Leak repair and pipeline reinforcement at girth weld of DN700 mm oil pipeline

The pipeline operator detected a leak at the girth weld of a carbon steel pipeline operating at working pressure 16 bar. The damaged weld is on an elbow with a reduction from a diameter of 28-inch to 20-inch (reducer).

Challenge

Composite repair materials cannot be installed directly over the leaking pipe. Leaks need to be stopped always before moving on. This case study describes how to stop the leak. Second challenge was the geometry of the wrapping area. Using different width carbon cloth almost every geometry can be wrapped, like in this case the reducer section of the line.

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Repairing a massive carbon steel pipe within 24 hours

A small leak under a metal sleeve at a 28” pipe is a problem and requests a fast and proper solution. The size of the sleeve basically would be considered as the defected area which required a repair of a reasonable size. By dropping the pressure in the pipeline the small leak was stopped and contained. Immediately after the leak was stopped the engineered carbon fiber epoxy based system was applied covering the sleeve and surrounding pipe area. The multi-layer carbon fiber solution will last for many years.

Challenge

The timeframe between starting preparation of the 100 kg repair kit, shipping from the Netherlands to Croatia, installing the wrap and curing of the epoxy was roughly 24 hours.

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Repairing an active leak at a natural gas carbon steel pipeline

An active leak in a natural gas transmission pipeline is a nightmare for every gas distributor. It creates an environmental undesirable and dangerous situation that needs to be fixed as soon as possible. Stopping the leak was the first step in the process of repairing the pipeline. In this case the girth welds of the pipe were showing weak points and in one particular case there was a small leak. After the leak was stopped by using a low-profile leak sealing solution provided by CTE BV the engineered carbon fiber epoxy based system was wrapped around the repaired area. The particular area was secured for future leakages.

Challenge

Besides stopping an active leak also the winter circumstances did ask for a professional approach towards a successful repair according ISO 24817.

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