RETROWRAP H.D.

WRAPAROUND

RETROFIT

RISER, PILE AND SUBSEA PIPELINE

CORROSION PROTECTION SYSTEM

Designed by: Corrosion Control International

U.S. Patent No. 5,435,667

Corrosion Control International

www.corrosioncontrol.com
 CONTENTS

1. Introduction

2. Design Criteria

3. Construction

4. Physical Data

5. Conclusion

6. Installation Procedures
Introduction

RETROWRAP HD is a wrap around corrosion protection system specifically

designed to provide an easily installed retrofit installation for use on risers,
sub sea pipelines and jetty piles through the splash zone in off shore and
deep water locations or where heavy duty resistance to floating debris or ice
floes is required

RETROWRAP HD'S elastomeric properties and flanged closure system

provides the unique facility of removal and subsequent replacement to
facilitate routine inspection of the substrate and replacement of damaged
sections throughout the service life.

Hoop tension imposed in the tough resilient heavy duty outer skin acts to
force the inner layer against the surface of the substrate thereby causing the
sealant and its corrosion inhibitor to form a close association with the
substrate. The thixotropic nature of the sealant allows it to be exuded into any
surface irregularities thereby providing a seal thus terminating the supply of
oxygenated water to the riser, pipe or pile surface.

The system is modular and therefore a multiplicity of units may be deployed to

encapsulate virtually any length of circular, square or "H" section pile.

Design Criteria

In preparing our new technology package, we have based our design round a
combination of materials with proven performance within a variety of
operational environments. The components which combine to form the
RETROWRAP HD system are resistant to long term immersion in both
seawater and fresh water and to the attendant biological and chemical attack.
In addition, the system will withstand attack from environmental UV, ozone
and temperature variations while providing permanent protection in service,
by resisting wave and current forces.

The materials incorporated into the system are stressed below their
operational limits ensuring a high safety factor in all parameters while in
service. If accidentally punctured, the hoop tension will cause the gel
impregnated within the inner layer carrier to be exuded from the damaged area
and "self seal". The inhibitor within the gel will neutralize any oxygenated
water which has permeated through the damaged wrap at the time of impact.
The design of the laminar membrane and the hoop tensions involved combine
to ensure that in the extremely unlikely event of a tear being introduced to the
RETROWRAP HD, the tear will not propagate.

The basic objective was to design a system that while fulfilling all of the
requirements once in service, should be as quick and easy to install as
possible.

No labor intensive ancillary materials such as tapes, sealants or adhesives are

used in order to reduce to a minimum the possibility of human error and/or
non-compatibility of components in the installation of the system.
Construction

RETROWRAP HD panels are a multi-layer monocoque construction consisting

of a double polymeric textile reinforcement encapsulated within the
polyurethane matrix and outer layer and bonded in-line to a polyester or
polypropylene, penetration resistant, felt impregnated with a corrosion
inhibitor or biocide contained within a water resistant thixotropic gel, as
dictated by the application for which the system will be supplied.

The Outer Skin

In designing the system, we considered the following operational parameters
in addition to those necessary for the material to retain hoop tension
throughout the projected operational life of the fabric.

Polymer Coating to the Outer Skin

Various polymers were considered, however the following requirements
indicated the use of polyurethane:
1. Toughness
2. Abrasion resistance
3. Good U. V. resistance
4. Good ozone resistance
5. Resistance to high climatic temperature
6. Good adhesion to fabrics
7. Proven long life under seawater
8. Resistance to hydrocarbon oil contamination
9. Is not degraded by any form of marine life
10. Oxidization resistance
11. Capability of being fabricated by in line welding
Construction (continued)
The RETROWRAP HD panels are fabricated from a double textile reinforced
polyurethane multi-layer fabric. The material has been specifically fabricated
in response to 10 years of wrap development and utilizes the supportive data
resulting from 35 years of oil boom construction and deployment in a marine
environment.

Primary Penetration Layer

Polyester felt which provides the primary penetration and carrier for the
corrosion inhibiting gel is in line bonded during the production of the multi-
layer fabric to become an integral part of the RETROWRAP HD fabric.

The thixotropic gel and its attendant "active" corrosion inhibitors are factory
applied to the point of saturation in quantities calculated to provide protection
throughout the operational life of the product.

Thixotropic Inhibited Sealant Gel

Petrolatum based gel exhibiting a high degree of thixotropy, liquefying at
installation to convey the active corrosion inhibiting additives to the
interstices of the substrate whilst solidifying once again soon after.

The gel is intensely hydrophobic, dispersing water on contact with the

substrate while remaining inert to the physical and chemical effect of marine
and fresh water throughout the operational lifetime of the system.

Applied at elevated temperature in liquid form to the geotextile felt to the point
of saturation (≈ 3kg/sq. M). Once applied, the gel exhibits stability through an
extensive operational temperature range with slump and melt points being
outside those encountered in most applications.

Construction (continued)
Flanged Closure Seal
RETROWRAP HD units are tensioned and closed using marine and impact
resistant PVC extrusions. See page 3, where the fabric and supplementary felt
sealed under compression provides the environmental closure seal.

Stainless steel 316L fasteners are provided as a standard, however Monel or

Titanium alloys fasteners are available upon request.

Physical Data
Heavy Duty Wrap Fabric – BX-2-OUF
Typical Properties (Minimum)
Coating Material 100% PTMEG
Polyurethane
Color Black

Urethane Surface Finish (Max.) 350 R.M.S.

Total Thickness, Finished ± .015" 0.246” (6.25mm)

(inclusive of polyester felt)

Weight, Finished (± 3 oz) ASTM D-751 90 oz/sq yd(± 3 oz)

Base Fabric
Type Nylon 6/6
Weight ASTM D-751 12 oz/sq. yd x 2 ply

Strip Tensile MD/XMD ASTM D-751 1200/1200 lbs.

% Elongation at Break ASTM-D-751 45%

Tongue Tear MD/XMD ASTM D-751 200/200 lbs.

(± 20 lbs)

Impact Resistance ITI/1477 175 ft/lbs

Taber Abrasion ASTM 3389 >90,000 cycles (min)

1000 g weight Nylon reinforcing
H -18 wheel fabric exposure

Coating Adhesion ASTM D-751 40 (± 5) lbs/inch

Accelerated Weathering ASTM D-4396 1000 hrs excellent

Low Temperature Bend ASTM D-746 - 70° F

Wrap Operating Temp. Range -20° C to 120° C

Felt
Type Polyester
Weight ASTM D-751 19 oz/sq yd

Specifications subject to change without notice.

Corrosion Inhibiting Gel

This petrolatum based gel exhibits a high degree of thixotropy with active
corrosion inhibiting additives.

The gel is intensely hydrophobic, dispersing water on contact with the

substrate while remaining inert to the physical and chemical effect of marine
and fresh water throughout the operational lifetime of the system.

The inhibitor is applied at an elevated temperature in liquid form to the

2
geotextile felt to the point of saturation (≈ 3kg/M 0.6 lbs/ft²). The application of
the corrosion inhibiting gel is usually done during manufacture, but can be
done at the installation site. Once applied, the gel exhibits stability through an
extensive operational temperature range with slump and melt points being
outside those encountered in most applications.

Components of the gel are as follows:

Components Approximate ± %
Refined Petroleum Wax 50%
Thixatropic Media 40%
Oxyalkylates and Alcohol in
Heavy Aromatic Naphtha 10%

Color: Tan
Appearance: Soft Paste
Odor: Oily Hydrocarbon
Specific Gravity: 1.2
Conclusion

RETROWRAP HD provides an easily installed retrofit method of corrosion

protection of risers, jetty piles and sub sea pipelines in offshore locations or
where the coatings are subject to ice flow or floating debris impact.

To facilitate complete post installation inspection and/or maintenance of the

substrate at intervals indicated by the client, the ability exists to remove and
refit RETROWRAP HD units without detriment to the long term performance of
the material.

For deep water applications, where RETROWRAP HD is used in multiples to

suit the water depth, the units can be overlapped or butt joint and sealed using
a cummerbund connector to provide a continuous, retrofit "active" protection
system throughout the required length.

Note: RETROWRAP HD units are factory supplied in length's of 40", 60", 100"
and 120". (1.02 M, 1.5 M, 2.0 M & 3 M). Special lengths are available upon
request.
Installation Procedure
Installation Equipment
1 set of 1/2" Acme Threaded Draw Bolts
1 7/8" AF 1/2" Drive Extended Socket
1 7/8" AF Combination Wrench
1 1/2" Drive Compressed Air Driven Impact Wrench
1 1/2" drive 9/16" AF Socket Wrench
1 1/2" Drive 9/16" AF Combination Wrench

Instructions
Ensure that the substrate has been cleaned in accordance with the client's
cleaning procedure, and then:

1. Remove the plastic backing sheet, if fitted, by gripping it at one corner

and slowly pulling such that the sheet comes off completely.

2. Convey RETROWRAP HD unit to the riser pile and with overlap area
uppermost. Position wrap around the riser and tie off with temporary
rope support into closed position. Fit draw bolt in every other bolt hole
in flange and using impact wrench, drive draw bolt, complete with
washer, through opposing flange until nut and washer can be fitted.
Continue fitting draw bolts in every other bolt hole. Do not tighten draw
bolts at this stage.

3. Ensure that the wrap is in the required position and free from
obstruction at the closure face.

4. Using the extended box wrench fitted to the impact wrench, sequentially
tighten draw bolt nuts until wrap panels are under tension and the unit
has become self-supporting on Riser.
 5. Remove the ropes from the closure (if fitted for temporary support).

6. Continue sequentially tightening draw bolts, keeping the gap between

flange spaces as equal as possible.

7. Tighten all draw bolts until flange faces are closed.

8. Fit the Stainless Steel bolt with washer through vacant holes in flanges
and apply nuts finger tight.

9. Using a suitable socket attached to impact wrench, tighten stainless

steel nuts until flanges are in face to face contact.

10. Refit extended box wrench, reverse direction of impact wrench and
remove all draw bolts, taking care not to lose nuts and washers.

11. Repeat step 8, until all stainless steel 316L bolts are fitted.

12. Using impact wrench, tighten all stainless steel nuts and fit and tighten

nylon lock nuts.

13. Check wrap to ensure that it is seated correctly on pile.