Full-Scale Elevated Temperature Testing of Composite Repairs in Bending and Compression

Sheets, Colton; Rettew, Robert E.; Alexander, Chris; Axenova, Tanya

doi:10.1115/ipc2016-64213

Cited by 2 publications

(3 citation statements)

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“…Later stages of the assessment included full-scale, elevated temperature tests which allowed for a more in-depth analysis of the performance of selected repairs. [1] The methodology and benchmarks used in analyzing these systems is outlined in subsequent sections.…”

Section: Ipc2016-64211mentioning

confidence: 99%

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Experimental Study of Elevated Temperature Composite Repair Materials to Guide Integrity Decisions

Sheets

Rettew

Alexander

et al. 2016

Volume 3: Operations, Monitoring and Maintenance; Materials and Joining

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Over the past two decades, a significant amount of research has been conducted on the use of composite materials for the repair and reinforcement of pipelines. This has led to vast improvements in the quality of composite systems used for pipeline repair and has increased the range of applications for which they are viable solutions (including corrosion and mechanical damage). By using composite repair systems, pipeline operators are often able to restore the structural integrity of damaged pipelines to levels equal to or even in excess of the original undamaged pipe. Although this research has led to substantial advancements in the quality of these repair systems, there are still specific applications where questions remain regarding the strength, durability, and effectiveness of composite repair systems, especially in elevated temperature, harsh environment conditions. This program initially involved composite repair systems from six manufacturers. The test group included both carbon and E-glass based systems. Performance based qualifications were used to reduce the size of the test group from the initial six systems down to three. The experimental study consisted of small-scale testing efforts that ranged from tensile tests performed over a range of temperatures to 10,000-hour material coupon tests at elevated temperatures. The elevated temperatures used for testing were intentionally selected by the operator to reflect the 248 °F design temperature of the target pipeline. Using small-scale qualification testing outlined in ASME PCC-2 – Repair of Pressure Equipment and Piping standard (Article 4.1, Nonmetallic Composite Repair Systems: High-Risk Applications) as a foundation, the test program described in this paper was able to demonstrate that, when properly designed, and installed, some composite materials are able to maintain their effectiveness at high temperatures. This study combined short-term and long-term testing of composite systems and demonstrated the advantages of a 10,000 hour test when aging properties are unknown. Finally, the study showed that, although high-temperature reinforcement using composite repair systems is feasible and commercially available, this capability is not standard practice across the composite repair industry. Proper analysis and verification using experimental methods, including full scale testing should be conducted prior to installation of a composite repair system in these types of harsh conditions.

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Section: Ipc2016-64211mentioning

confidence: 99%

“…This pattern of performance can also be seen in follow-up full-scale testing that was performed. [1] 10,000-hour Creep-rupture Testing…”

Section: Tensile Couponsmentioning

confidence: 99%

Experimental Study of Elevated Temperature Composite Repair Materials to Guide Integrity Decisions

Sheets

Rettew

Alexander

et al. 2016

Volume 3: Operations, Monitoring and Maintenance; Materials and Joining

Self Cite

View full text Add to dashboard Cite

show abstract

“…The two prospective systems were selected using a full-scale testing regime that included internal pressure, axial compression, and bend tests [1]. Full-scale testing focused on the reinforcement of 12.75-inch x 0.375-inch, Gr X60 pipes.…”

Section: Ipc2016-64214mentioning

confidence: 99%

Finite Element Analysis of Composite Repairs With Full-Scale Validation Testing

Sheets

Rettew

Alexander

et al. 2016

Volume 1: Pipelines and Facilities Integrity

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Composite repair systems for pipelines are continuing to be used for increasingly difficult and complex applications which can have a high consequence of failure. In these instances, full-scale testing is typically pursued at a high-cost to the manufacturer or operator. Finite element analysis (FEA) modeling is a valuable tool that becomes especially attractive as a method to reduce the number of full-scale tests required. This is particularly true when considering the costs associated with recreating complex load and temperature conditions. In order for FEA to fill this role, it is necessary to validate the results through full-scale testing at the same loads and temperatures. By using these techniques, FEA and full-scale testing can be used in unison to efficiently produce accurate results and allow for the adjustment of critical parameters at a much lower cost than creating additional full-scale tests. For this program, a series of finite element analysis (FEA) models were developed to evaluate the performance of composite materials used to reinforce corroded steel pipe in critical applications at elevated temperatures up to 120 °C. Two composite repair manufacturers participated in the study which was conducted on 12-inch × 0.375-inch Gr. X60 pipes with machined simulated corrosion defects that represented 50% wall loss. Load conditions consisted of axial compressive loads or bending moments to generate compressive stresses in the machined defect. In the described evaluation program, FEA simulations were able to produce results which supported those found in full-scale validation testing. From the FEA models stresses and strains were extracted from the reinforced steel and composite materials. Good correlation was observed in comparing the results. Although limitations of the modeling included accurately capturing differential thermal strains introduced by the elevated test temperature, the results indicated that FEA models could be used as a cost-effective means for assessing composite repair systems in high-temperature applications.

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Full-Scale Elevated Temperature Testing of Composite Repairs in Bending and Compression

Cited by 2 publications

References 1 publication

Experimental Study of Elevated Temperature Composite Repair Materials to Guide Integrity Decisions

Experimental Study of Elevated Temperature Composite Repair Materials to Guide Integrity Decisions

Finite Element Analysis of Composite Repairs With Full-Scale Validation Testing

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