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Project: Cast Iron Pipe Strengthening at Gallery

Subject: Tyfo® Strengthening

FRP

1. DESIGN

1.1 Guidelines - Codes

- The design proposed is based on the following guidelines:

- ASME PCC-2-2008 Repair of Pressure Equipment and Piping, Article 4.1
Nonmetallic Composite Repair Systems for Pipelines and Pipework: High
Risk Applications

1.2 Design Assumptions

- The minimum yield strength (s) of the cast iron pipe has been assumed equal to
135 MPa.

1.3 Existing Section

1.3.1 Geometry of the sections

= 900 mm (external diameter of pipe)
= 25 mm (nominal wall thickness of original pipe)

1.4 Tyfo® System Properties

1.4.1 Tyfo® SCH-41 Carbon Composite System

∗
= 834 MPa (ultimate tensile strength)
∗
= 0.85% (ultimate rupture strain)
= 82.0 GPa (conservative design modulus of elasticity)
= 1.0 mm (thickness per layer)

1.5 Design Requirements

- The design goal is to repair damaged pipe sections with loss of their nominal original
wall thickness in order to be able to withstand the maximum allowable operating
pressure.

- The required maximum allowable operating pressure is assumed as:

P= 0.9 MPa (9 bar) (required maximum allowable operating
pressure)

- The corresponding required yield pressure of the pipe, , is determined

according to ASME B31 as:

P = = 1.25 MPa (required yield pressure based on SMYS)

.

FYFE Europe S.A.

53 Fleming Street, 16453 Argiroupolis, Athens, Greece
Office: +30.210.995.9595 Fax: +30.210.995.9965
Email: info@fyfeeurope.com www.fyfeeurope.com
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Project: Cast Iron Pipe Strengthening at Gallery

Subject: Tyfo® Strengthening

FRP

- The minimum required remaining wall thickness of the pipe, , is then

determined as:
∙
t = = 4.2 mm (minimum required remaining wall thickness of
∙
pipe)

- This corresponds to about 82% corrosion of the pipe. Thus, if the corrosion of the
pipe is up to 82%, it is considered that the pipe can sustain the required working
pressure, which is equal to 9 bar.

1.6 Tyfo® Design

- If the corrosion of the pipe is more than 82%, then the pipe needs strengthening,
in order to guarantee the working pressure.

- The long term tensile strength for the Tyfo® SCH Composite System based on the
ASME PCC-2-2008 1000hr test, is determined as following:
s = 482.6 MPa (long-term tensile strength, ASME PCC-2-2008
1000hr test)

- The minimum thickness of the repair system, , is determined according to

Eq. 11 of ASME PCC-2-2008 by using for partial wrapping application:
1 P ∙D
t s∙t
f∙s 2
Where:
f = 0.5 (service factor for 1000hr test data, Table 4 of
ASME PCC-2-2008)
ts = (1-corrosion) ∙ t (remaining thickness)

1.6.1 Assume full corrosion (100%) of the pipe

- Then strengthening is needed, in order to compensate for the minimum required

remaining wall thickness of pipe, namely 4.2 mm.
t 1 1 ∙ 25mm 0 mm

- Substituting at the equation above, the minimum thickness of the repair

system, , is determined as following:

1 1.25 MPa ∙ 900 mm

t 135 MPa ∙ 0 mm 2.33 mm
0.5 ∙ 482.6 MPa 2

- The number of layers in hoop direction needed to repair the pipe is then determined
as following:
t
N 2.33
t

FYFE Europe S.A.

53 Fleming Street, 16453 Argiroupolis, Athens, Greece
Office: +30.210.995.9595 Fax: +30.210.995.9965
Email: info@fyfeeurope.com www.fyfeeurope.com
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Project: Cast Iron Pipe Strengthening at Gallery

Subject: Tyfo® Strengthening

FRP

Therefore, 3 layers of the Tyfo® SCH-41 Carbon Composite System in the hoop
direction are required for the structural repair of the pipe for the given assumptions.

1.6.2 Assume 95 % corrosion of the pipe

- Then strengthening is needed, in order to compensate for the minimum required

remaining wall thickness of pipe, namely 4.2 mm.
t 1 0.95 ∙ 25mm 1.25 mm

- Substituting at the equation above, the minimum thickness of the repair

system, , is determined as following:

1 1.25 MPa ∙ 900 mm

t 135 MPa ∙ 1.25 mm 1.63 mm
0.5 ∙ 482.6 MPa 2

- The number of layers in hoop direction needed to repair the pipe is then determined
as following:
t
N 1.63
t

Therefore, 2 layers of the Tyfo® SCH-41 Carbon Composite System in the hoop
direction are required for the structural repair of the pipe for the given assumptions.

1.6.3 Assume 90 % corrosion of the pipe

- Then strengthening is needed, in order to compensate for the minimum required

remaining wall thickness of pipe, namely 4.2 mm.
t 1 0.9 ∙ 25mm 2.5 mm

- Substituting at the equation above, the minimum thickness of the repair

system, , is determined as following:

1 1.25 MPa ∙ 900 mm

t 135 MPa ∙ 2.5 mm 0.93 mm
0.5 ∙ 482.6 MPa 2

- The number of layers in hoop direction needed to repair the pipe is then determined
as following:
t
N 0.93
t

Therefore, 1 layer of the Tyfo® SCH-41 Carbon Composite System in the hoop
direction are required for the structural repair of the pipe for the given assumptions.

FYFE Europe S.A.

53 Fleming Street, 16453 Argiroupolis, Athens, Greece
Office: +30.210.995.9595 Fax: +30.210.995.9965
Email: info@fyfeeurope.com www.fyfeeurope.com
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Project: Cast Iron Pipe Strengthening at Gallery

Subject: Tyfo
FRP® Strengthening

1.7 Conclusions

- Assuming maximum allowable operating pressure of 0.9 MPa, the required repair
scheme according to the corrosion level is as following:
- 1 layer of Tyfo® SCH-41 Carbon Composite System in the hoop
direction for corrosion level from 80% to 90%
- 2 layers of Tyfo® SCH-41 Carbon Composite System in the hoop
direction for corrosion level from 90% to 95%
- 3 layers of Tyfo® SCH-41 Carbon Composite System in the hoop
direction for corrosion level from 95% to 100%

- It is advised application of 1 layer of the Tyfo® SCH-41 Carbon Composite

System in the hoop direction even if the corrosion level on the pipe is less than
80%, in order to protect the pipe from further deterioration.

- It is required application of 1 layer of the Tyfo® SEH-51A Glass Composite

System in the hoop direction prior to the application of the Tyfo® SCH-41 to act
as a dielectric barrier.

FYFE Europe S.A.

53 Fleming Street, 16453 Argiroupolis, Athens, Greece
Office: +30.210.995.9595 Fax: +30.210.995.9965
Email: info@fyfeeurope.com www.fyfeeurope.com