GRIWrap Metric Manual 032205

CLOCK SPRING
GRIWrap Metric Analysis Users Manual

CLOCK SPRING IS MANUFACTURED UNDER AND/OR PROTECTED BY ONE OR MORE OF THE FOLLOWING PATENTS: UNITED STATES #6,336,983, #4,589,562, #4,559,974, #4,676,276, #4,700,752, #5,632,307, CANADA #1,209,495, #1,251,151, #1,278,225 #1,255,915, #2,142,816, #2,028,524, MEXICO #161,633, #191,427, #194,849. ADDITIONAL PATENTS PENDING AS WELL AS FOREIGN COUNTERPARTS THERETO. FOREIGN PATENTS ISSUED AND PENDING IN, BUT NOT LIMITED TO THE FOLLOWING COUNTRIES: USA, CANADA, MEXICO, FRANCE, UK, JAPAN, NEW ZEALAND, AUSTRALIA, EUROPE, CHINA, ISRAEL, TAIWAN, SAUDI ARABIA, GERMANY, SPAIN, ITALY, EGYPT, RUSSIA, ARGENTINA, COLOMBIA, INDONESIA, MALAYSIA, AND VENEZUELA. CLOCK SPRING IS A REGISTERED TRADEMARK OF NCF INDUSTRIES, INC. ALL RIGHTS RESERVED. MANUFACTURED UNDER LICENSE FROM NCF INDUSTRIES, INC. THE CLOCK SPRING SYMBOL IS A TRADEMARK OF CLOCK SPRING COMPANY, L.P.
Clock Spring Company L.P. 14107 Interdrive West Houston, Texas, 77032 Phone: 281-590-8491, 800-471-0060 Fax. 281-590-9528 www.clockspring.com
03/22/05
TABLE OF CONTENT SECTION 1.0 DISCLAIMER AND LEGAL NOTICE 2.0 INTRODUCTION 3.0 MANUAL ORGANIZATION 4.0 USERS GUIDE 4.1 SETUP 4.2 COMMENTS 4.3 USER INPUTS 4.4 OUTPUT MESSAGES 4.5 ADDITIONAL INFORMATION 4.6 PRINT SHEET APPENDICES B31G SUMMARY GRIWrap GOVERNING EQUATIONS CLOCK SPRING CONTACT INFORMATION FIGURES DISCLAIMER SHEET B31G CALCULATOR GRIWRAP SHEET PRINT SHEET SCREEN COMMENTS USER INPUT OPERATING CURVES PIPELINE IS OPERATING SAFELY REDUCE PRESSURE REPAIR DEFECT MOP IS HIGHER THAN DESIGN PRESSURE DEFECT IS LESS THAN 10% WALL PRINT SHEET TABLES DEFECT SHAPE FACTOR LINKS CLOCKSPRING.COM INSTALLATION MANUALS APPLICATION NOTES PAGE: 1 1 2 3 5 5 5 6 9 9 APPENDIX APPENDIX A APPENDIX B APPENDIX C FIGURE 1 FIGURE 2 FIGURE 3 FIGURE 4 FIGURE 5 FIGURE 6 FIGURE 7 FIGURE 8 FIGURE 9 FIGURE 10 FIGURE 11 TABLE 1 11 14 19 3 3 4 5 5 6 7 7 8 8 10 9
Clock Spring is a registered trademark of NCF Industries Inc. All rights reserved. Manufactured under license from NCF Industries, Inc. The Clock Spring symbol is a registered trademark of Clock Spring Company, L.P.
1.0
DISCLAIMER AND LEGAL NOTICE This Microsoft Excel-based calculator was prepared by Clock Spring Company, L.P. based on the equations and work sponsored by Gas Technology Institute (GTI) and reported in GRI 98/0265 "Pipeline Repair Assessment Software GRIWrap for Windows" and GRI 95/0244 "GRIWrap Pipeline Repair Program". The B31 calculator is based on ASME B31G 1991, "Manual for Determining the Remaining Strength of Corroded Pipelines" and referred to as B31G in the balance of this manual. Neither Clock Spring Company, L.P. nor GTI, nor any person acting on behalf of them: A. Makes any warranty or representation, express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or that the use of any method or process disclosed may not infringe privately owned rights; or B. Assumes any liability with respect to the use of, or for damages resulting from the use of, any information, apparatus, method, calculation, or process in this work.
2.0
INTRODUCTION "Clock Spring" refers to a family of related fiber glass-and-resin matrix products used to repair blunt defects in pipes, arrest ductile fractures in high-pressure gas pipelines and reinforce dents or other mechanical defects. Clock Spring provides permanent structural reinforcement for corroded pipe having a minimum of 20% remaining wall thickness in pipe sizes from 102 1422 mm (4 to 56-inch) diameter. Proper installation will restore full strength in the repair zone. Installation Manuals and detailed technical information on Clock Spring is available at www.clockspring.com. The system operates by restricting bulging in the pipe at the defect location. The hoop stress is transferred through high compressive strength filler, to the composite sleeve (Clock Spring) wrapped around, and bonded to, the pipe. Clock Spring technology is suitable for various applications including the repair of corrosion defects (80% maximum through wall defect), blunt mechanical defects, girth weld zone repair (corrosion or mechanical damage), defects associated with bends or elbows and as a crack arrestor. Clock Spring Company, L.P. should be contacted for all non-standard repairs or applications including Crack Arrestors, girth weld and bend or elbow repairs. In addition to providing a permanent repair for external defects, Clock Spring technology may also be used to provide temporary reinforcement for internal corrosion defects. Clock Spring will not arrest the corrosion mechanism associated with internal corrosion and the durability of the repair will therefore be related to the growth rate of the defect. To ensure the effectiveness of the Clock Spring technology, the product must be properly installed and the technology correctly applied. Each defect to be repaired by 1
Clock Spring must be assessed to determine the effectiveness of the repair. This assessment is based on B31G and the mechanical properties of the Clock Spring system. Repair is allowed when the reinforced failure pressure of the pipe exceeds the pristine yield pressure of the pipe. This calculation is done in an Excel spreadsheet. This manual describes the process used in the calculations and the operation of the spreadsheet. Questions or comments should be directed to Clock Spring Company, L.P. 3.0 MANUAL ORGANIZATION The manual contains a 'Users Guide', which gives an overview of the spreadsheet operation. Additional information on the details of the calculations performed is presented in Appendices. Appendix A is a summary of B31G and includes the equations used in the spreadsheet calculations. Appendix B provides a description of the method used by GRIWrap to assess the defect for repair using Clock Spring. Each reference is hyper-linked to the referenced material. Hyper links are in blue text, underlined. Selecting a link will take the reader to that supplemental information. Selecting RETURN will return the reader to the current location. Please send comments or suggested revisions to the manual to Clock Spring Company, L.P. Microsoft and Excel are registered trademarks of Microsoft Corporation.
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4.0
USERS GUIDE All calculations are performed in an Excel spreadsheet, GRIWrap(mmddyy).xls. The mmddyy- is the date of revision and is used for version control purposes. The spreadsheet consists of three sheets, Disclaimer, B31G Calculator - GRIWrap and Print Sheet (Figures 1, 2 and 3).
Figure 1. Disclaimer Sheet
Figure 2. B31G Calculator GRIWrap Sheet
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Figure 3. Print Sheet
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4.1
SETUP The operator's computer must have Microsoft Excel loaded. Open the program by double clicking the Excel GRIWrapMetric icon. Set the Excel zoom for each page to a value that displays the full page conveniently on the screen (Figures 1, 2 and 3).
4.2
COMMENTS Cells that contain a red triangle in the upper right hand corner have comments attached. To access the comment place the Excel cursor on the cell. See Figure 4 for the comments in the Design Factor cell.
Figure 4. Screen Comments 4.3 USER INPUTS The only sheet that allows user input is the 'B31G Calculator GRIWrap' sheet. Inputs are restricted to; pipe diameter (Dia.), wall thickness (t), pipe strength (SMYS), defect depth, defect length, operating pressure (MOP), design factor (DF), temperature factor (TF), and pipe joint factor (JF). Inputs must be in the units specified.
Figure 5. User Input When these variables are entered, several calculations are completed.
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4.4
OUTPUT MESSAGES Operating curves are calculated and displayed (Figure 6).
Figure 6. Operating Curves B31G allows certain defects to remain in the pipeline based on the material properties of the pipe and the length and depth of the defect. B31G provides a method by which a graph can be plotted that quickly provides the maximum length / depth combinations allowed. The first curve is called "Design Length vs. Depth". This curve represents the maximum defect length - depth combination that can remain in the pipeline at the design MAOP (Figure 6). The second curve, "Operating Length vs. Depth", is based on the operating pressure input by the user. This curve represents the maximum defect length depth combinations that can remain in the pipeline at the MOP specified by the user (Figure 6). The specified defect length and depth is displayed. If the defect falls below the operating curves, it can remain in the pipeline (Figure 6). The Maximum Allowable Operating Pressure (MAOP or P) of the pipe, based on the B31 code, is calculated and is reported in the Output Message cells of the spreadsheet (Figure 7).
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Figure 7. Pipeline is Operating Safely In this example, (Figure 7) the user has input an operating pressure (MOP) of 45 bar. The defect is 3.8 mm deep and 254 mm long. The calculated MAOP Design Pressure from B31 is 54 bar and the safe operating pressure (P') from B31G is 48 bar. The pipeline is operating safely at the specified pressure. The defect can be repaired with Clock Spring if the operator decides to undertake the repair.
Figure 8. Reduce Pressure Repair Defect In Figure 8, the user has specified an operating pressure of 51.7 bar. The calculated safe pressure (P') is 48 bar. A warning message is displayed to alert the operator that the pipeline is not operating safely and that the defect must be repaired. The graph shows the defect outside the operating curves. 7
Figure 9. Operating Pressure Higher Than Design Figure 9 shows a condition where the user has input an operating pressure (MOP) of 55 bar. The calculated MAOP of the pipeline is 54 bar. This operating condition is not allowed. A warning message is displayed to alert the operator that the pipeline is operating at a pressure that exceeds MAOP and to reduce pressure immediately. The operating curve is not displayed in the graph.
Figure 10. Defect Less Than 10% Wall In Figure 10 the user has input a defect depth of 0.9 mm. A message is displayed to alert the operator that the defect is less than 10% wall and does not require repair. The graphs show the defect below both the Operating curve 8
and the Design curve. The safe pressure is calculated and displayed as 54 bar, equal to the design pressure. 4.5 ADDITIONAL INFORMATION Each defect has two variables, depth and length. In each of the previous examples the defect is assesses based on one variable with the second being calculated. In Figure 10 the defect is specified as being 254 mm long and 0.9 mm deep. B31G provides a method to calculate the maximum depth of a defect specified as 254 mm long. In this case, the defect depth could be 4.84 mm. Conversely, given a defect depth of 0.9 mm the maximum length can be calculated. In this case, since the defect is less than 10% wall, the defect length is not limited (NL). The defect can have one of three shape profiles. These are: Shape Profile Factor Flat Bottom 1 Slightly rounded profile 0.85 Parabolic 0.66 Table 1. Defect Shape Factor GRIWrap assess the defect specified by the user from the most conservative to the least conservative shape factor. The shape factor is then reported back to the user (Figure 10). 4.6 PRINT SHEET (FIGURE 11) The print sheet is a convenient form for reporting the calculation from the spreadsheet. In addition to reporting the calculation, it also reports the output of the GRIWrap analysis. The user is allowed to enter data into the Defect Identification cells. All other cells are protected. GRIWrap analysis calculates pristine yield pressure (Pyo) and reinforced failure pressure (Prf). B31G calculates Maximum Allowable Operating Pressure (MAOP) and safe pressure (Ps). Clock Spring repair is allowed if Prf / Pyo>1. Shape factor 1 is a very conservative assessment and assumes that the defect is flat bottomed. Shape factor 0.85 is slightly less conservative and based on modified B31G defect assessment. Shape factor 0.66 assumes a parabolic defect shape as detailed in B31G. The GRIWrap assessment assesses the defect from the most conservative assumption to the least conservative in turn. Shape factor is reported back to the user. The analysis in this spreadsheet is based on the long-term (50 year) properties of the Clock Spring composite repair. It cannot be used to assess other composite repairs. The properties used in the GRIWrap calculation are: o Failure stress of the Clock Spring 138 MPa o Modulus of the Clock Spring 34.5 GPa o Modulus of the pipe 207 GPa o Wrap thickness 1.59 mm o Number of wraps 8 9
o o
Thickness of the repair 12.7 mm Defect circumferential extent 100%
Figure 11. Print Sheet When an analysis is completed, the file can be saved with a unique file name for record keeping. The B31G Calculator and the Print Sheet are formatted to print on a single page. Excel functions such as "Goal Seeking" can be used and can provide the user with useful information.
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APPENDIX A SUMMARY OF B31G MANUAL FOR DETERMINING THE REMAINING STRENGTH OF CORRODED PIPELINES The following is summarized from B31G "Manual for Determining the Remaining Strength of Corroded Pipelines". The reader is cautioned that the B31G manual contains many cautions and limitations of which the reader should be aware. The equations presented here are those used in the spreadsheet. The reader should obtain, read and understand the full B31G manual. PART 2 DETERMINATION OF MAXIMUM ALLOWABLE LONGITUDINAL EXTENT OF CORROSION The depth of a corrosion pit may be expressed as a percent of the nominal wall thickness of the pipe by: % pit depth = 100 * d/t Equation 1
Where; d = measured maximum depth of the corroded area (inches). t = nominal wall thickness of the pipe (inches). Additional wall thickness required for concurrent external loads shall not be included in the calculations. A contiguous corroded area having a maximum depth of more than 10% but less than 80% of the nominal wall thickness of the pipe should not extend along the longitudinal axis of the pipe for a distance greater than that calculated from:
Equation 2 Where; L = maximum allowable longitudinal extent of the corroded area (inches). D = nominal outside diameter of the pipe (inches). B = a value which may be determined from:
Equation 3 except that B may not exceed the value 4. If the corrosion depth is between 10% and 17.5%, use B = 4.0 in Eq. (2).
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PART 4 EVALUATION OF MAOP IN CORRODED AREAS COMPUTATION OF A If the measured maximum depth of the corroded area is greater than 10% of the nominal wall thickness but less than 80% of the nominal wall thickness and the measured longitudinal extent of the corroded area is greater than the value determined by Equation (2) of Part 2, calculate
Where; Lm = measured longitudinal extent of the corroded area (inches). D = nominal outside diameter of the pipe (inches). t = nominal wall thickness of the pipe (inches). Additional wall thickness required for concurrent external loads shall not be included in the calculations. COMPUTATION OF P' (a) For Values of A Less Than or Equal to 4.0. A and d/t determine a unique point that allows calculation of an acceptable pressure level P. d = measured maximum depth of corroded area (inches). P = the safe maximum pressure for the corroded area.
Except that P may not exceed P. P = the greater of either the established MAOP or P = 2StFT/D Where; S = specified minimum yield strength (SMYS), (psi) F = appropriate design factor from ASME B31.4, ASME B31.8, or ASME B31.11 T = temperature de-rating factor from the appropriate B31 Code (if none listed, T = 1) D = nominal outside diameter of the pipe (inches). t = nominal wall thickness of the pipe (inches). Additional wall thickness required for concurrent external loads shall not be included in the calculations.
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(b) For Values of A Greater Than 4.0 P = the safe maximum pressure for the corroded area
Except that P may not exceed P. MAOP and P' If the established MAOP is equal to or less than P, the corroded region may be used for service at that MAOP. If the established MAOP is greater than P, then a lower MAOP should be established not to exceed P, or the corroded region should be repaired or replaced.
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APPENDIX B GRIWrap PIPELINE REPAIR ASSESSMENT SPREADSHEET GRIWrap is an Excel -based engineering assessment program designed to determine if blunt type (corrosion) pipeline defects must be repaired. It also allows the user to determine whether the Clock Spring will safely and effectively restore pipeline performance at the defect(s) to the maximum allowable operating pressure. The program is specifically designed for use with the Clock Spring composite material, although the general methodology is applicable to a wide range of materials if long-term mechanical properties are available. GRIWrap CAPABILITIES AND OVERVIEW GRIWrap will assess the geometry of the defect and, based on user inputs of the pipe material, determine if; i) You have the option to repair the defect with a Clock Spring; or ii) You must repair the defect with a Clock Spring; or iii) You must replace the section of the pipe where the defect exists. Once these defect geometry parameters are verified and pass GRIWrap criteria, the line may be repaired safely and effectively using the Clock Spring composite wrap, which restores the pipeline performance to the maximum allowable operating pressure. To facilitate ease of interpretation, GRIWrap presents the results in both a tabular and graphical format. GRIWrap calculates the effectiveness and feasibility of defect repairs using properties and specifications of the line pipe and Clock Spring composite reinforcement wrap. The user must initially specify the input variables, which include: pipe dimensions, yield strength, defect depth, defect axial length, pipeline operating pressure (MOP), and design factors. In addition, factors such as wrap thickness, elastic modules of the wrap, long-term design strength of the composite and the pipe steel elastic modulus are also used in the analysis. These parameters are designated variables and have default values specific to the Clock Spring composite reinforcement wrap which the user may not change. THEORY [1, 2] GRIWrap extends the ASME B31-G analysis by providing for the increases in strength due to the Clock Spring composite reinforcement. The GRIWrap model presented in this section is embedded into the spreadsheet. The set of governing equations and the computational algorithm are presented in the following sections. For interested users, a more detailed explanation of the results can be found in Reference 1. COMPUTATIONAL MODEL AND VARIABLES [1, 2] The basic analytical model used in the present analysis was previously developed using the results of extensive laboratory testing described in Reference 2. The set of governing equations can be efficiently expressed in terms of non-dimensional parameters using dimensional variables such as pipe, defect, wrap dimensions, and mechanical properties such as strength, stiffness of the pipe, and composite. The physical system used in developing the computational model is shown schematically in Figure 1. 14
Figure 1. Schematic of the Physical System Used in GRIWrap GRIWrap accepts user input with respect to both the pipe and defect properties. The variables used in the analysis are presented in two levels. Level 1 variables are specific to the pipe and defect properties. Level 2 are fixed variables and are specific to the properties of the Clock Spring composite wrap. The two sets of variables, Level 1 and Level 2, are summarized in Tables 1 and 2 respectively. LEVEL 1 VARIABLES User Input Variables Yield Strength (SMYS) Pipe Diameter Pipe Wall Thickness Defect Depth Defect Axial Length Defect Geometry Factor MAOP Class Location Units psi inches inches inches inches ---psi ---Value User defined User defined User defined User defined User defined Defined automatically Calculated User defined Symbol y 2Ro to d L MAOP ----
Table 1. Summary of Level 1 Variables Used in GRIWrap Computational Model
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LEVEL 2 VARIABLES Fixed Variables Circumstantial extent of Defect Circumstantial extent/pipe circumference Scale Factor on Yield Strength Strain Hardening Stiffness Coefficient Reinforcement Wrap Thickness Reinforcement Wrap Failure Strength Reinforcement Wrap Elastic Modulus Elastic Modulus of Pipe Units inches ---------inches psi psi psi Value, units =2Ro 1 1 0 0.5 20000 5x106 30x10
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Symbol S S* m tw wF Ew Eo
Table 2 Summary of Level 2 Variables used in GRIWrap Computational Model Note: 20,000-psi wrap failure stress is the predicted strength of the Clock Spring composite at year 50 under worst-case conditions. Both the values inputted in the Level 1 and Level 2 variables are designed to return conservative results for the use of the Clock Spring composite wrap material based on the following assumptions [1.2]: a. The value for the scale factor on yield strength is set equal to 1; therefore, the yield stress of the pipe is used, which is equal to the specified minimum yield strength for the pipe. In contrast, B31G uses m = 1.1 and consequently returns less conservative values for the repair feasibility analysis. RSTRENG sets the value for m equal to SMYS + 10 ksi. b. The failure strength of the Clock Spring is approximated as 20,000 psi for 50year-life, which is calculated based on empirical test results on small scale ASTM type specimens. This is believed to be a conservative value. c. Post yield strain hardening is neglected ( = 0). d. Defect depths greater than 80% of wall thickness cannot be repaired consistent with ASME B31-G analysis.
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GOVERNING EQUATIONS With the use of the above conservative assumptions, the full set of equations presented in Reference 2 reduce to the following simplified forms:
Note: The definition of the above variables is given in Tables 1 and Table 2.
COMPUTATION ALGORITHM With the use of the above equations, GRIWrap determines the safe repair of damaged line pipe using the Clock Spring composite wrap. REPAIR FEASIBILITY Repairs are considered safe if the calculated design pressure of the pipe reinforced with Clock Spring composite is equal to or greater than the yield pressure of the pristine pipe:
The computational algorithm is shown on the next page in Figure 2.
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Given Set of Input Conditions
Calculate Lambda Using Equation 1.3 Beta=1, then Beta=0.85, then Beta=0.66
Calculate Pristine Yield Strength (Pyo) Using Equation 1.5
Calculate Reinforced Failure Pressure (Prf) Using Equation 1.1 or 1.2
Prf/Pyo>1
Calculate the Ratio Prf / Pyo
Prf/Pyo<1
Repair is Acceptable Report Shape Factor
Repair is Unacceptable
Figure 2. Computational Algorithm for the Repair Feasibility Analysis
REFERENCES [1] Lindholm, U.S., C.J. Kuhlman, D.R. Stephens, T.J. Kilinski, and R.B. Francini, Long-Term Reliability of Gas Pipeline Repairs by Reinforced Composites, GRI Annual Report No. GRI-93\0453 for period July 1992-June 1993, Gas Research Institute, 1993. [2] Manual for Determining the Remaining Strength of Corroded Pipeline ASME B31-G, 1991.
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APPENDIX C
CLOCK SPRING COMPANY L.P. CONTACT INFORMATION

Clock Spring Company L.P. 14107 Interdrive West Houston, Texas 77032
Phone: 281-590-8491 800-471-0060 Fax. 281-590-9528 www.clockspring.com
Clock Spring Company L.P. UK 4A The Causeway Godmanchester, Huntingdon, Cambs PE29 2HA England
Phone: (44) 1480 414 703 Fax. (44) 1480 414 705 www.clockspring.com
Clock Spring Company L.P. Asia Pacific Kuala Lumpur Malaysia
Phone: (60) 3 2282 0560 e-mail asiansales@clockspring.com
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CLOCK SPRING

GRIWrap Metric Analysis Users Manual

Figure 1. Disclaimer Sheet

Figure 2. B31G Calculator GRIWrap Sheet

Figure 3. Print Sheet

Thickness of the repair 12.7 mm Defect circumferential extent 100%

Table 1. Summary of Level 1 Variables Used in GRIWrap Computational Model

The computational algorithm is shown on the next page in Figure 2.

Given Set of Input Conditions

Calculate Pristine Yield Strength (Pyo) Using Equation 1.5

Calculate Reinforced Failure Pressure (Prf) Using Equation 1.1 or 1.2

Calculate the Ratio Prf / Pyo

Repair is Acceptable Report Shape Factor

Figure 2. Computational Algorithm for the Repair Feasibility Analysis

CLOCK SPRING COMPANY L.P. CONTACT INFORMATION

Phone: 281-590-8491 800-471-0060 Fax. 281-590-9528 www.clockspring.com

Clock Spring Company L.P. Asia Pacific Kuala Lumpur Malaysia

Phone: (60) 3 2282 0560 e-mail asiansales@clockspring.com

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