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
- 21 m of severely degraded gas line reinforced
- 20-year engineered design life achieved
- Repair completed without taking the line out of service
- Downstream production disruption avoided
- Local delivery supported by ICR engineering expertise
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Challenges
- Internal erosion with significant wall loss
Benefits
- Rapid local repair supported by ICR engineering expertise
Scope
ICR’s South African partner, Rhokana, was engaged to repair a 30” T-section at a South African refinery carrying cooling water containing multiple trace elements. The carbon steel component was operating at 2 bar and 40°C and had suffered internal erosion, with a remaining wall thickness of 3.37 mm.
ICR provided engineering and technical support, developing a repair designed to withstand the full applied load and modelled against a circular 25 mm through-wall defect.
Solution
Rhokana completed the repair using eight layers of Technowrap™ 2K and high ambient resin. The composite repair was installed and completed within 10 hours before being allowed to fully cure.
Results
- Internal erosion successfully reinforced
- Full applied loads accommodated by the repair
- Repair completed within 10 hours
- System returned to service following full cure
- Local repair delivery supported by ICR engineering expertise
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Challenges
- Stress corrosion cracking with no remaining wall thickness
Benefits
- One-year life extension delivered by local, trained personnel
Scope
ICR’s South African partner, Rhokana, was engaged to repair the Stripping Column Condenser End Dome at a South African refinery. The stainless steel dome, with an outer diameter of 895 mm, had suffered stress corrosion cracking (SCC), resulting in a projected remaining wall thickness of 0 mm.
ICR provided the engineering design and technical support, developing a one-year engineered composite repair to allow the client to safely defer replacement until the following year. The repair was designed to withstand the full applied load and modelled against a through-wall defect comprising a fully circumferential slot measuring 2,812 mm × 25 mm.
Solution
Rhokana completed the repair using 10 layers of Technowrap™ 2K and high temperature resin. Heat was applied to accelerate curing, enabling the repair to be completed in just two days, with ICR providing technical oversight and support.
Results
- Through-wall defect successfully reinforced
- One-year integrity extension achieved pending replacement
- Repair completed in two days
- Repair delivered by local personnel trained in Technowrap™ composite repairs
- ICR engineering expertise combined with local technical capability
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Challenges
- Rope access
- Splashzone
- Significant corrosion
Benefits
- Completed on time and within budget
Scope
Our client identified significant corrosion affecting a 28″ conductor on its offshore asset located in the Caspian Sea, near Azerbaijan.
The client installed a large sheet of mild steel and requested ICR to secure it in place using a composite solution. However, due to the temporary sleeve, the precise condition of the conductor was uncertain.
As a precaution, contingency materials were supplied to the asset. In addition, ICR provided Technoseal™ FP to profile any holding straps that were applied to the sleeve.
Solution
Once personnel and materials were quickly mobilised to the site, our experts began applying the engineered composite repair solution to restore the integrity of the corroded area.
Our designed solution included two layers of Technowrap™ 2K, a multi-directional glass cloth, and a Splashzone epoxy resin system which effectively cures and adheres in wet or submerged conditions.
The entire scope was completed via rope access by our fully qualified technicians, and delivered in just three days.
Results
Technowrap™ proved to be a highly effective solution for this project, as our designed solution was able to be quickly installed despite the challenging offshore location and wet conditions.
This project was completed within the desired timeframe and budget, demonstrating the cost-effectiveness and efficiency of ICR’s composite repair solutions.
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Challenges
- Complex geometry
- Subsea application
- Diver applied
Benefits
- Cost-effective alternative
- Quick installation
- No shutdown
Scope
A critical defect was identified on a 48″ subsea crude oil pipeline in the Gulf region. ICR was engaged to design and execute a tailored repair solution that would maintain pipeline integrity under pressure while avoiding production shutdown.
The scope included engineering a custom clamp solution, subsea installation by trained divers, composite overwrapping, and full pressure testing to validate repair integrity.
Solution
ICR designed and implemented a custom-manufactured clamp installed over the defect, followed by an advanced Technowrap™ 2K Splashzone composite overwrap. Technowrap-trained third-party divers installed collars on either side of the clamp, with composite materials prepared topside and transferred subsea for application.
The entire operation was monitored via a live onboard video feed. The repair was engineered to retain pressure, ensure fluid containment, and allow for future pipeline purging, supporting long-term operational reliability.
Result
Pressure testing was successfully completed over a six-hour period, confirming the integrity of the repair. The complex subsea intervention was executed safely and efficiently, with the full project completed within an accelerated 10-day timeframe from mobilisation to completion.
The solution minimised production disruption, eliminated the risk of an emergency shutdown, and significantly reduced the potential for future oil spills.
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Have a question for our team? You can find out about our subsea capabilities, or get in touch, by clicking here.
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Please complete the form below, and a member of our team will be in touch as soon as possible. Alternatively, please send your enquiry directly to sales@icr-world.com.
Challenges
- Subsea application
- Diver applied
Benefits
- Cost-effective alternative
- Quick installation
- No shutdown
Scope
A critical defect was identified on a 36″ subsea crude oil riser in the Gulf region. ICR was engaged to design and implement a tailored repair solution using Technowrap™ subsea resin system.
The scope included subsea application by air divers, composite overwrapping, controlled curing, and verification of repair integrity.
Solution
The repair involved applying wet composite cloth directly onto the 36″ riser. Once applied, the system was secured with structural reinforcement to ensure adequate compression and proper adhesion to the substrate.
ICR’s Technowrap™ subsea resin system, specifically engineered to bond to metallic surfaces and cure in fully submerged conditions, was utilised.
Four layers of Technowrap™ Splashzone composite were applied within just one hour, demonstrating the system’s efficiency and suitability for rapid subsea repairs.
Result
The repair was successfully executed by air divers, highlighting the practicality and ease of application of the Technowrap™ system.
The composite was allowed to cure over approximately 36 hours, achieving full structural integrity. The solution delivered a cost-effective and durable repair, minimised operational downtime, and extended the service life of the riser. The resin’s underwater curing capability ensured reliable performance in harsh marine environments.
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For more on ICR’s subsea repairs, or to get in touch with our team, please click here.
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Challenges
- 16 internal repairs
- Significant external repair of 21,625mm circumference and 1,600mm depth
Benefits
- Two-year design life
- Cost-effective and timely
- Safe and non-intrusive
Scope
ICR was requested to restore the integrity of a corroding carbon steel firewater tank in Iraq using Technowrap™ composite repairs.
The tank was suffering from multiple through-wall defects both internally and externally. ICR was tasked with providing engineered repair solutions with a two-year design life, as well as supplying equipment and personnel to complete both the full circumference external repair and the internal reinforcement works.
Solution
After analysing the tank’s condition, operating temperature range (−6°C to 50°C), and the required two-year design life, ICR’s technical team engineered a Technowrap™ composite repair system to restore structural integrity. Materials and specialist technicians were then mobilised to site in Iraq to complete repairs.
External Repair: Surface preparation was carried out using grit blasting prior to composite application. The repair consisted of:
- One layer of 2K glass fibre cloth
- Six layers of SRS carbon fibre cloth
- High-ambient (HA) resin system
This repair was applied around the full circumference of the tank base.
Internal Repairs: The internal through-wall defects had previously been sealed using welded steel patches. ICR was requested to reinforce these areas with composite repairs following surface preparation. The internal scope included:
- Five repair patches measuring 950 mm × 500 mm applied to the tank base
- One continuous repair measuring 21,000 mm × 300 mm applied around the internal tank base
- Ten repair patches measuring 950 mm × 300 mm applied to vertical seam welds on the internal tank wall
All internal repairs utilised the same composite system as the external repair.
Results
The project was completed within the agreed budget and schedule. With the large number of defects requiring remediation, the use of Technowrap™ composite repairs proved to be more cost-effective and significantly faster to implement than traditional replacement or hot-work repair methods.
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Challenges
- Multiple repairs with different geometries
Benefits
- Cost-effective
- Quick installation
- No hot work
- Completely engineered repair
Scope
A multinational oil and gas company engaged ICR to deliver multiple composite repairs aboard one of its major LNG carriers. Located in Doha – Qatar, the tanker featured carbon steel ballast water lines that had developed through-wall defects as a result of corrosion.
After assessing the asset condition, including defect dimensions, pipe geometry, operating pressure, temperature and coating condition, ICR engineered Technowrap™ composite repair solutions to restore the structural integrity of the ballast water system with a design life of 10 years.
Once the repair design was approved, we quickly mobilised personnel and materials to the vessel.
Solution
The first repair location, situated on a valve within the ballast line, required full encapsulation using eight layers of our Technowrap™ composite system incorporating our High Ambient (HA) resin.
The second repair location on the main line required an eight-layer patch repair to address a through-wall defect on a 24″ carbon steel section.
Following surface preparation at each defect location, our technicians systematically applied the composite layers according to the engineered design. Final QA/QC checks, including visual inspection and hardness testing, were performed to verify the quality and integrity of each repair before demobilisation.
Results
Despite the need for two different repair types, complete valve encapsulation and a patch repair, ICR’s team successfully engineered, mobilised, and delivered the repairs within the customer’s required timeframe and budget.
A seamless project from start to finish, ICR has since continued to support this client with further composite repairs across its major assets.
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This is just one of the composite repair scopes that ICR has delivered in the Middle East. To find out more, or to get in touch with our team, please click here.
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Please complete the form below, and a member of our team will be in touch as soon as possible. Alternatively, please send your enquiry directly to sales@icr-world.com.
Challenges
- Challenging geometry
Benefits
- Cost-effective
- Quick installation
- No hot work
- Completely engineered repair
Scope
An international shipping company contacted ICR to provide an engineered composite repair solution for its specialised reefer vessel, which was recently operating in Netherlands.
The vessel featured a 10” carbon steel cross-over pipe located in the engine room floorplate, which was suffering from a through-wall defect caused by internal corrosion.
ICR engineered a single composite repair solution to restore the integrity of the line, designed to provide a service life of 10 years.
Solution
After reviewing the conditions of the cross-over pipe, including defect size, tee geometry, temperature, pressure, and other factors, our team determined that 14 layers of our 2K cloth and Low Temperature (LT) resin system would effectively restore the line.
Personnel and materials were quickly mobilised to the site, and surface preparation was completed via bristle blasting.
Our technicians then applied the layers before completing final QA/QC checks to verify the integrity of the cross-over pipe.
Results
The defect was fully resolved, achieving the targeted 10-year design life. This repair provided a quick, cost-effective solution and showcased the capabilities of Technowrap™, even despite the challenging geometry.
Contact Us
If you would like to learn more about Technowrap™ Composite Repairs and our capabilities in the Netherlands, please contact our Key Account Manager, Ryan Crabb (ryan.crabb@icr-world.com).
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Challenges
- Multiple significant defects
Benefits
- Cost-effective
- Quick installation
- No hot work
- Completely engineered repairs
Scope
A leading multinational energy and petrochemical company engaged ICR to restore several corroded I-beams using Technowrap™ engineered composite repairs.
Located offshore Malaysia, the asset featured six carbon steel I-beams suffering from corrosion, with an average remaining steel thickness ranging from 0.1 mm to 1 mm.
The customer requested that ICR restore the load bearing capacity of the I-beams with engineered repairs designed for a 20-year service life.
Solution
After analysing the corroded I-beams, ICR’s technical team determined that a Technowrap™ solution comprising two to four layers of 2K glass fibre cloth with High Ambient (HA) resin would effectively repair each defect and ensure a 20-year design life.
In conjunction with a local partner, highly experienced technicians and materials were mobilised to the asset to install the engineered repairs which were completed with minimal disruption, ensuring no production downtime.
Final QA/QC inspections were completed on each repair, verifying the quality of every Technowrap™ installation.
Results
This project highlighted the speed, versatility, and reliability of Technowrap™. Despite significant defect sizes, all repairs were successfully restored to achieve a 20-year design life.
As a safer and more cost-effective alternative to steel replacement, we look forward to helping more customers across Asia adopt this technology in their operations.
Contact ICR Today
Please complete the form below, and a member of our team will be in touch as soon as possible. Alternatively, please send your enquiry directly to sales@icr-world.com.