timberline repair tool for damaged pe pipe nw natural timberline product demonstration september 18,...

Timberline Repair Tool for Damaged PE Pipe

NW Natural Timberline Product Demonstration

September 18, 2009 Portland, OR

Agenda for Meeting

10:00 – 10:15 Meet & Greet

10:15 – 10:45 PowerPoint – History of Project

10:45 – 11:30 Repair Tool Demonstration

11:30 – 12:15 PowerPoint – Repair Process

12:15 – 13:00 Discussion/Feedback

Introductions

Timberline Tool – Kalispell, MT

Oregon State University – Corvallis, OR

Ripple Marketing – Bozeman, MT

Watlow Electric Manufacturing – St. Louis, MO

Entek International – Lebanon, OR

Timberline Tool Ken Green, Chief Executive Officer Jeanine Green, Chief Financial Officer John Clark, Mechanical Engineer Ripple Marketing

Kitch Walker, Marketing ConsultantKurt Palmer, Marketing Consultant

Oregon State University

Dr. Skip Rochefort, PhD, Associate Professor Dr. Nick Wannenmacher, PhD Kevin Harris

Watlow Electric ManufacturingMark Tettambel (Kansas City Sales Office)Seth Stewart (Product Engineer)Bob Cameron (West Coast Office)

Entek International Dr. Rick Pekala (VP of Research &

Development)Robert Waterhouse (……)

Suppliers

History of Innovation Timberline developed a revolutionary fire

hose shut-off tool for wildland firefighters

In 1989, Timberline incorporated to manufacture the firefighter’s clamp

Montana Power Company needs improved squeeze tools In 1991, Montana Power Company engineers

suggested modifications to the firefighter clamp design to squeeze-off their PE gas service lines.

In 1992, the new squeeze-off tool, Topside clamp, was introduced to the natural gas industry to improve their squeeze-off operations

Vertical, top-down approach to the pipe rather than horizontal squeeze bars

Topside Tools Provides safe, reliable, quick

operation without under-the-pipe excavation

TC1-S for ½” – 1” PE pipeTC1-S for ½” – 2” PE pipe

Natural Gas Industry needs improved keyhole tools In 1997, the natural gas industry turned to

keyhole technology to maintain & repair their pipelines

Timberline TopReach Tools fit the need for keyhole application

TopReach Tools Top-down approach to

the pipe

Does not require excavation under the pipe

TR150 for ½” – 1” PE pipe

TR250 for ½” – 2” PE pipe

DOE requests improved tools for natural gas industry In 2002, DOE requested keyhole tools for

the natural gas industry to maintain & repair large diameter PE pipe

“Top Down” approach critical

TopReach Tools

Timberline partnered with DOE to develop keyhole squeeze tools

TR650 for 3”, 4”, 6”TR270 for ½” – 2” TR170 for ½” – 1”

DOE mandates delivery reliability of natural gas Natural gas industry needs improved tools that

will ensure the safe reliable delivery of nations gas supply.

DOE solicitation for:

External method to repair natural gas pipelines

Keyhole applications

Repair Tool Background

In 2003, Ken Green, Timberline Tool & Dr. Rochefort, OSU submitted a proposal to DOE/NETL to develop a new repair process for the external repair of PE pipe

DO/NETL Cooperative Agreement for R&D of new external repair method

NW Natural’s Involvement Critical Partner for Repair Tool Project

In-kind SupportMaterials – Pipe for testingField evaluations and demonstrations

OTD Funding

Research Team Timberline Tool

Ken Green, Chief Executive OfficerJeanine Green, Chief Financial OfficerJohn Clark, Mechanical EngineerRipple Marketing

Kitch Walker, Marketing ConsultantKurt Palmer, Marketing Consultant

Oregon State University

Principal InvestigatorDr. Skip Rochefort, PhD, Associate Professor

Research DirectorDr. Nick Wannenmacher, PhD

Research AssociateLyuba Kabalnova, PhD

ChemE Research Team

Oregon State University

Masters Degrees Granted on Project

Kevin Harris, M.S. ChE 2007 Cheryl Carbone, M.S. Materials Science 2004 John Hunt, M.S. ChE 2003

ChemE Research Team

Oregon State University

8 Undergraduate Research Students

6 ChE/EnvE senior projects

19 HS students involved in summer research over 5 years

ChemE Research Team

Integral Suppliers Watlow Electric Manufacturing - Provides

controllers and heating element for patch Mark Tettambel (Kansas City Sales Office) Seth Stewart (Product Engineer) Bob Cameron (West Coast Office)

Entek International – Provides the PE foam Dr. Rick Pekala (VP of Research & Development) Robert Waterhouse

Technology Assessment No method is currently available for

external permanent repair of PE pipe. Current repair methods require costly

excavation, isolation and removal of damaged pipe section

Damaged section is replaced by fusing new section in place

Service is interrupted

R&D for New Repair Method Cost Shared Project:

6 Year Project - $1.5 million Cooperative agreement between Timberline Tool, US Department

of Energy (National Energy Technology Laboratory) and Operations Technology Development

Research Team Oregon State University, Chemical Engineering – Polymer Lab Timberline Tool – Mechanical engineering Field Testing Partners:

NW Natural Sempra SW Gas Nicor Enbridge

Results of R&D Efforts Developed a unique mechanical tool that applies a

thermo-chemical patch Fully encapsulates pipe at site of damage Accomplished without interrupting gas flow Implemented under a variety of environmental

conditions Using current field technicians trained in process

Repair Tool Benefits Remote operation keeps the operator safely out

of the trench Keyhole application minimizes impact to

environment and neighborhood Time and labor savings due to reduced

excavation and ease of application are significant

Maintenance and repair costs significantly lowered – estimated average savings of $2,250 per repair

Repair Tool Features Aluminum construction for high strength, light

weight Portable - requires only one person to operate Mechanical operation for ease of use. Curved jaw completely encapsulates the pipe &

immediately stops the flow of gas Applies a thermo-chemical patch One tool for many diameters (2”,3”,4”,6”) Process performed safely above the hole

Repair Tool Demonstration

Repair Tool Components Ratchet handle Handle extensions Main assembly Jaws with inserts for 2”, 3”,

4” & 6” PE pipe PE composite patch with

internal heater Tool DimensionsLength: 6.5 ft (2.0 m)Width: 11.0 in (28.25 cm) Weight: 53.0 lbs (24.00 kg)

PE Patch ComponentsRevolutionaryComposite Patch:

1. HDPE patch back2. HDPE/UHMWPE

Foam3. HDPE mesh w/

internal heating element

4. HDPE/UHMWPE Foam

5. HDPE (packaging)

HDPE Patch Back

HDPE/UHMWPE Foam

HDPE w/ Stitched Heater

HDPE Sheet

HDPE/UHMWPE Foam

Thermo-Chemical Fusion Bond

Micrograph image shows that the bond between the pipe and patch is nearly seamlessInoculating the PE foam

layers with solvent

Repair Process

Step 1. Patch Insertion Step 2. Encapsulation

Repair Process

Step 4. Completed Repair

Step 3. Fusion Bonding

Testing on PE Pipe Quick burst, sustained pressure and

accelerated age (long term) tests performed per:ASTM D 1598ASTM D 1599

Results:Quick Burst – PassedSustained Pressure – 200 psi > 5

months (test completed)Long Term – Passes 50 year

mark & shows bond strengthens with age

Quick burst test at 600 psi

Benefits of Repair Process Increases operator safety – out of trench, away

from hazardous situation Reduces operating costs

Time & Labor Materials Excavation

Solves emergency repair problems due to third party damage, etc.

Solves problems with the aging PE pipe systemLeaking jointsPinhole leaksGouges & scrapesSlow crack growth

New Repair Solution

Reduced risk & improved safety No loss of service to customer Less repair time Repairs pipe under pressure Smaller excavation Keyhole application Substantial cost savings

Repair Tool Highlights

Average savings per incident = $2,250 depending on the complexity

There are an estimated 150,000 incidents/year Savings to the natural gas industry expected to

be > $300M annually

Cost Savings

Discussion Repair Tool

Keyhole Tools

Tracer Wire Tool

Other Tooling Needs

Ken H. Green

Timberline ToolPO Box 1328

Whitefish, MT 59937

khg@timberlinetool.com800.735.6845