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Picture of underground natural gas pipeline with successful composite wrap repair applied.

Translatable Benefits of Carbon Fiber Composite Repair Applications Throughout Pipeline Networks

By advmarketing on April 28, 2023

For upstream, midstream, and downstream sectors, pipelines are vital to gathering, transmitting, and distributing the energy people need. These pipelines create a complex network of lines, with a complex network of supervising entities. Whether you are an operator of a major gas transmission network or a utility company servicing customer homes, composite repairs are a proven solution for repairing pipelines susceptible to many common threats, including corrosion, dents, cracks, and hydrogen embrittlement. Composite repairs meet established regulatory standards, and they are a proven solution for pipeline repairs to address these threats in all parts of the utility pipeline network.

Regulatory Impact

PHMSA (Pipeline and Hazardous Materials Safety Administration) of the U.S. Department of Transportation sets federal standards for gas transportation (including natural gas, flammable gas, or other toxic or corrosive gases). According to the 49 CFR Sec 192 code, pipelines experiencing corrosion must be repaired or replaced if one of the two conditions are met:

  • Wall thickness degrades beyond what is required for the MAOP (maximum allowable operating pressure)
  • Wall thickness degrades to 30% less than nominal wall thickness.

If repair is the chosen course of action, the repair method must be shown by reliable engineering testing and analysis to be effective and permanently restore the serviceability of the pipe.

Typical methods that may meet these requirements include:

  1. Grinding out and recoating
  2. Steel reinforcement sleeve repair (Type A)
  3. Steel pressure-containing sleeve repair (Type B)
  4. Composite wrap repair
  5. Hot tap section
  6. Pipe replacement

Not all of these methods are feasible or the best solution for the threat at hand. Oftentimes, expert consultations will make choosing the right method easier and will lead to a more effective repair.

Engineering Critical Assessment

Performing an engineering critical assessment, which is a set of engineering tests and analyses to establish MAOP, provides a better understanding of the repair needs and where the repairs should be performed based on inspection data and physical testing. ECA is an acceptable method established by the 49 CFR Sec 192 code for reconfirming MAOP for gas transmission lines.

Composite Repairs for Pipeline Gas Transportation

Composite repairs are a common practice for high-pressure, high-risk gas transmission lines. Their application in other parts of the pipeline network, such as distribution and service lines, might not be as common, but the principles that make composites applicable for transmission lines still apply.

The Translatable Benefits of Composite Repairs

First, composite repairs offer much more flexibility, ease of use, and safety in repair situations. Composites can fit complex pipe geometries, such as around flanges or elbows. Composites can also be applied in many cases while systems are still online, maximizing efficiency, and they can be applied quicker than alternatives (i.e. welding steel sleeves). Composites are also applied without heat, which is especially important when the pipeline is transporting highly flammable and dangerous substances.

Advanced FRP System’s carbon fiber composite systems are structurally reinforcing, eliminate external corrosion, and have a 50-year, maintenance-free service life. The system can handle 1,000 psi internal pressure even with a through-wall failure. The repair is also compliant with ASME PCC-2 and ISO 24817 requirements.

Demonstrated Success in Utilities: Refurbishment of Natural Gas Transmission Lines

A major utility provider needed to repair badly corroded pipe and pipe supports for a natural gas main transmission line. When the severe corrosion was identified on the natural gas line, the pipe had to be downrated to 200 psi as a safety precaution. As a result, the supply of natural gas was restricted during the coldest stretch of winter in the Northeast.

Composite wrap repair for natural gas transmission line operated by major utility provider.

Advanced FRP Systems worked closely with an experienced contractor to apply the repair system elements. One layer of fiberglass and 4 layers of bi-directional carbon fiber composite were applied and coated with an epoxy coating. The utility provider was able to successfully repair 600 linear feet of 24” pipeline with carbon fiber composites in 6 weeks.

Advanced FRP System’s experience and expertise combined with third-party, independent testing factored into the recommendations for installing a composite repair system on the pipeline. Ultimately, the operator opted to use composites, which would 1) allow the natural gas line to return to full-pressure services much faster, and 2) provide a long-term, proven solution for a high-strength, maintenance-free repair.

For questions about the applications of composite repairs for many different types of gas pipelines, contact Advanced FRP Systems for a free consultation.

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