Integrity issue

A 4 inch Hi Ex foam stainless steel foam line was suffering from localised internal corrosion at a weld resulting in a small through wall defect close to a flange. It was proposed to use a Futurewrap Glass/LT composite repair to reinstate the pipework strength and provide a long term seal. Furthermore, as the repair was required to have fire performance requirements then over the composite repair a Futurewrap Fire repair was proposed.

Design 

The design of the Futurewrap repair was according to ISO 24817. The design approach was to strengthen and locally leak seal. The assumed defect size was fully circumferential of width 25 mm. The design parameters were; internal pressure 6 bar, temperature 200C, design lifetime 20 years. The repair design resulted in a thickness of 5 mm (6 layers) of Futurewrap Glass/LT composite repair with an axial length of 200 mm. 10 layers of Futurewrap Fire were applied over the repair to meet the fire performance requirement of the pipework not exceeding 9000C.

Installation

The installation steps are shown in the photographs from surface preparation through to curing of the 6 layers of the Futurewrap Glass/LT repair and 10 layers of the Futurewrap Fire repair. Full QA/QC measurements were made to demonstrate that the Futurewrap repair was applied in accordance with ISO 24817. 

Summary

A 4 inch Hi Ex foam line suffering internal corrosion was repaired using a Futurewrap Glass/LT composite repair and fire protected with a Futurewrap Fire repair.  The repair was completed within 5 days allowing the pipework to be returned to its original integrity.