biodata: mr. alan leong position/company: senior researcher, petronas...
TRANSCRIPT
Biodata of Speaker :-
Biodata: Mr. Alan Leong
Position/Company: Senior Researcher, PETRONAS Research Sdn. Bhd. (PRSB)
Mr. Alan Leong graduated with Bachelors degree in Aerospace engineering but been
working with composite materials since 2000. He specialises in composites testing and low
cost composites manufacturing techniques, and worked in University of London on
composite materials for wind turbines prior to joining PETRONAS. Alan joined PETRONAS
Research Sdn Bhd in 2007 and has been working on the application of composites materials
in O&G, specifically in the field of repair and rehabilitation.
Abstract of Papers:-
Title: ““PIPEASSURETM Composite Repair and Rehabilitation of Risers and Pipelines”
This paper describes the work carried out to develop, test and field-demonstrate the
Pipeassure™ composite overwrap system capable for use in the repair and/or corrosion
protection of pipeline and risers in the oil and gas industry. The system is applicable in dry
conditions, e.g. for pipelines and sections of risers at and close to the platform; in wet
conditions, e.g. risers at the splash zones; and in fully submerged underwater conditions,
e.g. for subsea pipelines. Pipeassure™ is currently being qualified to ISO 24817 and results
from the testing program and field demonstrations will be presented.
By
KH Leong, AYL Leong, YC Tan, PFM Liew (PETRONAS)
CD Wood, W Tian & KA Kozielski (CSIRO)
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS)All rights reserved. No part of this document may be reproduced, stored in a retrieval system or transmitted in any form or by any means (electronic, mechanical, photocopying, recording or otherwise) without the permission of the copyright owner.
Presented at the
7th Asian Pipeline Conference and Exhibition
Kuala Lumpur, Malaysia
11 – 12 October 2011
PIPEASSURE™ COMPOSITE REPAIR
AND REHABILITATIION OF RISERS
AND PIPELINES
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
Benefits of Composite Repairs
Patch and Overwrap Repairs
PipeAssure™
Experimental: Materials development
Resin development
Prepregging
Characterisation and Testing
Results and Discussion
Field Demonstrations
Summary and Conclusions
Outline
1
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
• Why composites repair?– operational efficiency
– occupational safety
– flexibility
• Advantageous properties– corrosion resistance
– superior mechanical performance
– lightweight
– good thermal insulation
– design flexibility
– cost-effective
Benefits of Composite Repairs
5
Source: http://en.wikipedia.org
Source: http://en.wikipedia.org
Source: http://en.wikipedia.org
Source: CRC-ACS
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
Overwrap repairs have been used to repair, rehabilitate and
rejuvenate piping, risers and also pressure vessels.
Patch and Overwrap Repairs
Source: Malcolm, Reinf. Plast., 2009. Source: Beckman, Offshore, 2005.
References: 1. Furlow, Offshore,
2002.
The patch is adhesively bonded to the substrate to repair the damage
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
• PIPEASSURE™ is a novel pre-impregnated composite resin system for pipeline repairs, both onshore and offshore.
• Consists of “E-Glass fibre” pre-impregnated with a proprietary underwater epoxy resin formulation with effective corrosion protection and pipe reinforcement properties.
• PIPEASSURE™ is curable underwater and is capable of withstanding wet environments with minimal loss of adhesion and mechanical properties.
PIPEASSURE™
7
+ =
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
Experimental
4
Chemical approach to tailor propertiesMatrix resin
A blend of liquid & solid epoxy Nanoclay for reinforcement Surfactants Silane cure promoter
Hardener Amine hardener
Pre-impregnationMaterials
CSM backed E-glass plain woven fabric
Characterisation and mechanical testingGlass transition temperature (Tg) vs cure
time/temperature @ 30, 40, 90°CSalt spray @ 4500 hrsTransverse adhesion (“Dolly”)Hardness (Shore D)
Qualification Testing Program
Based on ISO/TS 24817 PETRONAS Technical Standard
for Coatings
Coupon Pipe spool
hole, and wall thinning
Two conditions Dry Wet
Field Demonstrations
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
Established necessary process controls 750 gsm CSM based plain weave glass fabric
> 50wt% resin content
30cm wide tape
460g per lineal metre
15 - 20m rolls
Largest batch produced
to-date 750m (in a day)
Results: Prepreg Production
6
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
Characterisation and Testing
10
Mechanical Properties Testing
Lap Shear
Thermal properties – Tg
CTE & Fire
Long Term ConditioningCathodic Disbondment
Adhesion
Accelerated Weathering
Hydrostatic Pressure Test
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
Results: Resin Characterisation
5
Cure duration
Estimate cure duration based on cure temperature
-20
0
20
40
60
80
100
120
0 2 4 6 8 10 12 14 16
Gla
ss t
ran
siti
on
tem
per
atu
re, T
g (o
C)
Cure duration (days)
Resin glass transition temperature (Tg) for different cure conditions
30°C 40°C 90°C
0
20
40
60
80
100
-20 0 20 40 60 80 100 120
Deg
ree
of
cure
(%
)
Glass transition temperature, Tg (oC)
Degree of cure versus Tg
Cured glass transition temperature
In-situ estimation of level of cure
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
Results: System Characterisation
7
0 hr 2000 hrs
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
Results: Qualification Program (In progress)
8
Out of Water In WaterTested @ RT Tested @ 55°C Tested @ RT Tested @ 55°C
Long. Modulus (GPa) 17.5 16.7 16.7 16.7
Trans. Modulus (GPa) 16.4 15.3 15.3 16.8
Long. Strength (MPa) 233 229 226 205Trans. Strength (MPa) 214 214 189 168Poisson’s Ratio 0.19 0.19 0.19 0.18
Lap Shear (MPa) 14.37a 14.83Tests to be carried out
Tests to be carried out
Transverse Adhesion (MPa) 18.5a - 8.6b -Tg (°C) 76 - 100 -Short term pipe spool survival test
Passedto 326bar c
-Tests to be carried out
-
a With PR25 out-of-water primer.
b With PR30 in-water primer.
c Repair was holding pressure at 380bar when steel pipe yielded.
NB Energy release rate: 96 J/m2
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
Field Demonstrations: Corrosion Protection
9
Surface Prep Installing Repair Quality Control Post-installation Monitoring
Topside Splash zone
Topside
Splash zone
Hardness measurement
Adhesion measurement
Grit blasting to achieve
SA2.5 surface finish
Carried out on 3 risers
Month 2, 7, 9, 12
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
Field Demonstrations: Leak Repair
9
Surface Prep Installing Repair Quality Control Post-installation Monitoring
Hardness measurement
Carried out on vessel
Month 3 & 6
Live repair ~95oC
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
Summary and Conclusions
11
A newly developed resin composite overwrap system has been successfully demonstrated for offshore riser repair/maintenance.
Substantial amount of testing, especially with regard to the performance of the material as a repair/ coating system for both dry and wet conditions, has been carried out prior to the field trials.
Post-installation inspections on the risers carried out after 2, 7, 9 and 12 months have revealed no discernible sign of any damage or degradation of key properties in the composite overwrap. This was confirmed through destructive tests that were carried out on the “dummy” test plate set adjacent to the riser repairs.
The developmental testing is currently undergoing verification through a comprehensive third-party qualification program per ISO/TS 24817 for the system to be used in structural repairs.
© 2011 PETROLIAM NASIONAL BERHAD (PETRONAS) 7th Asian Pipeline Conference and Exhibition ● Istana Hotel, Kuala Lumpur ● 11-12 October 2011
Thank You …..
www.petronas.com.my
For further information, please contact:
KH Leong
PETRONAS Research Sdn BhdT & E DivisionPETRONAS
Lot 3288 – 3289 Off Jalan Ayer ItamKawasan Institusi Bangi43000 KajangSelangor DEMALAYSIA
T +603 8928 1588M +6012 305 6272e [email protected] w www.petronas.com.my