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Syntho-Glass XT Hochfest

ISO PDTS 24817

ASME PCC-2-2008

XTREME STRENGTH
FIBERGLASS COMPOSITE SYSTEM

Description
Syntho-Glass XT® system is a unique pre-impregnated, bidirectional composite used to repair and reinforce both internal and external corrosion on pipelines or structures without expensive and time-consuming shutdowns. The initial development of this system was designed to conform to the ASME PCC-2 and ISO TS24817 documents for nonmetallic reinforcing solutions. This XTreme strength design minimizes the time and cost of refurbishment by reducing the time to repair, as well as the replacement cost. When used with the appropriate primary coating, it enables one to repair and reinforce virtually any geometry in minutes.

The Syntho-Glass XT system provides a cost-effective solution by:

• Eliminating field mixing and wetting of the composite system to ensure proper fiber-to-resin content
ratios that are crucial to reliable performance.
• Combining simplicity with flexibility to permit application to irregular shapes and geometries, thereby
reducing parts inventory.
• Incorporating proprietary load transfer and bonding technology results in a high-tensile wrap capable
of repairing pipes and pipelines beyond their original bursting strength.

Typical Applications

• Transmission and distribution pipelines
• Gathering lines
• Oil and gas risers
• Girth welds on vessels and pipelines
• Elbows, tees, and flanges
• High-pressure injection lines
• Process piping: chemicals, oil, gases,
water, and steam

Benefits

• Water-activated urethane resin reduces composite
preparation time by over 50%
• Increase in hoop tensile strength by 50%, thereby
doubling maximum pressure retention capability
• Elimination of electrolytic corrosion associated with
carbon fiber repair systems
• Installation in wet or submerged environments ensures
ease of application in virtually any situation
• No VOCs minimizes potential safety hazards while
making the entire installation user-friendly
• Full factory engineering consultation and support,
ensuring safe and successful repairs
• Conformance to ASME PCC-2, DOT, ISO TS24817, and
API570, ensuring product application integrity

Physical Properties

Coefficient of
Linear Expansion – Method: ASTM D648
Hoop: CTLE: 1.06E-05 inches/inches/ °F
Working Time: 30 Minutes
Initial Cure Time: 2 Hours
VOCs: None
Resin Type:
Water-activated polyurethane
Resin Application:
Micro-controlled, Pre-impregnated

Mechanical Properties

Tensile Strength – Method: ASTM D3039
Hoop: 56,700 PSI (3910.2 BAR)
Axial: 21,600 PSI (1489.6 BAR)
Hardness – Shore D
30 Minutes: 47
2 Hours: 76
24 Hours: 83
Flexural – Method: ASTM D790 - 3 Point Flex
Strength: 58,680 PSI (4046.8 BAR)
Lap Shear – Method: ASTM D5379
Strength: 7,520 PSI (518.6 BAR)

Additional Syntho-Glass XT
System Products:

• Kevlar® Reinforced Epoxy
• Reinforcing Load Transfer Epoxy
• UV Protectant Coating
• Installation Accessory Kit: Compression film,
film perforation tool, additional safety gloves,
and epoxy applicator tools

Kevlar® Reinforced 2-Part Epoxy – Load Transfer Agent Data

Temperature Resistance: Dry Applications	275ºF (135ºC)
Temperature Resistance: Wet Applications	160ºF (71ºC)
Flexibility	3.2% elongation at break
Tensile Strength	> 6,000 PSI (>413.7 BAR)
Compressive Strength	7,380 PSI (508.9 BAR)
Flexural Strength	4,550 PSI (313.7 BAR)
Adhesion, Dry, Abrasion Blasted	> 2,000
Abrasion Resistance	Taber Abrasion 34 mg/1,000 cycles (CS17/1,000 grams)

©Neptune Research Inc. (NRI) 1996, 2009. Syntho-Glass XT® is a registered trademark of NRI. Patent Pending. NRI utilizes a process of continuous product improvement for all of our products. While we do strictly adhere to our products’ specifications, we routinely implement product improvements. Therefore, please contact your local NRI distributor or office for the most current product specifications. NRI warrants the quality of this product when used according to directions. User shall determine suitability of product for use and assumes all risk. The seller will not accept liability for more than product replacement. SGXT 1009

Kevlar® is a registered trademark of E. I. du Pont de Nemours and Company.

1440psi OFFSHORE PIPELINE REHABILITATION

The design justification for the pipeline is a 96” composite
repair on a 16” O.D. 1440PSI carbon steel schedule API-5L
Grade B header. 96” of pipe was blasted to a NACE 2 rating
(near white metal) with a 1mil – 4mil anchor pattern. Once all
the corrosion was removed and a solvent wipe was completed.
NRI used a load transferring epoxy putty Syntho-Steel
to fill in the pitting and corroded areas. The putty was applied
to match the cylinder shape of the pipe creating a smooth
transition for the two part Kevlar epoxy and composite sleeve
to be applied.

A high compression strength two part Kevlar reinforced epoxy was
applied over the total repair area. The two part epoxy stopped the
corrosion and provided a load transfer median engineered to cycle
and work with the 1440 PSI pipeline. Syntho-Glass® XT, a 54,000
PSI tensile strength fiberglass composite sleeve, was wrapped
around the total repair providing structural integrity to the composite
repair system. This composite repair system strengthens the
damaged pipeline to meet the MOAP and provide corrosion protection
to the carbon steel pipe over the length of the 96” repair
application.

NATURAL GAS PIPELINE INSTALLATIONS

Problem

1275 psi carbon steel schedule 40 natural gas transmission line
with 50% wall loss at the ground to air interface. Shutting down
was not an option.

Conditions

DOT regulated, high consequence natural gas pipeline located
in a residential area next to an interstate highway.

Solution

In order to promote adhesion, the pipe was cleaned by removing
rust, paint, and other foreign matter in accordance with
Sa2.5, NACE 2 or near white metal (see Figure 1).
Syntho-Steel® Load Transfer Putty fills all pits, dents, and other
anomalies effectively transferring the hoop load to the high tensile
strength composite (see Figure 2).
Syntho-SubSea® High Compression Kelvar filled Epoxy ensures
a water tight seal over the repair area while providing
chemical resistance (see Figure 3).
Syntho-Glass® XT Extreme Tensile Strength Composite, a bidirectional
fiberglass, permanently repairs and reinforces both
the internal and external corrosion damage (see Figure 4).

Result

Syntho-Glass® XT fully restored the pipe’s hoop and axial
strength to enable operation at full MAOP. Syntho-Glass® XT
saved thousands of natural gas home owners from being without
service. The gas transmission company saved time, money
and maintained good public relations. How can Syntho-Glass®
XT help you?

PIPELINE INSTALLATION: GATE VALVE

Problem

The gate valve coupling is showing major distress areas
and in on the verge of a catastrophic breakdown.

Conditions

The gate valve has major corrosion and wall loss. Several
pinhole size leaks have already begun to form, making the
impending repair even more critical.

Solution

In order to promote adhesion, the pipe was cleaned by removing
rust, paint, and other foreign matter in accordance
with Sa2.5, NACE 2 or near white metal. It was then coated
with a two part Kevlar reinforced epoxy. The two part epoxy
halted the corrosion and ensured a water tight seal. The
valve was then wrapped with multiple layers of Syntho-
Glass® XT which provides structural integrity to the repair
system.

Result

The repair was an immediate success, as the gate valve
now has even more strength than the original pipe and
valve at the time of installation. The valve once again meets
the MAOP and is also protected from further corrosion.

Problem

An offshore Caisson needing a water impermeable
fix to repair numerous pinhole cracks and several
larger leaks.

Conditions

The Caisson is showing major internal wall loss due
to corrosion, numerous leaks and cracks throughout
the splash zone, and entire length of the Caisson.

Solution

The application requires removal of all existing
clamps, then sealing and reinforcing the Caisson.
Once surface area is cleaned, the entire Caisson is
coated with a two part Kevlar reinforced epoxy. Then
multiple layers of Syntho-Glass® XT are applied to
seal and reinforce the Caisson.

Result

The repairs were an immediate success as the Caisson stopped
billowing water. The wrap cured, forming a new pipe sleeve which
is now stronger than the original pipe itself. Upon drying, the Syntho-
Glass® XT was painted orange to match the rig, and also to
provide an external barrier against the elements.

PIPELINE INSTALLATION: PIPELINE REPAIR

Problem

A high pressure water injection line has external corrosion
on girth welds.

Conditions

Removal of the shrink sleeves revealed external corrosion
ranging from 20% to 50% wall loss.

Solution

Apply Syntho-Steel® epoxy mastic to corroded area and
wrap with the calculated number of layers of applied to
Syntho-Glass® XT. This solution brings the HPI line pressure
capability back to that of a pristine pipe.

Result

Thirty joints ultimately repaired with each, then subsequently
pressure tested with no failure. Normal operations resumed at
2300psi.

PIPELINE INSTALLATION:
REINFORCEMENT AND REPAIR

Problem

Numerous underground pipelines, with external wall loss
and corrosion, are in need of immediate repair. Shutdown
of the lines is not an option during repair and rebuild.

Conditions

The pipelines are unearthed to show multiple areas of
corrosion damage and external wall loss. The pipes are
old, still in workable condition, but in need of immediate
repair and reinforcement.

Solution

The pipeline problem areas are first prepared by sandblasting,
then applying a mastic epoxy to give added reinforcement
and prevent future corrosion. These areas are
then wrapped with multiple layers of Syntho-Glass® XT
which provides reinforcement, rebuilds the pipe wall, and
permanently repairs the pipe.

Result

The reinforced pipelines are brought back to their original
strength with a permanent repair of their problem areas. The
repair was completed without the need to shut down pressure
through the lines, thus saving the customer hundreds of thousands
in shutdown costs.

Syntho-Glass® XT Technical Specification

Product Name: Syntho-Glass® XT

1. Scope:

Syntho-Glass® XT is a unique pre-impregnated bi-directional fiberglass composite system that is used to repair and reinforce both internal and external corrosion damage without shutdown of the pipeline. XT is almost as strong as carbon fiber, yet much less expensive.
Composite consistency is critical to reliability and performance! As opposed to messy,
inaccurate, labor intensive field wetting, our pre-impregnated system eliminates field mixing and wetting out of the composite, ensuring optimum fiber to resin content ratios. Nobody’s XT saves money compared to welded and performed short composite sleeves. When using XT, long sections may be coated with one single application. XT is almost as strong as carbon fiber, yet much less expensive. E-glass comes near XT!
Simplicity and Flexibility: Our system is easy to use and conforms to irregular shapes and
geometries, making it suitable to a variety of leak repairs. XT is applied with no interruption to service. Repairs are made in minutes with no chance of causing further damage to the pipeline. The resins are non-fuming and safe to the applicator. XT has the highest tensile strength of any water activated system!
Custom Engineered Solutions: Let NRI’s Pipeline Integrity Division provide application guidance in accordance with the latest ASME PCC2 standards. Your XT inventory is taken into consideration when we engineer your repair, thus eliminating your need to keep large inventories on hand for various size and/or shape applications. Our Engineering Staff are certified instructors, and are authorized to train and certify your crews as operator qualified contractors in XT application.

2. Detailed Specifications:

Standards / Codes:

Product Approval: Repairs meet the requirements of the US DOT, ASME PCC2 article 4.1, ISO TS24817 and API 570 and can be used for Pipeline Remediation to any of the following surfaces: carbon, stainless and alloy steel pipe, fittings, flanges, structural supports, for above ground, below ground, sub-sea and splash zone service.
Testing: For over 25 years, NRI has focused its strategic initiatives on the research, development, manufacturing and marketing of pipe repair and reinforcement solutions. NRI has our own on internal engineering staff and testing facility, including but not limited to tensile testing. As part of our verification and validation, we contracted Stress Engineering Services, Inc to perform third party cyclical loading and burst testing of our products to ensure long term repair capabilities. In addition, we are involved in ongoing creep testing with the University of Wyoming, and a 10 year study with Stress Engineering.
Award Winning: We are proud to announce that Syntho-Glass® XT was recently awarded
“Product of the Year” by Plant Engineering Magazine! This follows a similar award received earlier in 2008 for Trident- Seal™ which is our natural gas repair kit.

Syntho-Glass XT® Product Data

Tensile Strength	Method: Poisson's Ratio
Hoop, psi	56,700
Axial, psi	21,600
Hardness	Shore D
30 Minutes	47
2 Hours	76
24 Hours	83
Flexural	Method: ASTM D790- 3 Point Flex
Strength, psi	58,680
Shear	Method: ASTM D5379
Strength, psi	7,520
Coefficient of Linear Expansion	Method: ASTM D648
CTLE	1.06E-05
Working Time, min	30
Initial Cure, hours	2
Properties
VOC's	None
Resin Type	Water activated polyurethane
Resin Application	Micro-Controlled, Pre-Impregnated

Kevlar Reinforced 2 Part Epoxy - Load Transfer Agent Data

Temperature Resistance
Dry Applications, °F (°C)	275 (135)
Wet Applications, °F (°C)	160 (71)
Flexibility	3.2% elongation at break
Tensile Strength, psi	6,000
Compressive Strength, psi	7,380
Flexural Strength, psi	4,550
Adhesion, Dry, Abrasion Blasted Steel, psi	3,000
Abrasion Resistance	Taber Abrasion 34 mg/1,000 cycles/CS17/1,000 grams

EXPERIMENTAL EVALUATION OF THE NEPTUNE SYNTHO-GLASS XT COMPOSITE REPAIR SYSTEM

Prepared for
Neptune Research, Inc.
West Palm Beach, FL

November 2008

PN118079CRA

Stress Engineering Services, Inc.
Houston, Texas

Experimental Evaluation of the Neptune Syntho-Glass XT Composite Repair System

SES PN 118079CRA

Prepared for Neptune Research, Inc. West Palm Beach, FL

EXECUTIVE SUMMARY
Stress Engineering Services, Inc. (SES) was contracted by Neptune Research, Inc. to conduct testing to evaluate the Neptune Syntho-Glass XT composite repair System. The evaluation involved conducting a burst test and a pressure cycle fatigue test on repaired 12.75-inch x 0.375-inch, Grade X42 pipe having simulated corrosion with 75% wall loss. The Neptune composite repair system consists of an E-glass fiber system with a wateractivated polyurethane resin matrix. Strain gages were applied to the pipe in the corroded region under the repairs to evaluate the level reinforcement provided by the composite materials.

The burst test sample failed at 4,254 psi (1.72 times SMYS). The fatigue test sample failed after 165,127 cycles with a pressure range of 900 – 1,800 psi (50% MAOP). From an applications standpoint, this number of pressure cycles corresponds conservatively to a design condition of 25 years for a moderately aggressive condition in a high pressure gas transmission pipeline, and 64 years for a light pressure cycle condition.

2.0 TESTING METHODS

The sections that follow provide specific details on testing methods associated with the burst and fatigue tests.

2.1 Sample Preparation
The test samples were fabricated using an eight foot long section of 12.75-in x 0.375-in, Grade X42 pipe. Weld caps were welded to the ends of the samples, and then simulated corrosion equivalent to 75% loss in wall thickness was machined in the wall of the pipe. A diagram of the simulated corrosion is shown in Figure 2.1. Bi-axial strain gages were installed in the machined area prior to the repair. The strain gage locations are shown in Figure 2.2. A photograph of the installed gages is shown in Figure 2.3. The corroded region was filled with epoxy prior to applying the glass fiber wrap and the thickness of the composite materials was 1.0 inches (52 layers).

GRAFIK SEITE 16

Figure 2.1: Sketch of Simulated Corrosion

Figure 2.3: Strain Gages in Simulated Corrosion

Provided in Appendix A are the wall thickness measurements made in the machined regions for the burst and fatigue samples using a hand-held ultrasonic meter. Nine equally-spaced measurements were made on each sample and as noted, little scatter was detected in the measured wall thicknesses. Appendix B includes the Mill Test Report (MTR) for the 12.75-inch x 0.375-inch, Grade X42 pipe used for testing.

3.0 RESULTS
The sections that follow provide specific details on results associated with the burst and fatigue testing efforts.

3.1 Burst Test
The repaired sample failed under the repair at a pressure of 4,254 psi. The hoop strains recorded during the burst test are shown in Figure 3.1. Gages #2 and #3 were located under the repairs in the machined corroded region; Gage #4 was located on the outside of the repair, while Gage #1 was located on the base pipe away from the repair. A photograph of the cross-section of the burst failure is shown in Figure 3.2.

3.2 Fatigue Test

Strain data were collected at different intervals during the pressure cycle testing. One of the objectives in making measurements at different period during the fatigue testing is to evaluate the ability of the composite material to provide reinforcement continuously during testing. From a fatigue standpoint, the difference between the maximum and minimum strains, known as the strain range, is the key variable of interest.

Strain data measured after 500 and 100,000 cycles are shown in Figures 3.3 and 3.4, respectively. Strain data for the corroded region as a function of cycle count are shown in Figure 3.5. The sample leaked under the repair after 165,127 cycles. The photograph of the cross-section of the fatigue failure is shown in Figure 3.6.

Seite 20 - 21

4.0 DISCUSSION

It is appropriate to discuss the significance of the findings associated with the burst and fatigue tests in terms of their applicability to pipeline operation. The burst test resulted in a leak before break condition in the corroded region of the pipe at a pressure of 4,254 psi. This pressure is 1.72 times the Specified Minimum Yield Strength of the Grade X42 pipe, or 2.39 times the MAOP of a pipeline operating at 72% SMYS (pressure of 1,778 psi). If one considers that the test pipe had an ultimate tensile strength of 73,970 psi (cf.
Appendix B), the predicted failure pressure is 4,351 psi. The actual burst pressure was within 2.2 percent of this estimated value. Additionally, had the composite material not been present, the 75% corrosion region would have failed at a pressure on the order of 1,100 psi.

In addition to the burst test, the cyclic pressure testing provides several significant observations worthy of discussion. First, the number of cycles to failure (165,127 cycles) is significant. Using data contained in a paper written by John Kiefner et al1, it is possible to estimate the years of service in a gas transmission pipeline to which the measured fatigue life corresponds.

B226

Figure 3.2: Cross Section of Burst Failure

3.2 Fatigue Test
Strain data were collected at different intervals during the pressure cycle testing. One of the objectives in making measurements at different period during the fatigue testing is to evaluate the ability of the composite material to provide reinforcement continuously during testing. From a fatigue standpoint, the difference between the maximum and minimum strains, known as the strain range, is the key variable of interest.

B333

B334

335

B337

4.0 DISCUSSION
It is appropriate to discuss the significance of the findings associated with the burst and fatigue tests in terms of their applicability to pipeline operation. The burst test resulted in a leak before break condition in the corroded region of the pipe at a pressure of 4,254 psi. This pressure is 1.72 times the Specified Minimum Yield Strength of the Grade X42 pipe, or 2.39 times the MAOP of a pipeline operating at 72% SMYS (pressure of 1,778 psi). If one considers that the test pipe had an ultimate tensile strength of 73,970 psi (cf. Appendix B), the predicted failure pressure is 4,351 psi. The actual burst pressure was within 2.2 percent of this estimated value. Additionally, had the composite material not been present, the 75% corrosion region would have failed at a pressure on the order of 1,100 psi.

Percent SMYS	Very Aggressive	Aggressive	Moderate	Light
72	20	4	1	0
65	40	8	2	0
55	100	25	10	0
45	500	125	50	25
35	1000	250	100	50
25	2000	500	200	100
Total	3660	912	363	175

Single equivalent number of cicles with DP as noted

72%	276	67	25	10
36%	3,683	889	337	128

1 Kiefner J. F. et al, Estimating Fatigue Life for Pipeline Integrity Management, Paper No. IPC04-0167, Presented at
the International Pipeline Conference, Calgary, Canada, October 4 – 8, 2008.

The number of design cycles can be calculated by dividing 165,127 cycles by 20 (based
on the methods of the ASME Boiler & Pressure Vessel Code2). This calculation results in
a design life of 8,256 cycles assuming a cyclic pressure range of 36% SMYS. Using the
Kiefner data with a stress range of 36%, a moderately aggressive gas transmission
pipeline will cycle annually 337 times. Correspondingly, the 8,256 design cycles
corresponds to 25 years of service (8,256 divided by 337). For the light condition the
period of service increases to 64 years.

Another point of discussion concerns data plotted in Figure 3.5 showing both mean and
alternating hoop strains as functions of cycle number. What is noteworthy is that the
alternating strains do not change significantly over the course of 100,000 cycles. If one
assumes an alternating strain of 1,000 microstrain (i.e. elastic hoop stress of 30,000 psi)
as presented in Figure 3.5 with a stress concentration factor of 1.65 to account for the
geometry of the machined region, the estimated cycles to failure using the API X’ curve
from API RP 2A3 and a multiplier of 20 is 164,839 cycles. This is relatively close to the
actual cycles to failure of 165,127.

In summary the following observations are made when reviewing the results from the
testing of the NRI Syntho-Glass XT composite repair system:
Burst pressure was near the theoretical value for the base pipe based on the MTR- based
ultimate tensile strength for a non-corroded pipe condition.
The presence of the composite reinforcement significantly reduces hoop strain in the
corroded region. Had the composite material not been present, the burst pressure
would have been on the order of 1,100 psi, as opposed to the actual leak pressure of
4,254 psi.

The presence of the composite reduces the stress in the corroded region to a sufficient
level that permitted a leak before break condition occurred. Had the composite
material not been present, a ductile overload failure would have resulted and opened
the pipe up with the traditional fish-mouth burst failure pattern.
The fatigue test results are significant in terms of the number of cycles achieved and
the relatively low alternating strains recorded during testing.
The results of the testing program as reported herein to date indicate that the NRI
composite system effectively reinforces 75% corrosion in 12-inch NPS pipe both in
terms of short-term strength and fatigue life.

5.0 CONCLUSIONS

This report has provided technical details on the performance of the NRI Syntho-Glass
XT composite repair system in reinforcing a 12.75-inch x 0.375-inch, Grade X42 pipe
sample with 75% corrosion. The experimental evaluation involved full-scale burst testing
and cyclic pressure fatigue testing to failure. Strain gages were installed in the corroded
region beneath the composite repairs in both test samples.

The burst test sample failed at a pressure of 4,254 psi (1.72 times SMYS), while the
fatigue sample that was cycled at 36% SMYS (900 – 1,800 psi or 50% MAOP) failed
after 165,127 cycles. From an applications standpoint, this number of pressure cycles
corresponds conservatively to a design condition of 25 years for a moderately aggressive
condition in a high pressure gas transmission pipeline, and 64 years for a light pressure
cycle condition..

It should be noted that the geometry of the simulated corrosion evaluated in this study is
aggressive in terms of both its area and depth. Typical external corrosion in a pipeline is
not uniform and the associated pitting results in an uneven wall loss pattern. Therefore,
the 8-inch x 6-inch simulated corrosion incorporated into both tests is an upper bound on
what one would expect in an actual corroded pipeline. Additionally, the estimated years
of service are conservative in that the cycles to failure have been divided by 20, resulting
in a lower bound estimate of the actual estimated years of service.

Test Certifikat

Weiter Sete 39