Application Procedure PRS-120 For Internal Defects-Manufacturing Defects

APPLICATION PROCEDURE
FOR
REPAIR AND REINFORCEMENT OF

LOSS OF THICKNESS
INTERNAL DEFECTS
MANUFACTURING DEFECTS
PRS-120
COMPOSITE PIPE REPAIR SYSTEM
Date of issue 04/03/2017
INTRODUCTION
This document is intended to be used as application procedure

specialized on repair and refurbishment of pipelines under operational
conditions affected by internal defects and manufacturing defects.
Internal defects and manufacturing defects causing metal loss
and compromising pipeline integrity include: Cracks (Fatigue,
ordinary, stress corrosion cracking), lamination, lapped grinding,
internal pitting, erosion, and internal corrosion.
The repair method to be used as structural reinforcement over the

pipeline affected by loss of thickness includes the PRS-120 Composite
Pipe Repair System.
The PRS-120 Pipe Repair System is a non-metallic, carbon fiber based

composite system developed in accordance with ASME-PCC2-2015, and
ISO/TS 24817.
IMPORTANT: The following procedure is designed to repair the

damaged pipeline under operational conditions.
THE PRS-120 Composite Pipe Repair System can only be installed

by certified applicators.
1. PRELIMINARY ACTIVITIES
1.1 In confined spaces such as excavations is strongly advisable to

verify the structural integrity of the excavation. Please ensure
walls are firm, in order to avoid collapse of the excavation. If
ponded water exist at the bottom of the excavation, this must
be removed prior any activity related to this procedure.
1.2 Where gas pipelines involved, it is highly recommended to verify
the pipeline integrity looking for gas leaks. This can be done
using a gas detector-explosimeter, and the inspection must be
carried out before start with the repair procedure.
2. SURFACE PREPARATION
2.1 The PRS-120 Composite Pipe Repair System only requires

manual cleaning of the surface (St2 SSPC-SP-2, SP3)
GN POLYMERS LTD 4700 Millenia Blvd, Orlando FL 32839, USA Tel +1 (407) 545 4604
Email: info@gnpolymers.com Please visit www.gnpolymers.com
Checklist for hand tool cleaning:

Protective plastic gloves
Plastic/metallic rasps
Sandpaper 40-60 grade
Wire Brush
Steel Spatulas
4 6 brushes
Chemical Remover for coatings
MEK (Methyl Ethyl Ketone)
Cleaning Clothes
Suitable plastic bags for debris disposal
2.2 Once the GN POLYMERS Technical Department determined the

repair measurements (coving plate length, number of layers of
the composite & length repair) for the PRS-120 Composite Pipe
Repair System, the first step is to establish the working area on
the pipeline. The defect to be repaired must be centered on the
length repair. For cleaning purposes, it is advisable to extend
the length to be cleaned 2 (5 cm) beyond each side. Place a
masking tape mark on the external edges of the cleaning limits
as reference. (Figure 1)
Length surface to be cleaned
Defect
Figure 1
2.3 Remove dust, debris and contaminants from the pipeline surface
using cleaning clothes.
2.4 Apply by brush enough chemical remover over the existing

coating, ensuring all surface is wetted out. Allow a 5 10
minutes period to let the chemical remover act, then scrape out
existing coatings from the pipeline surface. This process can be
done using steel spatulas, sandpaper or wire brushes. In high
thickness coatings this process must be repeated until expose
the steel surface of the pipeline.
2.5 Once the steel surface of the pipeline is exposed, a further

cleaning of the pipe surface must be carried out using MEK and
cleaning clothes, ensuring resulting debris from the cleaning
process are completely removed from the surface.
3. BONDING OF REINFORCEMENT METALLIC COVING PLATE
3.1 In order to ensure a complete performance for the PRS-120

Composite Pipe Repair System when applied on pipelines
affected by internal defects or manufacturing defects, it is
necessary to enhance the integrity of the pipeline placing a
metalling coving plate over the affected area. Although the PRS-
120 Composite Pipe Repair System has excellent chemical
resistance, its life expectancy can be reduced if a through-wall
defect caused by internal damage appears on the pipeline. The
PRS-120 Composite may be able to suffer erosion caused by the
transported fluid. To avoid this potential damage, and protect
the whole system it is necessary to place the metallic coving
plate as sacrifice surface over the pipe.
3.2 The GN POLYMERS Technical Staff must determinate the length

of the coving plate to be used. It depends on nature of defect,
pipe diameter, remaining loss thickness, operational pressure
and other factors. Once the plate length is defined it is required
the manufacturing of two pieces using a 1/8 carbon steel plate.
The coving plates must be cold rolled at the external diameter
of the pipeline and 180, with the specified length for the
particular case.
3.3 To obtain a suitable rough profile on the steel coving plates it is

required to abrade the surface. If possible, sandblast the coving
plates until achieve a Sa2 Commercial Standard (SSPC-SP6). If
sandblasting is not possible, use mechanical means such as
angle grinder to scarify the internal and external plate surfaces.
3.4 Measure 3 parts of the RM-PSC10 Base Component and place it

onto a suitable mixing board. Measure 1 part of the RM-PSC10
Activator Component and place it onto the same mixing board.
Mix both components until achieve a streak free, consistent
paste material. Once mixed, apply the mixed RM-PSC10 on the
internal surface of the coving plate, ensuring all plate surface is
covered and giving a uniform thickness of 3-4 mm. It also be
applied a contact layer over the pipeline surface using the RM-
PSC10 mixed material. Ensure all surface defects are filled,
pressing firmly the applied material over the pipe surface.
3.5 Place the prepared coving plates over the pipe surface, centered
on the defect. Press firmly the coving plates over the pipe
surface, squeezing excess material from the plates. The
squeezed material can be used to smooth edges of the plates.
The coving plates must be held in position using belts until the
RM-PSC10 achieves a hard dry state.
3.6 Once the RM-PSC10 achieves a hard dry state, the belts can be
removed from the pipeline.
4. APPLICATION OF PRS-120 COMPONENT A
4.1 The PRS-120 Component A is a two component paste grade

epoxy metal repair compound which must be mixed together
before use. The application can only be carried out a
temperatures between 5C and 35 C (40F 95F)
Checklist for PRS-120 Component A:

PRS-120 Component A (Base & Activator)
Plastic spatulas
Plastic mixing board
Cleaning clothes
Masking tape
Tape rule
Protective gloves
Methyl Ethyl Ketone
4.2 Using the masking tape, place a mark in each side of the repair
delimiting the edges of the area to be repaired. (Figure 2)
Composite Repair Length
Coving plate
Figure 2
4.3 Measure one part of the PRS-120 Component A Base, and

place it onto a plastic mixing board. Measure one part of the
PRS-120 Component A Activator, and place it onto the same
mixing board. Mix thoroughly both components until achieve a
streak free, homogenous material. Once mixed, the PRS-120
Component A has an estimated usable life of 40 minutes at 25
C (77F). Please note this time will increase at lower
temperatures, and will be reduced at higher temperatures.
4.4 Apply the mixed PRS-120 Component A over the pipeline

surface using plastic spatulas. Press firmly the mixed material
over the steel surface, ensuring all surface defects are
completely filed. The PRS-120 paste grade epoxy metal repair
compound must be applied at uniform thickness of 1 mm 1.5

mm. Ensure the PRS-120 Component A is applied over the
entire pipeline surface to be repaired.
5. APPLICATION OF PRS-120 COMPONENTS B AND C
5.1 Once the PRS-120 Component A is applied, and whilst is still

touch dry, the PRS-120 Component B and C must be applied.
The application can only be carried out a temperatures between
5C and 35 C (40F 95F)
Checklist for PRS-120 Component B and C application

PRS-120 Component B (Base & Activator)
PRS-120 Component C
Plastic spatulas
Plastic bucket for mixing
4 5 Brushes
Short pile rollers
Cutter
Protective gloves
Cleaning clothes
5.2 The Base & Activator components of the PRS-120 Component B

must be mixed separately to incorporate any slight separation of
material. After mixed, ensuring material settlements are

completely incorporated. Pour two parts of Base Component
onto the plastic bucket for mixing. Immediately pour one part of
the Activator Component onto the plastic bucket and mix
thoroughly both components until achieve a homogenous,
streak free material. Further mixing is advisable to ensure
complete incorporation of materials. The mixed PRS-120
Component B has an estimated usable life of 60 minutes at 25
C (77F). Please note this time will increase at lower
temperatures, and will be reduced at higher temperatures.
5.3 The first layer of PRS-120 Component C must be applied in axial

direction. Ensure the carbon fiber segment accomplish with the
required length for the repair. Place the PRS-120 Component C
over the previously applied PRS-120 Component A, pressing
firmly the carbon fiber, ensuring a smooth finishing is achieved.
Once the PRS-120 Component C is placed over the previously
applied PRS-120 Component A, the Component C must be
wetted out with PRS-120 Component B. Care must be taken
during application, ensuring the Component C is completely
wetted. The PRS-120 Component B can be applied by brush or
roller. This procedure must be repeated until the entire area to
be repaired is completely covered. The PRS-120 Component C
joints must be overlapped 2 during application.
5.4 The second layer of the PRS-120 Component C must be applied

in circumferential direction. Wrap the PRS-120 Component C
over the pipeline, applying further PRS-120 Component B over
the wrapped Component C. Overlap the PRS-120 Component C
edges approximately 2 (5 cm). Wrap the required number of
pieces until completely cover the area to be repaired.
5.5 The third layer must be applied in axial direction. Please refer to
section 5.3 of this document for detailed instructions.
5.6 The fourth and last layer of the PRS-120 Composite Pipe Repair
System must be applied in circumferential direction. For detailed
instructions please refer to section 5.4 of this document for
detailed instructions.
General view Axial layer Circumferential layer
5.7 The average thickness for the PRS-120 Composite Pipe Repair
System must be between 5-6 mm ().
6. DRYING AND CURING TIMES
6.1 The applied reinforcement system achieves a touch dry state 6

hours after applied at 25 C (77F)
6.2 The PRS-120 Composite Pipe Repair System achieves a Full

Cure State 24 hours after applied at 25 C (77F).
Please note that during the PRS-120 curing period, the

pipeline can still under complete operational service. No
shutdown or low operational pressure is required during
application/curing period of the system.
7. FINAL OVERCOATING
7.1 18 hours after applied at 25C (77F) the PRS-120 Composite

Pipe Repair System can be overcoated with the CR-UPL50, two
component epoxy novolac coating designed to be used as
protective system for buried pipelines.
Checklist for CR-UPL50 epoxy coating

CR-UPL50 (Base & Activator)
Plastic bucket for mixing
Plastic spatulas
4-6 Brushes
Short pile rollers
Masking tape
Cleaning Clothes
Protective Gloves
7.2 Mix both components separately to incorporate any slight

separation of material. Pour three parts of Base Component into
a plastic bucket, and add one part of Activator Component. Mix
thoroughly until achieve a homogenous, streak free material.
The mixed CR-UPL50 material has an estimated usable life of 20
minutes at 25C (77F). Apply by roller the mixed material over
the PRS-120 previously applied at an uniform film thickness of
500 microns wft/dft (20 mils). The CR-UPL50 applied coating
must be extended further 10 cm beyond PRS-120 edges.
7.3 6 hours after applied, the CR-UPL50 achieves a hard dry state.
12 hours after CR-UPL50 application, the pipeline can be buried.
These curing times are calculated at 25C (77F). Please note

this time will extend at lower temperatures, and will be reduced
at higher temperatures.
8. GENERAL CONSIDERATIONS
8.1 The PRS-120 Composite Pipe Repair System is designed under

ISO/TS24817, and ASME-PCC2-2015 standards. When applied
for certified installers it is expected to achieve the specified
expected life time included in the attached Repair Calculations
File. The specified measurements, thickness and number of
layers for the proposed repair have been obtained using the
data given by the final user, and we assume are correct.
8.2 Once applied, the PRS-120 Composite Pipe Repair System will
accomplish with Part 4, Article 4.1 Nonmetallic Composite
Repair System for Piping and Pipework: High Risk Applications.

Application Procedure PRS-120 For Internal Defects-Manufacturing Defects

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APPLICATION PROCEDURE

REPAIR AND REINFORCEMENT OF

This document is intended to be used as application procedure

The repair method to be used as structural reinforcement over the

The PRS-120 Pipe Repair System is a non-metallic, carbon fiber based

IMPORTANT: The following procedure is designed to repair the

THE PRS-120 Composite Pipe Repair System can only be installed

1.1 In confined spaces such as excavations is strongly advisable to

2.1 The PRS-120 Composite Pipe Repair System only requires

Checklist for hand tool cleaning:

2.2 Once the GN POLYMERS Technical Department determined the

2.4 Apply by brush enough chemical remover over the existing

2.5 Once the steel surface of the pipeline is exposed, a further

3. BONDING OF REINFORCEMENT METALLIC COVING PLATE

3.1 In order to ensure a complete performance for the PRS-120

3.2 The GN POLYMERS Technical Staff must determinate the length

3.3 To obtain a suitable rough profile on the steel coving plates it is

3.4 Measure 3 parts of the RM-PSC10 Base Component and place it

4. APPLICATION OF PRS-120 COMPONENT A

4.1 The PRS-120 Component A is a two component paste grade

Checklist for PRS-120 Component A:

4.3 Measure one part of the PRS-120 Component A Base, and

4.4 Apply the mixed PRS-120 Component A over the pipeline

compound must be applied at uniform thickness of 1 mm 1.5

5. APPLICATION OF PRS-120 COMPONENTS B AND C

5.1 Once the PRS-120 Component A is applied, and whilst is still

Checklist for PRS-120 Component B and C application

5.2 The Base & Activator components of the PRS-120 Component B

material. After mixed, ensuring material settlements are

5.3 The first layer of PRS-120 Component C must be applied in axial

5.4 The second layer of the PRS-120 Component C must be applied

General view Axial layer Circumferential layer

6. DRYING AND CURING TIMES

6.1 The applied reinforcement system achieves a touch dry state 6

6.2 The PRS-120 Composite Pipe Repair System achieves a Full

Please note that during the PRS-120 curing period, the

7.1 18 hours after applied at 25C (77F) the PRS-120 Composite

Checklist for CR-UPL50 epoxy coating

7.2 Mix both components separately to incorporate any slight

These curing times are calculated at 25C (77F). Please note

8.1 The PRS-120 Composite Pipe Repair System is designed under

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