Denso, a corrosion prevention and sealing technology company, has launched its Composite Pipe Repair Systems, which reinforce pipelines affected by corrosion, wall loss and mechanical damage.
The systems comprise two advanced, non-metallic solutions, Protal 3200CF and Protal 2800CF. These both reinforce pipelines while avoiding hot-welding and minimising disruption, according to the company.
Denso’s composite repair systems are designed for non-through-wall pipeline defects. They combine carbon fibre reinforcement with performance-driven epoxy primer systems to form a durable, load-bearing composite layer. This composite layer works with the existing pipe to restore structural integrity and extend service life.
The systems are suitable for applications such as pipelines, process piping, offshore topside piping, oil and gas risers and pressure vessels. They can be installed on in-service pipelines to reduce downtime and avoid complications from traditional welded repairs.
Protal 3200CF
Protal 3200CF is Denso’s high-strength composite repair system. It combinine dry carbon fibre fabric with Protal 3220 Epoxy Saturant, Protal 7200 Corrosion Barrier Epoxy Primer and Protal 3210 Load Transfer Structural Filler. The system delivers high tensile strength of 114ksi and an elasticity modulus of 9.32Msi.
Within the Protal 3200CF system, Protal 3210 Load Transfer Structural Filler is used to fill pits, dents, corrosion cavities and irregular surfaces so loads can transfer efficiently from the host pipe into the composite repair. Protal 7200 Corrosion Barrier Epoxy is applied beneath the wrap to protect the repair zone from future corrosion. Meanwhile the wet-out application of the Protal 3200CF carbon fibre fabric with Protal 3220 Epoxy Saturant supports controlled laminate quality and repeatable installation performance.
Protal 2800CF
For operators requiring quick pipeline repairs, Protal 2800CF provides a moisture-tolerant composite repair option. It uses Protal 7300 Corrosion Barrier Epoxy, Protal 3210 Load Transfer Filler and a pre-impregnated carbon fiber wrap supplied in a nitrogen-filled foil pouch. The wrap is activated by applying a continuous light water spray.
Protal 7300 can be applied to wet or sweating surfaces, where it displaces water as the coating is installed. The Protal 2800CF system provides tensile strength of 66.1 ksi and an elasticity modulus of 6.93 Msi.
Both systems require near-white metal surface preparation in accordance with SSPC-SP10 / NACE No. 2. Each system can also incorporate Denso ILI markers between wrap layers to help identify the repaired area during future in-line inspections.
For above-ground, UV-exposed applications, the cured composite may be topcoated with Archco 15 or Archco 65. Optional Denso ViscoWrap or Densyl Tape can be added when project specifications call for additional mechanical or environmental protection. Both systems are installable from 50˚F to 120˚F and feature a maximum operating temperature of 140˚F.
Both systems are also in accordance with industry standards such as ASME PCC-2 and ISO/TS 24817.
