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    Iso 24817-2006

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    TECHNICAL ISO/TS SPECIFICATION 24817 Fest edition Petroleum, petrochemical and natural gas. industries — Composite repairs for pipework — Qualification and design, installation, testing and inspection Industries du pétrofe, de la pétrochimio ot du gaz naturel ~ Réparations ‘en matériau composite pour canatisations — Conformité aux exigences de performance et conception, installation, essai et inspection Reference numeer ISOM 248172008) © 180 2008 ISO/TS 24817:2006(E) POF disclaimer This POF fle ay contin embeded tyoalaces. In accordance wit Adobe's Keanna poly his fe may be priniod or vawed but sal net be eed ress the yptaces whch are embeced ae Heansad te and ised ot the compute peg th eign ‘covmiading the fe, parts steep torino roeponsinly of rot nfingng Adobas beeing ply Tha ISO Cental Someta ‘22cepts no taiy ns area, ‘Adobe i a vaderask of Ade Syatems Incorporated ais ofthe sofware procs ured Io crest hs POF fe can he fund in be Generali athe othe fe; the POF-coaton paramere wero opbmized fr pining. Every care has toen talon fo erie to le ease for use by ISD memeer bods.) {he untely even that a problem ring Tots found, lease bora the Geral Seetaiat alIhe adoss given below. © 1502006 [At rp reserved. Unless otetwise spaced, no par f this publaton may be roproducod or ized i any rm a by any means ‘lestonic er mecnsneat include phcloosgying and meron, withow permeson m wlng kom ether ISO atthe ederess bolo oF 180% amber body the county to roquestr 180 copyriht otc (Casa posta CH1211 Ganova 20 Ta rat 227400111 Fax 431 22749 0947 Exmal eopyight@ico rg ied ws or Published in Swizerand pet tpt staan (©180 2006 Adrghts reserved ISOMTS 24817:2006(E) Contents Page Foreword. Introduction. : 7 - 1 SCOPE samanenninnnaiennnninnninnnnnn 2 Normative references 3 Toms and dofinitions.. 4 Symbols and abbreviated terms... 44° Symbols : 4.2 Abbroviated terms .. 5 Applications 6 Qualification and design 6.1 Risk assessment nnn 62 Repair class. 6.3 Repair lifetime 64 Required data 65 Design methodology . 6.6 Requalification 7 Installation. 74 General 7.2 Materials of construction 73 Storage conditions 74 — Method statements 7.5 Installer qualifications. 76 Installation quidance.. 7.7 Live repairs. een 7.8 Repair of clamps, piping components, tanks or vessels .. 78 Environmental considerations wvnnsssmmnininnsnenn 8 Testing and inspection. : B41 General : 8.2 Allowable defacts for the repair systom.. 83 Repair of dafects within the repair system 8.4 Inspection methods. 8.5 Repair system maintenance and replacement strategy 9 System testing 10 Future modifications... : 11 Decommissioning, Annex A (normative) Design data shest... Annex B (normative) Qualification data, Annex ¢ (normative) Short-term pipe spool survival test, Annex D (normative) Measurement of 7¢, for through-wall defect calculation Annex E (normative) Measurement of performance test data, Annex F (normative) Measurement of impact performance. Annex G (normative) Measurement of the degradation factor. meredith n S rOSev0d ISO/TS 24817:2006(E) Annex H (informative) Axial extent of repair fook-up table own ‘Annex | (normative) Installer qualification.. Annex J (normative) Installation requirements and guidance. Bibliography 67 (© 180 2005 ~ Al ight resend ISO/TS 24817:2006(E) Foreword SO (the Intesnational Organization for Standardization) is a worldwide federation of national standards bodies (ISO member bodies). The work of preparing Intemational Standards is normally carried out through {SO {echnical committees, Each member body interested in a subject for which a technical committee has been established has the right to be represented on that committee. International organizations, governmental and non-governmental, in liaison with ISO, also take part in the work. [SO collaborates closely with the International Electratechnical Commission (IEC) on all matters of electrotechnical standardization. International Standards are drafted in accordance with the rules glven in the ISOEC Directives, Part 2 ‘Te main task of technical committees is to propare Intemational Standards. Draft International Standards ‘adopted by the technical committees are circulated to the member bodies for voting. Publication as an Intemational Standard requires approval by at least 75 % of the member badies casting 3 vole. In other circumstances, particularly when there is an urgent market requirement for such documents, a technical committee may decide to publish other types of normative document: — an ISO Publicly Available Specification (ISO/PAS) represents an agreement belween fechnical experts in ‘an |SO working group and is accepted for publication if itis approved by more than 60 % of the members. ‘of the parent committee casting a vote; — an ISO Technical Specification (ISO/TS) represents an agreement between the members of a technical committee and is accepted for publication if tis approved by 2/3 of the members of the committee casting avote. ‘An ISO/PAS ot ISOITS i reviewed after three years in order to decide whether it wil be confirmed for a Turther three years, revised to become an International Standard, or withdrawn. If the ISOJPAS or 'SOJTS is, confirmed, tis reviewed again after a further tae years, at which tine i must either be transformed into an International Standard or be withdrawn, ‘Altention is drawn to the possibly that some of the elements of this document may be the subject of patent rights. [$0 shall not be held responsible for identifying any or all such patent rights. ISO/TS 24817 was prepared by Technical Committee ISO/TCG7, Materials, equipment and offshore structures for petroleum, petrochemical and natural gas industries, Subcommitee SC 6, Processing equipment and systems. ISO/TS 24817:2006(E) Introduction ‘The objective of ISOITS 24817 is to ensure that composite repairs fo pipework when qualified, designed, installed and inspected using ISO/TS 24847 will meet the speciied performance requirements. Composite repairs are designed for use in oll and natural gas industry processing and utility service applications. The ‘main users of this Technical Specification will be overs of the pipework, design contraclors, suppliers contracted to detver the repairs, cerlfying authorities, instalation contractors and maintenance contractors. epee tom Set: 16180 2006 — Alright eserves TECHNICAL SPECIFICATION ISOTS 24817:2006(E) Petroleum, petrochemical and natural gas industries — Composite repairs for pipework — Qualification and design, installation, testing and inspection 1 Scope ‘This Technical Specification gives requirements and recommendations for the qualifeation and design, Installation, testing and inspection for the external application of composite repairs to corroded or damaged pipework used in the patroloum, petrochemical and natural gas industries. 2 Normative references ‘The following referenced documents are indispensable for the application of this document, For dated references, only the edition cited applies. For undated references, the latest edition of the referenced document (ineluding any amendments) applies. 180 75-3, Plastics — Determination of temperature of deflection under load — Part 3: Higl-strenath thermosetting laminates and long-fbre-reinforced plastics ISO 527-1, Plastics — Dotormination of tonsite properties —~ Pert 1: General prinojples 1S0 527-4, Plastics — Determination of tensile properties — Part 4: Test conditions for isotropic and orthotropic fe-reinforced plastic composites 1S0 888, Plastics and ehonite —- Determination of indentation hardness by maans of a durometer (Shore hardness) 180 10982, Plastics pining systems — Glass-reinforced thermosetting plastics (GRP) pipes and fitings — Determination of resistance to chemical attack on the inside of a section in deflected condition 180 11357-2, Plastios — Differential scanning calorimetty (OSC) — Part 2: Determination of glass transition temperature 180 11359-2, Plastics — Thennomechanical analysis (TMA) — Part 2: Dotomination of coeficient of finear thermal expansion and glass transition temperature 1S0 14692 (at! parts), Petroleum and natural gas industrios — Glass-reinforced plastics (GRP) piping ANSUAPI RP 879, Recommended Practice for Filness-for-Service ASME B31, Manual for Determining the Remaining Strength of Corraded Pipelines: a Supplement to 831, Cade for Pressure Piping ASTM C581, Standard Practice for Determining Chemical Resistance of Thermosetting Resins Used io Glass-Fibre-Reinforced Structures Intended for Liquid Service ASTM D543, Standard Practices for Evaluating the Resistance of Plastics to Chemical Reagents ISOITS 24817:2006(E) ASTM D886, Standard Test Method for Cooffciont of Linear Thermal Expansion of Plastics Betwean ~ 30 °C ‘and 30 °C with a Vitreous Silica Dilatometer ASTM D1598, Standard Test Method for Time-lo-Failure of Plastic Pipe Under Constant Intomal Pressure ASTM D1589, Standard Test Method for Resistance fo Shori-Time Hyciaulic Failure Pressure of Plastic Pipe, Tubing, and Fitings ASTM 02583, Standard Test Method far Indentation Hardness of Rigid Plastics by Means of 8 Barco! Impressor ASTM 02992, Standard Practice for Obtaining Hydrostatic or Pressure Design Basis for “Fiberglass” (Gilass- Fiber-Reinforced Themosetting-Resin) Pipe and Fittings ASTM 03039, Standard Test Method for Tensile Properties of Polymer Matric Composite Materials ASTM 3165, Standard Test Method for Strength Properties of Adhesives in Shear by Tension Loading of Single-Lap-Joint Laminated Assemblies ASTM D3681, Standard Test Method for Chemical Resistance of "Fiberglass” (Glass-Fiber-Reinforced Themosetiing-Resin) Pipe in a Defiected Condition ASTM D5979/D5379N105, Slandard Test Method for Shear Properties of Composite Materials by the V-Notched Beam Method ASTM 08604, Stondard Practice for Glass Transition Temperatures of Hydrocarbon Resins by Ditferential Scanning Calorimetry ASTM E831, Standard Test Method for Linear Thermal Expansion of Solid Materials by Thermomechanical Analysis: ASTM E1640, Standard Test Method for Assignment of the Glass Transition Temperature by Dynamic ‘Mechanical Analysis ASTME2092, Standard Test Method for Distorian Temperature in Three-Point Bending by Thonnomechanical Analysis ASTM G8, Standard Test Methods far Cathodic Dishonding of Pipoline Coatings BS 7010, Guide to mothiods for assessing the acceptability of flav in motalic structures EN 59, Glass reinforced plastics — Measurement of hardness by means of a Barco! inpressor (BS 2782-10: Method 1001, Methods of festing plastics. Glass reinforced plastics. Measurement of hardness by means of a Bareolimpressor) EN 1465, Adhesives — Determination of tonsil lap shear strength of rgid-to-igid bonded assemblies 3. Terms and definitions For the purpases of this document, the following terms and definitions apply at anisotropic ‘exhibiting diferent physical properties in different crections 32 Barcol hardness: measure of surface hardness using a surface impressor corp Srnand past utesn {© 180 2008 ~All ig oxarved ISO/TS 24817:2006(E) 33 ‘composite thermoset resin system that is reinforced by fibres 34 curing setting of a thermosetting rosin systom, such as polyester or epoxy, by an ireversible chemical reaction 35 delamination separalion of layers within a repair laminate or between a repair laminate and the substrate 36 differential scanning calorimetry psc method of determining the glase transition temperature of a thermosetting resin 37 glass transition temperature Temperature at which a resin undergoes a marked change in physical properties 38 hardener component acted to a thermosetting resin fo effect cure a9 heat distortion temperature HOT temperature at which a standard test bar deflects by 2 specified amount under a given load 3.10 in-fill material material used to repair external surface imperfections prior fo the application ofthe composite laminate aa laminate repair laminate that part ofa repair system that is the composite NOTE Most composites considered in this Technical Spectication are composed of dcrote lamina or layers which ate wrapped or stacked one on top ofthe other. This stacked construction isthe laminate 3az leak Condition of @ substrate wall that can allow the contents to make contact with, and act directly upon, the (composite) repair laminate NOTE This does not reer‘ a fue leaking through 2 hole or breach in tha substrate 3.43, ‘occasional load Toad that occurs rarely and during a short time NOTE Occasional loads typically occur logs than 40 times in the feof the component and each load curation is less than 39min 344 owner organization that owns or operates the substrate to be repaired ISOMTS 24847:2006(E) 3.15 pipetine pipe with components subject to the same design conditions used to transport fluids between plants NOTE Components may include, fr example, bonds, flanges, valves. 3.16 pipework Inferconnectod piping subject to the same set or sots of design conditions 3a7 piping piping system ‘assemblies of piping components used to convey fluids within a plant NOTE Components may include pips, tings, flanges, gaskets, boling, valves. A piping system is often above ‘Found but sometimes buried 3.18 ply single wrap or layer (lamina) of a repair laminate 3.19 post cure Additional elevated-temperature éure 3.20 qualification application procedure application procedure used to apply the repair system for the qualification tests 3.21 ‘qualification test temperature test temperature at which qualification testing af the repair system is performod 3.22 jnforcement fibro embedded in the resin system NOTE Possible bre mateias include aramid, carbon, glass, polyester or similar materials. Relnforcement resus in ‘mechanical properties superios fo those of he base resin 3.23 repair system system comprised of the substrate, composite material repair laminate), filler material, surface preparation and installation methods used for repair of pipework sdhesive and including 3.24 repair system supplier ‘company thal supplies and installs the repair system 3.25 resin system all ofthe components that make up the matrix portion of @ composite NOTE Often tis mncudes a rein, ters), pigment, mechanical property modifiers and catalyst or hardener. 3.28 risk term describing an event encompassing whal can happen (scenario), Its ikethood (probability) and its tevel or degree of damage (consequences) cer mers cena sn (© 180 2006 Aig served ISO/TS 24817:2006(E) 327 substrate surface on which a repair is caried out NOTE The surface may belong to exiginal pipework. a plpework component, pipeline, tank or vessel 3.28 Shore hardness measure of surface hardness using a surface impressor ar durometer 3.29 thermoset resin system resin system that cannot be resoftened following polymerization 4 Symbols and abbreviated terms 4A Symbols 2% r9pair laminate thermal expansion cooffiient, axel direction, expressed in milimetres per milimetre degree Celsius 2, thermal expansion coefcient ofthe repair taminate fr either the axial or circumferential diections ISO/TS 24817:2006(E) intemal pressure after repair system Is applied ‘external design pressure ‘equivalent design pressure ‘external soil pressure internal pressure within the substrate during application of the repair ‘minimum (intemal pressure) load (or stress) of the load cycle ‘maximum (Internal pressure) load (or stress) of the load cycle ‘medium-term hydrostatic test pressure ‘maximum allowable working pressure (MAWP) short-term hydrostatic test pressure initial test pressure fixed linear increase in test pressure tensile stress cyolic loading severity, defined as: Prax allowable stress of the substrate material measured yield stress of substrate or mill certification yield stross ‘ower confidence limi of the long-term stress determined by performance testing design temperature lass transition temperature maximum operating temperate of ropaic system ambient temperature qualification test temperature wall thickness of substrate esign Hetime thickness ofan individual wrap or layer of repair laminate ol thickness of branch, tae wal thicknoss of flange ddosign thickness of repair laminate minimum thickness of epair laminate ‘minimum remaining substrate wall thickness, argh reserved ISO/TS 24817:2006(E) + lap shear strength + Poisson's rato forthe repair laminate » —Caxil) width of circumferential slot defect WWecig specific weight of soil 4.2. Abbreviated terms ASME American Society of Mechanical Engineers ASTM American Society for Testing and Materits, APL American Petroleum institute AWA American Water Works Association 85 (8S!) British Standards nsate CFR carbon-fbre-einforced plastic COSHH regulations for control of substances hazardous to health CSWIP certification scheme for welding inspection personnel DSC —_aiferental scanning calorimetry FRP ——_fibre-einforced plastic GRP glass-reinforces plastic HDT heat distortion temperature MAW maximum allowable working pressure MSDS materials safety data sheet NOT non-destructive testing OSHA —_ccupational Safety and Health Act Poo post-construction committee SMYS specified minimum yield strength 5 Applications ‘The qualification and design, installation, testing and inspection procedures for repair systems in this Technical Specification cover situations involving the repair of damage commonly encountered in ol, gas and tutlty pipework systems. The procedures are also applicable to the repair of pipelines, calssons, storage tanks ‘and vessels wilh appropriate consideration Procedures in this Technical Specification cover the repair of metallic and GRP pipework, pipework ‘components, pipelines orginally designed in accordance with a variety of standards, including ISO 18649, 180 13623, [SO 14692, ASME 891.1, ASME B31.3, ASME 831.4, ASME B31.8 and BS 8010. (© 180 2006 ~ aighs eservad ISO/TS 24817:2006(E) Repair systams are applied to achieve 2 satisfactory level of structural integrity ‘The following repair situations are addressed: — external corrosion, where the defect is or is not through-wall in this case the application of a repair system wil usually artest further deterioration; — extemal damage such 8s dents, gouges and fretting (at supports); — intemal corrosion, erosion, where the defects or is not through- wall in tis case corrosion and/or erosion ‘can continue after application of a repair system, and therefore the design of the repair system shall take {this into account; — structural strengthening in local areas. ‘As a general guide, Table 1 summarizes the types of defect that can be repaired using repair systems Table 1 — Guide to generic defect typos “Type of defect eee amen [General wal inning a cai wal tiring Peng ¥ [Souses me Bice ¥ Laminations Y ircamferential wacks ¥ rongitudinal cracks R Frivouah-wal ponetvaten ¥ + Vimptes goreraiyopprontte, +R inp con bo usd, bt reguees ene coneieration. Services thal are covered within the scope of this Technical Specification include all services normally found fon ain oil and gas production or processing installation. These include: — tly Muid, diesel, seawater, — chemicals (Iquids); — production fuids, including quid hydrocarbons, gaseous hydrocarbons and gas condensates. ‘The upper pressure and temperature limits are dependent on the type of damage being repaired and the type of repair system being used, These limits are determined from the qualification testing results presented in Clause 6. ‘The lower temperature limit is dependent on the type of repair laminate being used. This limit is determined by the dosign requirements presented in Clause 6. The lower pressure limit, e.g. vacuum conditions, is determined by the design requirements presented in 6.5.9.7. ISOITS 24817:2006(E) ‘The composite materials constituting the repair laminate considered within this Technical Specification are typically those with aramid (AFRP), carbon (CFRP), glass (GRP) or polyester (or similar materia) reinforcement in a polyester, vinyl ester, epoxy of polyurethane mattix. Other fibre and matric types are also permissible. 6 Qualification and design 6.1* Risk assessment {A risk assessment associated with both the defect and the repair method shall be completed by the owner prior to application of the repair system. ‘Thefollowing factors shall be considered within the risk assessment assessment ofthe nature and lacation of the dafacts; — design and operating conditions for the substrate and contents (Including pressure, temperature, sizes and combinations thereof); = repair fetime (6686.3); — geometry ofthe substrate being repaired — hazards associated with system sonvico; — availabilty of personnel withthe necessary skis; — 0080 with which it's practicable to execute surface preparation operations — performance under upset and major incident situations, including impact, abrasion, fire, explosion, ‘ollsion and environmental loading — operational measures, including (if relevant) permits, gas testing and fire protection requirements to censure safely in the vicinity of the repair area, — failure modes; — inspectabiity (both visual and non-destructive): — copair system materials. For clarification, the risk asseasment is not intended as a means to predetermine thal the ropair method is the: Seoropratsststeny of remedial action but rater to aeeoee te eke aatoiaad wih applying the ren ‘The information and data describing any hazards shall be included in the method statement (7.4) to be used onsite Since the application of these repair systems typically changes the mode of failure from rupture of the ‘substrate to 2 leak, the consequences of failure wil therefore be reduced. “The objective of the assessment shall be to establish the class of the repair (6.2), which determines the detail ‘of the design method (6.5) to be carried out, together with the requirements for supporting documentation, ‘This also determines the design margin of factor of safety fo be used in the design Guidance on performing a risk assessment can be obtained from Reference [36]. 19180 2006 ~All dghs reserved ISOTS 24817:2006(E) 6.2 Repair class Each repair shall be allocated to a particular class folowing completion ofthe risk assessment. Repair classes are defined in Table 2 Class 1 repairs cover design pressures up fo 1 MPa (10 bar) and design temperatures up to 40°C and are appropriate to the majority ofthe utility service systems. This class is intended for those systems that do not relate directly to personnel safety or safety-critical systems. ‘Class 2 repairs cover design pressures up to 2 MPa (20 bar) and design temperatures up to 100°C but ‘exclude hydrocarbons. This class is apprapriate to those systems that have specfic safety elated functions. Class 3 repairs cover all fuid types and pressures up to the qualified upper pressure limit. This class is appropriate for systems transporting produced fluids. Applications in which the service conditions are more onerous or not included in the above, shall be designated as Class 3, Table 2— Repair class Repair class “Typical service Design pressure [Design temperature Low specication duties, e.9. slate head. drains, cooling class 1 medium, sea (service) water, diesel and other ubity] <1 MPa 40°C hyérocatoons [class 2 Fire waterdeluge oystoms =2MPa 100°C [Produced water and hydrocarbons, flammable uds | 938 systems [class 3 alo covers operating contitions more onerous] than desernes Quatted upper tit 6.3 Repair lifetime The lifetime (in years) of the repair system shall be defined in the repair data sheet, Annex A. It may be limited by the defect type and service conditions, e.g. internal corrosion, ‘The minimum lifetime of the repair shall be 2 years. Shor lifetimes (2 years) are intended to apply to those situations where the repair Is requifed to survive until the next shutdown. Long lifeimes (up to 20 years) are intended to apply to those situations where the repair is required (0 reinstate the substrate to its original design lifetime or to extend ils design life fora specified period. ‘Once the lifetime of the repair has expired, the owner shail either remove or revalidate the repair system 6.4 Roquired data 6.4.4 Background ‘The following data shall be supplied for each repair application. The detail to which these requirements are fulfilled is determined by the output of the risk assessment, Original equipment design data, maintenance and ‘operational histories shall be provided by the owner and material qualification data shall be provided by the repair system supplier. The avallabilly of relevant data shall feature as part ofthe risk assessment oF ISOPTS 24817:2006(E) 8.4.2 Original equipment design data Original equipment design data are required, consisting of 2) piping line lists or other documentation showing process design conditions and a descriaton of the piping lass, including material specification, wall thickness, and pressure and temperature ratings; ')_ piping isometric drawings and, it propriate, the output ofa piping flexibility calculation: ©) specification ofall aperating mechanical loads not included in the above, Including upset conditions; 0) otiginal design calculations. 64.3. Mi tenance and operational histories Maintenance and operational histories are required, consisting of ) documentation of any changes in service conditions, including pressure, temperature, internal luis and corrosion rate; ') past service conditions ©) summary of all alterations and past repairs local to the substrate of concern; 4) inspection reports detaling the nature and extent of damage to be repaired. 8.4.4 Service condition data Service condition data are required, consisting of: 8) lifetime requirementsiexpectation of the repair system life: b) required dasign and operating pressures (internal and external)/temperatures, 6) expected future service conditions; ) if applicable, MAWP as calculated according to the requirements of ASME B31G, APIRP 579, BS 7910 oF another applicable standard. This shall be carried out taking into account the current position and any possible further degradation in the future, ‘An example of a design data sheet is presented in Annex A. 6.4.5 Repair system qualification data ‘The documentation and qualification data related to repair systems that shall be provided by suppliers are ‘shown in Table 3 Details of the qualification data to be provided by the suppliers are given in Annex B. Table 3 — Documentation and data requirements Documentation requirement lass 7 Glass 2 Class atonal documentation and dala ¥ 7 v [Design eapabity ieee 7 [Surface preparation documentation v 7 [Short-term test data ¥ Long-term test data v 7 12180 2008 — Allah eserved ISO/TS 24817:2008(E) Clarification af the terms used in Table 3is as follows a) Material documentation and data This shall include a statement of the resins and reinforcements used and any standards to which they are supplied, Basic data on material compatibility wth the working environment shall also be availabe. it shall be ensured that any chemical interaction between the resin (and associated curing agents) and substrate will not cause further degradation of the substrate. Also attention shall be given to CFRP laminates and the potential for bimetallic (galvanic) corrosion of the substrate, b) Design capatilty Suppliers who offer a repair option for Class 2 andi 3 repairs shall provide design calculations with supporting data. ©) Surface preparation The durability of a bonded assembly under applied load is determined to a large extent by the quality of the surface preparation used. Details of the surface preparation procedure and how it is to be Implemented shall be provided ) Short-term test data ‘These shail include tensile strength and modulus in both the hoop and axial directions and the strength of the (adhesive) bond between the repair laminate and the substrate. ©) Longsterm test dat ‘These shall include the strength of the adhesive bond between the repair laminate and substraie and ‘optionally the ullimate tensile strain of the repair laminate. Long-term is defined as greater than or equal 101 00h, ‘Table 4 lists the data required to comply with Class 3 requirements. Annex 8 contains the full details of the qualification data requirements, Table 4— Qualification test requirements Hart pope Tesinatiod ] Weckarial [Yours rats iSO sar ras GaN rare, |pekcant to IS0 sre fornSTM O3I39) Shearmotie pomcesrs fe 180 13862 (or ASTM Ds) tes vanston tera tren eat 180 19872 (or180 759, AST D804, itrtcn argue cro ast evoa nova ena AST Bate Barolo Shoe hardness [80 89 or EN 5 (or AST D258 Taoson lap sea EN 1485 or ASTIN D5165 cream erence [nga wna oa cots tial Energy release rate (optional) Annex D Shortness ron amex 3 ISO/TS 24817:2006(E) 6.5 Design methodology 6.5.4 Overview ‘There are two design cases 1a) Defect type A design case ‘The defect is within the substrate, not through-wall and not expected 1o become through-wall within the lifetime of the repair system, requiring structural reinforcement only. One of the folowing tee design ‘methods shall be used: 4) inclide allowance for the substrate (see 6.5.4): 2) exclude allowance for the substrate (see 6.5.5); 3) long-term performance test data (see 6.5.6) b) Defect type B design case ‘The substrate requires structural reinforcement and sealing of through-wall defects (leaks). For substrates with active Internal corrosion, the repair laminate shail be designed on the assumplion that a through-wall dofect will occur ifthe remaining wal thickness at the end of service tlfe Is expecied to be less than 1 mm. Bath of the folowing design methods shall be used: 41) the design method in 6.5.7; 2) the design method for the Defect ype A design case, The greater repair thickness from the Defect type A design case or the design mothod in 6.6.7 shall be taken as the repair laminate thickness, (sign ‘Subclauses 6.5.9 and 6.5.10 shail be considered for each design case and applied where appropriate, with the largest thickness being taken as the repair laminate thickness, ‘jes 6.5.2 Environmental compatibility ‘The sullabilty for use of the repair system in the service environment shall be based on the following ‘considerations. The service environment is the environment that contacts the repair laminate. it may be either the external or internal environment ‘The qualification of the repair system (6.4.5) demonstrates that the repair system is compatible with aqueous ‘and hydrocarbon environments at the qualification test temperature, In general, thermoset resins are ‘compatible with a wide range of environments, but consideration shall be given when the environment is strongly acidic (pH <3,5), strongly alkaline (pH>11) or is @ strong solvent, e.g. methanol, toluene in concentration greater than 25 % Resistance to UV degradation and weathoring {whore appropriate) shall be provided by data fram the resin supplier. When the environmental compatiblity of the repair sysiom is unknown, then the repair system supplier shall provide one of the folowing to demonstrate compatibility: — environmental compatiblity data or experience of previous applications from the resin supplier, ‘demonstrating thal the environment is no more aggressive than aqueous or hydrocarbon environments at {he design temperature, (© 180 2006 ~All igh esorvod ISO/TS 24817:2008(E) — if no compatibity data from the resin supplier are available, then specific environmental testing is required, One of the following test procedures ~ ISO 10952, ASTM DS43, ASTM C581, ASTM D3661 or equivalent ~ comparing the exposure of the specific environment and aqueous environinent to the repair laminate ai the design temperature shall be performed. The repair system shall be considered compatible ta the specific environment if the test results from the specific environment are no worse than for the ‘aqueous environment ‘When erosion is the cause of the degradation process of the substrate and the repair laminate is in contact with the eroding medium, then the repair laminate can suffer material loss. The repair system supplier shail calculate tha survival of the repair sysiom for the specified repair lifetime assuming a conservative ostimate of the loss of laminate material. Altematively, 2 metal plate can be placed over the affected area prior to pplication of the repair laminate to minimize material loss (of the taminate). 6.5.3 Design temperature effects For a design temperature, T, greater than 40 °C, the repair system shall not be used at a temperature higher ‘than the glass transition temperature (T,) less 30 °C. For repair systems for which a 7, cannot be measured, ‘the repair system shall not be used above the HDT less 20 °C. For repair systems which do not exhibit a clear transition point, 2. a significant reduction in mechanical properties at elevated temperatures, then an upper, ‘temperature limit, 7,,, shall bo defined (or quoted) by the repair supplier. For a repair systam where the dafect within the substrate is not through-wall, the temperature limit can be ralaxed to T, less 20°C of HDT less 15°C. 7y of HOT shall be measured in accordance with Table 4 Table 5 summarizes the upper temperature limit ofthe repair. ‘Table 5 — Service tomperature limits for repair systems Defect type B limit Defect type A limit boy Tr Ty measured 730°C 7-20 HDT measured HOT-20°0) HOT 18°C For design temperatures < 40°C (and Class 1 and Class 2 repairs), adequate cure of the fleld-applied repair laminate or adhesive shall be demonstrated by Barcol or Shore hardness testing, For these conditions, no acceptance criteria linked fo 7, ar HDT are stipulated. Adequate cure is defined as a measured hardness ‘value, and shall be no less tharl 90 % ofthe minimum obtained from repair system qualification in accordance with Table 4 The temperature de-rating factor, fy, to account for elevated design temporature application used in Equation (6) is givon in Table 6, where fj, i the upper temperature limit for the system (as defined in Table 5), In degrees Celsius. ‘Table 6 — Temperature de-rating factor for composite allowable strains, f, Design temperature “Temperature factor T% is c oro) Ty 29 O78, Tig 40 oo Tq 60 2.99) T= 6 1.00 45 ISO/TS 24817:2006(E) Factors for intermediate temperatures shall be obtained by interpolation. The additional requirements for repairs to through-wall defects are qualified through performance testing. To allow for higher design temperatures than the qualification test temperature, Table 7 defines the temperature de-rating factor, Jp, Urat shal be applied to Equations (11), (12) and (13). where Tans Is the ambient test temperature, in degrees Celsius, and Tiga the qualification test temperature, in degrees Celslus, Table 7 — Temperature de-rating factor for through-wal defects (type B defect. /-2 Tomporature “Tomporature factor °c Sa Tam Tica Toa) * Pn 0,70 : = Tine ~ Tans) = Foy 20 075 r= et ~ Tors) = Tn 40 085, = nat ~ Tas) * f= 80 090) a= Tet Tors) = Fy 60 1.00 For Table 7 to be appropriate, the same post-curing regime between quaification est sample preparation and in-service application shall apply. “Tho spit in requirement for service temperatures at 40 °C isto ensure consistency with ASME PCC-2[*#) 8.5.4 Design based on substrate-allowable stress (defect type A] Use of the design method in this subclause is appropriate if the contribution of the substrate is to be included inthe calculation for load-carrying capability For piping systems, Equations (1) and (2) shall be used. In the derivation of these equations i s assumed that the repair thickness is limited by the allowable stress in the substrate In tho circumferential rection, tho minimarn ropair laminate thickness, fn (expressed in milimetes), de to internal prossura Ie given by Equation (1) a In the axiat direction, the minimum repair laminate thickness, fay, (expressed in milmetres), due to internal pressure, bending and axial thrust is given by Equation (2): ele) | Bq iS the axial modulus of the repair laminate, expressed in megapascals; 2 where is the circurmferental modulus of the repair laminate, exprossed in mogapascals; e "5 _ is the modulus of substrate, expressed in meganascals; D isthe external diameter, expressed in milimetres; FFaq_ 6 the equivalent axial load, expressed in newtons {see Equation (3) (© 180 2006 ~ Al ight eserved ISO/TS 24817:2006(E) + isthe allowable stess ofthe substrate material, expressed In megapascals ‘Peq_ is the equivalent internal pressure, expressed in megasascals (sae Equation (3) rg isthe MAWP, expressed In magapascals. tn Equation 2), the contribution of fgg shall be taken as positive. Pog 29d Fag aro defined as: 16 2 2 on-field) Spo? frat 4F3, +4 zeus @ where {2 Isthe intemal design pressure, expressed in megapascals, Fyy_ isthe applied shear load, expressed in newtans: ‘Nig. isthe applied torsional moment, expressed in newton milimetres; Faq. fs the applied axial load, expressed in newtons; M, fax '8the applied axial moment, expressed in nawion milimetres, ‘The design repair thickness, tgpxign (@xpreSsed in milimetres), shall be the maximum vale Of fying 24 linge determined from Equations (1) an (2) the purpose of the repair system is to strengthen an undamaged section to carry additonal bending or other ‘axial load, the value of Fag shall be taken to be the increased total axial nad requirement, and the value of py ‘shall be the original MAWE: For pipelines, Equation (4) or Equation (6) shall be used. In the derivation of these equations it is sssumed that the repair thickness is limited by the allowable strain of the repair laminate (see 6.6.5). Only hoop foading 's considered in determining the rinimum wall thickness of the repair laminate, Jn the circumferential direction, the minimum repair laminate thickness, /njq (expressed in ilimetres), due to Internal pressure is given by Equation (4): Phve? “ ‘elnin 2Batnin + Bata) - where ive. 18 the internal pressure during repeir installation, expressed in megapascals: 1% isthe allowable repair laminate circumferential strain, exprossad in milimetres per milimetve; {,_ 16 tho minimum remaining substrate wall thickness, expressed in millimetres, ‘onan nman 2 7 ISO/TS 24817:2006(E) IF the repair is applied at zero intemal pressure, 2. j=, then Equation (4) can be rearranged to give: Peg? Peg .) 6 ‘The design repair thickness, fjasgq, shall be taken as the value determined from either Equation (4) or Equation (5) tin Euan (1) (9) ar vol fr rept fain <2 “The assumptions made in deriving Equations (4) and (5) are that the substrate is elastic and only contributes {o the load-sharing up to the allowable stress (of the substrate 6.6.8 Design based on ropair laminate allowable strains (defect type A) Uso of the design method in this subclause is appropriate ifthe contribution ofthe substrate is to be ignored in the calculation for load-carrying capability and if short-term material properties are to be used In the circumferential direction, the minimum repalr laminate thickness, jy (expressed in millimetres), due to internal pressure, bending and axial thrust is given by: 4f Pen 1 Fea ¥ eu Lee 6 ‘nine + 2 7D al _ In Equation (6) the contribution of F,q shall be taken as negative In the axial direction, the minimum repair trninato thickness, ny, (expressed in millimetres), du to internal prescure, bending ane axial trust, ven by 4 (Feat Poa? fama AGE a } ” Eqs the axial modulus ofthe repair laminale, expressed in megapascals; is the circumferential modulus ofthe repair laminate, expressed in megapascals; Dis the extemal diameter of test spool, exoressed in ilimetres: ‘ea _'8 the equivalent axial load, expressed in newtons [see Equation (3) ‘req_ isthe equivalent internal prescure, expressed in megapascals (see Equation (3)}; vig the Poiscon’s ratio ofthe repair laminate (see Annex B for definition); fq 6 the allowable ropak laminate axial strain, expressed in milimatres per milimetre; Gis the allowable repair laminate circumferential strain, expressed in milimetres per milimetv. In Equation (7) the contribution of F,q shell be taken as positive, ‘The design repair thickness, ‘Gorigy Shall be the maximum value Of fine AN fying determined from Equations (6) and (7) (© 180 2008 ~ Alig reserved ISO/TS 24817:2006(E) Eauaon (6) an (a0 volo ep OO yay <2 For occasional loads (short-duration loads), Glass 1 minimum repairifetme (2 year) strains shell be used; see Table 8. The allowable strains presented in Table 8 shall only be used if the short-term strain to failure of the repair laminate is greater than 1 %, otherwise performance data from 6.5.6 shall be used. The short-term strain to failure can be derived from the test carried out to determine the tensile properties ofthe laminate (Table 4). “The thermal expansion coefficient for a repair laminate is different from that of the substrate, resulting In the ‘generation of thermal strescos within the repair laminate when the design temperature is different from tho instalation temperature, This effect shall be considered in the design assessment by subtracting the thermally induced strains from the allowable strains. The temperature factor, f;;, shall be applied to the allowable strain before subtraction. The allowable repair laminate thermal strains in the citcumferential and axial directions, z, and ¢,, shall be calculated by: Fe = Sisto -[AT(as~ a0) @ 85> Sriay-[AT(as- aa) where 4 18 the allowable repair laminate axial strain (no temperature offect, see Table €), expressed in millimetres per milimetre; 44g, i8 the allowable repair laminate circumferential strain (no temperature effect, see Table 8), expressed in millimetres per milimetre; Jnx_is the temperature de-rating facior, see Table 6; aq. is the repair laminate thermal expansion coefficient, axial direction, expressed in milimetres per rmilimetre degree Celsius; 4% i the repair laminate thermal expansion coefficient, circumferential diroction, expressed in millimetres per milimetre degree Celsius; ‘a, is the substrate thermal expansion coefficient, expressed in milimetres per milimetze degree Celsius; AP is the difference between design and installation temperatures, expressed in degrees Celsius. Table 8 — Allowable strain for composite laminates as a function of repair lifetime: Allowable strain Allowable strain ‘Allowable strain Modulus Chass 1 cass 2 Class 3 % % % Ropaie lifetime z | 0 | 2 | 2 wm | 2% | 2 | = years Fore, 2086, be oa | os2 | 028 | os | 090 | 025 | 030 | oar | os 6a 40 | ose | 028 | 038 | ogo | 025 | 030 | oar | os Fork, < 05 a 040 | 032 | 025 | oas | oso | 025 | 030 | oar | os ho 026 | ete | oto | oto | oto | 010 | oro | 010 | 10 19 ISOrTs 24817:2006(E) Tablo 8 is used in the following manner. For example, for a Class 2 repair design lifetime of 8 years with (&. <05 £,), the allowable strains can be either extrapolated or taken fram the next highest repair lifetime, 2 10 years, implying the allowable clccumferential and axial strains are 0,3 % and 0,1 % rospectively “The values in Table 8 include a service factor for safely equivalent to 067. 6.5.6 Design based on repair-allowable stresses determined by performance testing (defect type A) Use of the design method in this subclause is appropriate i performance-based test data are available. ‘Annex provides three methods for the determination of long-torm failure stress (or strain) of the repair laminate, IFallowance for the substrate isnot to be included, then Equation (9) shall be used. In the circumferential direction, the minimurn repair laminate thickness, fpjq (expressed in milimetres), due to internal pressure, bending and axial thrust, is given by. 1 fe? rf ° mue el * In Equation (9) the contribution of Fy, shall be taken as negative. For axial stresses due to internal pressure, bending and axial thrust, the minimum repair laminate thickness, fin (@xpFeSSed in millimetres), is giver by Equation (2) or Equation (7) as appropriate ‘The design repair laminate thickness, iggy Shall be the greater ofthe values determined. Ifallowance for the substrate is to be included, then Equation (10) shall be used. Forhoop stresses due to internal pressure, the design repair laminate thickness, fjexin IS given by 1_}[ Pea? fase 0 10) rash) : where Fgq_ isthe equivalent axial load, expressed in newions [see Equation (3) aq. isthe equivalent intemal pressure, expressed in megapascals [see Equation (3) 1 isthe external diameter of test spoo!, expressed in milimetres; 4 isthe allowable stess ofthe substrate material, expressed in megapascal; 4. the minimum remaining substrate wal thickness, expressed in millmetres; six 16 the lower confidence imi of tho long-term stress, expressed in megapascals (see Annex E); ren is the service de-rating factor; see Table 9, Table 8 — Service factor, /zgy, for performance data of repair systems Service factor Class 4 Chass 2 Class 3 Repair Iietime, years 2], °]»|2]0][~{ 2 [ol ao 000 w data a3 [oss | os [oer |oss] os | on | 055] os Design tie data 1_| 003 | oer | 083 | o7s | os7 | 075 | ot | o67 1©180 2086 —Allahs reserved ISO/TS 24817:2006(E) 6.5.7 Design of repairs for through-wall defects (defect type B) {A defect within a substrate shall be considered through-wall if the wal thickness at any point of the affected ‘rea is determined to be less than 1 mm at the end of is life Use of the design method in this subclause is appropriate if the defect within the substrate is through-wall or deemed to become through-wall at the end of is life. The requirements of this subclause are in addition to those described in 6.5.4, 6.5.5 or 6.5.6. For a circular or near-circular defect, the minimum thickness for a repair taminate, ‘ing (expressed in millimetres), shall be calculated using ay where ag le the combined tensile modulus JEjE, . expressed in magapascals; isthe shear moduli ofthe repair laminate, expressed in meganascale isthe design intemal prossure, expressed in megapascals vv je the Poiesors ratio ofthe repair laminate (e0e Annex B fr definition; isthe diameter of defect, expressed in miimetrs: isthe thickness of repair laminate, expressed in milimetes; sto is the 95 % lower confidence limit of energy release rate, expressed in joules por square metre (eee Annex D); rg isthe temperature de-rating factor; see Table 7; Fax isthe service de-ating factor; see Equation (18). Where the design incorporates a plug fo allow the repair ofa live line, the procedure described shall be used. ‘The fests carried out to determine the value of z,¢,, (Annex D) shall be conducted on the whole assembly, including any plug arrangement, Equation (11) is valid for defect sizes 4 < J8Dr where D__ is the substrate external diameter, expressed in miimetres; 1 1s the substrate wall thickness, expressed in milimotros, For non-circular defects that have an aspect ratio <6, Equation (11) shall be used, where the value of (effective defect diameter) is selected such that it contains the defect, 24 ISO/TS 24817:2006(E) For a circumferential slot type defect, the minimum thickness for a repair laminate, fyyq, expressed in millimetres, is calculated using the smallest value of repair thickness calculated from both Equation (12) and Equation (19): (1) (13) “where wis the axial width of the slot, expressed in millimetres, For an axial slot type defect having a circumferential width of the slot r= #/2, expressed in millimetres, the minimurn thickness for a repair laminate, fn, expressed in millimetres, is calculated using Equation (14) = Srafene 800t ruc 14) aif, vt 4a, Ga" ye Fe [8° 3048,” ” 1152005, where the limit on the applicability of Equation (14) is given by #< 1, where # is the angle subtended by the ‘axial slot, expressed in radians, The value of the service factor, gah. shall be set to: Glass 1 Class 2 Class 3 (15) 1 0,83210°09208 Bipeano-1 75x10 28 vere) (668%10°9 9°56 gaa Fone Fe where faim is the design lifetime, expressed in years. {long-term performance test data are available in accordance with Annex E, then the service factor, shall be caleulated using Class 4 Class 2 Class 3 cr) Fiess = 9.89 fp Siew =0.75 ho Fiat = 8.508 fo where fp is the degradation factor [defined in Annex G, Equation (@.4)} ‘The design repair thickness, ‘ecign, Shall be the maximurn value of the minimum repair thickness determined fom one of Equations (11), (13), (13) or (14), iteratively, and the design repair thickness derived as in 6.5.4, 655 0r6.56. (© 150 2006 ~ Al og eserves ISO/TS 24817:2006(E) In some circumstances it may not be possible to prepare the substrate completely adjacent to the repair. Often @ protective metal plate is used {o protect the damaged substrate during surface preparation, e.g. git blasting. In these circumstances, the defect area shall be taken as the unprepared substiale surface area (including metal plate plus any faring material) and nol the size of the actual defect. 6.5.8 Axial extent of repair ‘The design thickness of the repair laminate shall extend beyond the damaged region in the substrate by the farger of 60 mm oF joy @xpressed in millimetres, where fy. 18 given by Equation (17) or Equation (18) For lot type defects: Foyer = 200 any For circular ype defects low =4d where <0.50D7 (19) where 4 isthe diameter of detect, expressed in milimetres Dis the extemal diameter of substate, expressed in milimetres 1 isthe thickness of substrate, expressed in mimetres IF the equality in Equation (18) is not satistied, then Equation (17) shall be used. Annex H presents a look-tp table of axial extent of repair as 2 function of both diameter and defact size. The total axial length of the repair, / (expressed in milimetres), is given by Equation (19). ' (19) 2 over *Faetoct +2 “The ends of the repair laminate shall be tapered if axial loads are presont. These axial loads can result solely from ond effects due to intemal pressure, or can result from system joads such as bending or thermal ‘expansion. A minimum taper of approximately 8:1 Is recommended, To check that the axial extent of the repair, foyer 16 sulicient to ensure that the applied axial load can be transfecred from the substrate to the repair, Equation (20) shall be salisted: (20) Is the axtal modulus of repair laminat expressed in megapascals; &% isthe allowable axial strain of repair system, expressed in milimetres per milimetre; Jing #8 the minimum thickness of repair laminate for axial applied loads, expressed in milimetres [see either Equation (2) or Equation (7); ris the lap shear strength, exprossod in magapascals (see Annex 8). H the geometry of the section to be repaired is such that itis not possible to achieve the required axial extent Df overlay, foyer including required taper length, the folowing shall apply. The folowing shall be treated as a special design Case and the analyeis shall be completed prior to application of the repair system, hts eserves 23 ISOITS 24817-2006(E) To account forthe tnited axial extent (ie. less than 60 mm) of avaliable substrate (/ayane): the design repair thickness, tggugy. determined from 6.54, 6.55, 6.56 or 6.57 shall be increased by the repair thickness increase facto. ii cretay: defined as: ata ower } co) hovesoy (a. where fgoagn «/n.ovatay!deskn agin ‘A detailed engingering stress analysis of the adhesive ‘ayer, demonstrating that the axial load can be transmitted between the repair and the substrate, shall be performed. The analysis shall also demonstrate that the average principal stess (averaged over the stressed part of the adhesive layer) is less than three times the average principal stress value from lap shear test data (see Table 4) The minimum axial extent of available overlay length that repairs can be applied to is defined as either 8) loyaiablo Shall be at least 25 min, or D) fevowesay Shall be n0 greater than 2,5 mm. If there is limited axial extent of available substrate, t will not be possible to taper the repair laminate. For this, case, the transition between the repair laminate and the restraining substrate, e.g. flange face, shall be as smooth as possible to minimize stress concentrations. However, where possible the repair laminate should always be tapered, particularly when axial joads are present, in order to minimize edge stresses within the repair laminate ‘The total axial extant of the repair for reduced axial extent is therefore as given below For one-sided reduced axial extent over *oerec *aper *Favaiabie For two-sided reduced axial extent (22) astoct avaiable. avaobie2 where the larger of the two Values Of fnoveroy iS taken fo determina the design thickness of the repair, Equation (21) When applying repairs over components, e.g. flanges, clamps, etc., to achieve the appropriate axial length of repair, the axial profile of the repair shell be as smooth as is practically possible to reduce sharp changes in diameter, thus mininizing focal stress concenivations, This may result in a thickening of the repair to ensure 3 smooth axiat prof, \When applying repairs up to raised faces, the transition from the repair to the raised face shall be contoured to ‘avoid sharp changes in directions. 6.68 Optional design considerations 6.594 Impact “The repair system supplier shall demonstrate thatthe repair to a through-wall defect (lype B defect) is capable of withstanding a low-velocity 8 J impact representative of a dropped tool. The demonstration test shall be cattied out in accordance with the procedure described in Annex F- 1180 2008 ~All aghte reserves ISO/TS 24817:2006(E) 6.58.2 Cyclic loading Cyclic loading is not necessarily limited to internal pressure loads, Thermal and other cyclic loads shall also be considered when assessing cyclic severity. If the predicted number of pressure or other loading cycles is less than 7 000 over the design life, then cyctic loading shall not be considered (in accordance with ISO 14692), If the predicted number of pressure or ether loading cycles exceeds 7 000 over the design Ife, then cyctic loading shall be considered. If the predicted number of pressure or other loading cycles exceeds 10° over the design life, then in Equations (24) and (25) W shall be set to 108. For 654 and 8.55, the composite allowable strain in both citcumferential and axial directions, 4 and é, (See Table 6), shall be deat by the Factor, je, 8 & = Fefevarcyctc Zs 2) 84 SePanoneyte where axe the allowable stiains in the axial and Greumforential directions [as defined in Equation (8)] prior to de-rating for cyclic loading, expressed in milimetres per rmilimetre; Fx poneyaies Sancti, fe is given by (2) fe 2808 lode, where Ry Is the cyclic lading seventy, defined as the ratio of minimum pressure to maximum pressure: Po Pee Wig the number of loading cycles. For 6.5.7, the servica Factor, igus in Equations (11), (12), (13) or (14) shal be replaced by: 2. Bee (1 R2) oe re 2 ‘Equations (24) and (25) are intended primarily for cyctic intemal pressure loading, but may be applied with caution to axial and thermal loads provided they remain tensile, ic. the equations are not applicable for reversible loading, 65.3 Live repairs If repairs are applied to substrates under live conditions, then the strength: and fracture-toughness of the bond at the interface belwoen the repair laminate and substrate shall be assessed for the specific case duting ‘operation when the intornal pressure, paper. after the repair system is appliod is loss than the intemal pressure, ‘Pe: Within the substrate during application of the repair, 1.0. Pater

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