Certified CSNRI Engineering Document:
Certified
CSNRI
Engineering
Document:
Design
Package
for Engineered
Composite
Repair System
Design Package for Engineered Composite Repair System
Repair system and installation specifications for:
DiamondWrap (Lite) Repair System
Design Package # PB101266-0
Date Completed - August 29, 2023
Component / Line ID - linea de 4" x 3" Ø descarga de PSV9720 y 9720A
Company - Paich
Contact Name - FERNANDO TORRES
E-Mail Address - fernando.torres@paich.com.mx
CSNRI Sales Rep
Carlos Egusquiza
CEgusquiza@cs-nri.com
CSNRI Design Engineer
Pedro Bordieri
PBordieri@cs-nri.com
www.CSNRIcomposites.com
621 LOCKHAVEN DR, HOUSTON, TX 77073, USA +1.281.590.8491
All information within this document is considered confidential and proprietary.
© 2023 CSC Operating Company, LLC. All Rights Reserved.
End-User Company Name
Distributor
Project ID
Component / Line ID
Additional Information
Default Units
Intended Service Life
Design Life
System Design Pressure
Operating Pressure
Install Pressure
Fluid in Pipe
Chemical Concentration
Temperature Concerns
Pipe Geometry
Unit Name
Damage Mechanism
Composite Repair Type
Expected Surface Prep
Additional Description
Primary Repair System
Secondary Repair System
Primary Load Transfer Filler
Adhesive Primer
Project Information
Paich
Contact Name FERNANDO TORRES
Contact Number (938) 134-3172
PB101266-0
Contact E-mail fernando.torres@paich.com.mx
linea de 4" x 3" Ø descarga de PSV-9720 y 9720A
del acumulador de reflujo FA-9708 hacia cabezal general de 8" Ø desfogue
de baja presion de la endulzadora V6-L en tercer nivel de la plataforma ABKN1
Imperial
10 years
20 years
Piping Standard
ASME B31.3
Design Method
ASME PCC-2
Pipe Material Carbon Steel (Other)
Pipeline Conditions
40 psi
Operating Temperature
6 psi
Installation Temperature
0 psi
Max design temperature
Gas
Min design temperature
Pipe Information Overview
Reducer
Main Line Diameter
Reducer_1
Nominal Wall Thickness
External Wall Loss
Pipe Classification
Type B - Leaking
Specified Min. Yield Strength
Power Tools
Design Stress
Repair Zone 4 in. past the weld on the smaller sized pipe,
4 in. past the weld on the larger sized pipe,
for a total repair length of 12 in.
12
°F
°F
°F
°F
4.5 in
0.237 in
A105
36,000 psi
18,700 psi
Summary Output
DiamondWrap (Lite) used for leak containment
None
EPN-101
Install Method
Spiral Wrap
PPR-220
Compression Method
Comp. Film
Layer Count 6 layers (0.063 in.) of DiamondWrap (Lite)
6
113
95
122
-20
Reducer_1 Design Considerations and Equations
Large Pipe Diameter (D)
Base Pipe Wall Thickness
Design Strength (s)
Repair Type
4.5 in
0.237 in
18,700 psi
Type B - Leaking
Small Pipe Diameter (D)
Branch Pipe Wall Thickness
Defect Location
Length of Reducer Segment (LR)
Defect Information for External Wall Loss
Defect Depth
Defect Length (Axial)
Defect Width (Hoop)
Defect Depth Used
0.237
1
1
0.237
3.5 in
0.216 in
In the reducer
4 in
Leaking Feature
in
in
in
in
Leak Type
Leak Stop Method
Axial Length
Hoop Width
Circular
Stop Gap
0.5 in
0.5 in
100.0% Wall Loss
ASME PCC-2 Considerations
Include Substrate Support
Allow Substrate to Yield
No
Yes
Installation Method
Fabric Width
Spiral Wrap
2 in.
Hoop Performance Testing
No
Compression Method
Comp. Film
Include Type A - Hoop
Yes
Filler Material
EPN-101
Include Type A - Axial
Yes
Adhesive Primer
PPR-220
Hoop ASME PCC-2 2022 Art. 401, Equation 8
Design Pressure (P)
40 psi
1 𝑃𝐷 1
𝐹 𝜈𝑐𝑎
=
+
𝜀𝑐 2 𝐸𝑐 𝜋𝐷 𝐸𝑎
Design Axial Force (F)
636 lbf
Allowable Strain (εc)
0.21%
𝑡𝑚𝑖𝑛
Hoop Composite Modulus (Ec) 7,260,000 psi
Eqn. Assumptions:
Axial Composite Modulus (Ea) 6,880,000 psi
Assumes no pipe contribution
Poisson's Ratio (νca)
Typo in PCC-2 regarding Ea
Calculated Thickness (tmin)
Minimum Layer Count
Axial ASME PCC-2 2022 Art. 401, Equation 9
𝑡𝑚𝑖𝑛
1 𝐹 1 𝑃𝐷 𝜈𝑐𝑎
=
−
𝜀𝑎 𝜋𝐷 𝐸𝑎
2 𝐸𝑐
Design Axial Force (F)
636 lbf
Allowable Strain (εa)
0.21%
Design Pressure (P)
Poisson's Ratio (νca)
Assumes no pipe contribution
Leaking ASME PCC-2 2022 Art. 401, Equation 13
𝛾𝐿𝐶𝐿
1 − 𝜈2
3
1
3
𝑑4 + 𝑑 +
𝑑2
3
𝐸𝑎𝑐 512𝑡𝑚𝑖𝑛
𝜋
64𝐺31 𝑡𝑚𝑖𝑛
Leak Derate Factor (fleak)
40 psi
0.069
Composite Modulus (Ec) 7,260,000 psi
Calculated Thickness (tmin)
Minimum Layer Count
Energy Release Rate (γLCL)
Temp. Derate Factor (FT)
0.006 in.
1 layers
Composite Modulus (Ea) 6,880,000 psi
Eqn. Assumptions:
𝑃 = 𝑓𝑇 𝑓𝑙𝑒𝑎𝑘
0.069
2 in-lb/in²
0.88
0.333
Design Pressure (P)
0.003 in.
1 layers
40 psi
Poisson's Ratio (ν)
0.069
Mixed Modulus (Eac) 7,067,446 psi
Hole Diameter (d)
Shear Modulus (G31)
0.50 in
164,000 psi
Calculated Thickness (tmin)
0.008 in.
Minimum Layer Count
1 layers
Reducer_1 Final Layer Count
Repair Thickness Type A - Hoop
Calculated Thickness
0.006 in.
Component Multiplier*
1.1
Limited Length Multiplier
1.0
Adjusted Minimum Thickness
0.007 in.
Repair Thickness Type A - Axial
Calculated Thickness
0.003 in.
Component Multiplier*
1.1
Limited Length Multiplier
1.0
Adjusted Minimum Thickness
0.003 in.
*Multiplier is only used if defect is near the intersection as more complicated stress fields may be present.
Type A Minimum Thickness
Type B Minimum Thickness
System Minimum Thickness
0.007 in.
0.008 in.
0.063 in.
1 layers
1 layers
6 layers
Final Minimum Thickness
Rounded Layer Count
Estimated Repair Thickness
0.063 in.
6 layers
0.063 in.
6 layers
Reducer_1 Repair Length
The repair of a reducer, either full or partial, requires special consideration due to the geometric conditions.
ASME PCC-2 - Type A Length
1.8 in.
ASME PCC-2 - Taper Length
𝐿𝑜𝑣𝑒𝑟 = 2.5 𝐷𝑡Τ2
ASME PCC-2 - Type B Length
0.0 in.
5 ∶ 1 𝑟𝑎𝑡𝑖𝑜
0.8 in.
𝐿𝑜𝑣𝑒𝑟 = 𝐸𝑎 𝜀𝑎 𝑡𝑟 Τ𝜏
Product Minimum Length Over
2.0 in.
Total Defect Length
1.0 in.
Recommended Length Over
2.0 in.
Total Affected Length
1.0 in.
Distance from intersection
Min. Repair Length on Smaller Pipe
Min. Repair Length on Larger Pipe
Reducer Length
Repair Zone (RZ)
Primer Length
Surface Prep Length
Smaller Pipe
4 in.
6 in.
8 in.
Smaller Pipe Repair Length
5.0
4.0
4.0
4.0
Total Length Calculation Type
in
in
in
in
Larger Pipe
4 in.
6 in.
8 in.
Reducer Repair Length
Total Repair Length
Reducer Length
4.0 in.
4.0 in.
4.0 in.
Automatic
Total Length
12 in.
16 in.
20 in.
Larger Pipe Repair Length
Additional notes on the application of the composite repair on a Reducer_1
The application of a composite repair on a reducer is different than that of a standard repair as it is
recommended to apply only in one direction using the spiral wrap method. In order to be effective, composite repairs
need to be applied tightly to the pipe and depending on the size of the reducer, pulling tightly while wrapping from big
to small can unravel the wrap. This section does not override other drawings, training, or installer manuals.
1)
1) Start on side one, applying the wrap around the entire
circumference, overwapping itself.
2)
2) With a 50% overlap, continue wrapping using the spiral wrap
technique ensuring that the application begins from the smaller
diameter pipe to the larger pipe.
3)
3) When the end of the marked repair zone is reached, apply the
final two layers
4)
4) Instead of reversing direction, per usual spiral wrap method, it
is recommended to cut the fabric, and begin the application of
the 3rd and 4th layer on the smaller diameter section again.
Continue this method of application until the required layer count
is achieved.
Recommended Minimum Material Output
Composite Material
Pipe Surface Area
Layer Count
Minimum Composite Area
Recommended Area
DiamondWrap (Lite) - Lengths for 2 in. wide fabric
1.06
6
6.35
10.00
ft²
layers
ft²
ft²
Adhesive Primer
Primer Surface Area
Max Application Thickness
Recommended Area
5.00 ft²
10.00 ft²
20.00 ft²
PPR-220 Primer Sizes
1.41 ft²
30 mils
3 ft²
Filler Material
Defect Volume
Weld Volume
Geometry Taper Volume
Recommended Volume
2 in. x 30 ft 2 in. x 60 ft 2 in. x 120 ft -
PPR-220-4OZ
PPR-220-16OZ
PPR-220-1Q
PPR-220-2G
1.5
6
13
106
ft²
ft²
ft²
ft²
EPN-101 Filler Sizes
0.01
0.24
0.00
0.41
pints
pints
pints
pints
EPN-101-7OZ
EPN-101-13OZ
0.41 pints
0.83 pints
Repair Specific Notes
Material Sizes
Materials are provided in multiple sizes to ensure best pricing efficiency and to minimize waste.
Changes in material sizes or quantity on actual repairs may not warrant a change to this engineering
package. Changes in material type may require a change in the design package.
Thermal Considerations and Curing
All composite repair systems require a minimum temperature and time to properly function.
Composite repair systems harden through chemical interactions. The speed of these interactions are based
on the temperature that the resin sees during its cure profile. Be sure to fully understand the thermal
requirements to achieve a full cure prior to purchasing and installing a composite repair system. Depending
on the situation, external heating units may be required. A repair system that is not properly heated and
cured may not achieve full strength or chemical resistance leading to a potential failure.
Design Life and Intended Service Life
All composite repairs are designed based on the expected conditions of the pipe at the end of the
stated "Design Life". For all design scenarios, a minimum design life of 2 years is utilized if the intended
service life is less than or equal to 2 years. Ultimately, the intended service life of a repair should never be
exceeded without Engineering approval. If the service life exceeds design life, then the repair shall be
inspected prior to extending the design life again. If the design life exceeds the intended service life, the
intent is to purposefully increase the safety factor of the repair and inspection may not be required before
removal of the system outside of routine inspection plans.
Disclaimer
*All designs performed were done with information provided prior to, or on the day, listed in this package. Any new information that
may change the design conditions of any repair requires a new design package or a documented statement of no change needed by
a CSNRI Engineer.
**The repair and all materials are subject to CSNRI standard warranty policy
***All information presented as part of this bid package (quote and any calculations) are confidential and shall not be shared with
anyone beyond the receiving company.
****Before using any CSNRI product, the user must review the most recent version of the product’s technical data sheet, installation
manual, safety data sheet and other applicable documents.
DiamondWrap (Lite)
System ID Designation
Fabric
Fabric Type
Fabric Weave
Wet-out Resin
Resin Type
Average Ply Thickness (tply)
DW-LCK
FCB-033
Carbon Fiber
Bi-Directional
SFE-220
2-Part Epoxy
0.0105 in
Material Properties
Hoop Tensile Strength
92,690 psi
Hoop Tensile Modulus (Ec) 7,260,000 psi
Hoop Strain to Failure
1.26%
Hoop CTE (αc) 2.28E-06 in/in/°F
Long-Term Tensile Strength N/A
psi
Long-Term Strain to Failure
N/A
Glass Transition Temp.
257 °F
Max Application Temp.
140 °F
Coupon Test Temp.
77 °F
Min. Thickness Non-Leak
0.042 in.
Axial Tensile Strength
73,600 psi
Axial Tensile Modulus (Ea) 6,880,000 psi
Axial Strain to Failure
1.05%
Axial CTE (αa) 1.46E-06 in/in/°F
Energy Release Rate (γLCL)
2 in-lb/in²
Shear Modulus (G)
164,000 psi
Poisson's Ratio
0.069
Min Application Temp.
50 °F
Leak Test Temp.
77 °F
Min. Thickness Leaking
0.063 in.
Material Sizes Available
Fabric
Width
2 in.
4 in.
6 in.
30 ft
15 ft
40 ft
Allowable Adhesives
Default Adhesive
Alternate Adhesive 1
Alternate Adhesive 2
Fabric Lengths
commonly stocked
60 ft
120 ft
30 ft
60 ft
80 ft
160 ft
120 ft
Allowable Filler Materials
Default Filler
Alternate Filler 1
Alternate Filler 2
Miscellaneous Information
86 Shore D
Long-Term Test Type
Average Hardness
Min. Inspection Hardness
77 Shore D
Temperature at Long-Term Test
Recommended Cure Profile*
Time at Temp.
24 hours
100 95
Temperature
Hold Temperature
95 °F
PPR-220
95
95
50 95
95
95
0 95
0
95
95
2
0
0
24
24
24
24
24
4 246
24
EPN-101
ESN-202
Not Applicable
N/A
Ambient
95
24
95
24
95
24
95
24
95
24
95
24
95
24
8 109512 14 16
24 18 20 22 24 26
Time
95(Hours) 24
*For additional cure profiles or options, please contact CSNRI representative directly or refer to the product installer manual.
ASME PCC-2 2022 Design Considerations
Design considerations required following the ASME PCC-2-2022 standard Part 4 (Nonmetallic and Bonded Repairs)
Article 401 (Nonmetallic Composite Repair Systems: High-Risk Applications)
Service Temperature Effects
-- Determines temperature derate factor -Repair System DiamondWrap (Lite)
Max Temp. - No Leak (TM)
122 °F
Max Temp. - Leaking (TM)
203 °F
221 °F
Equation 2 - 𝑓𝑇 = 2 𝑥 10−5 𝑇𝑚 − 𝑇𝑑
Derate Factor - No Leak (fT)
Max Design Temperature (Td)
2
+ 0.0006 𝑇𝑚 − 𝑇𝑑 + 0.7014
0.96
Derate Factor - Leaking (fT)
Initial Allowable Strains for Repair System
Design Pressure Occurances
Continuous
Hoop Tensile Modulus (Ec) 7,260,000 psi
Axial Tensile Modulus (Ea) 6,880,000 psi
Load Type used
Ea ≥ 0.5 Ec
0.88
ASME PCC-2 Table 401-3.4.4-1
Load Type
For Ea ≥ 0.5 Ec
Rarely
Occuring
Continuous
(Sustained)
εc0, εa0
0.40%
0.25%
Symbol
For Ea < 0.5 Ec
Hoop Allowable Strain (εc0)
0.25%
Circumferential
εc0
0.40%
0.25%
Axial Allowable Strain (εa0)
0.25%
Axial
εa0
0.25%
0.10%
Default Allowable Strains for Repair System
Temperature Differential (ΔT)
Composite Hoop CTE (αc)
18 °F
2.28E-06 in/in/°F
Equation 10a: 𝜀𝑐 = 𝑓𝑇 𝜀𝑐0 − Δ𝑇 𝛼𝑠 − 𝛼𝑐
Temperature Derated Allowable Strain - No Leak
Hoop Allowable Strain (εc)
0.23%
Axial Allowable Strain (εa)
Composite Axial CTE (αa)
1.46E-06 in/in/°F
Temperature Derated Allowable Strain - Leaking
Hoop Allowable Strain (εc)
0.21%
0.23%
Not Applicable
20 years
-
6.67E-06 in/in/°F
Equation 10b: 𝜀𝑎 = 𝑓𝑇 𝜀𝑐0 − Δ𝑇 𝛼𝑠 − 𝛼𝑎
Axial Allowable Strain (εa)
Performance Testing Allowable Strain
Long Term Test Type
Design Life
Service Factor (f)
Pipe CTE (αs)
0.21%
ASME PCC-2 Table 401-3.4.5-1
Short Term Hoop Strength
Long Term Strength (slt)
Final Estimated Stress (f * slt)
92,690 psi
- psi
- psi
Percent of Short Term Strength
Axial Load Design Calculations
Internal Design Pressure (P)
Diameter (D)
Internal pressure force
Add. Loads (Fax)
40
4.5
636
0
-
Equation 4 from ISO 24817: 2017
psi
in
lbf
lbf
𝐹=
𝜋
4
2 + 4𝐹 2 +
2 + 𝑀2
𝑃𝐷 2 + 𝐹𝑎𝑥
𝑀𝑎𝑥
𝑡𝑜
𝑠ℎ
4
𝐷
Moment Loads (Max)
0 ft/lbs
0 ft/lbs
Shear Load (Fsh)
0 lbf
Torsion Loads (Mto)
Total axial load force
0 lbf
Total moment load force
Resultant Axial Force (F)
636 lbf
0 lbf
Engineering Assessment Form*
621 Lockhaven Drive | Houston, TX 77073
Phone: +1 281 590 8491 E-mail: eng@cs-nri.com
Project Information
Priority Status Standard (<24 hours)
Contact Name FERNANDO TORRES
Owner / Operator
Contact Company Name FERNANDO TORRES
Contact Number (938) 134-3172
Contact E-mail
Shipping Address
fernando.torres@paich.com.mx
linea de 4" x 3" Ø descarga de PSV-9720 y 9720A del
acumulador de reflujo FA-9708 hacia cabezal general de
8" Ø desfogue de baja presion de la endulzadora V6-L en
tercer nivel de la plataforma ABK-N1
Project Name / Line ID
Repair Classification Permanent
Preferred Units
Design Life
Imperial
10 years
Design Method ASME PCC-2
Pipe Information
Component Shape Reducer
Defect Location
Pipe Material
Carbon Steel
Length of Reducer
inches
Larger Pipe Diameter
4 inches
Smaller Pipe Diameter
inches
Nom. Wall Thickness
0.237 inches
Nom. Wall Thickness
inches
Pipe Grade (SMYS) A105
Piping Standard B31.3 - process piping
Product in Pipe DESFOGUE GAS
Consider External Loads
Repair Environment
No
Seam Weld Type SIN COSTURA
Standard Environment
Location of Pipe Above Ground
Planned Surface Prep** Mechanical - acceptable
Operating Pressure
5.69 psi
Operating Temperature
45 °C
Installation Pressure
0 psi
Installation (Skin) Temperature
35 °C
System Design Pressure
39.82 psi
Design Temperature (max)
50 °C
Design Temperature (min)
50 °C
Cyclic Frequency
Defect Information
Defect Scenario
Repair Type
Single Defect
Seam Weld Interaction
Leak Repair - Hole
Girth Weld Interaction
Ext. Wall Loss Cause
Corrosion
Internal Wall Loss Cause
Ext. Wall Loss Length
0.001 inches
Internal Wall Loss Length
0 inches
Ext. Wall Loss Width
0.001 inches
Internal Wall Loss Width
0 inches
Ext. Wall Loss Depth
0.237 inches
Internal Wall Loss Amount
0 inches
External Erosion Rate
Mechanical Damage
in/yr
None
Mech. Damage Length
inches
Mech. Damage Width
inches
Max Height Differential
inches
Unknown
Internal Wall Loss Rate
in/yr
Leak Stop Method
Hole Diameter
inches
Total Affected defect Length
inches
Other Considerations
Additional Information (optional)
Obstacles Present No
Include Top Coat No
Include Pig Markers
Include Training No
Inspector's Name
Stocked Material Available
Maximum Repair Length
inches
Requested Repair Length
inches
Include Job Supervision
Date 7/27/2023
*The provided information will be used to perform a design assessment - inaccurate information may lead to an incorrect design
**All products were tested to a minimum of SSPC-SP11 "Power Tool Cleaning to Bare Metal"
Material Estimates for PB101266-0
Primary Repair System Material Calculations
Repair System DiamondWrap (Lite)
Recommended Area
10.00 ft²
Fabric Width
2 in.
Size 1:
Quantity
1 ea
Size
2 in. x 60 ft -
Coverage
10 ft²
Total provided area: 10 ft²
Primary Load Transfer Filler Material Calculations
EPN-101
Load Transfer Filler
Used to fill
Total volume to fill
Quantity
Size 1:
1 ea
All locations
0.41 pints
Size
EPN-101-7OZ
Coverage
0.41 pints
Total provided volume: 0.41 pints
Adhesive Primer Material Calculations
Epoxy Coating
Surface area to cover
Use Purpose
PPR-220
3.00 ft²
Adhesive Coating
Quantity
Size 1:
2 ea
Size
PPR-220-4OZ
Coverage
3 ft²
Total provided volume: 3 ft²
Epoxy Coating
Surface area to cover
Use purpose
SCHT
3.00 ft²
Top-Coat
Top-Coat Material Calculations
Quantity
Size 1:
1 ea
Size
SCHTPT
Coverage
20 ft²
Total provided volume: 20 ft²
Summary Material Output
1 ea DW-LCK-260-10
1 ea SCHTPT
1 ea AK-SM
1 ea EPN-101-7OZ
2 ea PPR-220-4OZ
ea
1 ea AS-SMALL
1 ea ACC-PERF2X2
1 ea ACC-COMP-05200