Case Study-R12 12

General Case Studies
Pipe Wrap, LLC

15832 W est Hardy Rd.
Suite 600
Houston, TX 77060
Tel: 281-999-7100
USA
www.piperepair.net
Case Study # 1- 16" Gas Transmission Line

A+ Wrap Repair
South Texas - USA
Project Overview
External corrosion on a 16 OD, API-5LX-42
cross country pipeline having 57% wall loss
within 4 foot wide region. Original pipe wall
was 0.281" and an MAOP of 1,062 psi
The Solution
Design a 20 year repair utilizing the A+ Wrap
System to restore the structural integrity of
the line back to pristine conditions.
Repair Method
Remove tape coating and sand blast to a NACE
#3 finish. The first step of repair is to fill the
anomaly with a load transfer epoxy putty.
Apply a corrosion barrier epoxy to the entire
repair zone prior to wrapping with A+ Wrap
using the cigar wrap method. Apply the
material until the calculated layers have been
achieved. Constrict and perforate, then allow
to cure for 2 hours. Top coat as applicable,
then back-fill.
Case Study #2- Sub Sea Level Bayou Repair

Damaged Gas Transmission Line
Louisiana, USA
OVERVIEW:
A 22 gas transmission pipeline12 below
sea level in a bayou, had been hit by a boat
anchor and required structural repair.
Coffer dam built to expose
damaged pipe
THE PROBLEM:
The pipeline (at 750 psi) needed to be exposed
for the repair. The anomaly was 4.36 and wall
loss was approximately 45%.
THE SOLUTION:
A coffer dam was built and the water was
pumped out before digging down to
expose dented pipe. A+ Wrap System
was applied, then top coated and pipe was
reburied.
Wrapping 3 foot of pipe
Pipe ready for topcoat
View of Constrictor Wrap
Case Study # 3- 16" Field Bend Repair Gas Transmission Line

A+ Wrap System
South Texas - USA
Project Overview
A Field Bend had external corrosion at the 6 - 9
O'Clock positions on a 16 OD, API-5LX-42 cross
country pipeline. The repair area encompassed a
9 Ft section having 62% wall loss. Original pipe
wall was 0.281" and an MAOP of 1,062 psi
The Solution
Design a 20 year repair utilizing the A+ Wrap
System to restore the structural integrity of the
line back to pristine conditions. The repair
required 18 layers (0.396" composite thickness).
Repair Method
Prep the pipe by removing any soft coating and
sand blast to a minimum of NACE #3 finish. Fill
the anomalies with a load transfer epoxy putty.
Apply a corrosion barrier epoxy to the entire
repair zone prior to wrapping with A+ Wrap
using the spiral wrap method. Apply the material
until the calculated layers have been achieved.
Constrict and perforate, then allow to cure for 2
hours. Top coat as applicable, then back-fill.
Case Study # 4- Oil Rig Caisson Repair

Offshore Oil Rig 24
Caisson Repair
Gulf of Mexico, USA
THE PROBLEM:
Dented caisson prevented proper operation and access
to pumping unit located within.
THE SOLUTION:
1. Abrade the caisson leg with sand
blasting.
2. Secure 24" dia x 180 deg x 36" long
FRP Sleeve with 12 bands.
(Note: The FRP Sleeve to be gasketed with
nitrile).
3. Apply EP-193 to create transitions around the FRP
Sleeve
4. Apply SplashBond all around the caisson .
5. Apply 6 layers of A+ W rap
(To extend 1 ft beyond both edges of the
sleeve).
6. Apply 6 layers of Pipe W rap (also has the 1 ft
extension).
7. Apply SplashBond over entire repair area.
Case Study #4-Oil Rig Caisson Repair

Offshore Oil Rig 24
Caisson Repair
Gulf of Mexico, USA
SWLP-B Caisson Current State: Front View
Dented Area (Area of

maximum curvature
change)
Case Study #4-Oil Rig Caisson Repair

Offshore Oil Rig 24
Caisson Repair
Gulf of Mexico, USA
SWLP-B Caisson Current State: Front View
Case Study #5 Riser Repair Offshore Platform

Production Platform
Offshore Eastern Canada
OVERVIEW:
A 3 MEG line with various
configurations needed coating
replacement.
THE PROBLEM:
Several areas including an elbow
where epoxy coating
was
corroding , system operating at
73C.
THE SOLUTION:
Pipe was sandblasted to near
white metal.
GenWrap polyolefinic corrosive
inhibitive under wrap was cut to
size to form over damaged
areas, then overwrapped with
MCU outer wrap for containment
and mechanical protection.
Preparing corroded elbow

repair zone
Applying GenWrap Overwrap
Case Study # 6 - Gouge Repairs at a Gas Plant

A+ Wrap System - Mechanical Damage
North Texas - USA
Project Overview
During the excavation of an area within the Gas
Processing Plant, a backhoe struck two (2) 8"
process lines located adjacently within 4 feet of
each other. The 3rd Party mechanical damage
occurred during preparation for installation of
an additional process line that was to run
perpendicular to the damaged lines.
Dig
Di site - Gas Plant
Both pipes were 8" pipe, API-5LX-46, 0.344"

wall and operating at 860 psi. The resultant
damage was a 0.4" wide x 8" long gouge with
40% wall loss on one pipe section and a 0.12"
wide x 1" long gouge with 35% wall loss on the
other pipe section.
The Solution
The A+ Wrap System was the selected material
of choice due to its ease of application and
structural strength. Based on the parameters
provided by the customer, a 12 layer (0.265"
material thickness) design was indicated to
ensure the continued integrity of the lines.
Distance between pipe sections
Inspection of the lines via Dye Penetrant Testing

verified that "no cracks" existed in the damaged
areas. An important requirement was stipulated
for preparation of the gouged areas and that
was the removal of all sharp edges to ensure the
elimination of potential stress concentrations.
Additionally, because the pipe coating was
fusion bonded epoxy, sandblasting was not
required. Abrading the existing coating with
sandpaper is sufficient.
View of 0.4" wide x 8" long gouge
Case Study # 6 - Cont.

Repair Method
Whenever mechanical damage occurs, the line
must be checked to ensure there are no cracks.
Once this is confirmed, the primary task in
preparing to repair a gouge type defect is to
remove "all sharp edges".
The pipe is coated with FBE, so the repair zone
only requires lightly abrading the surface with
24-80 grit sandpaper. Fill the anomalies with a
load transfer epoxy putty. Apply a corrosion
barrier epoxy to the entire repair zone prior to
wrapping with A+ Wrap using the spiral wrap
method. Apply the material until the calculated
layers have been achieved. Constrict and
perforate, then allow to cure for 2 hours. Top
coat as applicable, then back-fill.
View of 0.1" wide x 1" long gouge
Removing "sharp edges"
Abraded surface ready for putty
Putty applied to gouge
Applying primer to pipe
Continue applying primer
Repairs constrictor wrapped
Repairs curing for 2 hours
Ready to be back-fill
Case Study # 7- 14" Natural Gas Transmission Pipeline

A+ Wrap Repair
Victoria, Texas - USA
Project Overview
A large rehabilitation project by an Interstate Gas
Transmission company encompassed twenty-six
(26) miles of 14 Diameter pipe. The line had
been assessed by a High Resolution MFL
(Magnetic Flux Leakage) In-Line Inspection Tool.
The survey results indicated multiple regions with
sections having general corrosion anomalies
ranging from 35-65%.
Measuring the repair zone
The Gas Transmission Company worked closely

with PWLLC by providing the pigging log and
having PWLLC analyze the respective repair
zones to determine the amount of A+ Wrap
required to restore full structural integrity of the
line.
The pipe grade was an API-5LX-42,
schedule 30 (0.375" original wall). Since it was a
Class 1 line, it had 1,620 psi.
The Solution
Based on the analysis conducted by PWLLC, the
repairs ranged from 14 layers (0.308" of material
thickness) for 35% wall loss to 26 layers (0.572" of
material thickness) for the 65% wall loss
conditions. The design is to provide a minimum of
a 20 year service in accordance with ASME PCC2 Standards.
To simplify things for the installation crews,
PWLLC provided the A+ Wrap System in kits for
the respective repair zones. This additional effort
enabled the installation crews to focus just on the
material application by removing the necessity for
individual layer counting.
Pipe surface before prep
After Sandblast to NACE 3
Case Study # 7- Cont.
Repair Method
Apply a corrosion barrier epoxy to the entire repair
zone prior to wrapping with A+ Wrap using the
spiral wrap method. Apply the material until the
calculated layers have been achieved. Constrict
and perforate, then allow to cure for 2 hours. Top
"Marking" the repair zone
Applying Load Transfer Putty
Primer Application
Encapsulating ILI Marker
Begin applying A+ Wrap
Case Study # 7- Cont.
Spray & apply with 50% overlap
Begin constrictor wrap
"Lightly" perforate constrictor
Complete application
Pull constrictor tightly
Ready to rebury
Case Study # 8 - 24" Flare Line Repair

A+ Wrap Repair
Tennessee - USA
Project Overview
A 24" O.D. AISI-106-B carbon steel Flare line
having both external and internal wall loss for a
total two hundred and twenty seven (227 ft) foot
section required structural reinforcement. The
line had a combined wall loss of 54% with an
original wall thickness of 0.375". The medium in
the line was dilute HF and propane having an
operating pressure of 285 psi.
The Solution
Based on the analysis conducted by PWLLC, the
repair required 12 layers (0.264" of material
thickness) of A+ Wrap to store the structural
integrity back to its pristine conditions. The
solution was deemed as a temporary repair as per
the ASME Standards. The design provided a 5
year service life.
View Elbow Transition
The complete repair from surface prep to final

wrap was accomplished in 21 days without
interruption of the refineries process.
Repair Method
Prep the pipe by hand tools to remove any soft
coating and etch the surface with 24 grit sanding
pads. Fill the anomalies with a load transfer
epoxy putty. Apply a corrosion barrier epoxy to
the entire repair zone prior to wrapping with A+
Wrap using the spiral wrap method. Apply the
achieved. Constrict and perforate, then allow to
cure for 2 hours. Top coat edges of the repair to
add additional protection from potential moisture
ingress.
Repaired Branch Connection
Wide View of Entire Repair
Case Study # 9 - 54" Municipal Water Line

A+ Wrap Repair
San Juan, Puerto Rico - USA Territory
Project Overview
An underground 54" O.D. Grade B main water
feed line located in a concrete access tunnel had
extensive external corrosion due to constant
moisture droplets from the ceiling of the tunnel.
The line is direct fed from a Reservoir Dam and is
supported by 10 inch high concrete saddles
located approximately every 30 feet.
The 0.500" original wall had degraded by 50%.
The line operates at 55 psi in ambient
temperature. The designed repair required 26
layers (0.572" material thickness) of A+ Wrap
to restore structural integrity to a 392 foot long
section..
View of pipe towards the Dam
The Solution
Due to the restricted access of the lower half of
the pipe caused from the concrete saddles, it
required specifying the roll size of the A+ Wrap
to be 12" x 60 ft material. This particular size had
a diametric measurement sufficient for work
space. The A+ Wrap was selected because of
it performance capabilities on wet surfaces.
View of pipe towards the exit
The repair approach was to reinforce the sections

between the concrete saddles, then lift the pipe
(after materials were properly cured) and apply
the materials to the saddle support areas.
The entire repair from surface prep to final wrap
was completed in 20 days.
Repair Method
Prep the pipe by hand tools and sandblasting to
remove any soft coating and etch the surface with
24 grit sanding pads. Fill the anomalies with a
load transfer epoxy putty.
Preparing to prep the pipe
Case Study # 9 - cont.

Repair Method - cont
coat edges of the repair to add additional
protection from potential moisture ingress.
Applying putty
Applying primer
Applying A+ Wrap
Primer to larger area
Continue wrapping
Completed repair
Case Study # 10 - 8" Riser Repair - Soil to Air Interface

SplashGard Repair
Bakersfield, California - USA
Project Overview
An 8" O.D. riser at a meter station within a gas
plant had localized external corrosion at the "soil
to air interface" which is a common occurrence
due to the "wet-dry" conditions that the area is
exposed to during seasonal changes.
The external wall loss was minimal (less than
20% of original wall) and only required re-coating.
The SplashGard pipe protection system was
selected because this system was originally
designed for "wet-dry" conditions within the
splash zone area of off-shore platform risers.
Prepped repair zone
The Solution
Due to the minimal wall loss, no structural
reinforcement was required thus SplashWrap I
was selected as the over-wrap material. The
repair consisted of 2 ft above and below transition
zone. The intended service life was a minimum of
5 years.
Repair Method
Applying SplashBond
Prep the pipe by hand tools to remove any soft

coating and etch the surface with 24 grit sanding
pads. Fill the anomalies with a load transfer
epoxy putty. Apply the SplashBond corrosion
barrier epoxy to the entire repair zone prior to
wrapping with SplashWrap. Allow to cure for 2
hours, then top coat with SplashBond.
Over-wrapped
Completed repair
Case Study # 11 - Corrosion Under Insulation Repair

GenWrap Repair
Boston, Massachusetts - USA
Project Overview
Various piping sections developed Corrosion
Under Insulation (CUI) due to trapped moisture
within the insulating material around the pipe.
Although the corrosion appeared to be
aggressive, once the insulation was removed and
the piping surface was prepped, there was
minimal wall loss (less than 34%). Based on the
low operating pressure of the piping system (60
psi), the customer determined that only providing
a protective coating was required.
The
GenWrap System was selected because this
system prevents oxygen from reaching the pipe
surface. Without oxygen, a corrosion cell cannot
occur. This system is typically used on the top
side of off-shore platforms.
Initial view of CUI
The Solution
All the insulation to be removed from the affected
area and the surfaces to be prepped by removing
all loose scale. The GenWrap System to be
applied and extended beyond the defect area.
Repair Method
Corroded elbow - insulation

removed
Prep the pipe by hand tools to remove all rust,

scale and etch the surface with 24 grit sanding
pads. Apply the the GenWrap Underwrap and
then the GenWrap Outerwrap. Both materials
to be applied spirally in opposing directions.
Repaired Elbow section

View of repaired
reducing pipe
section
Case Study # 12 - 6" Pipe - Crevice Corrosion Repair

Pipe Sock Repair
Long Beach, California - USA
Project Overview
A common problem that occurs with supported
piping sections is the development of crevice
corrosion at the interface of the pipe and the
support. This problem manifests itself from the
relative movement of the pipe in relation to the
support thus abrading the existing coating. This
action may be cause by the physical movement
of the pipe due to "fluid hammering" or the
expansion/contraction
from
temperature
variations.
In this repair, the movement was caused by "fluid
hammer" which breached the coating under the
support and creating a pocket that collected
moisture which helped cause the corrosion cell.
For this application, the patented Pipe Sock
(Patent #US 8,087,431 B2) should solve the
problem.
Developing access under

support
The Solution
The installation of the patented Pipe Sock will
eliminate the moisture capture zone by bonding to
the pipe and creating a "watershed" along with a
wear surface that is not the pipe. Designed
service life is 10 years.
Initial positioning of Pipe Sock
Repair Method
Prep the pipe by hand tools to remove all rust,
scale and etch the surface with 24 grit sanding
pads. Attach the patented Pipe Sock to the
pipe with Black Magic polymer.
Final positioning of Pipe Sock

Close-up of
Installed Pipe Sock
Case Study # 13 - 12" Natural Gas Transmission Pipeline

A+ Wrap Repair
South Texas - USA
Project Overview
An Interstate Gas Transmission company
completed an ILI run using a High Resolution
MFL (Magnetic Flux Leakage) In-Line Inspection
Tool.
The survey results indicated multiple
regions with sections having general corrosion
anomalies ranging from 25-65%.
In working closely with PWLLC, PWLLC analyzed
the respective repair zones to determine the
amount of A+ Wrap required to restore the full
structural integrity of the line. This particular
repair was made on a 12" O.D. x 15 ft repair
section having the pipe grade as API-5LX-42,
with an original wall of 0.375". The system
design pressure was 2,470 psi with an MAOP of
1,778 psi for a Class 1 location designation.
Exposed pipe with wax coating

removed
The Solution
Designing the repair in accordance with ASME
PCC-2 & ISO 24817 resulted in 10 layer (0.22"
material thickness) design to restore the pipe back
to pristine condition. The design was based on a
20 year service life.
Sandblasting the repair zone
As part of the design approach, the repair zone
size was included and noted on the kits provided
to the installation crew. This results in assisting
the crew to focus specifically on applying the
materials and does not require them to count the
layers because by applying the materials provided
within the designated repair zone, the layer count
will come out correctly..
Measuring repair zone
Repair Method
Measuring the anomaly
Kneading the putty
Applying the primer
Completing primer application
Begin wrapping A+ Wrap and

spraying water during the
application
Complete wrapping process
Applying constrictor
Perforating the constrictor
Completed repair
Case Study #14- Underwater Repair

Underwater In-Situ SplashGard Application
Offshore Norway
THE PROBLEM:
A 6 diameter submerged pipeline20 meters below
sea level had 25 meters failed concrete coating.
THE SOLUTION:
It was necessary to clean the pipeline of loose
corrosion product. The SplashBond h a d t o
b e m i x e d topside, then placed in buckets,
brought down and applied at approximately 30 mil
thickness. The repair was completed by applying
4 layers of SplashWrap followed by a topcoat of
SplashBond.
Completed repair
Case Study #15 - Fresh Water Pump Station

Project Overview:
The Water Supplies Department in Hong Kong is
responsible for m aintaining the pipe repair work within the
district.
Water supply facilities such as, water treatm ent plants
were look ing f or new m aterial to repair and strengthen
the water pipe externally, in particular those large diam
eter pipes inside the water treatm ent work s.
Project Details:
T he sites needing reinforcement were Pum ping
Stations 1 & 2 located in Hong Kong.
Pipe Diameters ranged f rom 24 thru 54 with a total
coverage area of 190.4 square meters.
Structural Reinforc em ent f or 50 year design lif e operating at
10 bar (145 psi) was required.
The areas that needed reinforcing are highlighted in yellow
on the supplied drawings on the next pages.
For the areas of Ys, Ts and against flanges the contingenc y

was sm aller rolls sizes were used.
16
Case Study #15 - Fresh Water Pump Station

Table 1
Draw ing #1
17
Case Study #15 - Fresh Water Pump Stations

View s of Repair in Progress
Primer application for preparation

of continuing repair of Site M3
Application of A+ Wrap over the

primer undercoat
Application of A+ Wrap over

the primer undercoat
18
Case Study # 16- Fire Proofing Rural Water Line

Project Overview:
Pipeline pictured is located in Shek Kong
Hong Kong China. Due to a brush fire, the
external bitumen protection was burnt entirely.
Pipe W rap LLC was asked to provide a
replacement protective coating that would
enable the protection of the piping under the
same conditions.
Project Details:
The site is located in Shek Kong.

Each concrete pier about 16 m.
The pipeline OD is 1.2 meter. The length
(225 meter).
View of Repair Site
Solution Overview:
4 layers of A+W rap was used and covered 225 meters (738 f eet)
of 1.2 m (47.54 inch) diameter pipe.
After A+ W rap had cured (24 hours), a topically
applied intumescent Fire Resistant
coating was used to protect the pipe from future
brush fires.
View of completed Repair

4 layers of PWAP with Fire Resistant Coating
Note: View shows an individual walking a section of the line. T he dark exterior m aterial on the coating
is debris and leaves fallen f rom trees.
19
Case Study #17-Riser Splash Zone Repair

Riser Coating Repair
Mendicant Island
Louisiana , USA
OVERVIEW:
Badly corroded pipe under pier in need of coating
repair at the Splash Zone.
Pipe - 16 Diameter x .281 wall, API-5LX-42
Design Pressure = 1,475 psi; MAOP = 590 psi.
Recommended repair is the SplashGard
Coating System (a two-step corrosion barrier
system composed of an adhesive undercoating
and a fiberglass outer wrap), specifically
developed for off shore risers.
THE PROBLEM:
Repair to go 6 above barnacle line.
THE SOLUTION:
Materials needed f or wrapping the pipe with 6
layers using A+ W rap as follows:
1 each - Overwrap (4 x 50 roll)
1 each - SplashBond Epoxy Coating (2-gal kit)

1 each - EP913-2Q Epoxy Paste (2 qt kit)
2 each - AK25 Application Kits
1 each - Constrictor Wrap Small (5 x 600)
Risers were coated and wrapped using the
SplashGard Coating System (a two-step
corrosion barrier system composed of
an
adhesive under coating and a fiberglass outer
wrap), specifically developed for offshore risers.
View of completed repair using 6
layers of the SplashGard System
Case Study #18 Air Products & Chemicals

Dust Collector Structural Rehabilitation
California, USA
OVERVIEW:
Structural Repair for Dust Collector
Piping.
See piping schematics below
Client Contact:
Arun Mahabirsingh
Plant Engineer
Air Products Manufacturing Corporation
email: mahabia@airproducts.com
THE PROBLEM:
Very low efficiency of the dust collection
system due to holes and joint leakages.
Hole sizes ranged from 1 4 diameter.
Overall result: High operating costs with
minimal benefit.
Area 1 - View of Dust Collector pipe

before repair.
THE SOLUTION:
26 FRP customized leak stop sleeves
were used over each wall defect,
overwrapped with A+ Wraps and topically
coated with epoxy to provide a requested
extended life of 10 years and UV
protection.
Repair involved 171 feet of horizontal
piping including 22 elbows varying in
diameters of between 12 and 18.
Area 1 - View of Dust Collector pipe after repair.
Area 2 - View of before and after Dust Collector structural repair.
Case Study #18 - Air Products & Chemicals

California, USA
Area 3 - View of duct
before repair.
Area 3 - View of duct after using

the A+ Wrap System.
Case Study #18- Air Products & Chemicals

California, USA
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Case Study #18- Air Products & Chemicals

California, USA
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Case Study #18 - Air Products & Chemicals

California, USA
Aerial view of Facility Before
Aerial view of Facility After
Case Study # 19 Water Line Leak Repair

Combination Pipe Wrap & A+ Wrap Repair
Project Overview
12 Diameter main water line serving a
University.
The Problem
Thru-Wall crack in 12 Transite Pipe due

to lateral soil pressure.
Solution Overview
View of radial crack
Combination Composite System Repair

utilizing Epoxy Putty, Stop Gap Clamp,
Pipe Wrap and A+ W rap.
This approach contains the leak along
with providing structural integrity.
Repair Procedure
The surface was prepped. Putty was

applied to the crack to near-net
profile. The Stop Gap clamp was
installed. PPR-2 was then applied to the
surface. There were 6 layers of Pipe
Wrap applied as well as 8 layers of A+
Wrap. The constrictor wrap was applied
and allowed to cure for 2 hours.
Side view of defect
Completed Repair
Case Study #20 Penstock Pipe Repair

A+ Wrap Repair
Project Overview:
60Diameter penstock pipe with a 4 stub
out.
The Problem:
Thin wall due to corrosion, through wall
holes.
Solution Overview :
Customized leak repair made up of 5
layers designed to meet the customers
requirements f or a maximum 2 year
service lif e.
Area 1 View of 4 Stub out
before repair.
Area 2 Front View of 60 Diameter

penstock before repair.
Area 4 View of preparation of pipe by

blast cleaning.
Area 3 Side view of 4 Stub out before

repair.
Area 5 View o f fully exposed and clean 60

Diameter penstock pipe.
Case Study #20 Penstock Pipe Repair
Area 6 View of Epoxy application.
Area 7 View o f completed primer

application.
Area 8 Beginning of A+ Wrap application

on 4 Stub out.
Area 9 Near completion of A + Wrap

application.
Area 10 View of perforated constrictor

wrap.
Area 11 View of completed repair.
Case Study # 21 - Blast Furnace Cooling Water Lines

Project Overview
Leaks and thinning pipe wall on a 24 line. Severe
external corrosion had been caused by corrosive
solution dripping onto pipe surface. Concern was
greatest at four tees, where numerous leaks had
formed, the largest having been sealed with wooden
dowels. There was concern that any work on the pipe
could lead to a major rupture. The pipe was operating
at 100 psi (7bar) and 100F (40C)
View of Leaking Pipe
The Solution
Repair method comprised of sealing the leak with
expanding
polyurethane foam
and
applying
FormaShield ET (Epoxy Fiberglass) System
Repair Method
The wooden dowel was cut off
to about (5mm)
above the pipe surface. Water leaked through the split
that ran up the center of the dowel, and this was
sealed by drilling out a hole using a (5mm) bit and
then sealing this with an expanding polyurethane.
The leaking area was cleaned using grit blasting with a
low pressure system. The pin holes were sealed using
a fast-curing epoxy putty. First, small balls (5mm)
diameter of putty were rolled and pushed in the holes
and held in place until they cured. Then larger balls
(10mm) diameter were flattened over these to support
them before the whole area was covered. To do this.
The putty was mixed and held in a ball until it started to
warm from the cure. It was then spread quickly over
the area where it rapidly turned solid. Finally the area
was faired smooth using a spreadable epoxy putty.
Pipe Prep outside Defect Zone
Close-up of Putty application
The repaired area was left overnight to confirm the

putty had sealed the leaks.
Four (4) layers of FormaShield ET were then applied
over the tee. This supports the putty and bonds
strongly to the pipe, protecting it from further corrosion.
Completed Repair
Case Study #22Vessel Relief Line

4 Inch Line and Clamp Repair Using Pipe Wrap
Project Overview :
Repair of a 4 line on the outside of a natural gas storage vessel.
Included in the repair is an area under the clamp that holds the
line in place that has extensive corrosion and pin hole leaks
caused by water being trapped f or an extended period of time. Area
to be repaired will be the side of the vessel, the clamp and
the 4 inch line.
4 45 Elevated Pipe
Solution Overview :
Repair method was comprised of sealing the pin hole leaks under
the clamp and encapsulating the entire clamp using Pipe W rap. Once
this was accomplished 3 feet of 4 inch line was wrapped to prevent
any further corrosion.
Repair Method:
Repair required a technician to work from a man lift to at a
height of 45 feet. The entire area was prepped as close to
near white metal as possible and then cleaned with acetone. Once
this was accomplished the leaks were repaired using Pipe W rap
EP400 epoxy putty applied directly to the pin holes.
The two-part Epoxy Putty was kneaded until heat
began generating from the putty. This indicated that the
putty was near setting up. At this point the putty was
pressed into the pin holes and held for approximately 5 minutes
until cured. Once all leaks were confirmed stopped, the entire
area was primed using Pipe W rap PPR epoxy primer and all
voids were filled to make sure of a smooth transition.
.237 Original W all Thickness
Corrosion Under Clamp
The next step was to apply 8 layers of Pipe W rap to

encapsulate the entire clamp and 3 linear feet of
4 inch pipe. Once the repair was cured the vessel was placed
back into service. Work was accomplished within an 8 hour
period. This completed the repair.
Repair Cleaned and Primed
Six Layers of Pipe W rap

A+ to complete repair
Case Study # 23 - 26" Fresh Water Line - Active Leak Repair

RidgeBack Repair
Northern Arizona - USA
Project Overview
A 26" O.D. fresh water feed line for a Fish
Hatchery managed by the US Department of Fish
& Game developed multiple leaks within a section
of line running through a river. The line at the
river crossing was ductile iron and operating at 50
psi.
The operation of the line could not be interrupted
due to the impact on the hatchery. The initial
challenge was to divert the river to allow access
to the pipe for remediation. Once the river was
diverted, there were five (5) noticeable leaks from
holes that ranged in size from 1" to 3" in width.
Temporary Dam to allow

access to pipe
The existing coating on the pipe was a mastic

rubber tape which easily flaked off. An additional
problem incurred was the very limited ability to
conduct surface preparation.
The Solution
The product of choice for this type of active leak
defect is the RidgeBack because a compression
type seal is required that uniformly distributes the
compressive forces thus minimizing the possibility
of collapsing the pipe.
Water pooling due to active

leaks
Metal clamps had been tried by the contractor, but

did not succeed because the tightening process of
the clamps did collapse the pipe sections.
As an additional prevention method for future
leaks the Pipe Wrap system was incorporated in
the regions between the active leaks.
This
consisted of a primer and 24 layers of material
(0.528" material thickness) utilized.
Strapping attempting to stop
flow
Repair Method
Position and secure the RidgeBack to each
active leak area per the provided procedures.
Tighten as required until the area is "drip free" for
a minimum of 30 minutes.
Use hand tools to prep the pipe by removing all
soft coating. Apply a corrosion barrier epoxy to
the entire repair zone prior to wrapping with Pipe
Wrap using the spiral wrap method. Apply the
achieved. Allow to cure for 2 hours. Top coat as
applicable, then back-fill.
3rd leak area
Installing RidgeBack
2nd leak area - close-up of

make shift clamp
Attempt at wooden plugs
Close-up of installed
RidgeBack
Over-wrapping the RidgeBack
Applying Pipe Wrap
Top coating wrapped area
Repairing 2nd section
Repair approximately 75%

complete
Require final top coat
Case Study #24- Offshore Leak Repair

Offshore Platform
Lift Pump Piping Repair
Gulf of Mexico, USA
OVERVIEW:
Leak repairs on seawater lift piping
located on and offshore Truss SPAR.
THE PROBLEM:
The three alternating stainless steel
piping sections supplying seawater
ballast for the SPAR were corroding in
a variety of locations and had active
leaks in all three lines.
There were approximately 39 leaking
areas in both the pipe runs and tees
on the three 10 lines (A, B, and C)
(Photo 1). All piping was 14 above
the deck. It was difficult to be sure of
the exact number as some of the
leaks were covered with a variety of
clamps, tapes or screws.
THE SOLUTION:
Erect scaffolding so there is a safe
work area for the 2 man crew.
Schedule alternating shutdowns and
depressurize individual lines, working
on them one at a time.
Remove all existing repairs (clamps,
tapes, screws, etc.).
Prepare all three pipelines using a side
grinder to remove the rust and scale
build up, bringing the pipe down to
bare metal. Solvent wipe prior to
application of epoxies.
Case Study #24- Offshore Leak Repair

Offshore Platform
Lift Pump Piping Repair
Gulf of Mexico, USA
On line A, fill the holes and anomalies
with 2 part epoxy putty, apply 2 part
epoxy primer 360 circumferentially, and
overlap repair zone axially by 3-4 inches.
Next, wrap with 24 layers of Pipe W
rap.
On lines B & C, after preparing the
entire line, fill the holes and anomalies
with 2 part epoxy putty, then apply the
2 part epoxy paste from 3 oclock to the
9 oclock position, as all previous leaks
appeared to be in the bottom 180 of the
piping. This is in anticipation of new leak
zones developing . Next, apply 2 part
epoxy primer to remainder of bare piping,
and finish with 24 layers of Pipe W rap.
Case Study #25 Cooling Tower Line Repair

Delaware, USA
Project Overview
12 return water line from chiller unit.
The Problem:
The repair of thru wall defects near flange on a 12
carbon steel cooling tower waterline operating at
140 psi and 90F.
View of Thru wall defects
Solution Overview:
Multi-sequence repair requiring depressurization of
the line utilizing A+ W rap in conjunction with epoxy
putty and rubber .
Repair Procedure:
Grinded all surfaces to clean steel. Installed thick
piece of rubber stopgap over defects.
The rubber pieces were secured with galvanized
banding strap. Traditional method of repair (filling
pipe with putty stick) was not used due to extremely
thin bottom.
Covered the sharp sections of banding material and
all transitions between welded plate to pipe, flange to
pipe and rubber piece to pipe with fast set epoxy
putty stick.
Installed epoxy adhesive over entire repair.
Due to location of repair area (tight against flange
with bolts every 2) a change was made from the
suggested spiral wrap over the patch and tight
against the flange. Two rolls were used making the
repair six layers thick. A spiral wrap was done
overlapping 2 of the hoop wrap with 3 rolls of
material over the rest of the repair.
Constrictor Wrap was applied over the material.
Line was recharged 2 hours after completion. The
temperature was of an estimated 78F.
Pipe prepped for repair
Repair Applied and Curing
View of Completed Repair
Case Study #26 Gas Pipeline Dent Repair

Midstream Transmission Pipeline
Dent Repair 2010
Project Overview:
Dent Repair to Midstream Liquid
Transmission Pipeline in wet conditions
in Louisiana, USA.
The Problem:
Mechanical damage to Transmission
pipeline 6.625 OD,0.188 wt. and X42.
Dented pipe w ith all sharp edges ground

out before filler material applied.
Anomaly was a Dent 2.7 long, 1.9 wide,

0.12 depth at 11:16 OClock position.
Solution Overview:
The use of the A+ W rap System with
Smart Pig Markers.
The A+ W rap System is an alternative to
welding a sleeve or cut-out of the dented
pipe area.
A+ W rap is suited for wet conditions.
The repair took 2 hours to complete.
Dent filled w ith putty ready for Primer Coat.
View of Primer ap plied to repair

area.
Completed A+ Wrap repair w ith

constrictor w rap during cure.
34
Case Study #27- Active Leak Repair-Gas Line

Gas Storage Area 1
Project Overview:
A 6 gas pipeline had pinhole leaks, where metal
clamps have been previously installed, that required
the arrest of leaks with an approved leak repair
system.
The Problem:
Leaks and minimum corrosion at two 6 OClock
locations of the pipe about 2 above ground. The first
leaking pinhole was 0.3mm with a repair area of
6 and the two more leaking pinholes were 0.2mm
with a repair area of 12, with a minimal operating
temperature and pressure. The pipe has anticorrosion paint as coating.
Solution Overview:
The Active Leak Repair Kit (ALRK) is a three
component system for leak and corrosion protection.
Kits are specific to repair each area on the pipeline.
First the leak on the pipe was arrested using
QuikStrap and then the remaining repair zone was
prepped using sandpaper and a metal file to near
white finish. Then the EP913-2 epoxy was applied for
corrosion protection before wrapping with Pipe W rap
for containment and mechanical protection. A final
layer of the epoxy was applied as a topcoat.
Epoxy putty, (EP407), was applied prior to the
QuikStrap step for additional protection.
Case Study #28 Offshore Production Platform

Unique Emergency Offshore Riser Repair
Cook Inlet , Alaska USA
OVERVIEW:
Due to the PHMSA denial of a special permit shortly
after the Deepwater Horizon tragedy, the platform
operator was out of compliance, subject to
enforcement and was forced to immediately shut down.
View inside platform leg.
An emergency structural repair for a liquid

production line having a bend located inside of a
support leg on an offshore production platform
offered many challenges.
THE PROBLEM:
Repair location was inside the leg of an oil and gas
production platform located in the Cook Inlet,
Alaska. The pipeline was DOT regulated and carried
produced fluids.
The platform leg had an inside diameter of 7 feet
and protected not just one 12 inch riser, but two
additional 12 inch risers, plus several other pipes
ranging in size from 1 inch to 6 inches.
Diver ready to enter platform leg casing.
Work space was limited inside and the metal loss

location identified by ILI tool inspection was 100 feet
from the top of one of the 12 inch diameter risers under
30 - 60 feet of water depending on the tide.
Visibility was non-existent because the leg was
flooded with salt water and silt from many years of
tidal action. Water temperature ranged from 40 to
45F.
Down the hatch.
The outside pipe surface temperature was 37F.

Cure time of the proposed composite repair was
temperature dependent.
The riser had been de-rated from the original
operational pressure to 340 psig and this pressure
would be maintained as the maximum operational
pressure for continued service.
The 12 pipe was Grade B, original wall thickness
0.500 inches and had a maximum wall loss of 69%
due to external corrosion.
Up out of
the hatch
after
preliminary
pipe
preparation.

THE PROBLEM Continued:
Defect was located on a bend in the pipeline;
the bend radius was 24 - 3.
Defect was 10 ft. in length beginning 6 inches
from the entry of the pipe into support leg.
Primary defect was located plus 7 feet from the
entry of the support leg.
First round of pipe prep
The repair needed to comply with DOT

requirements (in compliance with ASME PCC-2
Repair Standard for Non-Metallic Repairs). In
addition, the crew needed to be trained and
certified onsite to complete the repair.
Pig marker delectability was also a concern

for future ILI inspections to show that the
anomaly had already been repaired.
Preliminary pipe prep
THE SOLUTION:
The line was shut down and depressurized.
Divers descended inside the 7 foot diameter
platform leg and by blind feel sketched the
location of the various risers inside platform leg.
(See page 4).
Next, removal of sediment and water was
required before the area of metal loss could be
identified, cleaned and examined.
Final pipe prep
Remote Access Technicians (RAT) then needed

to be trained topside by Pipe W rap, LLC as the
composite repair was designed to DOT
Standards.
A certified Pipe W rap LLC trainer was utilized for

instruction and application procedures and
supervision.
Primer Coat mixing to send down hatch

THE SOLUTION continued:
The repair was designed to return piping to
full strength from 69% wall loss using
26 layers of wrap.
Curing was assisted by forced heated air
down to the bottom of the riser. This resulted
in raising the pipe temperature to
95F for 12 hours.
Splashbond Epoxy Primer ready to

be sent down hatch in bucket
A PHMSA representative and the Director of

Technology from Pipe W rap LLC were on-site
to observe, assist and ensure compliance
with the riser repair.
Prior to product installation, a certified NACE

inspector went down-hole to verify surface
preparation requirements.
Splashbond Epoxy applied ready to

be overwrapped
Technicians installed Pipe W rap LLCs

exclusively licensed patented pig marker into
the repair in the direction of oil flow.
(See page 5.)
Due to the critical nature and location of the

repair , a project specific QC sign- off was
employed for each major step.
A+ W rap applied for structural repair
Once the repair cured to the required

hardness (minimum of 85 shore A scale), the
PHMSA representative agreed that the riser
had been adequately repaired and platform
was restarted.
Oil is again flowing through the seafloor

pipeline and the repaired riser is compliant
with 49 CFR Part 195.
Inspection of Cure Hardness

Sketches made by Diver inside platform leg
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Case Study #28 - Offshore Production Platform

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ILI Report
ILI Report
Repair Schematic
Case Study #29 Elbow Repair Transmission Pipeline

Gas Transmission Pipeline Elbow
Repair 2010
Project Overview :
Structural repair needed for a 10.75 OD
90 Elbow with 40% wall loss due to
external corrosion.
The Problem:
Immediate repair needed to
be
conformable, easy to apply, safe and
durable. This DOT regulated high
pressure gas transmission pipeline had
general corrosion with 40% wall loss and
needed pig detection for later pig runs.
Anom aly
area
sandblasted
to near
white m etal.
Coated elbow over wrapped with A+ W rap
Defect depth was 0.200 inches Defect

width was 8.40 inches Defect Length
was 28 inches.
Solution Overview:
The A+ Wrap System with Pig Detectible
Markers provided a repair thickness of
.320
inches
based
on
design
calculations.
W rapping conform able A+ W rap.
A UV protective topcoat was applied

after constrictor wrap had been
removed.
Continuation of wrapping process.
Cured repair to be topically coated f or UV protection.
Removing constrictor wrap after 1 hour.
Case Study # 30 24 Natural Gas Line Repair

A+ Wrap Repair-Kenner, LA
Project Overview
Repair of a 24 O.D., .500 wall X-46 Natural
Gas line at a metering station. The line had
27 of corrosion that gathered under pipe
support at the 6 oclock position that caused
45% wall loss.
The Problem
Cr evice
c or r os ion
r esult ed
f r om
c o n d e n s a t i o n s o a k in g t h e wo o d e n
s u p p or t , o ve r t i m e t h e con dens at io n
caused a 27 long def ect t o f or m . T he
c o r r o s i o n d eg r aded 45% of t he pip e
wa l l r e d u c i n g t h e m a xi m u m a l l o wab le
p r e s s u r e f r om 68 5 p s i t o 3 5 0 p s i.
24 Pipeline with corrosion
Solution Overview
Based on the extent of the defect, the
repair was designed in accordance to
ASME PCC-2 standards which resulted in
18 layers of A+ W rap having an overall
repair thickness of 0.396. The repair was
complete from start to finish in 2 hours.
Primer-East Side
The pipe was media blasted to near white

metal and cleaned with MEK solvent,
corrosion was filled with EP400 epoxy
putty and then coated with PPR primer.
A+ W rap was applied 31 f rom right to
left. T he pipe was then coated with a
corrosion and UV resistant paint as a
finishing
coat
over
the repair.
As
stipulated by the Standards, only certified
installers are allowed to apply the product .
Primer-West Side
Finished
Repair-East
and West
Side
Case Study #31 6 Vertical Caustic Line

Formashield ET Repair
Pasadena Texas
PROJECT OVERVIEW:
18 linear foot repair of a 6 x 0.281 wall Grade
B carbon steel caustic line at ambient
temperature.
THE PROBLEM:
The line had external corrosion with 65% wall
loss at ambient temperature; there was also a
leak that was present around a 6 clamp.
THE SOLUTION:
The repair was designed in accordance to
ASME PCC-2 standards. Presence of caustic in
the line required
Formashield System be
used.
Based on the extent of the defect area, 6 layers
of Formashield were required for an overall
repair thickness of 0.17. EP913 epoxy filler
and EP400 epoxy putty were used to
encapsulate the clamp.
The entire repair area was prepped using a
non-sparking grinder as well as wire brushes.
Pin hole leaks surrounding the clamp were filled
in using EP400 epoxy putty. All sharp edges
were ground away. A form was then built to
encapsulate the clamp and filled in using EP913
epoxy filler. The next day after determining the
area was leak free, the rest of the 6 inch pipe
was prepped using the same methods listed
above.
The pipe was primed using PPR-2 and the
required 6 layers of Formashield applied
spirally. Then the entire area was wrapped in
constrictor banding. After all material was fully
cured, the constrictor banding was removed
and the area was coated with an epoxy UV
topcoat.
Case Study #32 Formashield

Formashield ET
Pasadena Texas
OVERVIEW:
Repair of a 24 O.D x 0.375 wall, water line
inside a refinery had 31 feet of external
corrosion and 3 areas with pin hole leaks. The
external corrosion on the pipe had a defect
depth of 60 percent wall loss.
THE PROBLEM:
Sandblast Pipe
External corrosion resulted from natural causes

over a long period of time caused minor pin hole
leaks and external corrosion, over 31 feet to
occur. The corrosion degraded 60% of the pipe
wall.
THE SOLUTION:
Based on the extent of the defect, the repair
was designed in accordance to ASME PCC-2
standards which resulted in 6 layers of
Formashield of an overall repair thickness
of 0.20. The repair was complete from start
to finish in 3 days.
The pipe was first blasted to near white metal
and cleaned with MEK solvent. The 3 pin hole
repairs were stop- gapped and held leak free
for 1 full day. The remaining 31 feet of
corrosion was filled with proprietary epoxy
putty, coated with PPR primer, then 6 layers
of Formashield was applied to the entire 34
feet encapsulating the stop gaps.
Apply primer
Wrap prepared section
The pipe was then coated with a corrosion

and UV resistant paint as a finishing coat
over the repair.
As stipulated by the PCC-2 Standards, only
certified installers were allowed to apply the
product.
Top coat for UV resistance
Case Study # 33- 96 Water Pipe

A+ Wrap Repair
Nuclear Plant, Byron IL
Project Overview
Severe corrosion was determined at the lower portion of a
96 CW Return Line. Randomly selected UT measurements in the degraded area were performed to obtain a
baseline wall thickness of the 96 piping. From these
measurements, localized spots in corroded region are
below minimum wall thickness. Applying Pipe W raps
View of 96 W ater Pipe before Repair
A+ W rap will re-establish margin by restoring pipe strength,

Installation of the Pipe W rap material will be from the floor 18
up on the 96 pipe, completely around a 4 stub and, out to
the valve on 6 lines 1CW 20AA/B/C/D.
A 2-part elastomeric coating was applied to the wrap and the
floor to seal the interface between the wrap and the floor.
The wrap is validated through testing for use under the
ASME PCC-2 Article 4.1 2006 for B31.1, B31.3, B31.4, and
B31.8
12 Layers with A+ W rap
The Solution
Pipe - 96 Diameter located 1 story below ground level.
Repair was done using is A+ Wrap coated with PPR-2
Epoxy System Repair completed with RC-350 Rubber
Coating for an additional water barrier.
Repair Method
Pipe with beads of Black Magic followed by PPR-2
Repair was done with no down time and completed in less

than 2 days.
st
Pipe was wrapped with 12 layers of A+ Wrap for 1 10 and
an additional 5 layers for remaining 8. Photo shows A+
Wrap overwrapped with constrictor wrap.
Final view of completed repair
Case Study # 34- Special Sequencing Batch Reactor

Waste Water Piping
Smithville, TN
Project Overview
Our Client manufactures a special sequencing batch
reactor (SBR) system, demonstrating lower operating
costs and lower sludge production than conventional
SBRs, is providing greater than 99% removal of
organics for a 2.4 mgd wastewater treatment plant. Due
to trouble with internal nozzles the needed to cut two 8
inch holes in the 16 inch line to make repairs and then
seal the line. The close proximity of a smaller line
added to the difficulty of making the repair
The Solution
After reviewing the problem Pipe Wraps Formashield
was chosen for the repair due to its ability to be sized
to fit between the two lines and provide a repair that
would return the line to its original structural strength.
Repair Method
Step 1:
The first step in the repair after the internal repairs were
completed was to identify and prepare the repair zone
by abrading the entire area that was to have material
applied.
Case Study # 34- Special Sequencing Batch Reactor

Waste Water Process Piping
Smithville, TN
Step 2:
The second step of the repair was to apply epoxy
adhesive and place a fiberglass patch over the 8 hole,
fasten in place and allow to cure.
Step 3:
The third step of the repair was to apply epoxy putty
around the patch then coat the repair zone with Epoxy
paste and allow to set for a minimum of 15 minutes.
Step 4:
The final step in the repair was to wetout and apply
Formashield using 50%Overlap to provide 12 layers
over the center of the repair. Material was constricted,
lightly perforated and allowed to cure. The line was
returned to service 24 hours after start of repair.
Case Study # 35-Jet Fuel Line Skytanking, USA

Formashield
New River Airport, New River NC
Project Overview
Repair involves structural damage to a 6 GFE
Pipe that carries jet fuel from storage tanks to the
refueling area. Maintenance equipment had cut a
6 long hole in the elbow at ground level. Pressure
rating of the line is 150 PSI so the repair design
would be critical to assure at least original
pressure capability.
The Solution
Because standard pipe repair calculations would
not be accurate for this type of repair the design
was based on known parameters for this type of
pipe. Because of superior strength, ease of
application to this configuration, good service life
and excellent bonding characteristics
Formashield was chosen for the repair.
Repair Method
Step 1: The first step in the repair was to identify
the repair zone, in this case approximately a 15
long area and prep it using sandpaper to provide a
satisfactory anchor pattern.

Formashield
Step2: The second step of the repair was to apply

epoxy putty to the damaged area to create a
seal/load transfer. Putty is contoured then allowed
to harden.
Step 3: The next step of the repair was to mix and

apply epoxy paste to the entire repair zone and
allow to set until it has reached the consistency of
cold honey.
Step 4: At this point the pre-measured epoxy resin

was mixed and applied to the Formashield cloth.
Cloth was rolled up and moved from wet=out area
to the repair. For this particular repair 2 wide cloth
was used for ease of application to the curved
surface of the elbow.

Formashield
Step 5: 10 layers if Formashield cloth was

applied to the repair zone using the Spiral Wrap
method with 50% overlap. After wrapping was
complete, a constrictor wrap was applied and
lightly perforated to allow for out-gassing and for
the release of excess resin. Repair was allowed to
cure for 2 hours and then constrictor wrap was
removed.
Step 6: Exterior of repair was coated with Epoxy

Primer and entire repair was allowed to cure for 12
hours. Line was put back in service and functioned
perfectly.
Case Study #36- Production Platform Export Riser

GenWrap
Production Platform
Offshore Eastern Canada
OVERVIEW:
An 18 export riser had areas where
existing neoprene rubber coating was
cracking and needed patching using an
approved corrosion barrier system.
THE PROBLEM:
Corrosion under cracked neoprene on a 18
OD riser about 15 feet above water line.
Pitted area was 330.2 mm (13) x 50.8mm
(2), operating temperature 73C-78C.
The neoprene coating was 2mm (79 mils)
thick.
THE SOLUTION:
GenWrap had been laboratory
tested (per Exxon Mobil protocol ) to
have no disbondment , so a field trial
using the two-component corrosion
inhibitive system composed was
custom kitted to repair each area on
the W T riser.
Corrosion under failed neoprene

coating on 18 riser
First the pipe was sandblasted to

near white metal, then GenWrap
polyolefinic corrosive inhibitive under
wrap was cut to size to form over
damaged areas, then overwrapped
with MCU outerwrap for containment
and mechanical protection.
View of completed repair
Case Study #37- Crude Oil Pipeline Repair

Submerged Concrete Coated Crude
Oil Pipeline Repair Offshore
Columbia
OVERVIEW
Concrete coating on a submerged (15
meters) 48 diameter crude oil pipe
had been scratched and cracked by a
dragging anchor.
THE PROBLEM:
Failed
concrete
coating
from
mechanical damage in 15 meter deep
water
in
2
separate
locations
compromised
carbon
steel
pipe
underneath.
At almost 50 feet deep, all materials
needed to be mixed topside, and
brought down to ocean floor using
weighted buckets. Murky conditions
with limited visibility.
THE SOLUTION:
Divers removed damaged concrete,
then measured the concrete thickness
to replace coating. After measuring
the thickness of the existing cracked
concrete coating, a stainless steel
enclosure was fabricated to surround
repair areas to tie the existing concrete
OD on either side of repair zone. The
enclosure was secured with tie-downs
and epoxy aggregate was injected into
an annulus at the top of the stainless
steel enclosure. Final step was to
overwrap the enclosure with A+ Wrap
and topically coat with SplashBond.

INITIAL APPLICATION OF RESIN
FINAL FILL APPLICATION SHROUD
FINAL FILL APPLICATION
Mixing of com ponents A and B, SplashBond resin.
Mix Epoxy Resin and Gravel
Gravel to the Mix
Final Appearance of fill material
Enlistment of divers Final Photos.
AELD REPORT ACCOMPANYING THE AREA DURING THE ENTIRE BOARD REPAIR GW D-440
KM 5 +322 COVEN LINE OFFSHORE TERMINAL
REVISION CONTROL
Revision No. Date
0
Description
(DD I MM I YYY'I')
Documentation of the process.
271Jun I 2008
Developed:
Jotge Tormdo I Junior Engineer Integrity.
Reviewed I Approved:
carlos Vergara I Engineer lntegrity.
I. OBJECTIVE
Supply constraints In the field during the repair activities of system board siding GW0-440, located
Km 5 +322 OCENSA Offshore Line.In order to ensure and document this process.
2.
at
SCOPE
Field activities consisted of the permanent support to the process of implementation of ECO
Engineering Standard-IG-368-004-RP-056-E, for the completion of the repair ooating system
against extemal corrosion of the Board GW0-440 ,located at Km 5 +322 OCENSA Offshore Line.
3.
METHODOLOGY
The field visit took place between Monday June 16th and Monday June 23,2008 atTermlnal Covenas.

Submerged Concrete Coated Crude
Oil Pipeline Repair Offshore
Columbia
OVERVIEW
Concrete coating on a submerged (15
meters) 48 diameter crude oil pipe
had been scratched and cracked by a
dragging anchor.
THE PROBLEM:
Failed
concrete
coating
from
mechanical damage in 15 meter deep
water in 2 separate locations
compromised carbon steel pipe
underneath.
At almost 50 feet deep, all materials
needed to be mixed topside, and
brought down to ocean floor using
weighted buckets. Murky conditions
with limited visibility.
THE SOLUTION:
Divers removed damaged concrete,
then measured the concrete thickness
to replace coating. After measuring
the thickness of the existing cracked
concrete coating, a stainless steel
enclosure was fabricated to surround
repair areas to tie the existing concrete
OD on either side of repair zone. The
enclosure was secured with tie-downs
and epoxy aggregate was injected into
an annulus at the top of the stainless
steel enclosure. Final step was to
overwrap the enclosure with A+ Wrap
and topically coat with SplashBond.

INITIAL APPLICATION OF RESIN
FINAL FILL APPLICATION SHROUD
FINAL FILL APPLICATION
Mixing of components A and B, SplashBond resin.
Mix Epoxy Resin and Gravel
Gravel to the Mix
Final Appearance of fill material
Enlistment of divers Final Photos.
AELD REPORT ACCOMPANYING THE AREA DURING THE ENTIRE BOARD REPAIR GWD-440
KM 5 +322 COVEN LINE OFFSHORE TERMINAL
REVISION CONTROL
Revision No. Date
0
Description
(DD I MM I YYY'I')
Documentation of the process.
271Jun I 2008
Developed:
Jotge Tormdo I Junior Engineer Integrity.
Reviewed I Approved:
carlos Vergara I Engineer lntegrity.
I. OBJECTIVE
Supply constraints In the field during the repair activities of system board siding GW0-440, located
Km 5 +322 OCENSA Offshore Line.In order to ensure and document this process.
2.
at
SCOPE
Field activities consisted of the permanent support to the process of implementation of ECO
Engineering Standard-IG-368-004-RP-056-E, for the completion of the repair ooating system
against extemal corrosion of the Board GW0-440 ,located at Km 5 +322 OCENSA Offshore Line.
3.
METHODOLOGY
The field visit took place between Monday June 16th and Monday June 23,2008 atTermlnal Covenas.
Case Study #39- Underwater Dent Repair

Offshore Malaysia
OVERVIEW:
A 24 concrete coated X60 submersed
gas pipeline was caliper pigged that
identified three dent anomalies.
THE PROBLEM:
The pipeline lay on the sea bed with
nominal wall thickness of 15.9 mm and
the three defects were located in a 2
meter section.
The water depth was 25 meters,
expected free spanning and surrounding
in Dregs condition.
THE SOLUTION:
Concrete coating was removed for bare
surface area ready for
wrapping.
SplashGard was utilized to ensure the
structural integrity of damage caused
from anchors.
Case # 39- Underwater Dent Repair cont'd
Case # 39- Underwater Dent Repair cont'd
Case Study #40- Production Platform Water Line

Production Platform
with Leaks
Water Line
Offshore West Africa

OVERVIEW:
Production facility operating 250
miles offshore with a 24 carbon
steel line experiencing internal
corrosion.
THE PROBLEM:
Personnel from Pipe Wrap, LLC
needed to inspect sections of
UTd pipe that needed structural
wrapping. The produced water lines
had an operating pressure of 62 psi
with a defect area of 84 with 3 mm
(.118) remaining wall on Grade B
(original 9.52 mm (.375) wall
thickness.
Photo 1 I Beam Obstruction
Sections of pipe that needed

structural wrapping had an I beam
with 6.0 mm clearance above
component 53. As a result,
wrapping could only be performed
area illustrated in Figure 1.
(see next page for Sketch of
Inspected Repair Zone).
Photo 2 View of Repair Zone
THE SOLUTION:
Since the coating was fusion
bond epoxy, minimal surface
preparation (abraded with sand
paper) was all that was required.
Next, PPR (epoxy primer) and 19
layers of A+ W rap were applied.
Photo 3 Bottom View of I-Beam

Production Platform Produced
Water Line with Leaks
OVERVIEW:
FIGURE 1 Sketch of
Inspected Repair Zone
See next page for Isometric Drawing Reference

Production Platform
Produced Water Line with Leaks
OVERVIEW:
Isometric Drawing Reference
See next page for additional photos of repair

Production Platform
Photo 4 View of Prepped Pipe
Photo 5 View after Repair

Production Platform
Photo 6 Upstream View of Repair
Photo 7 Ground View of Completed Repair
Case Study #41- Production Platform Piping

Production Platform Piping
Gulf of Mexico, USA
Outside and Topside Platform Deck
Facilities
THE PROBLEM:
Pipe line to be repaired ranged in diameters
of 6, 4 and 3 Schedule 40 to Schedule 80,
Grade B. With an operating temperature of
40 F minimum to 100 F maximum and an
operating pressure of 50 psi. Four layers of
A+ W rap were applied to the pipe bodies
with less than 80% wall loss.
Repairs were to be done while the system
was operating. Some lines were actively
leaking.
THE SOLUTION:
W here the pipe works had leaks (100%
wall loss) a mechanical clamp was applied
to defect and over wrapped with 15 layers of
Pipe Wrap and then reinforced with 4
layers of A+ Wrap. Girth welds with less
than 80 % wall loss were repaired using
8 layers of A+ W rap.
Girth welds that leaked (100% wall loss)
were clamped first and then over wrapped
with 15 layers of Pipe Wrap and 8 layers of
A+ Wrap to provide additional axial
stiffness.

Case Study-R12 12

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General Case Studies

Pipe Wrap, LLC

Case Study # 1- 16" Gas Transmission Line

Case Study #2- Sub Sea Level Bayou Repair

Wrapping 3 foot of pipe

Pipe ready for topcoat

View of Constrictor Wrap

Case Study # 3- 16" Field Bend Repair Gas Transmission Line

Case Study # 4- Oil Rig Caisson Repair

Case Study #4-Oil Rig Caisson Repair

SWLP-B Caisson Current State: Front View

Dented Area (Area of

Case Study #4-Oil Rig Caisson Repair

SWLP-B Caisson Current State: Front View

Case Study #5 Riser Repair Offshore Platform

Preparing corroded elbow

Applying GenWrap Overwrap

Case Study # 6 - Gouge Repairs at a Gas Plant

Both pipes were 8" pipe, API-5LX-46, 0.344"

Distance between pipe sections

Inspection of the lines via Dye Penetrant Testing

View of 0.4" wide x 8" long gouge

Case Study # 6 - Cont.

View of 0.1" wide x 1" long gouge

Removing "sharp edges"

Abraded surface ready for putty

Putty applied to gouge

Case Study # 6 - Cont.

Applying primer to pipe

Continue applying primer

Repairs constrictor wrapped

Repairs curing for 2 hours

Case Study # 7- 14" Natural Gas Transmission Pipeline

Measuring the repair zone

The Gas Transmission Company worked closely

Pipe surface before prep

After Sandblast to NACE 3

Case Study # 7- Cont.

Applying Load Transfer Putty

Encapsulating ILI Marker

Begin applying A+ Wrap

Case Study # 7- Cont.

Spray & apply with 50% overlap

Begin constrictor wrap

"Lightly" perforate constrictor

Pull constrictor tightly

Case Study # 8 - 24" Flare Line Repair

View Elbow Transition

The complete repair from surface prep to final

Repaired Branch Connection

Wide View of Entire Repair

Case Study # 9 - 54" Municipal Water Line

View of pipe towards the Dam

View of pipe towards the exit

The repair approach was to reinforce the sections

Preparing to prep the pipe

Case Study # 9 - cont.

Primer to larger area

Case Study # 10 - 8" Riser Repair - Soil to Air Interface

Prepped repair zone

Prep the pipe by hand tools to remove any soft

Case Study # 11 - Corrosion Under Insulation Repair

Initial view of CUI