SplashGard™ & A+ Wrap™ System: Corrosion & Leak Repair
Three crude oil risers located in Southeast Asia needed both corrosion and leak repair. The pipes’ OD was 10.75” with a 0.365” wall thickness and a pipe grade of X42. After removing the damaged neoprene coating from two of the three risers, extreme corrosion was found. The last riser had two pinhole leaks that required immediate repair.
Based on the extent of the defect, a design calculation package was created by the engineering team in accordance with ASME PCC-2 standards, which determined that a nine-foot linear repair with 20 layers of the SplashGard system was required. The pipe was media-blasted to near-white metal and then wiped down with acetone to remove any oil residue.
An Emergency Pipe Repair Kit (EPRK™) was required for use on the third riser to stop two active leaks. The line was pressurized, and after 30 minutes of drip-free operation, EP400 putty was applied to the repair zone to create a smooth transition. The pipe was then structurally reinforced using SplashGard to encapsulate the stop gap. SplashBond™ was used as a load transfer filler for all three risers. Two layers of SplashGard were used as a starting point, then the composite was applied using the spiral wrap method with a 50% overlap until the design requirement of 20 layers was achieved with a completed repair thickness of 0.44”.
When all 20 layers were completed, four layers of constrictor wrap were applied and perforated. The repair was left to cure for two hours and the constrictor wrap was removed. A final coating using SplashBond was applied on all three risers over the entire repair area to provide corrosion and UV protection.
A hardness test was conducted and the A+ Wrap achieved a hardness of 85 on the Shore D scale. The three lines were returned to regular operations. All three repairs were completed within four hours, which includes the two-hour set time.