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Timberline Repair Tool for Damaged PE Pipe

Timberline Repair Tool for Damaged PE Pipe. NW Natural Timberline Product Demonstration September 18, 2009 Portland, OR. Agenda for Meeting. 10:00 – 10:15 Meet & Greet 10:15 – 10:45 PowerPoint – History of Project 10:45 – 11:30 Repair Tool Demonstration

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Timberline Repair Tool for Damaged PE Pipe

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  1. Timberline Repair Tool for Damaged PE Pipe NW Natural Timberline Product Demonstration September 18, 2009 Portland, OR

  2. Agenda for Meeting 10:00 – 10:15 Meet & Greet 10:15 – 10:45 PowerPoint – History of Project 10:45 – 11:30 Repair Tool Demonstration 11:30 – 12:15 PowerPoint – Repair Process 12:15 – 13:00 Discussion/Feedback

  3. Introductions • Timberline Tool – Kalispell, MT • Oregon State University – Corvallis, OR • Ripple Marketing – Bozeman, MT • Watlow Electric Manufacturing – St. Louis, MO • Entek International – Lebanon, OR

  4. Timberline Tool • Ken Green, Chief Executive Officer • Jeanine Green, Chief Financial Officer • John Clark, Mechanical Engineer • Ripple Marketing • Kitch Walker, Marketing Consultant • Kurt Palmer, Marketing Consultant

  5. Oregon State University • Dr. Skip Rochefort, PhD, Associate Professor • Dr. Nick Wannenmacher, PhD • Kevin Harris

  6. Suppliers • Watlow Electric Manufacturing • Mark Tettambel (Kansas City Sales Office) • Seth Stewart (Product Engineer) • Bob Cameron (West Coast Office) • Entek International • Dr. Rick Pekala (VP of Research & Development) • Robert Waterhouse (……)

  7. History of Innovation • Timberline developed a revolutionary fire hoseshut-off tool for wildland firefighters • In 1989, Timberline incorporated to manufacture the firefighter’s clamp

  8. Montana Power Company needs improved squeeze tools • In 1991, Montana Power Company engineers suggested modifications to the firefighter clamp design to squeeze-off their PE gas service lines. • In 1992, the new squeeze-off tool, Topside clamp, was introduced to the natural gas industry to improve their squeeze-off operations • Vertical, top-down approach to the pipe rather than horizontal squeeze bars

  9. Topside Tools • Provides safe, reliable, quick operation without under-the-pipe excavation TC1-S for ½” – 1” PE pipe TC1-S for ½” – 2” PE pipe

  10. Natural Gas Industry needs improved keyhole tools • In 1997, the natural gas industry turned to keyhole technology to maintain & repair their pipelines • Timberline TopReach Tools fit the need for keyhole application

  11. TopReach Tools • Top-down approach to the pipe • Does not require excavation under the pipe TR150 for ½” – 1” PE pipe TR250 for ½” – 2” PE pipe

  12. DOE requests improved tools for natural gas industry • In 2002, DOE requested keyhole tools for the natural gas industry to maintain & repair large diameter PE pipe • “Top Down” approach critical

  13. TopReach Tools • Timberline partnered with DOE to develop keyhole squeeze tools • TR650 for 3”, 4”, 6” • TR270 for ½” – 2” • TR170 for ½” – 1”

  14. DOE mandates delivery reliability of natural gas • Natural gas industry needs improved tools that will ensure the safe reliable delivery of nations gas supply. • DOE solicitation for: • External method to repair natural gas pipelines • Keyhole applications

  15. Repair Tool Background • In 2003, Ken Green, Timberline Tool & Dr. Rochefort, OSU submitted a proposal to DOE/NETL to develop a new repair process for the external repair of PE pipe • DO/NETL Cooperative Agreement for R&D of new external repair method

  16. NW Natural’s Involvement • Critical Partner for Repair Tool Project • In-kind Support • Materials – Pipe for testing • Field evaluations and demonstrations • OTD Funding

  17. Research Team • Timberline Tool • Ken Green, Chief Executive Officer • Jeanine Green, Chief Financial Officer • John Clark, Mechanical Engineer • Ripple Marketing • Kitch Walker, Marketing Consultant • Kurt Palmer, Marketing Consultant

  18. Oregon State University • Principal Investigator Dr. Skip Rochefort, PhD, Associate Professor • Research Director Dr. Nick Wannenmacher, PhD • Research Associate Lyuba Kabalnova, PhD ChemE Research Team

  19. Oregon State University Masters Degrees Granted on Project • Kevin Harris, M.S. ChE 2007 • Cheryl Carbone, M.S. Materials Science 2004 • John Hunt, M.S. ChE 2003 ChemE Research Team

  20. Oregon State University • 8 Undergraduate Research Students • 6 ChE/EnvE senior projects • 19 HS students involved in summer research over 5 years ChemE Research Team

  21. Integral Suppliers • Watlow Electric Manufacturing - Provides controllers and heating element for patch • Mark Tettambel (Kansas City Sales Office) • Seth Stewart (Product Engineer) • Bob Cameron (West Coast Office) • Entek International – Provides the PE foam • Dr. Rick Pekala (VP of Research & Development) • Robert Waterhouse

  22. Technology Assessment • No method is currently available for external permanent repair of PE pipe. • Current repair methods require costly excavation, isolation and removal of damaged pipe section • Damaged section is replaced by fusing new section in place • Service is interrupted

  23. R&D for New Repair Method • Cost Shared Project: • 6 Year Project - $1.5 million • Cooperative agreement between Timberline Tool, US Department of Energy (National Energy Technology Laboratory) and Operations Technology Development • Research Team • Oregon State University, Chemical Engineering – Polymer Lab • Timberline Tool – Mechanical engineering • Field Testing Partners: • NW Natural  Sempra • SW Gas Nicor • Enbridge

  24. Results of R&D Efforts • Developed a unique mechanical tool that applies a thermo-chemical patch • Fully encapsulates pipe at site of damage • Accomplished without interrupting gas flow • Implemented under a variety of environmental conditions • Using current field technicians trained in process

  25. Repair Tool Benefits • Remote operation keeps the operator safely out of the trench • Keyhole application minimizes impact to environment and neighborhood • Time and labor savings due to reduced excavation and ease of application are significant • Maintenance and repair costs significantly lowered – estimated average savings of $2,250 per repair

  26. Repair Tool Features • Aluminum construction for high strength, light weight • Portable - requires only one person to operate • Mechanical operation for ease of use. • Curved jaw completely encapsulates the pipe & immediately stops the flow of gas • Applies a thermo-chemical patch • One tool for many diameters (2”,3”,4”,6”) • Process performed safely above the hole

  27. Repair Tool Demonstration

  28. Repair Tool Components • Ratchet handle • Handle extensions • Main assembly • Jaws with inserts for 2”, 3”, 4” & 6” PE pipe • PE composite patch with internal heater Tool Dimensions Length: 6.5 ft (2.0 m) Width: 11.0 in (28.25 cm) Weight: 53.0 lbs (24.00 kg)

  29. PE Patch Components Revolutionary Composite Patch: HDPE patch back HDPE/UHMWPE Foam HDPE mesh w/ internal heating element HDPE/UHMWPE Foam HDPE (packaging) HDPE Patch Back HDPE/UHMWPE Foam HDPE w/ Stitched Heater HDPE/UHMWPE Foam HDPE Sheet

  30. Thermo-Chemical Fusion Bond Micrograph image shows that the bond between the pipe and patch is nearly seamless Inoculating the PE foam layers with solvent

  31. Repair Process Step 1. Patch Insertion Step 2. Encapsulation

  32. Repair Process Step 4. Completed Repair Step 3. Fusion Bonding

  33. Testing on PE Pipe Quick burst, sustained pressure and accelerated age (long term) tests performed per: ASTM D 1598 ASTM D 1599 Results: Quick Burst – Passed Sustained Pressure – 200 psi > 5 months (test completed) Long Term – Passes 50 year mark & shows bond strengthens with age Quick burst test at 600 psi

  34. Benefits of Repair Process Increases operator safety – out of trench, away from hazardous situation Reduces operating costs Time & Labor Materials Excavation

  35. Solves emergency repair problems due to third party damage, etc. Solves problems with the aging PE pipe system Leaking joints Pinhole leaks Gouges & scrapes Slow crack growth New Repair Solution

  36. Reduced risk & improved safety No loss of service to customer Less repair time Repairs pipe under pressure Smaller excavation Keyhole application Substantial cost savings Repair Tool Highlights

  37. Cost Savings • Average savings per incident = $2,250 depending on the complexity • There are an estimated 150,000 incidents/year • Savings to the natural gas industry expected to be > $300M annually

  38. Discussion • Repair Tool • Keyhole Tools • Tracer Wire Tool • Other Tooling Needs

  39. Ken H. Green Timberline Tool PO Box 1328 Whitefish, MT 59937 khg@timberlinetool.com 800.735.6845

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