A new technology for external rehabilitation of pipelines, known as XHab™, has been developed. This method involves wrapping multiple layers of ultra-high strength steel strip (UHSS) in a helical form continuously over an extended length of pipeline using a dedicated forming and wrapping machine. The reinforcement afforded by the strip can be used to bring a defective section of pipe (e.g. externally corroded or dented) back to its original allowable operating conditions, or even to increase the allowable operating pressure if the desired operating conditions exceed the original pipeline design limits. This paper describes the full scale burst testing and analysis of defective pipes which have been repaired using the XHab process. The full scale test sections are 30 × 0.5 API 5L X52 DSAW pipe and include the following specimens: • Bare pipe with no defects; • Bare pipe with single machined defect; • Wrapped pipe with single machined defect and designed reinforcement; • Wrapped pipe with single machined defect and insufficient reinforcement; • Wrapped pipe with interacting defect array and designed reinforcement. The above full scale burst tests are supplemented by FEA models using ABAQUS. The material models for the steel pipe, UHSS strip, defect patch material and strip adhesive are based on measured data from the batch tests and tuned against the control burst test results. The structural behavior in the individual metallic and non-metallic elements can therefore be examined more closely, particularly in the region of the defect and where the wrapped strip crosses seam and girth welds.

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