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