Contour Reinforces Corroded Cooling Water Line


Pipe Details

610-mm (24-inch) diameter – 25.4-mm (1-inch) elbow

6 BarG (87 psi) design pressure

3.5 BarG (51 psi) operating pressure

+12°C (+54°F) operating temperature

7.925 mm (0.31 inch) original wall thickness


  • Internal corrosion caused leaks in a 610-mm (24-inch) diameter cooling water line and a 25.4-mm (1-inch) tee
  • 2 CSNRI trained and certified technicians completed the Contour repair in 2 days
  • The composite installation replaced a temporary repair, allowing safe operations to continue
  • No hot work was required during the repair application.

Internal corrosion on a DN700 (24-inch) cooling water line in a refinery in Western Europe led to a loss of containment that required attention. The leak was stopped using a temporary leak sealing clamp, and a second leak on a DN 25 (1-inch) elbow from a nozzle off the DN700 pipe was addressed with a traditional leak box. The operator wanted the clamps to be wrapped with Contour to ensure the pipe would remain fit for purpose until the next planned shutdown for the cooling water system.

A composite solution was ideal for this pipeline because the remaining wall thickness was insufficient for a welded repair. The thin pipe wall posed a welding risk because of the danger of accidental burn through and creating a larger leak.

Having regularly used composites in the past to repair piping within the refinery, the owner turned to CSNRI for a solution.

After careful deliberation, the decision was made to repair the lines using Contour, an engineered wet applied repair system, featuring quad-axial stitched fiberglass cloth applied in a wet-lay system with two-part epoxy and a filler material.

CSNRI trained installers, inspected the pipe surface and grit blasted the areas deemed sound for repair. A team of 2 technicians applied load transfer filler material around the clamps to ensure there were no voids under the repair, creating a geometry suitable for application of the composite repair and ensuring the loads from the pipe would be transferred to the composite that provides reinforcement. With the pipe prepared, the technicians applied 9 layers of Contour to the straight pipe and 14 layers at the tee. When the composite was completely cured 8 hours later, the installers painted over the repaired area to provide barrier protection from damage caused at soil-to-air interface locations.

The entire repair was completed in only 2 days, with the cooling water system in normal service.

The leaks initially were contained using temporary clamps.
The completed repair gets a coat of paint.
Trained installers used load transfer filler to reshape the leaking pipe in preparation for the Contour repair.