1. PIPELINE SAFETY CONFERENCE-2018
Engineered Composite repair Solutions for RESTORING Integrity of pipelines
A step ahead in maintaining asset integrity
Presented By:
Mukesh Mishra
Asst. Manager- Marketing
8th -9th March 2018
Organised by: PESO
LIZMONTAGENS INDIA PVT. LTD.

2. LIZMONTAGENS GROUP HISTORY
Lizmontagens Group was established In 1978 in Portugal; with a specific focus in three main areas of expertise:
Refractory Linings (Turnkey services including Detailed engineering)
Furnace construction & associated structural work (Glass & Aluminum Industry)
Industrial Chimney construction and maintenance (EPC Basis)
Today Lizmontagens has over 25 subsidiaries operating in 4 continents.
Lizmontagens India was Established in December – 2010 as a 100% group subsidiary company to extend its range of services in India, far east and a part of middle east.

3. LIZMONTAGENS & IMG CompOSITES U.K
LIZMONTAGENS AND IMG COMPOSITES UK
LIZMONTAGENS & IMG CompOSITES U.K
In 2011 LIZMONTAGENS INDIA PVT LTD Associated with IMG Composite UK as their Authorised Installer For Composite Wrap solution in INDIA , Far East & Part of Middle East.
IMG Composites Ltd founded in 2001 (formerly as IMG Offshore) is also a founder member of the Composite Repair Industry.
IMG Composites Ltd is a market leader in design and supply of “Composite Reinforcement” products & repair systems for Corroded Assets.
Our MISSION is to provide innovative and cost effective Composite repair solutions to the Industry.

4. What is a Composite Repair ……..
WHAT IS COMPOSITE REPAIR SYSTEM
What is a Composite Repair ……..
Composite Repair System is a synergistic combination of 2 or more epoxy materials along with suitable reinforcement (Glass or Carbon Fibre tapes), used in the repair of aged or corroded assets both in Offshore / Onshore Equipments, structures & pipe works.
This non-metallic repair technology assists in restoration of operational integrity of Plant pipe work, Cross Country Pipelines, vessels & tanks.

5. COMPOSITE REPAIR HISTORY
The pipeline industry’s methods for repairing aging or damaged pipelines were bulky, expensive and difficult to install.
In view of meeting the production targets/ avoiding huge losses, the repairs needed to be faster, more reliable and easier to install.
In the 1990s, companies began determining that composite materials could meet the need proposed by the pipeline owners and maintenance providers.
Industry came up with the solutions for aging pipelines and prepared the way for a new composites industry.  
BUT THERE WAS NO PARTICULAR STANDARD FOR REPAIRS

6. COMPOSITE REPAIR HISTORY
In late 90’s, a Joint Industry program of Shell and other Major Oil & Gas Companies and Composite Repair Applicator / Manufacturers was Implemented to Design an Effective Composite Repair System, for Development of Design, Qualification and Installation which led to Development of standards like AEAT 57711, AEAT 57756, ISO and ASME PCC2.
Development of these repair standards led the foundation of Engineered Composite Repair System (ECR System)

7. DESIGN OF COMPOSITE REPAIR
The composite repair systems are designed as per the Guidelines of International standards based on the inputs of existing parameters of the structures such as:
Nominal pipeline thickness and thickness loss.
Operating and Design Pressures.
Operating and Design Temperature.
Fluid/material content.
The following Standard and codes are considered in Composite repair system.
ISO / TS
ASME PCC2
AEAT Design Document Design of Composite Repair Specification
AEAT Installation Document Installation Procedures for Composite Repair Specification
HSE 2001/038 - Temporary/Permanent Pipe Repair Guidelines

8. NEED OF COMPOSITES IN HYDROCARBON INDUSTRY
Corrosion has continued to be major concern in Hydrocarbon Industry. Industry runs at a high risk of encountering un-foreseen downtimes due to damage caused by corrosion and result in heavy commercial Losses.
Conventional methods of repairs such as sleeve welding possess safety risks and are also time consuming.
Loss of structure integrity due to corrosion, may sometimes lead to major fatal accidents.
Hence Lets be Pro Active

9. COMPOSITE REPAIR SOLUTIONS
Composites for
Repair and Reinforcement of Steel Structures
Cross Country Pipelines
Plant Pipings/ Nozzle Bores/fittings
Caissons and Large Diameter Pipes
Worn and Holed Tank Roofs, Decks
Subsea Pipelines, and other structures
Leak Sealing
Repair and Reinforcement of Concrete Structures

10. TECHNICAL HIGLIGHTS OF ECR PRODUCTS
TEMPERATURE RESISTANCE
SYSTEM has service limits of temperature - 50˚ C to 260˚C
OPERATING PRESSURE RESISTANCE
UPTO 275 bar
CHEMICAL RESISTANCE
SYSTEM can be used for Chemicals with values ranging
from PH 3.5 To Ph 11.
LAYERS / Maximum build up thickness
Maximum thickness as recommended by ISO is 25
mm.

11. BENEFITS OF ECR SYSTEM
Unique Online Repair Solution as No Shutdown ,Hot work or welding required, hence ‘zero risks’.
Restores Operational Integrity of corroded assets.
Saves OPEX / CAPEX Costs as system designed for 5 to 20 years life.
Compatible for repairing complex geometry locations like Tee, bends etc.
Temporary repair to production control fittings such as Valves, Actuators etc.

12. ADVANTAGES OVER OTHER SYSTEMS
In composite systems up to 25 mm thick repairs can be achieved.
Salt spray resistance to over 1008 hrs. No blistering, no loss of adhesion, no discoloration.
Class “ O “ Certification for FIRE.
Provides structural reinforcement /strength due to thickness. Can handle INTERNAL and EXTERNAL corrosion defects including pressure retaining repairs designed to ISO
Mechanical clamps used to repair corroded and leaking sections require tightening of bolts that induce greater stress on an already weakened system

13. CASE STUDIES Examples & case study
Composite Repair – Strengthening of Pipes
ONGC Uran Plant had severe corrosion problems on its Flare Header Lines LP Oil lines, KOD pipeline and Intermediate Tank line of 36”,30” & 14”.
Pipelines laid in 1950’s and integral part of the process Unit required to perform 24x7x365 days as it supplies processed crude to 2 Major Refineries in Mumbai.
Lizmontagens India provided a total turnkey solution for Design, supply and installation of IMG Composite Repairs solution, executed over a period of 6 months with a guarantee period of 20 years performance.

14. CASE STUDIES Composite Repair - Strengthening of Pipeline
Project location : ONGC ,Uran
Type of defect : External , Corroded Surface thickness loss up to 70%
Pipe diameter : 10 inch
Service : LPG line in Sludge Catcher Area.
Pressure : 20 bar
No. of layers : 8
Repair Lifetime : 10 years
A typical installation of repairing complex geometries showing a combination of an elbow, tee and reducer in plant pipework that has been repaired and over coated .

15. CASE STUDIES Composite Repair - Nozzle Bore Points at ONGC Hazira
Project location : ONGC , Hazira
Type of defect : External , Corroded Surface thickness loss up to 70%
Pipe diameter : 3/4 inch
Service : Gas Lines
Pressure : 60 bar
No. of layers : 8
Repair Lifetime : 10 years
No. of Points: 60
Leak Sealing and Composite repair of Nozzle Bore Points

16. CASE STUDIES Examples & case study
Composite Repair – Strengthening of Flare Header Line
36” & 48” dia Flare header pipeline through composite material repair system of metallic pipelines.
Length of Pipeline : 400 & 350 Rmt
Nominal Wall thickness : 9.97 & 10.95mm
Operating Pressure of 1 kg/cm2
Scaffolding erection &
Dismantling up to 22 mtr
Height.
Metal loss up to 60%
Operating temperature of the Product : Ambient.

17. CASE STUDIES Examples & case study IMG Composite Repair Application –
CompoSol Vessel
Line detail : Propane tank
Defect type : External corrosion on welds Remaining wall : 90% wall loss (during application) prone to 100% Cause for defect : Condensation

18. CASE STUDIES Examples & case study IMG Composite Repair Application –
CompoSol Vessel
Line detail : LPG STORAGE TANK
Defect type : Pin holes and leak situation Remaining wall : 90% wall loss (during application) prone to 100% Cause for defect : Condensation

19. Certification requirements
IMG COMPOSITES complies all tests required as per ISO / TS & ASME PCC2
THE CERTIFICATION BY ESR Technology as per ACoReS Audit Report. Backup\Acores\Acores Audit Report IMG Composites Rev A.pdf
Class ‘O’ Certification
Axial Load Testing
Burst medium term Testing
Compressive Test
Adhesion Test
Burst / Pressure Test
Salt Spray Test

20. Work completed in india
EXPERIENCE LIST
Work completed in india
Sr.No
Client
Owner/Consultant
Duration
Location
Industry
Job Description 1
Balmer Lawrie & Co.
IOCL
2012
Haldia WB
Oil & Gas
Composite wrap to ½” to 24” pipeline at Jetty Area 2
BPCL Mumbai
ONGC
2013
Mumbai Refinery
Strengthening of 24” crude pipeline 225 mtr. 3
Composite wrap to ½” to 36” pipeline at Refinery Area including Flare Header Line 4
2014
ONGC Uran
8”, 10” & 12 inch sludge Catcher and column line. 5
2015
30” 36” oil line & 36” & 48” Flare Header Line total Cumulative length is 1.75 km 6
2016
20” 24” & 30” Oil line total Cumulative Length is 2.54 Km

21. PRESSURE TEST REPORT
Pressure Test report

22. For your valuable enquiries, we are at your service
THANK YOU
For your valuable enquiries, we are at your service
Rajesh Hariharan
Shyam Randive
Mukesh Mishra