Loctite Composite Repair System Pipe Repair Introduction ... · Composite Repair System: Pipe Repair 2. Introduction Industries where no standard is required: Power plant and waste

Loctite® Composite Repair System – Pipe Repair Introduction, training overview and target

Bernd Hammer; Dec 3-4, 2014

Workshop Introduction: Loctite® Composite Repair System 2 2

1. Workshop Agenda

2. Introduction of Composite Repair System – Pipe Repair -

3. Product Management Information

4. Technical data

5. Approval, calculation tool and applicator certification

6. Marketing support material: Illustrations, brochure, video and article

7. Training overview and target

8. Basic skills, experience and validity of qualification (installer and supervisor)

9. Benefits of Composite Repair System (general & Loctite system)

10.References and application areas

Table of Contents


Wednesday , Dec 3 at Xiang Mao

Composite Repair System – Pipe Repair - 1. Workshop Agenda

Time Description Who

09:00 Theory

- Introduction, training overview

and target, market & marketing

Bernd

10:00

10:30

Theory

- Definition, H&S, tool and products to be used

Communication break

Ged

All

10:45 Theory

- Repair process (A & B Repair)

Ged

11:45 Practical session 1

- Surface preparation (Demonstration Sample)

- Type A : Rebuilding surface

Ged/Tom

12:30 Lunch All


- Type A & B : Reinforcement

Tom/Ged

14:45 Communication break All

15:00 Theory

- Repair process components

Ged


- Reinforcement of components

Ged

16:30 Communication break All

16:45 Meeting room

- Debriefing: Type A & B

Ged

17:15 Finish of Day 1 All


Thursday , Dec 4 at Xiang Mao

Composite Repair System – Pipe Repair - 1. Workshop Agenda

Time Description Who

09:00 Meeting room

- Recap and questions from Day 1

Ged/All

09:30

10:30

Practical session 4

- Demonstration Sample Preparation

Communication break

Tom/Ged

All

10:45 Theory

- Supervisor responsibilities including

Calculation Tool & quality control

– inspection method

Ged


- Protect repair area

(Top Coat application Demonstration Piece)

Ged/Tom

12:45 Lunch All

13:30 Exam

- Theory

All

14:00 Communication break &

End of pipe certification workshop

All

14:10 Next action steps Bernd

14:30 Market roll out & business John

15:00 Finish of training All

Workshop Introduction: Loctite® Composite Repair System 5

Composite Repair System: Pipe Repair 2. Introduction

“The Composite Repair System, Pipe Repair ” is

a repair system developed according the ISO

Standard 24817 ( = Petrochemical and natural

gas industries – composite repair for pipe work)

The pipe repair system consists of a 2 C Epoxy

and reinforcement fibre

The application will be carried out on the

“outside of pipes” in case of corrosion and

through - wall defects

It can be used on pipes and pressure equipment

in power plants, waster water plants and

refineries & petrochemical plants



The “Composite Repair System” consists of:

2 Component Epoxy

Fibre (mixed with glass & carbon)

+ =

In addition a top coat with:

Loctite 7255 Sprayable Ceramic Grey

(As UV and fire retardant coating; Protective

coat against outside exposure)

= >



Industries where no standard is required: Power plant and waste water

Petroleum, petrochemical and natural gas industry: It is only possible to

carry out a pipe repair with an approved repair solution

Different state of pipes: Corroded pipes and pipes with through – wall

defects

According to the defect and application area, different repair methods are

possible and different classes are required:

The repair method:

• Repair of corroded

pipes

• Repair of through

wall defects


ISO global (2006) DIN CEN ISO/TS European (2011)

(European & German harmonization) (Compliance to ASME PCC -2)

Composite Repair System: Pipe Repair 2. Introduction: The ISO / TS Standard


Composite Repair system is available under the following grade codes

A) Loctite 7210 = Epoxy (A&B) + Spatulas Single pack size of resin: 1kg Qty. per carton: 6 x 1kg of resin + 6 spatulas

B) Loctite 5085 = Reinforcement Fiber

1 roll á 30m (120mm in width) packed in a single carton

Composite Repair System: Pipe Repair 3. Product management information


A) Loctite 7210 (Epoxy + Spatula)

B) Loctite 5085 (Fiber)

NOTE:

Both epoxy and fiber are available as separate items

this is to keep flexibility for additional business

Composite Repair System: Pipe Repair 3. Product management information

Product Pack Size Language

version

Language IDH MOQ

(CON)

Loctite® 7210 1kg EDFN UK, DE, FR, NL 1634917 1kg KIT A&B

EPIG ES, PT, IT, GR 1638401 1kg KIT A&B

SFDN SE, FI, DA, NO 1638421 1kg KIT A&B

Loctite® 5085 1 Roll á 30m EN EN 1647020 1 Roll á 30m 1

6*


Loctite® Composite Repair System – Pipe Repair 4. Technical Data

Product 7210 5085 3478 7255 7515

Type 2C Epoxy Glass-Carbon

Fiber Tape 2C Epoxy 2C Epoxy

Corrosion

Inhibitor

Colour Beige Grey Grey Green / Grey Brown

Viscosity 33 Pa.s

(Plate-plate at 40 sec-1,

@25°C)

n/a Putty

5 Pa.s (Brookfield @25°C,

spindle 7, speed 100

rpm)

Liquid

Mix Ratio by

weight 100 : 16 n/a 100 : 21 100 : 50 n/a

Mix Ratio by

volume 3,125 : 1 n/a 4 : 1 2 : 1 n/a

Shelf Life 18 Months 120 Months 24 Months 18 Months 12 Months

Pot Life

(at 25°C) 35 - 40 Minutes n/a 20 Minutes 40 Minutes n/a

Package Size 1 KG 1 roll á 30 M 453 G / 3,5 KG 900 ML / 30 KG 5 L / 20 L


ISO/TS 24817 certified by Germanischer Lloyd:

Loctite ® Composite Repair System – Pipe Repair

Calculation Tool

Certified training of applicators

Composite Repair System: Pipe Repair 4. Approval, calculation tool and applicator certification

Merge of GL & DNV in 2013:

New approval with GL & DNV Logo will follow


• Loctite Composite Repair System for reduced wall-thickness („Defect Type A“)

Loctite® Composite Repair System – Pipe Repair Certificate: Defect type - Reduced Wall thickness


• Loctite Composite Repair System for through-wall defects („Defect Type B“)

Loctite® Composite Repair System – Pipe Repair Certificate: Defect type - Through-wall


• Loctite Composite Repair System for Straight pipes and complex geometries

Flanges, T-Pieces, Reducers and Bends

Loctite® Composite Repair System – Pipe Repair Certificate: Geometry – Pipe Components


• Loctite Composite Repair System for Vessels, tanks and

pipes of large diameter (>600 mm)

Loctite® Composite Repair System – Pipe Repair Certificate: Geometry – Vessels and tanks

D> 600 mm



Full approval we will achieve with:

Qualified repair solution (ISO 24817 A or A&B)

Handing out to our customer in petrochemical industry

Calculation tool (approved from GL)

To calculate how to carry out the repair in dependence of many parameter

In order to have a documentation of the most important characteristic of the

repair

Applicator Training

Repair method should only be carried out from experienced applicator

That applicator still need to be trained in theory and practical part (e.g.

application method of repair)

Training according the standard ISO 24817 – Trainer to be certified from GL


Roll out plan 2013 2014

Q2 Q3 Q4 Q1 Q2 Q3 Q4

GL Certification – A

GL Certification – B

A & B Approval

• B approval in place

(through wall defects)

• Patch Method

• Certified calculation tool

A Approval

• Full A approval in place

(corrosion

• Components approval

Completion of

approval (2014)

• Scale up 5 mm

• Surface preparation

• Additional substrates

(stainless steel)

• Improve impregnation



Current situation:

• Full A approval achieved (Q1 – 2013)

• Approval for complex geometries: Bends – T-joints – etc (Q4-2013)

• B approval in place (Q1-2014)

• NEW: Tank & pressure vessel approval – Patch method (Q2-2014)

• NEW: Merge of GL & DNV

• NEW: Calculation tool: Certified by GL & DNV (Q2-2014)

• Transferring approval (acceptance): Lloyd`s Register & TÜV

Approval available Currently approaching:



Calculation tool:

Calculation of number of wraps

and length of repair

Repair is depending on many

parameters like repair class, kind

of defect, repair lifetime or

system to repair

Calculation tool will be certified

from GL



4 Loctite® 7255

Sprayable Ceramic

3 Loctite® 7210 & 5085

Composite Repair

2 Loctite® 3478

Superior Metal

1 Loctite® 7515

Surface Preparation

Repair System:

Composite Repair System – Pipe Repair 6. Marketing Support: Illustration, Flyer & Video


Illustrations for two different kind of repairs:

Repair of corroded pipe & pipeline (A = none through wall defect)

Repair of cracks and holes (B = through wall defect)

Corroded pipes Holes and cracks




2 page flyer


Two detailed technical video; One for A and one for B Approval –

(Corrosion & Through wall defects)



Composite Repair System – Pipe Repair 6. Marketing Support: Customer Presentation

• 34 page customer presentation, linked with technical video & pressure testing

• In general used for customer introduction, providing a good overview of the

repair system and technical detail for supervisor, engineers and maintenance

managers


http://www.gl-nobledenton.com/en/1336.php

Composite Repair System – Pipe Repair 6. Marketing Support: GL Article (external)


Press article available: UK & German version

Composite Repair System – Pipe Repair 6. Marketing Support: Adhesive Technology News


http://www.loctite.co.uk/pipe-repair-8890.htm

Composite Repair System – Pipe Repair 6. Marketing Support: Internet site

29

• Display for pipe available to support local activities (exhibition &

customer presentations

• New: Additional 5 pcs large diameter pipe displays

Workshop Introduction: Loctite® Composite Repair System

Composite Repair System – Pipe Repair 6. Displays


Composite Repair System: Pipe Repair 7. Training overview and target

Explain the Henkel Composite repair system It is not just a product, it is a full system

Training to handle Henkel composite repair system

You will have to practice all steps Fulfill requirement for qualification as applicator

According to ISO/TS 24817 Training approved by GL on: Theoretical knowledge & Practical

ability (= Theoretical + practical test) Practical test (according ISO/TS 24817 – annex I §I.4)

On pipes that you will repair (lab. Session) including: - Visual qualification - Pressure test qualification - Instant test pressure up to leakage


Composite Repair System: Pipe Repair 8. Basics skills, experience and validity of qualification

Requirements for installer and supervisor ISO/TS 24817 Annex I

Basic skills and experience:

Installer shall be minimum 18 years of age

Minimum of two years experience in repair and maintaining with

pipe related system (Polymer Composite experience); Or having

supervised 12 repair applications;

In house & on site training of at least two weeks in duration in sum

Validity of qualification:

Type specific qualification is valid for a period of one year

Requalification is necessary after not having carried out a repair

for longer than one year


Composite Repair System: Pipe Repair 8. Basics skills, experience and validity of qualification

Support & training on site with Henkel MRO Specialists

Surface Engineering Solutions

Henkel certified “applicator training”

Advanced Module:

Composite Repair System

– Pipe Repair –

Requires SES Training

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September 2, 2016 Loctite® Composite Repair System – Pipe Repair 33

Composite Repair System for Pipework 9. Benefits

• No need to replace pipes

• Cost efficient repair method in comparison to

welding

• In situ repair method, avoidance or reduction of plant

shut down time

• „Cold Repair Method“ and no heat required in

comparison to welding (Ex – zone repair method)

• Repair of complex geometries, for example flanges

and bends

• Certified solution: Repair System, Calculation Tool

and Installer Training

• Increase pipe lifetime by up to 20 years

September 2, 2016 Loctite® Composite Repair System – Pipe Repair 34

Application:

•Industry: Refinery / UK

•Process.: Crude oil / buried pipe / 35 bar design

pressure; Class 3

•Kind of repair: A Repair– corroded pipe – 20 years

lifetime extension

•12“ (305 mm) diameter; 4 Layer (7,1 mm

Thickness); 600 mm repair width,

Costs in comparison:

•Welding (material & labor): 13.000 €

•Plant shut down during welding: 2 days / 159.000 €

•Henkel Repair System: 2.500 € (material & labor)

Composite Repair System for Pipework 9. Benefits: Cost comparison

2. September 2016 Loctite Composite Reparatursystem – Rohrreparaturen 35

• Full certified system by GL & DNV: Repair System,

Calculation Tool, Applicator & Supervisor Workshop

• Especially developed System according ISO/TS 24817

• High value & comfortable calculation tool, based on C

programming

• All areas of pipe work: Complex geometries, like

flanges and T – Joints (certified and approved)

• Safe and improved surface preparation and opening of

process window: Loctite 7515 Corrosion Inhibitor

• High elongation @ break of repair system to withstand

all needs of dynamic loads

• Henkel: European & global available product solution

and also support in all regions with our maintenance

specialists in project planning and application

Composite Repair System for Pipework 9. Benefits: Specialties of Loctite System


Composite Repair System – Pipe Repair 10. Application Areas & Industries

Refinery &

Petrochemical

Industry

Oil & Gas

Water Utilities

Power Plants:

Hydroelectric

Nuclear

Gas fired

Oil fired


Refinery & Petrochemical Industry




Refinery & Petrochemical Industry


Gas Pipes & Pipelines

Advantage: Repair without plant shut down –

in situ repair




Water pipes for hydrolectric power plants



Off Shore Pipe & Pipeline: Processing Hydrocarbons



Power Plant

Thank you!

Documents

Loctite Composite Repair System Pipe Repair Introduction ... · Composite Repair System: Pipe Repair 2. Introduction Industries where no standard is required: Power plant and waste