Challenges

Through-wall defect on a critical gas line

Benefits

Rapid live repair that avoided downstream unit shutdowns

Scope

Rhokana was engaged to repair a 24” carbon steel gas line at a South African refinery following a through-wall defect. Rhokana initially stopped the leak using their strapping machine, allowing the engineered composite repair to be installed while the line remained in service.

ICR provided engineering and technical support, designing the repair for a 20-year service life, 35.5 bar design pressure and 60°C design temperature. The repair was designed to withstand the full applied load and, in the event of further corrosion, tolerate a modelled full circumferential through-wall slot measuring 1,915 mm × 15 mm.

Solution

Rhokana applied 14 layers of Technowrap™ SRS to reinforce the affected section. The repair was completed in just 15 hours while the gas line remained live.

Results