LIQUID ENERGY GLOBAL SERVICES LIMITED

Document number:
PCT_PCR_14001_WI02 PCR-GX APPLICATION NG21-101-PCR-LEGSL-00021
METHOD STATEMENT
Revision: 01
Document Type :
Discipline : CON Date : 09-02-2021
PCR
Page 1 of 12

Liquid ENERGY GLOBAL SERVICES limited

PCT_PCR_14001_WI02 PCR-GX APPLICATION METHOD

STATEMENT

Rev. Status Rev. Date Revision Memo Issued by Checked by Approved by

Omer Khalid Alberto Moro Ekeke.C
D0 IFA 19-01-2021 Issue For Approval
00 IFC 02-02-2021 Issue For Construction Omer Khalid Alberto Moro Ekeke .C

01 IFC 09-02-2021 Issue for Construction Omer Khalid Alberto Moro Ekeke .C

NG21-101-PCR-LEGSL-00021
 LIQUID ENERGY GLOBAL SERVICES LIMITED
Document number:
PCT_PCR_14001_WI02 PCR-GX APPLICATION NG21-101-PCR-LEGSL-00021
METHOD STATEMENT
Revision: 01
Document Type :
Discipline : CON Date : 09-02-2021
PCR
Page 2 of 12

The following installation method statement should be read and understood prior to beginning the
composite repair application. The MSDS sheets for all materials should also be reviewed and
understood prior to beginning the application.

The following steps should be followed for the application of a PCR-GX composite repair. Any
modifications to these instructions should be approved in writing by PCT Management in advance of
the repair application.

1. OBJECTIVE:

To provide the correct installation techniques for the application of Premier Composite Technologies
LLC (PCT) PCR-GX composite repair system.

2. 2. SCOPE:

These instructions apply to the PCR-GX repair system; all PCT certified employees and qualified
installers who are responsible for applying PCT composite repair systems.

NG21-101-PCR-LEGSL-00021
 LIQUID ENERGY GLOBAL SERVICES LIMITED
Document number:
PCT_PCR_14001_WI02 PCR-GX APPLICATION NG21-101-PCR-LEGSL-00021
METHOD STATEMENT
Revision: 01
Document Type :
Discipline : CON Date : 09-02-2021
PCR
Page 3 of 12

3. DEFINITIONS:

• PCR Composite Repair System:

o PCR-GX Composite Repair System:

A combination of epoxy adhesive primer, epoxy resin laminating system and a stitched fabrics of
multiaxial E-glass reinforcement fabric used by PCT to repair or strengthen a substrate.

 Glass fibre reinforcement fabric:

PCR-GX uses a stitched multiaxial E-glass reinforcement fabric with a quadraxial fibre
orientation (0, +45, 90, -45). Ply thickness of the laminated fabric is 1mm.

 Epoxy resin system: a two-part thermoset polymer matrix consisting of a resin and hardener
that, when the components are mixed, exhibits a cross-linking of the polymer and causes the
matrix to harden and solidify.

 Adhesive Primer: a toughened epoxy adhesive that is applied to the substrate prior to the
application of the glass fibre reinforcement plies. The primer serves to provide a smooth
surface profile to even out pits and rough spots for an even load transfer and also greatly
improve the adhesion between the substrate and the composite repair system.

 Wet-out: the process whereby the low viscosity epoxy resin system is impregnated into the
glass fibre reinforcement fabric by means of spreaders, brushes and rollers.

 Epoxy Putty: a high compressive modulus steel filled epoxy putty that is used to profile and
replace lost wall thickness (external corrosion or through-wall holes) and to transfer the pipe
load to the composite repair system.

 Stricture Banding: the application of the Polyethylene (PE) Blue Stricture Banding Film
serves several purposes for the composite repair as it will keep all epoxy resin system in the
repair as the wrap cures (preventing resin drainage) and it will also keep the repair clean from
debris that may land and stick to the repair whilst it cures.

 Stricture banding will also help ensure that there are no wrinkles or air trapped within the
repair as it may be pulled taught while applying, ensuring good compression of the repair
laminate, adhesion to the substrate and that the repair fits closely to the substrate profile.

 Peel ply: a tightly woven polyester or nylon fabric that can be placed against a wet resin
surface. The peel ply can be easily removed from the cured laminate and leaves behind a
textured surface which provides an excellent surface key for and secondary bonding,
additional laminate layers or coatings

NG21-101-PCR-LEGSL-00021
 LIQUID ENERGY GLOBAL SERVICES LIMITED
Document number:
PCT_PCR_14001_WI02 PCR-GX APPLICATION NG21-101-PCR-LEGSL-00021
METHOD STATEMENT
Revision: 01
Document Type :
Discipline : CON Date : 09-02-2021
PCR
Page 4 of 12

 Gel Time: is the time taken for the resin to start becoming more viscous and begin
transitioning from the liquid state to the solid state.

 Pot Life: the time taken from mixing to gel time and to where the product can no longer be
effectively applied or transferred from the pot. NB – varies with quantity in pot and ambient
temperature.

 Cure Time: time from mixing to when the repair has effectively reached designed strength.

1. APPLICATION:

The PCR-GX composite repair system is applied using the following steps:

4.1 Site Consignment Kit and Storage:

 Check batch numbers and ensure that all the supplied contents of the consigned kit match the
inventory sheet supplied with the kit.

 Where possible, it is recommended that prior to mobilisation to the worksite, that the
materials should be stored and maintained at a constant temperature of between 10°C and
32°C and kept in a dry location away from direct sunlight.

4.2 Worksite Preparation:

 Prepare the work area for the epoxy resin system mixing and reinforcement fabric wet-out.
The ideal set-up is a large, level, polythene covered wet-out table (folding wallpaper table or
similar,) that is shaded from direct sunlight. Position this work area as close as possible to the
repair location.

 The PCR installer is to check and record ambient conditions prior to and during the repair
application. It is important to maintain a relative humidity (RH) level below 80% during the
application of the initial 2 layers of the repair system.

 Once the substrate surface has been “sealed,” it is possible to apply the remaining layers of
repair system at a higher RH level not exceeding 90%.

4.3 Surface Preparation (PCR_WI01 Surface Preparation Requirements_01):

NG21-101-PCR-LEGSL-00021
 LIQUID ENERGY GLOBAL SERVICES LIMITED
Document number:
PCT_PCR_14001_WI02 PCR-GX APPLICATION NG21-101-PCR-LEGSL-00021
METHOD STATEMENT
Revision: 01
Document Type :
Discipline : CON Date : 09-02-2021
PCR
Page 5 of 12

 Surface Preparation of the substrate is one of the most critical factors for a successful
composite repair. Prior to the undertaking of the surface preparation, ambient temperature and
humidity are to be recorded to ensure that the Relative Humidity (RH) level is below 80 %.

 All loose dirt, oil, grease, rust or other build up should firstly be removed from the pipe and
should be prepared using a grit blast preparation. Where the wall thickness is greater than 3
mm then the pipe surface should have a minimum surface roughness of 65 microns and a
surface cleanliness of Sa 2.5.

 Areas with adjacent wall thickness less than or equal to 3 mm may not be blasted but will be
protected by a doubler plate to prevent the blast media from damaging the defective areas of
pipework.

 Testex Press-O-Film replica tape should be used to measure the surface roughness and ensure
that the minimum surface roughness profile defined (65 micron) is obtained.

 Where Sa 2.5 is not possible to achieve, the use of power tool cleaning (St 3) or hand tool
cleaning (St 2) is permitted.

 It is important that any surface preparation methods employed does not provide a smooth or
glass-like finish.

 In order to provide a clearly defined area for the repair application, the area of the repair
should be prepared and masked off at least 50mm wider than area of the composite repair
application. This can be marked off prior to commencing the surface preparation.

 The adhesive primer and the first layers of the composite repair system must be applied
within four hours of completion of the surface preparation of the substrate. Outside of this
window, flash rusting will create an oxidised layer that prevents the primer bonding to the
substrate. Failure to apply the first layers within the four-hour period will require the surface
to be sweep blasted prior to commencing with the repair application.

4.4 Applying Epoxy Putty (when required):

 All sharp corners, weld stand offs, dents should be smoothed off or ground back to the
original pipe wall circumference.

 Mix the steel filled epoxy putty by adding the hardener to the resin component.

 Mix until the colour is even and no marbling is present and until the mixtures becomes
homogeneous.

 Make sure that all hardener is mixed thoroughly into the resin.

NG21-101-PCR-LEGSL-00021
 LIQUID ENERGY GLOBAL SERVICES LIMITED
Document number:
PCT_PCR_14001_WI02 PCR-GX APPLICATION NG21-101-PCR-LEGSL-00021
METHOD STATEMENT
Revision: 01
Document Type :
Discipline : CON Date : 09-02-2021
PCR
Page 6 of 12

 Using the same stir stick, or a putty knife, smooth the epoxy putty into the area required and
return the substrate surface as close as possible to the original surface.

 Use this material to fill voids, cracks and other surface irregularities so that there will be no
voids between the pipe and repair system.

 Once the putty has fully hardened the repair application can commence immediately.

4.5 Applying the Adhesive Primer:

 Pour the hardener into the resin container – taking care to mix only as much product as can be
used in 30 minutes.

 Mix thoroughly for a minimum of 1 or 2 minutes and until the colour is even and no marbling
is present.

 Ensure sure that all hardener is mixed thoroughly into the resin.

 Using one of the brushes supplied, apply a layer of primer evenly over the area that has been
prepared.

 For severe external corrosion pitting and where there is a significant and irregular wall loss,
use the epoxy putty to provide an even surface profile.

4.6 Wetting-Out the Glass Fibre Reinforcement Fabric for application of PCR-GX Repair
System:

 Prepare the reinforcement fabric layers which will be either supplied as a pre-cut kit of parts
such as when applying to Tees and Elbow pipe sections or, is to be cut on site to the
dimensions as detailed in the repair datasheet.

 If the axial width of the cloth is less than the total extent of the repair, the buildup of full
circumferential layers (from an axial perspective) alternate layers should overlap (i.e. as in
brickwork).

 Lay out the reinforcement fabric on the previously prepared polythene covered wet-out table.

 Mix the epoxy resin system components thoroughly but slowly so as not to introduce air
bubbles into the mixture.

NG21-101-PCR-LEGSL-00021
 LIQUID ENERGY GLOBAL SERVICES LIMITED
Document number:
PCT_PCR_14001_WI02 PCR-GX APPLICATION NG21-101-PCR-LEGSL-00021
METHOD STATEMENT
Revision: 01
Document Type :
Discipline : CON Date : 09-02-2021
PCR
Page 7 of 12

 Allow the mixed resin system to stand for 2-3 minutes prior to use although take care not to
mix too much resin and hardener, especially at high ambient temperatures when working
times are lower and the risk of exotherm is higher.

 Wet out the reinforcement fabric layers using plastic spreaders, rollers or brushes. Thoroughly
distribute the resin system evenly over the entire fabric, turning it over to apply resin from
both sides if necessary.

 Use gentle movements so as not to disturb the fibre orientation in the reinforcement fabric.

4.7 Composite Repair Application to the Substrate:

 Ensure that the installer is familiar with the installation and application orientation by
reviewing the design procedures; it is often an advantage to perform a “dry run” before
mixing epoxy resin systems for application.

 A flood wash of acetone is to be applied to the bonding surfaces for final cleaning prior to
application.

 Transfer the wet-out reinforcement fabric to the repair location and centre it over the defect
area. (The fabric layers can be carefully rolled following the wetting out or transferred on
polythene covered board.)

 Apply the 1st reinforcement fabric layer taking care to position it and ensuring that all air
bubbles have been removed and that the fabric is tightly and smoothly wrapped around the
substrate without creases. Note that PCR-GX reinforcement fabric should always be
applied with the 45-degree fibre against the substrate and the 0 degree circumferential
fibres facing up.

 Press it into the surface with gloved hands, work out any trapped air bubbles forcing the
repair system into tight contact with the surface below.

 The initial reinforcement fabric layers are critical and it important to limit the time between
the wet-out and application.

 Smooth out all of the edges, wrinkles, and bubbles.

 Apply the second layer of reinforcement fabric and then apply a layer of peel ply. The peel
ply wrapping tape should be wrapped around the repair, starting at one end and winding in a
spiral pattern with at least a 10mm overlap. Take care not to apply too much tension as this
can crease the laminate. (In the event of the final repair thickness being three layers, it may be
possible to apply the complete repair in one single application.)

NG21-101-PCR-LEGSL-00021
 LIQUID ENERGY GLOBAL SERVICES LIMITED
Document number:
PCT_PCR_14001_WI02 PCR-GX APPLICATION NG21-101-PCR-LEGSL-00021
METHOD STATEMENT
Revision: 01
Document Type :
Discipline : CON Date : 09-02-2021
PCR
Page 8 of 12

 Once the peel ply has been applied, the stricture banding should then be tightly wrapped
around the repair, starting at one end and winding in a spiral pattern with at least a 10mm
overlap so that it tightens onto the wrap taking care not to pull overly hard, as this will simply
cause the film to slide around the wrap.

 Apply at least 2 complete layers of the Stricture Banding.

 Allow the resin system to cure and then fully remove the stricture banding and the peel ply.

 Apply subsequent layers according to the design calculation. It is best to set the starting point
of each layer at a different location around the pipe circumference. (For example, start the
first layer at the 12 o’clock position, the second layer at the 3-o’clock position, etc.)

 In the event of the repair application being interrupted due to shift patterns, inclement weather
or site evacuations, wherever possible, the peel ply is to be applied over the repair and then
removed prior to commencing with the repair following the interruption.

 Once the final layer has been applied, apply the stricture banding.

 Allow the composite repair system to cure until it is dry to the touch and the Barcol Hardness
reading is greater than 35 and then remove the stricture banding ensuring that all of the
stricture is fully removed.

 The eventual cure times will vary with ambient conditions, however, in cold conditions or
where higher Tg (Glass Transition) temperatures are desired, the cure temperature may be
increased or accelerated by using an outside heat source such as a heated blanket. Repair
section to be cured @ 60 O C using heat blankets for minimum 4 hours.

4.8 Post Application Inspection:

 Inspect the repair system confirming that there are no de-laminations, air pockets or defects as
specified on the in-service and application inspection checklist.

 Using a Barcol hardness gauge, check readings all over the repaired section and ensure that
readings are a minimum of 35. The point of the impressor must be aligned with an area of
well cured resin without visible defects. If the needle penetrates an air bubble or void, no
reading will display on the dial. Several attempts may be needed to obtain a true reading.
Repeat the process, taking a reading at the 3, 6, 9 and 12 o’clock positions. This should be
done every 300mm along the axial extent of the repair with at least one set of readings taken
from the pipe circumference where the defect is located. One reading must be taken at the
location directly above the defect. For every additional axial repair extent of 300mm a further
4 readings should be taken around the pipe circumference. Note that the surface will continue
to harden above the minimum reading of 35 and in some instances may be as high as 60 to 70.

NG21-101-PCR-LEGSL-00021
 LIQUID ENERGY GLOBAL SERVICES LIMITED
Document number:
PCT_PCR_14001_WI02 PCR-GX APPLICATION NG21-101-PCR-LEGSL-00021
METHOD STATEMENT
Revision: 01
Document Type :
Discipline : CON Date : 09-02-2021
PCR
Page 9 of 12

 This value should be measured and recorded on the repair data sheet before signing off the
repair.

 Ensure that all Testex replica tapes, matrix batch numbers and all other required variables are
completed on the repair datasheet.

 Tidy up and safely dispose of all scrap materials and consumable waste.

4.9 UV Protection:

 UV protection coatings may be applied for aesthetic reasons, to match client’s existing
pipework and where excessive sunlight and UV may discolour the repair over a long period of
time.

 As and when required and in consultation with the client, PCT will apply a UV Resistant
Polyurethane Topcoat where the composite repair will be exposed to high levels of UV.

 These coatings may be applied as soon as the repair has cured.

4.10 QA and HSE:

 PCT provide Material Safety Data Sheets with every product and the materials handling
instructions are to be used.

 Generic Task and Site Risk Assessments are provided.

 PCT is committed to the concepts of Health and Safety at Work as described in OSHAS
18001:2007 and Environmental Management as described in ISO 140001:2004.

 PCT fully recognises that fully adequate Quality Assurance (QA) is critically important and
the QA department team comprises 27 staff, this includes managers, engineers & inspection
staff.

 The team has dedicated resources for the Quality Management System, CMM inspection,
DSC testing, and NDT capability. This focus on quality is a major step forward in developing
our capabilities as a world class composite supplier.

 The Health Safety & Environment (HSE) team advises on all safety, health and
environmental related matters of the company and to ensure that all statutory obligations both
external and internal are met. The team also controls and updates all HSE documentation

NG21-101-PCR-LEGSL-00021
 LIQUID ENERGY GLOBAL SERVICES LIMITED
Document number:
PCT_PCR_14001_WI02 PCR-GX APPLICATION NG21-101-PCR-LEGSL-00021
METHOD STATEMENT
Revision: 01
Document Type :
Discipline : CON Date : 09-02-2021
PCR
Page 10 of 12

while liaising with the different departments across the company to ensure that they operate
as per the procedures and instructions contained within the HSE management system.

 The HSE team works to ensure that personnel are wearing the correct personal protective
equipment (PPE) for the job/process they are undertaking are being addressed in equal
measures.

4.11 Clothing and Equipment:

 Protective clothing is to be worn during the application. Recommended clothing includes, but
is not limited to Tyvek suit, coveralls, apron, rubber foot coverings, safety glasses or chemical
splash goggles, and impervious gloves (vinyl, latex, or neoprene) to cover exposed areas of
skin.

 PCT will also comply with client industry safety PPE regulations to include the use of hard-
hats, protective footwear, fire-retardant coveralls etc.

2. RELATED DOCUMENTS:

 PCR_WI01 Surface Preparation Requirements_03

 PCR_WI04 Barcol Hardness Testing_01

 PCR_WI05 Testex Tape Testing of Surface profile_01

 PCR_DOC13 Composite Repair Inspection Report Form_01

 PCR_DOC09 Site Daily Report Sheet_01

Appendix A - Application guidelines for bends (elbows) and tees.

Bend (elbows).

NG21-101-PCR-LEGSL-00021
 LIQUID ENERGY GLOBAL SERVICES LIMITED
Document number:
PCT_PCR_14001_WI02 PCR-GX APPLICATION NG21-101-PCR-LEGSL-00021
METHOD STATEMENT
Revision: 01
Document Type :
Discipline : CON Date : 09-02-2021
PCR
Page 11 of 12

 The standard PCR application process should be followed but it is recommended to take
addition care with preparing the reinforcement fabrics and completing a dry fit to ensure that
the fabric layers conform well to the substrate.

 It is critical to ensure that circumferential fibres (the warp of 0° axis fibres in the
reinforcement) are not wrinkled and crimped as this will impact the load bearing ability of the
composite repair.

 Recommended fabric cutting pattern (circumferential bands of reinforcement fabric sized

according to the elbow or bend in question) and application sequence is illustrated below with
grey reinforcement fabric sections applied to the blue substrate in number order working
outwards from a central starting point.

 Make sure that the circumferential fibres are always positioned so that they follow a radial
pattern around the elbow. The winding should be centred on a point (in red) as the centre of
the arc formed by the bend.

NG21-101-PCR-LEGSL-00021
 LIQUID ENERGY GLOBAL SERVICES LIMITED
Document number:
PCT_PCR_14001_WI02 PCR-GX APPLICATION NG21-101-PCR-LEGSL-00021
METHOD STATEMENT
Revision: 01
Document Type :
Discipline : CON Date : 09-02-2021
PCR
Page 12 of 12

 Try to avoid excessive overlaps and use peel ply tension to compress the layers when applied.
There will always be some increased thickness due to overlaps on the inside of the elbow but
large creases and wrinkles are to be avoided.

Tees

 The standard PCR application process should be followed but it is recommended to take
addition care with preparing the reinforcement fabrics and completing a dry fit to ensure that
the fabric layers conform well to the substrate.

 It is critical to ensure that circumferential fibres (the warp of 0° axis fibres in the
reinforcement) are not wrinkled and crimped as this will impact the load bearing ability of the
composite repair.

 Recommended fabric cutting pattern (circumferential bands of reinforcement fabric around

the branches of the tee with a central fabric piece wrapping around the belly of the tee) and
application sequence is illustrated below with grey reinforcement fabric sections applied to
the blue substrate in number order working outwards from a central starting point.

 The most critical part of wrapping a tee is to ensure that the laminate is adequately
compressed to ensure bonding to the substrate and the removal of any air voids within the
laminate. Throng winding tension on peel ply and stricture can help here.

NG21-101-PCR-LEGSL-00021
 LIQUID ENERGY GLOBAL SERVICES LIMITED
Document number:
PCT_PCR_14001_WI02 PCR-GX APPLICATION NG21-101-PCR-LEGSL-00021
METHOD STATEMENT
Revision: 01
Document Type :
Discipline : CON Date : 09-02-2021
PCR
Page 13 of 12

 It is suggested to use a spiral winding pattern around the branches of the tee to ensure that
laminate is compressed even in the tight radius areas where the braches leave the body of the
tee.

NG21-101-PCR-LEGSL-00021