Certified CSNRI Engineering Document:

Certified
Design CSNRI
Package Engineering
for Engineered Document:
Composite Repair System
Design Package for Engineered Composite Repair System
Repair system and installation specifications for:

DiamondWrap (Lite) Repair System

Design Package # PB101424-0

Date Completed - September 8, 2023

Component / Line ID - ECOABA-GC-FG-4110

Company - Paich
Contact Name - Fernando Torres
E-Mail Address - [email protected]

CSNRI Sales Rep CSNRI Design Engineer

Carlos Egusquiza Pedro Bordieri
[email protected] [email protected]

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.
 Project Information
End-User Company Name Contact Name Fernando Torres
Installer Paich Contact Number (938) 134-3172
Project ID PB101424-0 Contact E-mail [email protected]
Component / Line ID ECOABA-GC-FG-4110
Elemento No.14
Additional Information

Default Units Imperial Piping Standard ASME B31.3

Intended Service Life 10 years Design Method ASME PCC-2
Design Life 20 years Pipe Material Carbon Steel (Other)

Pipeline Conditions
System Design Pressure 783 psi Operating Temperature 85 °F
Operating Pressure 711 psi Installation Temperature 85 °F
Install Pressure 711 psi Max design temperature 140 °F
Fluid in Pipe Gas Combustible Min design temperature -20 °F
Chemical Concentration
Temperature Concerns

Pipe Information Overview

Pipe Geometry Straight Main Line Diameter 1.05 in
Unit Name Straight_1 Nominal Wall Thickness 0.219 in
Damage Mechanism External Wall Loss Pipe Classification Minimum
Composite Repair Type Type A - No Leak Specified Min. Yield Strength 30,000 psi
Expected Surface Prep Power Tools Design Stress 15,000 psi
Additional Description

Summary Output
Primary Repair System DiamondWrap (Lite) used for structural reinforcement
Secondary Repair System None
Primary Load Transfer Filler EPN-101 Install Method Spiral Wrap
Adhesive Primer PPR-220 Compression Method Comp. Film

Layer Count 4 layers (0.042 in.) of DiamondWrap (Lite)

Repair Zone 18 in. linear repair on straight pipe

4 18
 Straight_1 Design Considerations and Equations
Pipe Diameter (D) 1.05 in
Wall Thickness 0.219 in
Design Strength (s) 15,000 psi
Repair Type Type A - No Leak

Defect Information for External Wall Loss Leaking Feature

Defect Depth 0.115 in Leak Type
Defect Length (Axial) 1 in Leak Stop Method
Defect Width (Hoop) 3.299 in Axial Length in
Defect Depth Used 0.115 in Hoop Width in
52.5% Wall Loss
ASME PCC-2 Considerations
Include Substrate Support Yes Installation Method Spiral Wrap
Allow Substrate to Yield Yes Fabric Width 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 6 Design Pressure (P) 783 psi
Allowable Strain (εc) 0.22%
1 𝑃𝐷
𝑡𝑚𝑖𝑛 = − 𝑠𝑡𝑠 Hoop Composite Modulus (Ec) 7,260,000 psi
𝜀𝑐 𝐸𝑐 2
Remaining Wall (ts) 0.104 in
Eqn. Assumptions:
Does not utilize B31.G estimates.
Assumes pipe can / will yield. Calculated Thickness (tmin) 0.000 in.
Minimum Layer Count 0 layers
Axial ASME PCC-2 2022 Art. 401, Equation 7 Design Pressure (P) 783 psi
Allowable Strain (εa) 0.22%
1 𝑃𝐷
𝑡𝑚𝑖𝑛 = − 𝑠𝑡𝑠 Composite Modulus (Ea) 6,880,000 psi
𝜀𝑎 𝐸𝑎 4
Remaining Wall (ts) 0.104 in
Eqn. Assumptions:
Does not utilize B31.G estimates.
Assumes pipe can / will yield. Calculated Thickness (tmin) 0.000 in.
Minimum Layer Count 0 layers
 Straight_1 Final Layer Count and Repair Length
Repair Thickness Type A - Hoop Repair Thickness Type A - Axial
Calculated Thickness 0.000 in. Calculated Thickness 0.000 in.
Component Multiplier 1.0 Component Multiplier 1.0
Limited Length Multiplier 1.0 Limited Length Multiplier 1.0
Adjusted Minimum Thickness 0.000 in. Adjusted Minimum Thickness 0.000 in.

Type A Minimum Thickness 0.000 in 0 layers

Type B Minimum Thickness 0 in. 0 layers
System Minimum Thickness 0.042 in. 4 layers
Final Minimum Thickness 0.042 in. 4 layers
Rounded Layer Count 4 layers
Estimated Repair Thickness 0.042 in.

Repair Length
ASME PCC-2 - Type A Length 0.8 in. ASME PCC-2 - Taper Length 0.2 in.
𝐿𝑜𝑣𝑒𝑟 = 2.5 𝐷𝑡Τ2 5 ∶ 1 𝑟𝑎𝑡𝑖𝑜
ASME PCC-2 - Type B Length 0.0 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.
Total Length Calculation Type Manual Manual Length 18 in.
Composite Repair Zone 18 in. 8.5 in. beyond edge of affected length
Adhesive Primer Length 22 in. 2 in. beyond edges of repair zone
Surface Prep Length 26 in. 2 in. beyond edges of primer zone

Recommended Minimum Material Output

Composite Material DiamondWrap (Lite) - Lengths for 2 in. wide fabric
Pipe Surface Area 0.41 ft² 2 in. x 30 ft - 5.00 ft²
Layer Count 4 layers 2 in. x 60 ft - 10.00 ft²
Minimum Composite Area 1.65 ft² 2 in. x 120 ft - 20.00 ft²
Recommended Area 5.00 ft²
Adhesive Primer PPR-220 Primer Sizes
Primer Surface Area 0.50 ft² PPR-220-4OZ 1.5 ft²
Max Application Thickness 30 mils PPR-220-16OZ 6 ft²
Recommended Area 1.5 ft² PPR-220-1Q 13 ft²
PPR-220-2G 106 ft²
Filler Material EPN-101 Filler Sizes
Defect Volume 0.01 pints EPN-101-7OZ 0.41 pints
Weld Volume 0.00 pints EPN-101-13OZ 0.83 pints
Geometry Taper Volume 0.00 pints
Recommended Volume 0.41 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 DW-LCK
Fabric FCB-033
Fabric Type Carbon Fiber
Fabric Weave Bi-Directional
Wet-out Resin SFE-220
Resin Type 2-Part Epoxy
Average Ply Thickness (tply) 0.0105 in

Material Properties
Hoop Tensile Strength 92,690 psi Axial Tensile Strength 73,600 psi
Hoop Tensile Modulus (Ec) 7,260,000 psi Axial Tensile Modulus (Ea) 6,880,000 psi
Hoop Strain to Failure 1.26% Axial Strain to Failure 1.05%
Hoop CTE (αc) 2.28E-06 in/in/°F Axial CTE (αa) 1.46E-06 in/in/°F
Long-Term Tensile Strength N/A psi Energy Release Rate (γLCL) 2 in-lb/in²
Long-Term Strain to Failure N/A Shear Modulus (G) 164,000 psi
Glass Transition Temp. 257 °F Poisson's Ratio 0.069
Max Application Temp. 140 °F Min Application Temp. 50 °F
Coupon Test Temp. 77 °F Leak Test Temp. 77 °F
Min. Thickness Non-Leak 0.042 in. Min. Thickness Leaking 0.063 in.

Material Sizes Available Allowable Adhesives

Fabric Fabric Lengths Default Adhesive PPR-220
Width commonly stocked Alternate Adhesive 1
2 in. 30 ft 60 ft 120 ft Alternate Adhesive 2
4 in. 15 ft 30 ft 60 ft 120 ft
6 in. 40 ft 80 ft 160 ft Allowable Filler Materials
Default Filler EPN-101
Alternate Filler 1 ESN-202
Alternate Filler 2

Miscellaneous Information
Average Hardness 86 Shore D Long-Term Test Type Not Applicable
Min. Inspection Hardness 77 Shore D Temperature at Long-Term Test N/A

Recommended Cure Profile* Ambient

Hold Temperature Time at Temp. 100
85 0 85 24
85 °F 24 hours 85 0 85 24
Temperature

85 24 85 24
50 85 24 85 24
85 24 85 24
85 24 85 24
0 85 24 85 24
85
0 2 4 246 8 10 8512 14 1624 18 20 22 24 26
85 24 Time85(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 Design Temperature (Td) 140 °F
Max Temp. - No Leak (TM) 221 °F Max Temp. - Leaking (TM) 203 °F

Equation 2 - 𝑓𝑇 = 2 𝑥 10−5 𝑇𝑚 − 𝑇𝑑 2
+ 0.0006 𝑇𝑚 − 𝑇𝑑 + 0.7014
Derate Factor - No Leak (fT) 0.88 Derate Factor - Leaking (fT) 0.82

Initial Allowable Strains for Repair System ASME PCC-2 Table 401-3.4.4-1
Design Pressure Occurances Continuous Rarely Continuous
Hoop Tensile Modulus (Ec) 7,260,000 psi Load Type Symbol Occuring (Sustained)
Axial Tensile Modulus (Ea) 6,880,000 psi For Ea ≥ 0.5 Ec εc0, εa0 0.40% 0.25%
Load Type used Ea ≥ 0.5 Ec 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) 0 °F Pipe CTE (αs) 6.67E-06 in/in/°F
Composite Hoop CTE (αc) 2.28E-06 in/in/°F Composite Axial CTE (αa) 1.46E-06 in/in/°F

Equation 10a: 𝜀𝑐 = 𝑓𝑇 𝜀𝑐0 − Δ𝑇 𝛼𝑠 − 𝛼𝑐 Equation 10b: 𝜀𝑎 = 𝑓𝑇 𝜀𝑐0 − Δ𝑇 𝛼𝑠 − 𝛼𝑎

Temperature Derated Allowable Strain - No Leak Temperature Derated Allowable Strain - Leaking
Hoop Allowable Strain (εc) 0.22% Hoop Allowable Strain (εc) 0.20%
Axial Allowable Strain (εa) 0.22% Axial Allowable Strain (εa) 0.20%

Performance Testing Allowable Strain ASME PCC-2 Table 401-3.4.5-1

Long Term Test Type Not Applicable Short Term Hoop Strength 92,690 psi
Design Life 20 years Long Term Strength (slt) - psi
Service Factor (f) - Final Estimated Stress (f * slt) - psi
Percent of Short Term Strength -

Axial Load Design Calculations Equation 4 from ISO 24817: 2017

Internal Design Pressure (P) 783 psi
𝜋 4
Diameter (D) 1.05 in 𝐹= 𝑃𝐷 2 + 𝐹𝑎𝑥
2 + 4𝐹 2 +
𝑠ℎ
2 + 𝑀2
𝑀𝑎𝑥 𝑡𝑜
Internal pressure force 678 lbf 4 𝐷
Add. Loads (Fax) 0 lbf Moment Loads (Max) 0 ft/lbs
Shear Load (Fsh) 0 lbf Torsion Loads (Mto) 0 ft/lbs
Total axial load force 0 lbf Total moment load force 0 lbf

Resultant Axial Force (F) 678 lbf

 Engineering Assessment Form*
621 Lockhaven Drive | Houston, TX 77073
Phone: +1 281 590 8491 E-mail: [email protected]
Project Information
Priority Status Standard (<24 hours) Owner / Operator
Contact Name FERNANDO TORRES Contact Company Name FERNANDO TORRES
Contact Number (938) 134-3172 Shipping Address
Contact E-mail [email protected]
ECOABA-GC-FG-4110 Elemento No.14
Project Name / Line ID
Repair Classification Permanent Design Life 10 years
Preferred Units Imperial Design Method ASME PCC-2
Pipe Information
Component Shape Straight Pipe Defect Location
Pipe Material Carbon Steel
Nominal Pipe Size 0.75 inches
Nom. Wall Thickness 0.219 inches
Pipe Grade (SMYS) A106 Grade B Piping Standard B31.3 - process piping
Product in Pipe GAS COMBUSTIBLE Repair Environment Standard Environment
Consider External Loads No Location of Pipe Above Ground
Seam Weld Type SIN COSTURA Planned Surface Prep** Mechanical - acceptable
Operating Pressure 711 psi Operating Temperature 22 °C
Installation Pressure 711 psi Installation (Skin) Temperature 22 °C
System Design Pressure 783 psi Design Temperature (max) 60 °C
Cyclic Frequency Design Temperature (min) 18 °C
Defect Information
Defect Scenario Single Defect Seam Weld Interaction
Repair Type Struct. Reinforcement Girth Weld Interaction
Ext. Wall Loss Cause Corrosion Internal Wall Loss Cause Unknown
Ext. Wall Loss Length 0.78 inches Internal Wall Loss Length 0 inches
Ext. Wall Loss Width 3.29 inches Internal Wall Loss Width 0 inches
Ext. Wall Loss Depth 0.115 inches Internal Wall Loss Amount 0 inches
External Erosion Rate in/yr Internal Wall Loss Rate in/yr
Mechanical Damage None Leak Stop Method
Mech. Damage Length inches
Mech. Damage Width inches
Max Height Differential inches Total Affected defect Length inches
Other Considerations
Additional Information (optional)
Obstacles Present No Stocked Material Available
Include Top Coat No Maximum Repair Length inches
Include Pig Markers Requested Repair Length inches
Include Training No Include Job Supervision
Inspector's Name 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 PB101424-0
Primary Repair System Material Calculations
Repair System DiamondWrap (Lite) Quantity Size Coverage
Recommended Area 5.00 ft² Size 1: 1 ea 2 in. x 30 ft - 5 ft²
Fabric Width 2 in.
Total provided area: 5 ft²

Primary Load Transfer Filler Material Calculations

Load Transfer Filler EPN-101 Quantity Size Coverage
Used to fill All locations Size 1: 1 ea EPN-101-7OZ 0.41 pints
Total volume to fill 0.41 pints
Total provided volume: 0.41 pints

Adhesive Primer Material Calculations

Epoxy Coating PPR-220 Quantity Size Coverage
Surface area to cover 1.50 ft² Size 1: 1 ea PPR-220-4OZ 1.5 ft²
Use Purpose Adhesive Coating
Total provided volume: 1.5 ft²

Top-Coat Material Calculations

Epoxy Coating SCHT Quantity Size Coverage
Surface area to cover 1.50 ft² Size 1: 1 ea SCHTPT 20 ft²
Use purpose Top-Coat
Total provided volume: 20 ft²

Summary Material Output

1 ea DW-LCK-230-5 1 ea SCHTPT

1 ea AK-SM

1 ea EPN-101-7OZ ea
1 ea AS-SMALL

1 ea ACC-PERF2X2
1 ea PPR-220-4OZ 1 ea ACC-COMP-05200