Challenges

0.74 mm remaining wall thickness on critical gas line

Benefits

20-year live repair protecting downstream production

Scope

In 2022, ICR’s South African partner, Rhokana, was engaged to repair a 30” carbon steel gas line at a South African refinery. The line had a remaining wall thickness of just 0.74 mm, creating an urgent integrity challenge. Failure would have required multiple downstream units to be taken out of service.

ICR provided engineering and technical support, developing a composite repair designed for a 20-year service life, with a design pressure of 47 bar and design temperature of 60°C. The repair was designed to share the load with the remaining 0.74 mm wall thickness and tolerate a localised pinhole defect.

Solution

Rhokana installed approximately 21 m of Technowrap™ SRS, applying 11 layers of composite reinforcement. The repair was completed while the gas line remained in service.

Results