Veracruz, Mexico
36" Flare Pipeline Repair with External and Internal Corrosion using FormaShield® System

Members of our Milliken Pipe Wrap team traveled to Veracruz, Mexico, to utilize our FormaShield system by repairing both internal and external corrosion defects on a flare line in mid-July 2017. Read on to see how. 

Project Overview:

A damaged flare line had both internal and external corrosion defects, which called for a 10-foot FormaShield repair. The line has a 36" OD, with a wall thickness of .375" and a pipe grade of API 30,000. The MAOP is 150 PSI, with an operating pressure of 14 PSI. 

Repair Solution:

Using the defect and pipe information, a design package was created in accordance with ASME PCC-2 standards. The design required four layers of FormaShield over a 10-foot repair zone. The pipe was first prepared to near-white metal (NACE 3) using mechanical hand tools and cleaned with acetone to remove any oil residue. A EP420 filler application created a smooth transition on weld seams and the general corrosion areas. Once the EP420 had cured, PPR-adhesive primer was applied to the entire repair zone to prevent any moisture ingress. Four layers of FormaShield were applied as the structural reinforcement, using the "layer over layer with an offset" method. The final repair thickness was 0.132". Peel ply was applied as the final step, to compact the repair while it cured and avoid any contaminants. The repair was left to cure for two hours, then the peel ply was removed and a final coating was applied over the entire repair for corrosion and UV protection.


The repair was a success; the pipeline was never taken out of service, which allowed the customer to operate safely and continue with production. Installation was completed within five hours, including the two hours of setting time. Finally, a Shore D hardness test was conducted, which received an 85 value. 

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