NATURE OF DEFECT
Severe internal corrosion and low wall thickness were identified across multiple sections of a live refinery flare line. Initial inspection confirmed five repair locations; however, further UT readings during the works identified additional low-thickness areas requiring scope extensions.
SOLUTION
An ISO 24817 compliant composite repair system using Dragon Q-UHT was designed to restore structural integrity and maintain pressure containment.
Repairs were installed across straight pipe sections, supports and a 24” tee connection. As further low-thickness areas were identified, the repair design was extended to incorporate new sections without interrupting plant operations.
REPAIR METHOD
Pipework was mechanically prepared, cleaned and profiled prior to installation. Engineered composite wrap (typically 4–6 layers) was applied across all defect areas with additional reinforcement at supports.
Repairs were cured using heater blankets, hardness tested and coated with UV protection prior to final inspection and handover.
All seven repairs were successfully completed under live refinery conditions, restoring integrity to the flare line system without pipe replacement.
