Process Piping & Pipeline Repair Services

Process piping and pipelines routinely develop defects that may be non-through-wall or progress to full loss of containment over time. These defects are commonly driven by:

• External corrosion or under-deposit corrosion
• Internal corrosion or erosion
• Manufacturing defects such as laminations or blisters
• Mechanical damage progressing under cyclic loading

Without intervention, these defects can continue to grow, increasing the risk of leakage or rupture.

At Icarus Composites, engineered composite wrap systems are applied using spiral wrapping or patch repair methods to restore integrity and reinforce the affected area. Repairs can be designed for live or isolated systems, depending on risk, operating conditions, and defect characteristics.

Key performance benefits include:

• Repair of non-through-wall and through-wall defects
• Spiral wrap or patch repair tailored to geometry
• Compatibility with hydrocarbons, seawater, chemicals, and production fluids
• Systems qualified across a wide temperature range, including:
  • BioWrap 102 (up to 72–82°C)
  • Helios 158 (up to 128–138°C)
  • Hyperion 223 (up to 193–203°C)

The result is a compliant, load-sharing repair that restores containment and structural performance while extending asset life.

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Process piping and pipelines routinely develop defects that may be non-through-wall or progress to full loss of containment over time. These defects are commonly driven by:

• External corrosion or under-deposit corrosion
• Internal corrosion or erosion
• Manufacturing defects such as laminations or blisters
• Mechanical damage progressing under cyclic loading

Without intervention, these defects can continue to grow, increasing the risk of leakage or rupture.

At Icarus Composites, engineered composite wrap systems are applied using spiral wrapping or patch repair methods to restore integrity and reinforce the affected area. Repairs can be designed for live or isolated systems, depending on risk, operating conditions, and defect characteristics.

Key performance benefits include:

• Repair of non-through-wall and through-wall defects
• Spiral wrap or patch repair tailored to geometry
• Compatibility with hydrocarbons, seawater, chemicals, and production fluids
• Systems qualified across a wide temperature range, including:
  • BioWrap 102 (up to 72–82°C)
  • Helios 158 (up to 128–138°C)
  • Hyperion 223 (up to 193–203°C)

The result is a compliant, load-sharing repair that restores containment and structural performance while extending asset life.

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Internal corrosion and erosion present a unique challenge, as the defect may continue to grow during the repair lifetime if not properly assessed and managed. These defects are commonly caused by:

• Corrosive or erosive process media
• Multiphase or particulate-laden flow
• Local turbulence and flow disturbances
• Long-term chemical exposure

Careful engineering is required to ensure repair suitability and longevity.

At Icarus Composites, composite repair systems are designed following detailed defect assessment to account for potential ongoing degradation. Repairs are applied externally to restore pressure containment and structural capacity while maintaining compatibility with internal service conditions.

Key performance benefits include:

• Repair of internally driven defects (non-through-wall or through-wall)
• Engineering assessment to account for defect growth
• Compatibility with aggressive internal media
• Reinforcement without internal access or lining

The result is a controlled, engineered repair that restores integrity while enabling continued safe operation.

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Crack-like defects and areas subject to high local stress require targeted reinforcement to prevent crack propagation and structural failure. These defects are commonly driven by:

• Fatigue and cyclic loading
• Thermal expansion and contraction
• Manufacturing defects or weld-related stresses
• External loads and vibration

Crack length must be known and stable for composite repair to be viable.

At Icarus Composites, composite reinforcement systems are used to bridge cracks, redistribute stresses, and stiffen local areas. Repairs can be applied to both live and isolated systems and are commonly used to reinforce high-risk features or previously repaired locations.

Key performance benefits include:

• Repair of crack-like defects where growth is halted
• Localised strengthening and stiffness enhancement
• Management of cyclic and external loads
• Long-term performance without cutting or welding

The result is a structurally stabilised repair that arrests crack propagation and extends pipeline service life.