Live Pipe Leak Seal & Composite Wrap

The challenge

A process line developed a weeping leak after corrosion thinned the pipe wall over a run of the pipe. Lost wall thickness reduces the integrity of the section and the leak puts product and people at risk. Welding a clamp or replacing the spool means hot work and, in most cases, a shutdown, both of which the plant wanted to avoid. The line needed to stay in service while the repair was made.

Our approach

We seal the active leak on the live line, then prepare the corroded run and build an engineered composite wrap over it. We design the wrap to recognized composite-repair standards, ISO 24817 and ASME PCC-2, so the repaired section is reinforced to a defined case. The work uses no welding, and in many cases we complete it while the line stays in service.

1. Assess and designWe inspect the leak and the run of lost wall thickness and design the composite wrap to ISO 24817 / ASME PCC-2 for the line conditions.
2. Seal the live leakWe stop the active weep on the line so the surface can be prepared and the wrap can cure.
3. Surface preparationWe clean and roughen the pipe over the degraded section to give the composite a sound surface to bond to.
4. Install the composite wrapWe build up the engineered SuperWrap II layers over the prepared run to reinforce the thinned section, with no welding required.
5. Cure and return to serviceWe let the wrap cure and inspect the finished repair, keeping the line in service through the work where conditions allow.