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REINFORCEKiT® 4D, Leak on nozzle – Africa
High-performance composite repair solution for pipe reinforcement

Overview

The aim of the job, performed in November 2024 by 3X ENGINEERING (3X) specialists was to seal a leak occuring on a 1" nozzle on CW line because of external corrosion. To fix the leak and restore pipe integrity, the repair was performed using 3X ultimate composite solution REINFORCEKIT® 4D (R4D).

Results

Samples of resin were taken during each installation steps for quality control and hardness measurements were performed after job completion and concluded this successful repair. The system now operates efficiently and safely.

Defect type
 Leak on nozzle
Details
 1" nozzle on CW water line, calculated pressure 4.90 bar, temp. 25°C
Location
 Africa
3X Product type
 REINFORCEKiT® 4D

SCOPE OF WORK


The existing hole with residual leak (30mmx20mm) is situated at the beginning of the nozzle between two weldings. According to ISO 24.817 standard and 3X calculations, it was decided to apply 8 layers of R4D (Kevlar® tape impregnated with bi-component epoxy resin) to seal the leak. Surface preparation was completed using abrasive blasting to achieve a good surface roughness (leading to 100µm Rz) and confirmed using the surface roughness comparator. Hygrometric conditions were checked before FIXOKIT® installation. To plug the defect with residual flow, it was necessary to apply this 3X sealing system (ball of specific filler was positioned on galvanized plate and installed over the leak and tightened with straps until the leak is stopped. After filler curing, the straps and the plate were removed and the surface was cleaned with acetone before composite wrapping.

The composite repair was then completed following the main stages mentioned below:

  1. Thick layer of 3X resin application over the defect to provide good adhesion with the composite material.
  2. Four Kevlar® patches impregnated with resin were applied around the nozzle.
  3. Composite wrapping was then completed using Kevlar® tape impregnated with 3X resin (eight layers were applied).
  4. Last layer of resin was applied over the repair, including edges, and id plate was installed for traceability.
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