High performance composite repair solution for pipe reinforcement, Africa
Overview
In May 2025, a critical 8" crude oil offshore (FPSO) washing line presented multiple defects, including five corroded areas and four leaks. The pipeline operated at a temperature of 60°C with a pressure of 16 bar. Immediate reinforcement using
3X Engineering
high-performance composite solution REINFORCEKiT® 4D (R4D) was essential to avoid operational downtime and environmental risks.
Scope of work
In accordance with ASME PCC-2 standard, the repair procedure specified the application of 4 layers of R4D (Kevlar® tape impregnated with a bi-component epoxy resin) for areas affected by metal loss due to corrosion and 10 layers of R4D for locations presenting through-wall defects.
To ensure optimal adhesion of the composite material, the pipe surface was prepared using Bristle Blaster® machine, achieving a cleanliness level equivalent to St3/SA 2.5 and a surface roughness greater than 60 µm (Rz), verified with a calibrated roughness tester.
Following confirmation of appropriate hygrometric conditions, the surface was degreased with acetone prior to the
composite application. The composite reinforcement was completed following below stages:
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LEAK SEALING ==> FIXOKiT® (specific device made of steel plate and high-performance filler) was installed over the through-wall defects to seal active leaks. This step is not needed for non-leaking corroded areas.
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SURFACE RECONSTRUCTION ==> F3X8 filler was applied to rebuild the original geometry of the pipe and smooth the surface.
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RESIN APPLICATION ==> A first layer of 3X high-temperature resin was applied to provide strong adhesion between the substrate and the composite material.
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COMPOSITE WRAPPING ==> Four layers of R4D were wrapped around corroded areas and 10 layers in case of leaking defect.
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FINALISATION ==> Final resin layer was applied over the repaired areas and ID plate was installed to ensure traceability. For long-term protection, UV-resistant coating was recommended to the client.
Results
REINFORCEKiT® 4D intervention fully restored the mechanical integrity of the pipeline, extending its service life and preventing costly shutdowns. This line was part of a series of eight repairs completed on the FPSO. All reinforcements were completed successfully and all assets are now fully operational.
