upper
temperature limit, T
m
, shall be defined (or quoted by the repair supplier). For polyurethane a
default upper temperature limit of 70
o
C is recommended.
For repairs where the pipe is not leaking or the repair has a design lifetime of less than 2
years the temperature limit can be relaxed to T
g
less 20
o
C or HDT less 15
o
C. T
g
or HDT
shall be measured in accordance with ISO 113572 or ISO 75 (or equivalent) respectively.
Table 6 summarises the upper temperature limit of the repair.
Substrate Leaking
T
m
Substrate not Leaking
T
m
T
g
measured T
g
30
o
C T
g
20
o
C
HDT measured HDT-20
o
C HDT-15
o
C
Table 6: Service Temperature Limits for Repair Systems
For service temperatures less than 40
o
C adequate cure of the repair laminate should be
demonstrated by Barcol hardness values measured in accordance with BS EN 59 or Shore
hardness in accordance with ISO 868. Measured values should be no less than the
minimum obtained from qualification laminates.
For service temperatures less than 40
o
C no acceptance criteria linked to T
g
or HDT are
stipulated. This is to ensure that repairs do not require elevated temperature post cures,
which experience has demonstrated are not necessary. Adequate resin cure is ensured
through the Barcol or Shore hardness testing.
In principle T
g
measurements can be taken from any representative sample of material, but
the values obtained are sensitive to the extent of cure the material has experienced. For
these reasons the laminate used should be of similar thickness to repair material and have
been laid up using the same procedures and under the same conditions as would be present
during site application.
For service temperatures greater than 40
o
C the allowable strains to be used in Equations (5)
and (6), and the service factors to be used in Equations (7), (8), (9) and (10) shall be down-
rated by the factors given in Table 7. In Table 7 T
d
is the design temperature and T
m
is the
upper temperature limit for the system (HDT - 20
o
C, T
g
-30
o
C or T
g
-20
o
C as appropriate).
Factors for intermediate temperatures may be obtained by interpolation.
==
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=
Temperature (
o
C) Temperature Factor,
f
T1
T
d
= T
m
0.70
T
d
= T
m
- 20 0.75
T
d
= T
m
- 40 0.85
T
d
= T
m
- 50 0.90
T
d
= T
m
- 60 1.00
Table 7: Composite allowable strain service factors for elevated temperatures
Thermal expansion coefficients for composites are different than those for steel so thermal
stresses will be generated where operating temperatures vary from installation. Where this
absolute temperature change is greater than 40
o
C the effect of differential thermal expansion
between the composite and the steel shall be considered in the design assessment. This
shall be done by subtracting the thermally induced strains from the allowable strains in Table
4. The temperature factors listed in Table 7 should be applied to the allowable strain in
Table 4 before subtraction of the thermally induced strains. The thermal strains shall be
calculated by:
( )
) (
0 1
0 1
a s a T a
c s c T c
T f
T f
=
=
(19)
where
c0
and
a0
are from Table 5.
The additional requirements for leaking repairs are qualified through testing. To allow for
designs at higher temperatures than the qualification test temperature Table 8 defines the
temperature de-rating factor, f
T2
, that shall be applied to Equations (9), (10), (11) and (12).
Temperature (
o
C) Temperature Factor,
f
T2
T
d
- (T
test
-T
amb
) = T
m
0.70
T
d
- (T
test
-T
amb
) = T
m
- 20 0.75
T
d
- (T
test
-T
amb
) = T
m
- 40 0.85
T
d
- (T
test
-T
amb
) = T
m
- 50 0.90
T
d
- (T
test
-T
amb
) = T
m
- 60 1.00
Table 8: Additional requirements for leaking repairs temperature de-rating factor
Transients causing temperature excursions shall be considered in design if they are
considered to be a frequent occurrence, although composites are noted for their capacity to
absorb thermal shocks of short duration.
Factors for elevated temperatures were derived from prEN 13121.
==
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=
11. MINIMUM BOND STRENGTH
The achievement of a minimum bond strength shall be demonstrated for all repair laminate
combinations. This is a requirement regardless of whether or not the steel pipe is (or will be)
leaking. The minimum average lap shear strength of the bonded connection shall be 5 MPa
for carbon steel and other metal substrates when tested in accordance with BS EN 1465 or
similar test method.
Alternatively, it shall be demonstrated that the adhesive bond is stronger than the shear
strength of the composite material by assessing the surface of the steel used in a lap shear
specimen after testing. The presence of remaining composite laminate over at least 30% of
the bonded surface of the steel shall be evidence of a satisfactory bond.
Where evidence of long term durability on the bond between the composite and steel is
required (see Table 3) and performance based testing has not been carried out to provide
data for design (see Section 9) water immersion tests shall be carried out. Lap shear
specimens shall be immersed in water at the service temperature for 1000 hrs after which
the residual lap shear strength shall be at least 30% of the unaged values.
Lap shear tests shall be carried out on the steel/surface preparation/composite combination
to be used in service.
It shall be ensured that any chemical interaction between the composite and steel will not
cause further degradation in the surface of the steel. Consideration may need to be given to
the effects of the resin systems and their associated curing agents. Particular attention may
need to be given to CFRP laminates and the potential for galvanic corrosion.
The objectives of the tests in this section are not to produce data for use in design. The
intent is to demonstrate that bonds can be achieved of adequate strength and durability with
the selected materials and surface preparation methods. It should be noted that short term
strength measurements are not necessarily a good indicator of long term performance.
The ASME standard PCC-2 requires a minimum bond strength of 4 MPa.
==
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=
12. OPTIONAL DESIGN CONSIDERATIONS
12.1 Impact
The supplier shall demonstrate that the repair is capable of withstanding a low velocity 5
Joule impact representative of a dropped tool. Tests should be carried out in accordance
with the procedure described in Appendix 6.
12.2 Cyclic loading
Cyclic loading is not necessarily limited to internal pressure loads. Thermal and other cyclic
loads should also be considered when assessing cyclic severity.
If the predicted number of pressure or other loading cycles is less than 7000 over the design
life, then cyclic loading does not require consideration (ISO 14692).
If the predicted number of pressure or other loading cycles exceeds 7000 over the design life
then cyclic loading should be considered.
If the predicted number of pressure or other loading cycles exceeds 10
8
over the design life
then if the following Equations (20) and (21) N should be set to 10
8
.
For Sections 9.1 and 9.2, the composite allowable strain in both circumferential and axial
directions,
c
and
a
, (Table 4), shall be de-rated by the factor, f
c
, where f
c
is given by;
|
|
.
|
\
|
+ = ) 1 (
108 . 7 ) Log( 888 . 2
1
2 2
c c c
R
N
R f (20)
For Section 9.4, the service factor, f
leak
, in Equations (9), (10), (11) or (12) shall be replaced
by;
|
|
.
|
\
|
+ = ) 1 (
108 . 7 ) Log( 888 . 2
1
333 . 0
2 2
c c leak
R
N
R f (21)
These equations are intended for cyclic internal pressure loading only, but may be applied
with caution to axial loads provided they remain tensile, i.e. the equations are not applicable
for reversible loading.
12.3 Live repairs
When repairs are applied to pipe systems under live conditions then the strength and the
fracture toughness of the bond between the composite laminate/steel pipe interface should
be assessed for the specific case during operation when the internal pressure, P
after
, is less
than the internal pressure, P
live
, when the repair was applied, i.e. P
after
< P
live
.
To assess the strength of the bond of the repair interface, the tensile stress acting on the
bond should be compared to the minimum bond strength, defined in Section 11.
==
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=
Denoting the conditions when the repair is applied as
live
and by for conditions after the
application of the repair as
after
, Figure 2 schematically describes the key variables;
D
P
Pipe before
(live)
Pipe - after
t
s
Repair
q tensile pressure on interface
Figure 2: Schematic diagram of live repair situation
where t
s
is the substrate wall thickness (m). The tensile stress, q, acting on the interface is
given by;
D
t E
) T T )( (
) t E t E (
t E
) P P ( q
s s
after live s c
design c s s
s s
after live
2
1 +
|
|
.
|
\
|
+
= (22)
where is the thermal expansion coefficient (defined in Section 10). The value of q should
be compared with the minimum bond strength, Section 11 to confirm that q is less than the
minimum bond strength.
To assess the possibility of delamination of the repair interface the energy release rate, G,
for a delamination of crack length, c, should be assessed and compared to the critical
energy release rate, , (defined in Appendix 4). Figure 3 schematically describes the key
variables;
==
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=
L/2
a
h
q tensile pressure on interface
q c
M
Figure 3: Schematic diagram for energy release rate determination
The energy release rate, G, is given by;
2 2
2
4
2
2
1 12
1 1
2 2 1
1
s
repair steel s s
t D
) (
) EI ( I E )) c L ( cos( )) c L ( exp(
q
G
=
|
|
.
|
\
|
|
|
.
|
\
|
=
+
where
(23)
where L is the axial length of the repair and I is the second moment of area and the subscript
steel+repair
refers to the combined region of the repair laminate the steel substrate.
The value of G should be compared with the critical energy release rate, , (Appendix 4) to
confirm that G is less than i.e. the interface will not delaminate.
12.4 Fire Performance
The requirements for fire performance shall be identified in the risk assessment. Flame
spread and smoke generation shall also be considered in the assessment. Due account
shall be taken of the response of the complete system (original pipe and the repair). In
many cases additional fire protection will not be necessary, as the damaged steel pipe may
still be able to perform satisfactorily during the short duration of a fire event.
Strategies for achieving fire performance include the following:
==
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=
application of additional repair material such that enough basic composite will remain in
tact for the duration of the fire event;
application of intumescent external coatings;
application of intumescent and other energy absorbent materials within the laminate;
use of resin formulations with specific fire retardant properties.
Further guidance on the design and testing of composites for fire performance may be
obtained from ISO14692.
12.5 Gas service
For steel pipe that is not leaking repairs can be carried out as with liquid systems.
For pipe systems that do or are predicted to leak within their lifetimes composite repair
systems will be satisfactory within the operating envelope defined in the scope of this
document.
The approximate permeability of GRP composites is quoted as 1 10
-9
cm
2
/s/bar and this is
equivalent to 100 10
-15
m
3
/s for a repair of 1 cm
2
area, 5 mm thick under 50 bar. Typical
allowable gas leak rates from valve glands are in the region of 50 -100 ft
3
/yr (45 - 90 10
-9
m
3
/s), i.e. very much greater than gas leakage thought typical thickness' of composite
laminates. Explosive decompression is not reported to be a problem at the pressures
considered in this document.
12.6 Environmental Compatibility
The suitability for use of the repair system in the service environment shall be based on the
following considerations. The service environment is the environment that will contact the
repair laminate. It may be either the external or internal environment.
The qualification of the repair system (Section 8.3) will ensure that the repair system is
compatible with aqueous and hydrocarbon environments at the qualification temperature. In
general, thermoset resins are compatible with a wide range of environments but
consideration needs to be given when the environment is strongly acidic (pH<3.5), strongly
alkaline (pH>11) or is a strong solvent, e.g. methanol, toluene in concentration greater than
25%.
When the compatibility of the repair system is unknown then the repair laminate supplier
shall provide the one of the following to demonstrate compatibility;
Environmental compatibility data from the resin supplier, demonstrating that the
environment is no more aggressive than aqueous or hydrocarbon environments at
the design temperature.
If no compatibility data from the resin supplier is available, then specific
environmental testing is required. Results from tests according to one of the following
test procedures, ASTM D543, ASTM C 581, ASTM D 3681, ISO 10952 or equivalent,
comparing the exposure of the specific environment and aqueous environment to the
repair laminate at the design temperature shall be performed. The Repair System
shall be considered compatible to the specific environment if the test results from the
specific environment are no worse than for the aqueous environment.
==
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=
The quoted test standards should be used as a guide on how to age and test aged
composites. The standards may not need to be followed to their exact letter, it is the
guidance within the standard that is important.
The quoted test standards refer to tests on GRP pipes or rings. The repair laminate should
be manufactured into a comparable geometry as described by the relevant test method.
12.7 External Loads
To resist external pressure or vacuum applied to the Repair System, the minimum repair
thickness, t
min
, is given by;
3 1
2
2
1 3
/
c
e
min
E
P ) (
D t
(
(24)
For soil loads, to prevent the collapse of a buried repaired pipeline, the external soil pressure
P
ext,soil
must be less than the collapse resistance of the Repair System, P
c
,
g )
D
h (
D
)
D
h ( D
D
P
D
t
) (
E
P
soil soil , ext
min c
soil , ext
(
(
+ + + =
|
.
|
\
|
<
2
2
3
2
2 3
1
8 2
4
1 3
2
where
(25)
where
2
is defined as (
ca
2
.E
a
/E
c
).
The design repair thickness, t
design
, shall be the maximum value of the minimum repair
thickness determined from Equation (23) or (24) and the design repair thickness derived in
Section 9.
==
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=
13. REPAIR OF OTHER COMPONENTS
The supplier shall demonstrate that the design of repairs to components other than straight
pipework complies with the intent of the design through prototype pressure testing.
Prototype testing is recommended for repairs to other piping system components. Equations
(1) to (12) assume circular geometry, whereas the external surface of the component is likely
to be more complex leading to local variations in stress. Testing will confirm that these
features do not adversely affect the performance of the repair. ASTM D1599 provides
guidance on pressure testing procedures.
13.1 Clamps and other repair systems
Clamps are generally applied over defects much smaller than themselves. However, when a
clamp is repaired it is possible that a poor level of bonding will be achieved. Furthermore, the
clamp will protrude or stand-off from the pipework. Therefore the size of the defect to be
considered for the design of the repair is the axial extent of the clamp plus an extra axial
distance of 3 times the stand-off distance. Under these circumstances Equation (11) is
appropriate.
If perfect bonding can be demonstrated over the clamp surface, the size of the defect to be
considered is limited to a circumferential defect at each end of the clamp of axial extent, 1.5
times the stand-off height. Under these circumstances either Equation (10) or (11) is
appropriate.
The design of composite repair for other repair systems may be carried out using the
procedures given in Section 9 of this document. Unless it can be demonstrated otherwise
the size of the defect to be considered in the design calculations shall be the total area of the
existing repair.
13.2 Piping system components
The following piping system components are considered;
Bends
Tees
Reducers
Flanges
The repair design procedure for each piping system component is a comparative approach
based on the equivalent straight pipe component. The repair design process is to calculate
the thickness of the repair for an equivalent straight pipe section followed by a further
calculation of a multiplicative factor, called the repair thickness increase factor, which
accounts for the stress intensification due to the geometry of the component.
The first step in the design approach, therefore is to calculate the thickness of the repair for
the equivalent pipe section, Section 9, i.e. same diameter and wall thickness, t
design,straightpipe
.
==
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=
The second step is to calculate the repair thickness increase factors based on the stress
intensity factor corresponding to the piping system component, f
th,stress
The design repair thickness for the piping system component is given by the product of the
repair thickness increase factor times the repair thickness for the equivalent straight pipe
section, i.e.;
stress , th e raight pip design, st mponent design, co
f t t = (26)
Table 9 presents repair thickness increase factors for each piping component. They are a
function of the geometry of the component.
AEAT 75484 contains derivations of these factors plus their verification.
Piping system
component
Repair thickness
increase factor,
f
th,stress
Comment
Bend 1.2
Tee
25 0
2
2
1
4 1
.
b
b
D
t
t
D
.
|
|
.
|
\
|
(
Minimum value, f
th,stress
= 1.2
Maximum value, f
th,stress
= 3
Flange
|
|
.
|
\
|
+
f
t
t
. 1 064 0 1
t
f
> t where t
f
is the wall thickness of
the flange
Reducer
|
|
.
|
\
|
+
2
2
1 064 0 1
D
D
.
r
D > D
r
where D
r
is the (smaller)
diameter of the reducer
Table 9: Repair thickness increase factors for piping system components
The axial length of repair shall be based on the (larger) dimension of the main body and
applies to both the axial length of repair along the main body and branch (where
appropriate).
For the repair of tees, the maximum allowable design pressure for the repair laminate design
thickness, t
design,component
, is restricted to;
b
component , design c c
D D
t E
P
+
2
(27)
13.3 Tank and vessel components
The following tanks and vessel components are considered;
Cylindrical vessels
o End dome, main body connection
o Supports/saddles/rigid attachments
o Tees/nozzles
Spherical vessels
o Supports/saddles/rigid attachments
o Tees/nozzles
==
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=
The repair design procedure for each vessel component is the same as described in a
Section 13.2.
Table 10 and Table 11 present repair thickness increase factors for cylindrical and spherical
tank and vessel component respectively. They are a function of the geometry of the
component.
Cylindrical vessel
component
Repair
thickness
increase factor,
f
th,stress
Comment
End dome, main body
connection
2
2
032 0 1
d
D
D
. +
D > D
d
where D
d
is the (smaller) diameter of the
dome end
Supports/saddles/rigid
attachments
( )
4 3
2
2
1 K K
Dt
D
a
+ +
D
a
is equivalent area of attachment and
( ) ( )
3 0 5 0
4
3
2
4 0 1 8 1
2
22 0
.
al
rt
.
ha
al rt
) C ( Log
) C ( Log
Cos C . . K
C ) C ( Log
Cos . K
|
.
|
\
|
=
|
.
|
\
|
=
L
C
C
D
C
t
D
C
C
C
C
a
al
i
a
i
i
rt
a
h
ha
2
, 128 ,
2
=
|
|
.
|
\
|
= =
h a a
C C . D 35 2 =
Note: Minimum value, f
th,stress
= 1.2, maximum value,
f
th,stress
= 3
Tees/nozzles
45 0
2 1
522 5
.
r
) t . (
.
+
t
t
t ,
Dt
D
b
r
b
= =
2
Note: Minimum value, f
th,stress
= 1.2, maximum value,
f
th,stress
= 3
Table 10: Repair thickness increase factors for cylindrical vessel components
==
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=
Spherical vessel
component
Repair thickness increase
factor, f
th,stress
Comment
Supports/saddles/rigid
attachments
( )
4 3
2
1 K K
Dt
D
a
+ +
D
a
is equivalent area of attachment
and
|
|
.
|
\
|
(
=
|
|
.
|
\
|
(
=
5 0
4
25 0
3
287 1
2 2 2 1
287 1
3 2 38 0
.
a
.
a
Dt
D .
. Exp . K
Dt
D .
. Exp . K
Note: Minimum value, f
th,stress
= 1.2,
maximum value, f
th,stress
= 3
Tees/nozzles
( )
(
(
+
31 0
88 0
95 0 75 0 1
2
.
r
.
r
t
t . .
t
t
t ,
Dt
D
b
r
b
= =
2
Note: Minimum value, f
th,stress
= 1.2,
maximum value, f
th,stress
= 3
Table 11: Repair thickness increase factors for spherical vessel components
The solution for the repair thickness increase factors for supports, saddles and rigid
attachments for either a cylindrical or a spherical vessel is conservative.
The axial length of repair shall be based on the (larger) dimension of the main body and
applies to both the axial length of repair along the main body and branch (where
appropriate).
For the repair of tees or nozzles on either a cylindrical or spherical vessel, the maximum
allowable design pressure for the repair laminate design thickness, t
design,component
, is restricted
to;
b
component , design c c
D D
t E
P
+
2
(28)
AEAT 75484 contains derivations of these factors plus their verification.
The application of repairs to vessels may not be fully circumferential around the vessel body.
It has been demonstrated both by design and experiment that a patch repair has identical
performance to that of a fully circumferential repair assuming that the extent of the repair is
at least that of the appropriate overlay lengths.
==
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=
14. RE-QUALIFICATION
Where there has been a change to the materials comprising the repair laminate, including
surface preparation, the design shall be re-qualified. Guidance on the type of change
requiring re-qualification may be obtained from ISO14692.
Where re-qualification has not taken place, the allowable strains and service factors for the
original design may be used provided that it has been demonstrated that the laminate
strength of the material variant, and lap shear strength of the adhesive connection, is at least
as good as the original. This may be done using short term tests except where evidence of
the long term durability of the bond between the composite and steel is required (see Table
3). In this case lap shear specimens shall be immersed in water at the service temperature
for 1000 hrs after which the residual lap shear strength of the variant shall be at least that of
the original.
15. INSPECTION AND TESTING
Procedures for system hydrotesting are described in AEAT - 57756.
Information on inspection methods can be obtained from AEAT 75394.
16. HEALTH AND SAFETY
All repair materials shall be designed to minimise operator exposure to chemical agents. The
principle of as low as reasonably possible shall apply in all circumstances. The supplier shall
provide all relevant COSHH documentation for the materials in use.
17. ENVIRONMENTAL CONSIDERATIONS
All repair materials shall be designed to allow for satisfactory disposal according to prevailing
environmental regulations. Special attention should be given to the disposal of unused
chemicals and resins that may be left after a repair operation. The material supplier shall
provide appropriate guidance.
==
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=
18. BIBLIOGRAPHY
Background standards and references are given in the following sections.
Reference Standards
1 ISO 14692, Specification and recommended practice for the use of GRP piping in the
petroleum and natural gas industries.
2 ISO 15649, Petroleum and natural gas industries -- Piping
3 ISO 13623, Petroleum and natural gas industries -- Pipeline transportation systems
4 prEN 13121, GRP tanks and vessels for use above ground.
5 API 579, Recommended practice for fitness for service.
6 BS 7910, Guide on methods for assessing the acceptability of flaws in fusion welded
structures.
7 BS 8010, Code of practice for pipelines. Pipelines on land
8 ASME B31.1, Power Piping
9 ASME B31.3, Chemical plant and refinery piping
10 ASME B31.4, Pipeline Transportation Systems for Liquid Hydrocarbons and Other
Liquids
11 ASME B31.8, Gas Transmission and Distribution Piping Systems
12 BS EN 1465, Determination of tensile lap shear strength of rigid to rigid bonded
assemblies.
13 ISO 75, Plastics - Determination of temperature of deflection under load.
14 ISO 113572, Plastics - Differential scanning calorimetry (DSC).
15 ISO 527, Plastics - Determination of tensile properties.
16 ISO 178, Plastics - Determination of flexural properties.
17 BS EN 59, Measurement of hardness by means of a Barcol impressor.
18 ASTM D2583, Standard test method for indentation hardness of rigid plastics by
means of a Barcol impressor
19 ISO 868, Plastics and ebonite - Determination of indentation hardness by means of a
durometer (Shore hardness)
20 ASTM D1598, Test method for the time to failure of plastic pipe under constant
internal pressure.
21 ASTM D2992, Practice for obtaining hydrostatic or pressure design basis for glass
fibre reinforced thermosetting resin pipe and fittings.
22 ASTM D1599, Test method for short time hydraulic failure pressure of plastic pipe,
tubing and fittings.
23 ISO 11359-2:1999 Plastics - Thermomechanical analysis (TMA) - Part 2:
Determination of coefficient of linear thermal expansion and glass transition
temperature
24 ASTM D5379/D5379M-98 Standard Test Method for Shear Properties of Composite
Materials by the V-Notched Beam Method
25 ASTM D543, Standard Practices for Evaluating the Resistance of Plastics to
Chemical Reagents
26 ASTM C581, Standard Practice for Determining Chemical Resistance of
Thermosetting Resins Used in Glass-Fiber-Reinforced Structures Intended for Liquid
Service
27 ASTM D3681, Standard Test Method for Chemical Resistance of Fiberglass (Glass-
Fiber-Reinforced Thermosetting-Resin) Pipe in a Deflected Condition
==
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=
28 ISO 10952:1999 Plastics piping systems -- Glass-reinforced thermosetting plastics
(GRP) pipes and fittings -- Determination of the resistance to chemical attack from
the inside of a section in a deflected condition
29 ASTM G8, Standard Test Methods for Cathodic Disbonding of Pipeline Coatings
30 ASME PCC-2, Repair Standard, Non-metallic composite repair systems for pipelines
and pipework: High risk applications
31 ASTM D3039, Standard Test Method for Tensile Properties of Polymer Matrix
Composite Materials
32 BS 5500, Specification for unfired fusion welded pressure vessels
Reference Publications
1 Mableson, R, Patrick, C, Dodds N and Gibson G, Refurbishment of steel tubulars
using composite materials, Rehabilitation of Piping and Infrastructure Conf, University
of Newcastle upon Tyne, 1999
2 AEAT - 57756, Installation procedures for composite repairs, January 2004
3 AEAT - 75394, NDT Methods for composite repairs, January 2004
4 AEAT - 02529, Documentation for the use of composite repairs, January 2004
5 AEAT - 75484, Composite repairs for piping systems, tank and pressure vessel
repair, January 2004
6 AEAT - 57394, Composite repairs - medium term testing and analysis, January 2004
==
AEA Technology 38
=
APPENDICES
CONTENTS
Appendix 1: Design data sheets
Appendix 2: Qualification requirements
Appendix 3: Short term pipe spool survival test
Appendix 4: Measurement of for leaking pipe calculation
Appendix 5: Measurement of performance test data
Appendix 6: Measurement of impact performance
Appendix 7: Measurement of the degradation factor
Appendix 8: Axial extent of repair
==
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=
Appendix 1: Design data sheets
This Appendix provides an example of a design data sheet as referenced in Section 8
PIPE REPAIR DATA SHEET
This document will form the basis of the clients scope of work and be used in the
preparation of a design solution. One sheet is to be completed for each type of repair
required.
Where possible, (digital) photographs of the defective areas are to be provided.
Customer Details
Contact
Company
Address
Postcode Country
Telephone
Fax
E-mail
Job Reference
Pipe Details
Installation
Location
Quantity
Pipe Identification
Pipe Reference
Pipe Specification
Material / Grade
External Diameter
Wall Thickness
Medium
Operating Temperature Minimum Maximum
Pipe Coating (existing)
==
AEA Technology 40
=
Risk Assessment (see Section 5)
Repair Class
Repair Lifetime
Other Data
Pipe Loading Operating Design Test Comments
Pressure Rating
Axial Load
Bending Moment
Shear Load
Torsion
Other loads
Notes:
1. Any original design calculations, piping isometrics should be appended
to this datasheet
2. Loads should be defined as either sustained or occasional in the comments column
Details of Defect Area
Attach drawings of pipe system, inspection reports, etc where available. Indicate
any access restrictions and proximity to other equipment.
Repair Specification
Type of Defect
Nature of Defect
Current Size Area Depth
Projected Size Area Depth
Cause Corrosion Erosion
Effect External Internal
Perforated
MAWP (API 579)
Note: MAWP is the maximum allowable working pressure as defined in API 579 or other
calculation method.
==
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=
Anticipated Conditions during Implementation of Repair
Pipe Temperature Minimum Maximum
Ambient Temperature Minimum Maximum
Humidity
External Environment
Constraints
Facilities to be Provided by Client / Installation (surface prep. etc.)
Other Information
Note
1. This should include any remarks on previous repairs, fire protection requirements, etc
Prepared by:
Date:
==
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=
Appendix 2: Qualification requirements
Introduction
This Appendix describes the qualification data that suppliers must provide to be in
compliance with this design specification.
It is a requirement that all tests are carried out using laminate materials, laminating
procedures and surface preparation methods that will be used to carry out repairs.
Data for Repair Laminates
For all repair classes the following data is required:
Tensile modulus and strength in the circumferential direction determined by test
according to Table 3;
Tensile modulus and strength in the axial direction determined by test according to Table
3;
Poisson's ratio for the composite laminate determined by test according to Table 3;
Barcol hardness determined by test according to Table 3;
Glass transition temperature (T
g
) or heat distortion temperature (HDT) for the resin
system determined by test according to Table 3;
Thermal expansion coefficient in the axial and circumferential directions determined by
test according to Table 3.
Data for Repair/Pipe Interface
For all repair classes the following data is required:
Lap shear strength determined by test according to Table 3. This short term test shall be
used to determine the average shear strength (minimum value 5 MPa) or the locus of
failure (composite remaining on a min of 30% of the bonded area). The substrates used
in this test should be identical. Alternatively, it shall be demonstrated that the adhesive
bond is stronger than the shear strength of the repair laminate by assessing the surface
of the substrate material used in a lap shear specimen after testing.
For Class 3 repairs the following data is required:
Where evidence of long-term durability of the adhesive bond between the repair laminate
and the substrate is required and performance based testing has not been carried out to
provide data for design (see Section 9.3), a long-term lap shear strength determined by
test according to Table 3 shall be performed. This test shall be carried out following
immersion in water (or other relevant medium) at the design temperature (minimum 40
0
C
) for 1000 hrs. The average shear strength determined from this test shall be at least
30% of the values from the short-term lap shear tests determined above.
Additional Requirements for Structural Repairs to Non-Leaking Pipes
The objective of the following test is not to produce data for use in design. The intent is to
demonstrate that for a severe defect adequate strength of the repair system can be
achieved.
==
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=
Short term pipe spool survival test, Appendix 3.
Additional Requirements for Leaking Pipes
For all repair classes the following data is required:
Bending modulus for the composite laminate determined by test according to Table 3.
Alternatively, the tensile modulus for the laminate may be used as a conservative
estimate for the value in bending;
Shear modulus determined by test according to Table 3. Alternatively, the shear modulus
of the polymer matrix may be used.
Fracture toughness parameter determined by test according to Appendix 4;
Impact performance determined by test according to Appendix 6.
Performance Testing
The supplier may carry out performance testing to determine design allowables in
accordance with Appendix 5. This is not a mandatory requirement.
The following design allowables are determined:
Long term strength, either from 1000 hour survival test or regression testing;
Long term strain to failure from representative repair laminate regression testing.
==
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=
Appendix 3: Short term pipe spool survival test
Introduction
This Appendix describes the test method for demonstration of the repair system for non-
leaking defects.
Method
The following test shall be completed using a steel pipe of at least 100mm diameter, and
minimum length of six times the diameter in addition to the length of the repair.
The repair system supplier can select the size of the defect, i.e. amount wall loss. The repair
system shall be qualified only for defects sizes up to this chosen size.
A fully circumferential defect of at least 150 mm in width and to a depth equivalent to the wall
loss for which the repair system is being qualified shall be machined into the external pipe
wall.
The test pressure of the spool shall be calculated using Equation (29):
D
ts
P
SMYS
f
2
= (29)
where t is the wall thickness of the undamaged spool, s
SMYS
is the specified minimum yield
stress (SMYS) of the steel.
A repair laminate shall be applied to the pipe to restore the pipe spool to pressure, P
f
. The
thickness of the repair shall be calculated using Equation (4), where s is replaced by s
SMYS
of
the steel, t
s
is the remaining wall thickness of the pipe spool at the defect and
c
is replaced
by the ultimate short-term strain to failure of the composite repair in the hoop direction.
The repaired spool shall be pressurized to P
f
. Pressure testing shall be in accordance with
ASTM D1599. Measurement of short-term failure strain shall be in accordance with ASTM
D3039 or an equivalent standard.
Qualification requires the repaired pipe to survive the loading to P
f
.
Report
A report shall be prepared giving the test conditions, details of the Repair System and the
individual test results.
==
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=
Appendix 4: Measurement of for leaking pipe
calculation
Introduction
This Appendix describes the test method for measurement of the toughness parameter for
the composite steel interface, , to be used in Equations (9), (10), (11) and (12) in Section
9.4.
Method
Sections of steel pipe of minimum diameter 100 mm and minimum thickness of 3 mm shall
be used. To represent typical defects circular holes shall be drilled through the wall
thickness and the repair applied using the relevant materials and surface preparation
methods. It is important that the laminating procedures to be applied for site repair are those
that are employed in the preparation of specimens. All samples should be laminated with
the holes in the 6 o'clock orientation.
The steel pipe section used for the preparation for the test specimen should be appropriate
for the anticipated failure pressure of the repair. Yielding of the steel pipe prior to failure
should not take place.
Internal pressure shall be applied and the value at which the repair begins to leak shall be
recorded.
The test shall be carried out at the temperature at which the repair is to be used.
The test pressure shall be increased uniformly until the specimen fails. The loading rate shall
be such that failure occurs between 60 and 70 seconds. Failure Further guidance on
pressure testing procedures may be obtained from ASTM D1599.
A number of tests shall be carried out covering a range of hole sizes, typically of diameter
10, 15 and 25 mm. For the larger diameters the flaw may be simulated by using a smaller
hole and a circular polymeric release film of the appropriate diameter placed over the hole
prior to application of the repair. A minimum of 3 test shall be done for each hole size.
Alternatively a minimum of 9 tests should be performed over a range of hole sizes varying
from 10 to 25 mm.
Failures should take the form of delamination of the composite from the substrate followed
by leaking from the edge of the laminate. At small hole sizes failure can occur through
weeping of the test fluid through the thickness of the laminate or through yielding of the steel
pipe. In this event the tests should be repeated with a larger hole size. All failure points
should relate to the delamination failure mechanism.
Calculation of
The value of shall be calculated by fitting Equation (9) in Section 9.4 to the data.
The following procedure shall be followed;
Definitions;
==
AEA Technology 46
=
n = the number of observed data points (A(d
i
), P
i
)
P
i
= the pressure at failure of observation i, where i = 1,n
A(d
i
) = the function of defect size and repair laminate properties of observation i,
where i = 1,n (see below for definitions of A(d
i
))
Note: A(d
i
) is defined as;
i i i
d A P ) ( =
The mean energy release rate,
mean
, is calculated from;
2
1
2
1
) (
) (
|
|
|
|
.
|
\
|
=
=
=
n
i
i
n
i
i i
mean
d A
P d A
(30)
The lower confidence limit of the energy release rate,
LCL
, is calculated from;
2
1
2
1
2
1
) (
1
) (
) (
(
(
(
(
= =
=
n
i
i
v n
i
i
n
i
i i
LCL
d A
t
d A
P d A
(31)
where, is the variance of measurement of pressure and is given by;
) 2 (
) ) ( (
1
2
=
n
d A P
n
i
mean i i
=
and where t
v
is the Students t value and is based on a two-sided 0.025 level of significance,
i.e. 95% lower confidence limit. Values of t
v
are given as a function of number of variables, n,
in Table 12.
==
AEA Technology 47
=
n
Number of
variables
n-2
Degrees of
freedom
Students t(0.025)
5 3 3.163
6 4 2.969
7 5 2.841
8 6 2.752
9 7 2.685
10 8 2.634
11 9 2.593
12 10 2.560
13 11 2.533
14 12 2.510
15 13 2.490
16 14 2.473
17 15 2.458
18 16 2.445
Table 12: Students t value for double sided 0.025 level of significance
The value of calculated by Equation (30),
LCL
should be used in Equation (9) to predict the
performance capability of the repair.
The value of calculated by Equation (30),
LCL
may also be used in Equations (10), (11) and
(12).
Definitions of A(d
i
);
For circular defects (Equation (9)), i.e. d is the diameter of the defect;
+
)
`
=
2 4
3
2
64
3 1
512
3 ) 1 (
1
) (
d
Gt
d
d
t E
d A
For circumferential width slots (Equation (10)), i.e. d is the width of the slot;
+
|
.
|
\
|
+
+
)
`
=
2 4
3
2
) 1 (
2 5
4
16
3
4 24
1 ) 1 (
1
) (
d
Gt
d
d
t E
d A
For large circumferential width slots (Equation (11)), i.e. d is the width of the slot;
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=
Et
D
A 8
1
=
In this last example, A is independent of the slot width. Therefore Equation (30) for the
energy release rate,
LCL
, simplifies to;
2
2
1
1
1
(
(
(
(
=
nA
t
A
P
n
v
n
i
i
LCL
For axial width slots (Equation (12)), i.e. d is the width of the slot;
(
(
(
+
+ +
=
3 2
6
3
4 2
180
) 2
4
(
24 4
) 1 (
1
) (
t D
G
E
d
t
d d
E
d A
where in the above equations t is the average thickness of the repair.
Qualification of other substrates
If the repair system has been fully qualified for one substrate then a simplified qualification
procedure is available for other substrates. In this procedure only 3 tests are required to be
completed. The 3 tests should be identical to three of the nine tests in terms of repair
thickness and defect size used in the full qualification test programme.
The value of for this substrate, substrate 2,
LCL,substrate 2
, is given by;
1
2
1 2
substrate , mean
substrate , mean
substrate , LCL substrate , LCL
=
In this equation, mean, implies the average of the 3 tests (for both substrates).
Report
A report shall be prepared giving the test conditions, details of the repair method including
the materials of construction and surface preparation technique, the individual data points
and the derived value of .
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=
Appendix 5: Measurement of performance test data
Introduction
This Appendix describes the test methods for measurement of the design allowables to be
used in Section 9.3. The test methods are:
1) Survival testing where the repair system is subjected to a period of sustained load for
1000-hrs for measurement of the long term strength.
2) Regression testing based on a series of tests on the repair system over different time
periods and extrapolation to design life for measurement of the long term strength.
3) Coupon testing based on regression testing of representative coupons followed by
confirmation of long-term coupon test results with survival testing for measurement of
the long term strain.
All tests shall be carried out at the maximum temperature at which the repair system is to be
used in service.
Methods
1) Survival testing
Sections of pipe of minimum diameter 100 mm and minimum thickness of 3 mm shall be
used and the repair system applied.
A value of internal pressure shall be applied (defined by the supplier) and sustained for 1000
hrs. If any deterioration of the repair laminate in the form of cracking, delamination or
leaking occurs the repair system will be deemed to have failed the test. Three identical tests
shall be performed and repair qualification is only possible if all three tests survive.
The 95% lower confidence long-term stress is calculated using;
( )
s s c
c test
lt
t E t E
DE P
s
+
=
min
2
Further guidance on survival pressure testing procedures may be obtained from ASTM
D1598.
2) Regression testing
Sections of pipe of minimum diameter 100 mm and minimum thickness of 3 mm shall be
used and the repair system applied.
A series of test specimens shall be subject to sustained pressures of different values. The
time at which the repair laminate shows signs of deterioration defined as cracking,
delamination or leaking shall be recorded. The results shall be plotted (log/log) and the
required pressure determined by a regression analysis using the 95% lower confidence limit
and extrapolation to design life. The conversion from pressure to stress within the repair
laminate for each data point shall be according to;
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=
( )
s s c
c test
t E t E
DE P
s
+
=
min
2
At least 18 results are required in order to carry out the regression analysis. ASTM D2992
provides further guidance on the long term testing of composite materials and ISO 14692
provides guidance on the analysis of the data to calculate s
lt
.
3) Representative coupon testing
Representative coupons of the repair laminate should be made up and tested in a
comparable manner to the actual repair system laminate. Representative implies same
laminate constituents, volume fraction and fibre orientation. Comparable loading implies
coupons should be loaded identically as the in-service repair laminate (e.g. uni-axial tension
or bi-axial tension).
At least 18 coupons should be tested under constant load to failure (data points in terms of
number and length of time of testing according to ASTM D2992, with the statistical analysis
of data according to ISO 14692).
Output of these coupon tests is the regression gradient, G, in terms of either log(stress or
strain) against log(time).
To determine the long-term failure stress or strain of the repair system, 5 medium term tests
(according to ASTM D1598) shall be performed on sections of pipe of minimum diameter
100 mm (4 inch) and minimum thickness of 3 mm (0.12 inch). In these tests the pressure is
fixed and the time to failure recorded. It is recommended to select a test pressure so that
failure occurs after about 1000 hours.
The lower confidence limit (in terms of time) for these five tests is calculated according to the
mean failure time minus 2 standard deviations. The long-term design strength (or strain) of
the Repair System is the extrapolation of the lower confidence limit to the design lifetime
using the measured regression gradient from the coupon tests.
Further guidance on survival pressure testing procedures may be obtained from ASTM
D1598.
Further guidance on long term testing and data interpretation may be obtained from ISO
14692.
Report
=
A report shall be prepared giving the test conditions, details of the repair method including
the materials of construction and surface preparation technique, the individual data points
and the derived performance design data.
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=
Appendix 6: Measurement of impact performance
Introduction
This Appendix describes the test method for measurement impact performance. The
supplier shall demonstrate that the repair is capable of withstanding the impact from a low
velocity 5 J impact representative of a dropped tool.
Methods
A section of steel pipe of minimum diameter 100 mm and minimum thickness of 3 mm shall
be used and the repair applied using the relevant materials and surface preparation
methods. The steel pipe shall have a representative defect of 10 mm. The details of
specimen preparation are described in Appendix 4.
The repair shall be subject to a 0.5 kg weight with a 12 mm hemispherical indentor dropped
from a height of 1 m. The pipe shall be supported so that the hole is in the 12 o'clock
orientation and the weight shall strike the repair at the position of the hole in the steel pipe.
The pipe shall be empty for the duration of the impact test.
The impacted specimen shall be subject to a pressure test as described in Appendix 4. The
failure pressure obtained shall be no less than the minimum of the pressure test results
obtained from specimens not subject to impact.
Report
=
A report shall be prepared giving the test conditions, details of the repair method including
the materials of construction and surface preparation technique, the individual data points
and the derived performance
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=
Appendix 7: Measurement of the degradation factor
Introduction
This Appendix describes the test method for measurement of the degradation factor for the
leaking repair situation through using a low speed loading rate test. Within Section 9.4 a
service factor for down-rating the predicted failure pressure is set at 0.333. This factor is
based on the product of two effects, the degradation from short term to long term failure plus
a safety factor, derived from ISO 14692 of 0.67. Within Section 9.4 the default value for the
degradation factor is set at 0.5.
Method
=
Sections of steel pipe of minimum diameter 100 mm and minimum thickness of 3 mm shall
be used. Circular holes shall be drilled through the wall thickness and the repair applied
using the relevant materials and surface preparation methods. It is important that the
laminating procedures to be applied for site repair are those that are employed in the
preparation of specimens. All samples should be laminated with the holes in the 6 o'clock
orientation (to minimise the ingress of resin into the defect).
The steel pipe section used for the preparation for the test specimen should be appropriate
for the anticipated failure pressure of the repair. Yielding of the steel pipe prior to failure
should not take place.
The thickness of all repairs shall be identical to that used in Appendix 4.
Internal pressure shall be applied and the value at which the repair begins to leak shall be
recorded.
The test shall be carried out at the temperature at which the repair is to be used.
The test pressure shall be increased daily until the specimen fails. The loading rate shall be
such that failure occurs after approximately 1000 hours.
Note: As a guide to selecting the daily increment in pressure the estimated 1000 hour failure
pressure will be approximately 0.75 of the short term failure pressure. p
sthp
.
The low speed loading rate test is defined by the following;
t P P t P
&
+ =
0
) (
where P
0
is the initial pressure (bar) and P
&
is the fixed linear increase in pressure (bar/hour),
AEAT - 57394.
It is recommended to set the initial pressure, P
0
(bar) to
sthp
P P 1 . 0
0
= and the linear increase
in pressure, P
&
bar/hour) to
sthp
P P
3
10 * 9 . 0
=
&
. In terms of units bar/day, then
sthp
P P 0216 . 0 =
&
Five tests shall be carried out in total, with a defect diameter set at 25 mm.
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=
Failures should take the form of delamination of the composite from the substrate followed
by leaking from the edge of the laminate.
Calculation of the degradation factor
The short term failure pressure shall be calculated using the following formula;
+
)
`
=
2 4
3
2
64
3 1
512
3 ) 1 (
d
Gt
d
d
t E
P
mean
sthp
where t is the average thickness of the repair.
The average failure pressure of at least 5 medium term tests shall be calculated and defined
as, P
mthp
The regression gradient, B, (see AEAT 57394) shall be calculated according to;
1
log
log
1
|
|
|
|
|
|
.
|
\
|
|
|
.
|
\
|
|
|
.
|
\
|
=
mthp
sthp
sthp
P
P
P
P
B
&
(32)
The degradation factor, D
f
, shall be calculated as, where it is assumed that the design life of
the repair is 20 years;
B
f
D
24 . 5
10
= (33)
Report
=
A report shall be prepared giving the test conditions, details of the repair method including
the materials of construction and surface preparation technique, the individual data points
and the derived value of the degradation factor.
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=
Appendix 8: Axial extent of repair
Axial extent of repair look-up table
Defect size - diameter (mm)
5 10 15 20 25 slot
Pipe size
(inch)
Pipe outside
diameter
(mm)
Wall
thickness
(mm)
Schedule Axial length (mm)
2 60.3 3.9 40 50 50 50 50 50 50
5.5 80 50 50 50 50 50 50
3 88.9 5.5 40 50 50 50 50 50 50
7.6 80 50 50 52 52 52 52
4 114.3 6 40 50 50 52 52 52 52
8.6 80 50 50 60 63 63 63
6 168.3 6.6 40 50 50 60 67 67 67
9.5 80 50 50 60 80 80 80
8 219.1 6.4 20 50 50 60 75 75 75
7 30 50 50 60 78 78 78
8.2 40 50 50 60 80 85 85
10.3 60 50 50 60 80 95 95
12.7 80 50 50 60 80 100 106
10 273 6.4 20 50 50 60 80 84 84
7.8 30 50 50 60 80 92 92
9.3 40 50 50 60 80 100 101
12.7 60 50 50 60 80 100 118
15.1 80 50 50 60 80 100 128
12 323.8 6.4 20 50 50 60 80 91 91
8.4 30 50 50 60 80 100 104
10.3 40 50 50 60 80 100 116
14.3 60 50 50 60 80 100 136
17.5 80 50 50 60 80 100 151
16 406.4 6.4 10 50 50 60 80 100 102
7.9 20 50 50 60 80 100 113
9.5 30 50 50 60 80 100 124
12.7 40 50 50 60 80 100 144
16.7 60 50 50 60 80 100 165
21.4 80 50 50 60 80 100 187
20 508 6.4 10 50 50 60 80 100 114
9.5 20 50 50 60 80 100 139
12.7 30 50 50 60 80 100 161
15.1 40 50 50 60 80 100 175
20.6 60 50 50 60 80 100 205
26.2 80 50 50 60 80 100 231
24 610 6.4 10 50 50 60 80 100 125
9.5 20 50 50 60 80 100 152
14.3 30 50 50 60 80 100 187
17.5 40 50 50 60 80 100 207
24.6 60 50 50 60 80 100 245
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=
31 80 50 50 60 80 100 275
30 762 7.9 10 50 50 60 80 100 155
12.7 20 50 50 60 80 100 197
15.9 30 50 50 60 80 100 220
36 914 7.9 10 50 50 60 80 100 170
12.7 20 50 50 60 80 100 215
15.9 30 50 50 60 80 100 241
19 40 50 50 60 80 100 264