Nature of Defect
The 16” Seawater valve has suffered from internal corrosion. This has resulted in a severe through wall defect. The client required a composite repair to restore structural integrity and bring the line back up to its full operation design specification.
SOLUTION
Metalyte Pipeworks Technical team developed a calculated repair method using our Live leak Titan 505 system to seal the leak with our Dragon-Q-STD composite system overwrap to add integrity, part of the flange will be built up to gain as much landing area as possible using our lightweight filler. Herculyte LV will be applied as a bonding coat for our final engi-neered repair. 6 Layers of our Dragon-Q-STD composite is applied, Hardness test will be done to check for full cure.
REPAIR METHOD
A divert was attached to control the leak and divert it away from the worksite, a second leak started 10cm away from the original leak, another divert was attached to control the second leak. Steel stick was applied to make sure that the leak was fully diverted through the divert and away from the work site. Herculyte 101 was used to build up the profile of the diverts in preparation of the lightweight filler being applied. Three bolts have been encapsulated in the lightweight filler to allow a longer landing area, once cured Herculyte LV was applied to the whole pipe and the top of the flange this was left to cure overnight. 6 Layers of Dragon-Q-STD composite was applied, 6 layers of compression film was applied and this was left to cure overnight. The next day the diverts were then injected with A202 sealant, once this has cured and confirmed that the leak stop was successful, a series of hardness tests are done to make sure the composite has fully cured and that the compost is a successful repair. Red UV paint was applied as the final stage.
