Belzona Presentation by NICCO

RELIANCE INDUSTRIES COMPOSITE REPAIR WEBINAR
Wednesday July 7TH - 2021
Composite Repair Solutions
for Buried Pipelines
Presenter: Yusuke Nishi
Senior Technical Service Engineer
Belzona Polymerics Ltd.
International Conference on India Corrosion Technology Forum
24-25 September 2021

Belzona Asia Pacific
Chonburi, Thailand
Belzona Polymerics Ltd.
Harrogate, UK
Belzona Inc.
Miami, Florida, USA
Belzona Canada Inc.
Ontario, Canada
Belzona Molecular Technology
Nanjing, China
GLOBAL PRESENCE, LOCAL SUPPORT
More than 140 Distributors operating in over 120 countries

Belzona
SuperWrap II
Composite
Pipe Repair
SOLUTIONS
Belzona
SuperWrap II
Composite
Pipe Repair
SOLUTIONS

COMPLIANT COMPOSITE REPAIR
Standards and Compliance
Belzona SuperWrap II materials are developed for composite repair applications
in accordance with the following 2 standards:
• ISO 24817
Requirements and recommendations for the qualification and design, installation, testing and inspection
of composite pipe repairs.
• ASME PCC-2
Repair of Pressure Equipment and Piping
 Article 4.1
Nonmetallic Composite Repair Systems: High-Risk Applications

The standards specify the type of assets
that can be repaired with a non-metallic
repair system including:
• Pipelines and pipework, above and
below ground.
• Pipe components including bends,
tees, reducers and flanges.
• Repairs to existing clamps.
• Patch repairs to pressure vessels and
utility tanks.
COMPLIANT COMPOSITE REPAIR

COMPLIANCE REQUIREMENTS
Repair system to be qualified & designed as per
standard.
Application can only be carried out by trained
personnel.
Inspection regime to be written and agreed by
all parties.
All trained personnel are issued with unique
Validation No. for identification.
Control
Application
Design
Validation
The manufacturer provides qualification data as
per standard.
Qualification

COMPLIANCE PROCESS
A problem is detected by
the asset owner. Operating
conditions and variables are
recorded.
A design is made and shared
with asset owner,
manufacturer, and chosen
installers and supervisors.
Repair is made by installer in
accordance with design.
Repair is supervised and
QA/QC forms submitted.
Upon review of all QA/QC
documentation, a notice of
compliance is issued.
NEED DESIGNING ACTION COMPLIANCE

KEY ELEMENTS OF SUPERWRAP II
What needs to be considered
for a successful repair?
Load Transfer
Material
Successful
Repair

DEFECT TYPES – TYPE A vs TYPE B
Substrate – Defective Area

COMMON DEFECTS ON PIPES
Substrate – Defective Area
N.B. Some of these defect will need treatment prior to installation of a composite solution.

REPAIR TYPES – WRAP vs PATCH
Application Variations
Wrap
Repair mostly used on piping and pipework
components as long as it is practical to
encompass the full circumference.
Patch
Based on using a reduced area of composite
material as it is impractical to encompass
the full circumference of the component.

APPROVALS
Type Approval and Major Clients
Belzona SuperWrap II has Type approval from ABS.
The repair system has been widely used by the Oil
Majors around the world as well as many others.

COMPONENTS OF SUPERWRAP II
Belzona SuperWrap II Components
3 Components:
• Resin
• Reinforcement Sheet
• Release Film
Reinforcement Sheet
Resin (Solidifier)
Resin (Solidifier)
Release Film

RESINS OF SUPERWRAP II
100% solids two-component epoxy phenol Novolac Resin
to form the matrix of repair composite.
• Belzona 1981
Fast curing resin designed for cold environments
Application Temperatures: 5 – 20°C
• Belzona 1982
Long working life resin for warmer environments
• Belzona 1983
For high temperature services up to 150°C

REINFORCEMENT SHEET (Belzona 9381)
Hybrid reinforcing fabric sheet made of
glass/carbon (70:30)
Available in 3 sizes:
• 84 mm x 64 m
• 254 mm x 64 m
• 1.27 m x 10 m

RELEASE FILM (Belzona 9382)
Features:
• Releasing properties from epoxy systems.
• High tensile strength.
• Ideal for compacting & consolidation of resin
impregnated sheets.

TESTS FOR KEY PROPERTIES
Pre-qualification Tests
Material properties:
• High Young’s modulus (~38000MPa)
• Low Poisson’s ratio
• Similar thermal expansion coefficients to carbon steel
• High Adhesion to metal substrate
Belzona 1981 Belzona 1982 Belzona 1983
Young’s modulus 38800 MPa 38600 MPa 36900 MPa
Poisson’s ratio 0.26 0.26 0.25
Thermal expansion
coefficient
0.00000994 mm/mm 0.00001126 mm/m 0.00000519 mm/mm
Tensile Shear Adhesion
(after 1000hrs immersion)
15.5 MPa 19.0 MPa 10.3 MPa

CASE HISTORIES

BELZONA SUPERWRAP BURIED PIPE REPAIR
Damaged Area of Buried Pipe Composite Wrap being Applied Completed Application
Compliant Repairs – Oil and Gas Company, Thailand
System Utilised : High Temperature Modified ASME / ISO Compliant Resin System
reinforced with Carbon Fibre / Glass Fibre Hybrid Reinforcement.
System Properties :
 Compliant with ISO and ASME Composite Repair Standards
 In Service temperature resistance up to 150°C
 Pressure retention in excess of 200 bar
 Installed by trained and validated applicators and supervisors

Gas Distribution Pipelines - China
In-Service gas transmission pipeline suffering from
loss of wall thickness due to pitting corrosion following
failure of eternal corrosion protection system.
Surface preparation carried out using ATEX rated vapor
blasting system after which Belzona Superwrap system was
used to restore the integrity of the pipeline

Petrochemical Plant - Slovakia
Failure of patch weld repairs on flowline leading to
leakage of process fluids.
Operating pressure of 15 bar.
Belzona Superwrap applied to overwrap existing
repairs and prevent further deterioration due to
accelerated groundwater corrosion.

Deterioration of circumferential welds on main
Buried cooling water pipework in refinery.
Pitted weld areas repaired with Belzona 1111 and then
Belzona Superwrap system applied to restore integrity
and protect against further deterioration.
Seawater Pipelines - Italy

The underground pipeline (O/D = 355.6 mm) had
developed a thin wall defect with only 2.7 mm wall
thickness remaining.
The operating temperature was 40°C and the
operating pressure was 70 bar.
Belzona SuperWrap II was then applied in accordance
with the engineered design as a 9 wrap system.
The total length of the repaired section was 8 m.
High Pressure, Hydrocarbon Pipeline - Australia

THANK YOU

Belzona Presentation by NICCO

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