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Vasitars Ltd. is a technology based startup which aims at developing new dimensions of comfort and social ease
utilizing technological innovation as the weapon. As the world enters a new era of innovation where much of
monotonous and hazardous human work is going to be replaced by technology, Vasitars aims to take up the leadership
on this new stage.
We being the first Indian company to provide complete composite repair solutions to all kind of damage
scenarios in transmission pipelines. We also indulge in suggesting an appropriate design & manufacturing
for any composite structures such as composite pressure vessels, any automobile & aerospace components
armor design using composites as backing layer for impact resistant applications. We also do composite
patch repair for any failed mechanical components. Our main focus is quality.
Steel pipelines are used to transport oil and gas in the industry as well as to the storing tanks. The operating
conditions are in harsh environments and transporting a wide range of high-pressure fluids, pipelines suffer
by a variety of damage scenarios. These are damage in coating, erosion, corrosion or mechanical damage.
One of the most common problems experienced by the industry is internal and external corrosion of the pipe
lines. Depending on the severity of the problem this can have significant detrimental effects on the pressure
bearing capability of the pipelines and may lead to reduced life spans or at worst to a loss of structural
integrity, i.e. failure. In order to extend the durability of pipelines, methods to repair such damage have been
developed. A repair must be able to prevent leakage and also to restore all or part of the maximum allowable
transporting capacity of the pipeline. Usually, traditional repair methods require that the corroded or
damaged piping is taken offline while the affected pipe section is replaced or reinforced by external steel
strengthening/sealing elements. A recent application of composites for the oil and gas industry involves the
repair of corroded pipelines by external wrapping of FRP in the affected sections. Primary benefits associated
with FRP overwrap repairs are a continuous fluid transmission while the repair is installed and the fact that
no hot work or ignition is required and thus, the explosion potential is eliminated. Using composite wrap as
an alternative to pipeline replacement often saves enough resources to pay back repair costs immediately.
Sources reported completing 2 to 65 composite wrap repairs per year on pipelines 10'' and larger can save
526 thousand cubic feet (Mcf) to 27,500 Mcf of natural gas per repair. They saved 106,133 Mcf gas by
choosing composite wrap over pipeline replacement over a period of 5 years.
There are no Indian players indulged in pipeline repair using composite layup although there are few foreigen
players such as Clock Spring®, Strong Back, Armor Plate®, and Perma WrapTM. Technically, we have a different
repair methodology and proves to be one of the best and cheapest to install for all kind of repair scenarios
for pipelines ranging from 4’’ to 48’’ or more. The following section will elaborate on the materials,
technology & installation procedure.
II. Adhesive-
The adhesive used is commercially available epoxy (Araldite LY556, Hardener HY951) which is used to
hold the repair in place.
Fig. 1-3 shows the complete procedures of our repair methodology. (P.T.O.)
Figure 1: Pipe with a localized corrosion damage repaired with composite sleeve system
Figure 2: (a) Filling of the defect portion with/without nanoclay particles (b) Shear mixer for mixing clay in epoxy
A proper installation of the VASITARS composite wrap system, the following simple steps must be followed:
Tightening the composite wrap sleeve onto the pipe to give compressive loading
The employees of our company are highly experience in these works can perform the complete repair in as
less as 2 hours. After installation, the filler, adhesive, and composite layers bond together to form a
permanent repair system that will last at least 50-55 years.
Novelty
Fiber roll
Direction of wrapping
Fiber wrap
Using composite wrap repair system as an alternative to pipeline replacement can lead to significant
economic and environmental benefits:
• Reduction in costs associated for ensuring uninterrupted service during a repair, such as installing
bypasses or temporary service lines.
• Using composite wraps no methane is vented to the atmosphere and hence the income lost through
natural gas losses is minimized.
• Easier and faster installation without the need for special equipment or highly skilled labor, such as
welders. A single composite wrap can be installed by a trained two-person crew within 30 minutes.
• Ability to perform repairs at full line pressure, although it is recommended to reduce the line pressure
for repair.
Economics
Estimation of cost for a 12” pipeline having working pressure of 5 bars over a length of 1m.
Total cost to repair 1 meter of damaged pipeline is Rs. 8724/- which is much less than the conventional
method.
References