June 26, 2020

Designed for : MPNU-IDIOHO

Project Info : 6” straight pipe on P-1029-6’’-120-AGA-3

Project ID : EATL/MPNU.IDOHO/ED/002/020
Contact : Stephen Onyenobi
Number : (909) 103-6258

Package contains :
Repair Summary, Detailed Calculations and Directions

Not yet reviewed by a Milliken Pipe Wrap Engineer

Designed in accordance to the ISO 24817 Standard.

15832 West Hardy Road, Suite 600

Houston, Texas 77060
Phone: 281-999-7100
Fax: 281-999-7110
WrapCalc Version 2.2.3

© 2015 Milliken Infrastructure Solutions LLC.

 Project Input and Design Summary
Contact Name Contact Number Address
Stephen Onyenobi (909) 103-6258 MPNU-IDIOHO
Contact E-mail Project ID
stephen.o.ebaretonbofa@exxonmobil.com EATL/MPNU.IDOHO/ED/002/020
Repair Type Structural Reinforcement Type A Defect
Component Type Process piping Additional Information
Repair System FormaShield
Intended Service Life 5 year design
Project Description 6” straight pipe on P-1029-6’’-120-AGA-3
Pipe Information
Pipe Material Carbon Steel Component Shape Straight pipe
Actual Pipe Diameter 6.625 inches Product in Pipe HydroCarbons
Original Wall Thickness 11.000 mm Chemical Concentrations
Pipe Grade (SMYS) 65,000 psi Chemical Resistance Good
Pipe Tensile Modulus 30,000,000 psi Long inches
Surface Prep Available Media Blasting - ideal 90
Design Conditions
External Corrosion External Erosion Internal Wall Loss Gouge Dent Crack
Defect Type
Other:

Repair Zone options Requested length Requested repair length 42 inches

Defect Length (Axial) 38.000 inches
Defect Width (Hoop) 6.750 inches
Defect Depth 7.900 mm 24.0
Weld Interaction Not Applicable 8
Operating Pressure 250.0 psi Operating Temperature 65 °F
Installation Pressure psi Installation Temperature °F
System Design Pressure 2,035.0 psi Design Temperature 100 °F
Additional Considerations None

Repair Design
Number of Layers 4 layers Repair Thickness 3.352 mm
Wall Loss Percentage 71.82 % Repair Zone 42.0 inches
Pristine Pipe Pdesign 8,498 psi Pristine Pipe MAOP 3,399 psi
Damaged Pipe Pdesign 2,395 psi Damaged Safety Pressure 958 psi
Repaired Failure Pressure 5,163 psi Repaired Safety Pressure 2,035 psi
Repair Materials(3 inch Overlap - Spiral Wrap)
REPAIR KIT Calculated Material Custom Design Material
Quantity & Roll Sizes 3 each - 6" x 20ft Q Kits
(inch x feet)

20 each - 4 OZ Stick of EP-400

Quantity of Filler

1 each - 2 Pt Kits of PPR

Quantity of Coating

© 2015 Milliken Infrastructure Solutions LLC. Page 2

 Design Input Parameters and Material Properties
Process piping FormaShield
Carbon Steel Pipe Parameters Composite Properties
Geometric Conditions Generic Properties
Actual Outsdie Diameter (D) : 168.275 mm Ply Thickness : 0.8382 mm
Wall Thickness : 11.000 mm Company Min. Layer Count : 4
Strength of Materials Strength of Materials
Tensile Modulus (Es) : 206,843 MPa Hoop Modulus (Ec) : 21,374 MPa
Yield Strength (s) : 448 MPa HoopTensile Strength : 498 MPa
Long Term Strength (slt) : 349 MPa
Pressure Conditions Axial Modulus (Ea) : 9,653 MPa
Operating Pressure : 1.724 MPa Shear Modulus (G) : 8,963 MPa
Installation Pressure (Plive) : 0.000 MPa Bending Modulus (Eac) : 20,684 MPa
System Design Pressure (P) : 14.031 MPa Poisson's Ratio (v) : 0.37
Pristine Pipe Design Pressure : 58.591 MPa Effective Poisson's (v2) : 0.25
Piping system components - Repair thickness increase factor
Component Dimensions Component Multiplier Factor
Diameter of branch pipe of Tee : 0.000 mm Tee : N/A
Thickness of Branch Pipe of Tee : mm Bend : N/A Factor Used:
Wall Thickness of Flange : 0.000 mm Flange : N/A 1.00
External Diameter of Reducer : 0.000 mm Reducer : N/A
Pipe Design Factors Composite Design Factors
Class Design Factor : 0.40 Temperature Factor : 1.00
Pipe Temperature Factor : 1.00 Service Factor : 0.50
Pipe Joint Factor (PJF) : 1.00 Defect Type Factor : 1.00
Defect Dimensions
Repair Zone options Requested length Requested repair length 1066.8 mm
Primary Defect Type : External Corrosion Corrosion Depth : 7.900 mm

Defect Length : 965.20 mm Remaining Wall (ts) : 3.100 mm

Defect Width : 171.45 mm Wall Loss : 71.8%
Leaking now or at end of life : No
Parameters for leak repair only
Defect Properties Composite Leak-Related Properties
Is pipe being depressurized : Yes Is a Stop-Gap being used : No
No Leak Present Energy Release Rate (γ) : 166.546 J/m²
Defect Shape : No Leak Adhesive Lap Shear Strength : 19 MPa
Thermal Considerations
Composite Hoop CTE : 4.83E-06 °Cˉ¹ Glass Transition Temp. (Tg) : 176.6666667 °C
Composite Axial CTE : 9.67E-06 °Cˉ¹ Heat Distortion Temp. (THDT) : °C
Substrate CTE : 6.00E-06 °Cˉ¹ System Design Temp. (Td): 38 °C
Ambient Test Temp. : 22 °C System Operating Temp. : 18 °C
Qualification Test Temp. : 22 °C Installation Temperature : -18 °C
Tm : Service Temperature Limits for Repair systems (°C) Temperature Derating Factor
Pipe Condition : leaking no leaking Service Temperature (Tm) : 157 °C
From Tg Measurement : 147 157 Temp. Differential (Tm-Td) : 119 °C
From HDT Measurement : Temperature Factor (fT) : 1.00
Temperature Factor (fT2) : 1.00
Allowable Repair Laminate Strains
Design Life of: 5.00 years Performance Factor (fperf) : 0.58
Long Term Strain (ɛLT) : 1.63% Performance Strain (ɛc) : 0.95%
Initial Allowable Strain
Allowable Strain
Hoop Direction
εc0 0.29%
Adjusted for Temperature
c = fTc0 −T s −c ( ) (Equation 10)

εc see perf. strain a = fTa0 −where T(ΔT s=−36.1111111111111°C

a)
Initial Allowable Strain c = fTc0 −T s −c( )
εa0 0.10%
Allowable Strain
Axial Direction Adjusted for Temperature
a = fTa0 −T(s −a) (Equation 10)
εa 0.09% where ΔT = 36.1111111111111°C

© 2015 Milliken Infrastructure Solutions LLC. Page 3

 FINAL DESIGN OUTPUTS
Final Repair Thickness Determination
Repair Type Structural Reinforcement
Structural Design Methodology (Hoop) : Performance Testing Minimum structural reinforcement is calculated. Shows
Calculated Thickness (Hoop) : 3.353 mm methodology and minimum thickness results.
Calculated Thickness (Axial) : 0.000 mm Axial loading assumed to be a non-issue.

Piping System Component Multiplier :
Calculated Minimal Repair Thickness :
Company Minimal Repair Thickness :
Defect Type Multiplier :
1.00 Added safety factor to component shape.
Factor to compensate for limited repair length.
3.353 mm Largest thickness listed above.
3.353 mm Based on minimum layers to ensure stress transfer.
1.00 Added safety factor due to defect considerations

Spiral Wrap Layer Adjustment : + 0 layer

Recommended Repar Thickness : 3.353 mm Largest thickness multiplied by added safety factors results in
Corresponding Layer Count : 4 final repair thickness and layer count.
7.5.8 Axial extent of repair ISO 24817 ASME PCC-2 Article 4.1
Minimum length over defect edge : 3.39 inches ( X 2 )
𝐿𝑜𝑣𝑒𝑟 = 2 𝐷𝑡 𝐿𝑜𝑣𝑒𝑟 = 2.5 𝐷 𝑡Τ2
Length of defect : 38.00 inches
(Equation 18) (Equation 16)
𝐿𝑜𝑣𝑒𝑟 = 4𝑑
Sum of Lengths : 44.78 inches 𝐷𝑡 𝐸𝑎 𝜀𝑎 𝑡𝑟
𝑤ℎ𝑒𝑟𝑒 𝑑 < 0.5 𝐷𝑡 𝐿𝑜𝑣𝑒𝑟 = max 2.5 𝑜𝑟
(Equation 19) 2 𝜏
2Τ 3
𝑙𝑜𝑣𝑒𝑟 (Equation 17)
𝑓𝑡ℎ,𝑜𝑣𝑒𝑟𝑙𝑎𝑦 =
𝑙𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒
Initial Calculated Length required : 44.78 inches Equation 22
𝐿 = 2𝐿𝑜𝑣𝑒𝑟 + 𝐿𝑑𝑒𝑓𝑒𝑐𝑡 + 2𝐿𝑡𝑎𝑝𝑒𝑟
Requested length 42 inches (Equation 20) / (Equation 18)
Pressure Analysis
Pristine Pipe
9,000
Design Pressure (of pipe) 8498 psi
8,000
System MAOP 3399 psi
7,000
System Design Pressure 2035 psi
6,000
Pressure (psi)

Damaged Pipe 250

5,000
Re-rated Design Pressure 2395 psi
Re-rated MAOP (ps) 958 psi 4,000
3,000
Operating Pressure 250 psi
Composite Only 2,000
Design Pressure 2768 psi 1,000
Equivalent MAOP 1107 psi 0
Rehabbed Pipe Pristine250
Pipe Damaged Pipe Rehabbed Pipe

Design Pressure 5163 psi Design Pressure (of pipe) System MAOP Operating Pressure
MAOP 2065 psi
Geometric Design Results
Calculated Adjusted Values
Recommended Roll Width : 6 inches Recommended Roll Width : 0 inches
Total Fabric Material Required : 25 sq. ft Total Fabric Material Required : 25.25 sq. ft
Total Fabric Material Used : 30 sq. ft Total Fabric Material Used : 0 sq. ft
Total Coating Material Required : 12.14 sq. ft Total Coating Material Req. : 0.00 sq. ft
Total Defect Volume : 76.0 cubic inches Total Defect Volume : 0.0 cubic inches
Repair Material Results
Calculated Custom Design
Material Quantity and Size Material Quantity and Size
Kits of FormaShield 3 each - 6" x 20ft
Kits of FormaShield

EP-400 20 each - 4 OZ Stick

Filler Material

1 each - 2 Pt Kits
Coating Material PPR

© 2015 Milliken Infrastructure Solutions LLC. Page 4

 Calculation of repair thickness and length (ISO 24817)
7.5.4.1 Limited by allowable stress in substrate --- Repair thickness sufficient to prevent substrate yielding at design pressure.
Hoop Stress Axial Stress
Ps: 6.6 MPa
tmin: 18.2 mm tmin: 0.0 mm
# layer 22 # layer 0
trepair: 18.4 mm trepair: 0.0 mm

𝐷 𝐸𝑠 2ν𝐹𝑒𝑞 𝐷 𝐸𝑠 2𝐹𝑒𝑞 ν𝐸𝑎

𝑡𝑚𝑖𝑛,𝑐 = ∙ ∙ 𝑝𝑒𝑞 + − 𝑝𝑠 𝑡𝑚𝑖𝑛,𝑎 = ∙ ∙ − 𝑝 − 𝑝𝑠
2𝑠 𝐸𝑐 𝜋𝐷 2 2𝑠 𝐸𝑎 𝜋𝐷 2 𝐸𝑐 𝑒𝑞
(Equation 1) (Equation 2)
7.5.4.2 Limited by repair laminate allowable strains --- Substrate provides strength, repair limited by strain. Long term properties may be used.
Hoop Stress Axial Stress
tmin: 3.1 mm tmin: 46.9 mm
# layer 4 # layer 56
trepair: 3.4 mm trepair: 46.9 mm

𝐷 1 𝐹𝑒𝑞 𝑝𝑒𝑞 𝐷ν
𝑡𝑚𝑖𝑛 = 𝑝 − 𝑝𝑠 𝑡𝑚𝑖𝑛,𝑎 = ∙ −
2ε𝑐 𝐸𝑐 𝑒𝑞 𝜀𝑎 𝜋𝐷𝐸𝑎 2𝐸𝑐
(Equation 5) (Equation 6)
7.5.5 Repair laminate allowable strains --- Assumes substrate provides no strength; only short term material properties to be used.
Hoop Stress Axial Stress
tmin: 4.0 mm tmin: 46.9 mm
# layer 5 # layer 56
trepair: 4.2 mm trepair: 46.9 mm

1 𝑃𝑒𝑞 𝐷 𝐹𝑒𝑞 ν 1 𝐹𝑒𝑞 𝑝𝑒𝑞 𝐷ν

𝑡𝑚𝑖𝑛,𝑐 = ∙ − 𝑡𝑚𝑖𝑛,𝑎 = ∙ −
𝜀𝑐 2𝐸𝑐 𝜋𝐷𝐸𝑐 𝜀𝑎 𝜋𝐷𝐸𝑎 2𝐸𝑐
(Equation 8) (Equation 9)
Defining equivalent internal pressure and equivalent axial load
Equivalent internal pressure - Peq Equivalent axial load - Feq
p: 14.0 MPa fperf : 0.582
Fsh : 0N Fax : 0N
Mto : 0 N-mm Max : 0.000 N-mm
peq : 14.0 MPa Feq : 312,041.0 N
2
16 2 4 2
𝑝𝑒𝑞 = 1 + 𝐹𝑠ℎ + 𝑀 𝑓𝑜𝑟 𝑝 ≥ (𝐹 + 𝑀 ) 𝜋 2 4
𝜋𝐷2 𝑝 2 𝐷 𝑡𝑜 𝜋𝐷2 𝑠ℎ 𝐷 𝑡𝑜 2 + 4𝐹 2 + 2 + 𝑀2
𝐹𝑒𝑞 = 𝑝𝐷 + 𝐹𝑎𝑥 𝑠ℎ 𝑀𝑎𝑥 𝑡𝑜
4 2 4 2 4 𝐷
𝑝𝑒𝑞 =𝑝+ 𝐹 + 𝑀 𝑓𝑜𝑟 𝑝 < (𝐹 + 𝑀 )
(Equation 3) 𝜋𝐷2 𝑠ℎ 𝐷 𝑡𝑜 𝜋𝐷2 𝑠ℎ 𝐷 𝑡𝑜 (Equation 4)
7.5.7 Leaking Components --- Only used when system is leaking or expected to leak at before end of life.
Defect Shape: No Leak Hole Diameter: 0 mm
Circular or Near-Circular Hole
(Equation 12) coeff-a 2.1E+06 0.0 01γ𝐿𝐶𝐿
𝑃 = 𝑓𝑇 2 𝑓𝑙 𝑒 𝑎 𝑘
tmin: mm coeff-b 1−0.0E+00
ν2 3 0.0E+001 3
3 𝑑4 + 𝑑 + 𝑑2
trepair: mm coeff-d 𝐸0.0E+00
𝑎𝑐 512𝑡𝑚 𝑖 𝑛 0.000
π 6 4 𝐺 𝑡 𝑚𝑖𝑛
delta 0.0E+00 0.000
coeff-a 2.11E+06
Axial Slots (small width)
(Equation 14)
𝑃 = 𝑓𝑇2 𝑓coeff-b 0.00E+00 0.001γ0.000𝐿𝐶𝐿
𝑙𝑒𝑎𝑘
tmin: mm coeff-d 0.00E+00 0.000 𝐸
1 − ν2 π𝐷 𝐷4 𝐷 4 4𝑎𝐺𝑐 + 2
trepair: mm delta 𝐸 𝑎 𝑐 ɸ+
0.00E+00 3 ɸ4 +
0.000 ɸ6
8 384𝑡 𝑚𝑖𝑛11520𝑡 3 𝑚𝑖𝑛

coeff-a 2.11E+06
Hoop Slots (small width)
(Equation 13) coeff-b 0.00E+00 0.001γ𝐿𝐶𝐿
0.000
𝑃 = 𝑓𝑇2 𝑓𝑙𝑒𝑎𝑘
tmin: mm coeff-d 2 0.00E+00 0.000 4 ν
1−ν 1 π 3 +
4 5 2
trepair: mm delta𝐸 𝑎 𝑐 𝑊 + 𝑊 0.000+ 𝑊2
2 40.00E+00
𝑡3
𝑚𝑖𝑛
4 1 6 𝐺 𝑡 𝑚𝑖𝑛 ( 1 + ν )
FALSE
Large Width Slots (Upper Bound) (Equation 15) Max Pressure 152
tmin: mm 𝑓𝑇2 𝑓𝑙𝑒𝑎𝑘 For slot: #DIV/0!
𝑃 = 0 . 0 0 8 𝐸𝑎𝑐 𝑡 𝑚𝑖𝑛 γ 𝐿𝐶𝐿
𝐷
trepair: mm Leak Repair Thickness: 0.000

© 2015 Milliken Infrastructure Solutions LLC. Page 5

 Installation Summary for FormaShield
Surface preparation with Media Blasting - ideal.
Mediablast pipe to 2.5 mil profile (NACE 3 minimum) and ensure the removal all SHARP EDGES and
soft coatings for repair zone. Solvent wipe.
Apply the Load Transfer Filler, EP-400.
Put on protective gloves and knead EP-400 epoxy putty until uniform in color. Apply to all voids and
"tented" areas.
Apply Base Coating of PPR.
Measure equal parts, by volume, of the PPR-2 Coating material in a clean container. Mix thoroughly
and allow material set 10-20 minutes before applying to the pipe surface. Ensure a minimum of 30-
mil coverage.

FormaShield Preparation method.

Prepare a clean "work surface". Pour the pre-measured "B" component into the "A" component
container and mix thoroughly for 1 -2 minutes. Unroll the required fabric, then apply the mixed resin
onto the fabric. Use a squeegee to spread the resin to ensure fabric wet-out. Gently roll material
onto application stick.
Apply the FormaShield repair.
Begin wrapping around the pipe surface (“Repair Zone”) while applying uniform tension. When the
fabrics roll has overlapped itself, pull tightly and continue with application while ensuring tensioning
throughout the process. Repeat wet-out process and application until all rolls have been used. "De-
bulk" materials as required.

Completing the FormaShield installation.

Using the provided constrictor wrap, tightly apply 4-6 layers extending over the repair. Perforate the
surface of the Compression Wrap (constrictor).

Allow FormaShield system to cure.

Allow to cure for 2 hours. Excess resin may drip through the constrictor wrap. Once hardened,
remove Constrictor Wrap. If the repaired area is to be top-coated, lightly abrade the surface with 120
grit sandpaper, then solvent wipe.

Apply Top Coating of PPR if neccessary.

Measure equal parts, by volume, of the PPR-2 Coating material in a clean container. Mix thoroughly
and allow material set 10-20 minutes before applying to the pipe surface. Ensure a minimum of 30-
mil coverage.

© 2015 Milliken Infrastructure Solutions LLC. Page 6