SplashGard

Our SplashGard system is specifically designed for use in wet or submerged conditions, which means it can be applied underwater and adheres easily to wet steel surfaces. SplashGard is ideal for structural reinforcement on offshore risers because of its dual-component specialized coating, SplashBond™ adhesive and Splash Wrap, a fiberglass cloth impregnated with moisture-cured urethane (MCU) resin.

Applications

  • Offshore risers
  • Corrosion and wave action

Applications

  • Offshore risers
  • Corrosion and wave action
SplashGard Composite Repair System

Milliken Infrastructure Solutions is proud of the strength and unique capabilities of our SplashGard system to provide a safe, sustainable repair. Please reach out to our Pipe Wrap engineering team with any questions or for a copy of the technical data sheet.

 

SplashGard I

Repair Use

  • Protective Coating

Material

  • Knitted fiberglass

Set Time

  • 5 minutes

SplashGard II

Repair Use

  • Structural rehabilitation

Material

  • Woven fiberglass

Set Time

  • 2 hours

SplashGard III

Repair Use

  • Severe structural rehabilitation

Material

  • Woven carbon fiber

Set Time

  • 2 hours
FAQs
Pipe Wrap Composites
Have questions? Check out our frequently asked questions regarding our Pipe Wrap composite wrap systems. Contact us if you would like to know more.

Milliken Infrastructure Solutions currently provides solutions for these industries:

  • Oil & Gas:
    • Plants and Refineries
    • Transmission Pipelines
    • Marine and Offshore
    • Storage Tanks
  • Industrial
  • Municipal
  • Mining
  • Power Generation 

Browse our pipe repair and engineering solutions in our interactive Oil & Gas industry map. 

There are many variables to consider when designing a composite repair, including: 

  • operating pressures and temperatures
  • defect type and severity 
  • pipe geometry
  • external or internal chemical presence 

Finding a product that is engineered to the exact specifications of a given scenario will not only offer the best design required to provide a functional and lasting repair, but it can also reduce costs. There are many other conditions, such as bending or combined loading, that the repair must address. 

These conditions can more easily be considered if the repair is custom designed instead of assuming that an off-the-shelf product has already considered these loads. “Pre-designed,” ready-made repair products should only be used to address very specific situations, which should be clearly and plainly understood by their manufacturer and communicated to you. 

Read a more detailed answer under Misconception 1 in our white paper: “5 Common Composite Repair Misconceptions.”

The universal answer, no matter who the manufacturer, is yes. Inspection standards can be vague and the development on education is lacking, but it’s the responsibility of the operator, who is the final decision-maker on product selection, to know if the composites have been inspected for use.  

There are several non-destructive tests (NDTs) to analyze defects within the pipe’s walls and the surrounding composite material, regardless of composite the manufacturer. 

  • Tap Test
  • Phased Array
  • EMAT
  • Pulsed Eddy Current
  • Digital Radiography
  • Microwave
  • Thermography 

Read a more detailed answer under our Composite Inspection: Non-Destructive Tests (NDTs) document or under Misconception 2 in our white paper: “5 Common Composite Repair Misconceptions.” 

The words “temporary” and “permanent” seem to mean something different to each operator, manufacturer and auditor. A general definition for both could be:

  • Temporary repair: the repair is installed for a specified, usually short, amount of time with scheduled inspections or a planned service removal
  • Permanent repair: the repair is installed without requirements for inspections other than routine, entire-pipe inspections 

All internal wall loss defects, external abrasion or extremely high fatigue scenarios will be treated as temporary, as well as cracking in the composite or further corrosion growth under the repair. If no growth is expected, however, meaning the current and end-of-life conditions are predicted to be the same, then a permanent composite repair becomes a viable option, but not before considering composite creep and cyclic fatigue life of the composite and the pipe.  

Read a more detailed answer under Misconception 3 in our white paper: “5 Common Composite Repair Misconceptions.” 

As it currently stands, composite repairs should only be considered a temporary repair for situations where the crack or crack-like feature cannot be removed without additional, focused testing. As a temporary repair, composites can bridge the gap until a more permanent solution can be installed. 

Read a more detailed answer under Misconception 4 in our white paper: “5 Common Composite Repair Misconceptions.”

Maintenance engineers should pay close attention to a product’s fabric or laminate construction. Uni-, bi-, tri- or quad-directional fabrics are important structural characteristics to make sure you’re selecting the right composite for your repair. 

  • Uni-directional: The fibers in this material are oriented and aligned in a single direction, making these fabrics extremely strong in that direction but extremely weak to any loads not parallel with the fiber construction.  

  • Bi-directional: These fabrics are created in a 0°/90° woven configuration, which can support both the hoop and axial stresses if designed accordingly, but it’s weak when exposed to torsional or shear forces along the 45° line. The thin composition of bi-directional fabrics makes them relatively flexible and easily formed to complex shapes when wet or dry. 

  • Tri-directional: The fabric is typically engineered in a stacked fashion (great for leak repairs) with strength in the hoop direction. The alignment along the 0°, +45° and -45° lines provides greater load-bearing capabilities and makes it the best option for conforming to irregular shapes. 

  • Quad-directional: This composite is relatively strong in every direction and is ideal for leak repairs due to its strength and sequencing. Its thick- and stiffness in all directions makes these fabrics extremely difficult to apply to complex shapes. Quad-directional fabrics have the highest average overall strength and modulus in stress but the lowest in any single direction. 

  • Randomly oriented: These fabrics contain no directional preference and are typically used in low-stress applications in a preventative measure because their construction provides minimal strength.  

Read a more detailed answer under Misconception 5 in our white paper: “5 Common Composite Repair Misconceptions.”

  • Tap Test: A great preliminary test to determine if further inspection is needed. An inspector uses a metal object, like a quarter, to tap along the outside of the composite and use the resulting sound to determine if a defect exists within the composite. More sophisticated methods exist for this form of testing: Tap Hammer, RD3 and CATT 

  • Phased Array: This ultrasonic method can be used to detect defects within the pipe, voids between the pipe and the composite repair, and the voids or delamination within the composite itself. The results can be viewed as either a C-scan (2D, top-down view) or a B-scan (2D, side-on view) 

  • EMAT: This method inspects pipes and composites by producing electromagnetic waves that interact with the conductive materials found in some composite repairs, which give off their own electromagnetic waves. The combination of the waves creates sound waves that are used to locate damages and defects. EMAT does not need to come into direct contact with the inspected area. 

  • Pulsed Eddy Current: This electromagnetic testing method uses a transmitter to produce alternating currents that induce looping currents, or eddy currents, in nearby conductive materials—in this case the substrate. Existing defects interfere with the flow of the current and are presented in the form of a color-coded grid based on severity of wall loss. 

  • Digital Radiography: This method, also known as X-ray, uses penetrating radiation to inspect delamination and disbanding within the tested materials and find defects in both the composite and the pipe wall. This option is primarily chosen for pipes that are already completely exposed. Transmitted waves that haven’t been interrupted by defects help form an image that gives an actual photographical representation of the insides of the pipe or composite.  

  • Microwave: This method detects delamination and disbonds in non-conductive materials, so not carbon fiber composites. Transmitted waves are reflected back when meeting a void or discontinuation in material, and the voids are identified as areas of delamination, disbonding or gouged composite and case the microwaves to be reflected back to the inspection instrument at a different rate.  

  • Thermography: Thermography can find defects by detecting the change of thermal activity within a material and creating a heat map of the surface of a stressed object by using an infrared camera and equipment. This method is better suited for defects closer to the surface because of the energy required is higher the deeper the defect is in the ground. 

Read a more detailed answer under Misconception 2 in our white paper: “5 Common Composite Repair Misconceptions.” 

Our Products At Work in the Field


SplashGard™ & A+ Wrap™ System: Corrosion & Leak Repair


Offshore Southeast Asia
June 18, 2015

Project Overview
Three crude oil risers located in Southeast Asia needed both corrosion and leak repair. The pipes’ OD was 10.75” with a 0.365” wall thickness and a pipe grade of X42. After removing the damaged neoprene coating from two of the three risers, extreme corrosion was found. The last riser had two pinhole leaks that required immediate repair. 

Repair Solution
Based on the extent of the defect, a design calculation package was created by the engineering team in accordance with ASME PCC-2 standards, which determined that a nine-foot linear repair with 20 layers of the SplashGard system was required. The pipe was media-blasted to near-white metal and then wiped down with acetone to remove any oil residue. 

An Emergency Pipe Repair Kit (EPRK™) was required for use on the third riser to stop two active leaks. The line was pressurized, and after 30 minutes of drip-free operation, EP400 putty was applied to the repair zone to create a smooth transition. The pipe was then structurally reinforced using SplashGard to encapsulate the stop gap. SplashBond™ was used as a load transfer filler for all three risers. Two layers of SplashGard were used as a starting point, then the composite was applied using the spiral wrap method with a 50% overlap until the design requirement of 20 layers was achieved with a completed repair thickness of 0.44”. 

When all 20 layers were completed, four layers of constrictor wrap were applied and perforated. The repair was left to cure for two hours and the constrictor wrap was removed. A final coating using SplashBond was applied on all three risers over the entire repair area to provide corrosion and UV protection. 

Results
A hardness test was conducted and the A+ Wrap achieved a hardness of 85 on the Shore D scale. The three lines were returned to regular operations. All three repairs were completed within four hours, which includes the two-hour set time. 

SplashGard_Offshore Riser_SE Asia_BeforeSplashGard_Offshore Riser_SE Asia_SandblastingSplashGard_Offshore Riser_SE Asia_During InstallSplashGard_Offshore Riser_SE Asia_After

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