UTComp Inc., based in Cambridge, Ontario, has successfully completed a comprehensive nondestructive evaluation of a phosphoric acid fiber-reinforced polymer (FRP) pipeline system for a major chemical manufacturing plant in the Middle East. The assessment was carried out to evaluate the condition of existing pipeline systems at the facility in preparation for its expansion.
The plant utilizes two phosphoric acid pipelines — one an export line and the other an emptying line — each with diameters ranging from 100-300 millimeters and spanning approximately five kilometers. These pipes transport acidic solutions from various plant sections to a port storage facility for export. The pipes, some of which have been in service since the late 1990s, are designed for operating pressures of 1,000 kPa. The plant’s daily production capacity exceeds 1,300 tonnes of phosphoric acid, used in various applications such as fertilizers, food additives, and cleaning products.
The plant operates in harsh desert coastal conditions, where extreme heat, humidity fluctuations, sand, and salt pose significant challenges to infrastructure. In this environment, FRP composite pipes provide a distinct advantage, as the material is effective in safely transporting and storing corrosive materials, where metals and alloys would typically fail or become prohibitively expensive.
However, inspecting FRP piping networks presents challenges. Traditional inspection methods, such as destructive testing and visual inspections, are often ill-suited to the needs of large-scale, in-service pipeline networks. These conventional approaches are not ideal for smaller pipe diameters or extensive pipe systems, and may require confined space entry.
This is where UTComp’s UltraAnalytix NDT system comes into play. The nondestructive, nonintrusive assessment system provides an efficient, repeatable, and scalable solution for inspecting in-service FRP pipelines, ensuring their safety and longevity. The system equips inspectors with the necessary tools to assess the Fitness for Service, gather data to calculate FRP thickness, determine corrosion barrier condition, assess percentage design stiffness (PDS), and estimate remaining service life (RSL).
For the phosphoric acid plant’s pipeline evaluation, UTComp divided the pipelines into 100-meter sections, following standard operating procedures. Ultrasonic surveys were conducted, complemented by external visual inspections to identify surface damage such as cracks, UV degradation, gouges, blisters, corrosion to supports, and the condition of flanges, nozzles, and other key components.
Results were presented in detailed Circuit Reports, summarizing the findings at each condition monitoring location (CML). The reports included ultrasonic inspection results, minimum RSL, and findings from external inspections.
The assessment revealed corrosion barrier damage, evidence of leaks, and corrosion-related damage to clamps, joints, supports, and other critical components that required repairs. However, the FRP piping systems were generally found to be in good condition, with the RSL exceeding six years for most sections of the pipeline.
UTComp’s UltraAnalytix NDT system has demonstrated its value in providing quantifiable insights into the condition of FRP pipelines, regardless of their age. This ability to monitor changes within the material’s structure over time is crucial for planning repairs and replacements.
According to UTComp, “This case study demonstrates how its UltraAnalytix NDT system provides quantifiable knowledge about the condition of FRP at any age — new or in-service — by monitoring the changes that take place within the material’s structure. These changes can be used as the basis for repair and replacement planning.”
