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Case study – 24 inch export manifold

Integrity issue

A 24 inch manifold section of export pipework was suffering from internal corrosion. Further internal corrosion was expected to occur and therefore a composite repair solution was sought. To reinstate the integrity of these sections of pipework it was proposed to use a Futurewrap Carbon/HT composite repair.



The design of the Futurewrap Carbon/HT repair was to strengthen the pipework assuming the internal corrosion rate was 1 mm/year. The design parameters were; pressure 154 bar, temperature 1000C, design lifetime 2 years. It was assumed that the remaining wall thickness at the end of design life was 15 mm. An HT repair was used as the pipework surface temperature during application would be 700C implying that rapid curing of the repair during installation would be an issue. The repair design resulted in a thickness of 18.9 mm (16 layers) of Futurewrap Carbon/HT composite repair with an axial length of 1050 mm.


The installation steps are shown in the photographs. The surface preparation was to Sa2.5. Rapid resin curing was controlled. Full QA/QC measurements were made to demonstrate that the Futurewrap repair was applied in accordance with ISO 24817.


A 24 inch manifold section of export pipework system suffering internal corrosion was repaired using Futurewrap Carbon/HT composite repair.  The repair was completed within 3 days reinstating the integrity of the pipework.

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