Project ID JK032820-2-1

Designed forXXXXX
EEPNL
LLLLL
Project Info : HPC1 3rd Stage Suction Line

Design report is for KKKKKKKK

HHHHHHHHHHHHHHHHHHH
a Tee with an intended service life of 5 years.
XXXXXX
Salesperson : James Knights
XXXXX
Design Engineer : Casey Whalen

Submission Date : March 28, 2020

60 minute drip free condition required before wrap application begins at full
operating pressure.

Composite repair only designed to reinforce clamp and protect from external
damage; repair not designed to contain leak should clamp fail.

621 Lockhaven Drive

Houston, TX 77073
P: +1-281-590-8491
F: +1-281-590-9528

All information within is considered confidential and proprietary

WrapCalc Version : 3.3.0

 Project Information
xxxxxxx
Company Name EEPNL Address

xxxxxxxxxxx
Contact Name Ugbedeojo Agada
Contact Number 909-102-2353
Contact E-mail XXXXXXXXXXXXX
ugbedeojo.agada@exxonobil.com
XXXXXXXXXXXXXXXXXXXXX
Project ID EATL/EEPNL/ERHA/ED/013B/020
Project Description HPC1 3rd Stage Suction Line
Additional Information Leak to be stopped with a clamp - 1 hour pressure hold prior to wrap install required
Repair Type Structural Reinforcement Design Method Custom Design
Intended Service Life 5 year Repair System FormaShield™ LT
Default Units Metric

Pipe Information
Component Type Tee Defect Location On the Branch Pipe
Pipe Material Carbon Steel
Base Pipe Diameter 6.625 inches Branch Pipe Diameter 2.375 inches
Nominal Wall Thickness 21.900 mm Branch Pipe Wall Thickness 7.500 mm
Pipe Grade ASTM A106 - B Piping Standard B31.3 - Process Piping

Pipe Design Strength 21,500 psi Repair Environment Standard Environment

Longitudinal Joint Type Unspecified Pressure design thickness 5.645 mm
Product in Pipe Hydrocarbons-Refinery Assumed Mech. Allowance 1.855 mm
Pipe Location : Underwater Wet Dry Buried Above Ground

Operating and Design Conditions

Operating Pressure 189.0 bar Operating Temperature 37.0 °C
Installation Pressure 0.0 bar Installation Temparture 37.0 °C
System Design Pressure 300.0 bar Design Temp. (max) 90.0 °C
Cyclic Frequency Ignored Design Temp. (min) 20.0 °C
Are external loads present? No lbf Applied Shear Load 0.0 lbf
Add'l Install Axial Load 0.0 lbf Applied Axial Moment 0.0 lb-in
Add'l Design Axial Load 0.0 lbf Applied Torsional Moment 0.0 lb-in

Defect Conditions
Defect Cause : External Wall Loss External Erosion Internal Wall Loss Dent Wrinkle Bend Gouge Crack-like

Other Issue :

Weld Interaction : No Interaction Girth Weld Seam Weld Spiral Weld

External Wall Loss Length 2.000 inches

External Wall Loss Width 2.000 inches
External Wall Loss Depth 7.500 mm

Wall Loss at Install 100%

Distance from intersection 0 inches Total Affected Length 2.000 inches

3/28/2020 Confidential and Proprietary 2

 Design Considerations
Include substrate support Yes Performance Testing Not Available
Allow substrate to yield Yes B31.G Pressure Method Barlow's Formula
Repair Composition One repair system Compression Method Constrictor Wrapping

Primary Adhesive Primer PPR (Standard) Primary Load Transfer Filler EP-420 (Standard Paste)

The FormaShield™ LT Repair System

Resin Matrix Used CS-105 (Standard)
Repair Fabric Used FG-200 (Fiberglass)
Fabric Width 2 inches 2
Fabric Orientation Hoop Direction Hoop Direction
Installation Method Spiral Wrap Spiral Wrap
Fabric Offset 1.00 inches
Number of Layers 12 layers
Equivalent Thickness 6.706 mm

Repair Zone Considerations

Surface Prep Available media blasting Repair Length on side 1 13.8 inches
Repair Zone Options No limitation Repair Length on side 2 13.8 inches
Length past branch weld 18.0 inches
Include Top-Coat Yes
Base Pipe Repair Zone 762.0 mm Branch Pipe Repair Zone 457.0 mm

Summary of Pressure Analysis (with end-of-life conditions)

Pristine Pipe Yield Pressure 60.0 MPa Internal Design Pressure 30.0 MPa
Damaged Yield Pressure 0.0 MPa Damaged Max Pressure 0.0 MPa
Repaired Failure Pressure 103.6 MPa Repaired Max Pressure 86.3 MPa

Recommended Repair Materials

Final quote may differ based on materials available or considerations not covered specifically by this design.

Kit Name Fabric Resin

25 ea 02x15 FSK-LT Q-Kits 02 in. x 15 ft. FG-200 25 ea 100g Kits of CS-105

Composite
Kits

Size 1 Size 2
PPR Paste 1 each - 2 Pt Kit
Adhesive Primer

EP-420 Paste 1 each - 1/2 Pt Kit

Load Transfer Filler

Accessory Kits 1ea AK-55 Complete Application Kit

2ea 12" Applicator Stick 1ea Small Constrictor Wrap - 5"x100ft
Supplemental Tools
1ea Large Perforator Tool

3/28/2020 Confidential and Proprietary 3

 Pipe Information
Substrate Material Properties and Relevant Vessel Information
The structure being repaired is a Carbon Steel pipe carrying Hydrocarbons-Refinery. The following information lists the material
properties and generic information with regards to the substrate pipe.

Pipe Material Carbon Steel Piping Standard B31.3 - Process Piping

Product in Pipe Hydrocarbons-Refinery Repair Standard Custom Design

Component Type Tee Component Factor (fth) 2.0
Base Pipe Diameter 168.275 mm Pipe Wall Thickness 21.9 mm
Branch Pipe Diameter 60.325 mm Branch Pipe Wall Thickness 7.500 mm

Defect Location On the Branch Pipe Repair Environment Standard Environment

Defect pipe Diameter (D) 60.30 mm Design Coefficient (Y) 0.40
Defect pipe wall thickness (t) 7.500 mm Longitudinal Joint Type Unspecified
Pipe Design Strength (s) 148.24 MPa Basic Quality Factor (E) 1.00
Pipe Modulus (Es) 198,555 MPa Design Temperature 90.0 °C
Poisson's Ratio 0.33 Weld Joint Str. Factor (W) 1.000
Substrate CTE 1.17E-05 1/°C Assumed Mech. Allowance 1.855 mm

Cross-Sectional Area Calculations for the Affected Pipe

Pristine Pipe Dimensions - The dimensions of the Pipe with no defect.
Pipe Outside Diameter 60.30 mm Pipe Inside Diameter 45.300 mm
Nominal Wall Thickness 7.500 mm Cross-Sectional Area (A) 1,244.07 mm²

Pipe and Defect Dimensions at Install - The dimensions of the remaining pipe wall at time of installation.
External Defect Depth 7.500 mm
External Defect Length 50.800 mm
External Defect Width 50.800 mm
Volume of External Defect 19354.800 mm³
Min Remaining Pipe Wall - mm Cross-Sectional Area (Alive) 910.46 mm²

Pipe and Defect Dimensions at End of Life - The estimated dimensions of end of life conditions
Internal Wall Loss Rate 0.000 mm/year
Time for 80% Wall Loss N/A
Time for Through-Wall N/A
Min Remaining Pipe Wall (ts) - mm Cross-Sectional Area (As) 910.46 mm²

Operating and Design Conditions

Operating conditions - the normal values at which the pipe operates at.
Installation conditions - the temporary values the pipe will be at during the repair application.
Design conditions - the maximum value at which the pipe is designed for.
Operating Pressure 18.9 MPa Operating Temperature 37.0 °C
Installation Pressure 0.0 MPa Installation Temperature 37.0 °C
Design Pressure 30.0 MPa Max. Design Temperature (Td) 90.0 °C
Min. Design Temperature 20.0 °C

3/28/2020 Confidential and Proprietary 4

 Composite Repair Properties
Generic Composite Properties

After reviewing the design requirements and chemical resistance (if applicable), the final proposed repair system is the
FormaShield™ LTsystem. The following lists the material properties of this composite component of the repair system.

Repair System FormaShield™ LT Secondary Repair System #VALUE!

Wet-out Resin Item Number CS-105 (Standard)
Fabric Item Number FG-200 (Fiberglass) Fabric Item Number
Fabric Width 2.000 inches Fabric Width 2.000
Fabric Orientation Hoop Direction Fabric Orientation Hoop Direction
Fabric Offset 1.0 inches Fabric Offset
Minimum Layer Count 6 layers Minimum Layer Count 0 layers

Adhesive and Filler Properties

Load Transfer Filler Used : EP-420 (Standard Paste) Compressive Strength 101 MPa
Secondary Filler Used : Compressive Strength 1 MPa
Adhesive Primer Used : PPR (Standard) Lap Shear Strength 19 MPa
Secondary Primer Used : Lap Shear Strength 0 MPa

Material Properties
As with any composite using a woven fabric, the properties are highly dependent on the direction being tested. In general, the
two directions are known as:
Longitudinal - refers to the "length wise" orientation of a roll.
Transverse - refers to the direction perpendicular to the roll length.
If installing a hybrid repair or multi-directional repair, an average value will be used. Additionally, the fabric orientation will
determine if the longitudinal properties are in the hoop or axial direction.

Properties in Hoop Secondary Repair System Hybrid Values (Calculated)

Fabric Orientation Longitudinal Longitudinal N/A
Tensile Strength 466 MPa #VALUE! MPa #VALUE! MPa
Long-Term Strength (slt) N/A MPa N/A
Tensile Modulus (Ec) 27,579 MPa #VALUE! MPa #VALUE! MPa
Ultimate Strain 2.30% #VALUE! #VALUE!
Long-Term Strain (εlt) N/A N/A N/A
Layer Thickness 0.559 mm 0.000 mm #DIV/0! mm
Poisson's Ratio 0.14 #VALUE! #VALUE!
Coef. Of Thermal Exp. (αc) 1.57E-05 1/°C #VALUE! 1/°C #VALUE! 1/°C

Properties in Axial Secondary Repair System Hybrid Values (Estiamted)

Fabric Orientation Transverse Transverse N/A
Tensile Strength 131 MPa #VALUE! MPa #VALUE! MPa
Tensile Modulus (Ea) 12,827 MPa #VALUE! MPa #VALUE! MPa
Ultimate Strain 1.80% #VALUE! #VALUE!
Poisson's Ratio 0.14 #VALUE! #VALUE!
Coef. Of Thermal Exp. (αa) 3.13E-05 1/°C #VALUE! 1/°C #VALUE! 1/°C

3/28/2020 Confidential and Proprietary 5

 Safety Pressure - Using B31.G as Guidance
Pressure Analysis - Pristine Conditions

The first step of performing a design analysis is to determine the remaining structural capabilities of the substrate material. A summary
of the pressure ratings of the system as well as the remaining substrate thickness (if any) is represented below.

Repair Environment Standard Environment Safety Factor 1.63

Pristine Pipe Yield Pressure 60.0 MPa Component MAOP/MOP 27.8 MPa
System Design Pressure 30.0 MPa Operating Pressure 18.9 MPa
Pressure Analysis - Defect Conditions
The first step of performing a design analysis is to determine the remaining structural capabilities of the substrate material. A summary
of the pressure ratings of the system as well as the remaining substrate thickness (if any) is represented below. The values used are
assumed to be end-of-life, worst-case conditions.

Original Wall Thickness (t) 7.500 mm Defect Depth (d) 7.500 mm

Remaining Wall (ts) 0.000 mm Defect Length (L) 50.80 inches
Wall Loss 100.0% Defect Width 50.80 inches
2
pipe constant z (L /Dt) 5.7 Operating Hoop Stress (SO) 76 MPa
Determining Flow Stress - refer to B31G section 1.7 for flow stress definition and parameters
SMYS 241 MPa Sflow Definition 1 265 MPa
Minimum Tensile at Ambient 310 MPa Sflow Definition 2 310 MPa
Yield Strength at Temp. 234 MPa Sflow Definition 3 269 MPa
Ultimate Tensile at Temp. 303 MPa Minimum Sflow value 265 MPa
Level 0 Evaluation - Barlow's Formula
Pipe Diameter (D) 60.30 mm
2 ∗ 𝑆𝑀𝑌𝑆 ∗ 𝑡𝑠 𝐷𝑃𝐹 Estimated Stress Failure Level (SF) 0 MPa
𝑃𝐹 = 𝑆𝐹 =
𝐷 2𝑡 Estimated Pressure Failure Level (PF) 0.0 MPa
Flaw Unacceptable Ratio #DIV/0!
Level 1 Evaluation - Original B31G
1 − 2𝑑Τ3𝑡 Bulging Stress Magnification Factor (M) 2.36
𝑖𝑓 𝑧 ≤ 20, 𝑠𝐹 = 𝑠𝑓𝑙𝑜𝑤
2𝑑Τ3𝑡
1− 𝑀 Estimated Stress Failure Level (SF) 123 MPa
𝑑 Estimated Pressure Failure Level (PF) 30.7 MPa
𝑖𝑓 𝑧 > 20, 𝑠𝐹 = 𝑠𝑓𝑙𝑜𝑤 1−
𝑡 Flaw Unacceptable Ratio 100%
Level 1 Evaluation - Modified B31G
𝑖𝑓 𝑧 ≤ 50, 𝑀 = 1 + 0.6275𝑧 − 0.003375𝑧 2 Bulging Stress Magnification Factor (M) 2.11
𝑖𝑓 𝑧 > 50, 𝑀 = 0.032𝑧 + 3.3 Estimated Stress Failure Level (SF) 67 MPa
1 − 0.85 𝑑Τ𝑡
𝑠𝐹 = 𝑠𝑓𝑙𝑜𝑤 Estimated Pressure Failure Level (PF) 16.6 MPa
0.85𝑑Τ𝑡
1− 𝑀 Flaw Unacceptable Ratio 186%
Level 2 Evaluation - Modified B31G
Local Area of Metal Loss mm²
1 − 𝐴Τ𝐴0 Estimated Stress Failure Level (SF)
𝑠𝐹 = 𝑠𝑓𝑙𝑜𝑤 MPa
𝐴 Τ𝐴
1− 𝑀0 Estimated Pressure Failure Level (PF) MPa
Flaw Unacceptable Ratio
Determining Safety Pressure
Safe operating pressure is based on the lowest operating pressure that can safely be held with current defect conditions. This
value can change based on the evaluation method.
Safe Pressure Method Barlow's Formula Safe Operating Pressure (Ps) 0.0 MPa

3/28/2020 Confidential and Proprietary 6

 Justification of Increased Minimum Layer Count
The following are an explanation of potential increases to the minimal layer account recommended for a product. The items
considered are not discussed in any standards, but are based on actual experience and testing.
Repair System FormaShield™ LT Standard Min. Layer Count 6 layers
Repair Location
Offshore or Coastal No Additional Layers Required N/A

Explanation : Not Needed

Pipe Support No Additional Layers Required N/A

Explanation : Not Needed

Chemically Aggressive Env. No Additional Layers Required N/A

Explanation : Not Needed

Defect Types
Wrinkle Bend No New Minimum Layer Count N/A

Explanation : Not Needed

Dent No New Minimum Layer Count N/A

Explanation : Not Needed

Defect in the Seam Weld No New Minimum Layer Count N/A

Explanation : Not Needed

Leak Repairs
Design Life over 2 Years No Additional Layers Required N/A

Explanation : Not Needed

High Pressure Scenario No Additional Layers Required N/A

Explanation : Not Needed

Geometric Configurations
Elbows / Bends / Tees Yes New Minimum Layer Count 12 layers
Due to the stress intensification that occurs on a tee, a minimum layer account is utilized to account for anticipated
Explanation :
stress loads

Conformity to the Standards

Meets B31.3 Standards Yes Additional Layers Required N/A

Explanation : Not Needed

Other (Misc.)
Reason :

Explanation :

New Minimum Layer Count 12 layers Additional Layers Required 0 layers

3/28/2020 Confidential and Proprietary 7

 Initial Design Considerations - Custom Design
The following section discusses basic input requirements for a custom design. Information is heavily reliant upon the
ASME PCC-2 and ISO 24817 standards as well as more rigorous internal requirements.
Thermal Properties
The installation, operating and design temperatures are all used to determine the physical response of the repair system under
the proposed conditions. First, the maximum service temperature is determined.

Substrate is Not Leaking Tm = Tg - 20°C

Substrate not leaking
Design Lifetime (tlifetime) 5 years Tm = HDT - 15°C
Limiting Temp. component is the PPR resin. Substrate leaking Tm = Tg - 20°C
Property measured as Glass Transition Temp (Tg). Design Lifetime ≤ 2 years Tm = HDT - 15°C
Measured HDT Value 150.0 °C Substrate leaking Tm = Tg - 30°C
Max Service Temp. (Tm) 130.0 °C Design Lifetime > 2 years Tm = HDT - 20°C

Determining Temperature De-rate Factor

To account for temperatures above tested conditions, a linear de-rate factor is used to extrapolate.
Max. Design Temp. (Td) 90.0 °C Std. Operating Temp. (Top) 37.0 °C
Min. Design Temp. (Tdm) 20.0 °C Installation Temp. (Tlive) 37.0 °C

Coupon level Test Temp (Tt1) 25.6 °C 0.3 𝑇𝑡𝑖 − 𝑇𝑑

𝑓𝑇𝑖 = + 1 ; 𝑛𝑜𝑡 𝑡𝑜 𝑒𝑥𝑐𝑒𝑒𝑑 𝑣𝑎𝑙𝑢𝑒 𝑜𝑓 1
Standard Temperature De-Rate Factor (fT1) 0.81 𝑇𝑚 − 𝑇𝑡𝑖
Leak Qual. Test Temp (Tt2) 25.6 °C Performance Test Temp (Tt3) 25.6 °C
Leak Temperature De-Rate Factor (fT2) 0.81 Performance Temp De-Rate Factor (fT3) 0.81

Evaluating Effects of Thermal Expansion

When there is a difference between the pipe temperature at installation and the design temperature, the composite and pipe will
expand (or contract) at different rates. These strain differences will result in a thermal stress in the hoop, axial and radial directions. In
extreme temperature swings, these stresses may result in a composite failure. The values below are used later to ensure that failure is
not achieved by considering temperature and pressure variations.

Coefficient of Thermal Expansion Composite - Hoop (αc) Composite - Axial (αa) Substrate (αs)
(CTE) Values 1.57E-05 1/°C 3.13E-05 1/°C 1.17E-05 1/°C

Installation to Max. Temp 53 ∆𝑇 = 𝑇𝑑 − 𝑇𝑙𝑖𝑣𝑒 Installation to Min. Temp -17 ∆𝑇 = 𝑇𝑑𝑚 − 𝑇𝑙𝑖𝑣𝑒
Composite Substrate Difference Composite Substrate Difference
Hoop Strain 0.083% 0.062% 0.021% Hoop Strain -0.027% -0.020% -0.007%
Axial Strain 0.166% 0.062% 0.104% Axial Strain -0.053% -0.020% -0.033%

Determining Safety Factor and Stress Concentration Factor

Safety Factor - The default safety factor used is loosely based on the ISO 24817 safety factors. This value may be replaced.
Default Safety Factor (SFc) 1.7 Safety Factor Override 1.2
𝑆𝐹𝑐 = 1Τ 0.612 ∗ 10−0.0043𝑡𝑙𝑖𝑓𝑒𝑡𝑖𝑚𝑒 Safety Factor Used (SF) 1.2
Stress Concentration Factor - The SCF is determined by the geometric shape and mechanical deformation. Estimated.
Component Type Tee Mechanical Damage Type N/A
Component Type Multiplier 2.00 Length of Mech. Damage 0.0 mm
Estimated SCF 1.00 Width of Mech. Damage (dw) 0.0 mm
Long-Term Safe Pressure (Ps) 0 MPa Max Damage Height / Depth 0.000 mm

3/28/2020 Confidential and Proprietary 8

 Hoop - Structural Pressure Containment - Custom Design
Structural Minimum Thickness Equations - The following two pages represent the simple state scenario that a composite
repair undergoes. Using strain as the limiting design factor, a minimum required thickness is determined to handle loading
conditions in both, the hoop and axial, stress states.

Hoop stress - The fundamental equation below is presented as the starting equation for all hoop stress calculations. The variables ΔP
and εc can be modified based on the design scenario.

Pipe Diameter (D) 60.3 mm Hoop Modulus of Repair (Ec) 27,579 MPa
Equation 1 - stress in the hoop direction Equation 1 Direct influence from axial loading ignored.
1 ∆𝑃𝐷 Basic Influence from external forces ignored.
𝑡𝑚𝑖𝑛,𝑐 =
𝜀𝑐 𝐸𝑐 2 Assumptions
Design is limited by chosen strain value.

Determining Pressure Load - The first step is to determine the pressure load that the composite repair is expected to handle. The main
determination here is whether or not the substrate is to be ignored.
System Design Pressure (P) 30.0 MPa Safe Pressure with SCF (Ps) 0 MPa
Include Substrate Strength : Yes By including the substrate strength in the equation, the
Additional
Target Pressure Range (ΔP) 30.0 MPa target pressure, ΔP, can be reduced by the safe
Explanation pressure of the substrate at end-of-life conditions.
∆𝑃 = 𝑃 − 𝑃𝑠 (𝑖𝑓 𝑠𝑢𝑏𝑠𝑡𝑟𝑎𝑡𝑒 𝑖𝑛𝑐𝑙𝑢𝑑𝑒𝑑)

Limiting Substrate Strain - If the repair system is to prevent the substrate from reaching a critical strain value, the composite allowable
strain must be determined as the difference between install strain and design strain.
Modulus of Substrate (Es) 198,555 MPa Install Pressure (Plive) 0 MPa
Design Stress (s) 148 MPa Thickness at Install (tlive) 0.000 mm
Allow beyond design strain : Yes The pipe can and is allowed to yield. The pipe is
Additional
assumed to provide no more strength beyond it's
Pipe Yield Strain (εhy) 0.07% Explanation specified yield or failure point.
Pipe Strain at Install (εhlive) 𝑠 𝑃𝑙𝑖𝑣𝑒 𝐷 𝜀ℎ𝑦 − 𝜀ℎ𝑙𝑖𝑣𝑒
𝜀ℎ𝑦 = 𝜀ℎ𝑙𝑖𝑣𝑒 = 𝜀ℎ𝑠𝑓 =
Strain avail. to yield (εhsf) N/A 𝐸𝑠 2𝐸𝑠 𝑡𝑙𝑖𝑣𝑒 𝑆𝐹

Performance Based Strain - If the repair system has undergone extensive long-term testing and the substrate strain is not limited, a
performance based strain value can be used. Refer to the ASME PCC-2 or ISO 24817 standard for guidance.

Use Performance Testing : N/A Additional The composite has no performance testing to date or is
Long Term Strain (εlt) N/A Explanation limited by substrate strain.

Long Term Strain with SF (εslt) N/A 𝜀𝑠𝑙𝑡 = 𝑓𝑇3 𝜀𝑙𝑡 Τ𝑆𝐹

Standard Allowable Strain - In the case where no other design strains are available, an allowable strain value that closely follows the
ISO 24817 standard is used. See prior pages for more information.
Comp. Strain to failure (εcf) 2.30% Additional This is a very conservative default value.
Allowable Strain (εcT) 0.51% Explanation 𝜀𝑐𝑇 = 𝑓𝑇1 ∗ 0.75%Τ𝑆𝐹

Design Methodology Used - Default Allowable Strain including substrate support.

Composite Design Strain (εc) 0.51% Target Pressure Range (ΔP) 30.0 MPa
Min. Repair Thickness (tmin,c) 6.439 mm Minimum Layers Required 12 layers

The minimum repair thickness required due to hoop loading is 6.439 mm as determined by Clock Spring | NRI's custom design.
This thickness corresponds with a minimum layer count of 12 layers.

3/28/2020 Confidential and Proprietary 9

 Axial - Structural Pressure Containment - Custom Design
Axial stress - The fundamental equation below is presented as the starting equation for all axial stress calculations. The variables ΔF
and εa can be modified based on the design scenario.

Pipe Diameter (D) 60.3 mm Axial Modulus of Repair (Ea) 12,827 MPa
Equation 2 - stress in the axial direction Equation 2 Direct influence from hoop loading ignored.
1 ∆𝐹 Basic Influence fro external forces ignored.
𝑡𝑚𝑖𝑛,𝑎 =
𝜀𝑎 𝐸𝑎 𝜋𝐷 Assumptions Design is limited by chosen strain value.

Determining Axial Loads - The following contains the cross sectional pipe areas and the axial loading condtions.

𝐹𝐴𝑑𝑑𝑖𝑡𝑖𝑜𝑛𝑎𝑙 = 2 + 𝐹 2 + 4Τ𝐷 𝑀2 + 𝑀2
𝐹𝑎𝑥
A general equation for determining additional axial loads can be 𝑠ℎ 𝑎𝑥 𝑡𝑜

Pristine Pipe Conditions

Area of Pristine Pipe (A) 1,244.07 mm² Pristine Pipe Max Load (Ff) 184,418 N
Design Stress (s) 148 MPa 𝐹𝑓 = 𝐴 ∗ 𝑠

Install Conditions
Area of Pipe at Install (Alive) 910.46 mm² Axial Load at Install (Flive) 0N
Install Addtl. Axial Load (Fai) 0N 𝐹𝑙𝑖𝑣𝑒 = 𝜋𝑃𝑙𝑖𝑣𝑒 𝐷 2 Τ4 + 𝐹𝑎𝑖

End of Life Conditions

Pipe Area at End of Life (As) 910.46 mm² Safe Axial Load with SCF (Fs) 𝑑𝑤 1
𝐹𝑠 = 𝑠𝐴𝑠 −1 +1
Include Substrate Strength : Yes 134,964 N 𝜋𝐷 𝑆𝐶𝐹

System Design Pressure (P) 30.0 MPa Design Axial Load (F) : 85,673 N
2Τ
Additional Axial Loads (Fa) 0N 𝐹 = 𝜋𝑃𝐷 4 + 𝐹𝑎
Target Load Range (ΔF) 0N Additional The target load, ΔF, is reduced by the safe end-of-life
∆𝐹 = 𝐹 − 𝐹𝑠 (𝑖𝑓 𝑠𝑢𝑏𝑠𝑡𝑟𝑎𝑡𝑒 𝑖𝑛𝑐𝑙𝑢𝑑𝑒𝑑) Explanation axial load capacity of the substrate.

Limiting Substrate Strain - If the repair system is to prevent the substrate from reaching a critical strain value, the composite allowable
strain must be determined as the difference between install strain and design strain.

Allow Substrate to Yield : Yes The pipe can and is allowed to yield. The pipe is
Additional assumed to provide no more strength beyond it's
Pipe Yield Strain (εay) 0.07% specified yield or failure point.
Explanation
Pipe Strain at Install (εalive) 0.00% 𝑠 𝐹𝑙𝑖𝑣𝑒 𝜀𝑎𝑦 − 𝜀𝑎𝑙𝑖𝑣𝑒
𝜀𝑎𝑦 = 𝜀𝑎𝑙𝑖𝑣𝑒 = 𝜀𝑎𝑠𝑓 =
Strain avail. to yield (εasf) Not considered 𝐸𝑠 𝐸𝑠 𝐴𝑙𝑖𝑣𝑒 𝑆𝐹

Standard Allowable Strain - In the case where no other design strains are available, an allowable strain value that closely follows the
ISO 24817 standard is used. See prior pages for more information.
Comp. Strain to failure (εaf) 1.80% Additional This is a very conservative default value.
Allowable Strain (εaT) 0.34% Explanation 𝜀𝑎𝑇 = 𝑓𝑇1 ∗ 0.5%Τ𝑆𝐹

Design Methodology Used - Default Allowable Strain including substrate support.

Composite Design Strain (εa) 0.34% Target Load Range (ΔF) 0N
Min. Repair Thickness (tmin,a) 0.000 mm Minimum Layers Required 0 layers

The minimum repair thickness required due to hoop loading is 0 mm as determined by Clock Spring | NRI's custom design. This
thickness corresponds with a minimum layer count of 0 layers.

3/28/2020 Confidential and Proprietary 10

 Other Design Considerations
External Pressure or Vacuum
Timoshenko's equation for the collapse of a round steel pipe has been modified below to account for the additional support provided
by a composite repair while including the substrate up to a specified hole size (if applicable).
Soil Loading
Depth Buried (h) N/A 2
4 𝐷 𝜋𝐷2 1 𝐷
Soil Weight (γsoil) 18 kN/m³ 𝑃𝑠𝑜𝑖𝑙 = 𝐷 ℎ+ − + ℎ+ 𝛾𝑠𝑜𝑖𝑙
𝜋𝐷 2 8 3 2
Soil Pressure (Psoil) N/A
Internal Vacuum
Vacuum Pressure (Pvac) N/A 𝑃𝑣𝑎𝑐 = −𝑃 𝑃𝑐 = 𝑃𝑠𝑜𝑖𝑙 + 𝑃𝑣𝑎𝑐

Target Pressure (Pc) 0.0 MPa Effective Wall Thickness (ts) 0.000 mm
1 Τ3 Effective ts is assumed to be minimum remaining wall
𝑡 3
1 − 𝑣2 2𝐸𝑠 𝐷𝑠 Assumptions
unless leaking, in which case it decreases linear until it
𝑡𝑚𝑖𝑛 = 𝑆𝐹 · 𝐷 ∙ 𝑃𝑐 − is assumed a value of 0 with a hole diameter of 3
2𝐸𝑐 1 − 𝑣𝑠2
inches or more.
Min. Repair Thickness (tmin,e) 0.000 mm

Determining the Repair Thickness

The initial minimum thickness is determined by comparing the appropriate structural, axial or leak repair thickness and
determining which value is highest, if applicable.
Structural - Hoop Direction Structural - Axial Direction Leak Repair Scenario
6.439 mm 0.000 mm N/A
Initial Minimum Calculated Thickness (tmin,i) 6.439 mm 12 layers

The initial minimum calculted thickness is then multiplied against the limiting length multiplier, if applicable.
Limited Length (fth,overlay) N/A if Lover is larger than Lavailable
Multiplied Calculated Thickness (tmin,m) 6.439 mm 12 layers

Any additional layers are then added, whether from external erosion protection or due to other non-standard influences on the
substrate or repair system.

Multiplied Minimum Thickness 6.439 mm 12 layers

External Erosion Protection 0.000 mm 0 layers
Additional Recommended Layers 0.000 mm 0 layers
Final Calculated Thickness (tmin,f) 6.439 mm 12 layers

Next, the calculated thickness is compared with the company minimum layer count to determine the final minimum repair
thickness required.
Final Calculated Thickness (tmin,f) 6.439 mm 12 layers
Company Minimum Thickness (tmin,c) 6.706 mm 12 layers
External Loading or Vacuum (tmin,e) 0.000 mm 0 layers
Final Minimum Repair Thickness 6.706 mm 12 layers

Lastly, the final minimum repair thickness is rounded up to the nearest layer thickness and adjusted, if needed, to fit with the
prescribed installation technique.

Installation Considerations Spiral Wrap 0 extra layers

Rounded Thickness (trep) 6.706 mm 12 layers

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 Determining the Repair Zone
The minimum length past the defect is guided by ISO 24817 section 7.5.8.

Repair Type Structural Reinforcement Axial Modulus (Ea) 12,827 MPa

Defect length (Ldefect) 50.800 mm Axial Strain (εa) 0.34%
Pipe Outside Diameter (D) 60 mm Lap Shear Strength (τ) 19 MPa
Pipe Wall Thickness (t) 7.500 mm Repair Thickness (trepair) 6.706 mm
For slot type defects : 𝐿𝑠,𝑜𝑣𝑒𝑟 = 2 𝐷𝑡 3𝐸𝑎 𝜀𝑎 𝑡𝑟𝑒𝑝𝑎𝑖𝑟
If the repair is leaking : 𝐿ℎ,𝑜𝑣𝑒𝑟 =
For Circular type defects : 𝐿𝑐,𝑜𝑣𝑒𝑟 = 4𝑑 where 𝑑 < 0.5 𝐷𝑡 𝜏
Min. Length Over (Ls,over) 42.53 mm Axial Min. Length Over (Lh,over) 44.97 mm
Circ. Min. Length Over (Lc,over) N/A Minimum Length Over (Lmin) 50.80 mm

If goverend by axial loads, a 5:1 taper is required For low cyclic frequency, a 2 inch (50.8mm) Lover is sufficient
Axial goverend repair No Cyclic Frequency Ignored
Taper Length (Ltaper) N/A Min. Length Over (Lf,over) 50.80 mm

The final minimum repair length is determined by adding the correct Lover, Ltaper and Ldefect.
Length Over (Lover) 50.80 mm
𝐿 = 2𝐿𝑜𝑣𝑒𝑟 + 𝐿𝑑𝑒𝑓𝑒𝑐𝑡 + 2𝐿𝑡𝑎𝑝𝑒𝑟
Defect length (Ldefect) 50.80 mm
Taper Length* (Ltaper) N/A Minimum Repair Length (L) 152.4 mm
*ASME PCC-2 Article 4.1 Section 3.4.8(d) states: "The ends of the repair shall be tapered if the repair thickness is goverened by axial loads."

In addition to the minimum required repair length, factors that may increase the total repair length are reviewed.
Pig Markers to be wrapped No Pig Marker Length N/A
Surface Preparation media blasting Prep. Penalty Length 0.0 mm
Repair Zone Options No limitation Override Length N/A
Geometric Considerations Tee Modified Min. Repair Length 152.4 mm

If limited lengths exist and Lover exceeds this value, ISO 24817 equation 22 can be utilized.
Limiting Length on side 1 350.8 mm Min. Repair Length on side 1 50.8 mm
Limiting Length on side 2 350.8 mm Min. Repair Length on side 2 50.8 mm
2
Is there sufficient space? Yes 𝑙𝑜𝑣𝑒𝑟 3
𝑓𝑡ℎ,𝑜𝑣𝑒𝑟𝑙𝑎𝑦 = 𝑀𝐴𝑋 2.5 𝑜𝑟 ISO 24817
Available Length (lavailable) N/A 𝑙𝑎𝑣𝑎𝑖𝑙𝑎𝑏𝑙𝑒 Equation 22

Limited Min. Repair Length 152.4 mm Limitation factor (fth,overlay) N/A

Installation method will also need to be examined to ensure sufficient space is available.
Installation Method Spiral Wrap Repair length on base pipe 762.0 mm
Fabric Width 50.8 mm Repair on branch pipe 457.0 mm
Fabric Offset 25.4 mm Surface Area of Repair 0.48 m²

Lastly, the area beyond the composite is examined. It is recommended that the adhesive primer extends beyond the composite
repair to act as a tie-in for any re-coating efforts. It is recommended to prep a few inches past the tie-in.
Addt'l Primer per Side 50.8 mm Addt'l Surface Prep per Side 50.8 mm
Primer length on base pipe 863.6 mm Prep length on base pipe 965.2 mm
Primer length on branch pipe 507.8 mm Prep length on branch pipe 558.6 mm
Surface Area of Primer 0.54 m² Required Prep Surface Area 0.60 m²

3/28/2020 Confidential and Proprietary 12

 Estimated Stress States
These calculations use Barlow's Formula as a guideline for hoop stress. Substrate stress is capped at SMYS; includes SCF.
At Installation Pressure
Installation Pressure 0.0 MPa Interface Pressure 0.0 MPa
Substrate Hoop Stress 0.0 MPa Composite Hoop Stress 0 psi
Substrate Hoop Strain 0.000% Composite Hoop Strain 0.000%
Substrate Axial Stress 0.0 MPa Composite Axial Stress 0 psi
Substrate Axial Strain 0.000% Composite Axial Strain 0.000%

At Operating Pressure
Operating Pressure 18.9 MPa Interface Pressure 18.9 MPa
Substrate Hoop Stress 0.0 MPa Composite Hoop Stress 95.4 psi
Substrate Hoop Strain 0.346% Composite Hoop Strain 0.346%
Percent to Failure 0.00% Percent to UTS (short term) 20.47%
Substrate Axial Stress 53.4 MPa Composite Axial Stress 3.4 MPa
Substrate Axial Strain 0.027% Composite Axial Strain 0.027%
Percent to Failure 20.12% Percent to UTS (short term) 2.63%

At Design Pressure
Max Design Pressure 30.0 MPa Interface Pressure 30.0 MPa
Substrate Hoop Stress 0.0 MPa Composite Hoop Stress 151.4 MPa
Substrate Hoop Strain 0.549% Composite Hoop Strain 0.549%
Percent to Failure 0.00% Percent to UTS (short term) 32.50%
Percent to LTS (long term) N/A

Substrate Axial Stress 84.8 Composite Axial Stress 5.5

Substrate Axial Strain 0.043% Composite Axial Strain 0.043%
Percent to Failure 31.93% Percent to UTS (short term) 4.18%
Percent to LTS (long term) N/A
Stress Effects on the Adhesive
The effects of temperature increase and decrease are calculated below by examining the thermal strain differences between the
composite and the pipe. Additionally, Radial stresses examined in order to determine if the adhesive primer used will fail under a worst
case scenario.

Increase of temperature by 53.0 °C Decrease in temperature by -17.0 °C

Difference in Hoop Strain 0.021% Difference in Hoop Strain -0.007%
Radial Stress from Temp. 1 MPa Radial Stress from Temp. 0 MPa
Difference in Axial Strain 0.104% Difference in Axial Strain -0.033%
Lap Shear Stress in Adhesive 1 MPa Lap Shear Stress in Adhesive 1 MPa

Internal Pressure at 30.0 MPa Internal Pressure at 0.0 MPa

Pressure Change from Install 30.0 MPa Pressure Change from Install 0.0 MPa
Tensile Stress in Adhesive -2 MPa Tensile Stress in Adhesive 0 MPa

Max Lap Shear Stress Calc. 1 MPa Max Tensile Stress Calc. 1 MPa
Max Lap Shear Stress Allowed 19 MPa Max Tensile Stress Allowed 7 MPa

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 Recommended Surface Preparation
The minimum recommended surface prep is a NACE 3, commercial blast cleaning although a NACE 1 or NACE 2 surface is
preffered. This surface preparation can be achived by either media blasting or aggressive mechanical grinding. In certain environments
where the above may be difficult to achieve, consult a qualified Pipe Wrap Engineer or trained representative to discuss other options
that may be available.
NACE 1

NACE 2

NACE 3
Job-Site Accessories Items
AK-25 (Primer Application Kit)
The purpose of the AK-25 application kit is to provide all the essential materials for the following stages of a repair:
- Application of the load transfer filler
- Application of the adhesive primer / top-coat
- General tools for composite application
The quantity of AK-25's supplied are based on the surface area to be covered by the adhesive primer. A larger, bulk version
(denoted as an AK-25B) is available and is designed to meet the needs of five AK-25 kits. The items provided in a standard AK-25
application kit include:

Cardboard Mixing Pads Primer Applicators Razor Blade Large Zip-Close Bag
Quart Mixing Buckets Large Mixing Sticks Scissor Nitrile Gloves
Putty Knives (for mixing) Squeegee Can Opener Trash Bag
AK-30 (Fabric Wet-out Application Kit)
The purpose of the AK-30 application kit is to provide all the essential materials for the following stages of a repair:
- Assist in creating a plastic wet-out area
- Mixing resin dump-kits
- Wetting out fabric with resin
The quantity of AK-30's supplied are based on the total fabric area to be wet-out with resin. A larger, bulk version (denoted as an
AK-30B) is available and is designed to meet the needs of five AK-30 kits. The items provided in a standard AK-30 application kit include:

Plastic Sheeting Scissor Trash Bag Large Mixing Sticks

Duct Tape Squeegee Gloves Small Stir Sticks
AK-55 (Combined Application Kit)
For smaller repairs, an AK-55 may be provided to simplify packaging. An AK-55 contains 1ea AK-25 and 1ea AK-30. No bulk version
of AK-55's are avaialble.

Constrictor Wrapping
The purpose of the Constrictor Wrapping is to compress the composite repair against the substrate until it has cured.
Additionally, it will protect the wrap from debris and outside fluids until it has set.

Perforator Tool
If constrictor wrapping is used, a perforator may be recommended. This tool is used to create many small holes in the constrictor
wrap which serves to release excess resin or gas (if applicable) in the composite throught the constrictor.

Additional Material Required - Provided by Installer

In addition to the accessories provided by Clock Spring | NRI, the following materials should be provided or accessable on-site as
needed:

Site Required PPE Tenting / Tarp Measuring Tape Solvent (Acetone, MEK or
Cleaning Rags Surface Prep Tools Sandpaper Toluene Only)
It is recommended that a Repair Area and a Staging Area are established prior to beginning the repair. It is important that both
locations have proper environmental protection and temperature control measures if necessary.

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 Load Transfer Filler
The primary load transfer filler being used is the EP-420 system. It is a 2-part epoxy with very high compressive strength and
modulus. Its primary purpose is to reshape any defect or provide a transitional zone while maintaining stress distribution from the
substrate to the composite.

Load Transfer Filler Name EP-420 Working Time 20 minutes

Filler Type Paste Set Time 1 hour
Filler Item Number EP-420 Cure Time 24 hours
Compressive Strength (psi) 101 MPa Defect Volume 19,354.8 mm³
Compressive Modulus (psi) 3,999 MPa Weld Transition Volume 0 mm³
Minimum Cure Temp. 4 °C Additional Volume (shaping) 682.7 mm³
Glass Transition Temp. 177 °C Total Filler Volume Required 20,037.5 mm³

Load Transfer Filler Application Overview

The EP-420 resin comes as pre-measured dump kits. When ready to begin, open up the jars and and mix A & B together on a
cardboard mixing pallet. Once uniform in color (minimum 2 minutes of mixing), begin applying to the defect area - apply to all voids
and "tented" areas.

Adhesive Primer / Top-Coat

The primary adhesive primer being used is the PPR adhesive system. It is a 2-part epoxy used to ensure maximum bonding
between the composite system and the substrate material. For any composite repair, the bond-line is the most critical element in the
repair system. Below are the relevant material properties.

Adhesive Name PPR Working Time (minutes) 30 minutes

Adhesive Type Standard Set Time (minutes) 2 hours
Ahesive Item Number PPR-2L Cure Time (hours) 24 hours
Lap Shear Strength 2,826 Primer Surface Area 0.54 m²
Energy Release Rate 1.000 Top-Coat Surface Area 0.48 m²
Glass Transition Temp. 150 °C Total Surface Area Required 1.02 m²

Adhesive Primer Application Overview

The adhesive primer resin comes in 2 equal volume containers. With a 1:1 mix ratio by volume, scoop out the required amount of
Part A and Part B and mix on a cardboard mixing pallet or in a disposable mixing bucket. Mix until uniform in color (2-3 minutes
minimum) and then apply as needed.

External Wall Loss Overview

View of pipe wall thickness -

circumferential cut

View of pipe wall thickness - axial cut

External Defect Volume 19,354.8 mm³

After applying the load transfer filler and primer adhesive to the pipe, the surface to be wrapped should be concentric with no
sharp points or stress risers present. It is expected that all further external wall loss has been stopped.

Properly applying the load transfer filler and adhesive primer is critical to the long-term success of a repair. Ensure that sufficient
time is provided beforehand to discuss any unique circumstance and what the best approach may be for a specific repair. Time well
spent on this step will ensure a quicker and easier composite installation.

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 Composite Repair Fabric
The FG-200, Fiberglass fabric was chosen for this design to meet the stiffness, thermal and structural requirements. Specifically,
the FG-200 fabric is best used when arresting general corrosion or addressing very small diameter pipe. FG-200 is a high-strength, bi-
directional, white fabirglass woven fabric.

Fabric Name FG-200 Fabric Name

Fabric Type Fiberglass Fabric Type Fiberglass
Fabric Weave Bi-Directional Fabric Weave Bi-Directional
Approx. Available Widths 25, 50, 100, 150 and 300 mm Approx. Available Widths 12 inches

Component Type Tee

Surface Area of Repair Zone 5.1 ft² Surface Area of Repair Zone 5.1 ft²
Layer Count 12 layers Layer Count 0 layers
Installation Method Spiral Wrap Installation Method Spiral Wrap
Actual Fabric Width 2 inches Actual Fabric Width 0 inches
8,877 in² #VALUE! in²
Total Fabric Minimum Total Fabric Minimum
61.65 ft² #VALUE! ft²
Install Segment Length 0 inches Install Segment Length 0 inches
Number of Segments 1 segment Number of Segments 1 segments
Fabric Length Needed 4,439 inches Fabric Length Needed inches
per Install Segment 369.89 feet per Install Segment feet
Recommended Material per Segment Recommended Material per Segment
Size Quantity Coverage Length Size Quantity Coverage
02 in. x 15 ft. 25 375.0 feet feet

Total Material per Segment 375.0 feet Total Material per Segment 0.00 feet

Wet-Out Resin Matrix

The resin matrix to be used for this repair is the CS-105 resin. It was chosen for this design to meet the chemical, thermal and
practical requirements. The wet-out resin determines the thermal and chemical limits of a composite.

Primary Resin System CS-105 Working Time (minutes) 15 minutes

Resin Type Standard Epoxy Set Time (minutes) 1 hour
Resin Container 2-Part Epoxy Kit Cure Time (hours) 24 hours
Application Style Field Wet-Out Minimum Cured Hardness 80 Shore D

Fabric Kit Size Area Coverage Grams Needed Resin Kits Total Kits Needed
FG-200 02 in. x 15 ft. 2.5 ft² 26 g/ft² 65 g 1 ea 100g Kit 25 ea 100g Kits of CS-105

Resin Matrix Application Overview

The wet-out resin comes as pre-measured dump kits. When ready to begin wetting out fabric, open up the jar containing Part B and
pour into the Part A jar. Mix for 1 minute using the small stir sticks provided in the application kits. Once mixed, pour a small portion
onto the fabric and apply until the fabric is adequately covered in resin.

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 Installation Overview
This section is only intended to provide a brief overview of the general repair process.
This section does not override the installer manual, any custom procedures or any quality control documents.
Composite
Before beginning a composite repair, the pipe surface must be prepped. This is Repair Zone
typically performed with media-blasting or with mechanical tools. The defect shall
than be cleaned with Acetone, MEK or Toluene and then re-examined to verify that
the original design is still valid. Defects

Mark the edge of the adhesive primer and composite wrap locations as noted
Adhesive primer
within this design package. zone

Mix and apply the EP-420 load transfer filler over the entire defect region.
Additionally, any welds or other non-smooth surfaces should be filled until a smooth
transition is created. Depending on the conditions present, additional filler material
types may be provided.

Mix and apply the PPR adhesive primer over the indicated primer length.
Typically, this primer can be used as a top-coat as well, however, a different top-
coat may be used. Allow the primer to thicken before applying the composite wrap.

Apply the composite wrap. The technique of applying the wrap will change
based on various factors. The following page has a summary of installation
techniques. For a detailed explanation of each technique, please refer to the
installer manual.

Installation notes on the FormaShield™ LT repair system:

This repair system utilizes a field-applied epoxy resin. The resin typically comes in pre-measured dump kits - simply pour the jar of
Part B into the jar of Part A and mix for 30 seconds. Once mixed, apply the resin to the dry fabric until saturated - be careful not to
oversaturate the resin or leave dry spots. Roll the fabric onto the applicator stick and begin wrapping the pipe. Repeat process when
multiple rolls are required. For further information, refer to the product's installation manual.

Apply 6 layers of constrictor wrap over the repair zone using the spiral wrap
method if applicable. Once wrapped, use the Perforator and perforate the
constrictor wrap around the entire repair zone. Doing these steps will compress the
repair while it cures and allow excess resin or gases to escape.

Allow 2 hours (temperature dependent) for the system to harden, or "set".

Once hardened, remove the constrictor wrap completely and examine the
composite for any defects.

Upon inspection and approval, apply a top-coat to the repair system (if
needed). Typically, the adhesive primer used earlier can double as a top-coat,
however, most common top-coat technologies will work as well.

General Note :
This overview only considers straight pipe. For repairs with different geometries, please refer to a later page in this design
package or a custom procedure (if created) for guidance.

3/28/2020 Confidential and Proprietary 17

 Composite Wrap Installation Techniques Overview
Before beginning, verify which installation technique should be used. The following section depicts a brief summary of each
installation technique commonly used. These steps assume that all steps are complete up to composite wrapping.

Layer over Layer

The layer over layer technique is the most basic installation technique. This is used when the repair zone is equal to or smaller
than the width of fabric to be applied. With this technique, the wrap is applied to the center of the repair zone and continuously
applied, overlapping itself, until all the provided material has been utilized.

1) 2) 3)

Offset Method
The offset method is used primarily for large diameter pipes with repair zones greater than 12 inches. The core element of this
method is that the first two layers are offset from each other by two inches. This creates a tie-in region between multiple segments.
After these first two layers are applied, the remaining layers are applied similar to the "Layer over Layer" installation technique. When
beginning the next section, this two inch offset continues until the last segment is reached. On the last segment, directly wrap over the
offset tab using the standard "Layer over Layer" install.

1) 2)

3) 2 inch 4)
offset
tab

Spiral Wrap
The spiral wrap technique is used primarily for long repair zones on small / medium sized pipes. This technique involves wrapping
the pipe at an angle causing the wrap to overlap itself, typically 50% of the fabric width. By spiral wrapping from one edge to the other,
two layers are applied before reversing direction. At the edges of the repair, always wrap 2 full layers before the initial spiral wrap and
always when reversing direction.
For very long repairs, spirally wrapped segments may be pieced together similar to the offset method.

1) 2)

3) 4)

Overlap
The overlap method is used only on small repairs with a low layer count where space may be limited. In this technique, two
segments of fabric will overlap each other a specified distance. This overlap is to ensure that the composite repair will fit within the
restricted repair length. It is best to alternate layers as much as possible.

1) 2)

3) 4)
0 2 Overlap 2
region
0 2 4 4

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 Tee Repair - Additional Considerations
Geometric considerations on a Tee.
Wrapping a tee requires special consideration due to the geometric conditions. Although a standard Tee installation process is
presented, some circumstances may require modifications to this process.

Base Pipe Diameter 168 mm

Branch Pipe Diameter 60 mm Branch Pipe
Location of Defect On the Branch Pipe
Branch Weld
Distance to intersection 0 mm Distance from intersection
***note: If defect is in base pipe, consider that region "side 1"

Weld 2
Weld 1
Repair Length Side 1 351 mm
Defect
Repair Length Side 2 351 mm
Base Pipe Base Pipe
Total Base Pipe Repair Length 762 mm Side 1 Side 2
Repair Length - Branch 457 mm

Repair Surface Area 477,274 mm²

Primer Surface Area 540,472 mm²
Branch Repair Length
Required Surface Prep Area 603,671 mm² Repair Length 1 Repair Length 2

Additional Filler Needed 683 mm³

Filler material should be applied at the intersection to ensure Filler Material
a smooth transition region.
Adhesive

Additional notes on the application of the composite repair on a simple Tee.

When installing a composite repair on a Tee, a combination of installation methods is required. Depending on the pipe sizes, two
fabric widths may be needed.

1) Lay strips from the branch pipe onto the base pipe. 2) Lay strips across the length of the base pipe with 50%
Proceed around the entire branch pipe with 50% overlap. overlap. Apply until the branch pipe interferes.

3) Apply cross layers ensuring that the center-side of the Tee 4) Capture the outside layers. The whole Tee should now
achieves 2 additional layers with a 50% overlap. have a minimum of four layers - repeat as needed.

0 0
0 0

3/28/2020 Confidential and Proprietary 19