REINFORCEKiT® 4D, Metal loss & leaks – Africa
High-performance composite repair solution for pipe reinforcement
Overview
In May 2025, a critical 8" crude oil washing line presented multiple defects, including five corroded areas and four leaks. Immediate reinforcement using 3X high-performance composite solution REINFORCEKIT® 4D (R4D) was essential to avoid operational downtime and environmental risks.
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.
 Defect type |
Metal loss & leaks (9 defects) |
Details |
8" COW line, temperature 60°C, pressure 16 bar |
Location |
Africa |
3X Product type |
REINFORCEKiT® 4D |
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:
- 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.
- Surface reconstruction: F3X8 filler was applied to rebuild the original geometry of the pipe and smooth the surface.
- Resin application: A first layer of 3X high-temperature resin was applied to provide strong adhesion between the substrate and the composite material.
- Composite wrapping: Four layers of R4D were wrapped around corroded areas and 10 layers in case of leaking defect.
- 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.
