Date	Client	Location
August 2019	Major North Sea Operator	Onshore Aberdeen

Scope

ICR were engaged to provide a engineered composite repair solution on a produced water caisson prior to installation offshore. The previous caisson was corroded due to wave action causing thermal cycling.

Solution

Two new sections of a 12” caisson were fabricated and sprayed with an internal coating prior to ICR applying the composite solution. It was a design requirement that surface preparation to Sa2.5 and was achieved prior to the application of 4 layers of Technowrap™ 2K using HT (High Teemperature) resin.

These were then welded together and an angular profile of 45μ was achieved using bristle blasters. A composite wrap was then applied to cover the welded section. Heat blankets were used througout the process to assist curing.

Design Temperature	100°C
Design Pressure	2.5bar
Material Grade	Super Duplex
Surface Preparation	Sa2.5

The change in temperature was taken into consideration by derating the allowable strains in line with ISO 24817.

Results & Benefits

ICR technicians worked day and night for a total of 7 days to complete the repair
A repair lifetime of 20 years was given
The solution will prevent future corrosion due to thermal cycling, maintaining the integrity of the structure