SBIR-STTR Award

This Small Business Innovation Research Phase I project will investigate the incorporation of carbon nanotubes (CNTs) into the cross-section of fiber reinforced polymer composite (FRPC) laminates used for the repair of oil and gas pipelines. The effects of the addition of CNTs will be improved creep-fatigue strength and life at operational temperatures. Previous research indicates that fatigue failure within composite materials initiates at the fiber?matrix resin interface due to limitations in the physical properties of the resin and its inability to chemically bond with the fiber. Incorporating functionalized CNTs within the interfacial bondline region provides a chemical reinforcement to delay this initiation of failure, resulting in improved tensile strength and stiffness, and most significantly, an increase in fatigue life. The Phase I research will test and optimize a method for CNT incorporation, and will perform mechanical, electrical, and thermal characterization of the resultant material. It is also anticipated that the resulting material may also exhibit enhanced thermal and electrical conductivity, leading to secondary benefits for pipeline applications. The broader impact/commercial potential of this project will be the development of a cost-effective, easy-to-install, in-situ composite product for pipeline repair, with an operational design life of over 50 years. The anticipated result of this project will lead to a new and transformative composite material technology for the use in pipeline repair and for other civil infrastructure applications. The significance of the development of high-strength and durable fiber reinforced polymer composite (FRPC) wraps based on nanomaterials, for applications in repair and rehabilitation of oil and gas piping and other civil infrastructure systems is fourfold. First, the new product will result in direct sales revenues of the resulting material, creating manufacturing jobs in the US. Secondly, efficient and economical methods to repair oil and gas piping systems will have a significant broader benefit for the world?s energy infrastructure. Thirdly, costs related to demolition of old pipelines and new pipeline construction will be reduced. Finally, the expansion of scientific knowledge expected during the development of this emerging nanotechnology will drive further research and innovation in this key area of technology

This Small Business Innovation Research (SBIR) Phase II project will continue the development, validation, and full-scale testing of a new patent-pending nanoparticle-reinforced composite product for the repair and rehabilitation of piping and other civil infrastructure systems. The overarching goal of the research is to develop and demonstrate a composite system that can be used to repair pipes without requiring expensive, and sometimes dangerous, cutout and repair of pipe sections, while also meeting Department of Transportation (DOT) requirements to qualify it as a permanent rather than temporary repair. In order to meet these requirements, a composite wrap system is needed with fatigue properties that are much better than current systems. Test results obtained in Phase I demonstrate that the fatigue resistance of our new nanoparticle-reinforced composite repair system outperforms traditional pipeline repair composite materials currently on the market. The specific goals of Phase II will be: 1) validation of initial results from Phase I; 2) extension of property testing to prepare for full-scale testing under American Society of Mechanical Engineers (ASME) PCC-2 requirements; 3) design of a manufacturing machine to produce the new composite product and 4) completion of full-scale testing to prove compliance with DOT regulations. The broader impact/commercial potential of this project will be to significantly improve the safety and reduce costs for repair of DOT-regulated and industrial pipelines through the development of a high-strength, fatigue- and corrosion-resistant pipe repair system with a design life over 50 years. There were 6,042 "significant incidents" related to pipeline damage from 1988 to 2008, resulting in 427 fatalities, 1,805 injuries and property damage totaling $3.8 billion. Composite repair products currently used to prevent pipeline failures are economical, easy to apply, and can be used to repair other civil infrastructures such as bridge columns and piers. However, current composite repair systems for pipelines qualify only as a temporary repair due to their susceptibility to fatigue, and therefore require eventual replacement via cut-out. Development of a composite wrap system that qualifies as a permanent repair would have a transformational impact on the pipeline industry, placing the commercial potential of this product at $50-100 million, even with a relatively small market share. In addition, with the availability of stronger and less expensive field repairs, pipeline companies are likely to become more proactive with their composite repair programs, resulting in an overall reduction in catastrophic failures and incidents.