Client challenge

Our client who is based in the Middle East, commissioned our team to help repair their 32” produced water line, which showed substantial internal erosion and corrosion, resulting in a minimal remaining wall thickness of only 4mm. The repair was going to cover around 550 meters of pipeline and included multiple saddle supports, with some requiring welding. Additionally, our client specified the requirement for a qualification test to validate the proposed repair solution, and we had to conduct this test on-site before proceeding with the actual repair work.

What we did

Our solution began by defining a comprehensive scope of work, which included engineering an innovative design to ensure a 20-year repair lifetime. This encompassed providing trained personnel and the necessary materials, specifically Technowrap™ 2K with Technowrap™ HP PRS, to execute the repair. The line’s design parameters included a pressure of 47 bar g and a temperature of 82ºC. We meticulously developed an installation procedure for the composite repair, which was thoroughly tested and approved by the client before on-site installation. To ensure complete encapsulation of the pipeline, we also devised a detailed lifting plan for the pipeline over the supports. This plan addressed additional requirements, including applying the repair in areas where the pipework rested on the pipe supports.

Results

The execution of the qualification test was a resounding success, meeting the client’s approval and verifying the effectiveness of the repair solution. The repair was installed, confidently meeting the design pressure of 47 bar g and operating within the specified temperature range of 82ºC. Our detailed lifting plan was meticulously executed, ensuring the complete encapsulation of the pipeline. This case study showcases our dedication to delivering reliable and enduring solutions, providing clients with the confidence to address complex challenges in maintaining critical infrastructure.