06:08 - metalyte pipeworks · 2015-12-11 · could provide a composite solution based on asme ppc-2...

Case History

Case History

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PIPE INTEGRITY AND LEAK REPAIR

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www.metalytepipeworks.comwww.metalytepipeworks.com

www.metalytepipeworks.comMetalyte Pipeworks Riverside Industrial Estate, Fazeley, Tamworth, StaffsB78 3RW.

The Problem:During inspection an engineer noted deep pitting on the top side of the pipe to a depth of 8mm. Thenominal pipe thickness was 9.5mm leaving a remaining wall thickness of 1.5mm, this was deemed,“not suitable” for service and recorded with the recommendation that the defective section shouldbe replaced within a calendar month. The wall loss through external corrosion covered an area of152mm by 304mm.The repair was safety critical and would close the site if a solution was not found. Client required animmediate solution with a 20 year design life. The effluent line carrying oily water would be difficultto replace without effecting process.

The Solution:The following narrative and photographs show how Metalyte Pipeworks, mobilised, engineeredand completed the repair within 10 days of the initial inspection.

Effluent Treatment Interceptor Pipework Repair

Case History

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Effluent Treatment Interceptor Pipework RepairEngineering InformationOD 24”Schd: 40 - 9.52mmDesign temperature: 50°COperating Temperature: 35°COperating Pressure: 4.80 BargDesign Pressure: 10.20 BargMaterial: CSRemaining wall thickness: Assumed worst case scenario 1.5mm (remaining strength of steelneglected in calculation as added safety factor)Nature of defect: Wall loss due to external corrosion, pitting over area 152mm linear, 304mmcircumferential.Repair design life: 20 years

Engineering reports and CalculationsAs soon as the client had provided the necessary line design conditions, Metalyte Pipeworks could provide a composite solution based on ASME PPC-2 with a 20 year design life. Immediately the full engineering report, repair design calculations and method of the repair wereapproved a specialised Metalyte Pipeworks team left for site.

Safety and RiskA method of safe working was agreed with site management. RAM’s were prepared and all aspectsof the site management ’s PTW are understood and complied with before work commenced.

Surface preparationThe surface area to be repaired was prepared with an MBX machine over 20 linear inches.




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Case History

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Method of repairStage 1:The surface pitting was repaired with Syntho Epoxy High Compression, which reformedthe geometry of line.


Syntho Epoxy HC

Stage 2:The collar of the shoulder was faired into the line with Steel Stik epoxy.




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Method of repairStage 3: 1mm of Sub Sea LV Kevlar reinforced epoxy was applied to 20 inches of line with the defect in the centre.


Stage 5: 2 layers of the Syntho Glass XT were installed on to the part cured Sub Sea LV Kevlar reinforced epoxy then immediately covered in a further 4 layers of Viper carbon fibre compositesystem.

Viper SkinSyntho Glass XT




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Metalyte Pipeworks: Unit M, Riverside Industrial Estate, Fazeley,Tamworth, Staffs B78 3RW. Telephone 01827 283322 Fax 01827 250143

For full factor engineering calculations, consultations and support...Call our Metalyte Pipeworks Technical Advisors on 0800 121 7777

Case History

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TestingThe completed repair was overwrapped with 6 layers of compression film and perforated to allowthe trapped gases to escape. After cure the compression film was removed and Shore D hardnessreadings were taken and recorded in the quality assurance documents.


Protection, coatings and completion of the repairTo add further protection and also to highlight the repair area, the finished repair was coated with twocoats of two pack epoxy red. The line was returned to full service 24 hours from the start of the repair process.

06:08 - metalyte pipeworks · 2015-12-11 · could provide a composite solution based on asme ppc-2...

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