12-Inch Fuel-Oil & 1.5-Inch MGO Line Repairs
Case History
12-INCH FUEL-OIL &
1.5-INCH MGO LINE REPAIRS
1.5-INCH MGO LINE REPAIRS
BioWrap 102 reinforcement across mixed pipework, branches and support geometry
Customer/site: Confidential
12-INCH FUEL-OIL AND 1.5-INCH MGO LINE REPAIRS
Twelve treatment areas restoring structural integrity and corrosion protection across two hydrocarbon lines
12
treatment areas
12 in & 1.5 in
fuel-oil / MGO lines
4-6
BioWrap 102 layers
20 years
engineered design life
Project overview
Asset and service conditions
- Location: Confidential - UK port fuel facility
- Assets: 12-inch fuel-oil line and 1.5-inch MGO stripping line
- Service media: fuel oil and marine gas oil
- Substrate: carbon steel
- Geometry: straight pipe, elbows, tee, branches and support
- 12-inch design / operating conditions: 16 / 14 barg and 50 / 50°C
- 1.5-inch design / operating conditions: 16 / 5 barg and 30 / 30°C
- Completion date: October 2024
Customer requirement
- Repair 11 external-corrosion areas over 8.144 m of the 1.5-inch MGO line and one defect on the 12-inch fuel-oil line.
- Design for live-line conditions and protect the 1.5-inch line between the engineered repairs.
- Reinforce the 12-inch defect at a stab-in connection above a foot support.
- Incorporate the pre-installed welded saddle into the engineered composite repair.
- Provide controlled specifications, QA records, photographs and completion certification.
Challenge
- No NDT data were available for the 1.5-inch line, so its substrate strength contribution was conservatively ignored.
- The 12-inch defect had 4 mm remaining wall and was located at a stab-in connection directly above a foot support.
- The welded saddle, elbow step-ups and support webbing created abrupt geometry requiring controlled profiling.
- The scope combined pressure-retaining reinforcement with continuous corrosion protection across 8.2 m of small-bore pipework.
- Repairs had to accommodate mixed pipe sizes, branches, elbows and support geometry within one controlled programme.
Before condition
External corrosion across fuel-oil and MGO pipework
Before condition: corrosion, welded saddle repair and complex geometry
External corrosion at the 12-inch stab-in connection above a foot support.
Severe external corrosion on the 1.5-inch MGO line; no NDT data were available.
Pre-installed welded saddle over the 12-inch defect before profiling and composite reinforcement.
Engineered repair method
01
Review and design
Two repair specifications covered 12 treatment areas using verified live-line inputs and conservative assumptions.
02
Surface preparation
UHP jetting and power-tool preparation achieved SSPC-SP10/SP11 requirements before degreasing.
03
Profiling
Support webbing was removed and the welded saddle perimeter and abrupt geometry were profiled.
04
Composite application
Four BioWrap 102 layers were applied to the 1.5-inch line and six layers to the 12-inch repair.
05
Cure and sign-off
A 16-hour ambient cure, compression film, Shore D >80 and final QA checks were recorded.
Repair data and technical controls
| Composite system | Repair areas | Layers applied | Design life |
|---|---|---|---|
| BioWrap 102 | 12: 9 engineered, 3 corrosion protection | 4 layers (1.5 in); 6 layers (12 in) | 20 years (engineered repairs) |
Why this was a specialist repair
- One project combined a 12-inch tee/support repair with full-length treatment of an 8.2 m small-bore MGO line.
- The 1.5-inch engineered repairs were conservatively designed with no substrate strength contribution.
- The welded saddle and support geometry had to be incorporated without introducing abrupt laminate transitions.
Technical controls
- Separate controlled repair specifications were used for the 12-inch and 1.5-inch lines.
- BindFast 1 and silica paste were used to restore profiles and remove stress concentrations.
- Compression film, cure duration, Shore D hardness and final visual/QA checks were recorded.
- Repair data sheets, calculations, project photographs and completion certification supported close-out.
Completed repairs
Profile restoration, BioWrap 102 application and completed reinforcement
Repair execution and completed 12-inch and 1.5-inch line repairs
Completed six-layer BioWrap 102 repair over the 12-inch tee, welded saddle and support geometry.
Completed four-layer BioWrap 102 reinforcement around the 1.5-inch MGO elbows and branches.
Completed 12-inch support landing detail, maintaining clearance at the movement interface.
Outcome
What was achieved
- Twelve treatment areas were completed: nine engineered repairs and three corrosion-protection sections.
- The 12-inch defect was reinforced and the full 8.2 m 1.5-inch MGO line was composite wrapped.
- The pre-installed welded saddle was incorporated into the engineered reinforcement.
- Controlled cure, Shore D hardness and final visual/QA checks were completed and recorded.
What this demonstrates
- BioWrap 102 can address mixed pipe sizes, elbows, branches, welded saddle repairs and support geometry.
- Conservative ASME PCC-2 design can provide engineered reinforcement where NDT data are unavailable.
- A single controlled programme can combine structural reinforcement with continuous corrosion protection.
Need an engineered repair assessment?
Send the minimum engineering inputs and Icarus Composites can confirm feasibility, repair approach and the next technical steps.
01
Defect photos
02
Dimensions
03
Pressure / temperature / service
04
Required design life
