United States Department of Transportation
i
New In-Field Composite Repair Techniques for Transmission or Distribution Pipelines
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2009-05-18
[PDF-4.49 MB]
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Alternative Title:SBIR Phase I: New In-Field Composite Repair Techniques for Transmission or Distribution Pipelines
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Edition:Final Report
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Abstract:In-field repair of a damaged pipeline must be performed safely, efficiently, rapidly and reliably. Reinforcement of damaged pipelines is typically accomplished by welding a repair patch and then recoating the repaired area. The welded full-encirclement sleeve is still the most common repair system due to the lower risk, potential cost savings, and simplicity of the repair. Recent developments in fiber reinforced composite repair patches have led to their increased usage across other industries. A composite repair offers an alternative to welding as the strength is claimed to be comparable. The pipeline surface conditions play a role in the long term performance of the composite patch. Odyssian Technology will introduce a new composite repair technology that uses thermoplastic as the composite matrix in place of the conventional thermoset. A thermoset polymer sets up under heat or when mixed with a two part system having chemical hardeners. The elevated cure thermoset systems require exposure to heat over prolonged periods of time. This can be problematic during infield repair under harsh weather conditions. A two part system can be used that significantly reduces the time of cure of the thermoset resin, yet typically at a cost to the structural performance of the polymer matrix material. Two part system achieve cross-linking or cure through the addition of hardeners. These hardeners act as catalysts to promote and accelerate cross-linking of the polymer system. The disadvantage is that they typically cause a significant reduction in mechanical properties, which can cause a corresponding reduction in compressive strength of the composite material system. The advantage of thermoplastic over themoset is that a thermoplastic melts and fuses when heated. This process does not rely upon extended heating to cause complete cross-linking and full realization of mechanical properties. In addition, thermoplastics can be recycled which may allow the thermoplastic composite repair materials to be made from lower cost recycled plastics. Odyssian Technology will perform a design study of a composite repair wrap using layered cover that includes the use of hybrid fiber composite material with an embedded thick film of HDPE for improved toughness and sealing. A high flow bonding adhesive would be used to assure adequate fill and bonding to the aged or damaged pipe. This is a two piece configuration, with the advantage of this concept being reduced time and improved ease in repair. The official start of this program was September 18, 2008 with completion of the scheduled technical tasks by May 1, 2009 and final reporting and documentation by May 18, 2009.
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