NATURE OF DEFECT
Internal Cement lining of a 40” Carbon steel sea water pipeline, had worn off due to which the client faced multiple pin holes and wall thinning from up to 80% of original wall thickness.The client had initially welded steel plates over defects to improve integrity but that was not sufficient. Metalyte Pipeworks was requested to find a solution to offer guaranteed design life of 3 years until next shutdown.
SOLUTION
Metalyte Pipeworks produced a repair method using Herculyte leak seal system & TITAN leak seal system to successfully arrest all pin hole leaks and further reinforced the repair with Herculyte resins and with 20+ layers of the Dragon UHT composite system, to offer the 3-year design life.
REPAIR METHOD
Metalyte team applied Herculyte leak seal system to stop the major pin hole and then our TITAN high-tensile injectable system was applied to arrest the other pin holes live. Once the leaks were stopped, the surface was prepared using MBX tool to gain a surface profile to SSP.SP11, followed by which Herculyte resins were applied to reinforce the surface, and increase wall thickness. Flanges was profiled using Metalyte’s Light weight filler materials to offer smooth surface. 500 microns of Dragon resin was applied as a bonding coat followed by which the repair area was wrapped in 20 layers of Engineered Dragon Q-UHT composite and then allowed to cure until a minimum of 74.5 Shore D hardness was achieved.
Total repair length was 1.6 meters.
