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Co
mp
osite R
epairs
Providing onshore and offshore services to the Oil & Gas,
Petrochemical, Utilities, Construction, Facilities Management and
Heavy Industries
Total Solutions Middle East
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About Us
Total Solutions Middle East is a leading:
Specialists service provider to:
Oil & Gas
Petrochemical
Utilities
Construction
Facilities Management and
Heavy Industries
Rope access and working at height
provider in the Middle East.
SERVICES
Painting
Blasting
Pipe-Work Inspection
NDT/NDE
Composite repairs
Welding & fabrication
Rigging & lifting
Insulation
CUI
Building Maintenance
Electrical Installation
Plumbing & Piping
Confined space work
General maintenance
Surveys and
inspections
Safety systems
Fire Protection
Bolt Torque Testing
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About Us
ISO9001:2008 Accredited company
Member of IRATA (Trainer and Operator)
Undertake works for Oil & Gas companies throughout the
Middle
East
Employ qualified and experienced tradesmen
Provide dedicated training facilities
Provide unique solutions in the Middle East:
Work positioning nets
Temporary working platforms for under-jetty/pier works
Guy wire tensioning
Flare stack works
Removable insulation blankets
….. and more
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Tradesmen
Painters
Blasters
Welders
NDT Technicians
Electricians
Plumbers
Insulators
Welding Inspectors
Pipe Fitters
General Maintenance
Engineers
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Composite Repairs
A system that reinstates
wall thickness of pipes,
storage tanks and
equipment affected by
external or internal
corrosion.
Applied using epoxy resins
and glass fabrics
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Technology used by:
What it is
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Benefits of Composite Technology
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Repairs and reinstates steelwork
integrity quickly and cost
effectively
Installed online minimising plant
shut down
No hot works
Avoids section replacement
therefore reducing plant
downtime
Rapid application
Highly flexible - repairs irregular
shapes such as bends, t-joints,
etc.
Reduces cost
20 year warranty
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Features of Composite Technology
Can be installed on any repair length
Can withstand operating pressure exceeding 120 bar
Application temperature -5 ºC to + 90 ºC
Service temperature -50 ºC to +150 ºC
Minimal risk to personnel
Proven and certified by HSE and AEA
Surface preparation requirement to ST2 standard (manual
cleaning)
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Installation
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Kevlar Reinforced Epoxy Paste mixed and applied onto the
prepared steel substrate
by trowel and levelled off.
This will fill in any surface pitting and cover over welds.
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Installation
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The next step is to apply
the Composite wrap
manually around the pipe.
This is spiral applied by
overlapping 50% building
up the layers.
The epoxy saturated
composite wrap is applied
with 4 passes from
upstream to downstream
to give a total of 8 layers.
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Installation
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The repair is wrapped in polythene and compressed using rubber
uniwraps.
Uniwraps are removed the following day.
The operator’s pipe coating is then applied on both ends of the
repair.
The pipeline can be backfilled so painting may not be
required.
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Remote Location Working
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The installation teams do not require heavy equipment.
This reduces mobilisation time and cost.
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Case Study
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Pipe line rehabilitation
program to maintain more
than 2,000 kms of pipeline
buried deep in desert plains,
remote mountain passes
and rock strewn wadis
Most of the line was in good
condition
In some areas the original
coating had broken down
and there was localised
external corrosion damage
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Case Study – The Findings
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Corrosion had resulted in wall thickness
loss of up to 85%.
Most of the defects identified for repair had
between 50 to 80% wall loss.
The operator wanted to minimise the risk of
leaks developing.
They needed to restore the integrity of the
line.
The operator wanted to avoid shutting down
the line so cutting out and replacing
sections was not an option.
Welding steel sleeves would require hot
work on already weakened lines raising
safety concerns.
Composite repairs were specified.
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Case Study - Preparation
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Composite repairs designed
for each pipe on the
network taking into account
operating parameters.
Design includes min
thickness, length of the
repair and length of taper at
each end of the repair.
This allows the installation
teams to calculate the
quantity of material required
for each repair.
Each location was identified on the pipeline and grit blasted
to
SA 2.5
On defects with severe wall loss hand preparation was
carried out to ST2
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Case Study - Installation
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Line detail: 20 inch Gas
transmission line
Defect type: External
corrosion pitting
Remaining wall: 80% wall
loss
Cause of defect: Failure of
coating
Design pressure: 120 bar
Design temp: 40 ºC
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Example Installation
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Line detail: 12 inch export oil line
Defect type: Thinning of elbow wall thickness
Remaining wall: 80% wall loss
Cause for defect: Internal erosion
Design Pressure: 62 bar
Design temperature: 50 ºC
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Example Installation
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Line detail: 12 inch Fuel
Gas Line to boilers
Defect type: Extensive
external Corrosion pitting
Remaining Wall: 2mm
(recorded in places).
Average – 60% wall loss
Cause of Defect: Deluge /
condensation from plant
Operating Pressure: 10
bar
Design Temp: 25 ºC
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Example Installation
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Line Detail: 36 inch sea
cooling water line
Cause of defect: Internal
erosion pitting due to failure
of internal rubber lining
Remaining Wall: 60% wall
loss
Design temperature: 50 ºC
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Example Installation
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Line Detail: 42 inch main oil
line
Cause of defect: Internal
wall loss close to flange joint
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Example Installation
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Composite repair to well
head tower risers
Composite repair to LPG
Tank dome
Using Rope Access
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Complex Geometry Repairs
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NEW – Splash Zone Repairs
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Repairs for caissons and risers suffering external
corrosion with up to an 80% wall loss.
Can be used for pressures up to 250 barg/ 3625
psi and temperatures ranging from -75°C to
+220°C/ -103 to 428°F.
At present all composite technology is
applied to a dry surface, but this repair
type can cure in the wet.
This is due to a specially formulated
epoxy-based resin.
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How can we support your needs?
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Pipe repairs?
Tank repairs?
Leaks?
Corrosion?
Valve decommissioning?
NDT indicating pipe
thinning?
Mission critical steel work
requiring repair?
Are you considering pipe
replacement?
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Contact Information
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Bahrain
India
Iraq
Kuwait
Oman
Qatar
Saudi Arabia
United Arab Emirates
Mick Flaherty COO
+971 50 370 4686
[email protected]
Francis Doherty CFO
+971 50 804 7978
[email protected]
Head Office
Total Solutions Middle East
PO Box 283712
Dubai
UAE
T: +971 4 450 8368
F: +971 4 450 8371
W: www.totalsolutionsme.com
