Industrial Metal Epoxy Paste and SylWrap HD Pipe Repair Bandage make a repair independently tested as qualified to ASME PCC-2 Appendix 401-III – Short Term Spool Survival standard by rebuilding a pipe weakened by 86 percent to withstand over 309.6 bar pressure.

Case Study Overview

Site Test site
Location United Kingdom
Pipe Type 170mm carbon steel pipe spool
Repair Type Pipe reinforcement
Products Industrial Metal Epoxy Paste, SylWrap HD Pipe Repair Bandage

Pipe Defect

ASME PCC-2 Appendix 401-III – Short Term Spool Survival assesses the ability of a composite pipe repair to restore the integrity of a weakened pipeline back to the strength of the original pipe.

Industries like oil and gas, chemical processing and power generation where high pressure systems and hazardous pipe content are present require pipe repairs to be ASME PCC-2 401-III compliant.

To qualify Industrial Metal Epoxy Paste and SylWrap HD Pipe Repair Bandage for PCC-2 401-111, a test repair was independently witnessed and verified by UKAS registered LRQA Verification Limited.

The test was performed on a 170mm diameter, 1.4-metre-long ASTM A106 B Grade pipe spool. This type of carbon steel pipe is used in high temperature applications such as steel and gas pipelines.

A defect was machined into the spool covering an area 84mm long by 42mm wide. The defect reduced the wall thickness of the pipe from 7.1mm down to 1mm, accounting for an 86 percent weakening of the line.

SylWrap Solution

Before the repair, a flap wheel was used to clean the area back to bare metal. The pipe was then thoroughly cleaned using a solvent degreaser to remove any remaining traces of foreign substances.

Industrial Metal was mixed and applied using a hand tool. It filled in the defect, rebuilding the pipe wall back to its original 7.1mm thickness and also acting as a load transfer medium between the spool and the SylWrap HD Bandage.

The Sylmasta Pipe Refurbishment Calculator determined the SylWrap size and number of bandages needed to reinforce the pipe so it became strong enough to hold 309.6 bar pressure.

It calculated five SYL633HD Bandages were needed to create a 32 layer repair, 9.55mm thick and covering an area of 406mm.

A total of 33 layers ended up being wrapped around the pipe from the five bandages. The fast working, water activated resin began to cure within minutes to form a rock-hard, impact resistant shell over the spool.

Outcome

Based upon the yield strength, diameter and wall thickness of the pipe spool, the repair needed to withstand 309.6 bar pressure to be certified as PCC-2 401-III qualified.

Technical Valve Services used calibrated and certified pressure gauges to test the repair, witnessed by LRQA Verification Limited. The results were recorded on a data logger.

The repair reached 310.29 bar before failing when water began leaking through the edges, certifying Industrial Metal and SylWrap HD for ASME PCC-2 401-III standard repairs.

Follow Up

Since achieving ASME PCC-2 401-III qualification, Industrial Metal and SylWrap HD have been used by major oil and gas companies for pipeline reinforcement across the Middle East and Africa.

Products Used

Industrial Metal
Epoxy paste rebuilds weakened and degraded pipelines to original specification

SylWrap HD Bandage
Water-activated wrap which strengthens pipes by forming a thick, hard outer shell

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