DESIGN CALCULATION

CARBONTECH COMPOSITE SYSTEMS (PTY) LTD

Revowrap ISO 24817 Design Calculations

Client Information
Customer CTA
End user name contact details Carigali Hess Operating Company
Site -
Equipment number CKP-6-VH-5060-B31-2023-CVI-6-TPP5
Project details 6" straight with 71% wall loss
Work order number -
Tag number/Client reference -
Priority P2
Carbontech design number CTD3712

Revision Date Initials Comments

0 2023/09/24 CL

Digital Signatures

Carbontech Design Engineer

Professional/chartered Engineer

Client representative Engineer

Rehabilitating asset integrity through

progressive composite engineering

Author: du Preez, D
Publish date: 04 September 2023
Revision: 02 Page 1
DESIGN CALCULATION

Design input information

Equipment number CKP-6-VH-5060-B31-2023-CVI-6-TPP5

Plant area -
Area engineer -
Process service Unknown Repair recommendation and design conclusion
Compatible (Yes/No) TBC
Through wall defect (N/A) N/A mm Date 2023/09/24
Total wall loss defect length (L_defect) 300 mm Repair system Revowrap185
Pipe size 6 Inch Calculated repair length 459,17 mm
Operating temperature 134 DegC *Recommended repair length 460 mm
Operating pressure 7 BarG Calculated repair thickness 2,08 mm
Design temperature (Td) 149 DegC **Recommended repair thickness 2,08 mm
Design pressure (P) 18,3 BarG Number of layers 4
Defect description External Corrosion Repair lifetime 20 years
Surface preparation SSPC-SP3 *Repair to be centred on the defect area.
Substrate material Carbon steel **Repair thickness based off of ply thickness
Material grade A333 6

Defect Visualization Selected material properties

Revowrap185
Ea 19,60 GPa Tensile modulus in axial direction
Ec 37,60 GPa Tensile modulus in circumferential direction
Eac 27,15 GPa Combined tensile modulus
G31 1,30 GPa Shear modulus
γLCL 89,49 J/m² Energy release rate
τ 4,8 MPa Lap shear strength
ν 0,370 Composite Poisson's ratio
tply 0,52 mm Composite single layer thickness
HDT 226,8 DegC Heat distortion temperature

Pipeline/asset information used in calculations Repair material design parameters

Tinstall= 134 DegC Installation temperature Tm = 211,8 DegC service temperature limit
Plive= 0,70 MPa Live pressure at time of repair εc= 2,415E-03 Circumferential allowable strain
P = 1,83 MPa Specified design pressure εa= 2,415E-03 Axial allowable strain ((Equation 10)
Ps = 0,71 MPa MAWP pressure αc = 1,880E-06 mm/mmDegC Laminate circumferential CTE
s = 138 MPa Allowable stress (ASME B31.3) αa = 1,880E-06 mm/mmDegC Laminate axial CTE
D = 168,3 mm Component outside diameter Ea = 19600 MPa Tensile modulus in axial direction
αs = 1,170E-05 mm/mmDegC Substrate CTE Ec = 37600 MPa Tensile modulus in hoop direction
Es = 207000 MPa Tensile modulus of substrate Repair Class = Class 3
Limited by repair laminate allowable strains (no substrate
Peq = 1,84 MPa Equivalent design pressure Design Basis Type A =
contribution)
Feq = 48081,1 N Equivalent axial thrust force Design Basis Type B = Type B assessment not followed
t= 7,11 mm Original wall thickness Long-term test data = No long-term test data is available
ts = 2,06 mm Remaining wall thickness
νs= 0,303 Substrate poisson ratio

Author: du Preez, D
Publish date: 04 September 2023
Revision: 02 Page 2
DESIGN CALCULATION

EQUIVALENT FORCE LOADING DUE TO APPLIED LOADS

For cases where there are applied loads on the pipe that need to considered in addition to the internal pressure, these applied forces and moments will sum up to an equilalent internal
pressure. Below is a illustration showing how these forces and moments will be applied.

2 4 2
16 2
𝑃𝑃𝑒𝑒𝑒𝑒 = 𝑝𝑝 1 + 𝐹𝐹𝑠𝑠𝑠 + 𝑀𝑀 where : 𝑝𝑝 ≥ 𝐹𝐹 + 𝑀𝑀
𝜋𝜋𝐷𝐷 2 𝑝𝑝 2 𝐷𝐷 𝑡𝑡𝑡𝑡 𝜋𝜋𝐷𝐷 2 𝑠𝑠𝑠 𝐷𝐷 𝑡𝑡𝑡𝑡

or Equation (3)
4 2 where : 4 2
𝑃𝑃𝑒𝑒𝑒𝑒 = 𝑝𝑝 + 𝐹𝐹 + 𝑀𝑀 𝑝𝑝 < 𝐹𝐹 + 𝑀𝑀
𝜋𝜋𝐷𝐷2 𝑠𝑠𝑠 𝐷𝐷 𝑡𝑡𝑡𝑡 𝜋𝜋𝐷𝐷2 𝑠𝑠𝑠 𝐷𝐷 𝑡𝑡𝑡𝑡

𝜋𝜋 2 2 2
4 2 2
𝐹𝐹𝑒𝑒𝑒𝑒 = 𝑝𝑝𝐷𝐷 + 𝐹𝐹𝑎𝑎𝑎𝑎 + 4𝐹𝐹𝑠𝑠𝑠 + 𝑀𝑀𝑎𝑎𝑎𝑎 + 𝑀𝑀𝑡𝑡𝑡𝑡 Equation (4)
4 𝐷𝐷

Applied/resultant shear load and is Force and Moment parameters

where : 𝐹𝐹𝑠𝑠𝑠 = calculated from the weight of the pipe Outside diameter of substrate 168,30 mm
and product as follows: Nominal wall thickness 7,11 mm
Substrate mass 28,26 kg/m
Process medium density 1000 kg/m3
Applied axial force applied to piping, Process medium mass 18,65 kg/m
where : 𝐹𝐹𝑎𝑎𝑎𝑎 = specified by piping engineer or taken as the Combined mass 46,91 kg/m
same value as the resultant shear load Substrate span 7,10 m

Applied/resultant axial moment due to self Resultant shear force calculation

where : 𝑀𝑀𝑎𝑎𝑎𝑎 = weight of the pipe or an applied external Shear force (Fsh) 3267,04 N
force and is calculated as follows:

Resultant axial force

Applied/resultant tortional moment, Axial force (Fax) 3267,04 N
where : 𝑀𝑀𝑡𝑡𝑡𝑡 = specified by piping engineer or taken as
the same value as the resultant axial

Resultant axial moment calculation

Resultant moment (Max) 1933,00 N.m
4 2
Such that: 𝐹𝐹 + 𝑀𝑀 = 0,15
𝜋𝜋𝐷𝐷2 𝑠𝑠𝑠 𝐷𝐷 𝑡𝑡𝑡𝑡

Resultant torsional moment calculation

Resultant moment (Mto) 1933,00 N.m
where p = 1,83 MPa

Therefore, the equivalent design pressure and equivalent axial load can be obtained as:

∴ 𝑃𝑃𝑒𝑒𝑒𝑒 = 1,84 MPa 𝐹𝐹𝑒𝑒𝑒𝑒 = 48081,05 N

Author: du Preez, D
Publish date: 04 September 2023
Revision: 02 Page 3
DESIGN CALCULATION

REPAIR LAMINATE ALLOWABLE STRAINS (NO SUBSTRATE CONTRIBUTION) - TYPE A

ALLOWABLE STRAIN AND TEMPERATURE DE-RATING FACTOR

𝑓𝑓𝑇𝑇𝑇 = 0.000 062 5 𝑇𝑇𝑚𝑚 − 𝑇𝑇𝑑𝑑 2

+ 0.001 25 𝑇𝑇𝑚𝑚 − 𝑇𝑇𝑑𝑑 + 0.7 = 1,025 Table 7

Δ𝑇𝑇 = 𝑇𝑇𝑑𝑑 − 𝑇𝑇𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙 = 15 °C

𝜀𝜀𝑐𝑐 = 𝑓𝑓𝑇𝑇𝑇 𝜀𝜀𝑐𝑐𝑐 − ∆𝑇𝑇(𝛼𝛼𝑠𝑠 − 𝛼𝛼𝑐𝑐 ) = 0,00241 Equation (10)

𝜀𝜀𝑎𝑎 = 𝑓𝑓𝑇𝑇𝑇 𝜀𝜀𝑎𝑎𝑎 − ∆𝑇𝑇(𝛼𝛼𝑠𝑠 − 𝛼𝛼𝑎𝑎 ) = 0,00241

It is assumed that the contribution of the substrate is to be ignored in the calculation for load carrying capability. Therefore equations 8 and 9 are used to determine the minimum repair
laminate thickness.

Parameters used in calculation

Diameter D 168,3 mm
Tensile Modulus of Com Ec 37,6 GPa
Tensile Modulus of Com Ea 19,60 GPa
Equivalent Design Press Peq 1,84 MPa
Poisson's Ratio of comp υ 0,37
Equivalent Axial Load Feq 48081,05 N

The minimum repair thickness as determined by circumferential (hoop) loads is determined by:

Equation (8)
1 𝑝𝑝𝑒𝑒𝑒𝑒 𝐷𝐷 1 𝐹𝐹𝑒𝑒𝑒𝑒 𝜐𝜐
𝑡𝑡𝑚𝑚𝑚𝑚𝑚𝑚,𝑐𝑐 = +
𝜀𝜀𝑐𝑐 2 𝐸𝐸𝑐𝑐 𝜋𝜋𝜋𝜋 𝐸𝐸𝑐𝑐

tmin,c = 2,078 mm

The minimum repair thickness as determined by axial loads is determined by:

1 𝐹𝐹𝑒𝑒𝑒𝑒 1 𝑝𝑝𝑒𝑒𝑒𝑒 𝐷𝐷 𝜐𝜐
𝑡𝑡𝑚𝑚𝑚𝑚𝑚𝑚,𝑎𝑎 = −
𝜀𝜀𝑎𝑎 𝜋𝜋𝜋𝜋 𝐸𝐸𝑎𝑎 2 𝐸𝐸𝑐𝑐 Equation (9)

tmin,a = 1,290 mm

The minimum repair thickness for the type A solution is determined from the maximum of the minimum repair thickness as determined by the equations above.

→ 𝒕𝒕𝒎𝒎𝒎𝒎𝒎𝒎 = 2,078 mm

Author: du Preez, D
Publish date: 04 September 2023
Revision: 02 Page 4
DESIGN CALCULATION

LENGTH OF REPAIR

The total axial repair length is calculated based on the surface preparation, if a different surface condition is used on site than stated above, the repair has an increased chance of failure.

The surface preparation method for this design is: SSPC-SP3

The axial extent of design thickness of repair is calculated by:

𝐿𝐿𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 = 2 𝐷𝐷𝐷𝐷 Equation (18)

Lover = 69,2 mm

To ensure sufficient axial extent to provide adequate load transfer between the substrate and the repair laminate, equation 21 is required to be satisfied.

3𝐸𝐸𝑎𝑎 𝜀𝜀𝑎𝑎 𝑡𝑡𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑,𝑎𝑎

𝐿𝐿𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 > Equation (21)
𝜏𝜏

3𝐸𝐸𝑎𝑎 𝜀𝜀𝑎𝑎 𝑡𝑡𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑,𝑎𝑎

= 38,15 mm
𝜏𝜏

𝐿𝐿𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 = 69,2 mm

This repair length is required to be applied to each defect of the listed defect size.

The repair is requried to satisfy the following inequality:

𝐷𝐷� = 14,03 mm > 𝑡𝑡𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑

12

This is satisfied for the repair thickness:

→ 𝑡𝑡𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 2,08 mm based on ply thickness

The repair length is determined using the following factors.

Lover = 69,18 mm Ldefect = 300 mm Ltaper = 10,4 mm

The axial extent of the repair is:

𝐿𝐿𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 = 2𝐿𝐿𝑜𝑜𝑜𝑜𝑜𝑜𝑜𝑜 + 𝐿𝐿𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 + 2𝐿𝐿𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡

𝐿𝐿𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡𝑡 = 459,17 mm Equation (20)

Author: du Preez, D
Publish date: 04 September 2023
Revision: 02 Page 5
DESIGN CALCULATION

CHECKS ON DESIGN

The defect is not actively leaking and it is known that the gauge pressure at a later stage could potentially be lower than the repair live pressure. To assess the strength of the bond of the repair
interface, the tensile stress acting on the bond, q, shall be compared to the minimum bond strength (short-term lap shear strength divided by 3). The parameters used below are to test reasonable
possible extremes and are not necessarilly equal to the input parameters for the design of the repair laminate thickness.

P_live= 0,7 MPa T_live= 134 DegC

P_after= 0 MPa T_after= 20 DegC

𝐸𝐸𝑠𝑠 𝑡𝑡𝑠𝑠 2𝐸𝐸𝑐𝑐 𝑡𝑡𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑

𝑞𝑞 = 𝑝𝑝𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙 − 𝑝𝑝𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 1− − 𝛼𝛼𝑐𝑐 − 𝛼𝛼𝑠𝑠 𝑇𝑇𝑙𝑙𝑙𝑙𝑙𝑙𝑙𝑙 − 𝑇𝑇𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎𝑎 Equation (29)
𝐸𝐸𝑠𝑠 𝑡𝑡𝑠𝑠 + 𝐸𝐸𝑐𝑐 𝑡𝑡𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 𝐷𝐷

The tensile strength must satisfy the following constraint:

𝜏𝜏
𝑞𝑞 < 𝑞𝑞 = 1,1477 MPa
3
𝜏𝜏
= 1,6 MPa
3

Since the the constraint is satisfied the following repair thickness is suitable:

→ 𝑡𝑡𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑𝑑 = 2,08 mm

Repair recommendation and design conclusion

Date 2023/09/24
Repair system Revowrap185
Calculated repair length 459,17 mm
*Recommended repair length 460 mm
Calculated repair thickness 2,08 mm
**Recommended repair thickness 2,08 mm
Number of layers 4
Repair lifetime 20 years
*Repair to be centered on the defect area.
**Repair thickness based off of ply thickness

NOTES:
1. It is assumed that the substrate temperature at the time of installation is no less than specified T_install..
2. All defects must see the minimum length of repair (L_over+L_taper on either side of the defect - see equation 20). If this is not possible the design must be
reviewed.
3. This design is only valid for the parameters used in this report to generate the design.
4. Design life and material warantee is linked/ subject to the details and parameters used in the generation of the design.

Author: du Preez, D
Publish date: 04 September 2023
Revision: 02 Page 6