News Briefs
Composi-Sleeve™ is the only industry non-welded anomaly repair solution that protects pipeline flow. Composi-Sleeve™ is a patented pipeline anomaly repair solution that protects and supports pipeline flow. It utilizes a military-grade chemical welding process to repair pipeline anomalies (cracks, dents, corrosion, wall loss and leakage). In most cases the pipeline does not need to be taken out of service to make the repair.
The bottom line benefits of Composi-Sleeve™ is that it allows the pipeline uninterrupted service while in repair. It is a quick and easy repair that requires no mechanical (hot) welding. It reduces stress and strain with patented clamping system (that secures the steel sleeves to the pipe in the chemical welding process). It reinforces bad seams and vintage welds. It increases pipeline strength and rating. It is not vulnerable to creep. It is Smart PIG detectable. Ultimately, the Composi-Sleeve™ saves time and money. The Composi-Sleeve™ has two steel half sleeves that are “chemically welded” to the damaged pipe. It is much safer than a Type B Welded Sleeve. There is no hot welding or hot work involved, that results in hydrogen bubbles (that over time produce cracking).
During the installation of a Composi-Sleeve™, the entire inner surface of the steel repair sleeves are permanently bonded (fused) to the outer surface of the pipeline, creating a 100% chemical weld. Traditional mechanical welding only bonds the edges of the repair sleeve to the pipeline, effectively creating a capsule to contain the pressure. This method has less than 10% metal-to-metal bonding.
Additionally, engineering testing and analysis concludes that by reducing the stress level in the repair region, defect growth and/or continued deterioration is arrested (or eliminated). And, “Chemical Welding” is a much more effective bond that distributes stresses and does not affect the grain structure.
Composi-Sleeve™ has had all testing was performed on a third party bases with Stress Engineering Services (SES) in Houston, Texas. The tests included load bearing testing, axial testing, cyclic fatigue, vintage weld, leak-test, strain gauge analysis and a burst test. See “Results” section for copies of the SES testing documents.
Additionally, Western Specialties has performed its own long term testing over the eight years of development. In October 2015, Western Specialties dug up a Composi-Sleeve™ that was installed in July 2011 in Hermiston, Oregon to examine its condition and long-term material performance. After almost 5 years in service, the repair system integrity was determined to be “as good as new!”
Composi-Sleeve™ is a patented pipeline repair solution.
Repair Apparatus & Method for Pipe & Fittings
U.S. Patent #7,938,146 B2
Repair Apparatus & Method
U.S. Patent #8,424,571S
Composi-Sleeve™ works. It is a D.O.T. compliant solution, is an ASME PCC-2 sanctioned solution, it meets PHMSA requirements/standards, it is considered a permanent repair and it keeps the pipeline in service while in repair.
Composi-Sleeve™ is supported by a world class team. Western Specialties is the Composi-Sleeve™ solution creator, developer and manufacturer. LMC Industrial Contractors is the manufacturer and supplier of the steel sleeves. The LORD Corporation is the creator, developer, manufacturer and supplier of the chemical welding agents. Primoris Services Corporation, and their family of operating companies, is the trained and certified service agents/applicators of Composi-Sleeve™ pipeline repair system and projects.
Additionally, in some cases Western Specialties and/or other pipeline repair contractor(s) may be used as the certified service agents/applicators of Composi-Sleeve™ pipeline repair system and projects. Generally speaking, each repair situation is dictated by the requirements of the pipeline operator.
The Composi-Sleeve™ anomaly repair solution is a patented pipeline anomaly repair solution that can be completed in quick and easy steps. Composi-Sleeve™ utilizes a military-grade chemical welding process to repair pipeline anomalies (cracks, dents, corrosion, wall loss and leakage).
Composi-Sleeve™ offers more structural support than a Type B Welded Sleeve. With any welded sleeve, it is only attached (fused) to the pipe at the welds on the sleeves, whereas with a Composi-Sleeve ™ the sleeves are 100% attached (fused) to the pipe.
As Stress Engineering Services said in testing, the Composi-Sleeve™ and the pipe “are one” unit (which also applies to insuring cathodic protection). Additionally, “Chemical Welding” is a much more effective bond that distributes stresses and does not affect the grain structure.
Composi-Sleeve™ Installation/Application Process
Prepare both the surfaces of the pipe and the steel sleeve (by sandblasting, steel brush, rough grade sand paper and/or all methods). Then double check how the steel sleeves fit on the pipe.
Apply the chemical welding agent (adhesive) to the steel sleeves with a thick and even coat.
Fit the steel half sleeves (that have the chemical agent applied to them) to the pipe. The steel sleeves remains the core component of the repair. There is NO mechanical hot welding required.
Apply and adjust the patented tension clamps (designed by Western Specialties) to the steel sleeves and pipe. Typically, the clamps will be spaced three to four (3″ – 4″) apart from one another. The objective is to apply even pressure across the surface of the steel sleeves and pipe.
Once all the clamps are installed on the steel sleeves and pipe, and the appropriate even pressure is applied across the surface, some of the adhesive will begin to ooze out. It is important to collect and smooth out that adhesive along the surface of the pipe at the seams of the steel sleeves.
Allow the adhesive to cure and chemically weld the steel sleeves together. The Composi-Sleeve™ offers more structural support than a Type B Welded Sleeve. With any welded sleeve, it is only attached (fused) to the pipe at the welds on the sleeves, whereas with a Composi-Sleeve ™ the sleeves are 100% attached (fused) to the pipe.
As Stress Engineering Services said in testing, the Composi-Sleeve™ and the pipe “are one” unit (which also applies to insuring cathodic protection). Additionally, “Chemical Welding” is a much more effective bond that distributes stresses and does not affect the grain structure.
The actual cure/chemical welding timeframe is conditional to the individual situation. Typically the curing of the chemical welding process is subject to the environment and ambient temperatures and conditions.
Once the adhesive is allowed to cure and chemically weld the steel sleeves together, then take the clamps off of the steel sleeves and prepare the steel sleeves for the Western Specialties e-glass composite overwrap Ultra-Wrap™.
Prepare both the surfaces of the steel sleeve (by means of a grinder and rough grade sand paper). Then apply the Western Specialties e-glass composite overwrap Ultra-Wrap™ to the steel sleeves with the appropriate number of layers.
Then apply a shrink wrap over the Ultra-Wrap™. Then perforate the shrink wrap to allow the excess adhesive to weep out of the perforation holes. Allow the Ultra-Wrap™ to cure. The actual cure timeframe of Ultra-Wrap™ is conditional to the individual situation. Typically the curing process is subject to the environment and ambient temperatures and conditions.
Once all curing is well in process (subject to the environment and ambient temperatures and conditions) and meets minimal hardness, it is ready for burial.
A Composi-Sleeve™ is installed by a trained and certified installer. Western Specialties is the Composi-Sleeve™ solution creator, developer and manufacturer. The LORD Corporation is the creator, developer, manufacturer and supplier of the chemical welding agents. Primoris Services Corporation, and their family of operating companies, is the trained and certified service agents/applicators of Composi-Sleeve™ pipeline repair system and projects.
Additionally, in some cases Western Specialties and/or other pipeline repair contractor(s) may be used as the certified service agents/applicators of Composi-Sleeve™ pipeline repair system and projects. Generally speaking, each repair situation is dictated by the requirements of the pipeline operator.
Composi-Sleeve™ is the only industry non-welded anomaly repair solution that protects pipeline flow. Composi-Sleeve™ is a patented pipeline anomaly repair solution that protects and supports pipeline flow.
It utilizes a military-grade chemical welding process to repair pipeline anomalies (cracks, dents, corrosion, wall loss and leakage). In most cases the pipeline does not need to be taken out of service to make the repair.
The bottom line benefits of Composi-Sleeve™ is that it allows the pipeline uninterrupted service while in repair. It is a quick and easy repair that requires no mechanical (hot) welding. It reduces stress and strain with patented clamping system (that secures the steel sleeves to the pipe in the chemical welding process).
It reinforces bad seams and vintage welds. It increases pipeline strength and rating. It is not vulnerable to creep. It is Smart PIG detectable. Ultimately, the Composi-Sleeve™ saves time and money.
The Composi-Sleeve™ has two steel half sleeves are “chemically welded” to the damaged pipe. It is much safer than a Type B Welded Sleeve. There is no hot welding or hot work involved, that results in hydrogen bubbles (that over time produce cracking).
Composi-Sleeve™ is D.OT. Compliant. According to clause 195.415(f), Federal Register, Vol. 64 No. 239 of the Federal Register states that a repair method shall repair the pipe “by a method that reliable engineering tests and analysis show can permanently restore the serviceability of the pipe.” Composi-Sleeve™ has been wholly tested and analyzed by Stress Engineering Services (SES) in Houston, Texas.
All the completed engineering testing and analysis demonstrates that by reducing the stress level in defect region below and threshold level effectively arrests defect growth or defect deterioration.
Composi-Sleeve™ has ASME PCC-2 Certification. It is one of the few solutions worldwide that hold the ASME PCC-2 certifications (which pertains to the repair for pressurized steel pipeline) and is the only repair solution that utilizes steel sleeves that are not mechanically welded
All testing was performed on a third party bases with Stress Engineering Services (SES) in Houston, Texas. The tests included load bearing testing, axial testing, cyclic fatigue, vintage weld, leak-test, strain gauge analysis and a burst test. Dr. Chris Alexander, industry leading composite and sleeve repair expert, has been the principal team leader on all tests performed.
Additionally, Western Specialties has performed their own long term testing over the eight years of development. In October 2015, Western Specialties dug up a Composi-Sleeve™ that was installed in July 2011 in Hermiston, Oregon to examine its condition and long-term material performance. After almost 5 years in service, the repair system integrity was determined to be “as good as new!”
Is there any hot work involved with a Composi-Sleeve™?
No…no welding and no preheating is required. The two steel half sleeves are “chemically welded” to the pipe, utilizing a military-grade chemical welding process to repair pipeline anomalies (cracks, dents, corrosion, wall loss and leakage). In most cases the pipeline does not need to be taken out of service to make the repair. Additionally, “Chemical Welding” is a much more effective bond that distributes stresses and does not affect the grain structure.
Is a Composi-Sleeve™ safe?
Yes…it is much safer to install than a Type B Welded Sleeve. There is no welding or hot work involved. The two steel half sleeves are “chemically welded” to the pipe, utilizing a military-grade chemical welding process to repair pipeline anomalies (cracks, dents, corrosion, wall loss and leakage). In most cases the pipeline does not need to be taken out of service to make the repair. Additionally, all the completed engineering testing and analysis demonstrates that by reducing the stress level in defect region below and threshold level effectively arrests defect growth or defect deterioration. And, “Chemical Welding” is a much more effective bond that distributes stresses and does not affect the grain structure.
Is Composi-Sleeve™ a pressure containing repair for a through the wall penetration?
Yes…it has been pressured to over 4000 psi. in testing at Stress Engineering Services (SES) in Houston Texas, with a 1/4 inch hole drilled into the pipe. In other testing, on a cracked pipe (cut out from the field), the Composi-Sleeve™ system was tested by pressured up the pipe and repair. The pipe yielded outside the repair zone (the Composi-Sleeve™) at approximately 2,100 psi, and failed (burst) at 2,788 psi.
Is Composi-Sleeve™ environmentally safe?
Yes…there are little or no environmental concerns. All installations are performed in accordance with any state and/or federal practices and standards that apply.
Is Composi-Sleeve™ DOT compliant? What is the regulatory acceptance?
Yes…Clause 195.415(f), Federal Register, Vol. 64 No. 239 of the Federal Register states that a repair method shall repair the pipe “by a method that reliable engineering tests and analysis show can permanently restore the serviceability of the pipe.” Composi-Sleeve™ has been wholly tested and analyzed by Stress Engineering Services (SES) in Houston, Texas. Additionally, all the completed engineering testing and analysis demonstrates that by reducing the stress level in defect region below and threshold level effectively arrests defect growth or defect deterioration.
Can Composi-Sleeve™ be used to reinforce vintage welds and seams?
Yes…in third party testing it has shown that the Composi-Sleeve™ anomaly repair system has achieved the best results in the industry by a large margin. Additionally, the Composi-Sleeve™ system is able to put the pipe in compression. All the completed engineering testing and analysis demonstrates that by reducing the stress level in defect region below and threshold level effectively arrests defect growth or defect deterioration. Additionally, “Chemical Welding” is a much more effective bond that distributes stresses and does not affect the grain structure.
When using a Baker’s Plug to initially stop a leak (during hydro-testing) will the plug protrude into the pipeline?
No…the “Baker’s Plug” breaks off clean and will not protrude into the pipeline.
Does Composi-Sleeve™ remove stress from a pipe?
Yes…the Composi-Sleeve™ anomaly repair system (and processes) actually puts the pipe into compression, reducing all stress in that area of the pipe. Additionally, all the completed engineering testing and analysis demonstrates that by reducing the stress level in defect region below and threshold level effectively arrests defect growth or defect deterioration. Additionally, “Chemical Welding” is a much more effective bond that distributes stresses and does not affect the grain structure.
Does the application of Composi-Sleeve™ increase the strength of the pipeline?
Yes…The finished repair will be stronger than the original pipeline. Composi-Sleeve™ offers more structural support than a Type B Welded Sleeve. With any welded sleeve, it is only attached (fused) to the pipe at the welds on the sleeves, whereas with a Composi-Sleeve ™ the sleeves are 100% attached (fused) to the pipe. As Stress Engineering Services said in testing, the Composi-Sleeve™ and the pipe “are one” unit (which also applies to insuring cathodic protection). Additionally, “Chemical Welding” is a much more effective bond that distributes stresses and does not affect the grain structure.
What is the cost of a Composi-Sleeve™?
The “cost” has many factors involved it in… from the actual dig to the degree of difficulty of the terrain to pipe itself. In comparison to a Type B Welded Sleeve, the Composi-Sleeve™ anomaly repair system is approximately one third the cost. It does not require additional testing or radiographic inspection (x-ray). It doesn’t require that the pipeline be taken out of service for repair, which translates into saving millions of dollars. For more information or to talk to a Western Specialties professional… CLICK HERE.
What type of pipeline service can the Composi-Sleeve™ be installed on?
The Composi-Sleeve™ anomaly repair system can be utilized on all types of pipelines, which includes natural gas, petroleum, chemical or any other service.
What tests have been performed on the Composi-Sleeve™, and what organization performed them?
All testing was performed on a third party basis with Stress Engineering Services (SES) in Houston, Texas. The tests included load bearing testing, axial testing, cyclic fatigue, vintage weld, leak-test, strain gauge analysis and a burst test. See “Results” section for copies of the SES testing documents.
Additionally, Western Specialties has performed their own long term testing over the eight years of development. In October 2015, Western Specialties dug up a Composi-Sleeve™ that was installed in July 2011 in Hermiston, Oregon to examine its condition and long-term material performance. After almost 5 years in service, the repair system integrity was determined to be “as good as new!”
What is the maximum internal pressure that can be repaired? Do you need to shut down or lower operating pressure?
There is no maximum internal pressure issue, therefore it is usually not necessary to shut down or lower the operating pressure. The Composi-Sleeve™ repair system will be engineered to restore the pipe back to MAOP, or better. However, in the case of severe and deep corrosion, lowering the pressure should be considered for safety reasons. Additionally, a Composi-Sleeve™ is not affected by pipe creep.
Is Composi-Sleeve™ patented?
Yes…the Composi-Sleeve™ non-welded pipeline anomaly repair system and installation design is a patented process. See below.
Repair Apparatus & Method for Pipe & Fittings
U.S. Patent #7,938,146 B2
Repair Apparatus & Method
U.S. Patent #8,424,571S
Is a Composi-Sleeve™ Smart Pig detectable?
Yes…since the Composi-Sleeve system uses two steel half sleeves, it leaves the best signature in the industry for the Smart Pig to detect. As Stress Engineering Services said in testing, the Composi-Sleeve™ and the pipe “are one” unit (which also applies to insuring cathodic protection).
When installing a Composi-Sleeve™, what pre-engineering analysis is required?
Very little if any. Typically the wall thickness of the existing pipeline dictates the thickness of the two steel sleeves. The system is designed to restore the pipe back to its full MAOP. However, if the pipeline operator desires a heavier wall for the steel sleeves (in special cases), that will be acceptable. Cases of this nature may involve river crossings and slide areas that require additional strength and protection.
Can Composi-Sleeve™ lower the strain at the repair location?
Yes…third party testing by Stress Engineering Services (SES) has shown that Composi-Sleeve™ actually puts the pipe in compression which significantly reduces or eliminates pipe strain of the repair. This is accomplished with the patented tension clamps designed by Western Specialties. Additionally, “Chemical Welding” is a much more effective bond that distributes stresses and does not affect the grain structure.
What is the major difference between Composi-Sleeve™ and other repair systems?
Composi-Sleeve™ closest (comparative) competition is the Type B Welded Sleeve. The Composi-Sleeve™ offers more structural support than a steel welded sleeve. With a welded sleeve it is only attached to the pipe at the welds on the sleeves, whereas with a Composi-Sleeve ™ the sleeves are 100% attached to the pipe. Additionally, “Chemical Welding” is a much more effective bond that distributes stresses and does not affect the grain structure.
Also, a Composi-Sleeve™ is much safer. There is no welding and no preheating that is required. The two steel half sleeves are “chemically welded” to the pipe, utilizing a military-grade chemical welding process to repair pipeline anomalies (cracks, dents, corrosion, wall loss and leakage). In most cases the pipeline does not need to be taken out of service to make the repair.
Additionally, Stress Engineering Services said in testing that the Composi-Sleeve™ and the pipe “are one” unit (which also applies to insure cathodic protection). The Composi-Sleeve™ is a pressure con-retaining repair and actually strengthens pipe, as well as provides re-enforcement that can be used to strengthen pipe in unsupported spans.
Who can install a Composi-Sleeve system?
A Composi-Sleeve™ trained and certified installer. Western Specialties is the Composi-Sleeve™ solution creator, developer and manufacturer. LMC Industrial Contractors is the manufacturer and supplier of the steel sleeves. The LORD Corporation is the creator, developer, manufacturer and supplier of the chemical welding agents. Primoris Services Corporation, and their family of operating companies, is the trained and certified service agents/applicators of Composi-Sleeve™ pipeline repair system and projects.
Additionally, in some cases Western Specialties and/or other pipeline repair contractor(s) may be used as the certified service agents/applicators of Composi-Sleeve™ pipeline repair system and projects. Generally speaking, each repair situation is dictated by the requirements of the pipeline operator.
Will Composi-Sleeve™ be resistant to corrosion after installation?
Yes…Composi-Sleeve™ is a non-shielding repair. Cathodic protection and/or the pipeline will also protect the Composi-Sleeve™ repair. As Stress Engineering Services said in testing that the Composi-Sleeve™ and the pipe “are one” unit (which also applies to insure cathodic protection).
What lengths do the Composi-sleeve™ half pipes come in?
Composi-Sleeve™ is a customized anomaly repair solution, and length is conditional to the repair situation. Typically, the steel sleeve length is three feet (3′), however it can come in lengths up to ten feet (10′).
Do you (and how do you) repair damages over ten feet (10′)?
Yes…we would install as many Composi-Sleeve™ joints as necessary to cover long (range) damages. This application is particularly useful with river crossings and slide areas (exposures and wash-outs) for additional strength and protection.
Can Composi-Sleeve™ be use for a span?
Yes…Span Reinforcements are an expensive and difficult procedure, and necessary to protect against washouts and falling rocks. In many cases the pipeline must be take out of service in order to make this type of repair. Using Composi-Sleeve on a span adds structural support and reinforcement by applying another layer of steel to the pipe. Additionally, the seams of the steel sleeves can be oriented to address the vertical load and potential horizontal load. Also, the additional structural support and reinforcement protects against falling or sliding soil, rocks and boulders. See ATTACHMENT.
Can Composi-Sleeve™ be installed on pipe that is out-of-round?
Yes…Composi-Sleeve™ actually puts the pipe in compression (which significantly reduces or eliminates pipe strain of the repair), and the “out-of-round” pipe has a history of not being an issue. In third party testing (by Stress Engineering Services) has shown that Composi-Sleeve™ actually puts the pipe in compression which significantly reduces or eliminates pipe strain at the location of the anomaly repair. This is accomplished with the patented tension clamps designed by Western Specialties. Additionally, “Chemical Welding” is a much more effective bond that distributes stresses and does not affect the grain structure.
How long does it take to install a Composi-Sleeve™?
Everything is conditional to the individual situation. The “how long does it take” has many factors involved it in… from the actual dig to the degree of difficulty of the terrain to pipe itself. With regard to the actual installation time of a Composi-Sleeve™, typically it is approximately one hour to install the sleeves after the preparation work is complete (digging, shoring, etc.). The curing of the chemical welding process is subject to the environment and ambient temperatures and conditions. Most repairs can be completed within one or two days.
When can I backfill a repair after installation?
Backfill can take place immediately after the chemical welding process has acceptable level of cure (hardness), and the final composite wrap has been applied. The curing of the chemical welding process is subject to the environment and ambient temperatures and conditions.
Is any hoisting equipment required for installation?
Yes…up to thirty inch (30″) sleeves can be handled without equipment, but due to the additional weight of up to forty two inch (42″), hoist equipment is recommended.
Western Specialties is the Composi-Sleeve™ solution creator, developer and manufacturer. LMC Industrial Contractors is the manufacturer and supplier of the steel sleeves. LORD Corporation is the creator, developer, manufacturer and supplier of the chemical welding agents. Primoris Services Corporation, and their family of operating companies, is the trained and certified service agents/applicators of Composi-Sleeve™ pipeline repair system and projects.
Additionally, in some cases Western Specialties and/or other pipeline repair contractor(s) may be used as the certified service agents/applicators of Composi-Sleeve™ pipeline repair system and projects. Generally speaking, each repair situation is dictated by the location of the repair work and the requirements of the pipeline operator.
Western Specialties™ is the inventor and developer of the pipeline anomaly repair solutions Composi-Sleeve™ and Ultra-Wrap™. The team is built around the core competencies of solution development, testing and quality. Additionally, training, certification and contractor qualifications are primary areas of focus. Finally, marketing and business development are critical to our success strategy.
Carl “Whitey” Brooks
Sr. Vice President, Inventor of Composi-Sleeve™ and Ultra-Wrap™
Carl “Whitey” Brooks has distinguished himself, over a 60 year window of time as a “Pipeliner”. He pioneering an innovative non-welded pipe repair and reinforcement solution set. It utilizes a military-grade chemical welding process to repair pipeline anomalies. The solutions, Composi-Sleeve™ and Ultra-Wrap™, has revolutionized the pipeline repair industry. The solution set improves the quality and integrity of pipeline repairs with a cost effective system, that out performs mechanical welding and composite wraps. “Whitey” started his pipeline career in 1955 as a welder’s helper. In a very short time he moved up in the ranks to become an accomplished welder, foreman and pipeline repair solutions pioneer. As “Whitey” worked as a “pipeliner” he always believed there was a better solution to be found to repair pipeline anomalies. He observed the limitations of mechanical welding and composite wraps which caused him to develop the Composi-Sleeve™ and Ultra-Wrap™ pipeline repair systems.
Ryan LaVergne
Director of Technology
Ryan LaVergne is South East Texas native from “The Groves”. Ryan studied Mechanical Engineering at the University of Houston. Ryan spent the previous ten years at Stress Engineering Services Houston, with the last six with their pipeline division under the direction of Dr. Chris Alexander. He was intimately involved in the testing of many different types of scenarios that concentrated on composite repair systems. Ryan has refocused his efforts in the past year, from full scale destructive (pipeline) testing to designs to insure against full scale destruction. Ryan is charged with the responsibility of overseeing the designs of our repair systems, as well as quality assurance and control of all products that Western Specialties has.
Technology, Quality Assurance and Operations
Carl “Whitey” Brooks
Sr. Vice President, Inventor of Composi-Sleeve™ and Ultra-Wrap™
Email: cbrooks@westernspecialtiesllc.com
Cell: (916) 870-8425
Ryan LaVergne
Director of Technology
Email: ryan.lavergne@westernspecialtiesllc.com
Cell: (713) 899-3975